Case IH MAXXUM 100 User manual

PrintedinU.S.A.
Copyright © 2010 CNHAmerica LLC. All Rights Reserved.
Case IHisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.
MAXXUM 100
MAXXUM 110
MAXXUM 115
MAXXUM 120
MAXXUM 125
MAXXUM 130
MAXXUM 140
Tractor with/without Multicontroller
Part number 84276322ANA
English
November 2010
SERVICE MANUAL

SERVICEMANUAL
MAXXUM100,MAXXUM110Multicontroller,MAXXUM110,MAXXUM115
Multicontroller,MAXXUM115,MAXXUM120Multicontroller,MAXXUM120,
MAXXUM125Multicontroller,MAXXUM125,MAXXUM130Multicontroller,
MAXXUM130,MAXXUM140Multicontroller,MAXXUM140
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Contents
INTRODUCTION
HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMSA
PRIMARYHYDRAULICPOWERSYSTEM...............................................A.10.A
PRIMARYHYDRAULICPOWERSYSTEMClosedcentermechanicalremotevalve....A.10.B
PRIMARYHYDRAULICPOWERSYSTEMElectro-hydraulicremotevalve..............A.10.C
PRIMARYHYDRAULICPOWERSYSTEMOpencentermechanicalremotevalve......A.10.D
SECONDARYHYDRAULICPOWERSYSTEM...........................................A.12.A
HYDRAULICCOMMANDSYSTEM.......................................................A.14.A
ELECTRICALPOWERSYSTEM.........................................................A.30.A
ELECTRICALPOWERSYSTEM.........................................................A.30.A
ELECTRONICSYSTEM..................................................................A.50.A
FAULTCODES............................................................................A.50.A
ENGINEANDPTOIN....................................................................B
ENGINE...................................................................................B.10.A
FUELANDINJECTIONSYSTEM.........................................................B.20.A
AIRINTAKESYSTEM.....................................................................B.30.A
EXHAUSTSYSTEM.......................................................................B.40.A
ENGINECOOLANTSYSTEM............................................................B.50.A
STARTINGSYSTEM......................................................................B.80.A
TRANSMISSION,DRIVEANDPTOOUT.........................................C
POWERCOUPLINGClutch..............................................................C.10.C
TRANSMISSIONMechanical.............................................................C.20.B
TRANSMISSIONPowerShuttle..........................................................C.20.C
TRANSMISSIONSemi-Powershift.......................................................C.20.D
ADDITIONALREDUCERSCreeper......................................................C.30.C
ADDITIONALREDUCERSOverdrive....................................................C.30.D
REARPTOHydraulic.....................................................................C.40.C
FRONTPTOHydraulic...................................................................C.42.C
AXLES,BRAKESANDSTEERING..................................................D
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FRONTAXLE.............................................................................D.10.A
REARAXLE...............................................................................D.12.A
2WD-4WDSYSTEMHydraulic...........................................................D.14.C
STEERINGHydraulic.....................................................................D.20.C
SERVICEBRAKEHydraulic..............................................................D.30.C
PARKINGBRAKEMechanical............................................................D.32.B
BRAKECONNECTIONHydraulic........................................................D.34.C
SUSPENSIONHydraulic.................................................................D.40.C
WHEELSANDTRACKSWheels.........................................................D.50.C
FRAMEANDCAB.........................................................................E
FRAMEPrimaryframe....................................................................E.10.B
SHIELD....................................................................................E.20.A
USERCONTROLSANDSEAT...........................................................E.32.A
USERPLATFORM........................................................................E.34.A
ENVIRONMENTCONTROLHeating,ventilationandair-conditioning....................E.40.D
HITCHANDWORKINGTOOL........................................................H
HITCHFronthitch.........................................................................H.10.B
HITCHRearhitch.........................................................................H.10.C
HITCHElectronicdraftcontrol............................................................H.10.D
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INTRODUCTION
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Contents
INTRODUCTION
Foreword........................................................................................3
Safetyrules.....................................................................................9
Torque........................................................................................21
ConsumablesLubricationsandCoolants.....................................................25
Capacities.....................................................................................27
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INTRODUCTION
Foreword
TechnicalInformation
Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver
technicalinformationelectronicallythroughCD-ROMandinpapermanuals.AcodingsystemcalledICEhasbeen
developedtolinkthetechnicalinformationtootherProductSupportfunctionse.g.Warranty.
Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomers
machine.Whenacustomerhasaconcernonhismachineitisusuallybecauseafunctionorsystemonhismachine
isnotworkingatall,isnotworkingefciently,orisnotrespondingcorrectlytohiscommands.Whenyourefertothe
technicalinformationinthismanualtoresolvethatcustomersconcern,youwillndalltheinformationclassiedusing
thenewICEcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthetechnical
informationforthatfunctionorsystemthenyouwillndallthemechanical,electricalorhydraulicdevices,compo-
nents,assembliesandsubassembliesforthatfunctionorsystem.Youwillalsondallthetypesofinformationthat
havebeenwrittenforthatfunctionorsystem,thetechnicaldata(specications),thefunctionaldata(howitworks),
thediagnosticdata(faultcodesandtroubleshooting)andtheservicedata(remove,installadjust,etc.).
ByintegratingthisnewICEcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttheright
pieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhismachine.Thisismadepossibleby
attaching3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.
TherstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:
•LOCATION-isthecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingto
describee.g.Fueltank.
•INFORMATIONTYPE-isthepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentor
functiononthemachinee.g.CapacitywouldbeatypeofTechnicalDatathatwoulddescribetheamountoffuel
heldbytheFueltank.
•PRODUCT-isthemodelthatthepieceoftechnicalinformationiswrittenfor.
Everypieceoftechnicalinformationwillhavethose3categoriesattachedtoit.Youwillbeabletouseanycombination
ofthosecategoriestondtherightpieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhis
machine.
Thatinformationcouldbe:
•thedescriptionofhowtoremovethecylinderhead
•atableofspecicationsforahydraulicpump
•afaultcode
•atroubleshootingtable
•aspecialtool
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INTRODUCTION
HowtoUsethisManual
ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedatthe
beginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincludedatthe
endofaChapter.PagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedintheChapter
ContentsorChapterIndex.
EachChapterisdividedintofourInformationtypes:
•TechnicalData(specications)forallthemechanical,electricalorhydraulicdevices,componentsand,assemblies.
•FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,componentsandassemblies.
•DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalorhydraulic
devices,componentsandassemblies.
•Servicedata(removedisassembly,assemble,install)forallthemechanical,electricalorhydraulicdevices,com-
ponentsandassemblies.
Sections
Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentiedby
aletterA,B,Cetc.TheamountofSectionsincludedinthemanualwilldependonthetypeandfunctionofthe
machinethatthemanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.This
tableillustrateswhichSectionscouldbeincludedinamanualforaparticularproduct.
SECTION
A-DistributionSystems
B-PowerProduction
C-PowerTrain
D-Travelling
E-BodyandStructure
F-FramePositioning
G-T oolPositioning
H-WorkingArm
J-ToolsandCouplers
K-CropProcessing
L-FieldProcessing
PRODUCT
TractorsXXXXXXXX
Vehicleswithworkingarms:backhoes,
excavators,skidsteers,.....
XXXXXXXXX
Combines,forageharvesters,balers,....XXXXXXXXXX
Seeding,planting,oating,spraying
equipment,....
XXXXXXXXX
Mountedequipmentandtools,.....XXXX
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INTRODUCTION
ThismanualcontainstheseSections.ThecontentsofeachSectionareexplainedoverthefollowingpages.
Contents
INTRODUCTION
DISTRIBUTIONSYSTEMSA
POWERPRODUCTIONB
POWERTRAINC
TRAVELLINGD
BODYANDSTRUCTUREE
TOOLPOSITIONINGG
CROPPROCESSINGK
SectionContents
SECTIONA,DISTRIBUTIONSYSTEMS
ThisSectioncoversthemainsystemsthatinteractwithmostofthefunctionsoftheproduct.Itincludesthecentral
partsofthehydraulic,electrical,electronic,pneumatic,lightingandgreaselubricationsystems.Thecomponentsthat
arededicatedtoaspecicfunctionarelistedintheChapterwhereallthetechnicalinformationforthatfunctionis
included.
SECTIONB,POWERPRODUCTION
ThisSectioncoversallthefunctionsrelatedtotheproductionofpowertomovethemachineandtodrivevarious
devices.
SECTIONC,POWERTRAIN
ThisSectioncoversallthefunctionsrelatedtothetransmissionofpowerfromtheenginetotheaxlesandtointernal
orexternaldevicesandadditionalProcessDrivefunctions.
SECTIOND,TRAVELLING
ThisSectioncoversallthefunctionsrelatedtomovingthemachine,includingtracks,wheels,steeringandbraking.It
coversalltheaxlesbothdrivenaxlesandnon-drivenaxles,includinganyaxlesuspension.
