Ford Falcon. Manual — part 3

100-00-9 General

Information 100-00-9

DESCRIPTION AND OPERATION (Continued)

Make sure there is adequate ventilation when

checked for integrity following the specified

handling and using gasolene. Great care must be

procedures.

taken to avoid the serious consequences of inhalation If the fuel tank is to be removed for service or repair

in the event of vapour build up arising from spillages

the fuel must be evacuated using dedicated

in confined spaces.

equipment and following the specified procedures.

Special precautions apply to cleaning and

Gas Cylinders

maintenance operations on gasolene storage tanks.
Gasolene should not be used as a cleaning agent. It

See also Fire.

must not be siphoned by mouth. See First Aid.

Gases such as oxygen, acetylene, argon and propane

are normally stored in cylinders at pressures of up to

Gas-oil (Diesel Fuel)

138 bar (2000 psi) and great care should be taken in

Combustible.

handling these cylinders to avoid mechanical damage

to them or to the valve gear attached. The contents of

Gross or prolonged skin contact with high boiling point

each cylinder should be clearly identified by

gas oils may also cause serious skin disorders

appropriate markings.

including skin cancer.

Cylinders should be stored in well ventilated

Kerosene (Paraffin)

enclosures, and protected from ice and snow, or

direct sunlight. Fuel gases, for example acetylene and

Used also as heating fuel, solvent and cleaning agent.

propane, should not be stored in close proximity to

Flammable - observe No Smoking policy.

oxygen cylinders.

Irritation of the mouth and throat may result from

Care should be exercised to prevent leaks from gas

swallowing. The main hazard from swallowing arises if

cylinders and lines, and to avoid sources of ignition.

liquid aspiration into the lungs occurs.

Only trained personnel should undertake work

Liquid contact dries the skin and can cause irritation

involving gas cylinders.

or dermatitis. Splashes in the eye may be slightly

irritating.

Gases

In normal circumstances the low volatility does not

See Gas Cylinders.

give rise to harmful vapours. Exposure to mists and

vapours from kerosene at elevated temperature

Gaskets (Fluoroelastomer)

should be avoided (mists may arise in dewaxing).

See Viton.

Avoid skin and eye contact and make sure there is

adequate ventilation.

General Workshop Tools and Equipment

Alternative Fuel

It is essential that all tools and equipment are

Highly flammable. Observe “NO SMOKING” signs.

maintained in good condition and the correct safety

equipment is used where required.

Make sure there is adequate ventilation when working

on alternative fuelled vehicles. Great care must be

Never use tools or equipment for any purpose other

taken to avoid the serious consequences of inhalation than that for which they were designed. Never

in the event of vapour build up in confined spaces.

overload equipment such as hoists, jacks, axle and

chassis stands or lifting slings. Damage caused by

Inhalation in high concentrations may cause

overloading is not always immediately apparent and

dizziness, headache, nausea and loss of

may result in a fatal failure the next time that the

co-ordination. Very high concentrations may result in

equipment is used.

loss of consciousness.

Do not use damaged or defective tools or equipment,

Contact with liquidified petroleum gas (LPG) or

particularly high speed equipment such as grinding

compressed natural gas (CNG) to skin may cause

wheels. A damaged grinding wheel can disintegrate

cold burns and may cause frost bite.

without warning and cause serious injury.

Long sleeved cotton overalls, steel toe capped safety

Wear suitable eye protection when using grinding,

boots and rubber neoprene gloves should be worn

chiselling or sand blasting equipment.

during removal and installation of LPG/CNG fuel

system components.

Wear a suitable breathing mask when using abrasive

blasting equipment, working with asbestos-based

LPG/CNG fuel leaks could cause a fire and be a

materials or using spraying equipment.

hazard to health that can lead to personal injury,

illness or even death.

Make sure there is adequate ventilation to control

dusts, mists and fumes.

If a leak is detected, under no circumstances attempt

to seal the leak by tightening the union/connection

until the fuel in the system or component is

depressurised. Once tightened the system should be

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100-00-10 General

Information 100-00-10

DESCRIPTION AND OPERATION (Continued)

Wash with soap and water to make sure all oil is

High Pressure Air, Lubrication and Oil

removed (skin cleansers and nail brushes will

Test Equipment

help). Preparations containing lanoline replace the

See also Lubricants and Greases.

natural skin oils which have been removed.

Always keep high pressure equipment in good

Do not use gasolene (petrol), kerosene (paraffin),

condition, and regularly maintained, particularly at

diesel fuel (gas oil), thinners or solvents for

joints and unions.

cleaning skin.

