New Holland TT4.80 User manual

SERVICE MANUAL
TT4.80 / TT4.90
Tractor
Part number 47866580
1st edition English
December 2015
© 2016 CNH Industrial (India) Pvt.Ltd. All Rights Reserved.

SERVICEMANUAL
TT4.80
TT4.90
4786658011/12/2015
EN
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.106]Valvedriveandgears..............................................................10.3
[10.101]Cylinderheads.....................................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.103]Crankshaftandywheel............................................................10.6
[10.110]Balanceranddamper..............................................................10.7
[10.216]Fueltanks..........................................................................10.8
[10.206]Fuellters..........................................................................10.9
[10.218]Fuelinjectionsystem.............................................................10.10
[10.202]Aircleanersandlines............................................................10.11
[10.250]Turbochargerandlines...........................................................10.12
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.13
[10.400]Enginecoolingsystem...........................................................10.14
[10.414]Fananddrive....................................................................10.15
[10.310]Aftercooler........................................................................10.16
[10.304]Enginelubricationsystem........................................................10.17
Clutch.......................................................................................18
[18.110]Clutchandcomponents............................................................18.1
Transmission..............................................................................21
[21.114]Mechanicaltransmission...........................................................21.1
[21.112]Powershuttletransmission.........................................................21.2
[21.110]Masterclutchhousing..............................................................21.3
[21.134]Powershuttletransmissionexternalcontrols......................................21.4
[21.154]Powershuttletransmissioninternalcomponents..................................21.5
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[21.120]Gearbox............................................................................21.6
[21.126]Gearboxexternalcontrols..........................................................21.7
[21.145]Gearboxinternalcomponents......................................................21.8
[21.160]Creeper............................................................................21.9
[21.200]Dropbox..........................................................................21.10
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
PowerT ake-Off(PTO).................................................................31
[31.114]Two-speedrearPowerTake-Off(PTO)............................................31.1
Brakesandcontrols....................................................................33
[33.120]Mechanicalservicebrakes.........................................................33.1
[33.202]Hydraulicservicebrakes...........................................................33.2
[33.110]Parkingbrakeorparkinglock......................................................33.3
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.104]Fixeddisplacementpump..........................................................35.2
[35.204]Remotecontrolvalves.............................................................35.3
[35.100]Mainliftsystem.....................................................................35.4
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
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[41.216]Cylinders...........................................................................41.3
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.201]Enginestartingsystem.............................................................55.3
[55.301]Alternator...........................................................................55.4
[55.302]Battery..............................................................................55.5
[55.012]Enginecoolingsystem.............................................................55.6
[55.404]Externallighting....................................................................55.7
[55.408]Warningindicators,alarms,andinstruments......................................55.8
Platform,cab,bodywork,anddecals.............................................90
[90.118]Protectionsandfootboards.........................................................90.1
[90.114]Operatorprotections...............................................................90.2
[90.120]Mechanically-adjustedoperatorseat...............................................90.3
[90.100]Enginehoodandpanels...........................................................90.4
[90.116]Fendersandguards................................................................90.5
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INTRODUCTION
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Contents
INTRODUCTION
Foreword........................................................................................3
Safetyrules.....................................................................................4
Safetyrules.....................................................................................5
Safetyrules.....................................................................................7
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INTRODUCTION
Foreword
Importantnotice
AllmaintenanceandrepairoperationsdescribedinthismanualshouldbecarriedoutexclusivelybyNEW
HOLLANDauthorisedworkshops.Allinstructionsshouldbecarefullyobservedandspecialequipmentwhere
indicatedshouldbeused.
Anyonewhocarriesoutserviceoperationsdescribedwithoutcarefullyobservingtheseprescriptionswillbe
directlyresponsibleforanydamagecaused.
Notesforequipment
EquipmentwhichNEWHOLLANDproposesandshowsinthismanualis:
-StudiedanddesignedexpresslyforuseonNEWHOLLANDtractors.
-Necessarytomakereliablerepair.
-Accuratelybuiltandstrictlytestedtoofferefcientandlong-lastingworkinglife.
Notice
Thewords“front”,“rear”,“right-handside”and“left-handside”refertothedifferentpartsasseenfromthe
operator’sseatorientedtothenormaldirectionofmovementofthetractor.
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INTRODUCTION
Safetyrules
Thiswarningsymbolpointsoutimportantmessagesinvolvingpersonalsafety.Carefullyreadthesafety
rulescontainedhereinandfollowadvisedprecautionstoavoidpotentialhazardsandsafeguardedyoursafety.
