MTU 12V 4000 L32 F Operating Instructions Manual

Operating Instructions

Gas engine

12V 4000 L32 F

16V 4000 L32 F

MS150104/02E

Engine model kW/cyl. Application group

12V4000L32F 100 kW/cyl. 3A, continuous power, unrestricted

16V4000L32F 100 kW/cyl. 3A, continuous power, unrestricted

Table 1: Applicability

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-

ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-

filming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH

reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents

1 Safety

1.1 Important provisions for all products 5

1.2 Correct use of all products 6

1.3 Personnel and organizational requirements 7

1.4 Safety regulations for initial start-up and

operation 8

1.5 Safety regulations for startup and operation,

specific information for gaseous fuel or dual

fuel supply applications 10

1.6 Safety regulations for maintenance and

repair work 12

1.7 Safety regulations for maintenance and

servicing work, specific information for

gaseous fuel and dual fuel supply or

applications

16

1.8 Fire prevention and environmental

protection, fluids and lubricants, indirect

materials 17

1.9 Fire prevention and environmental

protection, fluids and lubricants, auxiliary

materials, specific information for gaseous

fuel supply in gaseous-fuel or dual-fuel

applications

19

1.10 Standards for safety notices in the text 20

2 Transport

2.1 Transport 21

3 Product Summary

3.1 Engine layout 22

3.2 Engine side and cylinder designations 24

3.3 Engine – Main dimensions 25

3.4 Firing order 26

3.5 Technical Data 27

3.5.1 12 V 4000 L32F, 16 V 4000 L32F engine data,

fuel optimized (TA-Luft) 27

3.5.2 12 V 4000 L32F, 16 V 4000 L32F engine data,

emission optimized (1/2 TA-Luft) 31

3.6 Monitoring, Control and Regulation

Equipment 35

3.6.1 Gas engine phase 4 system – Overview 35

3.6.2 Purpose of the units 37

4 Operation

4.1 Runtimes at partial load 39

4.2 Putting the engine into operation after

extended out-of-service periods (>3 months) 40

4.3 Putting the engine into operation after

scheduled out-of-service-period 41

4.4 Control, starting and stopping sequences 42

4.5 Engine – Start 44

4.6 Operational checks 45

4.7 Emission values – Check 46

4.8 Engine – Shutdown 48

4.9 Engine – Emergency shutdown 49

4.10 After stopping the engine – Engine remains

ready for operation 51

4.11 After stopping the engine – Putting the

engine out of operation 52

5 Maintenance

5.1 50-hours check 53

5.2 Maintenance task reference table [QL1] 54

6 Troubleshooting

6.1 Fault messages - Key 55

6.2 Fault messages in genset control system log 57

6.3 Engine Control Unit – Fault messages 122

7 Task Description

7.1 Engine 162

7.1.1 Engine – Barring manually 162

7.1.2 Machine room – Check for smell of gas 163

7.2 Crankcase Breather 164

7.2.1 Oil separator – Filter replacement 164

7.3 Ignition System 166

7.3.1 Spark plug – Replacement 166

7.3.2 Spark plug – Removal 167

7.3.3 Spark plug – Installation 168

7.3.4 Spark plug connector – Replacement 170

7.3.5 Spark plug connector – Removal 171

7.3.6 Spark plug connector – Cleaning and check 172

7.3.7 Spark plug connector – Installation 173

7.3.8 Ignition system – Ignition timing check 175

7.4 Valve Drive 176

7.4.1 Valve protrusion – Measurement 176

7.4.2 Valve clearance – Check and adjustment 179

7.4.3 Valve gear – Lubrication 181

7.4.4 Cylinder head cover ‒ Removal 182

7.4.5 Cylinder head cover ‒ Installation 183

7.5 Gas System 184

7.5.1 Gas supply - Checking gas lines for leaks 184

7.6 Air Filter 185

7.6.1 Air filter – Replacement 185

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7.6.2 Air filter – Removal and installation 186

