Fuel Injectors & Pumps

Section 2.1 General Safety Precautions to Observe When Working On the Engine

Section 2.1
General Safety Precautions to Observe When Working On the Engine

The following safety measures are essential when servicing the unit fuel injector and the unit injector pumps.‪

Section 2.1.1
EXHAUST (START/RUN ENGINE)

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

caution

EXHAUST FUMES

To avoid injury or injury to bystanders from fumes, engine or vehicle fuel system service operations should be performed in a well ventilated area.‪

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, never remove any engine component while the engine is running.‪

Section 2.1.2
ITEMS UNDER TENSION

To avoid injury from an injector unit pump, do not completely loosen the mounting bolts if under tension. Before removing the unit pump, rotate the crankshaft to relieve the tension on the pump.‪

warning

PERSONAL INJURY

To avoid injury from an ejected injector unit pump, do not completely loosen the mounting bolts until you have tested the spring tension. If the spring tension is at maximum and you remove the mounting cap screws, the pump will be ejected from the engine crankcase.‪

warning

EYE INJURY

To avoid injury from flying parts when working with components under spring tension, wear adequate eye protection (face shield or safety goggles).‪

Section 2.1.3
WORK PLACE

To avoid injury from slipping and falling, organize your work area and keep it clean.‪

warning

PERSONAL INJURY

To avoid injury from slipping and falling, immediately clean up any spilled liquids.‪

Eliminate the possibility of a fall by:‪

  • Wiping up oil spills
  • Keeping tools and parts off the floor

A fall could result in a serious injury.‪

Section 2.1.4
FLUIDS AND PRESSURE

Be extremely careful with fluids under pressure.‪

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

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.‪

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.‪

Section 2.1.5
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.‪

caution

EYE INJURY

To avoid injury from flying debris, wear a face shield or goggles.‪

Section 2.1.6
FIRE

Keep a charged fire extinguisher within reach. Be sure you have the correct type of extinguisher for the situation. The correct fire extinguisher types are listed in Table "The Correct Type of Fire Extinguisher" .‪

Fire Extinguisher

Work Environment

Type A‪

Wood, Paper, Textile and Rubbish‪

Type B‪

Flammable Liquids‪

Type C‪

Electrical Equipment‪

Table 10. The Correct Type of Fire Extinguisher
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.

Section 2.1.7
BATTERIES

Electrical storage batteries give off 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 the engine.‪

Section 2.1.8
CLOTHING

Make sure that safe work clothing fits and it is in good condition. Use work shoes that are sturdy and rough soled. Bare feet, sandals or sneakers are not acceptable foot wear when adjusting and/or servicing an engine. Do not wear rings, wrist watches, bracelets, necklaces and loose fitting clothing that could catch on moving parts causing serious injury.‪

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.‪

warning

PERSONAL INJURY

To avoid injury when working on or near an operating engine, wear protective clothing, eye protection, and hearing protection.‪

Section 2.1.9
AIR

Observe the following caution when using compressed air.‪

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.‪


Unit Fuel Injectors and Unit Pumps Technician's Guide - 7SE500
Generated on 10-13-2008

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