Scania1 585 267

00:01-02 CV AB 2012, SwedenIssue 13 en-GB

Safety and fire protection in service workshops

ContentsContentsIntroduction Preconditions for safety............................................ 3

Safety requirements .................................................. 6Personal safety.......................................................... 7

Safety around the vehicle General safety precaution ......................................... 8Tilting the cab........................................................... 8Working under vehicles.......................................... 10Heavy equipment.................................................... 12Several mechanics working on one vehicle............ 13

Mechanical work Noise....................................................................... 14Vibrations ............................................................... 15Dust......................................................................... 16Rotating components and tools .............................. 18Fragments from tools.............................................. 20Flying parts............................................................. 21Tensioned springs................................................... 22Airbag and belt pretensioner .................................. 24

Fluids and gases Risk of fire and explosion....................................... 25Pressurised fluids or gases...................................... 27Solvents .................................................................. 28Ethanol.................................................................... 30Vehicle gas ............................................................. 33Coolant ................................................................... 36Refrigerant.............................................................. 37Air pollution ........................................................... 38

Electricity General ................................................................... 40Electric motors........................................................ 41Generator set........................................................... 42

2 Scania CV AB 2012, Sweden 00:01-02

IntroductionIntroductionPreconditions for safetyThe intention of this section is to inform you of the risks involved in service workshops.

Since it is not possible to give a comprehensive account in this format, the information is based on the following preconditions: That inspection information instructions

are followed.

That local laws and regulations are complied with.

That the mechanic carries out the work in a correct manner.

Using the inspection informationThe inspection information provides instructions for working methods to reduce the risk of damage and injury. Scania assumes that the inspection information is available to the mechanics and that the instructions are adhered to.00:01-02 Scania CV AB 2012, Sweden 3

Observe warnings

IntroductionThe inspection information contains symbols to indicate dangerous or essential tasks. Always read and follow these warnings and instructions.

Do not make the mistake of thinking you are aware of all the risks. The properties of a part or the chemical composition of a product may have changed since you last used it.

Note: Used when an incorrect action could result in a poor result or unnecessary work.

IMPORTANT!Used when an incorrect action could result in damage to the vehicle or other property.

WARNING!Used when an incorrect action could result in personal injury.

Warnings in the inspection information do not cover risks that can arise when driving the vehicle. Such information is available in the Operator's Manual of the vehicle.

It is a good idea to be aware that the operations supervisor is also responsible for fire safety. Scania has therefore published the manual Scania Fire Prevention, which is available on Scania's website.Environment

The environmental advisory is used when there is a risk that used material could be hazardous to the environment. Find out how the used material in the workshop must be disposed of according to national and international laws.4 Scania CV AB 2012, Sweden 00:01-02

IntroductionIncidentsAn incident may be a chance accident that does not cause any injuries or damage.

On the other hand, it does point out the risks involved. Each incident must be taken as a warning, just as important as an accident or case of illness.

The next time the incident occurs, the consequences may be much more severe unless your level of attention has been raised.

FeedbackReport any incidents, injuries and damage that may have been caused by insufficient inspection information, etc. A report can be made on the form 00:01-04 Workshop information, Feedback. The form is found in the binders for the 4 series under group 0.00:01-02 Scania CV AB 2012, Sweden 5

IntroductionSafety requirements

Laws and local regulationsMost countries have laws and local regulations that are intended to prevent damage, injuries and accidents at work. These regulations must be followed.

Safety instructionsTake note of any existing safety instructions before commencing work involving a risk of damage or injury.

KnowledgeScania assumes that the mechanic has the necessary professional training as an automotive mechanic and has taken part in Scania courses for mechanics. It is impossible to foresee all the safety risks involved if the mechanic does not possess these qualifications.

AttentionThe mechanic must be attentive to the risks involved with the task. New risks may arise and experience, both your own and your colleagues', may not be enough. It is therefore important that instructions are always available and are read.

CautionThere must be no carelessness or nonchalance. Hazardous work must always be carried out with a safety margin.

Protective equipment and safety devices must be used whenever specified in the instructions.

Common sense should always prevail when working in a workshop.6 Scania CV AB 2012, Sweden 00:01-02

IntroductionPersonal safety

JewelleryRemove necklaces, rings and bracelets. Jewellery can conduct current, cause electric arcs, get caught in machines, etc., and consequently cause serious injury.

HairLong hair must be tied back or gathered in a hairnet or the like. Hair can easily get caught in machinery or in moving parts. Hair is extremely flammable. Observe caution when welding or using naked flames.

ClothingMake sure all clothing is intact. Remove loose clothing such as ties and scarves. Never wear clothing with wide sleeves or legs.00:01-02 Scania CV AB 2012, Sweden 7

Safety around the vehicleTilting the cab

Instructions, tilting the cabThe work descriptions for tilting the cab in the inspection information must always be followed.Safety around the vehicleGeneral safety precautionThe power should be disconnected from damaged vehicles standing in the workshop before repairs are commenced. This is to avoid a fire hazard in the event of a short circuit in the cable harness.8 Scania CV AB 2012, Sweden 00:01-02

Safety around the vehicleWARNING!Danger of crushing when working on cab suspension. Ensure that the cab is secured with a cab lifting device to avoid injuries.

