New Holland T6.110 User manual

SERVICE MANUAL
T6.110 / T6.120 / T6.130
Tractor
Part number 47705279
English
September 2014
Copyright © 2014 CNH INDUSTRIAL LATIN AMERICA LTDA.All Rights Reserved.
SERVICE
MANUAL
T6.110
T6.120
T6.130
Tractor
Part number 47705279

SERVICEMANUAL
T6.110Cabinado,T6.110Semcabine,T6.120Cabinado,T6.120Semcabine,
T6.130Cabinado,T6.130Semcabine
4770527911/09/2014
EN
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LinkProduct/Engine
ProductMarketProductEngine
T6.110Cabinado
[HCCZ6110HECS24371-]
LatinAmericaF4CE0484C*B601
T6.110Semcabine
[HCCZ6110TECS23550-]
LatinAmericaF4CE0484C*B601
T6.120Cabinado
[HCCZ6120XECS23550-]
LatinAmericaF4CE0484A*B605
T6.120Semcabine
[HCCZ6120HECS24546-]
LatinAmericaF4CE0484A*B605
T6.130Cabinado
[HCCZ6130LECS24656-]
LatinAmericaF4CE0484B*B602
T6.130Semcabine
[HCCZ6130XECS23550-]
LatinAmericaF4CE0484B*B602
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.216]Fueltanks..........................................................................10.2
[10.218]Fuelinjectionsystem...............................................................10.3
[10.250]Turbochargerandlines.............................................................10.4
[10.254]Intakeandexhaustmanifoldsandmufer.........................................10.5
[10.400]Enginecoolingsystem.............................................................10.6
Clutch.......................................................................................18
[18.110]Clutchandcomponents............................................................18.1
Transmission..............................................................................21
[21.114]Mechanicaltransmission...........................................................21.1
[21.112]Powershuttletransmission.........................................................21.2
[21.134]Powershuttletransmissionexternalcontrols......................................21.3
[21.109]Transmissioncoolerandlines......................................................21.4
Four-WheelDrive(4WD)system..................................................23
[23.304]Four-WheelDrive(4WD)gearbox.................................................23.1
[23.314]Driveshaft..........................................................................23.2
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.120]Planetaryandnaldrives..........................................................27.3
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PowerT ake-Off(PTO).................................................................31
[31.114]Two-speedrearPowerTake-Off(PTO)............................................31.1
Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
[33.110]Parkingbrakeorparkinglock......................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.104]Fixeddisplacementpump..........................................................35.2
[35.102]Pumpcontrolvalves................................................................35.3
[35.359]Maincontrolvalve..................................................................35.4
[35.204]Remotecontrolvalves.............................................................35.5
Hitches,drawbars,andimplementcouplings..................................37
[37.110]Rearthree-pointhitch..............................................................37.1
Framesandballasting.................................................................39
[39.140]Ballastsandsupports..............................................................39.1
Steering.....................................................................................41
[41.200]Hydrauliccontrolcomponents......................................................41.1
[41.216]Cylinders...........................................................................41.2
[41.432]Autoguidancesteering.............................................................41.3
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
[44.520]Rearwheels........................................................................44.2
Cabclimatecontrol.....................................................................50
[50.200]Airconditioning.....................................................................50.1
Electricalsystems.......................................................................55
[55.100]Harnessesandconnectors.........................................................55.1
[55.201]Enginestartingsystem.............................................................55.2
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[55.301]Alternator...........................................................................55.3
[55.302]Battery..............................................................................55.4
[55.045]Frontaxlecontrolsystem..........................................................55.5
[55.408]Warningindicators,alarms,andinstruments......................................55.6
Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.110]Operatorplatformlesscab.........................................................90.2
[90.114]Operatorprotections...............................................................90.3
[90.120]Mechanically-adjustedoperatorseat...............................................90.4
[90.124]Pneumatically-adjustedoperatorseat..............................................90.5
[90.100]Enginehoodandpanels...........................................................90.6
[90.102]Engineshields,hoodlatches,andtrims...........................................90.7
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INTRODUCTION
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Contents
INTRODUCTION
Advice...........................................................................................3
Internationalsymbols...........................................................................4
Foreword........................................................................................5
Advice...........................................................................................6
Safetyrules.....................................................................................7
Safetyrules.....................................................................................8
Safetyrules...................................................................................10
Safetyrules...................................................................................12
Torque-Minimumtighteningtorquesfornormalassembly...................................16
Basicinstructions-ShopandAssembly......................................................21
Consumables.................................................................................23
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INTRODUCTION
Advice
Allrepairandmaintenanceworkslistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven;andusing,wheneverpossible,thespecialtools.
