Usage:
3306 Generator Set ( 3RG1-279 ),
930R ( 57Z1275-2179 ),
966R ( 58Z1133-1632 ),
D4E ( 2DJ1-147,7PB650-714,31C474-662,34C1237-1977 ),
D5B ( 8HD1-559,5LD1-329 ),
D6D ( 7XF1-137,36C1050-1481,37C946-1393,38C371-458 ),
D6E Tractor ( 2MJ1-47)
Introduction
This special instruction provides the necessary information to rework the fuel lines and install a new primary fuel filter for the above models.
The former fuel pre-filter did not allow adequate filtering. As a result the pump valve can cause the fuel filter to fail. Also, the injection lines group tube assemblies, between the filters and the governor, have been changed to hose assemblies. The earlier tube assemblies might crack in certain applications. New supply hoses are used between the fuel tank and filter that will not crack as the former tube assemblies did.
The rework consists of installing a new primary fuel filter and the new hose assemblies.
Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.
General Information
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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. |
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- * Disconnect the main switch.* Cover the alternator to prevent fuel from getting into the housing. If this is not done, there is a serious risk of fire when the engine is started.* Remove any traces of fuel after completing the work.
NOTE: The fuel tank must be empty before performing the following procedures.
Installing the Primary Filter and Hose Assemblies for D4E Tractors
NOTE: You must read and understand the warning and instructions contained in the topic entitled General Information, before performing the following procedure.
5Y1324 Primary Fuel Filter Group (1).
5Y1326 Fuel Filter Group (10).
1. Disconnect the transfer fuel pump inlet and outlet tube assemblies.
2. Disconnect and remove the fuel feed line from the fuel injection pump.
3. Remove fuel filter inlet and outlet tube assemblies with the clamp that hold them.
4. Remove three nuts (55) which hold fuel transfer pump group (56) to the injection pump housing and remove fuel transfer pump group (56).
Fuel transfer pump group (56).
NOTE: Cover the fuel injection pump assembly so that the nuts and bolts do not fall into the crankcase guard.
5. Remove bolt (57) and fuel transfer pump pre-filter (58) and install elbow (21) and seal (22).
NOTE: Install and tighten elbow (21) in the correct position, since there is not space to turn it when the transfer pump is fastened on the fuel injection pump housing. The elbow should be pointing out away from the fuel injection pump housing.
6. Remove the three old 2Y5793 Valves from fuel transfer pump body assembly (59) and install three new valves (23).
Fuel transfer pump body assembly (59). One valve (23) under each of the plugs.
Section A-A. Location of valve (23) in fuel transfer pump body assembly.
7. If necessary remove the 321268 Elbow (90°) from the fuel transfer pump body assembly outlet and install elbow (24).
8. Install fuel transfer pump body assembly (59) and nuts (55) on the pump housing.
9. Mount primary fuel filter group (1) as shown. Install elbow (21) and seal (22) in the outlet of the primary filter.
Fuel injection lines for D4E Tractor.
10. Install hose assembly (25) to primary fuel filter elbow (21) and the transfer pump inlet elbow (21).
11. Install hose assembly (26) to the transfer pump outlet elbow (24) and to the secondary fuel filter inlet (A).
12. Install hose assembly (26) to secondary fuel filter outlet (B) and injection pump inlet (B).
13. Fasten the two hose assemblies (26) together with strap (27).
14. Remove the former fuel lines as necessary to install new hose as shown.
5Y1420 Fuel Lines Group for D4E Tractors.
15. Cut the old hose from the connectors and use the connectors again.
16. Test all joints for leaks.
Installing the Primary Filter and Hose Assemblies for D6D and D6E Tractors
NOTE: You must read and understand the warning and instructions contained in the topic entitled General Information, before performing the following procedure.
5Y1324 Primary Fuel Filter Group (1).
5Y1326 Fuel Filter Group (10).
1. Disconnect the transfer fuel pump inlet and outlet tube assemblies.
2. Disconnect and remove the fuel feed line from the fuel injection pump.
3. Remove fuel filter inlet and outlet tube assemblies with the clamp that hold them.
4. Remove three nuts (55) which hold fuel transfer pump group (56) to the injection pump housing and remove fuel transfer pump group (56).
Fuel transfer pump group (56).
NOTE: Cover the fuel injection pump assembly so that the nuts and bolts do not fall into the crankcase guard.
