Ford Workshop Service and Repair Manuals

Introduction

Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This subsection lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. Precautions necessary to avoid these hazards are identified.

The list is not exhaustive and all operations and procedures, and the handling of materials, should be carried out with health and safety in mind.

Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be consulted.

Acids and Alkalis

See also Battery Acids.

For example caustic soda, sulphuric acid.

Used in batteries and cleaning materials.

Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing.

Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists.

Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.

Display Eye Hazard sign.

Air Bags

See also Fire, Chemical Materials - General

Highly flammable, explosive – observe No Smoking policy.

Air bags are safety restraint systems that are mounted in the steering wheel, passenger side instrument panel, and in some variants as side air bags in the driver and passenger seats.

The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C).

The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be worn when dealing with the spillage.

After normal deployment, gloves and safety goggles should be worn during the handling process.

Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste site.

Following any direct contact with gas generant:

• wash affected areas thoroughly with water.
• seek medical assistance if necessary.

Air Bags - Do's

• Do store modules in an upright position.
• Do keep modules dry.
• Do carry modules with the cover side pointing away from the body.
• Do place modules with their cover side upwards.
• Do carefully inspect modules for damage.
• Do stand to one side when connecting modules.
• Do make sure all test equipment is properly calibrated and maintained.
• Do wash your hands after handling deployed air bags.

Air Bags - Do Nots

• Do not store highly flammable material together with modules or gas generators.
• Do not store gas generators at temperatures exceeding 80°C.
• Do not store modules upside down.
• Do not attempt to open a gas generator housing.
• Do not expose gas generators to open flame or sources of heat.
• Do not place anything on top of a module cover.
• Do not use damaged modules.
• Do not touch a fired module or gas generator for at least 10 minutes.
• Do not use any electrical probes on the wiring circuit.

Air Conditioning Refrigerant

See also Chlorofluorocarbon, Chemical Materials

Highly flammable, combustible – observe No Smoking policy.

Skin contact may result in frostbite.

Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles.

If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.

Air Conditioning Refrigerant - Do Nots

• Do not expose refrigerant bottles to sunlight or heat.
• Do not stand refrigerant bottles upright; when filling, hold them with the valve downwards.
• Do not expose refrigerant bottles to frost.
• Do not drop refrigerant bottles.
• Do not vent refrigerant to atmosphere under any circumstance.
• Do not mix refrigerants for example R12 (Freon) and R134a.

Adhesives and Sealers

See also Fire, Chemical Materials

Highly flammable, flammable, combustible – observe No Smoking policy.

Generally should be stored in `No Smoking' areas. Cleanliness and tidiness in use should be observed, for example disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled appropriately.

Solvent-based Adhesives/Sealers - See Solvents

Follow manufacturer's instructions.

Water-based Adhesives/Sealers

Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives

In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic fumes.

Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate extraction.

Resin-based Adhesives/Sealers for example Epoxide and Formaldehyde Resin-based

Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released.

Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes.

Provide adequate ventilation and avoid skin and eye contact.

Anaerobic, Cyanoacrylate (Super-glues) and other Acrylic Adhesives

Many are irritant, sensitizing or harmful to the skin and/or respiratory tract. Some are eye irritants.

Skin and eye contact should be avoided and the manufacturer's instructions followed.

Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and seek immediate medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas as vapours can cause irritation to the nose and eyes.

For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.

Isocyanate (Polyurethane) Adhesives/Sealers

See also Resin-based Adhesives

Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur.

Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapour concentrations may result in adverse health effects.

Prolonged contact with the skin may have a deflating effect which may lead to skin irritation and, in some cases, dermatitis.

Splashes entering the eye will cause discomfort and possible damage.

Any spraying should preferably be carried out in exhaust ventilated booths removing vapours and spray droplets from the breathing zone.

Wear appropriate gloves, eye and respiratory protection.

Antifreeze

See also Fire, Solvents.

For example isopropanol, ethylene glycol, methanol.

Highly flammable, flammable, combustible.

Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.

Vapours may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these vapours.

Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal and medical attention should be sought immediately.

These products must not be used in any cooling or industrial water system which is connected or linked to general, food preparation or drinking water supplies.

Asbestos

See also Warning Symbols on Vehicles at the end of this subsection.

Breathing asbestos dust may cause lung damage or, in some cases, cancer.