WARNING!Working on the cab tilting mechanism disables the integral safety functions. Always follow the instructions and use the special tools specified. There is otherwise a risk of the cab falling back and causing personal injury.

When the cab is tilted, the engine should be switched off, the parking brake should be applied and the gearbox should be in neutral.

If it is necessary to tilt the cab with the engine running, ensure that the gearbox is in neutral and that the gear lever in the cab can be moved freely.

No loose objects or heavy equipment should remain in the cab during tilting.

Do not tilt the cab if the ground slopes more than 10%.

Do not stand in front or behind the cab during tilting.

Always tilt the cab fully until it falls past the centre of gravity and into the end position.

Position the pump valve in the lowering position when the cab is fully tilted.

Risk of crushing when the cab is lowered. The cab falls freely during the last part of the lowering phase.

Always use a cab strut when working under the cab.

Ensure that no persons are in the vicinity of a cab being raised or lowered.00:01-02 Scania CV AB 2012, Sweden 9

Safety around the vehicleWorking under vehicles

Working under the chassisA raised vehicle must never be supported on or lifted by parts that belong to the wheel suspension or steering. The vehicle must only be supported under the frame or an axle. Do not walk under a vehicle that is raised on a jack only. Follow the instructions in the inspection information.

Working underneath bodyworkRaised bodywork must always be supported.

Working under vehicles with air suspensionAlways support vehicles with air suspension under the frame. Otherwise, the vehicle may drop as the air pressure in one or more bellows is reduced.

Work under vehicles with air suspension must be performed in such a way that there is no risk of personal injuries.

If the frame drops on to the axle there is a risk of crush or impact injuries.

WARNING!Always use axle stands to support the vehicle when working under vehicles with air suspension.The frame may drop on to the axle if: An air bellows is punctured.

A compressed air line is disconnected.

Voltage is applied to a valve for the purpose of emptying the bellows.

A levelling valve is operated when the starter voltage is on.10 Scania CV AB 2012, Sweden 00:01-02

Safety around the vehicleWorking under the cabMake sure there are no loose objects inside the cab before tilting it. The cab must always be tilted all the way to its front stop position. Position the pump valve in the lowering position when the cab is fully tilted.

The cab must always be supported on cab struts when tilted.

RisksMechanical or hydraulic tools and lifting devices may tip over or their level may drop due to malfunctions or incorrect operation.

Safety precautions Use reliable and correctly dimensioned

axle stands, struts and locks with standard locking devices.

Stands and struts must be sturdy.

Lifting tools must have been inspected and approved for use.00:01-02 Scania CV AB 2012, Sweden 11

Safety around the vehiclewill be necessary.

Stands must lock automatically (braking device or irreversible screw).Heavy equipment

Careless handling of heavy equipment may result in severe personal injury and damage to property.

Use approved lifting tools or other aids to move heavy equipment. Make sure the device is sturdy and intact.

Risks Unsuitable lifting straps could break or

slip.

The equilibrium of the equipment or device may be disturbed while work is being carried out, which can cause unexpected movements. This may cause severe personal injury and damage to property.

Equipment being lifted in a stand may start to revolve if its equilibrium is disturbed.

Equipment being lifted with an overhead hoist may start to swing and cause severe crush injuries or damage to property.

Safety precautions Use approved lifting tools or other aids,

especially when they are suitably adapted to a specific task.

If it is still necessary to lift without aids:

- Lift with the equipment close to your body.

- Keep your back vertical.

- Use your arms and legs to lift and lower equipment, do not bend your back.

- Do not turn your body while lifting.

- Ask for help beforehand if you think it Use gloves. They usually offer good protection against getting your fingers pinched.

Use protective shoes with steel caps.

Use a jack with fixture as instructed in the inspection information for lifting gearboxes, rear axle gears, clutches, leaf spring assemblies, rear wheel hubs, torque converters, etc.12 Scania CV AB 2012, Sweden 00:01-02

Safety around the vehicleSeveral mechanics working on one vehicleInadvertent movements may cause another person injury if there are several mechanics working on the same vehicle.

Risks A wheel being rotated on a driving axle

may make the driving wheel in another location to rotate causing injury or damage.

Working on axle suspension (springs and shock absorbers) can initiate movement in components on the opposite side.

Operations controlled from the driver area, such as tilt, tag axle lift or bodywork, could initiate movement in other parts and cause serious personal injury.

Safety precautions Be aware of the risks involved when more

than one person is working on the vehicle.

Make colleagues aware of the work being carried out.

Wait until the half shafts have been removed before commencing work on more than one driving wheel at the same time.

When work is conducted on a bus, a sign must be placed on the steering wheel and on the rear central electric unit. Move the start selector on the rear central electric unit to 0 to prevent attempts to start the vehicle. If signs have been posted or if the start selector is in position 0, check before starting the engine that it is safe to do so.00:01-02 Scania CV AB 2012, Sweden 13

Mechanical workMechanical workNoiseBeing exposed to noise louder than 85 dB(A) for longer than 8 hours is considered harmful to your hearing. (Noise level limits may vary from country to country.) High-frequency noise is more harmful than low-frequency noise at the same volume.