Anyonewhocarriesouttheaboveoperationswithoutcomplyingwiththeproceduresshallberesponsibleforthe
subsequentdamages.
Themanufacturerandalltheorganizationsofit'sdistributionchain,including-withoutlimitation-national,regional,
orlocaldealers,rejectanyresponsibilityfordamagesduetotheanomalousbehaviorofpartsand/orcomponentsnot
approvedbythemanufacturerhimself,includingthoseusedfortheservicingorrepairoftheproductmanufactured
ormarketedbythemanufacturer.Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedor
marketedbythemanufacturerincaseofdamagesduetoananomalousbehaviorofpartsand/orcomponentsnot
approvedbythemanufacturer.
Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor
continuousimprovement.Someinformationcouldnotbeupdatedduetomodicationsofatechnicalorcommercial
type,aswellastosuitthelawsandregulationsofdifferentcountries.
Incaseofquestions,refertoyourSalesandServiceNetworks.
4770527911/09/2014
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INTRODUCTION
Internationalsymbols
Asaguidetotheoperationofthemachine,variousuniversalsymbolshavebeenutilizedontheinstruments,controls,
switches,andfusebox.Thesymbolsareshownbelowwithanindicationoftheirmeaning.
Heaterplugfor
coldstartTurningsignalPowerTake-Off
(PTO)Reactioncontrol
Alternator
chargingActivatedmemoryTransmissionin
neutral
Accessories
socket
FuellevelTurnsignalsCreeperselectionImplementsocket
Automaticfuel
shut-off
Turnsignals-one
trailer
Lowspeed
selectionPercentageslip
Enginespeed
(rpmx100)
Turnsignals-two
trailers
Highspeed
selection
Raisingofthe
hydrauliclift
HourmeterWindshield
washerRoadspeedRearhitchlower
Engineoil
pressure
Windscreenwash
wipeDifferentialLockHydrauliclift heightthreshold
Enginecoolant
temperature
Heating
temperature
control
Rearaxleoil
temperature
Hydrauliclift
disabled
CoolantlevelCabrecirculation
fan
Transmissionoil
pressure
Transmission
ltersand
hydrauliclters
MachinelightsAirconditioner
AuxiliaryFront
WheelDrive
(AFWD)operated
Remotecontrol
valveextension
MainbeamheadAirFilter
RestrictionWarning!
Remotecontrol
valvecommand
retraction
LowbeamParkingbrakeDangerwarning
lights
Remotecontrol
valveotation
WorklampsBrakeuidlevelVariablecontrolMalfunction!See
Operator’s
StoplampTrailerbrakePressurized!
Opencarefully
Malfunction!
(alternative
symbol)
Klaxon
Warning!
Corrosive
substance
PositioncontrolBrakeuidlevel
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INTRODUCTION
Foreword
Soil,air,andwaterarevitalfactorsofagricultureandlifeingeneral.Wherelegislationdoesnotyetrulethetreatment
ofsomeofthesubstanceswhicharerequiredbyadvancedtechnology,commonsenseshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
Thefollowingarerecommendationswhichmaybeofassistance:
•Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyourcountry.
•Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,antifreeze,cleaning
agents,etc.,withregardtotheireffectonmanandnatureandhowtosafetystore,useanddisposeofthesesub-
stances.Agriculturalconsultantswill,inmanycases,beabletohelpyouaswell.
HelpfulHints
•Avoidllingtanksusingunsuitablecontainersorinappropriatepressurizedfueldeliverysystemsthatmaycause
spillages.