Inthismanualyouwillndthissymboltogetherwiththefollowingkeywords.
WARNING:Itgiveswarningaboutimproperrepairoperationsandpotentialconsequencesaffectingtheservicetech-
nician’spersonalsafety.
DANGER:Itgivesspecicwarningaboutpotentialdangersforpersonalsafetyoftheoperatororotherpersonsdirectly
orindirectlyinvolvedintheoperation.
Topreventaccidents
Mostaccidentsandpersonalinjuriestakingplaceinworkshopsareduefromnon-observanceofsomeessentialrules
andsafetyprecautions.
Thepossibilitythatanaccidentmightoccurwithanytypeofmachinesshouldnotbedisregarded,nomatterhowwell
themachineinquestionwasdesignedandbuilt.
Awiseandcarefulservicetechnicianisthebestprecautionsagainstaccidents.
Carefulobservanceofthisonlybasicprecautionwouldbeenoughtoavoidmanysevereaccidents.
DANGER
Nevercarryoutanycleaning,lubricationormaintenanceoperationswhentheengineisrunning.
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INTRODUCTION
Safetyrules
Generalities
Carefullyfollowspeciedrepairandmaintenanceprocedures.
•Donotwearrings,wristwatches,jewels,unbuttonedorappingclothingsuchasties,tornclothes,scarves,open
jacketsorshirtswithopenzipswhichcouldgetcaughtinmovingparts.Useapprovedsafetyclothingsuchas
anti-slippingfootwear,gloves,safetygoggles,helmets,etc.
•Wearsafetyglasseswithsideguardswhencleaningpartsusingcompressedair.
•Damagedorfrayedwiresandchainsareunreliable.Donotusethemforliftingortowing.
•Wearsuitableprotectionsuchasapprovedeyeprotection,helmets,specialclothing,glovesandfootwearwhenever
welding.Allpersonsstandinginvicinityoftheweldingprocessshouldwearapprovedeyeprotection.Neverlook
attheweldingarcifyoureyesarenotsuitablyprotected.
•Nevercarryoutanyrepaironthemachineifsomeoneissittingontheoperator’sseat,excepttheyarequalied
operatorsassistingintheoperationtobecarriedout.
•Neveroperatethemachineoruseattachmentsfromaplaceotherthansittingattheoperator’sseatorattheside
ofthemachinewhenoperatingthefenderswitches.
•Nevercarryoutanyoperationonthemachinewhentheengineisrunning,exceptwhenspecicallyindicated.Stop
theengineandensurethatallpressureisrelievedfromhydrauliccircuitsbeforeremovingcaps,covers,valves,etc.
•Allrepairandmaintenanceoperationsshouldbecarriedoutwithgreatestcareandattention.
•Disconnectthebatteriesandlabelallcontrolstowarnthatthetractorisbeingserviced.Blockthemachineandall
equipmentwhichshouldberaised.
•Nevercheckorllfueltanksorbatteries,norusestartingliquidifyouaresmokingornearopenamesassuch
uidsareammable.
•Thefuelllinggunshouldalwaysremainincontactwithllerneck.Maintainthiscontactuntilthefuelstopsowing
intothetanktoavoidpossiblesparksduetostaticelectricitybuild-up.
•T otransferafailedtractor,useatrailerofalowloadingplatformtrolleyifavailable.
•T oloadandunloadthemachinefromthetransportationmeans,selectaatareaprovidingarmsupporttothe
trailerortruckwheels.Firmlytiethemachinetothetruckorthetrailerplatformandblockwheelsasrequiredby
thetransporter.
•Alwaysuseliftingequipmentofappropriatecapacitytoliftormoveheavycomponents.
•Chainsshouldalwaysbesafelyfastened.Ensurethatfasteningdeviceisstrongenoughtoholdtheloadforeseen.
Nopersonsshouldstandnearthefasteningpoint.
•Theworkingareashouldbealwayskeptcleananddry.Immediatelycleananyspillageofwateroroil.
•Neverusegasoline,dieseloilorotherammableliquidsascleaningagents.Usenon-ammablenon-toxicpropri-
etarysolvents.
•Donotpileupgreaseoroilsoakedrags,astheyconstituteagreatrehazard.Alwaysplacethemintoametal
container.
Startup
•Neverruntheengineinconnedspaceswhicharenotequippedwithadequateventilationforexhaustgasextrac-
tion.
