SHAFT 1787302 - Caterpillar

Image1.4.1
Crank the engine with the starter motor for 30 seconds.
Record the amount of fuel that has been collected from the leak off connector on the cylinder head which is now in the container.
Repeat the test a total of 3 times.
If the average fuel volume for the 3 leak off measurement readings are >50ml/30 seconds then the following fuel system components will also be required to be changed:
6 x Injectors
6 x High-pressure pipes (from fuel rail to injector)
6 x Injector clamp bolt(278-5170)
6 x Top cover sleeve(277-5067)
If the average fuel volume for the 3 leak off measurement readings are
The leak off pipe (1) should be re-connected to the cylinder head and the three wiring harness plugs (10) should be reconnected.
SYSTEM DIAGRAM OF LOW PRESSURE FUEL SYSTEM.
Image1.5.1
SYSTEM FITTING
The field re-fit kit contains:
2 X Secondary 4m fuel filter assembly.
Fuel filter bracket.
Nylon and steel fuel pipe (Leak off / Fuel return).
Steel fuel pipe (Secondary fuel filter to HP fuel pump inlet).
2 X Flexible fuel hose (Supplied by OEM)
1 X 277-6165 connector.
The below notes describe the fitting process required for fitting the rework kit (this assumes the machine is already fitted with an existing two filter Low Pressure fuel system with V0201 configuration).
Removal Of Existing Components:
Remove low pressure fuel pipes: A, B, and C Steel or plastic pipe. Remove pipe-to-pipe clamps indicated in Image 1.6.1. For Pipe A, B, and C quick connectors, depress the release button and pull pipe off the spigot. Immediately cap the spigot with a new clean cap. For steel version of pipe C with compression fittings, completely undo the nut nearest the spigot and remove the pipe assembly. Immediately cap the pump spigot with a new clean cap. Leave nut and olives in place.
Image1.6.1
Undo and remove bolts to remove filter assembly and bracket indicated in Image 1.7.1
Image1.7.1
Fitting of the new Fuel Filter Bracket
Image1.8.1
Assemble fuel filter bracket Pt. No. 311-1666 onto induction cover (see Image 1.8.1) use 2 M8 flange head bolts Pt. No. 6I-0260 tighten to a torque of 22 Nm +/- 5.5 Nm.
Ensure filter assembly has hole as shown in Image 1.9.1. The ID mark identifies the filter head has a long spigot to seal against the O-ring of the new filter.
New filter assembly:
Image1.9.1
Image1.9.2
Assemble fuel filter assembly 308-7480 onto filter bracket (see Image 1.9.2) use 2 M10 flange head bolts 6I-0593 tighten to a torque of 55 Nm +/- 10 Nm.
Leak Off Pipe Assembly:
Assemble leak off pipe, 311-1175 in the position shown in Image 1.10.1. Connect quick connector to fuel pump leak off spigot A, Connect quick connector to filter bleed spigot B, Assemble steel injector leak off pipe C,using fitting 277-6165.
Put the nut then the olive onto the pipe end, push the pipe fully into the fitting and tighten by hand.
If the original fitting in the fuel rail is damaged - then replace it, otherwise just use the nut and olive from the new connector.
Press pipe into the pipe clamps indicated.
Image1.10.1
Steel Pipe Assembly:
Care must be taken to ensure part cleanliness, assemble immediately after removing protective caps.
Assemble steel