Usage:
D333C, 3306 ( 23C, 66D67D );
D346 ( 39J40J ),
D348 ( 36J, 38J, 57K );
D349 ( 61P, 62P, 32R );
1673C, 3306 ( 76R );
D353C ( 46B, 47B );
D379 ( 68B, 69B );
D398 ( 66B, 67B );
D399 ( 35B, 91B );
3208 ( 90N, 40S, 75V,79V, 32Y );
3406 ( 90U, 91U,92U );
3408 ( 67U, 99U, 28V );
3412 ( 38S, 60M );
613B ( 38W );
641B ( 65K );
651B ( 67K );
657B ( 68K );
777 ( 84A );
992B ( 25K1170 );
992C ( 42X );
D10 ( 84W, 76X );
245 ( 95V)
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Fuel lines that are bent, damaged or have leakage can cause a fire. Fuel lines must not rub (come in contact with) other parts. Make a good inspection of all fuel lines and fuel line connections. Make a repair or replacement of parts at any location that has damage or leakage. All fuel line connections must be tightened to the correct torque. |
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1 Install the fuel heater in a location that is as near as possible to the fuel filter base, but in a location that will keep the heater and its connecting hoses away from the manifolds, or any other area of extreme heat.
NOTE: At installation of the fuel heater, the fuel line that comes from the fuel supply tank must connect to the FUEL IN end of the fuel heater. The fuel heater must be installed ahead of (before) all fuel filters and the water separator, if so equipped.
2A. For 641B, 651B and 657B Tractors, remove the fuel line and the fittings that connect the fuel transfer pump to the engine fuel filters. Install an 8M755 Connector at each location where a fitting is removed.
2B. For 777, 992B, 992C and D10, remove only the last section of the fuel supply line that connects the fuel supply tank to the engine fuel filters.
2C. For 3208 Engines, remove the fuel line between the fuel filter base and the fuel block at the right rear of the engine.
2D. For D353, D379, D398 or D399 Industrial Engines, connect the fuel ports of the fuel heater into the fuel supply line, either before the fuel transfer pump, or after the primary fuel filter, if so equipped.
NOTE: After steps 1 and 2 are done, the remainder of fittings and connectors that are needed will be according to the location of fuel heater installation. In the procedure that follows, part numbers are given for both straight connectors and for elbow connectors. Use the type connector that will make the best installation.
3 Use a 2M9780 O-ring Seal on each fitting and install either a 6K3607 Connector or a 54173 Elbow in FUEL IN port (A) and FUEL OUT port (B) of 8N9593 Fuel Heater (1).
4 For 777, 992B, 992C or D10 Machines, and D353, D379, D398, D399 or 3406 Engines, use 6V1744 Hose and either 4N5560 Hose Couplings or 680556 Elbows to connect the machine fuel supply line to FUEL IN port (A), and to connect FUEL OUT port (B) to the fuel inlet port of the fuel filter base.
5 For 641B, 651B and 657B Tractors, use 6V1744 Hose and either 4N5560 Hose Couplings or 680556 Elbows to connect the fuel transfer pump to the FUEL IN port (A) of fuel heater (1). Use 6V1744 Hose and either 4N5560 Hose Couplings or 680556 Elbows to connect the FUEL OUT port (B) of the fuel heater to the inlet port of the fuel filter base.
NOTE: It may be necessary to also use additional connectors, not given in this instruction, to adapt the fuel supply and return hoses of the fuel heater to the fuel supply line of an engine.
6 For 3208 Engines, the original fuel lines and connections from the fuel supply tank to the engine, can be different from one engine to another. For this reason, make reference to A, B or C that follow, and use the procedure needed to connect the fuel lines to the fuel heater.
A) Junction Block on Right Rear of Engine - No Water Separator:
1. Install either a 619463 Connector or 6L9777 Elbow in the outlet port of the fuel junction block, and the inlet port of the fuel filter base.
2. Use 6V1744 Hose and 4N5560 Hose Couplings to connect the outlet port of the junction block to FUEL IN port (A) of fuel heater (1).
3. Use 6V1744 Hose and 4N5560 Hose Couplings to connect FUEL OUT port (B) of fuel heater (1) to the inlet port of the fuel filter base.
B) Junction Block on Right Rear of Engine - Fuel System Equipped With Water Separator:
NOTE: The fuel heater fuel lines must be connected between the water separator and the fuel filter.
1. Install either a 619463 Connector or 6L9777 Elbow in the fuel outlet port of the water separator.
NOTE: The threads in the ports of a later type water separator have straight threads. For these water separators, use a 5P4675 Adapter and 1J9671 Seal, before installation of the connector or elbow.
2. Use 6V1744 Hose and 4N5560 Hose Couplings to connect the fuel outlet of the water separator to FUEL IN port (A) of fuel heater (1).
