C32 Fuel System Service Manual

Service Repair Manual
Models
C32 Locomotive Engine

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Product: INDUSTRIAL ENGINE
Model: C32 INDUSTRIAL ENGINE BT4
Configuration: C32 Industrial Engine BT400001-UP
Disassembly and Assembly
C27 and C32 Industrial Engines
Media Number -KENR8167-05 Publication Date -01/08/2015 Date Updated -30/04/2018
i04130649
Fuel Priming Pump - Remove and Install
SMCS - 1258-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench Assembly 1
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
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1. Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
2. Remove the fuel filter. Refer to Operation and Maintenance Manual, "Fuel System Primary
Filter/Water Separator - Drain".
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2019/11/3https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...

Illustration 1 g02330633
3. Disconnect the fuel line (1) to the ARD manifold from both ends.
4. Disconnect the solenoid harness (4).
5. Use Tooling (A) to remove bowl assembly (6).
6. Use Tooling (A) to remove fuel filter (5).
7. Remove bolts (3) and remove fuel pump assembly (2).
8. Remove plugs (11), O-Ring seals (10), springs (9), check valves (8), and seals (7)
Installation Procedure
1. Install the fuel pump assembly (2) in the reverse order.
a. Tighten plug (11) to a torque of 95 ± 10 N·m (70 ± 7 lb ft)
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Sun Nov 3 12:15:31 UTC+0800 2019
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i04046634
Fuel Filter Base - Remove and Install
SMCS - 1262-010
Removal Procedure
Table 1
Required Tools
A 185-3630 Strap Wrench 1
1. Turn the fuel supply to the OFF position.
2. Disconnect harness assemblies (4) and disconnect hose assemblies (5).
3. Use Tooling (A) to remove fuel filters (1) from fuel filter base (2).
4. Remove bolts (3) and remove the fuel filter base (2).
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5. Remove fuel temperature sensor (6).
6. Remove fuel filter by-pass pressure switch (7) and remove fuel pressure sensor (8) from the
fuel filter base (2).
1. Install fuel filter base (2) in the reverse order.
a. Tighten fuel pressure sensor (8) to a torque of 10 ± 2 N·m (89 ± 18 lb in).
b. Tighten fuel temperature sensor (6) to a torque of 20 ± 3 N·m (177 ± 27 lb in).
c. Use Tooling (A) in order to tighten fuel filters (1) to a torque of 74 ± 7 N·m
(55 ± 5 lb ft).
Sun Nov 3 12:16:27 UTC+0800 2019
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i05768549
Fuel Lines - Remove and Install
SMCS - 1250-010; 1252-010; 1274-010
Remove Nonmetallic Fuel Lines
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
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
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1. Mark fuel lines (1) for reinstallation purposes. Remove fuel lines (1) .
2. If any hoses are worn or damaged, replace with new parts.
ReferenceRefer to the Operation and Maintenance Manual for information on when to replace the
fuel lines.
Install Nonmetallic Fuel Lines
Note: During installation, ensure that the hoses do not contact nearby parts. Pressure pulsations in
these hoses cause the hoses to flex. Inadvertent contact with nearby surfaces will produce
chafing/abrasion damage that could eventually lead to a leak. A properly installed hose will contact
only the hose clips.
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Rear Left Side View - Hose Length = 475 mm (18.7 inch)
Rear Right Side View - Hose Length = 620 mm (24.4 inch)
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Front Left Side View - Hose Length = 581 mm (22.9 inch)
Front Right Side View - Hose Length = 581 mm (22.9 inch)
1. Install fuel lines (1) .
2. Loosely install clips (2) . Position fuel lines (1) so that there is no contact with any other surfaces.
Tighten clips (2) . Tighten fuel lines using standard torque.
Best Practices for Installing Nonmetallic Fuel Lines
Use the following best practices for proper fuel line installation and maintenance.
1. Do not twist the hose when installing, allow the hose to find the natural position.
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(1) Torque wrench
(2) Back-up wrench
2. When torquing hose fittings, use a back-up wrench to prevent twisting as in Illustration 6.
3. Use the proper length of hose to prevent the hose being too tight or slack.
4. Keep the bending radius of the hose as large as possible to prevent kinking.
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5. Ensure proper alignment of the grommets when installed in the fuel line clips as shown in Illustration
8. Proper alignment of the opening of the grommet with the mating faces of the clips ensures proper
clamp load.
6. Clips should support the natural position of the fuel line and guide routing as in Illustration 9. Clips
should not create strain on the fuel hoses.