Used in brake and clutch linings, transmission brake bands and gaskets. Ford original production and replacement items for this model are asbestos free.

The use of drum cleaning units, vacuum cleaning or damp wiping is preferred.

Asbestos dust waste should be dampened, placed in a sealed container and marked to make sure of safe disposal. If any cutting or drilling is attempted on materials containing asbestos the item should be dampened and only hand tools or low speed power tools used.

Battery Acids

See also Acids and Alkalis.

Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries.

Make sure there is adequate ventilation.

Brake and Clutch Linings and Pads

See Asbestos.

Brakes Fluids (Polyalkylene Glycols)

See also Fire.

Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation vapour hazards do not arise at ambient temperatures because of the very low vapour pressure.

Brazing

See Welding.

Chemical Materials

See also Legal Aspects.

Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, an irritant or highly flammable and give rise to hazardous fumes and dusts.

The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life-expectancy.

Chemical Materials - Do's

• Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, posters or other instructions. Material health and safety data sheets can be obtained from manufacturers.
• Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned.
• Do organise work practices and protective clothing to avoid soiling of the skin and eyes; breathing vapours, aerosols, dusts or fumes; inadequate container labelling; fire and explosion hazards.
• Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials.
• Do keep work areas clean, uncluttered and free of spills.
• Do store chemical materials according to national and local regulations.
• Do keep chemical materials out of the reach of children.

Chemical Materials - Do Nots

• Do not mix chemical materials except under the manufacturer's instructions; some chemicals can form other toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together.
• Do not spray chemical materials, particularly those based on solvents, in confined spaces for example when people are inside a vehicle.
• Do not apply heat or flame to chemical materials except under the manufacturer's instructions. Some are highly flammable and some may release toxic or harmful fumes.
• Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, pits etc.
• Do not transfer chemical materials to unlabelled containers.
• Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.
• Do not use emptied containers for other materials except when they have been cleaned under supervised conditions.
• Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.

Chlorofluorocarbons (CFC)

There is concern in the scientific community that CFCs and Halons are depleting the upper ozone layer which filters out harmful ultraviolet radiation. Decreased filtration of ultraviolet radiation may result in increases in skin cancer, cataracts and immune system suppression in humans, as well as decreased productivity of crops and aquatic systems.

CFCs are used primarily as refrigerants in vehicle air conditioning systems and as aerosol propellants. Halons are used as fire extinguishants.

Ford supports worldwide elimination of CFC usage and it is recommended that Company subsidiaries and affiliates should phase out CFC usage as soon as acceptable substitutes are commercially available.

Clutch Fluids

See Brake fluids.

Clutch Linings and Pads

See Asbestos.

Corrosion Protection Materials

See also Solvents, Fire.

Highly flammable, flammable – observe No Smoking policy.

These materials are varied and the manufacturer's instructions should be followed. They may contain solvents, resins, petroleum products etc. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not in confined spaces.

Cutting

See Welding.

Dewaxing

See Solvents and Fuels (Kerosene).

Dusts

Powder, dusts or clouds may be an irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and/or sources of ignition.

Electric Shock

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition.

Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be labelled and preferably removed from the work station.

Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged.

Make sure that electrical equipment and flexes do not come into contact with water.

Make sure that electrical equipment is protected by the correct rated fuse.

Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.

Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.

Make sure that the designated electrical workers are trained in basic First Aid.

In cases of electrocution:

• switch off the power supply before approaching the victim.
• if this is not possible push or drag the victim from the source of electricity using dry non-conductive material.
• commence resuscitation if trained to do so.
• SUMMON MEDICAL ASSISTANCE.

Engine Oils

See Lubricants and Grease.

Exhaust Fumes

These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.

Gasolene (petrol) engine

There may not be adequate warning of odour or of irritation before toxic or harmful effects arise. These may be immediate or delayed.

Diesel engine

Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.

Fibre Insulation

See also Dusts.

Used in noise and sound insulation.

The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect.

Precautions should be taken to avoid excessive skin contact through careful organisation of work practices and the use of gloves.

Fire

See also Welding, Foams, Legal Aspects.

Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if burnt.

Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or welding processes.

Make sure, before using electrical or welding equipment, that there is no fire hazard present.

Have a suitable fire extinguisher available when using welding or heating equipment.

First Aid

Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.

