C4.4 Industrial Engine High Pressure Fuel Lines Caterpillar

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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.

Illustration 1	g03452057
(1) High-pressure line (2) High-pressure line (3) High-pressure line (4) High-pressure line (5) High-pressure fuel manifold (rail) (6) High-pressure supply line (7) High-pressure supply line

The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the high-pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems.

This difference is because of the following items:

• The high-pressure fuel lines are constantly charged with high pressure.

• The internal pressures of the high-pressure fuel lines are higher than other types of fuel system.

• The high-pressure fuel lines are formed to shape and then strengthened by a special process.

Do not step on the high-pressure fuel lines. Do not deflect the high-pressure fuel lines. Do not bend or strike the high-pressure fuel lines. Deformation or damage of the high-pressure fuel lines may cause a point of weakness and potential failure.

Do not check the high-pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped, allow 90 seconds to pass in order to allow the pressure to be purged before any service or repair is performed on the engine fuel lines.

Do not loosen the high-pressure fuel lines in order to remove air from the fuel system. This procedure is not required.

Visually inspect the high-pressure fuel lines before the engine is started. This inspection should be each day.

If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, "General hazard Information".

• Inspect the high-pressure fuel lines for damage, deformation, a nick, a cut, a crease, or a dent.

• Do not operate the engine with a fuel leak. If there is a leak, do not tighten the connection in order to stop the leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, "Fuel injection lines - Remove and Fuel injection lines - Install".

• If the high-pressure fuel lines are torqued correctly and the high-pressure fuel lines are leaking, the high-pressure fuel lines must be replaced.

• Ensure that all clips on the high-pressure fuel lines are in place. Do not operate the engine with clips that are damaged, missing, or loose.

• Do not attach any other item to the high-pressure fuel lines.

• Loosened high-pressure fuel lines must be replaced. Also removed high-pressure fuel lines must be replaced. Refer to Disassembly and assembly manual, " Fuel Injection Lines - Install".