SECTIONE,BODYANDSTRUCTURE
ThisSectioncoversallthemainfunctionsandsystemsrelatedtothestructureandbodyofthemachine.Including
theframe,theshields,theoperator’scabandtheplatform.
SECTIONG,TOOLPOSITIONING
ThisSectioncoversallthefunctionsrelatedtothenaland/orautomaticpositioningofthetooloncethetoolisposi-
tionedusingtheWorkingArmorthemachineframe.
SECTIONK,CROPPROCESSING
ThisSectioncoversallthefunctionsrelatedtocropprocessing.
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INTRODUCTION
Chapters
EachChapterisidentiedbyaletterandnumbercombinatione.g.EngineB.10.ATherstletterisidenticaltothe
Sectionletteri.e.ChapterB.10isinsideSectionB,PowerProduction.
CONTENTS
TheChapterContentslistsallthetechnicaldata(specications),functionaldata(howitworks),servicedata(remove,
installadjust,etc..)anddiagnosticdata(faultcodesandtroubleshooting)thathavebeenwritteninthatChapterfor
thatfunctionorsystemonthemachine.
Contents
POWERPRODUCTION
ENGINE_10.A
TECHNICALDATA
ENGINE-Generalspecication(B.10.A-D.40.A.10)
CS6050
FUNCTIONALDATA
ENGINE-Dynamicdescription(B.10.A-C.30.A.10)
CS6050
SERVICE
ENGINE-Remove(B.10.A-F.10.A.10)
CS6050
DIAGNOSTIC
ENGINE-Troubleshooting(B.10.A-G.40.A.10)
CS6050
INDEX
TheChapterIndexlistsinalphabeticalorderallthetypesofinformation(calledInformationUnits)thathavebeen
writteninthatChapterforthatfunctionorsystemonthemachine.
Index
POWERPRODUCTION-B
ENGINE
ENGINE-Dynamicdescription(B.10.A-C.30.A.10)
CS6050
ENGINE-Generalspecication(B.10.A-D.40.A.10)
CS6050
ENGINE-Remove(B.10.A-F.10.A.10)
CS6050
ENGINE-Troubleshooting(B.10.A-G.40.A.10)
CS6050
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INTRODUCTION
InformationUnitsandInformationSearch
Eachchapteriscomposedofinformationunits.EachinformationunithastheICEcodeshowninparentheseswhich
indicatesthefunctionandthetypeofinformationwritteninthatinformationunit.Eachinformationunithasapageref-
erencewithinthatChapter.Theinformationunitsprovideaquickandeasywaytondjusttherightpieceoftechnical
informationyouarelookingfor.
exampleinformationunitStackvalve-SectionalView(A.10.A.18-C.10.A.30)
InformationUnitICEcodeA10.A18C10.A.30
ICEcodeclassicationDistribution
systems
Primary
hydraulic
power
StackvalveFunctional
data
Sectionalview
CRIL03J033E011
Navigatetothecorrectinformationunityouaresearchingforbyidentifyingthefunctionandinformationtype
fromtheICEcode.
•(1)Functionand(2)Informationtype.
•(A)correspondstothesectionsoftherepairmanual.
(B)correspondstothechaptersoftherepairmanual.
(C)correspondstothetypeofinformationlistedinthechaptercontents,T echnicaldata,FunctionalData,Diag-
nosticorService.
(A)and(B)arealsoshowninthepagenumberingonthepagefooter.
THERESTOFTHECODINGISNOTLISTEDINALPHANUMERICORDERINTHISMANUAL.
•Youwillndatableofcontentsatthebeginningandendofeachsectionandchapter.
Youwillndanalphabeticalindexattheendofeachchapter.
•Byreferringto(A),(B)and(C)ofthecoding,youcanfollowthecontentsorindex(pagenumbers)andquickly
ndtheinformationyouarelookingfor.
PageHeaderandFooter
Thepageheaderwillcontainthefollowingreferences:
•SectionandChapterdescription
Thepagefooterwillcontainthefollowingreferences:
•PublicationnumberforthatManual,SectionorChapter.
•Versionreferenceforthatpublication.
•Publicationdate
•Section,chapterandpagereferencee.g.A.10.A/9
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INTRODUCTION
Importantinformation
AllrepairandmaintenanceworkslistedinthismanualmustbecarriedoutonlybystaffbelongingtotheCaseIH
Servicenetwork,strictlycomplyingwiththeinstructionsgivenandusing,wheneverrequired,thespecialtools.