7.7 Lube Oil System, Lube Oil Circuit 187

7.7.1 Engine oil level – Check 187

7.7.2 Engine oil – Change 188

7.7.3 Engine oil – Sample extraction and analysis 189

7.8 Oil Filtration / Cooling 190

7.8.1 Engine oil filter – Replacement 190

7.9 Coolant Circuit, General, High-Temperature

Circuit 191

7.9.1 Engine coolant – Level check 191

7.9.2 Engine coolant – Change 192

7.9.3 Engine coolant – Draining 193

7.9.4 Engine coolant – Filling 195

7.9.5 Vent line of engine coolant circuit –

Replacement 196

7.10 Low-Temperature Circuit 197

7.10.1 Mixture coolant level – Check 197

7.10.2 Mixture coolant – Change 198

7.10.3 Mixture coolant – Draining 199

7.10.4 Mixture coolant – Filling 200

7.11 Wiring (General) for Engine/Gearbox/Unit 201

7.11.1 Engine cabling – Check 201

7.11.2 Sensors – Overview 202

7.11.3 Sensors – Removal 206

7.11.4 Sensors – Installation 208

8 Appendix A

8.1 Abbreviations 209

8.2 MTU Onsite Energy contact person / service

partner 211

9 Appendix B

9.1 Special Tools 212

9.2 Index 216

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1 Safety

1.1 Important provisions for all products

General information

This product may pose a risk of injury or damage in the following cases:

• Incorrect use

• Operation, maintenance and repair by unqualified personnel

• Changes or modifications which are neither made nor authorized by the manufacturer

• Noncompliance with the safety instructions and warning notices

Nameplates

The product is identified by nameplate, model designation or serial number and must match with the infor-

mation on the title page of this manual.

Nameplates, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the

EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-

cations.

Emission regulations and emission labels

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional compo-

nents including the execution of calibration processes that might affect the emission characteristics of the

product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-

changed or repaired if the components used for this purpose are approved by the manufacturer.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-

lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.

The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-

tional life.

Exception: Engines used exclusively in land-based, military applications other than by US government agen-

cies.

Please note the following when replacing components with emission labels:

• The relevant emission labels must be affixed to the spare part.

• Emission labels shall not be transferred from the replaced part to the spare part.

• The emission labels must be removed from the replaced part and destroyed.

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1.2 Correct use of all products

Correct use

The product is intended for use in accordance with its contractually-defined purpose as described in the rele-

vant technical documents only.

Intended use entails operation:

• Within the permissible operating parameters in accordance with the (→ Technical data)

• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants

Specifications of the manufacturer)

• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-

tion Specifications of the manufacturer)

• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-

tact/Service partner)

• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al-

so applies to engine control/parameters)

• In compliance with all safety regulations and in adherence with all warning notices in this manual

• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)

throughout the useful life of the product

• In compliance with the maintenance and repair instructions contained in this manual, in particular with

regard to the specified tightening torques

• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-

pair

• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul

The product must not be operated in explosive atmospheres, unless the engine fulfills the conditions for such

use and approval has been granted.

Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper

use increases the risk of injury and damage when working with the product. The manufacturer shall not be

held liable for any damage resulting from improper, non-intended use.

The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,

make sure that the latest version is used. The latest version can be found on the websites:

• For drive systems: http://www.mtu-online.com

• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversions

Unauthorized changes to the product represent a contravention of its intended use and compromise safety.

Changes or modifications shall only be considered to comply with the intended use when expressly author-

ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-

ized changes or modifications.

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1.3 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-

tion, or transportation.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,

repair, assembly, installation, and transport personnel at all times.

Personnel must receive instruction on product handling and repair based on this manual. In particular, per-

sonnel must have read and understood the safety requirements and warnings before starting work.

This is important in the case of personnel who only occasionally perform work on or around the product.

These personnel must be instructed repeatedly.

Personnel requirements

All work on the product must be carried out by trained, instructed and qualified personnel only:

• Training at the Training Center of the manufacturer

• Qualified personnel from the areas mechanical engineering, plant construction, and electrical engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-

sembly, installation, and transport in writing.

Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,

goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-

tions of the individual activities.

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1.4 Safety regulations for initial start-up and operation

Safety regulations for initial start-up

Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications

before putting the product into service. All necessary approvals must be granted by the relevant authorities

and all requirements for initial startup must be fulfilled.

Whenever the product is subsequently taken into operation ensure that:

• All personnel is clear of the danger zone surrounding moving parts of the machine.

Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched

on.

• All maintenance and repair work has been completed.

• All loose parts have been removed from rotating machine components.

• All safety equipment is in place.

• No persons wearing pacemakers or any other technical body aids are present.

• The service room is adequately ventilated.

• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.

These gases may be hazardous to health. Always wear respiratory protection in the operating room during

this period.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.