•Neverbringyourbody,arms,legs,feet,hands,ngersnearfansorrotatingbelts.
Engine
•Alwaysloosentheradiatorcapveryslowlybeforeremovingittoallowpressureinthesystemtodissipate.Coolant
shouldbetoppeduponlywhentheengineisstopped.
•Donotllupfueltankwhentheengineisrunning.
•Neveradjustthefuelinjectionpumpwhenthetractorismoving.Neverlubricatethetractorwhentheengineis
running.
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INTRODUCTION
Electricalsystems
•Ifitisnecessarytouseauxiliarybatteries,cablesmustbeconnectedatbothsidesasfollows.
(+)to(+)and(-)to(-).Avoidshort-circuitingtheterminals.Gasreleasedfrombatteriesishighlyammable.During
charging,leavethebatterycompartmentuncoveredtoimproveventilation.Avoidsparksoramesnearthebattery
area.Donotsmoke.
•Donotchargebatteriesinconnedspaces.
•Alwaysdisconnectthebatteriesbeforeperforminganytypeofserviceontheelectricalsystem.
Hydraulicsystems
•Someuidcomingoutfromaverysmallportcanbealmostinvisibleandbestrongenoughtopenetrateskin.For
thisreason,Neveruseyourhandstocheckforleaks,butuseapieceofcardboardorapieceofwoodforthis
purpose.Ifanyuidisinjectedintotheskin,seekmedicalaidimmediately.Lackofimmediatemedicalattention
mayresultinseriousinfectionsordermatitis.
•Alwaystakesystempressurereadingsusingtheappropriategauges.
Wheelsandtires
•Checkthatthetiresarecorrectlyinatedatthepressurespeciedbythemanufacturer.Periodicallycheckfor
possibledamagetotherimsandtires.
•Stayathetiresidewheninating.
•Checkthepressureonlywhenthetractorisunloadedandtiresarecoldtoavoidwrongreadingduetoover-pres-
sure.
•Nevercut,norweldarimwiththeinatedtireassembled.
•T oremovethewheels,blockbothfrontandreartractorwheels.Raisethetractorandinstallsafeandstablesupports
underthetractorinaccordancewiththeregulationsinforce.
•Deatethetirebeforeremovinganyobjectcaughtintothetiretread.
•Neverinatetiresusingammablegasesastheymayoriginateexplosionsandcauseinjuriestobystanders.
Removalandinstallation
•Liftandhandleallheavycomponentsusingliftingequipmentofadequatecapacity.Ensurethatpartsaresupported
byappropriateslingsandhooks.Useliftingeyesprovidedtothispurpose.T akecareofthepersonsneartheloads
tobelifted.
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INTRODUCTION
Safetyrules
Healthandsafetyprecautions
Manyoftheproceduresassociatedwithvehiclemaintenanceandrepairinvolvephysicalhazardsorotherrisksto
health.Thissectionlists,alphabetically,someofthesehazardousoperationsandthematerialsandequipmentasso-
ciatedwiththem.Theprecautionsnecessarytoavoidthesehazardsareidentied.
Thelistisnotexhaustiveandalloperationsandproceduresandthehandlingofmaterials,shouldbecarriedoutwith
healthandsafetyinmind.
Acidandalkalis
Seebatteryacids,e.g.causticsoda,sulfuricacid.
Usedinbatteriesandcleaningmaterials.
Irritantandcorrosivetotheskin,eyes,noseandthroat.Causesburns.
Avoidsplashestotheskin,eyesandclothing.Wearsuitableprotectiveglovesandgoggles.Candestroyordinary
protectiveclothing.Donotbreathemists.
Ensureaccesstowaterandsoapisreadilyavailableforsplashingaccidents.
Adhesivesandsealers
Seerehighlyammable,ammable,combustible.
Generallyshouldbestoredin“Nosmoking”areas,cleanlinessandtidinessinuseshouldbeobserved.E.g.dispos-
ablepapercoveringbenchesshouldbedispensedfromapplicatorswherepossiblecontainersincludingsecondary
containers,shouldbelabelled.
Solventbasedadhesive/sealers
Seesolvents.Followmanufacturer’sinstructions.
Waterbaseadhesive/sealers
Thosebasedonpolymeremulsionsandrubberlatticesmaycontainsmallamountsofvolatiletoxicandharmfulchem-
icals.Skinandeyecontactshouldbeavoidedandadequateventilationprovidedduringuse.
