Detroit Diesel Service Manual (EN)

TECHNICIAN GUIDE ® SERIES 4000 COMMON RAIL FUEL SYSTEM

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ATTENTION This bulletin is a guideline for qualified personnel. The information contained in this bulletin may not be complete and is subject to change without notice.

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Cautions WORK SAFELY ! CAUTION: The service procedures recommended by Detroit Diesel Corporation and described in this Technicians Guide are effective methods of performing service and repairs. Some of these procedures require the use of tools specially designed for this purpose. Accordingly, anyone who intends to use a replacement part, service procedure or tool which is not recommended by Detroit Diesel Corporation must first determine that neither their safety nor the safe operation of the engine will be jeopardized by the replacement part, service procedure or tool selected.

This Technician’s Guide contains various work procedures that must be carefully observed in order to reduce the risk of personal injury during service or repair or the possibility that improper service or repair may damage the engine or render it unsafe. It is also important to understand that these work procedures are not exhaustive, because it is impossible for Detroit Diesel Corporation to warn of all the possible hazardous consequences that might result from failure to follow these instructions. A service technician can be severely injured if caught in the pulleys, belts or rotating parts of an engine that is accidentally started.

To avoid personal injury, take this precaution before starting to work on an engine: Disconnect the battery from the starting system by removing one or both of the battery cables (disconnect negative [ground] cable first). With the electrical circuit disrupted, accidental contact with the starter button will not produce an engine start. Follow all lockout procedures as required. i

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Always use caution when using power tools.

1. Consider the hazards of the job and wear protective gear such as safety glasses, safety shoes, hard hats, hearing protection, etc. to provide adequate protection. 2. When using a lifting device, make sure the lifting device is fastened securely. Be sure the item to be lifted does not exceed the capacity of the lifting device. 3. Always use caution when using power tools. 4. When using compressed air to clean a component, such as flushing a radiator or cleaning an air cleaner element, use a safe amount of air. Too much air can rupture or in some other way damage a component and create a hazardous situation that can lead to personal injury.

Always wear adequate eye protection (safety glasses, safety face shield) when working with compressed air. 5. To avoid possible personal injury when working with chemicals, steam and/or hot water, wear adequate protective clothing (face shield, rubber apron, gloves, boots, etc.) work in a well ventilated area, and exercise caution. 6. Avoid the use of carbon tetrachloride, carbon dissolved, methylene, chloride, perchloroethylene and trichloroethylene as cleaning agents because of harmful vapors they release. Use 1.1.1 – trichlorethane. Cautions However, while less toxic than other chlorinated solvents, use it with caution.

Be sure the work area is adequately ventilated and wear protective gloves, goggles or face shield and an apron. Follow chemical manufacturer’s use and safety recommendations. Mineral spirits or mineral spirits based solvents are highly flammable. They must be stored and used in “No Smoking” areas away from sparks and open flames. 7. Do not weld on or near the diesel fuel tank until it has been thoroughly emptied and ventilated. Possible explosion could result if this precaution is not taken. 8.

Failure to inspect parts thoroughly before installation, failure to install the proper parts or failure to install parts properly can result in component or engine mal-function and/or damage and may also result in personal injury. 9. When working on an engine that is running, accidental contact with the hot exhaust manifolds or turbochargers can cause severe burns. Avoid making contact across the two terminals of a battery, which can result in severe arcing. 10. Turbocharger air inlet shields should be used if operation of the turbocharger is necessary without normal piping, to avoid injury. ii SAFETY PRECAUTIONS TO OBSERVE WHEN WORKING ON THE ENGINE

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