02 09-14

1 0209-14
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Service Information Bulletin
SUBJECT DATE
High Pressure Fuel Rail Feed Lines - Two-Filter System February 2014

Additions, Revisions, or Updates

Publication Number / Title | Platform Section Title Change

Description and
Operation of the High
Pressure Fuel Rail Feed
Lines and Related Parts
- Two-Filter System

Removal of the High
Pressure Fuel Rail Feed
Lines - Two-Filter
DDC-SVC-MAN-0082 DD Platform System Updating procedures due to new permanent dampers on lines.
Inspection of the High
Pressure Fuel Rail Feed
Lines - Two-Filter
System
Installation of the High
Pressure Fuel Rail Feed
Lines - Two-Filter
System

tS) DETROIT

DEMAND PERFORMANCE”

13400 Outer Drive, West, Detroit, Michigan 48239-4001
Telephone: 313-592-5000
www.demanddetroit.com

All information subject to change without notice. 3
0209-14 Copyright © 2014 DETROIT DIESEL CORPORATION

2 Description and Operation of the High Pressure Fuel Rail Feed Lines and Related Parts - Two-Filter System

2 Description and Operation of the High Pressure Fuel Rail Feed Lines
and Related Parts - Two-Filter System

NOTICE: The high pressure fuel rail feed lines, vibration dampers, P-clips; mounting bracket and hardware are
one-time use components and MUST be replaced any time they are removed.

NOTE: KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.

NOTE: KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.

+ Return lines P-clip mounting bolt is used to secure the return lines P-clip to the mounting bracket. This is a reusable bolt.
Return lines P-clip is used to secure the return lines to the mounting bracket. This is a reusable P-clip.

Mounting bracket is used to secure the high pressure fuel rail feed lines and return lines to rear rail clamp. This is a one-
time-use component.

High pressure fuel rail feed lines are used to transfer high pressure fuel from the high pressure fuel pump to the fuel rail.
This is a one-time-use component.

Vibration dampers are used to lower the vibration in the high pressure fuel rail feed lines. This is a one-time-use
component,

Mounting bracket bolts are used to secure the mounting bracket to the rear rail clamp. This is a one-time use component.

P-clips are used to lower vibration and secure the high pressure fuel rail feed lines to the mounting bracket. This is a one-
time-use component.

4470252
1, Reusable Return Lines P-clip Bolt 4. Mounting Bracket Bolts
2. Mounting Bracket 5. P-clips and Bolts
3. High Pressure Fuel Feed Lines 6. Vibration Dampers and Bolts

Figure 1. KM59 GEN1 with Bolted Vibration Dampers High Pressure Fuel Rail Feed Lines and Related
Parts

4 All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 02 09-14

02 09-14

d470160c

1. Reusable Return Lines P-clip Bolt 4. Mounting Bracket Bolts

2. Mounting Bracket 5. P-clips and Bolts

3. High Pressure Fuel Feed Lines
Figure 2. KM59 GEN1 with Permanent Vibration Dampers High Pressure Fuel Rail Feed Lines and Related
Parts

470251
1. Reusable Return Lines P-clip Bolt 4. Mounting Bracket Bolts
2. Mounting Bracket 5. P-clips and Bolts
3. High Pressure Fuel Feed Lines
All information subject to change without notice. 5

0209-14 Copyright © 2014 DETROIT DIESEL CORPORATION

2 Description and Operation of the High Pressure Fuel Rail Feed Lines and Related Parts - Two-Filter System

Figure 3. KM63 GEN2 High Pressure Fuel Rail Feed Lines and Related Parts

6 All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 02 09-14

02 09-14

3 Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter System

Remove as follows:

WARNING: PERSONAL INJURY :
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been
~ : shut down for a minimum of 10 minutes before’ servicing any component within the high pressure
circuit. Residual high fuel pressure may be present within the circuit.
1. Disconnect batteries.

NOTE: Do not discard the return lines'P-clip and bolt. They will be reused on the installation of the high pressure
fuel rail feed lines. :

2. Remove the return lines P-clip bolt (1) from the mounting bracket (2).

Table 1.

KME59 GEN1 with Bolted Vibration Dampers

6470252a

All information subject to change without notice. 7
0209-14 Copyright © 2014 DETROIT DIESEL CORPORATION

3 Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter System

Table 2.

KM59 GEN1 with Permanent Vibration Dampers

d470160c

8 All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 02 09-14

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Table 3.

KM63 GEN2 with Permanent Vibration Dampers

d470251a

3. Remove and discard the two bolts and P-clips (5) from the mounting bracket (2). See illustrations above.

4. Remove and discard the mounting bracket bolts (4) from the fuel rail clamp and discard the mounting bracket (2). See
illustrations above.

NOTE: For KMS9 GEN1: When using tool J-48770 to remove the high pressure pump rail feed lines, hold the high
pressure pump fitting with a 24mm wrench.

5. Using tool J-48770, remove and discard the high pressure pump rail feed lines (3) and vibration dampers from the fuel
rail and high pressure fuel pump. See illustrations above.

All information subject to change without notice. 9
0209-14 Copyright © 2014 DETROIT DIESEL CORPORATION

4 Inspection of the High Pressure Fuel Rail Feed Lines — Two Filter System

4 Inspection of the High Pressure Fuel Rail Feed Lines — Two Filter
System

Inspect as follows:

WARNING: PERSONAL INJURY : Bee ee
, All parts provided within this kit must be installed i in the proper locations, and MUST be fastened to
ae the specified torque. Failure to properly torque hardware/components will result in failure of a high
pressure fuel feed line, resulting in possible fire and/or personal i injury. ©

WARNING: PERSONAL INJURY. : :
All parts provided within this kit are single-use items. ana cannot be re-used. Re-use of hardware/

component items may result in the failure of a high pressure fuel line, cus in possible fire
and/or personal injury. 3

NOTICE: Failure to follow these instructions will result in catastrophic damage ‘to the engine and will riot ‘be
covered under warranty.

NOTE: KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts. .

NOTE: KM63 GEN2 fuel filter module return fines are: secured to the module with'e al mounting plate attached to the
PLV return line.

1. Inspect and verify the mounting bracket (2) and its attaching bolts (4), the two P-clips (5), and the high pressure fuel
feed lines (3) with two vibration dampers are not missing or loose. Do not attempt to loosen, tighten or otherwise
disturb any of the parts.

10 All information subject to change without notice.

Copyright © 2014 DETROIT DIESEL CORPORATION 02 09-14

02 09-14

Table 4.

KM659 GEN1 with Bolted Vibration Dampers