DEUTZ engines User notes Damaged injection lines and high-pressure pipes must be renewed. z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel sys- tem. Injection lines and high pressure fuel lines must never be connected when the engine is running. Do not place hands near to a leak in the high pressure fuel system. z Only work on the fuel system in a clean environ- ment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regu- larly. No brake or performance test benches may be kept or operated in the same room.
3 Also carefully check all high pressure compo- nents visually before performing tests on the running engine. Wear suitable protective clothing (for example protective glasses). Leaks are a potential source of danger for workshop personnel. z Air currents which kick up dust, such as those caused by brake repairs or the starting of en- gines, should be avoided. Even if no leaks are discernible on the high pressure fuel system, the workshop personnel should avoid the immediate danger zone or wear suitable protective clothing (such as pro- tective glasses) when performing tests on the running engine and during the first trial run.
z For work such as removal and installation on de- fective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out. Always stay out of range of a fuel jet, as it could cause severe injury. Smoking is strictly prohibited when working on the fuel system. z No general machine tools may be operated in this room. z Regular cleaning of the workshop area is manda- tory. Draughts, ventilation systems and heating fans should be minimised. Do not work near to sparks and flames.
Never disconnect an injector when the engine is running. z Areas of the engine room from which particles of dirt could be loosened (for example the bottom part of the tipped driver cab) must be covered with fresh clean film. 3.2.2 Cleanliness instructions and meas- ures for handling the DEUTZ Com- mon Rail System z Working materials and tools must be cleaned be- fore work. Only use tools without damage to the chrome plating or tools which are not chrome- plated. The DEUTZ Common Rail system used in the DEUTZ engines consists of high-precision compo- nents which are exposed to extreme stress.
Great attention must be paid to cleanliness when working on the fuel system due to the high precision technol- ogy. Notes and measures to be observed during work on the fuel system or with the fuel system open. z Only work in clean overalls. Notes and measures to be observed before starting work on the fuel system z Only lint-free cleaning cloths may be used for work on the fuel system. z The fuel system must be closed. Make a visual inspection for leaks / damage to the fuel system. z Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel sys- tem.
z Clean the whole engine and engine room with the system closed before starting work on the fuel system. z The engine must be dry when you start working on the fuel system. z Working materials and tools must be cleaned be- fore work. Only use tools without damage to the chrome plating or tools which are not chrome- plated. z Blowing (dry) with compressed air is only permis- sible with the fuel system closed. z When using a steam jet, first cover up the control unit, the cable plugs, all other electrical plug con- nections and the generator. Also, the steam jet may not be pointed directly at them. z Do not use used cleaning fluid or test fluid for cleaning.
z Compressed air must not be used for cleaning on the open fuel system. z Electrical plug connections must be plugged when spraying. z Work on removed components may only be per- formed at a suitably equipped workbench. © 01/2009 18610-001 4/8