5. Remove bolt (57) and fuel transfer pump pre-filter (58) and install elbow (21) and seal (22).
NOTE: Install and tighten elbow (21) in the correct position, since there is not space to turn it when the transfer pump is fastened on the fuel injection pump housing. The elbow should be pointing out away from the fuel injection pump housing.
6. Remove the three old 2Y5793 Valves (from fuel transfer pump body assembly (59) and install three new valves (23).
Fuel transfer pump body assembly (59). One valve (23) under each of the plugs.
Section A-A. Location of valve (23) in fuel transfer pump body assembly.
7. If necessary remove the 321268 Elbow (90°) from the fuel transfer pump body assembly outlet and install elbow (24).
8. Install fuel transfer pump body assembly (59) and nuts (55) on the pump housing.
9. Mount primary fuel filter group (1) as shown. Install elbow (21) and seal (22) in the outlet of the primary filter.
Fuel injection lines for D6D and D6E Tractors.
10. Install hose assembly (25) to primary fuel filter elbow (21) and the transfer pump inlet elbow (21).
11. Install hose assembly (26) to the transfer pump outlet elbow (24) and to the secondary fuel filter inlet (A).
12. Install hose assembly (27) to secondary fuel filter outlet (B) and injection pump inlet (B).
13. Fasten the two hose assemblies (26, 27) together with straps (28).
14. Remove the former fuel lines as necessary to install new hose as shown.
5Y1414 Fuel Lines Group for D6D, D6E Tractors.
15. Cut the old hose from the connectors and use the connectors again.
16. Test all joints for leaks.
Installing the Primary Filter and Hose Assemblies for 930R Loaders
NOTE: You must read and understand the warning and instructions contained in the topic entitled General Information, before performing the following procedure.
5Y1324 Primary Fuel Filter Group (1).
5Y1326 Fuel Filter Group (10).
1. Disconnect the transfer fuel pump inlet and outlet tube assemblies.
2. Disconnect and remove the fuel feed line from the fuel injection pump.
3. Remove fuel filter inlet and outlet tube assemblies with the clamp that hold them.
4. Remove three nuts (36) which hold fuel transfer pump group (37) to the injection pump housing and remove fuel transfer pump group (37).
Fuel transfer pump group (37).
NOTE: Cover the fuel injection pump assembly so that the nuts and bolts do not fall into the crankcase guard.
5. Remove bolt (38) and fuel transfer pump pre-filter (39) and install elbow (21) and seal (22).
NOTE: Install and tighten elbow (21) in the correct position, since there is not space to turn it when the transfer pump is fastened on the fuel injection pump housing. The elbow should be pointing out away from the fuel injection pump housing.
6. Remove the three old 2Y5793 Valves (from fuel transfer pump body assembly (40) and install three new valves (23).
Fuel transfer pump body assembly (40). One valve (23) under each of the plugs.
Section A-A. Location of valve (23) in fuel transfer pump body assembly.
7. If necessary remove the 321268 Elbow (90°) from the fuel transfer pump body assembly outlet and install elbow (24).
8. Install fuel transfer pump body assembly (40) and nuts (36) on the pump housing.
9. Mount primary fuel filter group (1) as shown. Install elbow (21) and seal (22) in the outlet of the primary filter.
Fuel injection lines for 930R Loaders.
10. Install hose assembly (25) to primary fuel filter elbow (21) and the transfer pump inlet elbow (21).
11. Install hose assembly (26) to the transfer pump outlet elbow (24) and to the secondary fuel filter inlet (A).
12. Install hose assembly (26) to secondary fuel filter outlet (B) and injection pump inlet (B).
13. Fasten the two hose assemblies (26) together with strap (27).
14. Remove the former fuel lines as necessary to install new hose as shown.
2Y9744 Fuel Lines Group for 930R Loaders.
15. Cut the old hose from the connectors and use the connectors again.
16. Test all joints for leaks.
Installing the Primary Filter and Hose Assemblies for 966R Loaders
NOTE: You must read and understand the warning and instructions contained in the topic entitled General Information, before performing the following procedure.
5Y1324 Primary Fuel Filter Group (1).
5Y1326 Fuel Filter Group (10).
