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Safety Information
Common Rail Safety Checklist
The following safety checklist is intended to help remind you of safety procedures and
practices relating to a common rail engine.
SAFETY IS YOUR RESPONSIBILITY
- Do make sure the engine and surrounding area has been thoroughly cleaned prior to
completing any maintenance tasks.
- Do complete all work in accordance with the Service Manual procedures.
- Do disconnect both the battery positive (+) and battery negative (-) cables prior to
completing any welding on the machine.
- Do use the recommended grade of fuel (EN590). The fuel injection pump, injector or
other parts of the fuel system can be damaged if you use a fuel or fuel additives not
recommended by JCB.
- Do make sure all the necessary new parts are available before starting any
maintenance work.
- Do not ‘crack’ the injector high pressure fuel lines to bleed the fuel system. The
system operates at pressure in excess of 1200 bar (17400lbs/in²).
- Do not steam clean the electronic control unit (ECU) or the ECU connectors.
- Do not touch the ECU connector pins, this will eliminate the possibility of damage
caused by electrostatic discharge.
- Do not leave any fuel connections ‘open’ for any extended period of time.
- Do not open any new parts packaging until the part is ready to be fitted. Unnecessary
exposure will increase the risk of contamination.
- Do not reuse high pressure fuel pipes. Reusing the pipes will lead to potential fuel
leaks.
- Do not attempt to remove and replace the rail pressure sensor or high pressure valve.
It is not possible to refit these components without the risk of fuel leaks. If the valve
or sensor is diagnosed as faulty then a new common rail assembly must be fitted.
