- Engine:
- C9 (S/N: C9S1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
Before replacing any C9 high pressure fuel line, follow the instructions that are listed below.
Note: The following procedures were written for the complete removal of all of the fuel lines and clamps. If only specific fuel lines need to be replaced then only remove the fuel lines and clamps that need replacement.
Note: Failure to follow this procedure may result in a leaking fuel line.
Safety Section
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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
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| NOTICE |
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Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
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Fuel injection lines MUST only be used once. Discard all fuel injection lines after use. |
Fuel Line Removal and Installation Procedures
Required Parts
| Fuel Line Part Number | Description | Replacement Kit Part Number | Description |
| 292-3740 | Fuel Line Tube Assembly | 310-6031 | Fuel Lines Kit |
| 284-9380 | Fuel Line Tube Assembly | 310-6032 | Fuel Lines Kit |
| 308-7062 | Fuel Line Tube Assembly | 310-6033 | Fuel Lines Kit |
Replace the removed high pressure fuel line with the corresponding Fuel Lines Kit. The clamp, the grommet, and the new fuel line that is supplied with the Fuel Lines Kit must be used as the replacements for the old parts. Refer to Table 1.
Note: Do not reuse the old clamp, the old grommet, and the old fuel line.
Removal Procedure
- Turn the fuel supply to the OFF position.
- Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
- Remove the bolts (9) and clamps (8) at locations (1), (2), (3), and (4). Take note of the rubber grommets (7) in clamps (8) at locations (1), (2), (3), and (4) .
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| Illustration 1 | g01444743 |
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| Illustration 2 | g01630113 |
(7) Grommet (8) Clamp (9) Bolt | |
- Loosen nut (6) on each end of fuel line (5). Remove fuel line (5). Repeat for the remaining fuel lines. Discard the fuel lines.
Installation Procedure
- Install a new fuel line (5). Hand tighten nut (6) on each end of the fuel line. Repeat for the remaining fuel lines.
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| Illustration 3 | g01444743 |
- Install clamps (8) at locations (1), (2), (3), and (4). Make sure that the rubber grommets (7) are placed correctly in clamps (8) at locations (1), (2), (3), and (4). Refer to Illustration 2. Failure to correctly place the grommet in the clamp could result in a failed fuel line. Install the bolts (9) for the clamps (8) hand tight.
- Tighten nuts (6) at the fuel rail for the fuel lines to a torque of 27 ± 3 N·m (20 ± 2 lb ft).
Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use excessive force or bending in order to assemble the fuel lines.
- Tighten nuts (6) at the quill tube to a torque of 15 ± 3 N·m (135 ± 27 lb in). Turn nuts (6) at the quill tube for an additional 60 ± 5 degrees.
- Tighten the bolts (9) for clamps (8) at locations (1), (2), (3), and (4) to a torque of 12 ± 3 N·m (105 ± 27 lb in).
- Connect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
- Turn the fuel supply to the ON position.