Installing a Calibration Fluid Suction Port on the Fuel Injection Equipment Test Stand{0782} Caterpillar


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Installing a Calibration Fluid Suction Port on the Fuel Injection Equipment Test Stand{0782} [NEHS0640]
FUEL SYSTEM
TOOLS
Installing a Calibration Fluid Suction Port on the Fuel Injection Equipment Test Stand{0782}
1.1. Safety
2.1. Introduction
3.1. Secondary Filter
4.2. Nomenclature
5.2. Fabricated Parts
6.2. Installation
7.3. Assemble the Fuel Filter
8.3. Mount the Fuel Filter Assembly to the Test Stand
9.1. Primary Filter
10.2. Nomenclature
11.2. Fabricated Parts
12.2. Installation
13.3. Assemble the Fuel Filter
14.3. Mount the Fuel Filter Assembly to the Test Stand

Safety

------ WARNING! ------

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injury, and possibly death. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury.

-------WARNING!-------


NOTICE

Operations that may cause product damage are identified by notice labels in this publication.


Introduction

This Tool Operating Manual contains two filter installation procedures. This first procedure is for installing a primary filter system. This is a coarse filter and will protect the transfer pump from contamination in the oil. The second procedure outlines installing a secondary filter which is designed to protect injection pumps from contaminated oil. Fuel injection pumps used on the 3208 Engine are one example of a fuel injection pump that requires the secondary filter installation.

It will be the dealer choice as to which optional filter is installed on the test stand. Determine what type of filtering will be required most often, and install the appropriate type of filtering system.

NOTE: These filters can only be added to the 15 horsepower test stands.

Secondary Filter

Nomenclature


Illustration 1. Nomenclature for Secondary Filter Installation. Refer to Chart A for item identification.

Fabricated Parts

All the parts required for this installation can be ordered from AVSpare Parts Distribution, except bracket (1). This must be manufactured by the bench owner, using the dimensions provided below.

This bracket can be made from common SAE1018 steel. Weld the two pieces together.


Illustration 2. Filter Mounting Bracket. Refer to Chart B for dimensions.

Installation

Assemble the Fuel Filter

1. Install 053-0088 Fitting (17) with 3J-1907 Seal (18) into the inlet port (left side) of the filter base. (This converts a number 6 STOP port to NPT). Install 5P-4455 Fitting (19) into fitting (17).

2. Install 2R-6806 Fitting (15) with 3J-1907 Seal (16) into the outlet port (right side) of the filter base.

3. Install 6N-4414 Cover (7) onto the filter base using 1P-0436 Gasket (8), 4B-3388/6V-2317 (9), and OS-1616/6V-8490 Bolt (10).

4. Install 9S-4182 Plug (5) with 6V-5084 O-ring Seal (6) into the top of the filter base.

5. Install the filter base assembly onto filter bracket (1), as shown in Illustration 1, using the two OS-0509 Bolts (4).

Mount the Fuel Filter Assembly to the Test Stand

Mount the suction supply filter group and bracket assembly between the cooling fan and the fuel filter group, as shown in Illustration 1.

1. Remove the two lower left-side panels from the test stand to access the calibration fluid tank, and the controls and connections area under the test stand.


Illustration 3. Remove Plug From Under Connector (22).

2. Remove plug from the underside of connector (22), and install 6V-3523 Fitting (13) with 6V-0406 Dowty Seal (14). Refer to Illustration 3 for view of completed installation.


Illustration 4. Install Hose Assembly (12).
(13) Fitting. (14) Seal. (15) Fitting. (16) O-ring seal.

3. Remove bolt (2, Illustration 1) from the top of the test stand manufacturer's oil filter/fuel filter bracket.

4. Align the mounting hole in bracket (1) and install 8T-4908 Bolt (2) (not the bolt removed from this location).

5. Install 8N-7140 Hose Assembly (12) as shown in Illustration 4.


Illustration 5. Route Suction Tubing Into Test Oil Tank.
(20) Tubing. (21) Nylon Wire Tie.

6. Install tubing (20) (fuel suction line) between the calibration fluid tank and the inlet side of the new suction line fuel filter assembly, as shown in Illustration 5.


Illustration 6. Notch Bottom Of Suction Line.

NOTE: Install the suction line in the tank so the inlet of the tubing is always below the low level shutdown mark. Also cut two small notches, as shown in Illustration 6, in the end of the tubing to prevent the line from plugging.

7. Secure tubing (20, Illustration 5) with a 068-9941 Nylon Wire Tie (21) or equivalent.

8. Install side panels on test stand.

9. Mark the port on top of the test stand "SUCTION SUPPLY", as shown in Illustration 3.

Primary Filter

Nomenclature


Illustration 7. Nomenclature for Primary Filter Installation. Refer to Chart C for item identification.

Fabricated Parts

All the parts required for this installation can be ordered from AVSpare Parts Distribution, except bracket (1). This must be manufactured by the bench owner, using the dimensions provided below.

This bracket can be made from common SAE1018 steel. Weld the two pieces together.


Illustration 8. Filter Mounting Bracket. Refer to Chart D for dimensions.

Installation

Assemble the Fuel Filter

1. Install 5P-4455 Fitting (10) into the inlet port (left-side) and 8L-3282 Fitting (8) into the outlet port (right-side) of 8H-7204 Filter Group (3).

2. Install the filter group onto filter bracket (1), as shown, using two OS-0509 Bolts (2).

Mount the Fuel Filter Assembly to the Test Stand

Mount the suction supply filter group and bracket assembly between the cooling fan and the fuel filter group, as shown in Illustration 7.

1. Remove the two lower left side panels from the test stand to access the calibration fluid tank, and the controls and connections under the test stand.


Illustration 9. Remove Plug From Under Connector (12).

2. Remove plug from the underside of connector (12, Illustration 9), and install a 6V-3523 Fitting (6) with 6V-0406 Dowty Seal (7), as shown in Illustration 10.

3. Remove the bolt (location 2, Illustration 7) from the top of the bench manufacturer's oil filter/fuel filter bracket.

4. Align the mounting hole in bracket (1) and install 8T-4908 Bolt (2) (not the bolt removed from this location).


Illustration 10. Install Hose Assembly (5).
(5) Hose assembly. (6) Fitting. (7) Seal. (8) Fitting.

5. Install 8N-7140 Hose Assembly (5,) as shown in Illustration 10.

6. Install tubing (9) (fuel suction line) between the calibration fluid tank and the inlet side of the new suction line fuel filter assembly.


Illustration 11. Notch Bottom Of Suction Line (9).

NOTE: Install the suction line in the tank so the inlet of the tubing is always below the low level shutdown mark. Also cut two small notches in the end of the tubing to prevent plugging of the line, as shown in Illustration 11.


Illustration 12. Route Suction Tubing Into Test Oil Tank.
(9) Tubing. (11) Nylon wire tie.

7. Secure tubing (9) with a 068-9941 Nylon Wire Tie (11), or equivalent.

8. Install panels on test stand.

9. Mark the port "SUCTION SUPPLY", as shown in Illustration 9.

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