Followmanufacturersinstructions.
Resinbasedadhesives/sealers
E.g.Epoxideandformaldehyderesinbased.
Mixingshouldonlybecarriedoutinwellventilatedareasasharmfulortoxicvolatilechemicalsmaybereleased.
Skincontactwithuncuredresinsandhardenerscanresultinirritation,dermatitisandabsorptionoftoxicofharmful
chemicalsthroughtheskin.Splashescandamagetheeyes.
Provideadequateventilationandavoidskinandeyecontact.Followmanufacturers’instructions.
Anaerobic,cyanoacrylateandotheracrylicadhesives
Manyareirritant,sensitizingorharmfultotheskin.Someareeyeirritants.
Skinandeyecontactshouldbeavoidedandthemanufacturers’instructionsfollowed.
Cyanaocrylateadhesives(super-glues)mustnotcontacttheskinoreyes.Ifskinoreyetissueisbondedcoverwitha
cleanmoistpadandgetmedicalattention.Donotattempttopulltissueapart.Useinwellventilatedareasasvapors
cancauseirritationofthenoseandeyes.
Fortwo-packsystemsseeresinbasedadhesives/sealers.
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INTRODUCTION
Isocyanate(polyurethane)adhesives/sealers
Seeresinbasedadhesives.
Individualssufferingfromasthmaorrespiratoryallergiesshouldnotworkwithornearthesematerialsassensitivity
reactionscanoccur.
Anysprayingshouldpreferablybecarriedoutinexhaustventilatedboothsremovingvaporsandspraydropletsform
thebreathingzone.Individualsworkingwithsprayapplicationsshouldwearsuppliedairrespirators.
Antifreeze
Seere,solventse.g.isopropanol,ethyleneglycol,menthol.
Highlyammable,ammable,combustible.
Usedinvehiclecoolingsystems,brakeairpressuresystems,screenwashsolutions.
vaporsgivenofffromcoolantantifreeze(glycol)ariseonlywhenheated.
Antifreezemaybeabsorbedthroughskinintoxicorharmfulquantities.Antifreezeifswallowedisfatalandmedical
attentionmustbefoundimmediately.
Arcwelding
Seewelding.
Batteryacids
Seeacidsandalkalis.
Gasesreleasedduringchargingareexplosive.Neverusenakedamesorallowsparksnearchargingorrecently
chargedbatteries.
Brakeandclutchuids(polyalkyleneglycols)
Seerecombustible.
Splashestotheskinandeyesareslightlyirritating.Avoidskinandeyecontactasfaraspossible.Inhalationofvapor
hazardsdonotariseatambienttemperaturesbecauseoftheverylowvaporpressure.
Brazing
Seewelding.
Chemicalmaterials-general
Seelegalaspects.
Chemicalmaterialssuchassolvents,sealers,adhesives,paints,resinfoams,batteryacids,antifreeze,brakeuids,
oilsandgreaseshouldalwaysbeusedwithcautionandstoredandhandledwithcare.Theymaybetoxic,harmful,
corrosiveirritantorhighlyinammableandgiverisetohazardousfumesanddusts.
Theeffectsofexcessiveexposuretochemicalsmaybeimmediateordelayed,brieyexperiencedorpermanent,
cumulative,supercial,lifethreateningormayreducelifeexpectancy.
Do’s
Doremovechemicalmaterialsfromtheskinandclothingassoonaspracticableaftersoiling.Changeheavilysoiled
clothingandhaveitcleaned.
Docarefullyreadandobservehazardandprecautionwarninggivenonmaterialcontainers(labels)andinanyac-
companyingleaets,posterorotherinstructions.Materialhealthandsafetydatasheetscanbeobtainedfromman-
ufacturers’.
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INTRODUCTION
Doorganiseworkpracticesandprotectiveclothingtoavoidsolingoftheskinandeyes,breathingvapors/aerosols/
dusts/fumes,inadequatecontainerlabelling;reandexplosionhazards.
Dowashbeforejobbreaks,beforeeating,smoking,drinkingorusingtoiletfacilitieswhenhandlingchemicalmaterials.
Dokeepworkareasclean,unclutteredandfreeofspills.
Dostoreaccordingtonationalandlocalregulations.
Dokeepchemicalmaterialsoutofreachofchildren.
Donot’s
Donotmixchemicalmaterialsexceptunderthemanufacturers’instructions.Somechemicalscanformothertoxicor
harmfulchemicalsgiveofftoxicorharmfulfumesbeexplosivewhenmixedtogether.
