This instruction show you guide on how to do engine,injection aftertreatment system cleanliness.
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Introduction
When carrying out service procedures on the engine cleanliness is of paramount importance.
Whilst the requirement for a good level of cleanliness is well known and common practice, the introduction of high pressure common rail fuel injection necessitates working to new levels of cleanliness.
For more information about cleanliness requirements see the engine Service Manual.
Cleaning the Engine
Before carrying out any service procedures that require components to be removed, the engine must be properly cleaned.
Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned.
1 Make sure that the electrical system is isolated.
2 Make sure that all electrical connectors are securely coupled. If connectors are open obtain suitable caps or seal using water proof tape.
3 Cover the alternator with a plastic bag to prevent water ingress.
4 Seal the engine air intake, exhaust and breather system.
5 Make sure that the oil filler caps and dipstick are correctly fitted.
6 Use a low pressure water jet and brush to soak off any caked mud or dirt.
7 Apply a suitable cleaning and degreasing agent with a brush. Follow the manufacturer’s recommendations.
8 Use a pressure washer to remove the softened dirt and oil.
DO NOT aim the water jet directly at oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors.
DO NOT place the jet nozzle closer than 600mm (24 in) to any part of the engine.
9 When the pressure washing is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.
10 Before working on specific areas of the engine use a compressed air jet to dry off any moisture. When the area is dry use a soft clean brush to remove any sand or grit particles that may remain.
11 When removing components be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding.
Common Rail Fuel Injection System – Additional Cleaning Requirements
Warning: The high pressure fuel system is extremely susceptible to damage if it is contaminated. Always clean the engine using the correct procedures before carrying out maintenance. Contamination of the fuel system can cause catastrophic failure of the engine. (SN0004)
Additional cleaning must be carried out prior to working on the high pressure fuel system. It is extremely important that the high pressure fuel components and the adjacent parts of the engine are meticulously cleaned before any components are removed.
1.Clean the engine as described in “Cleaning the Engine” section above.
2.Remove hoses, electrical harnesses and ancillaries to improve access and expose any remaining trapped dirt close to the relevant high pressure components.
3.Wash away any remaining dirt or debris and then dry the area using a compressed air jet. When the area is dry use a soft clean brush to remove any sand or grit particles that may remain.
Before starting work on the high pressure fuel system make sure that the working environment is suitable. See the engine Service Manual for details.
Aftertreatment System
Warning:The exhaust aftertreatment system is extremely susceptible to damage if it is contaminated. Always clean the components and surrounding area using the correct procedures before carrying out maintenance. Contamination of the aftertreatment system can reduce its efficiency and result in machine derate. Damage caused to the aftertreatment as a result of contamination will not be covered by warranty. (SN00012)
Diesel Exhaust Fluid (DEF) can cause corrosion with metals and electrical connectors. Def will ‘creep’ up and along wires and harnesses as a result of capillary action meaning that damage can be spread through out a machine even from a minor spill. Any spillages must be cleaned up immediately with clean water to prevent long term damage.
Additional cleaning must be carried out prior to working on the exhaust aftertreatment system. It is extremely important that the aftertreatment components and the adjacent parts of the engine are meticulously cleaned before any components are removed.
1 Clean the engine as described in “Cleaning the Engine” section above.
2 Remove hoses, electrical harnesses and ancillaries to improve access and expose any remaining trapped dirt close to the relevant exhaust aftertreatment components. Always cap open electrical connectors and hoses.
3 Wash away any remaining dirt or debris and then dry the area using a compressed air jet. When the area is dry use a soft clean brush to remove any sand or grit particles that may remain.
When washing exhaust aftertreatment components, it is extremely important that only clean water is used. Use of any other cleaning products will cause contamination of the aftertreatment system.