Anyonewhocarriesouttheaboveoperationswithoutcomplyingwiththeprescriptionsshallberesponsibleforthe
subsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regionalor
localdealers,rejectanyresponsibilityfordamagesduetotheanomalousbehaviourofpartsand/orcomponentsnot
approvedbythemanufacturerhimself,includingthoseusedfortheservicingorrepairoftheproductmanufactured
ormarketedbytheManufacturer.Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedor
marketedbytheManufacturerincaseofdamagesduetoananomalousbehaviourofpartsand/orcomponentsnot
approvedbytheManufacturer.
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INTRODUCTION
Safetyrules
IMPORTANTNOTICE
Allmaintenanceandrepairoperationsdescribedinthismanualshouldbecarriedoutexclusivelybyauthorisedwork-
shops.Allinstructionsshouldbecarefullyobservedandspecialequipmentwhereindicatedshouldbeused.
Anyonewhocarriesoutserviceoperationsdescribedwithoutcarefullyobservingtheseinstructionswillbedirectly
responsibleforanydamagecaused.
NOTESFOREQUIPMENT
Equipmentshowninthismanualis:
•designedexpresslyforuseonthesetractors;
•necessarytomakeareliablerepair;
•accuratelybuiltandstrictlytestedtoofferefcientandlong-lastingworkinglife.
NOTICES
Thewords“front”,“rear”,“righthand”,and“lefthand”refertothedifferentpartsasseenfromtheoperator’sseat
orientedtothenormaldirectionofmovementofthetractor.
SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thiswarningsymbolpointsoutimportantmessagesinvolvingpersonal
safety.Carefullyreadthesafetyrulescontainedhereinandfollowadvised
precautionstoavoidpotentialhazardsandsafeguardyoursafety.
Inthismanualyouwillndthissymboltogetherwiththefollowing
key-words:
WARNING-itgiveswarningaboutimproperrepairoperationsandpotential
consequencesaffectingtheservicetechnician’spersonalsafety.
DANGER-itgivesspecicwarningaboutpotentialdangersforpersonal
safetyoftheoperatororotherpersonsdirectlyorindirectlyinvolvedin
theoperation.
TOPREVENTACCIDENTS
Mostaccidentsandpersonalinjuriestakingplaceinworkshopsareduefromnon-observanceofsomeessentialrules
andsafetyprecautions.
Thepossibilitythatanaccidentmightoccurwithanytypeofmachinesshouldnotbedisregarded,nomatterhowwell
themachineinquestionwasdesignedandbuilt.
Awiseandcarefulservicetechnicianisthebestprecautionsagainstaccidents.
Carefulobservanceofthisbasicprecautionwouldbeenoughtoavoidmanysevereaccidents.
DANGER
Nevercarryoutanycleaning,lubricationormaintenanceoperationswhentheengineisrunning.
B013
SAFETYRULES
Generalities
•Carefullyfollowspeciedrepairandmaintenanceprocedures.
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INTRODUCTION
•Donotwearrings,wristwatches,jewels,unbuttonedorappingclothingsuchasties,tornclothes,scarves,open
jacketsorshirtswithopenzipswhichcouldgetcaughtonmovingparts.Useapprovedsafetyclothingsuchas
anti-slippingfootwear,gloves,safetygoggles,helmets,etc.
•Wearsafetyglasseswithsideguardswhencleaningpartsusingcompressedair.
•Damagedorfrayedwiresandchainsareunreliable.Donotusethemforliftingortowing.
•Wearsuitableprotectionsuchasapprovedeyeprotection,helmets,specialclothing,glovesandfootwearwhen-
everwelding.Allpersonsstandinginthevicinityoftheweldingprocessshouldwearapprovedeyeprotection.
NEVERLOOKATTHEWELDINGARCIFYOUREYESARENOTSUITABLYPROTECTED.
•Nevercarryoutanyrepaironthemachineifsomeoneissittingontheoperator’sseat,exceptiftheyarequalied
operatorsassistingintheoperationtobecarriedout.
•Neveroperatethemachineoruseattachmentsfromaplaceotherthansittingattheoperator’sseatorattheside
ofthemachinewhenoperatingthefenderswitches.
•Nevercarryoutanyoperationonthemachinewhentheengineisrunning,exceptwhenspecicallyindicated.Stop
theengineandensurethatallpressureisrelievedfromhydrauliccircuitsbeforeremovingcaps,covers,valves,
etc.
•Allrepairandmaintenanceoperationsshouldbecarriedoutwiththegreatestcareandattention.
•Disconnectthebatteriesandlabelallcontrolstowarnthatthetractorisbeingserviced.Blockthemachineandall
equipmentwhichshouldberaised.
