09600-02910 PUMP ASSY, INJECTI Denso Cross

Introduction
This Special Instruction outlines the conversion of fuel injection pump lines from tubes to steel-braided hoses. It is intended for machine equipped with one of the following Fireplow arrangements:
Table 1
Sales Model Part Number
D3K2 375-8997
375-8998
D4K2 375-8999
375-9000
D5K2 375-9001
375-9002
375-9004 Safety Section
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Accidental engine starting can cause injury or death to personnel working on the equipment.To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.
Personal injury or death may result from failure to adhere to the following procedures.Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.
Required Parts
Table 2
Required Parts
Qty Part Number Part Name
1 228-6046 Connector
1 228-7088 O-Ring Seal
1 228-7089 O-Ring Seal
2 228-7100 O-Ring Seal
1 330-3036 Gasket
1 370-8363 Pump As
1 396-0380 Coupling
1 420-1641 Fuel Line
1 485-1627 Hose As
1 485-1630 Hose As
2 5P-9085 Clip
2 6V-8455 Bolt
1 7K-1181 Cable Strap
2 8T-4121 Hard Washer
1 8T-4191 Bolt Installation
Illustration 1 g06053849
Gaining access behind the secondary filter
(1) Bolt
(2) Washer
(3) Braided hose
(4) 8T-7487 Connector
(5) Fuel tubes
(6) Clip
(24) 227-5714 Elbow
Disconnect four fuel tubes (5) from the secondary filter.
Remove braided hose (3) from the secondary filter. Remove connector (4) and save for reuse.
Remove elbow (24) and discard.
Remove two clips (6) from the tubes and discard.
Remove two bolts (1) and washers (3) that secure the filter base. Lift the filter assembly from the engine and set aside.
Illustration 2 g06053866
(7) Tube
(8) Nut
(9) Fitting
(10) Primary filter base
Remove tube (7) by loosening nut (8). Use a backup wrench on fitting (9) to apply counter-torque to keep the assembly stationary. Remove the tube.
Install the new 370-8363 Pump As and 420-1641 Fuel Line. Refer to the Disassembly and Assembly manual in the Reference Section.
Illustration 3 g06054087
Correct ferrule orientation
(11) Nut
(12) Ferrule
(13) Ferrule
Illustration 4 g06054094
(11) Nut
(12) Ferrule
(13) Ferrule
Remove the smaller hex nut (15.88 mm) (10) from the new 396-0380 Coupling along with ferrule (11) and ferrule (12). Orient the parts as shown in Illustration 3. Loosely install the parts onto the existing half of the 396-0380 Coupling on the engine. Refer to Illustration 4. Do not tighten the nut at this time.Note: Failure to orient the ferrules as shown in Illustration 3 will result in leakage and the ne