DD15 Troubleshooting

Section 1.3 Safety Precautions

Section 1.3
Safety Precautions

The following safety precautions must be observed when working on a Detroit Diesel engine:‪

warning

PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.‪

  • Always start and operate an engine in a well ventilated area.
  • If operating an engine in an enclosed area, vent the exhaust to the outside.
  • Do not modify or tamper with the exhaust system or emission control system.
warning

PERSONAL INJURY

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.‪

All engine installations, especially those within enclosed spaces, should be equipped with an exhaust discharge pipe so that exhaust gases are delivered into the outside air. ‪

warning

PERSONAL INJURY

To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles. Bleed the air from the air starter system before disconnecting the air supply hose.‪

Section 1.3.1
Ether Start

The DDEC Ether Start System is a fully-automatic engine starting fluid system used to assist a DDEC equipped diesel engine in cold starting conditions. The amount of ether is properly controlled to optimize the starting process and prevent engine damage. DDEC will control ether injection using standard sensors to control the ether injection hardware.‪

warning

FIRE AND TOXICITY

Some pressurized fluid may be trapped in the system. To avoid personal injury, loosen all connections slowly to avoid contact with fluid. When required, spray fluid into a proper container. The engine starting fluid used in DDEC Ether Start Systems contains extremely flammable and toxic substances.‪

warning

FIRE AND TOXICITY

To avoid personal injury, spray the fluid from the bottom of the valve into an appropriate container. The engine starting fluid used in DDEC Ether Start Systems contains extremely flammable and toxic substances.‪

Section 1.3.2
Exhaust (Start/Run Engine)

Before starting and running an engine, adhere to the following safety precautions:‪

warning

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

warning

PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.‪

  • Always start and operate an engine in a well ventilated area.
  • If operating an engine in an enclosed area, vent the exhaust to the outside.
  • Do not modify or tamper with the exhaust system or emission control system.

Section 1.3.3
Glasses

Select appropriate safety glasses for the job. It is especially important to wear safety glasses when using tools such as hammers, chisels, pullers or punches.‪

warning

EYE INJURY

To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.‪

Section 1.3.4
Welding

Wear welding goggles and gloves when welding or using an acetylene torch. Ensure that a metal shield separates the acetylene and oxygen tanks. These must be securely chained to a cart. ‪

warning

PERSONAL INJURY

To avoid injury from arc welding, gas welding, or cutting, wear required safety equipment such as an arc welder's face plate or gas welder's goggles, welding gloves, protective apron, long sleeve shirt, head protection, and safety shoes. Always perform welding or cutting operations in a well ventilated area. The gas in oxygen/acetylene cylinders used in gas welding and cutting is under high pressure. If a cylinder should fall due to careless handling, the gage end could strike an obstruction and fracture, resulting in a gas leak leading to fire or an explosion. If a cylinder should fall resulting in the gage end breaking off, the sudden release of cylinder pressure will turn the cylinder into a dangerous projectile. Observe the following precautions when using oxygen/acetylene gas cylinders:‪

  • Always wear required safety shoes.
  • Do not handle tanks in a careless manner or with greasy gloves or slippery hands.
  • Use a chain, bracket, or other restraining device at all times to prevent gas cylinders from falling.
  • Do not place gas cylinders on their sides, but stand them upright when in use.
  • Do not drop, drag, roll, or strike a cylinder forcefully.
  • Always close valves completely when finished welding or cutting.
warning

FIRE

To avoid injury from fire, check for fuel or oil leaks before welding or carrying an open flame near the engine.‪

Section 1.3.5
Pressurized Fluids

Be extremely careful when dealing with fluids under pressure. Fluids under pressure can have enough force to penetrate the skin. These fluids can infect a minor cut or opening in the skin. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can result without immediate medical treatment.‪

warning

PERSONAL INJURY

To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.‪

warning

PERSONAL INJURY

To avoid injury from penetrating fluids, do not put your hands in front of fluid under pressure. Fluids under pressure can penetrate skin and clothing.‪

