Man D2862 LE221 Repair Manual Download

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INTRODUCTION

5. Information for working on the common rail system

General information
–

A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.

–

Never unscrew the screwed connections on the fuel high-pressure side of the common rail system whilst
the engine is running (high pressure line from the high-pressure pump to/on the rail and on the cylinder
head to the injector). Whilst the engine is running, the lines are constantly carrying fuel under a pressure of
1800 bar and more. Wait at least one minute to allow the pressure to dissipate before opening the screw
connections. Use MAN-cats

if available to check the rail is depressurised.

–

Avoid standing near the running engine.

Information for people with pacemakers
–

Any changes made to the original engine cabling can result in the limit values specied in pacemaker safety
regulations being exceeded, e.g. non-twisted injector cables or installing the test box (contact box).

–

There is no danger to drivers and co-drivers wearing a pacemaker if the vehicle is used for its intended, i.e.
approved, purpose.

–

There is no danger to operators wearing a pacemaker if units with MAN common rail engines are used for
their intended, i.e. approved, purpose.

–

In its original state, the product does not violate any of the currently known pacemaker limit values.

Danger of damage due to dirt ingress
–

Diesel-injection systems consist of precision engineered components that are subject to extreme loads;
Due to this high-precision technology, it is necessary to ensure

the greatest possible cleanliness

during

all work on the fuel system.

–

Even dirt particles

over 0.002 mm

can cause component failure.

Danger of damage due to dirt ingress
–

Before working on the clean side of the fuel system, clean the engine and the engine compartment (e.g.
steam cleaner). The fuel system must be sealed during this process.

–

Visually inspect the fuel system for leaks or damage.

–

Do not direct the steam cleaner jet directly at electrical components. Cover them if necessary.

–

Place the engine in a clean area in the workshop where there will be no work going on that could throw up
dust (grinding, welding work, brake repairs, brake and dynamometer tests, etc.).

–

Avoid air movements (possibility of throwing up dust by starting engines, the workshop ventilation/heating,
draughts, etc.).

–

Clean and dry the area of the still closed fuel system using compressed air.

–

Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint chippings
and insulating material.

–

Areas of the engine compartment from which dirt particles could become detached must be covered with a
new, clean covering lm.

–

Before removing any components, wash your hands and put on clean working clothes.

Danger of damage due to dirt ingress
–

The use of compressed air for cleaning is not permitted after opening the clean side of the fuel system.

–

During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit).

–

Only lint-free cleaning cloths are allowed to be used on the fuel system.

–

Clean tools and equipment before commencing work.

–

Only use tools that show no signs of damage (cracked chrome coatings).

–

Do not use materials such as cloths, cardboard or wood when removing and installing components as these
materials can produce particles and bres.

–

If unfastening connections causes the paint to chip (due to possible excess paint), carefully remove these
paint chippings before fully unfastening the connection.

–

All removed components on the clean side of the fuel system must be plugged

immediately

at their

connection openings using suitable caps.

–

These caps must be stored in dustproof packaging until they are used and disposed of after they have been
used once.

–

Then store the components in a clean, sealed container.

– Never

use used cleaning or test uids for these components.

–