•Nevercheckorllfueltanksorbatteries,norusestartingliquidifyouaresmokingornearopenamesassuch
uidsareammable.
•Thefuelllinggunshouldalwaysremainincontactwiththellerneck.Maintainthiscontactuntilthefuelstops
owingintothetanktoavoidpossiblesparksduetostaticelectricitybuild-up.
•Totransferafailedtractor,useatraileroralowloadingplatformtrolleyifavailable.
•Toloadandunloadthemachinefromthetransportationmeans,selectaatareaprovidingarmsupporttothe
trailerortruckwheels.Firmlytiethemachinetothetruckortrailerplatformandblockwheelsasrequiredbythe
transporter.
•Alwaysuseliftingequipmentofappropriatecapacitytoliftormoveheavycomponents.
•Chainsshouldalwaysbesafelyfastened.Ensurethatfasteningdeviceisstrongenoughtoholdtheloadforeseen.
Nopersonsshouldstandnearthefasteningpoint.
•TheworkingareashouldbealwayskeptCLEANandDRY .Immediatelycleananyspillageofwateroroil.
•Neverusegasoline,dieseloilorotherammableliquidsascleaningagents.Usenon-ammablenon-toxicpro-
prietarysolvents.
•Donotpileupgreaseoroilsoakedrags,astheyconstituteagreatrehazard.Alwaysplacethemintoametal
container.
STARTUP
•Neverruntheengineinconnedspaceswhicharenotequippedwithadequateventilationforexhaustgasextrac-
tion.
•Neverbringyourhead,body,arms,legs,feet,hands,ngersnearfansorrotatingbelts.
ENGINE
•Alwaysloosentheradiatorcapveryslowlybeforeremovingittoallowpressureinthesystemtodissipate.Coolant
shouldbetoppeduponlywhentheengineisstopped.
•Donotllupfueltankwhentheengineisrunning.
•Neveradjustthefuelinjectionpumpwhenthetractorismoving.
•Neverlubricatethetractorwhentheengineisrunning.
ELECTRICALSYSTEMS
•Ifitisnecessarytouseauxiliarybatteries,cablesmustbeconnectedatbothsidesasfollows:(+)to(+)and(-)to
(-).Avoidshort-circuitingtheterminals.GASRELEASEDFROMBATTERIESISHIGHLYFLAMMABLE.During
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INTRODUCTION
charging,leavethebatterycompartmentuncoveredtoimproveventilation.Avoidsparksoramesnearthebattery
area.Donosmoke.
•Donotchargebatteriesinconnedspaces.
•Alwaysdisconnectthebatteriesbeforeperforminganytypeofserviceontheelectricalsystem.
HYDRAULICSYSTEMS
•Someuidcomingoutfromaverysmallportcanbealmostinvisibleandbestrongenoughtopenetratetheskin.
Forthisreason,NEVERUSEYOURHANDSTOCHECKFORLEAKS,butuseapieceofcardboardorapiece
ofwoodforthispurpose.Ifanyuidisinjectedintotheskin,seekmedicalaidimmediately.Lackofimmediate
medicalattentionmayresultinseriousinfectionsordermatitis.
•Alwaystakesystempressurereadingsusingtheappropriategauges.
WHEELSANDTYRES
•Checkthatthetyresarecorrectlyinatedatthepressurespeciedbythemanufacturer.Periodicallycheckfor
possibledamagetotherimsandtyres.
•Stayatthetyresidewheninating.
•Checkthepressureonlywhenthetractorisunloadedandtyresarecoldtoavoidwrongreadingsduetoover-
pressure.
•Nevercut,norweldarimwiththeinatedtyreassembled.
•Toremovethewheels,blockbothfrontandreartractorwheels.Raisethetractorandinstallsafeandstable
supportsunderthetractorinaccordancewithregulationsinforce.
•Deatethetyrebeforeremovinganyobjectcaughtintothetyretread.
•Neverinatetyresusingammablegasesastheymaygenerateexplosionsandcauseinjuriestobystanders.
REMOVALANDINSTALLATION
•Liftandhandleallheavycomponentsusingliftingequipmentofadequatecapacity.Ensurethatpartsaresupported
byappropriateslingsandhooks.Useliftingeyesprovidedtothispurpose.T akecareofthepersonsneartheloads
tobelifted.
