- Industrial Engine:
- C9.3 (S/N: C9N1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
Before replacing any C9.3 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
 |
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. |
 |
| NOTICE |
|---|
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 |
|---|
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 |
|---|
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use. |
Fuel Line Removal and Installation Procedures
Required Parts
| Part Number | Line Designation | Description |
| 356-0828 | Cylinder 1 fuel line | Fuel Lines Kit |
| 356-5217 | Cylinders 2,3, and 4 fuel line | Fuel Injection Line Assembly |
| 356-0832 | Cylinders 5 and 6 fuel line | Fuel Lines Kit |
| 356-0831 | Fuel pump to rail line | 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 all components in order to access to the wiring harness.
- Loosen clamp assemblies (1) and remove hose (2) .
 | |
| Illustration 1 | g02140798 |
- Disconnect fittings (3) and (7) .
 | |
| Illustration 2 | g02140852 |
- Remove bolts (5), (6), and (8) and remove tube assembly (4) .
- Remove bolt (9) .
- Remove nuts (10) and remove bracket (11) .
 | |
| Illustration 3 | g02140971 |
- Disconnect harness assemblies (12) .
- Position harness assembly (13) out of the way. Remove the spacers (not shown) from studs (14) .
 | |
| Illustration 4 | g02141119 |
- Remove the bolt (15) and remove the clamp assembly. Discard the clamp assembly.
 | |
| Illustration 5 | g02241493 |
- Remove nuts (23), (19), and (20). Remove the corresponding clamp assemblies and discard the clamp assemblies.
- Loosen nuts (16) and (18). Remove fuel line (17) and discard the fuel line. Repeat for the remaining fuel lines.
- Loosen nuts (21) and (24). Remove fuel line (22) and discard the fuel line.
Installation Procedure
| NOTICE |
|---|
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use. |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order to prevent contamination. Ensure that the areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If any parts are worn or damaged, use new parts for replacement. Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.
- Install a new fuel line (17). Hand tighten nuts (16) and (18) on each end of the fuel line. Repeat for the remaining fuel lines.
| | |
| Illustration 6 | g02241493 |
| | |
| Illustration 7 | g02141119 |
Note: Make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order to prevent contamination.
- Install a new fuel line (22). Hand tighten nuts (21) and (24) .
- Position the clamp assembly and install bolt (15). Hand tighten the bolt.Failure to place the grommet correctly on the fuel line could result in a failed fuel line.
- Position the clamp assembly and install nuts (23), (19), and (20). Hand tighten the nuts. Failure to place the grommet correctly on the fuel line could result in a failed fuel line.
- Tighten nuts (24) and (18) at the fuel rail to a torque of 27 ± 3 N·m (239 ± 27 lb in).
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 (21) and (16) to a torque of 27 ± 3 N·m (239 ± 27 lb in).
- Tighten bolt (15) and nuts (23), (19), and (20) to a torque of 12 ± 3 N·m (105 ± 27 lb in).
- Position the spacers (not shown) and harness (13) onto studs (14) .
- Install bracket (11) and install nuts (10) .
| | |
| Illustration 8 | g02140971 |
- Connect harness assemblies (12) .
- Position tube assembly (4). Connect fittings (3) and (7). Install bolts (5), (6), and (8) .
| | |
| Illustration 9 | g02140852 |
- Install bolt (9) .
- Position hose (2) and install clamp assemblies (1) .
| | |
| Illustration 10 | g02140798 |
- Connect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Connect".
- Turn the fuel supply to the ON position.