• The product must be free of any damage, this applies in particular to lines and cabling.

• Protect battery terminals, generator terminals or cables against accidental contact.

• Check that all connections have been correctly allocated e.g. +/- polarity, direction.

Immediately after putting the product into operation, make sure that all control and display instruments as

well as the signaling and alarm systems work properly.

Smoking is prohibited in the area of the product.

Safety regulations during operation

The operator must be familiar with the control and display elements.

The operator must be familiar with the consequences of any operations performed.

During operation, the display instruments and monitoring units must be permanently observed with regard to

present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.

The following steps must be taken if a malfunction of the system is recognized or reported by the system:

• inform supervisor(s) in charge,

• analyze the message,

• respond by taking any necessary emergency action, e.g. emergency stop.

Operation

Do not remain in the operating room when the product is running unless absolutely necessary. Keep your

stay as short as possible.

Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed

to do so following a written procedure.

Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:

• Wear ear protectors.

• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.

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Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.

Follow the applicable operating and safety instructions when operating the devices and heed warnings at all

times.

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1.5 Safety regulations for startup and operation, specific

information for gaseous fuel or dual fuel supply applications

General safety regulations

Requirement for the user: Check the gas train every time the product is started.

During operation, the surface temperature of the gas-bearing parts must not fall below 5 °C anywhere within

the vicinity of the product.

Gas system, general requirements

The plant manufacturer/user shall establish the connection to the gas supply in accordance with the applica-

ble statutory requirements, e.g. DVGW, G490/I, G491/I, DIN EN 12186, NFPA37.

Gas supply shut-off: The plant manufacturer/user shall ensure that the gas shut-off device complies with lo-

cal regulations.

The pressure regulator shall be equipped with an approved safety shut-off valve and a safety exhaust valve to

handle the situation where the pressure at the outlet of the gas pressure regulator is too high. The gas must

be vented to a hazard-free zone (atmosphere).

The gas train shall be equipped with a temperature-monitored flame arrester if the gas supply system is con-

nected to a vessel or if oxygen-containing gases are used.

The gas shut-off valves are activated via two different paths from the control system, with one path assigned

to each of the gas shut-off valves.

The gas train shall feature minimum pressure monitoring.

Additional equipment may be necessary in the gas train, e.g. maximum pressure monitoring, if

• gas supply pressure exceeds 100 mbar

• gas volume flow exceeds 200 m³/h

• fuel efficiency exceeds 600 KW

Safety regulations for initial startup in dual fuel applications

Whenever the product is put into service, ensure that:

• Mobile application: The product shall only be used in the open.

• Stationary application: The product shall only be used with adequate ventilation.

Gas system, requirements for gas operation

The plant manufacturer/user shall use tested gas trains for the fuel supply of the product and connection to

the gas supply network. The manufacturer shall be consulted on matters related to connection conditions

and dimensions.

Gas trains have the following components fitted in the flow direction:

• a manual shut-off valve

• a gas filter

• two gas shut-off valves

• a pressure regulating device

The gas train shall feature automatic leak monitoring.

The plant manufacturer/user shall ensure that the gas train is positioned directly in front of the product, but

no more than 3 meters upstream of the product interface. The interface is the flange of the gas flow control-

ler or the connection of the gas/air mixer of the product.

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Gas system, requirements for dual fuel applications

Gas trains feature the following components in the direction of flow (plant manufacturer/user scope of sup-

ply):

• a manual shut-off valve

• a gas filter

Gas trains feature the following components in the direction of flow (MTU scope of supply):

• two gas shut-off valves (automatic)

• a pressure regulating device

• a manual shut-off valve

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1.6 Safety regulations for maintenance and repair work

Safety regulations when preparing to perform maintenance and repair work

Have maintenance or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk

of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-

ble containers of adequate capacity to catch fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.

Never carry out maintenance and repair work with the product in operation, unless:

• It is expressly permitted to do so following a written procedure.

• The product is running in the low load range and only for as long as absolutely necessary.

Lock-out the product to preclude undesired starting, e.g.

• Start interlock

• Key switch

• With hydraulic starting system: shut off supply line.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock circuit breakers.

Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-

ers are fitted.

Disconnect the control equipment from the product.

Use the recommended special tools or suitable equivalents when instructed to do so.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.

Only install them after painting the engine or mask them prior to painting.

The following applies to starters with copper-beryllium alloy pinions:

• Wear a respirator mask (filter class P3). 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 device.

