854137 Volvo.Penta Sign

Table 1
Item Qty New Part Number Part Name
1 24 494-6542 Washers
2 24 494-7086 Studs Safety Section
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines.Dispose of all fluids according to local regulations and mandates.
Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.
3500 Common Rail High-Pressure Rail - Safety Procedure
Do not loosen any high pressure fuel lines when the engine is running. The high pressure in the fuel lines can cause personal injury or death. Wait 60 seconds after the engine has stopped to allow pressure to purge before any service or repair is performed on the engine fuel lines.
Before servicing the common rail fuel system on 3500 Tier 4 Final Engines, fuel that is under high pressure must be vented.Note: Fuel will vent into the double wall system when performing this process and remain there. Fuel purge from this system is not required.
Illustration 1 g06028905
(1) End plug
Slowly loosen end plug (1) in the last high-pressure accumulator on either side of the engine. Make one full turn and wait for 30 seconds.
Verify that the fuel rail pressure is below 2 MPa (290 psi) using Cat® Electronic Technician (ET) or CANape prior to performing any fuel system service.
Perform the required fuel system service.
Upon completion of the service, retighten the end plug to 60 3 N m (44 2 lb ft). Failure to tighten the end plug will cause the fuel system to perform incorrectly.3500 High-Pressure Common Rail - Cleanliness
Follow the suggestions below to prevent contamination of the fuel system and related components during the removal and installation procedure.
Cap and/or plug the high-pressure fuel lines, junction block, and accumulator ports using 9U-7078 Tapered Cap/Plug.
During service, immediately cap and/or plug all openings.
Store parts in sealed, clean bags until the part is ready for installation.
Do not remove caps and/or plugs until parts ready for installation on the engine.High-Pressure Fuel System Components
Illustration 2 g06028998
(1) Accumulator lines
(2) Fuel line clamps
(3) Cross-over fuel lines and unions
(4) High-pressure pump fuel line
(5) Junction block
(6) Junction block to accumulator quill high-pressure fuel line
(7) High-pressure accumulator
(8) Fuel injector3500 Common Rail Fuel Flow Path
Illustration 3 g06029242
Fuel flows from the high-pressure fuel pump to the junction block.
Fuel flow is distributed to each cylinder bank through high-pressure fuel lines.
Fuel is delivered to fuel injectors through the high-pressure fuel lines and accumulators.High-Pressure Accumulator Removal and Installation
Prior to removal of any high-pressure components, ensure that the proper caps are available to protect the component sealing surfaces to prevent intrusion of debris. Prior to installation of new components, verify that the components were shipped properly with all the openings capped and sealed. Do not remove the caps from the components until the parts are ready for installation. Whenever servicing and/or replacing parts, use caps to protect the components.The high-pressure components connecting the high-pressure fuel pump to the injectors are reusable if care is taken to protect the sealing surfaces. Carefully inspect joints during assembly to ensure that foreign material is not present in the joints. The modular high-pressure accumulators and quills that connect to the injectors are also reusable.Note: Use proper protective caps and/or plugs to cap fuel lines, fittings, ports, and any openings on the fuel system to prevent contamination. Use clean latex gloves when handling cleaned components.Removal
Prior to loosening any high-pressure joints, use compressed air to remove any external debris from around the accumulator tube bore in the cylinder head.
Mark the high-pressure lines and accumulators with the parts location, so that the parts can be reinstalled at the same location.
Remove the high-pressure line clamp bolts and line clamps from the high-pressure lines connected to the accumulators.Note: Line clamps may need to be removed from the end of the high-pressure crossover line to allow the accumulator removal at cylinder #1. Removing the crossover line is not necessary.
Break open the joints between the accumulator lines and the accumulators.
Follow the steps below to ensure that the high-pressure fuel system does not become contaminated.