Splashes in the eye should be flushed carefully with clean water for at least ten minutes.

Soiled skin should be washed with soap and water.

Individuals affected by inhalation of gases, fumes etc. should be removed to fresh air immediately. If effects persist, consult a doctor.

If liquids are swallowed inadvertently consult a doctor giving him the information on the container or label. Do not induce vomiting unless this action is indicated on the label.

Fluoroelastomer

See Viton.

Foams - Polyurethane

See also Fire.

Used in sound and noise insulation. Cured foams used in seat and trim cushioning.

Follow manufacturer's instructions.

Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.

Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not work in or near uncured materials.

The components, vapours or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.

Vapours and spray mists must not be inhaled. These materials must be applied with adequate ventilation and respiratory protection. Do not remove the respirator immediately after spraying, wait until the vapour/mists have cleared.

Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames or the use of electrical equipment during foaming operations and until vapours/mists have cleared should not be allowed. Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation. See also the vehicle Body Repair Manual.

Freon

See Air Conditioning Refrigerant.

Fuels

See also, Fire, Legal Aspects, Chemicals and Solvents.

Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

Gasoline (Petrol)

Highly flammable - observe No Smoking policy.

Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, for example through vomiting, is a very serious hazard.

Gasolene dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe irritation.

Motor gasolene may contain appreciable quantities of benzene which is toxic upon inhalation, therefore the concentration of gasolene vapours must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.

Make sure there is adequate ventilation when handling and using gasolene. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces.

Special precautions apply to cleaning and maintenance operations on gasolene storage tanks.

Gasolene should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid.

Gas-oil (Diesel Fuel)

Combustible.

Excessive or prolonged skin contact with high boiling point gas oils may also cause serious skin disorders including skin cancer.

Kerosene (Paraffin)

Used also as heating fuel, solvent and cleaning agent.

Flammable - observe No Smoking policy.

Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into the lungs occurs.

Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.

In normal circumstances the low volatility does not give rise to harmful vapours. Exposure to mists and vapours from kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation.

Gas Cylinders

See also Fire.

Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 13.790 kPa, (2000 lb/in ²) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.

Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders.

Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition.

Only trained personnel should undertake work involving gas cylinders.

Gases

See Gas Cylinders.

Gaskets (Fluoroelastomer)

See Viton.

General Workshop Tools and Equipment

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required.

Never use tools or equipment for any purpose other than that for which they were designed. Never over-load equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used.

Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury.

Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.

Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment.

Make sure there is adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil Test Equipment

See also Lubricants and Greases.

Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.

Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the under-lying tissue etc. and cause serious injury.

Halon

See CFCs.

Legal Aspects

Many laws and regulations make requirements relating to health and safety in the use and disposal of materials and equipment in workshops. Some of these laws which apply in the U.K. are listed. Similar laws exist for other territories:

• The Factories Act (1961).
• The Asbestos Regulations (1969).
• Highly Flammable Liquids and Liquified Petroleum Gases Regulations (1972).
• Control of Pollution Act (1974).
• Health and Safety at Work Act (1974).
• The Classification, Packaging and Labelling of Dangerous Substances Regulations (1978, 1981, 1983, 1984).
• Control of Lead at Work Regulations (1980).
• Control of Substances Hazardous to Health (COSHH) Regulations (1989).
• Abrasive Wheels Regulations (1970).
• Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1985 (R1DD02).

Workshops should be familiar, in detail, with these and associated laws and regulations.

Consult the local factory inspectorate if in any doubt.

Lubricants and Greases

Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and skin.

Used Engine Oil

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.

There are publications describing the problems and advising on precautionary measures. For the UK a typical Health and Safety Executive publication is: SHW 397: Cautionary Notice: Effects of mineral oil on the skin.

Health Protection Precautions

• Avoid prolonged and repeated contact with oils, particularly used engine oils.
• Wear protective clothing, including impervious gloves where practicable.
• Do not put oily rags into pockets.
• Avoid contaminating clothes, particularly underpants, with oil.
• Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.
• First Aid treatment should be obtained immediately for open cuts and wounds.
• Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
• Wash with soap and water to make sure all oil is removed (use skin cleansers and nail brushes). Preparations containing lanoline replace the natural skin oils which have been removed.
• Do not use gasolene (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
• If skin disorders develop, obtain medical advice without delay.
• Where practicable, degrease components prior to handling.
• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

Environmental Precautions

Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. In the UK the heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the appropriate local authority and manufacturer of approved appliances.

