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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
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Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. |
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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, PERJ1017, "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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Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information. |
To service the common rail fuel system, the fuel that is under high pressure must be released. Depending on conditions, the fuel system may hold high rail pressure for potentially up to several hours or even days.
To release the pressure in the fuel rail, use the following steps:
- Loosen the fuel rail end plug on one of the last two accumulators on the rail by one full turn using hand tools only. Once the fuel rail end plug is loosened by one full turn, the fuel pressure will drop. The high-pressure fuel will escape into the double wall fuel line and return to the high-pressure fuel junction block, relieving the pressure in the system. Refer to Illustration 1.
- Verify the "Fuel Rail Pressure" in Cat® Electronic Technician (ET) is between
0 MPa (0 psi) to8 MPa (1160 psi) . - After the pressure has been released, the fuel rail end plug should be retightened to
60 N·m (44 lb ft) . - Following repairs made to the high-pressure fuel system, remove the accumulator plugs at the repair site. Perform a "Fuel System Functional Test" in Cat ET. Reinstall the accumulator plugs after completion of the test.
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| Illustration 1 | g06230526 |
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Fuel Rail End Plug Locations | |