Noise can be just as harmful intermittently as it is continuously. The noise of a striking blow can be harmful just because it occurs for a very short time.

Risks Noise levels higher than recommended

limits will impair your hearing. In severe cases, this damage may be permanent.

You cannot get used to noise. If you begin to perceive noise as being less severe, perhaps your hearing has been impaired.

Seek medical advice if you notice signs of hearing impairment.

Safety precautions Use ear defenders. Make sure the ear

defenders have been tried and tested for the relevant noise level.

Limit exposure to noise with sound-absorbing screens (also use sound-absorbing materials in ceilings and walls).14 Scania CV AB 2012, Sweden 00:01-02

Mechanical workVibrationsThe use of vibrating tools such as jackhammers, hammer drills, impact nut runners and grinders can cause injury when the vibration in the tool is conveyed to your hands.

Injuries are more likely to occur if your fingers are cold.

Vibration can cause vascular spasms (tingling and pain) in blood vessels near the surface of the skin. Fingers may become cold and numb. Damage may also be caused to the nervous system, muscles, bones, ligaments and joints.

Seek medical advice if you notice any signs of injuries caused by vibration. The damage can be cured if treated at an early stage.

Risks Cold increases the risk of injury, if the tool

is cold to the hand or if cold air is blowing on your hands for example.

The use of tobacco impedes blood circulation and increases the risk of injury.

Safety precautions Use thick gloves. They protect against

vibration and cold.

Alternate between working with and without vibrating tools so that your body is given the chance to rest.

Change working position and grip often so that not only one side of your body is exposed to vibration stress.

If possible, use tools that protect against vibrations.

Avoid smoking before and after work in order to maintain good blood circulation. 00:01-02 Scania CV AB 2012, Sweden 15

Mechanical workDust

Brake and clutch liningsBrake and clutch linings emit a very fine-grain dust. Brake and clutch linings may also contain asbestos. Use of components containing asbestos is prohibited by law in certain countries. Therefore, observe your local legislation concerning the use of asbestos.

Risks Inhaling dust can cause pulmonary disease.

Dust containing asbestos can cause cancer. Smokers run a much greater risk of getting lung cancer.

Safety precautions Bind the dust with water before working on

brakes and clutches.

Use respiratory protection with suitable dust filters. A simple paper mask is not sufficient.

Never blow with compressed air.

Clean brake components and clutch components with water or a special vacuum cleaner.

SCR catalytic converter and silencerSafety precautions must be taken when carrying out SCR catalytic converter and silencer work which may result in exposure to dust. Such work includes opening the silencer, machining and scrapping the SCR catalytic converter.RisksThe SCR catalytic converter contains vanadium, which is hazardous to health.

Inhalation of dust from the SCR catalytic converter can constitute a health hazard as it may cause irritation of the respiratory system.

Eye contact may cause eye irritation.

Skin contact may irritate the skin.

Ingestion can cause irritation in the mouth and throat and produce discomfort. The ingestion of large quantities may cause disorders in the gastric and intestinal canals.

There is a possible risk of permanent personal injury. There is also a risk of foetal damage.16 Scania CV AB 2012, Sweden 00:01-02

Mechanical workSafety precautionsAn FFP3 type respirator with fine-dust filter should be used for any work where there is a risk of exposure to dust from the SCR catalytic converter.

A vacuum with microfilter should be used to remove dust in order to minimise exposure.

You should not eat, drink or smoke while working.

Make sure you clean your hands after working with an SCR catalytic converter.

GrindingLead can enter the bloodstream through skin contact and cause lead poisoning.

RisksDust formed when grinding bodywork, solder and certain varnishes contains lead.

Safety precautions Avoid skin contact and inhaling.

Use protective gloves, respiratory protection and face mask.00:0

25400:01-02 Scania CV AB 2012, Sweden 17

Mechanical workRotating components and toolsExamples of rotating components and tools: Cooling fan

Drive belts

Injection pump coupling

Propeller shafts

Drilling machines

Lathes, grinders

Risks Rotating components such as fans and

shafts can cause injury if touched. It is also possible to get entangled in a completely smooth rotating shaft.

Drilling machines, lathes, grinders or other machinery with rotating parts can cause severe injury if clothing or hair gets entangled in it.

A hand-held drill with rotating bit can be forced out of your grip. The tool will be thrown aside or continue to rotate until the electrical cable has torn off.18 Scania CV AB 2012, Sweden 00:01-02

Mechanical workSafety precautions Do not use gloves when working with a

drilling machine.

Use a lever on the hand-held drill whenever suitable.

Remove loose scarves and ties.

Never wear clothing with wide sleeves or legs.

Make sure all clothing is intact.

Long hair must be gathered in a hairnet or the like.

Remove large or loose hanging jewellery from hands, arms and neck.

Always use a protective guard on grinding machines.00:01-02 Scania CV AB 2012, Sweden 19

Mechanical workFragments from tools

Risks Burrs can be knocked loose from drifts and

chisels.

The hammer head can fly off the shaft.

Circular saws can grab or wobble.

Flying particles from machining processes. (e.g. grinding, cutting or turning).

Safety precautions Inspect the tool.