Donotspraychemicalmaterials,particularthosebasedonsolvents,inconnedspaces.E.g.Whenpeopleareinside
avehicle.
Donotapplyheatorametochemicalmaterialsexceptunderthemanufacturers’instructions.Somearehighly
inammableandsomemayreleasetoxicorharmfulfumes.
Donotleavecontainersopen.Fumesgivenoffcanbuilduptotoxic,harmfulorexplosiveconcentrations.Some
fumesareheavierthanairandwillaccumulateinconnedareas,pitsetc.
Donottransferchemicalmaterialstounlabeledcontainers.
Donotcleanhandsorclothingwithchemicalmaterials.Chemicals,particularlysolventsandfuelswilldrytheskin
andmaycauseirritationwithdermatitis.Somecanbeabsorbedthroughtheskinintoxicorharmfulquantities.
Donotuseemptiedcontainersforothermaterials,exceptwhentheyhavebeencleanedundersupervisedconditions.
Donotsnifforsmellchemicalmaterials.Briefexposuretohighconcentrationsoffumescanbetoxicorharmful.
Clutchuids
Seebrakeandclutchuids.
Clutchliningsandpads
Seebrakeandclutchliningsandpads.
Corrosionprotectionmaterials
Seesolvents,re.
Highlyammable,ammable.
Thesematerialsarevariedandthemanufactures’instructionsshouldbefollowed.Theymaycontainsolvents,resins,
petroleumproductsetc.skinandeyecontactshouldbeavoided.Theyshouldonlybesprayedinconditionsofade-
quateventilationandnotinconnedspaces.
Cutting
Seewelding.
De-waxing
Seesolventsandfuels(kerosene).
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INTRODUCTION
Dusts
Powder,dustsorcloudsmaybeirritant,harmfulortoxic.Avoidbreathingdustsfrompowderychemicalmaterialsor
thosearisingfromdryabrasionoperations.Wearrespiratoryprotectionifventilationisinadequate.
Electricshocks
Electricshockscanresultfromtheuseofthefaultyelectricalequipmentorfromthemisuseofequipmentevenin
goodcondition.
Ensurethatelectricalequipmentismaintainedingoodconditionandfrequentlytested.
Ensurethatexes,cables,plugsandsocketsarenotfrayed,kinked,cut,crackedorotherwisedamaged.
Ensurethatelectricequipmentisprotectedbythecorrectratedfuse.
Nevermisuseelectricalequipmentandneveruseequipmentwhichisinanywayfaulty.Theresultscouldbefatal.
Usereducedvoltageequipmentwherepossibleinpreferencetoelectricalequipment.
Incasesofelectrocution:
•Switchoffelectricitybeforeapproachingvictim
•Ifthisisnotpossible,pushordragvictimfromsourceofelectricityusingdrynon-conductivematerial
•Commenceresuscitationiftrainedtodoso
•Summonmedicalassistance
Exhaustfumes
Thesecontainasphyxiating,harmfulandtoxicchemicalsandparticlessuchascarbonoxides,nitrogenoxides,alde-
hydes,leadandaromatichydrocarbons.Enginesshouldonlyberununderconditionsofadequateextractionor
generalventilatorandnotinconnedspaces.
Gasoline(petrol)engine
Theremaynotbeadequatewarningpropertiesofodourorirritationbeforeimmediateanddelayedtoxicorharmful
effectsarise.
Dieselengine
Soot,discomfortandirritationusuallygiveadequatewarningofhazardousfumeconcentrations.
Fiberinsulation
Seeducts.
Usedinnoiseandsoundinsulation.
Thebrousnatureofsurfacesandcutedgescancauseskinirritation.Thisisusuallyaphysicalandnotachemical
effect.
Precautionsshouldbetakentoavoidexcessiveskincontactthroughcarefulorganizationofworkpracticesandthe
useofgloves.
Fire
Seewelding,foams,legalaspects.
Manyofthematerialsfoundonorassociatedwiththerepairofvehiclesarehighlyinammable.Somegiveofftoxic
orharmfulfumesifburnt.
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INTRODUCTION
Observestrictresafetywhenstoringandhandlingammablematerialsorsolvents,particularlynearelectricalequip-
mentorweldingprocesses.
Ensurebeforeusingelectricalorweldingequipmentbutthatthereisnorehazardpresent.