• Observe the safety data sheet.

Safety regulations when performing maintenance and repair work

Take special care when removing ventilation or plug screws from the product.

Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-

surized lines, shut off the lines first, then release the residual pressure.

Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-

bly.

Carry out work only on assemblies or plants which are properly secured.

Use appropriate lifting equipment for all components. Use all specified attachment points and observe the

center of gravity.

Never work on engines or components when they are held in place by lifting equipment.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that

components/tools fall down.

Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Special instructions

for outdoor areas: There must be no risk of slipping e.g. due to icing.

Keep fuel injection lines and connections clean.

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Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness

(e.g. components carrying oil, fuel, or air).

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Never bend lines and avoid damaging lines, particularly the fuel lines.

Ensure that all retainers and dampers are installed correctly.

Ensure that O-rings are not installed in a slanted/twisted condition.

Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact

with other components. Do not place fuel or oil lines near hot components.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or

resinous appearance.

Note cooling time for components which are heated for installation or removal (risk of burning).

Pay particular attention to cleanliness at all times.

Remove any accumulation of condensate after assembling chilled components. Coat the components with a

suitable corrosion inhibitor as necessary.

Safety regulations after performing maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safety equipment has been installed and that all tools and loose parts have been removed

(especially the barring tool).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Ensure that the grounding system is properly connected.

Welding work

Welding operations on the product or mounted units are not permitted. Cover the product when welding in

its vicinity.

Before starting welding work:

• Switch off the power supply master switch.

• Disconnect the battery cables or actuate the battery isolating switch.

• Separate the electrical ground of electronic equipment from the ground of the unit.

No other maintenance or repair work must be carried out in the vicinity of the product while welding is in

progress. There is a risk of explosion or fire due to oil vapors or highly flammable fluids and lubricants.

Do not use product as ground terminal.

Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product. The

welding current can induce interfering voltages in the wiring harnesses which may damage the electrical sys-

tem.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

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

ces 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 which are under pressure.

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Before starting work, pay attention to the following:

• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.

• 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 device 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 with batteries

Observe the safety instructions of the manufacturer when working on batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow battery acids to come into contact with skin or clothing.

Wear protective clothing, goggles and protective gloves.

Do not place objects on the battery.

Before connecting the cable to the battery, check the battery polarity. The battery may explode and spray

acid if the battery terminals are connected incorrectly.

Working on electrical and 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.

ESD: Work on electrostatically endangered components which could be damaged by electrostatic discharge

(ESD) must always be carried out with appropriate equipment. Appropriate equipment is e.g. electrically con-

ductive work surfaces or antistatic wristbands.

Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur-

ing operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cables on lines carrying fluids.

Do not use cable ties to secure lines.

Always use connector pliers to tighten union nuts on connectors.

Subject the device as well as the product to functional testing on completion of all repair work. The emergen-

cy stop function must be tested in particular.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package

faulty electronic components or assemblies properly before dispatching for repair:

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil (as necessary)

Working with laser equipment

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-

structions in the manufacturer's user manual when working with laser equipment.

Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).

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

and application.

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Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-

perature of 20 °C.

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1.7 Safety regulations for maintenance and servicing work,

specific information for gaseous fuel and dual fuel supply or

applications

Safety regulations for work prior to maintenance and servicing

Assembly work shall be performed by specially trained/qualified and authorized personnel only.

The gas supply shall be connected by trained/qualified and authorized personnel only.

Work on the gas-bearing parts of the product shall be performed by specially trained/qualified and author-

ized personnel only.

Ensure adequate – possibly increased – ventilation before opening the gas system.

Shut down the gas supply to the product by closing the manual shut-off valve.

Lock-out / tag-out the drive unit to prevent starting.

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1.8 Fire prevention and environmental protection, fluids and

lubricants, indirect materials

Fire prevention

Flames, naked light and smoking are prohibited.

Ensure the area is well ventilated when working with combustible indirect materials (e.g. cleaning agents).

The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.

Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires so keep the product

clean at all times. Do not leave rags saturated with fluids and lubricants on the product. Do not store com-

bustible materials near the product.

Clean welding points with a non-flammable fluid before welding. Do not carry out welding work on pipes and

components carrying oil or fuel.

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.

Ensure that suitable extinguishing agents (fire extinguisher) are always available and that staff are familiar

with their correct handling.

Noise

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

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

ger are drowned.