Sharpen the tool if necessary.

Check hammers and shafts in advance. Repair or replace hammers and shafts if necessary.

Keep the supporting hand away from the underside of the saw.

Use protective screens or goggles. 20 Scania CV AB 2012, Sweden 00:01-02

Mechanical workFlying partsRubber repairs

Risks Dismantling wheels: Tyres, rims and

retaining rings can fly off.

Assembling wheels.

Pumping tyres: Tyres, rims and retaining rings can fly off.

Wheel balancing: Stones stuck in the tyre can fly off when the wheel is rotated.

Mechanical brushing and turning: Flying fragments

Safety precautions Let the air out before starting to dismantle

the wheel.

Make sure tyres, rims and retaining rings are not damaged. Never repair damaged rims or retaining rings.

Place the wheel in a cage for pumping. Fasten the pump hose to the tyre valve with a clamp. Stand far away with the pressure gauge when pumping. At no more than 3 bar, check that the retaining ring is positioned correctly.

Clean the tyre thoroughly, removing grit and sand before balancing. Use a protective casing over the wheel.

Use protective screens or goggles. 00:01-02 Scania CV AB 2012, Sweden 21

Mechanical workTensioned springsExamples of tensioned springs: Equaliser springs for bonnet and front

grille panel (3-series vehicles only).

Parking brake chambers

Return springs for brake shoes

Retaining rings

Valve springs

Gas springs or gas dampers

Risks If a tensioned spring comes loose, it will be

propelled by the spring force and may take with it some surrounding parts.

Small springs can cause eye injuries if they come loose.

Parking brake chamber springs are tensioned with great force and can cause very severe injuries if they are loosened in an uncontrolled manner.

Gas springs and gas dampers are tensioned with great force and can cause very severe injuries if they are loosened in an uncontrolled manner. Even scrapped gas springs and gas dampers can be dangerous to handle.

Gas dampers and gas springs can explode if heated, e.g. in a fire.22 Scania CV AB 2012, Sweden 00:01-02

Mechanical workSafety precautions Wear protective goggles.

Retaining ring pliers must be of suitable type and size for the purpose and in good condition.

Follow the instructions in the inspection information, or any special instructions for the component concerned, with regard to service and scrapping.

Always use recommended tools.00:01-02 Scania CV AB 2012, Sweden 23

Mechanical workAirbag and belt pretensionerAirbags and belt pretensioners contain explosive charges and can cause injury if not discharged in a controlled manner. They must therefore be handled by personnel who have the necessary training. Refer to the complete inspection information on Airbag and belt pretensioner for more information concerning handling and servicing these units.

Cut the power to the vehicle before starting repairs in order to avoid the uncontrolled discharge of airbags and belt pretensioners.

Airbags and belt pretensioners are triggered by applying electronic pulses to the connector pin or by extreme heat.

Safety precautions Cut the power to the vehicle before starting

repairs.

If a module is triggered:

Move away from the vehicle for about 10 minutes to allow the dust to settle. Do not spray water onto the module.

Vacuum clean the vehicle afterwards. Cleaning personnel must use gloves.

Do not allow the gas to come into contact with the respiratory system or eyes.

Do not inhale smoke or dust.

Wash your hands after touching a triggered module.

A triggered module must be placed in a plastic bag and transported to a facility that handles safe and environmentally responsible disposal of hazardous waste.

A scrapped module must be marked with a label for non-mountable materials, Bn 1947, and returned to the supplier.00:0

254

In the event of fire, units in storage can be cooled down with water to prevent inadvertent discharge. If the module has already discharged, it must not be cooled down with water.

Individual modules kept in the workshop must be stored in a locked cupboard marked "Airbag, Explosive".24 Scania CV AB 2012, Sweden 00:01-02

Fluids and gasesFluids and gases

Risk of fire and explosionExamples of flammable substances: Oils

Petrol

Diesel

Ethanol

Oxyhydrogen gas when batteries are being charged

Organic solvents (varnish, plastic, detergent)

Anti-corrosive agents

Glycol

Washer fluid

Welding gas such as acetylene and heating gas such as LPG

Examples of ignition causes Welding, cutting and sparks from grinder

discs

Smoking

Heat release from rags or other materials that have been soaked in oil or paint (linseed oil)

Short circuited power units.

Oxygen increases the risk of ignition. Containers, pipes or valves used for oxygen must be kept free from oil and grease.00:01-02 Scania CV AB 2012, Sweden 25

Fluids and gasesSpecial cases

DieselThe flashpoint, the temperature at which a liquid evaporates and can be ignited in air, will drop if petrol or other fluids with a low flashpoint are used as additives. This may also mean there is a risk of it igniting at room temperature. Heated diesel has a lower ignition temperature than petrol.

Welding close to the gearboxThe noise shield under the gearbox may become a fire hazard if the insulation material has absorbed oil. Red-hot welding spatter can cause ignition and the rapid spread of fire.

Battery chargingWhen a battery is being charged, its electrolyte will be divided into oxygen and hydrogen gas. This is an extremely explosive combination. The risk of an explosion is especially high when using an auxiliary battery or boost charger due to the increased risk of gases forming. Safety precautions Keep hazardous substances in approved

and airtight containers.