•Ifyouareexposedtoorcomeincontactwithhazardouschemicalsyoucanbeseriouslyinjured.Theuids,lubri-
cants,paints,adhesives,coolant,etc.requiredforthefunctionofyourmachinecanbehazardous.Theymaybe
attractiveandharmfultodomesticanimals,aswellashumans.
•Disposeofalluids,lters,andcontainersinanenvironmentally-safemannerandaccordingtolocallawsand
regulations.Checkwithlocalenvironmentalandrecyclingcentersoryourdealerforcorrectdisposalinformation.
Storeuidsandlterinaccordancewithlocallawsandregulations.Useonlyappropriatecontainersforthestorage
ofchemicalsorpetrochemicalsubstances.
•Modernoilscontainadditives.Donotburncontaminatedfuelsand/orwasteoilsinordinaryheatingsystems.
•Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,gearboxandhydraulicoils,brakeuids,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofina
properwaytocomplywithlocallegislationandavailableresources.
•Moderncoolantmixtures,i.e.,antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshouldnot
beallowedtogetintothesoilbutshouldbecollectedanddisposedofsafely.
•Theair-conditioningsystemcontainsgasesthatareharmfultotheenvironmentwhenreleasedintotheatmosphere.
Donotattempttoserviceorrepairthesystem.Yourdealerorairconditioningspecialisthasaspecialextractorfor
thispurposeandwillbeabletorechargethesysteminanycase.
•Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthiscouldcausethecomponentstoexplode.
•Protecthosesduringweldingaspenetratingweldsplattermayburnaholeorweakenthem,causingthelossof
oils,coolant,etc.
•Keepoutofreachofchildrenorotherunauthorizedpersons.Additionalprecautionsarerequiredforappliedchem-
icals.Obtaincompleteinformationfromthemanufacturerordistributorofthechemicalsbeforeyouusethem.
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INTRODUCTION
Advice
Mandatoryrecycling
Thebatteryisessentiallycomposedofleadplatesand
sulfuricacidsolution.Sincethebatterycontainsheavy
metalssuchaslead,CONAMAResolution401/2008or-
dersthatallusedbatteriesmustbereturnedtothebattery
dealeratthetimeofreplacement.Donotdisposeofthe
batteryinthegarbage.Pointsofsaleareobligedtoac-
ceptthereturnofyourusedbattery,andtostoreitina
suitableplaceandreturnittothemanufacturerforrecy-
cling.
Improperdisposalofbatteriescancontaminatethesoil,
groundwaterandwaterways.Theconsumptionofcon-
taminatedwatercancausehighbloodpressure,anemia,
depression,weakness,legpain,anddrowsiness.Con-
tactoftheacidsolutionwitheyescauseschemicalcon-
junctivitis.Contactoftheacidsolutionwithskincauses
contactdermatitis.Inthecaseofaccidentalcontactwith
theeyesorskin,immediatelywashwithrunningwaterand
seekmedicaltreatment.
CUIL13TRO0091AA1
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules
Standardsafetyprecautions
Beinformedandnotifypersonnelofthelawsinforceregulatingsafety,andprovidedocumentationavailablefor
consultation.
•Keepworkingareasascleanaspossible.
•Ensurethatworkingareasareprovidedwithemergencyboxes.Theymustbeclearlyvisibleandalwayscontain
adequatesanitaryequipment.
•Fireextinguishersmustbeproperlyidentiedandalwaysbeclearofobstructions.Theirefciencymustbechecked
onaregularbasisandpersonnelmustbetrainedonproperinterventionsandpriorities.
•Keepallemergencyexitsfreeofobstructionsandclearlymarked.
•Smokinginworkingareassubjecttoredangermustbestrictlyprohibited.
Preventionofinjury
•Wearsuitableworkattireandsafetyglasseswithnojewelrysuchasringsandchainswhenworkingclosetoengines
andequipmentinmotion.
•Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
•T oppingofforchanginglubricationoils.
•Usingcompressedairorliquidsatapressuregreaterthan2bar(29psi).