1. Disconnect the transfer fuel pump inlet and outlet tube assemblies.
2. Disconnect and remove the fuel feed line from the fuel injection pump.
3. Remove fuel filter inlet and outlet tube assemblies with the clamp that hold them.
4. Remove three nuts (35) which hold fuel transfer pump group (36) to the injection pump housing and remove fuel transfer pump group (36).
Fuel transfer pump group (36).
NOTE: Cover the fuel injection pump assembly so that the nuts and bolts do not fall into the crankcase guard.
5. Remove bolt (37) and fuel transfer pump pre-filter (38) and install elbow (21) and seal (22).
NOTE: Install and tighten elbow (21) in the correct position, since there is not space to turn it when the transfer pump is fastened on the fuel injection pump housing. The elbow should be pointing out away from the fuel injection pump housing.
6. Remove the three old 2Y5793 Valves (from fuel transfer pump body assembly (39) and install three new valves (23).
Fuel transfer pump body assembly (39). One valve (23) under each of the plugs.
Section A-A. Location of valve (23) in fuel transfer pump body assembly.
7. If necessary remove the 321268 Elbow (90°) from the fuel transfer pump body assembly outlet and install elbow (24).
8. Install fuel transfer pump body assembly (39) and nuts (35) on the pump housing.
9. Mount primary fuel filter group (1) as shown. Install elbow (21) and seal (22) in the outlet of the primary filter.
Fuel injection lines for 966R Loaders.
10. Install hose assembly (25) to primary fuel filter elbow (21) and the transfer pump inlet elbow (21).
11. Install hose assembly (26) to the transfer pump outlet elbow (24) and to the secondary fuel filter inlet (A).
12. Install hose assembly (27) to secondary fuel filter outlet (B) and injection pump inlet (B).
13. Fasten the two hose assemblies (26, 27) together with straps (28).
14. Remove the former fuel lines as necessary to install new hose as shown.
2Y9713 Fuel Lines Group for 966R Loaders.
15. Cut the old hose from the connectors and use the connectors again.
16. Test all joints for leaks.
Installing the Primary Filter and Hose Assemblies for D5B Tractors
NOTE: You must read and understand the warning and instructions contained in the topic entitled General Information, before performing the following procedure.
5Y1094 Primary Fuel Filter Group (1).
5Y1326 Fuel Filter Group (11).
1. Disconnect the transfer fuel pump inlet and outlet tube assemblies.
2. Disconnect and remove the fuel feed line from the fuel injection pump.
3. Remove fuel filter inlet and outlet tube assemblies with the clamp that hold them.
4. Remove three nuts (56) which hold fuel transfer pump group (57) to the injection pump housing and remove fuel transfer pump assembly (57).
Fuel transfer pump group (57).
NOTE: Cover the fuel injection pump assembly so that the nuts and bolts do not fall into the crankcase guard.
5. Remove bolt (58) and fuel transfer pump pre-filter (59) and install elbow (22) and seal (23).
NOTE: Install and tighten elbow (22) in the proper position, since there is not space to turn it when the transfer pump is fastened in the fuel injection pump housing. The elbow should be pointing out away from the fuel injection pump housing.
6. Remove the three transfer pump 2Y5793 Valves from fuel transfer pump body assembly (60) and install three new valves (24).
Fuel transfer pump body assembly (60). One valve (24) under each of the plugs.
Section A-A of fuel transfer pump body assembly.
7. If necessary remove the 321268 Elbow (90°) from the fuel transfer pump body assembly outlet and install elbow (25).
8. Install fuel transfer pump body assembly (60) and nuts (56) on the pump housing.
9. Mount primary fuel filter group (1) as shown. Install elbow (22) and seal (23) in the outlet of the primary filter.
Fuel injection lines for D5B Tractors.
10. Install hose assembly (29) to primary fuel filter outlet elbow (22) and fuel transfer pump inlet elbow (22).
11. Install hose assembly (26) to transfer pump outlet elbow (25) and to secondary fuel filter inlet (A).
12. Install hose assembly (27) to the secondary fuel filter outlet (B) and injection pump inlet (B).
13. Fasten the hose assemblies together with two strap (28).
14. Remove the former fuel lines group between the fuel tank and the primary fuel filter group and fuel pump housing.
15. Install the new fuel lines group between the fuel tank and the primary fuel filter group and fuel pump housing.
5Y1479 Fuel lines group for D5B Tractors.
16. Test all joints for leaks.