101602-9600 ZEXEL 9 400 610 092 BOSCH INJECTION-PUMP ASSEMBLY 9400610092 1016029600 16713z5609

Problem
The fuel lines on certain D9N Tractors, 589 Pipelayers, 631E Tractors, 637E Tractors, 657E Scrapers, 768C Tractors, 769C Trucks, 834B Tractors, and 988B Loaders may fail. New fuel line groups can be installed that have a longer service life.
Affected Product
Model & Identification Number
Group 1
D9N (1JD1288, 1JD1295, 1JD1296, 1JD1298-3280)
589 (31Z423-469)
631E (1AB965-1456; 1NB769-771)
637E TR (1FB361-537; 1JB612-724)
657E SC (90Z186-209; 91Z317-448)
768C (02X360-370)
769C (01X4394, 01X4403, 01X4418, 01X4420-5960)
Group 2
988B (50W08961, 50W8962, 50W8964-11257)
Group 3
834B (92Z368, 92Z370, 92Z373-512)
Parts Needed
Group 1
4 - 4B4274 Washer2 - 7C6525 Fuel Line Clamp2 - 7C6589 Fuel Line Clamp1 - 6I0030 Lines Group6 - 5M2894 Washer4 - 9N3388 Screw6 - 0S0509 BoltGroup 2
4 - 4B4274 Washer2 - 7C6525 Fuel Line Clamp2 - 7C6589 Fuel Line Clamp1 - 6I0030 Lines Group11 - 5M2894 Washer4 - 9N3388 Screw1 - 4P8261 Bracket1 - 4P8385 Bracket2 - 5P0537 Washer5 - 0S1571 Bolt6 - 0S0509 Bolt2 - 0S1615 Bolt3 - 8T1296 Washer1 - 1010462 RodGroup 3
4 - 4B4274 Washer2 - 7C6525 Fuel Line Clamp2 - 7C6589 Fuel Line Clamp1 - 1029884 Lines Group4 - 9N3388 Screw5 - 5M2894 Washer4 - 0S0509 Bolt1 - 0S1594 BoltAction Required
Parts Stock
Remove all 7C6931, 7C6932, 7C6933, 7C6934, 7C6935, 7C6936, 7C6937, and 7C6938 Fuel Lines from parts stock.
Affected Product
Remove the existing fuel lines and install the new fuel injection line group as a group. Do not disassemble the fuel line groups and install them one line at a time. See the attached (pending) procedure.
Do not over tighten the screws of the metal-to- metal fuel line clamps. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screw to a torque of 2.25 N m (20 lb.in.).
Service Claim Allowances
Parts Stock
Submit one claim for all 7C6931, 7C6932, 7C6933, 7C6934, 7C6935, 7C6936, 7C6937, and 7C6938 Fuel Lines removed from parts stock.
Affected Product
This is a 3-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the parts list and illustrations. Replace the existing fuel lines and their related parts with the new parts listed for each group.
To insure that the clamp locations are correct, install fuel line group as assembled. In a case where it is necessary to remove the clamps, mark their locations to insure correct positions when assembling.
1. Clean and paint the new 6I0030 or 102-9884 Fuel Line Group before proceeding to the job site.A) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the lines.B) Clean and paint the fuel line group.C) After drying, do not remove the plastic plugs and caps until the fuel line group is ready to be installed on the engine. Transport the fuel line group in it's original shipping box.2. Remove all mounting bolts from the fuel line brackets at the aftercooler housing. New mounting bolts and washers will be used. Keep the washers. The washers may be needed later as spacers.3. Remove the existing three line clamps from the 9Y4577 Bracket which is attached to the backside of the fuel injection pump (See Illustration 1). New 7C6525 Clamps, 7C6589 Clamps, 9N3388 Screws, and 4B4274 Washers