Immobilize the engine by turning off the power
supply to the engine at the main switch
(switches) and lock it (them) in the off position
before starting work. Post a warning notice at
the main circuit breaker.
Avoid opening the coolant filling cap when the
engine is hot. Steam or hot coolant can spray
out and system pressure will be lost. Open the
slowly, and release the pressure in the
cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.
As a rule, all service operations must be carried
out with the engine stopped. However, some
work, such as adjustments, will require the
engine to be running. Approaching an engine
which is running is a safety risk. Bear in mind
that loose clothing or long hair can fasten in
rotating parts and cause serious personal
Hot oil can cause burns. Avoid skin contact with
Ensure that the lubrication system is not
under pressure before any work is begun.
Never start or operate the engine with the oil
filler cap removed, because of the risk of oil
Be aware of hot surfaces (exhaust pipes, tur-
air pipes, starting heaters etc.) and
hot fluids in pipes and hoses on an engine that
is running or has just stopped.
If work is done adjacent to a running engine, a
careless movement or a dropped tool may in the
worst case lead to personal injury.
Never start the engine without installing the air
rotating compressor turbine in the tur-
bocharger can cause severe injury. Foreign
objects entering the intake ducts can also cause
mechanical damage. Install all protective cov-
ers before the engine is started.
Ensure that the warning symbols or information
the product are always clearly visible.
Replace decals which have been damaged or
Only start the engine in a well-ventilated space.
When running in a confined space, exhaust
fumes and crankcase gases must be led away
from the engine bay or workshop area.
Avoid getting oil on your skin! Protracted or
repeated exposure to oil can cause skin to
become dry. Irritation, dryness, eczema and
other skin problems may then result. From a
health standpoint, used oil is more dangerous
than new. Use protective gloves and avoid oil-
and rags. Wash regularly, espe-
cially before eating. Use suitable barrier creams
to counteract drying out of the skin and to aid
The majority of chemicals e.g. engine and trans-
mission oils, glycol, gasoline, and diesel oil,
chemicals for workshop use such
as degreasing agents, paints and solvents, are
injurious to health. Carefully read the instruc-
tions on the product packaging! Always follow a
product's safety directions, e.g. use of protec-
tive mask, glasses, gloves etc. Ensure that
other personnel are not exposed to substances
that are injurious to health. Ensure good venti-
lation. Handle used and leftover chemicals in
the prescribed manner.
Stop the engine and turn off the electrical supply
main switch(es) before carrying out work
on the electrical system.
Clutch adjustments must be carried out with the
05-1 Safety Instructions
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