Servicing the Outlet Check Plugs on the Fuel Injection Pump on C6.6 and C4.4 Engines{1251, 1290} Caterpillar

Asphalt Paver:

AP600D (S/N: TFZ201-242)

AP655D (S/N: GNN203-223,225-225,228-231; MAT203-206)

Backhoe Loader:

450E (S/N: EBL171-388)

Industrial Engine:

C4.4 (S/N: 4442325-2334,2336-2742,2745-2943,2945-3644,3647-3748,3750-3762,3764-4018,4020-4346,4348-4422,4425-4426,4429-4445,4447-4481,4483-4519,4521-4611,4613-4894,4896-5126,5129-5356,5358-5371,5373-5473,5475-5518,5521-5617,5620-5624,5627-5636,5638-5778,5783-5980,5982-6020,6022-6022,6024-6113,6115-6127,6129-6380,6382-6665,6667-6679,6682-6684,6686-6718,6720-6721,6723-6730,6732-6759,6798-6807,6810-6810,6825-6828,6832-6839,6850-6868,6871-6879,6882-6910,6912-6912,6914-6915,6918-6929)

C6.6 (S/N: 666825-825,6233-6320,6322-6328,6330-6404,6406-6522,6524-6546,6548-6616,6618-7010,7012-7013,7015-7045,7047-7084,7086-7215,7217-7340,7342-7354,7356-7435,7437-7455,7457-7506,7508-7649,7651-7653,7655-7660,7662-7669,7672-7877,7879-7885,7895-7920,7922-7927,7929-8075,8077-8078,8080-8087,8098-8189,8191-8249,8250-8252,8254-8268,8270-8299,8301-8353,8355-8544,8546-8718,8720-8821,8823-8863,8866-9165,9167-9253,9256-9258,9261-9311,9313-9381,9386-9420,9423-9479,9481-9578,9580-9581,9583-9590,9592-9653,9657-9826,9828-9923,9926-9988,9991-9991,9993-10193,10195-10196,10198-10198,10202-10203,10205-10206,10208-10210,10213-10217,10219-10273,10275-10294,10296-10326,10328-10329,10331-10361,10363-10565,10567-10595,10598-10601,10603-10682,10684-10766,10774-10877,10879-10900,10902-10907,10909-10911,10913-10913,10915-10921,10924-10931,10933-10939,10941-10941,10943-10944,10946-10952,10960-11028,11030-11067,11069-11182,11184-11192,11195-11221,11227-11235,11237-11307,11314-11330,11332-11339,11342-11379,11381-11506,11508-11513,11515-11537,11539-11541,11543-11544,11558-11567,11580-11585,11587-11609,11611-11615,11620-11657,11659-11659,11661-11675,11677-11691,11694-11726,11728-11737,11739-11760,11762-11794,11796-11851,11855-11857,11859-11875,11877-11884,11886-11887,11890-11890,11893-11893,11895-11896,11898-11901,11904-11904,11906-11910,11913-11913,11920-11920,11924-11929,11933-11936,11938-11954,11979-11979,11982-11982)

Generator Set:

C4.4 (S/N: D4B404-404,412-415,417-611,614-620,623-623,629-661,663-693,695-1077,1079-1106,1110-1110; D4D1-1,612-618,622-726,730-730,764-771)

C6.6 (S/N: N6D406-735,737-752,754-755,757-776,778-784,786-789,801-1050,1052-1081,1083-1199)

Excavator:

M313D (S/N: W3H332-850,852-852)

M315D (S/N: W5M322-338,340-761)

M316D (S/N: W6A705-1102,1104-1105)

M318D (S/N: W8P679-1152,1154-1157; W8R228-325,327-327)

M322D (S/N: W2S282-434; W2T288-431)

Integrated Toolcarrier:

IT38H (S/N: JNJ159-377)

Load Haul Dump:

R1300G Series II (S/N: RSL1-UP)

Motor Grader:

120M (S/N: B9C132-488; B9W1-184)

12M (S/N: B9F14-623)

Pipelayer:

PL61 (S/N: WGS101-175)

Vibratory Soil Compactor:

CP54 (S/N: C5Y1-104)

CP56 (S/N: C5P119-473,475-475; FCP1-130,135-137)

CP64 (S/N: P7F1-105; C6P102-117)

CP74 (S/N: P8F1-105)