Havesuitablereextinguisheravailablewhenusingweldingorheatingequipment.
Firstaid
Apartfrommeetinganylegalrequirementsitsidesirableforsomeoneintheworkshoptobetrainedinrstaidproce-
dures.
Splashesintheeyeshouldbeushedwithcleanwaterforatleast10min.
Soiledskinshouldbewashedwithsoapandwater.
Inhalationaffectedindividualsshouldberemovedtofreshairimmediately.
Ifswallowedorifeffectspersistconsultadoctorwithinformation(label)onmaterialused.
Donotinducevomiting(unlessindicatedbymanufacturer).
Foams
Seere.
Usedinsoundandnoiseinsulation.Curedfoamsusedinseatandtrimcushioning.
Followmanufacturers’instructions.
Unreactedcomponentsareirritatingandmaybeharmfultotheskinandeyes.Wearglovesandgoggles.
Individualswithchronicrespiratorydiseases,asthma,bronchialmedicalproblemsorhistoriesofallergicdiseases
shouldnotworkwithornearuncuredmaterials.
Thecomponents,vapors,spraymistscancausedirectirritation,sensitivityreactionsandmaybetoxicorharmful.
vaporsandspraymistsmustnotbebreathed.Thesematerialsmustbeappliedwithadequateventilationandrespi-
ratoryprotection.Donotremoverespiratorimmediatelyafterspraying,waituntilvapor/mistshavecleared.
Burningoftheuncuredcomponentsandthecuredfoamscangeneratetoxicandharmfulfumes.
Smoking,openamesortheuseofelectricalequipmentduringfoamingoperationsanduntilvapors/mistshave
clearedshouldnotbeallowed.Anyheatcuttingofcuredfoamsorpartiallycuredfoamsshouldbeconductedwith
extractionventilation.
Fuels
Seere,legalaspects,chemicals-general,solvents.
Usedasfuelsandcleaningagents.
Gasoline(petrol)
Highlyammable.
Swallowingcanresultinmouthandthroatirritationandabsorptionfromthestomachcanresultindrowsinessand
unconsciousness.Smallamountscanbefataltochildren.Aspirationofliquidintothelungs,e.g.throughvomiting,
isaveryserioushazard.
Gasolinedriestheskinandcancauseirritationanddermatitisonprolongedorrepeatedcontact.Liquidintheeye
causesseveresmarting.
Motorgasolinemaycontainappreciablequantitiesofbenzene,whichistoxicuponinhalationandtheconcentrations
ofgasolinevaporsmustbekeptverylow.Highconcentrationswillcauseeye,noseandthroatirritation,nausea,
headache,depressionandsymptomsofdrunkenness.Veryhighconcentrationswillresultinrapidlossofconscious-
ness.
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INTRODUCTION
Ensurethereisadequateventilationwhenhandlingandusinggasoline.Greatcaremustbetakentoavoidtheserious
consequencesofinhalationintheeventofvaporbuilduparisingfromspillagesinconnedspaces.
Specialprecautionsapplytocleaningandmaintenanceoperationsongasolinestoragetanks.Gasolineshouldnot
beusedasacleaningagent.Itmustnotbesiphonedbymouth.
Kerosene(parafn)
Usedalsoasheatingfuel,solventandcleaningagent.
Flammable.
Irritationofthemouthandthroatmayresultfromswallowing.Themainhazardfromswallowingarisesifliquidaspi-
rationintothelungsoccurs.Liquidcontactdriestheskinandcancauseirritationordermatitis.Splashesintheeye
maybeslightlyirritating.
Innormalcircumstancesthelowvolatilitydoesnotgiverisetoharmfulvapors.Exposuretomistsandvaporsfrom
keroseneatelevatedtemperaturesshouldbeavoided(mistsmayariseinde-waxing).Avoidskinandeyecontact
andensurethereisadequateventilation.
Gas-oil(dieselfuel)
Seefuels(kerosene).Combustible.
Grossorprolongedskincontactwithhighboilinggasoilsmayalsocauseseriousskindisordersincludingskincancer.
Gascylinders
Seere.
Gasessuchasoxygen,acetylene,carbondioxide,argonandpropanearenormallystoredincylindersatpressuresof
upto2000Ib/sq.in.(13,790kn/m2)andgreatcareshouldbetakeninhandlingthesecylinderstoavoidmechanical
damagetothemortothevalvegearattached.Thecontentsofeachcylindershouldbeclearlyidentiedbyappropriate
markings.
