Man D2862 LE221 - Working on Common Rail System and Dirt Prevention

INTRODUCTION
5.Informationforworkingonthecommonrailsystem
Generalinformation
–Ajetoffuelcancutthroughtheskin.Riskofreduetofuelatomisation.
–Neverunscrewthescrewedconnectionsonthefuelhigh-pressuresideofthecommonrailsystemwhilst
theengineisrunning(highpressurelinefromthehigh-pressurepumpto/ontherailandonthecylinder
headtotheinjector).Whilsttheengineisrunning,thelinesareconstantlycarryingfuelunderapressureof
1800barandmore.Waitatleastoneminutetoallowthepressuretodissipatebeforeopeningthescrew
connections.UseMAN-cats
®
ifavailabletochecktherailisdepressurised.
–Avoidstandingneartherunningengine.
Informationforpeoplewithpacemakers
–Anychangesmadetotheoriginalenginecablingcanresultinthelimitvaluesspeciedinpacemakersafety
regulationsbeingexceeded,e.g.non-twistedinjectorcablesorinstallingthetestbox(contactbox).
–Thereisnodangertodriversandco-driverswearingapacemakerifthevehicleisusedforitsintended,i.e.
approved,purpose.
–ThereisnodangertooperatorswearingapacemakerifunitswithMANcommonrailenginesareusedfor
theirintended,i.e.approved,purpose.
–Initsoriginalstate,theproductdoesnotviolateanyofthecurrentlyknownpacemakerlimitvalues.
Dangerofdamageduetodirtingress
–Diesel-injectionsystemsconsistofprecisionengineeredcomponentsthataresubjecttoextremeloads;
Duetothishigh-precisiontechnology,itisnecessarytoensurethegreatestpossiblecleanlinessduring
allworkonthefuelsystem.
–Evendirtparticlesover0.002mmcancausecomponentfailure.
Dangerofdamageduetodirtingress
–Beforeworkingonthecleansideofthefuelsystem,cleantheengineandtheenginecompartment(e.g.
steamcleaner).Thefuelsystemmustbesealedduringthisprocess.
–Visuallyinspectthefuelsystemforleaksordamage.
–Donotdirectthesteamcleanerjetdirectlyatelectricalcomponents.Coverthemifnecessary.
–Placetheengineinacleanareaintheworkshopwheretherewillbenoworkgoingonthatcouldthrowup
dust(grinding,weldingwork,brakerepairs,brakeanddynamometertests,etc.).
–Avoidairmovements(possibilityofthrowingupdustbystartingengines,theworkshopventilation/heating,
draughts,etc.).
–Cleananddrytheareaofthestillclosedfuelsystemusingcompressedair.
–Useasuitableextractorunit(industrialextractorunit)toremoveloosedirtparticlessuchaspaintchippings
andinsulatingmaterial.
–Areasoftheenginecompartmentfromwhichdirtparticlescouldbecomedetachedmustbecoveredwitha
new,cleancoveringlm.
–Beforeremovinganycomponents,washyourhandsandputoncleanworkingclothes.
Dangerofdamageduetodirtingress
–Theuseofcompressedairforcleaningisnotpermittedafteropeningthecleansideofthefuelsystem.
–Duringassembly,removeloosedirtusingasuitableextractorunit(industrialextractorunit).
–Onlylint-freecleaningclothsareallowedtobeusedonthefuelsystem.
–Cleantoolsandequipmentbeforecommencingwork.
–Onlyusetoolsthatshownosignsofdamage(crackedchromecoatings).
–Donotusematerialssuchascloths,cardboardorwoodwhenremovingandinstallingcomponentsasthese
materialscanproduceparticlesandbres.
–Ifunfasteningconnectionscausesthepainttochip(duetopossibleexcesspaint),carefullyremovethese
paintchippingsbeforefullyunfasteningtheconnection.
–Allremovedcomponentsonthecleansideofthefuelsystemmustbepluggedimmediatelyattheir
connectionopeningsusingsuitablecaps.
–Thesecapsmustbestoredindustproofpackaginguntiltheyareusedanddisposedofaftertheyhavebeen
usedonce.
–Thenstorethecomponentsinaclean,sealedcontainer.
–Neveruseusedcleaningortestuidsforthesecomponents.
–Newpartsmustnotberemovedfromtheiroriginalpackaginguntilimmediatelybeforeuse.
–Workonremovedcomponentsmayonlybecarriedoutinasuitablyequippedworkplace.
–Ifremovedpartsareshipped,alwaysusethenewpart'soriginalpackaging.
AE63stedition13