1.1 Safety instructions
WARNING:
In the use and service of the engine there is always the possibility of injury. Before
starting the service read and understand the safety instructions and remarks!
• Do not start any repair work that you do not fully understand.
• Make sure that the location and surroundings in which you are carrying out the repair provide a safe
environment in which to work.
• Always ensure the location is clean and free of clutter.
• Do not use faulty or otherwise unsuitable tools.
• Remove all rings, chains and watches before starting work.
• Use up-to-date protection equipment while you work. For example, eye protection, as you will be
working with compressed air for cleaning, grinding, hammering or similar.
• Use a lifting device for lifting and transporting heavy (over 20 kg) pieces. Ensure all lifting hooks and
chains are in good condition. The lifting eyes on the engine must not be subjected to side forces during
lifting.
• Never work under an engine that is hanging from a lifting device or raised up on a jack. Always use
strong supports before starting the work.
• Start the engine only by using the starting switch in the cabin.
• Do not start an engine if the protection covers are removed.
NOTE: The fan is difficult to see when the engine is running! Ensure that loose clothing or long hair
does not get caught in the rotating parts of the engine.
• If you start the engine indoors, ensure that there is proper ventilation.
• Never use an aerosol starting aid! (Risk of explosion, personal injuries and engine damage.)
• When you are operating the engine or working near it, use ear protection to avoid noise injuries.
• Always stop the engine before starting any servicing or repair work.
• Avoid touching the exhaust manifold, turbocharger and any other hot parts of the engine.
• Do not remove the thermal protection of the exhaust manifold.
• Open the radiator cap with care when the engine is hot, as the cooling system is pressurised. The
cooling liquid and lubrication oil of a hot engine will cause injury if they come into contact with skin.
• Do not open high pressure pipe connectors of the fuel system when the engine is running. Wait at least
30 sec. after the stopping of the engine. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
• Never allow a naked flame, smoking or sparks near the fuel system or batteries, especially when
loading batteries, as these are explosive.
• Always disconnect the negative (-) battery cable when servicing or repairing the electric system.
• At temperatures in excess of 300°C, e.g. if the engine is burnt by a fire, the viton seals of the engine
(i.e. the undermost cylinder liner O-ring) produce very highly corrosive hydrofluoric acid. Do not touch
with bare hands when viton seals are subjected to abnormally high temperatures. Always use neoprene
rubber or heavy-duty gloves and safety glasses when decontaminating. Wash the seals and the
contaminated area with a 10% calcium hydroxide or other alkali solution. Put all removed material in
sealed plastic bags and deliver them to the relevant disposal point provided by the authorities
concerned.
NOTE: Never destroy viton seals by burning!
• When checking fuel injectors do not allow the jet of high-pressure fuel to come into contact with your
skin. The fuel penetrates the skin causing severe injuries. Get medical help immediately!
• The fuel, lubricating oil and coolant cause long-lasting irritation on contact with skin.
• If you are carrying out welding or similar high current operations for the appliance, we recommend that
you disconnect the electronic control unit (ECU) main connector before starting work.
Important instructions
• Avoid unnecessary idling of the engine.
1. Introduction
4th Generation Engines 1-3
8370 79492
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