Workshop Manual

3
© 01/2009 18610-001
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DEUTZ enginesUser notes
– Damaged injection lines and high-pressure
pipes must be renewed.
– 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.
– 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.
– 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.
– 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.
– Do not work near to sparks and flames.
– Never disconnect an injector when the engine
is running.
3.2.2 Cleanliness instructions and meas-
ures for handling the DEUTZ Com-
mon Rail System
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 before
starting work on the fuel system
z The fuel system must be closed. Make a visual
inspection for leaks / damage to the fuel system.
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 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 Electrical plug connections must be plugged
when spraying.
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 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.
z Air currents which kick up dust, such as those
caused by brake repairs or the starting of en-
gines, should be avoided.
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.
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.
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.
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.
Notes and measures to be observed during work
on the fuel system or with the fuel system open.
z Only work in clean overalls.
z Only lint-free cleaning cloths may be used for
work on 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 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 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 Work on removed components may only be per-
formed at a suitably equipped workbench.