•Wearasafetyhelmetwhenworkingclosetohangingloadsorequipmentworkingatheadlevel.
•Alwayswearsafetyshoesandttingclothes.
•Useprotectioncreamforhands.
•Changewetclothesassoonaspossible.
•Inthepresenceofvoltagesexceeding48-60V,verifytheefciencyofthegroundandmasselectricalconnections.
Ensurethathandsandfeetaredryanduseisolatingfootboards.Workersshouldbeproperlytrainedtoworkwith
electricity.
•Donotsmokeorstartanopenameclosetobatteriesandanyfuelmaterial.
•Placesoiledragswithoil,dieselfuelorsolventsinspeciallyprovidedanti-recontainers.
•Donotuseanytoolorequipmentforanyuseotherthanwhatitwasoriginallyintendedfor.Seriousinjurymay
occur.
•Ifrunninganengineindoors,makesurethereisasufcientexhaustfaninusetoeliminateexhaustfumes.
Duringmaintenance
•Neveropenthellercapofthecoolingsystemwhentheengineishot.Hightemperatureliquidatoperatingpressure
couldresultinseriousdangerandriskofburn.Waituntilthetemperaturedecreasesunder50°C(122°F).
•Neveraddcoolanttoanoverheatedengineanduseonlyappropriateliquids.
•Alwaysworkwhentheengineisturnedoff.Certaincircumstancesrequiremaintenanceonarunningengine.Be
awareofalltherisksinvolvedwithsuchanoperation.
•Alwaysuseadequateandsafecontainersforengineuidsandusedoil.
•Keepenginecleanofanyspilleduidssuchasoil,dieselfuel,andorchemicalsolvents.
•Useofsolventsordetergentsduringmaintenancemayemittoxicvapors.Alwayskeepworkingareasaerated.
Wearasafetymaskifnecessary.
•Donotleavesoiledragsthatmaycontainanyammablesubstancesclosetotheengine.
•Alwaysusecautionwhenstartinganengineafteranyworkhasbeenperformed.Bepreparedtocutoffintakeair
incaseofenginerunaway.
•Neverdisconnectthebatterieswhiletheengineisrunning.
•Disconnectthebatteriespriortoperforminganyworkontheequipment.
4770527911/09/2014
8

INTRODUCTION
•Disconnectthebatteriestoplacealoadonthemwithaloadtester.
•Afteranyworkisperformed,verifythatthebatteryclamppolarityiscorrectandthattheclampsaretightandsafe
fromaccidentalshortcircuitandoxidation.
•Beforedisconnectinganypipelines(pneumatic,hydraulic,fuelpipes,etc.),verifythatallpressurehasbeenre-
leased.T akeallnecessaryprecautionsbleedinganddrainingresidualpressure.Alwayswearthepropersafety
equipment.
•Donotalterthelengthsofanywires.
•DonotconnectanyelectronicservicetooltotheengineelectricalequipmentunlessspecicallyapprovedbyNEW
HOLLAND.
•DonotmodifythefuelsystemorhydraulicsystemunlessapprovedbyNEWHOLLAND.Anyunauthorizedmodi-
cationwillcompromisewarrantyassistanceandmayaffectengineoperationandlifespan.
Forengineequippedwithanelectroniccontrolunit
•Donotweldonanypartoftheequipmentwithoutremovingthecontrolunit.
•Removetheincaseofworkrequiringheatingover80°C(176°F).
•Donotpaintthecomponentsandtheelectronicconnections.
•Donotalteranydataledintheelectroniccontrolunitdrivingtheengine.Anymanipulationoralterationofelectronic
componentswillvoidenginewarrantyassistanceandmayaffectthecorrectworkingorderandlifespanofthe
engine.
RespectoftheEnvironment
•Respectoftheenvironmentshouldbeofprimaryimportance.Takeallnecessaryprecautionstoensurepersonnel's
safetyandhealth.
•Informthepersonnelofthelawsregardingthedispensingofusedengineuids.
•Handlebatterieswithcare,storingtheminawellventilatedenvironmentandwithinanti-acidcontainer.