HEALTHANDSAFETY
CONTENT
SectionDescriptionPage
HEALTHANDSAFETYPRECAUTIONS..............................4
ACIDSANDALKALIS............................................5
ADHESIVESANDSEALERS-seeFire................................5
ANTIFREEZE-seeFire,Solventse.g.Isopropanol,EthyleneGlycol,Methanol......5
ARCWELDING-seeWelding........................................5
BATTERYACIDS-seeAcidsandAlkalis...............................5
BRAKEANDCLUTCHFLUIDS(PolyalkyleneGlycols)-seeFire.............6
BRAZING-seeWelding.............................................6
CHEMICALMATERIALS-GENERAL-seeLegalAspects.................6
DO’S...........................................................6
DONOTS........................................................6
CORROSIONPROTECTIONMATERIALS-seeSolvents,Fire...............6
DUSTS.........................................................7
ELECTRICSHOCK................................................7
EXHAUSTFUMES................................................7
FIBREINSULATION-seeDusts......................................7
FIRE-seeWelding,Foams,LegalAspects................................7
FIRSTAID.......................................................7
FOAMS-Polyurethane-seeFire........................................7
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INTRODUCTION
FUELS-seeFire,LegalAspects,Chemicals-General,Solvents.................8
GASCYLINDERS-seeFire..........................................8
GENERALWORKSHOPTOOLSANDEQUIPMENT.....................9
LEGALASPECTS.................................................9
LUBRICANTSANDGREASES.......................................9
PAINTS-seeSolventsandChemicalMaterials-General......................10
SOLDER-seeWelding..............................................10
SOLVENTS-seeChemicalMaterials-GeneralFuels(Kerosene),Fire............10
SUSPENDEDLOADS..............................................11
WELDING-seeFire,ElectricShock,GasCylinders.........................11
HEALTHANDSAFETYPRECAUTIONS
Manyoftheproceduresassociatedwithvehiclemaintenanceandrepairinvolvephysicalhazardsorotherrisksto
health.Thissectionlists,alphabetically,someofthesehazardousoperationsandthematerialsandequipmentasso-
ciatedwiththem.Theprecautionsnecessarytoavoidthesehazardsareidentied.
Thelistisnotexhaustiveandalloperationsandproceduresandthehandlingofmaterials,shouldbecarriedoutwith
healthandsafetyinmind.
ACIDSANDALKALIS
seeBatteryacids,e.g.causticsoda,sulphuricacid.
Usedinbatteriesandcleaningmaterials.
Irritantandcorrosivetotheskin,eyes,noseandthroat.Causesburns.
Avoidsplashestotheskin,eyesandclothing.Wearsuitableprotectiveglovesandgoggles.Candestroyordinary
protectiveclothing.Donotbreathemists.
Ensureaccesstowaterandsoapisreadilyavailableforsplashingaccidents.
ADHESIVESANDSEALERS
seeFire
HighlyFlammable,Flammable,combustible.
Generallyshouldbestoredin“NoSmoking”areas;cleanlinessandtidinessinuseshouldbeobserved,e.g.dispos-
ablepapercoveringbenches;shouldbedispensedfromapplicatorswherepossible;containers,includingsecondary
containers,shouldbelabelled.
SolventbasedAdhesives/Sealers
SeeSolvents.
Followmanufacturersinstructions.
WaterbasedAdhesives/Sealers
Thosebasedonpolymeremulsionsandrubberlatticesmaycontainsmallamountsofvolatiletoxicandharmfulchem-
icals.Skinandeyecontactshouldbeavoidedandadequateventilationprovidedduringuse.
Followmanufacturersinstructions.
ResinbasedAdhesives/Sealers
e.g.epoxideandformaldehyderesinbased.
Mixingshouldonlybecarriedoutinwellventilatedareasasharmfulortoxicvolatilechemicalsmaybereleased.
Skincontactwithuncuredresinsandhardenerscanresultinirritation;dermatitisandabsorptionoftoxicorharmful
chemicalsthroughtheskin.Splashescandamagetheeyes.
Provideadequateventilationandavoidskinandeyecontact.Followmanufacturersinstructions.
Anaerobic,CyanoacrylateandotherAcrylicAdhesives
Manyareirritant,sensitizingorharmfultotheskin.Someareeyeirritants.
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INTRODUCTION
Skinandeyecontactshouldbeavoidedandthemanufacturersinstructionsfollowed.
Cyanoacrylateadhesives(super-glues)mustnotcontacttheskinoreyes.Ifskinoreyetissueisbondedcoverwitha
cleanmoistpadandgetmedicalattention.donotattempttopulltissueapart.Useinwellventilatedareasasvapours
cancauseirritationofthenoseandeyes.
