JLG X20JP - X600AJ Service Manual - Manual (Page 127)

SECTION 3 - CHASSIS & TURNTABLE
3121623 – JLG Lift – 3-103
DO NOT LET THE TOPS OF FUEL INJECTORS TURN WHEN THE
FUEL LINE NUTS ARE LOOSENED OR TIGHTENED. THE FUEL
INJECTORS WILL BE DAMAGED IF THE TOP OF THE INJECTOR
TURNS IN THE BODY. THE ENGINE WILL BE DAMAGED IF A
DEFECTIVE FUEL INJECTOR IS USED BECAUSE THE SHAPE OF
FUEL (SPRAY PATTERN) THAT COMES OUT OF THE NOZZLE
WILL NOT BE CORRECT.
NOTE: The installation procedure is similar for the two cylinder,
the three cylinder and the four cylinder engines.
16. Remove the caps from fuel injectors (7). Install new
washers (6) and fuel return line (3) to fuel injectors
(7).
NOTE: The washers (6) have two small holes.
17. Install nuts (5) to fuel injectors (7).
For engines with a rigid fuel return line, install new wash-
ers (8) to fuel return line (3) and install banjo bolt (4) to the
fuel injection pump. Tighten banjo bolt (4) to a torque of 7
N·m (62 lb in).
The 402D-05, 403D-07, 403D-11 and 404D-15 engines
have a flexible fuel return hose.
For engines with a flexible fuel return hose, connect the
fuel return hose to the fuel injection pump.
18. Tighten nuts (5) to a torque of 27 N·m (20 lb ft).
19. Remove the caps from the outlet connections of the
fuel injection pump. Install the fuel injection lines to
the engine as a unit.
20. Connect fuel injection lines (2) to fuel injectors (7).
Tighten the union nuts (1) finger tight.
21. Use Tooling (A) to tighten union nuts (1) at the fuel
injection pump.
For 402D-05 and 403D-07 engines, tighten union nuts (1)
to a torque of 20 N·m (15 lb ft).
NOTE: For the three cylinder and the four cylinder engines,
tighten the center union nuts first.
22. Use Tooling (A) to tighten union nuts (1) at the fuel
injections.
For 402D-05 and 403D-07 engines, tighten union nuts (1)
to a torque of 20 N·m (15 lb ft).
23. Turn the fuel supply to the ON position.
24. Prime the fuel system. Refer to Operation and Main-
tenance Manual, “Fuel System - Prime” for more
information.