Converting Fuel Injection Pump Lines from Tubes to Steel-Braided Hoses on Certain D3K2, D4K2, and D5K2 Track-Type Tractors with Fireplow Modifications {1251, 1274, 1290} Caterpillar

Track-Type Tractor

D3K2 (S/N: KFF1-UP; KLL1-UP)

D4K2 (S/N: KMM1-UP; KRR1-UP)

D5K2 (S/N: TRF1-UP; KWW1-UP; KYY1-UP)

Introduction

This Special Instruction outlines the conversion of fuel injection pump lines from tubes to steel-braided hoses. It is intended for machine equipped with one of the following Fireplow arrangements:

Safety Section

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

Required Parts

Installation

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Illustration 1	g06053849
Gaining access behind the secondary filter (1) Bolt (2) Washer (3) Braided hose (4) 8T-7487 Connector (5) Fuel tubes (6) Clip (24) 227-5714 Elbow

1. Disconnect four fuel tubes (5) from the secondary filter.

2. Remove braided hose (3) from the secondary filter. Remove connector (4) and save for reuse.

3. Remove elbow (24) and discard.

4. Remove two clips (6) from the tubes and discard.

5. Remove two bolts (1) and washers (3) that secure the filter base. Lift the filter assembly from the engine and set aside.
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   Illustration 2	g06053866
   (7) Tube (8) Nut (9) Fitting (10) Primary filter base

6. Remove tube (7) by loosening nut (8). Use a backup wrench on fitting (9) to apply counter-torque to keep the assembly stationary. Remove the tube.

7. Install the new 370-8363 Pump As and 420-1641 Fuel Line. Refer to the Disassembly and Assembly manual in the Reference Section.
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   Illustration 3	g06054087
   Correct ferrule orientation (11) Nut (12) Ferrule (13) Ferrule

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   Illustration 4	g06054094
   (11) Nut (12) Ferrule (13) Ferrule

8. Remove the smaller hex nut (15.88 mm) (10) from the new 396-0380 Coupling along with ferrule (11) and ferrule (12). Orient the parts as shown in Illustration 3. Loosely install the parts onto the existing half of the 396-0380 Coupling on the engine. Refer to Illustration 4. Do not tighten the nut at this time.

   Note: Failure to orient the ferrules as shown in Illustration 3 will result in leakage and the need to replace the parts.

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   Illustration 5	g06054145
   (14) 485-1630 Hose As

9. Push the quick-connect end of hose (14) onto the fuel pump drain line tube. An audible click should be heard and the fuel line should stay attached when gently pulled.
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   Illustration 6	g06054154
   (14) 485-1630 Hose As (15) 5P-9085 Clip

10. Place two new clips (15) onto hose (14) as shown in Illustration 6.
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    Illustration 7	g06054168
    (14) 485-1630 Hose As (16) 6V-8455 Bolt (17) 8T-4121 Hard Washer

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    Illustration 8	g06054107

11. Lift the tube end of hose (14) and place the hose into the connector nut as shown in Illustration 8. Hand-tighten the nut, only.

12. Loosely secure the two clips with new bolts (16) and washers (17).
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    Illustration 9	g06054123

13. Mark the tube connector nut at the 6 o'clock position.
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    Illustration 10	g06054127

14. While holding the lower fitting stationary with another wrench and pushing the tube downward, tighten the nut one and one-quarter revolutions until the mark is at the 9 o'clock position. Refer to Illustrations 8,9, and 10.

15. Once the fitting is tightened, tighten bolts (16) securing the two clips (Illustration 7). Tighten the vertically mounted bolt first, then tighten the horizontally mounted bolt. Tighten each bolt to 25 ± 2 N·m (18.5 ± 1.5 lb ft).

16. Reuse the existing hardware and reinstall the secondary fuel filter base. Tighten the bolts to 45 ± 5 N·m (33 ± 4 lb ft). Hold the filter base vertical while tightening the bolts.
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    Illustration 11	g06054224
    (18) Banjo bolt (19) Spigot (20) Front port (21) Rear port (22) 485-1627 Hose As (25) 228-6046 Connector (26) 228-7100 O-Ring Seal

17. Remove banjo bolt (18) and spigot (19). Retain one of the washers. Replace the banjo bolt with the new 8T-4191 Bolt and the retained washer. Tighten the bolt to 22 ± 2 N·m (16 ± 1.5 lb ft).
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    Illustration 12	g06054327
    Hose release orientation (22) 485-1627 Hose As

18. Install hose (22) on the pump. It is important to note that the plastic release must be rotated so the flat is aligned with the body of the pump. Refer to Illustration 12.

19. Install connector (25) and O-Ring (26) at rear port (21). Tighten the connector to 30 ± 2 N·m (22 ± 1.5 lb ft).

20. Install the new 228-7089 O-Ring Seal onto the connector. Then, install the other end of hose (22) to the connector. Holding the hose angle at approximately 5 degrees clockwise from vertical down, tighten the hose to 30 ± 2 N·m (22 ± 1.5 lb ft).

21. Install a new 228-7100 O-Ring Seal onto the 8T-7487 Connector and install at front port (20). Tighten the connector to 30 ± 2 N·m (22 ± 1.5 lb ft).

22. Install the new 228-7088 O-Ring Seal on the 8T-7487 Connector.
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    Illustration 13	g06054360

23. Connect braided hose (3) to the secondary filter. Ensure that the angle of the hose is as specified in Illustration 13. Adjust as necessary. Tighten each coupling to 27 ± 4 N·m (20± 3 lb ft) while maintaining the proper hose angle.
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    Illustration 14	g06054386
    (22) 7K-1181 Cable Strap

24. Install cable strap (23) around the two new fuel lines between the injection pump and filters.

Reference Section

Reference: Disassembly and Assembly , UENR0642, Crankcase Breather and Fuel Injection Pump

Reference: Operation and Maintenance Manual , SEBU8498, "Fuel System - Prime"