CP76 (S/N: C7L1-122; JCP102-125)

CS54 (S/N: C5R114-344; C5W171-301,305-307)

CS56 (S/N: C5S106-787,789-814,816-821,831-831; FCS102-418,420-430,432-432,434-434,438-438,443-446,463-463,470-481,483-484)

CS64 (S/N: C7F1-139; C6S101-123)

CS74 (S/N: C8F101-285,287-302,305-307,309-309,311-313,316-365; C8S103-121)

CS76 (S/N: JCS1-150; CYX103-288,291-291,294-295,299-299,304-310)

Track-Type Loader:

953D (S/N: LBP706-923,925-925)

963D (S/N: LCS727-1030)

Track-Type Tractor:

D3K (S/N: FFF136-507,510-510,519-519,521-521,530-530,532-532,538-538,540-541,545-546; LLL165-403,405-453,455-532,534-565,567-570,573-591,593-602,612-612,633-633,638-638)

D4K (S/N: MMM152-453,456-456,458-460,465-465,471-471,474-477; RRR153-342,350-355,357-358)

D5K (S/N: JLF175-207,209-221; WWW212-805,808-814,819-819,829-834,836-837,847-847,851-852,862-862; YYY226-777,780-781,785-788,790-790,806-807,813-816,833-838,841-841)

D6K (S/N: DHA631-1099; NCF30-49; FBH794-1431,1433-1433,1436-1437,1440-1441,1443-1444)

D6N (S/N: DJA630-1199; JAH156-304,306-310; GHS1-206; MLW1-103; DJY837-1692,1695-1695,1704-1707,1709-1709)

Wheel Loader:

924H (S/N: HXC334-451,550-1315; JTM228-283,600-840,842-862; KLN1-398)

924HZ (S/N: WLB1-299; PED247-723)

928HZ (S/N: BYD258-404; CXK258-762)

930H (S/N: DHC310-409,600-1560; FTD196-248,650-1160)

938H (S/N: MJC63-681; JKM159-752; LKM144-533,535-538)

Introduction

If the engine turns over but the engine does not start, refer to Operation and Maintenance Manual, "Fuel System - Prime" and Troubleshooting, "Engine Cranks but Will Not Start".

If the engine will not start, new service parts are available.

The new service parts are the following components.

• 257-2382 Plug

• 257-2381 Pin

• 258-8149 Spring

Removal Procedure

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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.

Note: Put identification marks on all hoses and all plastic tube assemblies for installation purposes. Plug all plastic tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF position.

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Illustration 1	g02028780
Typical example

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Illustration 2	g02030553
Typical example

3. Remove one outlet check plug (2) from fuel injection pump (1). Remove the plug, the spring (5) and the outlet check valve (4) .

4. Clean the components with alcohol or contact cleaner. Inspect the components for wear or damage. If there is damage to the radius surface of the outlet check valve, replace with a new outlet check valve.

5. Flush out the head of the fuel injection pump (1) with clean alcohol or contact cleaner. Inspect the head of the fuel injection pump (1) for damage or debris on the seat area (3) .

6. Use a cotton swab with alcohol or contact cleaner applied, swab threads in counterclockwise direction. This will remove debris from the threads.

   Note: Caution is required to prevent pushing debris into the internal passages. Do not use a clockwise direction to clean debris from threads as debris could be pushed into the fuel injection pump.

Installation Procedure

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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.

1. Crank the engine until fuel comes out of one of the plug orifices, free of air.

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Illustration 3	g02030553
Typical example

2. Replace the plug, spring (5), and valve (4). Tighten the plug finger tight.

3. Crank the engine again until the fuel comes out the outlet check plug orifice, free of air.

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Illustration 4	g02028780
Typical example

4. Tighten the outlet check plug (2) finger tight. Tighten the outlet check plug (2) to a torque of 40 N·m (30 lb ft).

5. Repeat steps 3 to 6 of the removal procedure for the other outlet check plug (2). Repeat steps 1 to 4 of the installation procedure for the other outlet check plug (2) .

6. Turn the battery disconnect switch to the ON position.

7. Turn the fuel supply to the ON position.

8. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.

9. Start the engine. Refer to Operation and Maintenance Manual, "Starting the Engine" for the correct procedure. Check for fuel leaks.""

   Note: The threads can retain a small amount of fluid that will seep out during the early hours of operation and could be confused with a leak.