Safety regulations
12
5. Special instructions when working on the common rail system
Accident protection
D Risk of injury!
Fuel jets can cut through skin.
The atomisation of fuel creates a fire risk.
- When the engine is running never loosen the screw connections on the fuel's
high‐pressure side of the common rail system (injection line from the high‐pressure
pump to the rail, on the rail and on the cylinder head to the injector)
- Keep away from the engine when it is running
D Risk of injury!
When the engine is running the lines are constantly under a fuel pressure of up
to 1600 bar.
- Wait at least a minute until the pressure in the rail has dropped before loosening a
screw connection
- If necessary check the pressure drop in the rail with MAN‐Cats
D Risk of injury!
- People with pacemaker must keep at least 20 cm away from the running engine.
- Do not touch live parts on the electric connection of the injectors when the engine is
running.
Cleanliness
Today modern components of diesel injection consist of high‐precision parts which are exposed to extreme
stresses. The high‐precision technology requires the utmost cleanliness during all work on the fuel sys
tem.
Even a particle of dirt over 0,2 mm can lead to the failure of components.
The measures described as follows are therefore essential before work begins:
Risk of damage from penetration of dirt!
D Before working on the clean side of the fuel system clean the engine and the engine
compartment. During cleaning the fuel system must be closed.
D Carry out visual inspection for any leakage or damage to the fuel system
D Do not spray the high‐pressure cleaner direct onto the electric components, or alternati
vely keep them covered
D Do not carry out any welding or sanding work in the engine compartment during mainte
nance / repair
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