Cylindersshouldbestoredinwellventilatedenclosures,andprotectedfromiceandsnow,ordirectsunlight.Fuel
gases(e.g.acetyleneandpropane)shouldnotbestoredincloseproximitytooxygencylinders.
Careshouldbeexercisedtopreventleaksfromgascylindersandlines,andtoavoidsourcesofignition.
Onlytrainedpersonnelshouldundertakeworkinvolvinggascylinders.
Gases
Seegascylinders.
Gasshieldedwelding
Seewelding.
Gaswelding
Seewelding.
Generalworkshoptoolsandequipment
Itisessentialthatalltoolsandequipmentaremaintainedingoodconditionandthecorrectsafetyequipmentused
whererequired.
Neverusetoolsorequipmentforanypurposeotherthanthatforwhichtheyweredesigned.
Neveroverloadequipmentsuchashoists,jacks,axleandchassisstandsorliftingslings.Damagecausedbyover-
loadingisnotalwaysimmediatelyapparentandmayresultinafatalfailurethenexttimethattheequipmentisused.
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INTRODUCTION
Donotusedamagedordefectivetoolsorequipment,particularlyhighspeedequipmentsuchasgrindingwheels.A
damagedgrindingwheelcandisintegratewithoutwarningandcauseseriousinjury.
Wearsuitableeyeprotectionwhenusinggrinding,chisellingorsandblastingequipment.
Wearasuitablebreathingmaskwhenusingsandblastingequipment,workingwithasbestosbasedmaterialsorusing
sprayingequipment.
Glues
Seeadhesivesandsealers.
Highpressureair,lubricationandoiltestequipment
Seelubricantsandgreases.
Alwayskeephighpressureequipmentingoodconditionandregularlymaintained,particularlyatjointsandunions.
Neverdirectahighpressurenozzleattheskinastheuidmaypenetratetotheunderlyingtissueetc.andcause
seriousinjury.
Legalaspects
Manylawsandregulationsmakerequirementsrelatingtohealthandsafetyintheuseofmaterialsandequipmentin
workshops.
Workshopsshouldbefamiliar,indetail,withassociatedlawsandregulations.Consultlocalfactoryinspectorateifin
anydoubt.
Lubricantsandgreases
Avoidallprolongedandrepeatedcontactwithmineraloils,especiallyusedoils.Usedoilscontaminatedduringservice
(e.g.routineservicechangesumpoils)aremoreirritatingandmorelikelytocauseseriouseffectsincludingskin
cancerintheeventofgrossandprolongedskincontact.
Washskinthoroughlyafterworkinvolvingoil.Proprietaryhandcleanersmaybeofvalueprovidedtheycanbere-
movedfromtheskinwithwater.Donotusepetrol,parafnorothersolventstoremoveoilfromtheskin.
Lubricantsandgreasesmaybeslightlyirritatingtotheeyes.
Repeatedorprolongedskincontactshouldbeavoidedbywearingprotectiveclothingifnecessary.Particularcare
shouldbetakenwithusedoilsandgreasescontaininglead.Donotallowworkclothingtobecontaminatedwithoil.
Drycleanorlaundersuchclothingatregularintervals.Discardoilsoakedshoes.
Donotemployusedengineoilsaslubricantsorforanyapplicationwhereappreciableskincontactislikelytooccur.
Usedoilsmayonlybedisposedofinaccordancewithlocalregulations.
Therearepublicationsdescribingtheproblemsandadvisingonprecautionarymeasures.
Noiseinsulationmaterials
Seefoams,breinsulation.
Paints
Seesolventsandchemicalmaterials-general.
Highlyammable,ammable.
Onepack
Cancontainharmfulortoxicpigments,driersandothercomponentsaswellassolvents.Sprayingshouldonlybe
carriedoutwithadequateventilation.
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INTRODUCTION
Twopack
Canalsocontainharmfulandtoxicunreactedresinsandresinhardeningagents.Themanufacturersinstructions
shouldbefollowedandtheonresinbasedadhesives,isocyanatecontainingadhesivesandfoamsshouldbecon-
sulted.
Sprayingshouldpreferablybecarriedoutinexhaustedventilatedboothsremovingvaporandspraymistsfromthe
breathingzone.Individualsworkinginboothsshouldwearrespiratoryprotection.Thosedoingsmallscalerepairwork
intheopenshopshouldwearsuppliedairrespirators.
Paintthinners
Seesolvents.
Petrol
Seefuels(gasoline).