Section 1.3.6
Fuel

Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank when refueling.‪

warning

FIRE

To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling.‪

The following cautions should be followed when filling a fuel tank:‪

warning

FIRE

To avoid injury from fire caused by heated diesel-fuel vapors:‪

  • Keep those people who are not directly involved in servicing away from the engine.
  • Stop the engine immediately if a fuel leak is detected.
  • Do not smoke or allow open flames when working on an operating engine.
  • Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).
  • To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation.
warning

FIRE

To avoid injury from fire, contain and eliminate leaks of flammable fluids as they occur. Failure to eliminate leaks could result in fire.‪

Section 1.3.7
Batteries

Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to do so for some time after receiving a steady charge.‪

warning

Battery Explosion and Acid Burn

To avoid injury from battery explosion or contact with battery acid, work in a well ventilated area, wear protective clothing, and avoid sparks or flames near the battery. If you come in contact with battery acid:‪

  • Flush your skin with water.
  • Apply baking soda or lime to help neutralize the acid.
  • Flush your eyes with water.
  • Get medical attention immediately.

Always disconnect the battery cable before working on the electrical system.‪

warning

PERSONAL INJURY

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.‪

Section 1.3.8
Fire

Keep a charged fire extinguisher within reach. Ensure you have the proper type of extinguisher on hand.‪

warning

FIRE

To avoid injury from fire, keep a fire extinguisher near the grinding machine in case excessive heat should ignite the oil.‪

Section 1.3.9
Cleaning Agent

Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it releases. Ensure the work area is adequately ventilated. Use protective gloves, goggles or face shield, and apron.‪

warning

PERSONAL INJURY

To avoid injury from harmful vapors or skin contact, do not use carbon tetrachloride as a cleaning agent.‪

Section 1.3.10
Diagnostic Equipment

For mobile applications, Detroit Diesel Diagnostic Link (DDDL) must be used by personnel other than the vehicle operator. The vehicle operator must maintain control of the vehicle while an assistant performs the diagnostic evaluations.‪

warning

PERSONAL INJURY

To avoid injury from loss of vehicle/vessel control, the operator of a DDEC equipped engine must not use or read any diagnostic tool while the vehicle/vessel is moving.‪

Section 1.3.11
Working on a Running Engine

When working on an engine that is running, accidental contact with the hot exhaust manifold can cause severe burns. Remain alert to the location of the rotating fan, pulleys and belts. Avoid making contact across the two terminals of a battery which can result in severe arcing, or battery explosion.‪

warning

PERSONAL INJURY

To avoid injury from rotating belts and fans, do not remove and discard safety guards.‪

warning

PERSONAL INJURY

To avoid injury when working near or on an operating engine, remove loose items of clothing and jewelry. Tie back or contain long hair that could be caught in any moving part causing injury.‪

Section 1.3.12
Optimized Idle

Optimized Idle must be turned on by the factory via order entry or mainframe setup. ‪

caution

UNEXPECTED ENGINE START

To avoid injury from an unexpected startup of an engine equipped with the Optimized Idle system, remove the starter relay from the relay holder.‪

warning

PERSONAL INJURY

To avoid injury from accidental engine startup, replace a defective ECM with an ECM programmed with identical inputs and outputs.‪

Section 1.3.13
Fluoroelastomer

Fluoroelastomer (Viton®) parts such as O-rings and seals are perfectly safe to handle under normal design conditions. ‪

warning

CHEMICAL BURNS

To avoid injury from chemical burns, wear a face shield and neoprene or PVC gloves when handling fluoroelastomer O-rings or seals that have been degraded by excessive heat. Discard gloves after handling degraded fluoroelastomer parts.‪

A potential hazard may occur if these components are raised to a temperature above 600°F (316°C) (in a fire for example). Fluoroelastomer will decompose (indicated by charring or the appearance of a black, sticky mass) and produce hydrofluoric acid. This acid is extremely corrosive and, if touched by bare skin, may cause severe burns (the symptoms could be delayed for several hours).‪


EPA07 DD15 Troubleshooting Guide - DDC-SVC-MAN-0029
Generated on 10-13-2008

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