Make sure there are no sources of ignition in the vicinity of flammable or explosive substances. Keep them completely shielded off if possible.

Remove the noise shield under the gearbox whenever welding is carried out close to it. Protect the noise shield from welding spatter.

Provide for good ventilation or use an extractor system.

If not working specifically on the battery, always make sure to disconnect the power to the vehicle when working on the starter motor, for example. This is to avoid subsequent short-circuiting and damage to the cable harness.

Hot workHot work requires training and certification as well as written permission from the fire safety officer on site. If a fire should break out and these regulations have not been followed there is risk that the insurance will be void.26 Scania CV AB 2012, Sweden 00:01-02

Fluids and gasespoisoning.Pressurised fluids or gases

Pipes under high pressure can be damaged while work is being carried out and fluid or gas may escape.

Pipes may be under high pressure even if the pump has stopped so that fluid or gas can leak out after undoing a pipe connection.

A gas container that has been exposed to external damage can explode, for example if it falls against a hard surface. Gas can escape from damaged valves. Pressurised containers, such as gas bottles for welding, can be propelled with a force corresponding to 60 tonnes if the valve is damaged.

RisksWorking on the following components may involve a risk of injury: power steering

tag axle lift

loading crane

tipping device

brake system

compressed air from workshop pneumatic systems

rubber repairs (tyre repairs)

A jet of fluid or gas under pressure will entail the following risks: Gas could penetrate the skin and cause

severe tissue damage.

Gas penetrating body tissue could disrupt blood circulation.

Eyes could be seriously injured.

Many substances in gases can cause Safety precautions Wear protective gloves and goggles.

Never work on a pressurised system unless absolutely necessary.

Use liquids for leak testing.

Never clean clothing by blowing with gas or compressed air.

The valve cover must always be fitted when transporting pressurised vessels.00:01-02 Scania CV AB 2012, Sweden 27

Fluids and gasesSolventsFluids that dissolve grease, paint, varnish, wax, oil, glue, rubber, etc. (unlike water, for example), are called organic solvents.

Examples of organic solvents: White spirit

Toluene

Trichloroethylene

Thinner

Petrol

Alcohol

Xylene

Risks Solvents and products containing solvents

give off fumes that can cause dizziness, headache and nausea. They can also cause bronchial irritation.

Prolonged exposure to a solvent and its fumes could cause damage to the central nervous system. This will become evident through difficulty in sleeping, depression, nervousness, poor memory and general tiredness.

Solvent in direct contact with the skin will make it dry and crack. The risk of skin allergies will also increase. Solvents can also penetrate the skin and be taken up by the bloodstream. Many solvents are flammable.

Most solvents give off extremely flammable fumes at normal room temperature. These fumes can easily ignite, e.g. from a spark. Smoke issuing from a fire where solvent or some other flammable product is burning will contain large amounts of black, corrosive smoke.28 Scania CV AB 2012, Sweden 00:01-02

Fluids and gasesSafety precautions Avoid inhaling fumes by providing good

ventilation, fresh-air masks or other respiratory protection with suitable filter for hazardous gases.

Ventilation must be adequate for the relevant amount of solvent being used and the associated risk of fire.

Never leave a container of solvent without an airtight lid.

Use solvents with low levels of aromaticity. This will reduce the risks.

Avoid contact with the skin.

Wear protective gloves.

Make sure that protective clothing is resistant to solvents.

Electrical equipment must be approved and suited for use in environments where the air may have some degree of solvent content.00:0

25400:01-02 Scania CV AB 2012, Sweden 29

Fluids and gasesEthanol

RegulationsGreat care must be taken when handling ethanol. Ethanol is an extremely flammable substance and an ethanol fire can only be extinguished with a powder fire extinguisher.

Keep the tank well sealed and away from sources of ignition. Smoking is prohibited.

Avoid free-falling jets. Use a hose instead.

IMPORTANT!Comply with local regulations when handling ethanol fuel. Consult and obtain permits from the relevant authority for fire protection, environment and health.

151

973Risks Ethanol fuel is extremely flammable and

must be handled with great care. Both ethanol and petrol are classified as flammability class 1.

Ethanol fuel is hazardous to health. If ethanol has come into contact with eyes or skin, flush with water.

Ethanol fumes form an ignitable mixture with air at approximately 9C, both in closed and open containers.

The fumes are heavier than air and therefore spread along the ground and can catch fire a long way from the source.

Ethanol burns with a barely visible flame and no smoke. Burning ethanol is therefore hard to detect in daylight.

Avoid free-falling jets; otherwise there is a risk of static electricity, which would cause sparks. Use a hose instead.

Prevent sparking through equipotential bonding (grounding).30 Scania CV AB 2012, Sweden 00:01-02

Illustration 1. Display signs as in the example above during work requiring ethanol handling in the workshop.

Fluids and gases00:01-02 Scania CV AB 2012, Sweden 31Safety precautions Comply with applicable local instructions

when handling ethanol fuel.

Use a warning sign with the text "Working with flammable fuels in progress" during work that involves handling ethanol in the workshop (see the example in illustration 1). The service workshop is responsible for obtaining a sign in the relevant language.

