C175-16 and C175-20 Locomotive Engines Caterpillar

Removal Procedure

Start By:

1. Remove the air inlet manifold.

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This fuel system may contain high-pressure fuel for extended periods after engine shutdown. Do not open the high-pressure fuel system without first releasing the high-pressure fuel from the system. Refer to the Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" to properly release fuel pressure. Exposure to high-pressure fuel may result in personal injury.

Note: Use Tooling (D) to cap tube assemblies, fittings, ports, and any openings in the fuel system to prevent contamination.

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Illustration 1	g06205371
Typical Example

1. Loosen plug (1) one full turn, do not remove plug (1). After 30 seconds, use Cat^® Electronic Technician (Cat ET) to verify that the fuel rail pressure is below 2.0 MPa (290 psi). Refer to Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" for more information.
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   Illustration 2	g06202770

2. Remove tube assembly (2) and tube assembly (3).
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   Illustration 3	g06202890

3. Remove bolts (6) and (8), the washers, and clamps (5) and (9). Remove tube assemblies (4) and (7).

   Note: Use Tooling (A) on the tube assemblies and place the tube assemblies in a clean new resalable bag.

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   Illustration 4	g06202893

4. Remove nuts (11) and the spherical washers. Use Tooling (B) to remove accumulator (10).

   Note: Cap the bottom of the accumulator and place in a clean new resalable bag.

   Note: Cap the HP ports of the other two accumulators that are now exposed.

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   Illustration 5	g06202895

5. If required, use Tooling (E) to remove studs (12).
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   Illustration 6	g06202897

6. Remove O-ring seal (13) from accumulator (10).

7. If necessary, use Tooling (C) to remove any rust scale from the outer rim of the accumulator bore.

   Note: Surface does not have to be polished.

8. Carefully remove any remaining debris from the outer edge of the accumulator bore using a new lint-free towel moistened with brake cleaner.

9. Use Tooling (A) to plug the open accumulator bore in the cylinder head.

   Note: If replacing accumulator at either cylinder #19 or #20, ensure that a new end-plug and a new ball is available. Reuse of the end plug and ball in the accumulator is not recommended.

   Note: If removing accumulator at either cylinder #19 or #20 for inspection only, do not remove the end-plug.

Installation Procedure

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Illustration 7	g06202897

1. Lubricate O-ring seal (13) with clean engine oil.

   Note: If installing accumulator at cylinder #19 or #20, place ball and end-plug against mating cone in accumulator inlet port and hand tighten end-plug and lubricate the O-ring seal on end-plug with clean engine oil.

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   Illustration 8	g06202895

2. Install studs (12) if removed previously. Use Tooling (E) to tighten studs (12) to a torque of 55 N·m (41 lb ft).

   Note: Do not exceed 45 degrees of rotation from snug to the final torque position.

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   Illustration 9	g06202893

3. Install accumulator (10).

4. Install washers on studs (12). Install nuts (11) and hand tighten.

   Note: The spherical end of the washers must seat against the accumulator clamp.

   Note: Do not attempt to seat the accumulator by hand, damage to the accumulator tip will occur.

5. Evenly tighten nuts (11) to a torque of 35 ± 4 N·m (26 ± 3 lb ft) rotating each nut no more than 90° at a time.
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   Illustration 10	g06202890

6. Inspect the O-ring seals and sealing surfaces of tube assemblies (7) and (4). If damaged replace with new tube assemblies.

7. Lubricate the nut threads, O-ring seals, and collars of tube assemblies (7) and (4) with clean engine oil.

8. Install tube assemblies (7) and (4).

9. Install clamps (9) and (5).

10. Install bolts (8) and (6). Hand tighten bolts (8) and (6).

11. Tighten the nuts on tube assemblies (7) and (4) to a torque of 38 ± 3 N·m (28 ± 2 lb ft).

12. Tighten the nuts on tube assemblies (7) and (4) to a final torque of 100 ± 5 N·m (74 ± 4 lb ft).

13. Tighten bolts (8) and (6) to a torque of 47 ± 2 N·m (35 ± 1 lb ft).
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    Illustration 11	g06202770

14. Install tube assemblies (3) and (2).
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    Illustration 12	g06205371

15. Tighten plug (1) to a torque of 60 ± 3 N·m (44 ± 2 lb ft).

    Note: Following repairs to the high-pressure fuel system, accumulator plugs at the cylinders that were serviced should be removed and a fuel system functional test completed to confirm there is not a leak into the double wall fuel lines. Following the test, reinstall the accumulator plugs.

Note: Following repairs to the high pressure fuel system, accumulator plugs on opened cylinders should be removed. A successful completion of the "Fuel Systems Function Test (FSFT)" using CATET must be performed. Upon completion of the FSFT, accumulator plugs are to be reinstalled.

End By:

1. Install the air inlet manifold.