7. Use the proper torque to all line fasteners and connectors.
8. Recheck all fuel lines after completing installation to look for contact with surrounding components.
Fuel lines should only be in contact with rubber grommets and at the termination points.
Note: All third-party installations must meet prescribed installation guidelines. Third-party
components must not come in contact with Caterpillar components.
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9. Inspect fuel lines, grommets, and mounting hardware every 500 hours. Refer to the Operation and
Maintenance Manual maintenance schedule for replacement intervals of fuel system lines and
components.
Note: Certain components such as the side covers will need to be removed to conduct a proper
inspection of fuel lines and components.
The following illustrations below show proper line, clip, and grommet alignment to allow for sufficient
clearance from other components. Proper alignment creates gentle bends that guide fuel lines to the
termination points.
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Sun Nov 3 12:17:22 UTC+0800 2019
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i04047448
Fuel Transfer Pump - Remove and Install
SMCS - 1256-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Turn the fuel supply to the Off position.
2. Remove two nuts and remove bracket assembly (1).
3. Remove clamp assembly (3) and position tube assembly (2) out of the way.
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4. Disconnect fitting (8). Loosen clamp assembly (4) and remove tube assembly (5).
5. Remove clamp assembly (6). Disconnect hose assembly (7) and position the hose assembly
out of the way.
6. Remove bolts (9) and remove the fuel transfer pump (10). Remove the O-ring seal from the
fuel transfer pump (not shown).
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Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
7. Remove plug (11) and remove the spring (12) (not shown). Remove the O-ring seal that is
located on plug (11).
1. Install the fuel transfer pump (10) in the reverse order.
a. Tighten clamp assembly (3) to a torque of 8.5 ± 2 N·m (75 ± 18 lb in).
Sun Nov 3 12:18:18 UTC+0800 2019
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i04047485
Fuel Pressure Regulator - Remove and Install
SMCS - 1715-010
Removal Procedure
Start By:
a. Remove the Exhaust Sensor Lines.
1. Turn the fuel supply to the Off position.
View from above the engine looking down onto the fuel pressure regulator. The fuel pressure regulator is
mounted to the left side inlet manifold.
2. Remove clamp assembly (1) and remove tube assembly (3).
3. Disconnect hose assemblies (2), (4), and (5).
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4. Remove bolts (7) and remove the fuel pressure regulator (6).
5. Remove check valves (8) from manifold (6).
6. Remove O-ring seal (10) from check valve (9). Remove backup ring (11) and O-ring seal
(12) from check valve (9). Repeat this step for the other check valve.
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1. Install the fuel pressure regulator (6) in the reverse order.
a. Tighten check valves (8) to a torque of 28 ± 3 N·m (21 ± 2 lb ft).
Sun Nov 3 12:19:14 UTC+0800 2019
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i04036318
Exhaust Cooler (NRS) - Remove and Install
SMCS - 1087; 108C-010
Removal Procedure
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
2. Disconnect tube assembly (4).
3. Remove clamp assembly (1).
Note: Clamp assembly (3) is a one time use part. Discard the clamp assembly if the clamp is
loosened.
4. Remove clamp assembly (3) and position the tube assembly out of the way. Discard clamp
assembly (3).
5. Remove bolts (2) and remove the tube assembly.
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Note: Clamp assembly (5) is a one time use part. Discard the clamp assembly if the clamp is
loosened.
6. Remove clamp assembly (5) and discard the clamp assembly.
7. Remove clamp assembly (6).
8. Remove bolts (8) and remove tube assembly (7).
9. Remove 4 bolts (10) and remove exhaust cooler (9). The exhaust cooler weighs
approximately 16 kg (35 lb).
10. Repeat 1 through 9 for the opposite side.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary
1. Install exhaust cooler (9) in the reverse order.
a. Tighten clamp assemblies (5) and (3) to a torque of 7.5 ± 1 N·m (66 ± 9 lb in).
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b. Lubricate the O-ring seals that are found on tube assemblies (7) and (2) with the
lubricant that is being sealed.
Sun Nov 3 12:20:10 UTC+0800 2019
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i04146269
Electronic Unit Injector - Remove
SMCS - 1290-011
Removal Procedure
Table 1
Required Tools
A 5F-4764 Pry Bar 1
Start By:
A. Remove the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly,
"Rocker Arm and Shaft - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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