Dispose of used oil and used oil filters through authorised waste disposal contractors or licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the relevant local authority for advice on disposal facilities.

It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses.

Noise

Some operations may produce high noise levels which could, in time, damage hearing. In these cases suitable ear protection must be worn.

Noise Insulation Materials

See Foams, Fibre Insulation.

`0' Rings (Fluoroelastomer)

See Viton.

Paints

See also Solvents, Chemical Materials.

Highly flammable, flammable - observe No Smoking policy

One Pack

Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should be carried out only with adequate ventilation.

Two Pack

Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturer's instructions should be followed. See also Resin-based Adhesives and Isocyanate Adhesives and Sealers under Adhesives and Sealers.

Spraying should preferably be carried out in exhausted ventilated booths removing vapour and spray mists from the breathing zone. Individuals working in booths should wear appropriate respiratory protection. Those doing small scale repair work in the open workshop should wear air-fed respirators.

Pressurized Equipment

See High Pressure Air, Lubrication and Oil Test Equipment.

Solder

Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.

Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these should be avoided.

Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary.

Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.

High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.

Solvents

See also Chemical Materials, Fuels (Kerosene), Fire.

for example acetone, white spirit, toluene, xylene, trichloroethane.

Used in cleaning and dewaxing materials, paints, plastics, resins, thinners etc.

Some may be highly flammable or flammable.

Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities.

Splashes in the eye may cause severe irritation and could lead to loss of vision.

Brief exposure of high concentrations of vapours or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.

Repeated or prolonged exposure to excessive but lower concentrations of vapours or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects.

Aspiration into the lungs (for example through vomiting) is the most serious consequence of swallowing.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.

Make sure of good ventilation when in use, avoid breathing fumes, vapours and spray mists and keep containers tightly sealed. Do not use in confined spaces.

When spraying materials containing solvents, for example paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation.

Do not apply heat or flame except under specific and detailed manufacturer's instructions.

Sound Insulation

See Fibre Insulation, Foams.

Suspended Loads

CAUTION:Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load for example suspended engine, etc.

Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc. are adequate and suitable for the job, in good condition and regularly maintained.

Transmission Brake Bands

See Asbestos.

Underseal

See Corrosion Protection.

Viton

In common with many other manufacturers' vehicles, some components fitted to the Ford range have `O' rings, seals or gaskets which contain a material known as `Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for `O' rings, gaskets and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.

This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.

`O' rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky substance.

DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected `O' ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding

See also Fire, Electric Shock, Gas Cylinders.

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Resistance Welding

This process may cause particles of molten metal to be emitted at a high velocity. The eyes and skin must be protected.

Arc Welding

This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people.

CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens is removed from the eye.

Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from welded metals, the rods and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.

Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion.

The process will produce metal spatter and eye and skin protection is necessary.

The flame is bright, and eye protection should be used. The ultra-violet emission is much less than that from arc welding, and lighter filters may be used.

The process itself produces few toxic fumes, but fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts, inhalation of the fumes should be avoided.

In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.

Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.

These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service or repair operations on the vehicle.

The most commonly found decals are reproduced together with an explanation of the warnings as follows.

1. Components or assemblies displaying the warning triangle and open book symbol advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind.

2. Components or assemblies displaying the warning triangle with the `electrified' arrow and open book symbol give warning of inherent high voltages. Never touch these with the engine running or the ignition switched on. See Electric Shock in this subsection.

3. Ford vehicles and replacement parts which contain asbestos are identified by this symbol. See Asbestos in this subsection.

4. Components or assemblies displaying this symbol give warning that the component contains a corrosive substance. See Acids and Alkalis in this subsection.

5. Vehicles displaying the caution circle with a deleted lighted match symbol, caution against the use of naked lights or flames within the immediate vicinity due to the pressure of highly flammable or explosive liquids or vapours. See Fire in this subsection.

6. Vehicles displaying this symbol (normally in conjunction with 5) warn of the presence of potentially explosive matter within the immediate vicinity.

7. Vehicles displaying this symbol warn that children should not be allowed to investigate the immediate vicinity unsupervised.

White Spirit

See Solvents.