Powder is the best extinguishing medium for putting out ethanol fires.

Smoking and hot work is prohibited in conjunction with open handling of ethanol.

Ventilate properly when handling ethanol. Ventilation must be fireproof.

Establish ethanol decontamination routines for workshop work. There must be sand or other absorption material for decontamination.

Store ethanol spillage in a marked, closed container specially designed for ethanol in a manner that ensures it is not confused with diesel.

Wear protective gloves and goggles resistant to ethanol when handling the fuel. Cotton clothes are recommended.

Store replaced parts, such as fuel filters, in a container specially set aside for this.

Use only spark-proof or classified electrical tools within areas where open handling takes place and where there is risk of leakage.

32

Fluids and gasesProcedures for all work in the workshop

IMPORTANT!Read the regulations for ethanol before commencing any work. In addition, adhere to any local rules and regulations for working with ethanol applicable to the workshop.

EnvironmentHelp protect the environment! Avoid spillage and use a suitable container.

Before work in the workshop Check if there is any leakage of ethanol

from the fuel system before the vehicle is brought into the workshop. The recommended method is to leak test the fuel system using measuring instrument 588 875.

Cut the power to the vehicle via the main power switch before starting work. This minimises sparking, which can ignite ethanol fumes.

Note: If work is to be performed in the engine compartment of a vehicle equipped with fire-extinguishing equipment in the engine compartment, cut the power to the vehicle by disconnecting the battery connections.

During work in the workshop If work is to be carried out on the fuel

tanks, they must be drained as specified in the work description for Draining the fuel tank.

If hot work is to be carried out which may affect the fuel tanks, fuel pipes or other components which may contain ethanol, the fuel tanks must be drained according to the work description Draining the fuel tank. Scania CV AB 2012, SweAfter work in the workshop Start the vehicle and check for ethanol

leaks. The recommended method is to leak test the fuel system using measuring instrument 588 875.den 00:01-02

Fluids and gasesVehicle gas

WARNING!Vehicle gas refers to natural gas and biogas, both of which are primarily made up of methane. Methane is extremely flammable and must be handled with great care.

Vehicle gas is normally odourless, but can sometimes have an odorant added. The odorant makes it easier to detect small leaks before there is a risk of the gas being ignitable.

Tanks containing vehicle gas must be stored in a well-ventilated place, separate from sources of ignition.

When working on a vehicle with a gas engine, the gas supply must always be shut off manually at the gas tanks.

Risks Methane is extremely flammable and in

certain cases can even be ignited by static electricity from a person.

Methane is lighter than air and will therefore rise. Therefore, make sure that you ventilate the whole premises properly.

Methane burns with an almost invisible flame, so extra care must be taken. The gas is an explosion hazard and burns in an air mixture as low as 5-15%.

If the gas spreads and forms a flammable mixture, there is a risk of explosion.

The gas is not toxic but in a 50% mixture with air or greater, the oxygen content will be so low that there is risk of suffocation. The gas can be explosive in contact with halogens, nitrogen oxides and acetylene.00:01-02 Scania CV AB 2012, Sweden 33

Fluids and gasestemperatures as the gas pressure will increase as it warms up.Safety precautions

Illustration 1. Display signs as in the example above during work requiring ethanol handling in the workshop.

Comply with the applicable local instructions when handling vehicle gas.

Electrical components in the ventilation system must be adapted to the classification plan. Ventilation must be fireproof.

Smoking is prohibited in the vicinity of gas tanks.

Welding, grinding and other metalworking which can produce heat and sparks must not be performed in the vicinity of the vehicle.

Use only spark-proof or classified electrical tools within areas where open handling must take place.

Never refuel the vehicle immediately before driving it into the workshop. This is especially important in cold outdoor

Working withhighly flamma blefuels in p rogress

318

265 Drive the vehicle out of the workshop in the event of fire. Gas tanks must be taken to safety.

Inform all personnel in the workshop of the location of the shut-off valves in the vehicle.

Shut off each gas tank individually.

Do not empty any part of the vehicle's gas system in the workshop.

Never attempt to put out a burning gas flame. Try to stop the flow of gas instead. Move material that could be ignited by the flame.

Use a warning sign with the text "Working with flammable fuels in progress" during work that involves handling ethanol in the workshop (see the example in illustration 1). The service workshop is responsible for obtaining a sign in the relevant language.34 Scania CV AB 2012, Sweden 00:01-02

Fluids and gasesFire prevention requirementsAlways follow the regulations and requirements that apply in each individual country.

WARNING!Work on the gas tubes, such as replacing the main tap and pressure testing, may only be carried out by an organisation or person accredited for pressure testing gas tanks.

Procedures for work in the workshop

IMPORTANT!The steps below must always be carried out when working on a vehicle with a gas engine!

Before the vehicle is driven into the workshop:1 Carry out a visual inspection and check for

leaks with measuring instrument 588 875. Ensure that the measuring instrument is calibrated according to the measuring instrument's documentation.

When the vehicle has been driven into the workshop:2 Shut off the gas supply at the gas tanks and

empty the fuel system by leaving the engine idling until it stops.

