6/14/2019 C7.

1 XQ200 Generator Set MRP00001-UP(SEBP5586 - 17) - Documentation

Shutdown SIS

Previous Screen

Product: GENER ATO R SET

Mode l: C 7.1 GENER ATO R SET MR P
C onfiguration: C 7.1 XQ 200 Ge ne rator Se t MR P00001-UP

Disassembly and Assembly

C7.1 Generator Set
Media Number -UENR0656-00 Publication Date -01/05/2012 Date Updated -31/05/2012

i04401374

Fuel Manifold (ARD) - Remove and Install - Pilot Solenoid Only

SMCS - 1702-010

Removal Procedure
Table 1
Required Tools

Tool Part Number Part Description Qty

A 370-8376 Cap Kit 1

NOTICE
Ensure that all adjustments and repairs that are carried out to the fuel
system are performed by authorised personnel that have the correct
training.

Before begining ANY work on the fuel system, refer to Operation and
Maintenance Manual, "General Hazard Information and High Pressure
Fuel Lines" for safety information.

Refer to Systems Operation, Testing and Adjusting Manual,

"Cleanliness of Fuel System Components" for detailed information on
the standards of cleanliness that must be observed during ALL work on
the fuel system.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid with suitable containers

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before opening any compartment or disassembling any component

containing fluids.

Dispose of all fluids according to local regulations and mandates.

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF position.

3. Cleanliness is an important factor. Thoroughly clean the exterior of the component before commencing the
disassembly procedure. Thoroughly cleaning the exterior of the component will help to prevent dirt from entering
the internal mechanism.

Illustration 1 g02157019

4. Slide locking tab (3) into the unlocked position on connection for harness assembly (1) .

5. Disconnect harness assembly (1) from fuel pressure sensors (2) .

6. Slide locking tab on connection for harness assembly (4) into the unlocked position.

7. Disconnect harness assembly (4) for solenoid (5) .

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8. Disconnect hose assembly (8) from the fuel control manifold. Use Tooling (A) in order to plug the hose assembly
with a new plug. Use Tooling (A) in order to cap the connection with a new plug.

9. Remove O-ring seal (9) (not shown) from the connection on the fuel control manifold. Cap the open connection
on the fuel control manifold with a new cap.

10. Disconnect hose assembly (7) from the fuel control manifold. Plug the hose assembly with new plugs.

11. Remove O-ring seal (6) (not shown) from the connection on the fuel control manifold. Cap the open connection
on the fuel control manifold with a new cap.

12. Cut cable strap (10) and cable strap (11) for the harness assemblies.

Illustration 2 g02157394

13. Remove bolts (12) from fuel control manifold (14) .

Note: Support the fuel control manifold on removal of the bolts.

14. Remove bracket (13) and bracket (15) .

Note: Note position and orientation of bracket for installation purposes.

15. Remove fuel control manifold (14) from the bracket for the clean emission module.

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Illustration 3 g02157021

16. If necessary, follow Step 16.a through Step 16.g in order to disassemble fuel control manifold (14) .

a. Use a deep socket in order to remove fuel pressure sensor (2) from fuel control manifold (14). Remove O-
ring seal (20). Cap the fuel pressure sensor with a new cap. Plug the open port on the fuel control manifold
with a new plug.

b. Remove nut (16) from the valve assembly and remove solenoid (5). Use a deep socket in order to remove
valve assembly (17) from fuel control manifold (14). Plug the open port on the fuel control manifold with a
new plug.

c. Remove O-ring seal (18) and O-ring seal (19). Cap the valve assembly with a new cap.

d. Remove connection (21) from fuel control manifold (14). Plug all open ports on the fuel control manifold
with new plugs.

e. Remove O-ring seal (22) and cap connection (21) with new caps.

f. Remove connection (24) from fuel control manifold (14). Cap connection (24) with a new cap.

g. Remove O-ring seal (23) from fuel control manifold (14). Plug the open port on the fuel control manifold
with a new plug.

Installation Procedure
1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that
are worn or damaged.

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Illustration 4 g02157021

2. If necessary, follow Step 2.a through Step 2.f in order to assemble fuel control manifold (14) .

a. Remove the cap from connection (21). Install a new O-ring seal (22) to connection (21). Remove the plug
from the fuel control manifold. Install connection (21) to fuel control manifold (14). Tighten the connection
to a torque of 43 N·m (32 lb ft).

b. Remove plugs from fuel control manifold (14). Install new O-ring seal (23) to fuel control manifold (14) .

c. Remove the cap from connection (24). Install connection (24) to fuel control manifold (14). Tighten
connection (24) to a torque of 43 N·m (32 lb ft).

d. Remove the cap from valve assembly (17). Install new O-ring seals (18) and O-ring seals (19) to valve
assembly (17). Remove plug from the fuel control manifold. Use a deep socket in order to install valve
assembly (17) to fuel control manifold (14). Tighten the valve assembly to a torque of 50 N·m (37 lb ft).

e. Install solenoid (5) to valve assembly (17). Install nut (16 ). Tighten the nut to a torque of 20 N·m (177 lb
in).

f. Remove the cap from fuel pressure sensor (2). Install a new O-ring seal (20) to fuel pressure sensor (2).
Remove plugs from fuel control manifold (14). Use a deep socket to install the fuel pressure sensor to the
fuel manifold. Tighten the fuel pressure sensor to a torque of 20 N·m (177 lb in).

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Illustration 5 g02157394

3. Position bracket (13) and bracket (15) onto fuel control manifold (14). Install bolts (12) to fuel control manifold
(14) .

Note: Ensure the correct position and orientation of the brackets.

4. Position fuel control manifold (14) onto the bracket for the clean emission module. Tighten bolts (12) to a torque
of 55 N·m (41 lb ft).

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Illustration 6 g02157019

5. Remove caps from hose assembly (8). Flush hose assembly (8). Ensure that the hose assembly is clean and free
from restriction.

6. Remove caps from the connection for hose assembly (8). Install new O-ring seal (9) (not shown) to the
connections on fuel control manifold (14) .

7. Connect hose assembly (8) to fuel control manifold (14). Securely tighten hose assembly (8) .

8. Remove the cap from the connection for hose assembly (7). Install a new O-ring seal (6) (not shown).

9. Remove the plug from hose assembly (7) and flush the hose assembly. Ensure that the hose assembly is clean and
free from restriction. Connect hose assembly (7) to the fuel control manifold. Securely tighten hose assembly (7) .

10. Connect harness assembly (1) to fuel pressure sensors (2). Slide locking tab (3) for harness assembly (1) into the
locked position.

11. Connect harness assembly (4) for solenoid (5). Slide locking tab for harness assembly (4) into the locked
position.

12. Install new cable strap (10) and new cable strap (11) to the harness assemblies.

Note: Ensure that cable straps meet the OEM specification.

13. Turn the fuel supply to the ON position.

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14. Turn the battery disconnect switch to the ON position.

C opyright 1993 - 2019 C ate rpillar Inc.

Fri Jun 14 2019 07:11:20 GMT+0400 (Gulf Standard Tim e )
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