Diesel engine 12V 4000 G73, 16V 4000 G73. Manual - part 3

1.7 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair work

Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug

with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately

ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do

so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic

starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐

tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐

ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐

nents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the assembly or system.

After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐

bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards

have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:

• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐

ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or

the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐

vice as an additional measure.

Welding work

Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when

welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current

may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage

the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified

devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:

• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the

equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).

• For hydraulic installation, screw on the tool with the piston retracted.

• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft

end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the

component to be installed/removed.

Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work

or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during

operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐

fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐

ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐

diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to

type and application.

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For conducting light-beam procedures and measurement work, only the following laser devices must be

used:

• Laser devices of classes 1, 2 or 3A.

• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700

nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent

any risk to the eyes.

1.8 Fluids and lubricants, fire prevention and environmental

protection

Fire prevention

Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -

therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐

cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.

To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to

the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their

use.

Noise

Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating

danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo‐

nents as well as the execution of calibration processes that might affect the emission characteristics of

the engine are prohibited by emission regulations. Emission control units/systems may only be main‐

tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐

lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act

and involves the termination of the operating license by the emission authorities. MTU does not accept

any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-

relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐

ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are

subjected to proper recycling procedures.

Fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and

other chemical substances, follow the safety instructions that apply to the product. Take special care

when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do

not smoke.

Used oil

Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.

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