3 Check that the manometer on the gas panel shows 0.

4 Carry out an additional leak test with measuring instrument 588 875.

5 Place a notice in front of the vehicle's windscreen stating that the fuel system is free of gas.

6 Cordon off the area immediately around the vehicle so that no unauthorised persons come near the vehicle.7 Set up a warning sign at the entrance to the workshop site where the vehicle is located. In the event of fire, fire personnel must be aware that pressurised tanks containing highly flammable gas may be located in the building.

8 When removing and dismantling components in the fuel system: Disconnect the battery connections so that the vehicle is without power. Note that a small amount of gas may still be left in the fuel lines. Dismantle with great care.

Shut off the gas supply at the gas tanks.00:01-02 Scania CV AB 2012, Sweden 35

Fluids and gasesCoolantCoolant used in vehicle cooling systems consists of water and corrosion inhibitor and perhaps anti-freeze, ethylene glycol for example.

Coolant must not be disposed of in drains or directly on the ground. Drain the coolant using a coolant tank.

Concentrated glycol is a flammable substance and must be handled as such.

Risks Direct contact with coolant, e.g. in the eyes

or on the skin, will cause injury.

The cooling system runs at overpressure. Hot coolant can escape through leaks or when the filler cap is opened, causing burns.

Ethylene glycol and corrosion inhibitor is dangerous if imbibed.

Safety precautions Wear protective gloves and goggles if there

is any risk of splashing or spraying.

Open the filler cap first to relieve any pressure. Take care. Hot steam and coolant could be ejected.

If possible, avoid working on the cooling system until the coolant has cooled down.

Use equipment as instructed in the inspection information and follow any other instructions concerning work carried out on the cooling system.36 Scania CV AB 2012, Sweden 00:01-02

Fluids and gasesRefrigerantRefrigerant is used in the vehicle's climate system.

Work on the climate system must be carried out in compliance with the legislation of the market in question.

Use only tools that are especially designed for this purpose.

Observe local regulations concerning handling and recycling refrigerant.

Contact your importer for further directions.

Risks Air conditioning operates under pressure.

Escaping refrigerant can cause frostbite or personal injury.

Refrigerant that is heated by smoking or welding, for example, will form gases that are extremely dangerous to inhale.

Remember that refrigerant will contribute to the greenhouse effect if released into the air.

Safety precautions Wear protective gloves and goggles where

there is risk of leakage.

Ensure there are no sources of heat in the vicinity, welding and cigarettes for example.

Follow the instructions concerning refrigerant given in the service information and use any equipment specified there when working on the climate system.

Use local extractors at floor level. Any gas that is formed will be heavier than air and will sink to the floor. The gas is also invisible and almost odourless, which makes it difficult to detect.00:01-02 Scania CV AB 2012, Sweden 37

Fluids and gasesAir pollutionAir pollution is the pollutants found in the air and is considered as being hazardous to health. Certain pollutants occur in a more concentrated form in certain environments.

The following pollutants can be found especially in workshops: Carbon monoxide, from vehicle exhausts.

Carbon monoxide is odourless and therefore especially dangerous.

Nitrogen oxides or nitrous fumes, from vehicle exhausts.

Welding fumes, especially from galvanised or painted materials.

Oil mist, e.g. from anti-corrosion treatment.

Fuming sulphuric acid, e.g. from battery charging.

Grinding dust and gases formed when grinding and heating plastic, varnish, anti-corrosive agent, lubricant, paint, etc.

When heated, PVC will emit toxic smoke that when combined with moisture forms hydrochloric acid, which can cause corrosion damage to metal after about 2 hours.

Risks Carbon monoxide impairs the ability of the

blood to take up oxygen, reducing the supply of oxygen to the brain and other parts of the body. Carbon monoxide poisoning is therefore regarded as internal suffocation. This toxic process can take place rapidly without prior warning.

Remember also that cab heaters emit exhaust fumes.

Nitrogen oxides, gases and grinding dust can damage the lungs. Oil mist from certain oils can cause skin problems such as pimples, boils and eczema.

Fuming sulphuric acid is corrosive and can damage the respiratory system. 38 Scania CV AB 2012, Sweden 00:01-02

Fluids and gasessuch work is being carried out. Personnel should normally use respiratory protection with a supply of fresh air when carrying out this type of work.Safety precautions

Provide for good ventilation with fresh air during welding, battery charging or other work where hazardous gases can be emitted.

Use protective gloves and respiratory protection whenever there is risk of oil mist occurring. Make sure all protective equipment is oil resistant.

Cover unprotected skin with oil-resistant barrier cream.

Ensure there is an eye washing facility in the immediate vicinity when carrying out work with corrosive substances.

Avoid driving the vehicle unnecessarily in the workshop. Connect an extractor to the exhaust pipe to lead exhaust fumes out of the workshop in a closed system.

Use local extractors if the vehicle's short-stop heater is used.

IsocyanatesIsocyanates occur in some paints, putty, adhesives, plastics, etc. used in motor vehicles. Inhaling isocyanates in the form of vapour, dust or aerosol may cause mucous membrane irritation with asthmatic symptoms from the respiratory passages and impair the function of the lungs. Even short-term exposure to high levels can cause problems with a lasting hypersensitivity.