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INTRODUCTION
Safetyrules
Generalsafetyregulations
GeneralAspects
•Strictlyfollowrepairandmaintenanceprocedures.
•Donotwearrings,wristwatches,jewelry,accessories,unbuttoneditemsofclothing,unsecuredclothingliketies,
tornclothing,scarves,oropenjacketsorshirtswithopenzippersthatcouldgetcaughtinmovingparts.Useap-
provedsafetyclothing,suchasanti-slipfootwear,sleeves,protectivegoggles,helmets,etc.
•Wearsafetygoggleswithsideshieldswhencleaningpartsusingcompressedair.
•Wornordamagedcablesandchainsarenotreliable.Donotusetheseelementsinliftingortowingoperations.
•Useregulationsafetyequipment,suchasapprovedeyeprotection,helmets,clothes,sleeves,andspecialfootwear
wheneveryouarewelding.Allindividualsneartheweldingprocessmustuseregulationeyeprotection.Neverlook
attheweldingarcwithoutusingsuitableeyeprotection.
•Neverperformanyrepairsonthemachineifthereissomeoneintheoperatorseat,exceptwhenthepersonisa
qualiedoperatorwhoishelpingwiththeservicetobeperformed.
•Neveroperatethemachineoruseaccessoriesfromaplaceotherthantheoperatorseatornexttothemachine
whenoperatingthefenderswitches.
•Neverperformanyoperationsonthemachinewiththeenginerunning,exceptwhenspecicallyinstructedtodo
so.Shutdowntheengineandreleaseallthepressurefromthehydrauliccircuitsbeforeremovingcovers,cases,
valves,etc.
•Youmustconductallrepairandmaintenanceoperationswiththeutmostcareandattention.
•Disconnectthebatteriesandputwarninglabelsonallofthecontrolstowarnthatthemachineisbeingrepaired.
Lockthemachineandalltheequipmentthatyouremove.
•Nevercheckorllthefueltankorbatteriesorusestartinguidwhenyouaresmokingornearanakedame,
becausetheseuidsareammable.
•Thefuelllinggunmustremainincontactwiththellerneck.Maintainthecontactuntilthefuelstopsowinginto
thetankinordertoavoidsparkscausedbystaticelectricitybuild-up.
•T otransportafaultymachine,useatraileroralowloaderplatformtrolley,ifavailable.
•T oloadandunloadthemachinefromthemodeoftransportation,chooseaatareathatoffersrmsupportforthe
wheelsofthetruckortrailer.Securelyfastenthemachinetotheplatformofthetrailerortruck,inaccordancewith
thetransporter’srequirements.
•Alwaysusehoistmechanismswithanappropriatecapacityforliftingormovingheavycomponents.
•Chainsmustalwaysbesecurelyfastened.Thefasteningdevicemusthavesufcientcapacitytosupportthein-
tendedload.Itisprohibitedforbystanderstobenearthefasteningposition.
•Theworkareamustalwaysbecleananddry.Cleanitimmediatelyifanywateroroilisspilled.
•Neverusegasoline,diesel,orotherammableliquidsforcleaning.Useonlynon-toxicsolvents.
•Donotallowclothssoakedwithoilorgreasetoaccumulatebecausetheycancausearerisk.Alwayskeepthese
clothsinametalcontainer.
Starting
•Neverstarttheengineinenclosedspacesthatarenotequippedwithasuitableexhaustsystemorgas-extraction
system.
•Neverbringyourhead,body,arms,legs,feet,hands,orngersclosetofansorrotatingbelts.
Engine
•Alwaysloosentheradiatorcapslowlybeforeremovingit,inordertodissipatethesystempressure.Youmusttop
upthecoolantwiththeenginestopped.
•Donotllupthefueltankwhentheengineisrunning.
•Neveradjustthefuelinjectionpumpwhenthemachineisinmotion.
4770527911/09/2014
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INTRODUCTION
•Neverlubricatethemachinewhentheengineisrunning.