Fortwo-packsystemsseeResinbasedadhesives/sealers.
Isocyanate(Polyurethane)Adhesives/Sealers
seeResinbasedAdhesives.
Individualssufferingfromasthmaorrespiratoryallergiesshouldnotworkwithornearthesematerialsassensitivity
reactionscanoccur.
Anysprayingshouldpreferablybecarriedoutinexhaustventilatedboothsremovingvapoursandspraydropletsfrom
thebreathingzone.Individualsworkingwithsprayapplicationsshouldwearsuppliedairrespirators.
ANTIFREEZE
seeFire,Solventse.g.Isopropanol,EthyleneGlycol,Methanol.
HighlyFlammable,Flammable,Combustible.
Usedinvehiclecoolantsystems,brakeairpressuresystems,screenwashsolutions.
Vapoursgivenofffromcoolantantifreeze(glycol)ariseonlywhenheated.
Antifreezemaybeabsorbedthroughtheskinintoxicorharmfulquantities.Antifreezeifswallowedisfatalandmedical
attentionmustbefoundimmediately.
ARCWELDING
seeWelding.
BATTERYACIDS
seeAcidsandAlkalis.
Gasesreleasedduringchargingareexplosive.
Neverusenakedamesorallowsparksnearchargingorrecentlychargedbatteries.
BRAKEANDCLUTCHFLUIDS(PolyalkyleneGlycols)
seeFire.
Combustible.
Splashestotheskinandeyesareslightlyirritating.
Avoidskinandeyecontactasfaraspossible.
Inhalationofvapourhazardsdonotariseatambienttemperaturesbecauseoftheverylowvapourpressure.
BRAZING
seeWelding.
CHEMICALMATERIALS-GENERAL
seeLegalAspects.
Chemicalmaterialssuchassolvents,sealers,adhesives,paints,resinfoams,batteryacids,antifreeze,brakeuids,
oilsandgreaseshouldalwaysbeusedwithcautionandstoredandhandledwithcare.Theymaybetoxic,harmful,
corrosive,irritantorhighlyinammableandgiverisetohazardousfumesanddusts.
Theeffectsofexcessiveexposuretochemicalsmaybeimmediateordelayed;brieyexperiencedorpermanent;
cumulative;supercial;lifethreatening;ormayreducelife-expectancy.
DO’S
Doremovechemicalmaterialsfromtheskinandclothingassoonaspracticableaftersoiling.Changeheavilysoiled
clothingandhaveitcleaned.
Docarefullyreadandobservehazardandprecautionwarningsgivenonmaterialcontainers(labels)andinany
accompanyingleaets,posterorotherinstructions.Materialhealthandsafetydatasheetscanbeobtainedfrom
Manufacturers.
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INTRODUCTION
Doorganiseworkpracticesandprotectiveclothingtoavoidsoilingoftheskinandeyes;breathingvapours/aerosols/
dusts/fumes;inadequatecontainerlabelling;reandexplosionhazards.
Dowashbeforejobbreaks;beforeeating,smoking,drinkingorusingtoiletfacilitieswhenhandlingchemicalmaterials.
Dokeepworkareasclean,unclutteredandfreeofspills.
Dostoreaccordingtonationalandlocalregulations.
Dokeepchemicalmaterialsoutofreachofchildren.
DONOTS
DoNotmixchemicalmaterialsexceptunderthemanufacturersinstructions;somechemicalscanformothertoxicor
harmfulchemicals;giveofftoxicorharmfulfumes;beexplosivewhenmixedtogether.
DoNotspraychemicalmaterials,particularlythosebasedonsolvents,inconnedspacese.g.whenpeopleare
insideavehicle.
DoNotapplyheatorametochemicalmaterialsexceptunderthemanufacturers’instructions.Somearehighly
inammableandsomemayreleasetoxicorharmfulfumes.
DoNotleavecontainersopen.Fumesgivenoffcanbuilduptotoxic,harmfulorexplosiveconcentrations.Some
fumesareheavierthanairandwillaccumulateinconnedareas,pitsetc.
DoNottransferchemicalmaterialstounlabeledcontainers.
DoNotcleanhandsorclothingwithchemicalmaterials.Chemicals,particularlysolventsandfuelswilldrytheskin
andmaycauseirritationwithdermatitis.Somecanbeabsorbedthroughtheskinintoxicorharmfulquantities.
DoNotuseemptiedcontainersforothermaterials,exceptwhentheyhavebeencleanedundersupervisedconditions.
