New Secondary Fuel Filter{1261} Caterpillar

Engine:

C6.6 (S/N: 666211-211,234-236,247-247,264-264,286-286,306-306,323-323,349-350,354-354,372-373,377-377,384-384,387-387,390-392,397-402,406-407,410-410,415-415,417-417,419-419,421-422,425-429,440-441,460-460,462-464,467-467,472-472,474-477,479-484,528-529,532-532,543-543,551-552,554-554,556-557,560-564,568-568,570-573,575-575,578-578,583-584,586-587,590-590,593-594,597-597,599-599,601-601,603-607,609-609,611-611,613-614,635-635,638-639,643-644,647-647,649-649,676-677,679-682,684-685,687-688,691-692,697-697,699-701,703-703,705-705,707-710,716-716,718-718,749-749,814-816,818-819,825-828,845-846,848-851,853-855,857-857,860-860,862-862,870-875,878-879,881-882,899-900,904-909,911-913,922-922,938-944,962-962,965-965,968-968,971-975,977-977,979-980,982-982,984-984,986-986,1041-1044,1111-1113,1131-1131,1133-1135,1138-1139,1141-1145,1179-1182,1266-1266,1282-1282,1290-1290,1292-1292,1315-1315,1328-1328,1339-1339,1354-1354,1357-1359,1377-1378,1381-1388,1403-1403,1419-1421,1423-1423,1425-1429,1432-1432,1438-1439,1441-1442,1445-1445,1447-1448,1450-1452,1474-1479,1482-1482,1484-1484,1486-1487,1494-1494,1496-1499,1501-1503,1506-1509,1512-1517,1519-1521,1534-1534,1536-1537,1541-1549,1551-1555,1557-1562,1565-1566,1568-1569,1571-1572,1574-1575,1578-1579,1582-1587,1589-1589,1592-1595,1597-1598,1601-1601,1603-1605,1608-1608,1614-1615,1618-1620,1622-1627,1629-1630,1632-1632,1634-1638,1640-1640,1642-1647,1649-1658,1696-1696,1699-1711,1714-1714,1716-1728,1733-1735,1737-1737,1739-1741,1743-1743,1745-1745,1748-1749,1757-1757,1763-1772,1774-1774,1777-1778,1781-1782,1784-1792,1794-1796,1799-1801,1804-1804,1806-1806,1809-1809,1812-1814,1816-1818,1820-1821,1823-1823,1826-1827,1829-1831,1833-1834,1836-1836,1838-1840,1842-1845,1847-1849,1853-1853,1855-1860,1862-1864,1866-1867,1882-1887,1905-1906,1909-1910,1912-1915,1917-1919,1921-1925,1927-1927,1929-1929,1931-1931,1933-1936,1939-1946,1949-1951,1954-1954,1956-1957,1959-1961,1964-1965,1967-1969,1971-1971,1973-1976,1983-1984,1986-1987,1989-1989,1991-1994,1996-1997,2000-2000,2005-2007,2009-2010,2089-2091,2094-2096,2098-2098,2102-2102,2137-2137,2181-2192,2260-2260,2262-2262,2289-2290,2296-2298,2300-2300,2303-2304,2307-2307,2313-2313,2336-2338,2352-2352,2362-2362,2364-2365,2368-2370,2389-2391,2394-2397,2399-2407,2421-2423,2425-2426,2428-2428,2432-2436,2437-2438,2442-2442,2456-2457,2459-2464,2466-2467,2488-2488,2495-2606,2648-2648,2662-2663,2665-2666,2670-2670,2680-2680,2875-2875,2879-2879,2881-2881,2883-2884,2922-2926,2990-2990,2994-2996,3085-3086,3091-3093,3095-3104,3106-3107,3109-3109,3112-3112,3157-3157,3159-3159,3162-3166,3177-3177,3179-3179,3213-3224,3377-3377,3405-3405,3426-3427,3431-3431,3433-3433,3436-3436,3439-3439,3445-3445,3450-3450,3453-3453,3458-3458,3539-3539,3542-3543,3549-3551,3553-3553,3557-3563,3565-3566,3600-3600,3608-3611,3613-3614,3616-3619)

Introduction

There have been isolated instances of issues with accelerated wear on the electronic unit injectors. This Special Instruction, "New Secondary Fuel Filter" will prevent the issue.

Refer to Special Instruction, KENR6938, "High Leakoff of the Electronic Unit Injector" to determine the condition of the electronic unit injectors. After the Special Instruction, KENR6938, "High Leakoff of the Electronic Unit Injector" has been completed, carry out this Special Instruction, "New Secondary Fuel Filter".

Required Parts

Removal Procedure

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Illustration 1	g01613075
Typical example

1. Remove tube assemblies (1), (2) and (3) from the engine.

2. Remove the old secondary fuel filter canister. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.

3. Remove the existing secondary fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install (Secondary Fuel Filter)" for the correct procedure.

4. Remove the secondary fuel filter base mounting bracket from the inlet manifold. Discard the mounting bracket.

Installation Procedure

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Illustration 2	g01613193
Typical example

1. Install two setscrews (4) to new mounting bracket (2). Install the mounting bracket assembly to the inlet manifold. Tighten the setscrews (4) to a torque of 22 N·m (16 lb ft).

2. Install two setscrews (3) to new secondary fuel filter assembly (1) .

   Note: The new secondary fuel filter base will have a identification mark on the top of the secondary fuel filter base (A). The identification mark is a hole that has a depth of 3 mm (0.1181 inch).

3. Install new secondary fuel filter assembly (1) to new mounting bracket (2). Tighten setscrews (3) to a torque of 55 N·m (41 lb ft).

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Illustration 3	g01613217
Typical example

4. Install tube assembly (5) .

5. Install the steel section of the injector leak off pipe assembly (6) to the pressure relief valve.

6. Install the nut to the end of the injector leak off pipe. Install the olive to the end of the injector leak off pipe. Push the end of the injector leak off pipe into the connection. Tighten the nut finger tight.

7. Ensure that the connection does not move. Using a suitable tool, tighten the nut to a torque of 26 N·m (19 lb ft) for a steel connection or 21 N·m (15 lb ft) for a brass connection.

8. Press tube assembly (5) into the correct clip.

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Illustration 4	g01613219
Typical example

9. Install tube assembly (7) to the inlet connection of the fuel injection pump and the outlet connection of the secondary fuel filter base. Tighten the nuts to a torque of 26 N·m (19 lb ft) for a steel connection or 21 N·m (15 lb ft) for a brass connection.

   Note: If a compression fitting has been assembled to a connection, tighten the nut until a sharp rise in torque is felt, then tighten the nut an additional one third of a turn.

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Illustration 5	g01613220
Typical example

10. Install tube assembly (8). Install one end of tube assembly (8) to the ECM connection and install the other end of tube assembly (8) to the inlet connection of the secondary fuel filter base. Install two pipe clips. Clip tube assembly (8) onto the bracket.

11. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System Prime".

12. Run the engine. Check the fuel system for leaks.