When products containing isocyanates in combined form are heated, they may be set free and give high levels of exposure. This applies e.g. to grinding, welding and cutting products covered in paint containing isocyanates. Ensure therefore to provide for good ventilation where It is Scania's goal* to avoid the use of paints, putty and adhesives containing isocyanates but Scania cannot guarantee that this is the case for paintwork, etc. carried out on the vehicle once it has left the factory.

* The goal is to avoid these kinds of products but they can be present in the paint systems, etc. that are used on vehicles delivered from the factory.00:01-02 Scania CV AB 2012, Sweden 39

ElectricityElectricityGeneralRemember that dismantling a live electrical connection can cause sparks, resulting in a fire hazard.

Never cut a wire with several internal electrical cables when it is live. This would mean a high risk of a short circuit and consequently a fire hazard.

Battery chargingExplosive gas is formed when batteries are being charged. Smoking is prohibited and any apparatus that can cause sparks must not be in the vicinity. 40 Scania CV AB 2012, Sweden 00:01-02

ElectricityElectric motors

Safety precautions Be aware of the risks.

Disconnect the batteries. This is a sound safety precaution to prevent inadvertent operation of the electric motor.

Windscreen wipersEven after turning off the windscreen wipers with the relevant switch, there will still be power remaining in the wiper motor for its return stroke. It only requires an insignificant movement of the engine to make the wiper motor operate.

Safety precautions Do not detach the wiper motor without

making sure the power has been disconnected.

Starter motorThe vehicle will be set in motion if the starter motor is operated while a gear is engaged. In turn, the engine can start if the starter key is in drive position and the vehicle will move off with the gear engaged.

Remember that a moving truck is very difficult to stop if the cab is tilted forward.

Safety precautions First, disconnect the power to the vehicle.

This applies to all vehicles no matter what the condition.

Connect a hanging fuse (8A) between the negative battery terminal and the cable terminal if power is required in the electrical system. This measure will also reduce the danger of burns and fire caused by power from the battery.00:01-02 Scania CV AB 2012, Sweden 41

ElectricityGenerator setA generator set may be the primary power source, but can also work as a standby in an electrical consumer network and be connected in case of a fault on the regular network.

The generator set can operate separately or be connected together with other generator sets for joint operation.

Safety precautions

General Read and understand all safety precautions

and warnings before installation, commissioning, operation and performance of inspection of the generator set.

Bear in mind that the generator set may be remote-controlled and could start without warning.

Starting and stopping the generator set is only permitted if this can be done safely in relation to connected electrical consumers.

Never run a generator set with known faults.

Installation, commissioning, operation, inspection and repairs must be carried out by trained and qualified personnel who are authorised to perform the work.42 Scania CV AB 2012, Sweden 00:01-02

ElectricityElectrical installation

! WARNING!Installation and commissioning of a generator set may only take place in full agreement with current national, local or regional regulations, standards or other requirements.

! WARNING!Installation, commissioning, operation and inspection of the generator set may only be carried out by trained and qualified personnel.

! WARNING!During operation of a generator set with a canopy, all hatches must be closed. The hatches may only be opened once the generator set is stopped and when required by inspection work.

! WARNING!The generator set can be remote-controlled and start without prior warning. Therefore, set the battery master switch (option) to the OFF position or disconnect the battery negative cable before any work is carried out on the generator set.Connecting electrical consumers

! WARNING!Electrical consumers may only be connected by trained and qualified personnel authorised to carry out this work.

! WARNING!The connection of electrical consumers must be in full compliance with national or local regulations.00:01-02 Scania CV AB 2012, Sweden 43

ElectricityElectric shock

! WARNING!Always cut off the power and take a reading between a conductor and ground before starting work on the generator set. This is to ensure no voltage remains in the system. High voltage could lead to damage, injury or even death.

Moving parts

! WARNING!A generator set contains many mechanical moving parts. Remove protection devices and belt guards with caution and only if it is absolutely necessary to do so. Do not run a generator set without all protection devices in place.

Hot surfaces

! WARNING!The exhaust manifold, turbocharger, cooling package and alternator can become extremely hot during operation. Do not touch these areas when the generator set is in operation, and make sure that it has cooled down sufficiently before any inspection actions are carried out.NoiseA generator set without a canopy can cause noise levels above 105 dBA.

! WARNING!Ear defenders must be worn at all times in the vicinity of a generator set in operation. Long-term exposure to noise levels above 85 dBA is harmful to hearing.44 Scania CV AB 2012, Sweden 00:01-02

ElectricityLifting the generator setA generator set can be lifted in various ways depending on its equipment.

Lifting using straps connected to the four load securing eyes in the beam frame.

Lift using straps connected to lifting eyes on the roof that are part of a built-in lifting device. Only applies to generator set with canopy. The lifting device is an option.

Lifting in external fork pockets. Fork pockets are an option.Warning stickersThe generator set is supplied with general warning stickers; see the examples in the illustrations. The warning stickers must be replaced if they come off or cannot be read.

Warning! The generator set can be remotely-controlled and may start without warning.

Warning! A warning sticker with a lightning symbol indicates that there is a voltage within the casing that is dangerous for a person.00:01-02 Scania CV AB 2012, Sweden 45