DoNotsnifforsmellchemicalmaterials.Briefexposuretohighconcentrationsoffumescanbetoxicorharmful.
ClutchFluids
seeBrakeandClutchFluids.
ClutchLiningsandPads
seeBrakeandClutchLiningsandPads.
CORROSIONPROTECTIONMATERIALS
seeSolvents,Fire.
Highlyammable,ammable.
Thesematerialsarevariedandthemanufacturersinstructionsshouldbefollowed.Theymaycontainsolvents,resins,
petroleumproductsetc.Skinandeyecontactshouldbeavoided.Theyshouldonlybesprayedinconditionsof
adequateventilationandnotinconnedspaces.
Cutting
seeWelding.
De-Waxing
seeSolventsandFuels(Kerosene).
DUSTS
Powder,dustsorcloudsmaybeirritant,harmfulortoxic.Avoidbreathingdustsfrompowderychemicalmaterialsor
thosearisingfromdryabrasionoperations.Wearrespiratoryprotectionifventilationisinadequate.
ELECTRICSHOCK
Electricshockscanresultfromtheuseoffaultyelectricalequipmentorfromthemisuseofequipmenteveningood
condition.
Ensurethatelectricalequipmentismaintainedingoodconditionandfrequentlytested.
Ensurethatexes,cables,plugsandsocketsarenotfrayed,kinked,cut,crackedorotherwisedamaged.
Ensurethatelectricequipmentisprotectedbythecorrectratedfuse.
Nevermisuseelectricalequipmentandneveruseequipmentwhichisinanywayfaulty.Theresultscouldbefatal.
Usereducedvoltageequipment(110volt)forinspectionandworkinglightswherepossible.
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INTRODUCTION
Ensurethatthecablesofmobileelectricalequipmentcannotgettrappedanddamaged,suchasinavehiclehoist.
Useairoperatedmobileequipmentwherepossibleinpreferencetoelectricalequipment.
Incasesofelectrocution:-
•switchoffelectricitybeforeapproachingvictim
•ifthisisnotpossible,pushordragvictimfromsourceofelectricityusingdrynon-conductivematerial
•commenceresuscitationiftrainedtodoso
•SUMMONMEDICALASSISTANCE
EXHAUSTFUMES
Thesecontainasphyxiating,harmfulandtoxicchemicalsandparticlessuchascarbonoxides,nitrogenoxides,alde-
hydes,leadandaromatichydrocarbons.Enginesshouldonlyberununderconditionsofadequateextractionor
generalventilationandnotinconnedspaces.
Gasolene(Petrol)Engine
Theremaynotbeadequatewarningpropertiesofodourorirritationbeforeimmediateanddelayedtoxicorharmful
effectsarise.
DieselEngine
Soot,discomfortandirritationusuallygiveadequatewarningofhazardousfumeconcentrations.
FIBREINSULATION
seeDusts.
Usedinnoiseandsoundinsulation.
Thebrousnatureofsurfacesandcutedgescancauseskinirritation.Thisisusuallyaphysicalandnotachemical
effect.
Precautionsshouldbetakentoavoidexcessiveskincontactthroughcarefulorganisationofworkpracticesandthe
useofgloves.
FIRE
seeWelding,Foams,LegalAspects.
Manyofthematerialsfoundonorassociatedwiththerepairofvehiclesarehighlyammable.Somegiveofftoxicor
harmfulfumesifburnt.
Observestrictresafetywhenstoringandhandlingammablematerialsorsolvents,particularlynearelectricalequip-
mentorweldingprocesses.
Ensurebeforeusingelectricalorweldingequipmentbutthatthereisnorehazardpresent.
Haveasuitablereextinguisheravailablewhenusingweldingorheatingequipment.
FIRSTAID
Apartfrommeetinganylegalrequirementsitisdesirableforsomeoneintheworkshoptobetrainedinrstaidproce-
dures.
Splashesintheeyeshouldbeushedwithcleanwaterforatleasttenminutes.
Soiledskinshouldbewashedwithsoapandwater.
Inhalationaffectedindividualsshouldberemovedtofreshairimmediately.
Ifswallowedorifeffectspersistconsultadoctorwithinformation(label)onmaterialused.
Donotinducevomiting(unlessindicatedbymanufacturer).
FOAMS-Polyurethane
seeFire.
Usedinsoundandnoiseinsulation.Curedfoamsusedinseatandtrimcushioning.
Followmanufacturersinstructions.
Unreactedcomponentsareirritatingandmaybeharmfultotheskinandeyes.Wearglovesandgoggles.
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