Pressurisedequipment
Seehighpressureair,lubricationandoiltestequipment.
Resistancewelding
Seewelding.
Sealers
Seeadhesivesandsealers.
Solder
Seewelding.
Soldersaremixturesofmetalssuchthatthemeltingpointofthemixtureisbelowthatoftheconstituentmetals(nor-
mallyleadandtin).Solderapplicationdoesnotnormallygiverisetotoxicleadfumes,providedagas/airameis
used.Oxy-acetyleneamesshouldnotbeused,astheyaremuchhotterandwillcauseleadfumestobeevolved.
Somefumesmaybeproducedbytheapplicationofanyametosurfacescoatedwithgreaseetc.andinhalationof
theseshouldbeavoided.
Removalofexcesssoldershouldbeundertakenwithcare,toensurethatneleaddustisnotproduced,whichcan
givetoxiceffectsifinhaled.Respiratoryprotectionmaybenecessary.
Solderspillageandlingshouldbecollectedandremovedpromptlytopreventgeneralaircontaminationbylead.
Highstandardsofpersonalhygienearenecessaryinordertoavoidindigestionofleadorinhalationofsolderdust
fromclothing.
Solvents
Seechemicalmaterials-generalfuels(kerosene),re.
E.g.Acetone,whitespirit,toluene,xylene,trichlorethane.
Usedincleaningmaterials,de-waxing,paints,plastics,resins,thinnersetc.
HighlyInammable,ammable.
Skincontactwilldecreasetheskinandmayresultin.irritationanddematitisfollowingrepeatedorprolongedcontact.
Somecanbeabsorbedthroughtheskinintoxicorharmfulquantities.
Splashesintheeyemaycausesevereirritationandcouldleadtolossofvision.
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INTRODUCTION
Briefexposuretohighconcentrationsofvaporsormistswillcauseeyeandthroatirritation,drowsiness,dizziness,
headachesandintheworstcircumstances,unconsciousness.
Repeatedorprolongedexposurestoexcessivebutlowerconcentrationsofvaporsormists,forwhichtheremightnot
beadequatewarningindications,cancausemoreserioustoxicorharmfuleffects.
Aspirationintothelungs(e.g.throughvomiting)isthemostseriousconsequenceofswallowing.
Avoidsplashestotheskin,eyesandclothing.Wearprotectivegloves,gogglesandclothingifnecessary.
Ensuregoodventilationwheninuse,avoidbreathingfumes,vaporsandspraymistsandkeepcontainerstightly
sealed.Donotuseinconnedspaces.
Whenthesprayingmaterialcontainssolvents,e.g.paints,adhesives,coatings,useextractionventilationorpersonal
respiratoryprotectionintheabsenceofadequategeneralventilation.
Donotapplyheatorameexceptunderspecicanddetailedmanufacturersinstructions.
Soundinsulation
Seebreinsulation,foams.
Spotwelding
Seewelding.
Suspendedloads
Thereisalwaysadangerwhenloadsareliftedorsuspended.Neverworkunderanunsupportedsuspendedorraised
load,e.g.jackedupvehicle,suspendedengine,etc.
Alwaysensurethatliftingequipmentsuchasjacks,hoists,axlestands,slings,etc.areadequateandsuitableforthe
job,ingoodconditionandregularlymaintained.
Neverimproviseliftingtackle.
Underseal
Seecorrosionprotection.
Welding
Seere,electricshock,gascylinders.
Weldingprocessesincluderesistancewelding(spotwelding),arcweldingandgaswelding.
Resistancewelding
Thisprocessmaycauseparticlesofmoltenmetaltobeemittedathighvelocityandtheeyesandskinmustbepro-
tected.
Arcwelding
Thisprocessemitsahighlevelofultravioletradiationwhichmaycauseeyeandskinburnstothewelderandtoother
personsnearby.Gas-shieldedweldingprocessesareparticularlyhazardousinthisrespect.Personalprotectionmust
beworn,andscreensusedtoshieldotherpeople.
Metalspatterwillalsooccurandappropriateeyeandskinprotectionisnecessary.
Theheatoftheweldingarcwillproducefumesandgasesfromthemetalsbeingweldedandfromanyappliedcoatings
orcontaminationonthesurfacesbeingworkedon.Thesegasesandfumesmaybetoxicandinhalationshould
alwaysbeavoided.Theuseofextractionventilationtoremovethefumesfromtheworkingareamaybenecessary,
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