Series 60 DDEC VI Troubleshooting – Section 1.3 Safety Precautions

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.

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

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.‪

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.‪

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.‪

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.‪

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.

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.‪

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.

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

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

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.‪

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.‪

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.

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

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.

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

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

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

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.‪

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

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.‪

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

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

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.‪