3. Use 6V1744 Hose and 4N5560 Hose Couplings to connect FUEL OUT port (B) of fuel heater (1) to the inlet port of the fuel filter.
C) Engine Does Not Have A Water Separator or a Fuel Junction Block:
1. Connect a hose from the fuel supply to FUEL IN port (A) of fuel heater (1).
2. Use 6V1744 Hose and 4N5560 Hose Couplings to connect FUEL OUT port (B) of fuel heater (1) to the inlet port of the fuel filter.
Except for 3208 Engines, and D353, D379, D398 and D399 Industrial Engines, the coolant (water) connections for the fuel heater will be connected to the engine cooling system at the same ports that are used for connection of a cab heater. If the machine has a cab heater, the fittings used to connect heater hoses to the engine coolant lines must be removed, a tee installed at each location, and then the heater hoses connected to the tee. Use either 7D7026 Connectors or 3K7928 Elbow Connectors as needed, with 5P767 Hose and 5D1026 Hose Clamps to make the coolant hose connections needed, as given in the procedure that follows. The illustrations that follow show the location to make hose connections for the fuel heater. These locations are the same as those used for cab heater hose connection.
7 For 992C Loaders with 3412 Engine, connect WATER OUT port (C) of fuel heater (1) to heater return port (E) on the engine. Connect WATER IN port (D) of the fuel heater to heater supply port (F) on the engine.
8 For 992B Loaders with a D348 Engine, port (G) is shown in a side view of the water pump housing. Connect the WATER OUT port (C) of the fuel heater to port (G). Port (H) is shown in a top view of the housing for the thermostats (water temperature regulators). Connect the WATER IN port (D) of the fuel heater to port (H).
9 For 777 Trucks with the D348 Engine, connect the WATER OUT port (C) of the fuel heater to inlet port (J) on the water pump. Connect the WATER IN port (D) of the fuel heater to port (K) in radiator outlet pipe (2).
10 For 641B, 651B and 657B Tractors with the D346 Engine connect the WATER OUT port (C) of the fuel heater to return port (L) for cab heater coolant. Connect the WATER IN port (D) of the fuel heater to the coolant supply port (M) for the cab heater.
11 For 3208 Engines, use 7D7026 Connectors or 3K7928 Elbow Connectors, with 5P767 Hose and 5D1026 Hose Clamps to make the coolant hose connections needed, according to the procedure that follows:
1. Connect a hose from port (N) on the engine front cover, to WATER IN port (D) of the fuel heater.
NOTE: Port (N) is the only acceptable source of supply for coolant to the fuel heater. Port (N) is also the source of supply for coolant to the air compressor, on engines so equipped. If the engine has an air compressor, install a tee fitting in port (N) so coolant is available for both the air compressor and the fuel heater.
2. Connect a hose from WATER OUT port (C) to one of the ports (O) or (P) that are for coolant return from a cab heater. If it is necessary to connect the fuel heater WATER OUT return hose to the same port that is used for a cab heater coolant return port, it is permissible to install a tee connection so both coolant return hoses can use the same port.
12 For D353 Industrial Engines, connect WATER OUT port (C) of the fuel heater to port (Q). Remove the plug at location (R) and connect the WATER IN port (D) of the fuel heater to this location.
13 For D379, D398 or D399 Engines, remove 1B5174 Plug (S) from the rear support for the oil cooler. Install 520726 Tee (3) with a plug (4) in the tee as shown as a replacement for plug (S). Use the necessary connectors to install a shut off valve at port (T) of tee (3), then connect the shut-off valve to WATER IN port (D) of the fuel heater.
14 Remove the plug at port (U). Use the necessary connectors to install a shut-off valve as a replacement for the plug at location (U), then use the needed hose and connectors to connect this shut-off valve to the WATER OUT port (C) of the fuel heater.
NOTE: Plug (4) can be used as a coolant drain when necessary. The two shut-off valves make it possible to stop the flow of coolant through the fuel heater, if it is necessary to disconnect or remove the fuel heater.
15 For 3406, 3408 or 3412 Engines, connect port (V) to WATER IN port (D) of the fuel heater and connect port (W) to WATER OUT port (C) of the fuel heater.
NOTE: Within the 8N9593 Fuel Heater, there is a temperature control that will shut-off the coolant flow through the fuel heater when fuel temperature gets to approximately 94° to 102°F (34° to 39°C). For this reason, it is important that all hose connections are made correctly, so the flow of coolant through the fuel heater and the cab heater, if so equipped, is parallel.
16 Check the coolant level in the cooling system, and add coolant if necessary. Start the engine and check for coolant and fuel system leaks. Make any repairs that are necessary.
17 To decrease the possibility of filter waxing (restriction in fuel filters), when the engine is started at temperatures below 32°F (0°C), let it run at LOW IDLE speed until the coolant hoses for the heater become warm.