Electricalsystems
•Ifitisnecessarytouseauxiliarybatteries,youmustconnectthecablesonbothsidesasfollows:(+)to(+)and(-)
to(-).Avoidcausingtheterminalstoshortcircuit.GASRELEASEDFROMBATTERIESISHIGHLYFLAMMABLE.
Duringcharging,leavethebatterycompartmentopentoimproveventilation.Avoidsparksandnakedamesnear
thebattery.Donotsmoke.
•Donotchargethebatteriesinenclosedspaces.
•Alwaysdisconnectthebatteriesbeforecarryingoutanytypeofservicingontheelectricalsystem.
Hydraulicsystem
•Alittleuidcomingoutofasmallborecouldbealmostinvisible,butstrongenoughtopenetratetheskin.Forthis
reason,NEVERUSEYOURHANDSTOCHECKFORLEAKS.Instead,useapieceofcardboardortimber.Ifany
uidpenetratesyourskin,seekmedicalassistanceimmediately.Failuretoseekimmediatemedicalassistance
couldresultinseriousinfectionsordermatitis.
•Alwaysreadthesystempressureusingsuitablegauges.
WheelsandTyres
•Makesurethatthetiresarecorrectlyinatedatthepressurespeciedbythemanufacturer.Inspecttherimsand
tiresregularlyforanydamage.
•Remainnexttothetirewhenllingitwithair.
•Onlycheckthepressurewhentheplatformisunloadedandthetiresarecold,inordertopreventinaccuratereadings
causedbyoverpressure.
•Nevercutorweldarimwithafulltiretted.
•T oremovethewheels,lockboththefrontandrearwheelsofthemachine.Liftthemachine.Installstableand
securesupportsunderthemachine,asperthelegislationinforce.
•Deatethetirebeforeremovinganyobjectsthatmaybecaughtinthetiretread.
•Neverinatetiresusingammablegases,astheycouldcauseexplosionsandinjurebystanders.
Removeandinstall
•Liftandhandleallheavycomponentsusinghoistdevicesofappropriatecapacity.Youmustsuspendthepartsusing
suitablehooksandslings.Usethehoisteyesprovidedforthispurpose.Becarefulifthereareanybystandersnear
thehoistedload.
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INTRODUCTION
Safetyrules
Healthandsafetyprecautions
Manyoftheproceduresinvolvedinmachinemaintenanceandrepairservicesinvolvephysicalhazardsandother
healthrisks.Thissectionlistssomeofthesehazardousproceduresandthematerialsandequipmentassociatedwith
them.
Acidsandalkalis
Avoidsplashingintoyoureyesandnose,orontoyourskinandclothing.Wearsuitablesleevesandprotectivegoggles.
Irritateandcorrodetheskin,eyes,nose,andthroat.Causesburns.Donotinhalethefumes.
Adhesivesandsealants
Thesearehighlyammable.Youmuststoretheminnosmokingareas.Useapplicatorswhenpossibleorsecondary
containers.Thecontainersmustbelabeled.
Resin-basedadhesives/sealants
Skincontactcouldresultinirritation,dermatitis,andtheabsorptionoftoxicorharmfulchemicalsthroughtheskin.
Splashescouldcauseeyeinjuries.Ensurethatthereisadequateventilationandavoidcontactwiththeskinandthe
eyes.Followthemanufacturer’sinstructions.
Ensurethatthereisadequateventilationasvolatileharmfulortoxicchemicalsmaybereleased.
Anti-freeze
Thesearehighlyammable.Youmuststoretheminnosmokingareas.
Anti-freezecanbeabsorbedthroughtheskinintoxicorharmfulquantities.Ingestinganti-freezecancausedeath
andyoumustseekmedicalassistanceimmediately.
Chemicals–General
Youmustalwaystakecarewhenusingandhandlingchemicalssuchassolvents,sealants,adhesives,paints,foam
resins,batteryacids,anti-freeze,brakeuid,oilsandgreases.Theymaybeharmful,toxic,corrosive,irritant,orhighly
ammable.Theymayalsoemithazardousfumesordust.
Do
Removechemicalsfromskinandclothingassoonaspossibleaftercontact.Changeverydirtyclothesandmake
provisionforcleaningthem.