Environmental protection and disposal

Dispose of used fluids, lubricants and components in accordance with local regulations.

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-

cled.

Indirect materials, fluids and lubricants

Indirect materials, fluids and lubricants may be hazardous or contain toxic substances. Observe the informa-

tion provided in the safety data sheet for the product when using indirect materials and other chemical sub-

stances. The safety data sheet may be obtained from the relevant manufacturer or from MTU.

Used oil

Used oil contains harmful combustion residue.

Wear protective gloves!

Wash relevant areas after contact with used oil.

Lead

• Adopt suitable measures to avoid the formation of lead dust.

• Switch on extraction system.

• Avoid direct contact with lead or pastes containing lead.

• Do not inhale lead vapors.

• Wash affected areas after contact with lead or substances containing lead.

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Compressed air

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-

tainers, risks causing an explosion.

• Wear goggles when blowing off components or blowing away chips.

• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)

for drying purposes or to check for leaks risks bursting them.

• Pay special attention to the pressure level in the compressed air network or pressure vessel.

• Assemblies or products which are to be connected must be designed to withstand this pressure. Install

pressure-reducing or safety valves set to the admissible pressure if this is not the case.

• Hose couplings and connections must be securely attached.

• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).

• Relieve residual pressure before removing compressed-air equipment from the supply line. To depressu-

rize compressed-air lines, shut off the lines first, then release the residual pressure.

• Perform leak testing in accordance with instructions.

Paints and lacquers

• Observe the relevant safety data sheet for all materials.

• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure

that the area is well ventilated. Make sure that neighboring work areas are not impaired.

• Avoid open flames in the vicinity.

• No smoking.

• Observe fire prevention regulations.

• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen

• Observe the relevant safety data sheet for all materials.

• Work with liquid nitrogen may be carried out only by qualified personnel.

• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.

• Make sure that the working area is well ventilated.

• Avoid all knocks and jars to the containers, fixtures or workpieces.

Acids/alkaline solutions/urea (AdBlue

®

, DEF)

• Observe the relevant safety data sheet for all materials.

• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and protec-

tive clothing.

• Do not inhale vapors.

• If urea solution is swallowed, rinse out mouth and drink plenty of water.

• Remove any wet clothing immediately.

• Wash affected body areas with plenty of water after skin contact.

• Rinse eyes immediately with eyedrops or clean tap water after eye contact. Seek medical attention as

soon as possible.

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1.9 Fire prevention and environmental protection, fluids and

lubricants, auxiliary materials, specific information for

gaseous fuel supply in gaseous-fuel or dual-fuel applications

General notes on gas

Observe the information contained in the safety data sheet of the gas used. Consult with gas supplier/utility.

The gas used must comply with the (→ Fluids and Lubricants Specifications of the manufacturer).

Risk of poisoning due to hazardous impurities. The ingestion of even small quantities of hydrogen sulfide or

ammonia can be fatal.

Inhaling certain gases can be dangerous to life depending on concentration. Furthermore some gases can no

longer be detected by smell in higher concentrations.

Conduct in case of escaping gases:

• If safe to do so: Shut off main gas supply.

• If safe to do so: Execute an emergency stop.

• Cordon off danger zone.

• Ensure sufficient ventilation.

• Do not enter the hazard zone until it has been established (via measurement of the gas concentration with

a suitable gas detector) that the atmosphere is no longer hazardous.

Check all gas conveying lines for tightness prior to initial operation and at regular intervals during operation.

Natural gas (pipeline quality)

Highly flammable gas; forms an explosive mixture with air/oxygen.

Weakly narcotic gas; risk of suffocation at high concentrations.

Biogenic gases from fermentation processes

Highly flammable gas; forms an explosive mixture with air/oxygen.

Risk of poisoning due to hydrogen sulfide from the fermentation process. The ingestion of even small quanti-

ties of hydrogen sulfide can be fatal.

Weakly narcotic gas; risk of suffocation at high concentrations.

Biogenic gases have a tendency to segregate. In low-lying areas of the plant, carbon dioxide enrichment is

possible.

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1.10 Standards for safety notices in the text

DANGER

In the event of immediate danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

WARNING

In the event of a situation involving potential danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!

• Remedial action.

NOTICE

In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!

• Remedial action.

• Additional product information.

Warning notices

1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-

tion, maintenance, repair, assembly, installation, or transportation.

2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-

al injury shall be considered to include a warning of potential damage.

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