Readandstrictlyadheretothesafetyrecommendationsonthechemicalcontainers.
Whenworkingwithchemicals,washbeforebreaks,andbeforeeating,smoking,drinking,orusingthebathroom.
Keepworkareasclean,organized,andfreeofspillages.Storeaccordingtolocalandnationallegislation.Keep
chemicalsoutofthereachofchildren.
Donot
Donotmixchemicals,exceptinaccordancewiththemanufacturer'sinstructions.Somesubstancescouldformother
chemicalsubstancesthataretoxicorharmful,emittoxicorharmfulfumes,orbecomeexplosiveaftermixing.Donot
spraychemicals,especiallysolvent-basedchemicals,inenclosedspaces.
Donotapplyheatoramestochemicals,exceptinaccordancewiththemanufacturer'sinstructions.Somearehighly
ammableorcouldreleasetoxicorharmfulfumes.
Donotleavecontainersopen.Thefumesemittedcouldaccumulateintoxic,harmful,orexplosiveconcentrations.
Somefumesareheavierthanairandwillaccumulateinconnedareas,trenches,etc.Donotputchemicalsinun-
markedcontainers.
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INTRODUCTION
Donotcleanyourhandsorclotheswithchemicals.Chemicals,particularlysolventsandfuels,dryouttheskinand
cancauseirritationanddermatitis.Somecanbeabsorbedthroughtheskinintoxicorharmfulquantities.
Donotuseemptycontainerstostoreotherchemicals,exceptwhentheyhavebeencleanedundersupervision.Do
notattempttosnifforinhalechemicals.Rapidexposuretohighconcentrationsoffumescanbetoxicorharmful.
Anti-corrosiveprotectivematerial
Thesematerialsarevariedandyoumustfollowthemanufacturers'instructions.Theymaycontainsolvents,resins,
petroleumderivatives,etc.Youmustavoidcontactwiththeskinandtheeyes.Youmustcarryoutsprayingwith
adequateventilationandneverinenclosedspaces.
Post
Dust,powders,orcloudsmaybeirritant,harmful,ortoxic.Avoidinhalingthechemicalpowdersorduststhatresult
fromdryabrasionservices.Userespiratoryprotectionifventilationisnotadequate.
Electricshock
Electricshocksresultfromtheuseoffaultyelectricalequipmentorfromincorrectuse.
Youmustkeepelectricalequipmentingoodconditionandtestitfrequently.
Electricalequipmentmustbeprotectedbyafusewithanappropriatenominalcapacity.
Uselow-voltageequipment(110volt)forworklightsandinspectionlights,whereverpossible.Usepneumaticequip-
mentinsteadofelectricalequipmentwhereverpossible.
Intheeventofelectrocution:
•Turnofftheelectricitybeforeapproachingthevictim.
•Ifthatisnotpossible,pushorpullthevictimawayfromthesourceoftheelectricityusingadry,non-conductive
material.
•Ifyouhavebeentrained,startgivingrstaid.
•Seekmedicalassistance.
Exhaustfumes
Thesefumescontainasphyxiating,toxicorharmfulchemicalsubstances.Youmustonlyrunenginesinadequate
extractionorgeneralventilationconditions,andneverinenclosedspaces.
Fiberinsulation
Thebrousnatureofcutsurfacesandedgescancauseskinirritation.Ingeneral,theeffectisphysicalandnot
chemical.Youmusttakeprecautionstoavoidexcessiveskincontact.Takecarewhenorganizingyourworkmethods.
Wearsleeves.
Fire
Manymaterialsrelatingtovehiclerepairarehighlyammable.Somereleasetoxicorharmfulfumeswhenburned.
Scrupulouslyobservetherepreventionsafetyrecommendationswhenstoringandhandlingammablematerialsor
solvents,particularlyinthevicinityofelectricalequipmentorweldingprocesses.
Beforeusinganyelectricalorweldingequipment,ensurethatthereisnoriskofre.Alwayshaveanappropriatere
extinguishernearbywhenusingweldingorheatingequipment.
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