Never direct a high pressure nozzle, for example

If skin disorders develop, obtain medical advice

diesel injector, at the skin as the fluid may penetrate

without delay.

to the underlying tissue, and cause serious injury.

Where practicable, degrease components prior to

handling.

Halon

Where there is a risk of eye contact, eye

See CFCs.

protection should be worn, for example chemical

goggles or face shields; in addition an eye wash

Legal Aspects

facility should be provided.

There are many laws and regulations relating to

Environmental Precautions

health and safety in the use and disposal of materials

and equipment in a workshop.

Burning used engine oil in small space heaters or

For a safe working environment and to avoid

boilers can be recommended only for units of

environmental pollution, workshops should be familiar, approved design. If in doubt check with the

in detail, with the many health and safety laws and

appropriate local authority and manufacturer of

regulations within their country, published by both

approved appliances.

national and local authorities.

Dispose of used oil and used oil filters through

authorized waste disposal contractors or licensed

Lubricants and Greases

waste disposal sites, or to the waste oil reclamation

Avoid all prolonged and repeated contact with mineral trade. If in doubt, contact the relevant local authority

oils. All lubricants and greases may be irritating to the for advice on disposal facilities.

eyes and skin.

It is illegal to pour used oil on to the ground, down

sewers or drains, or into water courses.

Used Engine Oil

Noise

Prolonged and repeated contact with mineral oil will

result in the removal of natural fats from the skin,

Some operations may produce high noise levels

leading to dryness, irritation and dermatitis. In

which could, in time, damage hearing. In these cases,

addition, used engine oil contains potentially harmful

suitable ear protection must be worn.

contaminants which may cause skin cancer. Adequate

means of skin protection and washing facilities must

Noise Insulation Materials

be provided.

See Foams, Fibre Insulation.

Do not employ used engine oils as lubricants or for

any application where appreciable skin contact is

O-Rings (Fluoroelastomer)

likely to occur.

See Viton.

Health Protection Precautions

Paints

Avoid prolonged and repeated contact with oils,

See also Solvents, Chemical Materials.

particularly used engine oils.

Highly flammable, flammable - observe No Smoking

Wear protective clothing, including impervious

policy

gloves where practicable.
Do not put oily rags into pockets.

One Pack

Avoid contaminating clothes, particularly

Can contain harmful or toxic pigments, driers and

underpants, with oil.

other components as well as solvents. Spraying

Heavily soiled clothing and oil-impregnated

should be carried out only with adequate ventilation.

footwear should not be worn. Overalls must be

Two Pack

cleaned regularly.
First Aid treatment should be obtained

Can also contain harmful and toxic unreacted resins

immediately for open cuts and wounds.

and resin hardening agents. The manufacturers

instructions should be followed. See also Resin-based

Use barrier creams, applying them before each

Adhesives and Isocyanate Adhesives and Sealers

work period, to help the removal of oil from the

under Adhesives and Sealers.

skin.

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100-00-11 General

Information 100-00-11

DESCRIPTION AND OPERATION (Continued)

Spraying should preferably be carried out in

Avoid splashes to the skin, eyes and clothing. Wear

exhausted ventilated booths removing vapour and

protective gloves, goggles and clothing if necessary.

spray mists from the breathing zone. Individuals

Make sure there is good ventilation when in use,

working in booths should wear appropriate respiratory avoid breathing fumes, vapours and spray mists and

protection. Those doing small scale repair work in the keep containers tightly sealed. Do not use in confined

open workshop should wear air-fed respirators.

spaces.
When spraying materials containing solvents, for

Pressurized Equipment

example paints, adhesive, coatings, use extraction

See High Pressure Air, Lubrication and Oil Test

ventilation or personal respiratory protection in the

Equipment.

absence of adequate general ventilation.
Do not apply heat or flame except under specific and

Solder

detailed manufacturers instructions.

Solders are mixtures of metals such that the melting

point of the mixture is below that of the constituent

Sound Insulation

metals (normally lead and tin). Solder application

See Fibre Insulation, Foams.

does not normally give rise to toxic lead fumes,

provided a gas/air flame is used. Oxy-acetylene

Suspended Loads

flames should not be used, as they are much hotter

and will cause lead fumes to be produced.

CAUTION: Never improvise lifting tackle.

Some fumes may be produced by the application of

There is always a danger when loads are lifted or

any flame to surfaces coated with grease, and

suspended. Never work under an unsupported,

inhalation of these should be avoided.

suspended or raised load, for example a suspended

Removal of excess solder should be undertaken with

engine.

care, to make sure that fine lead dust is not produced,

Always make sure that lifting equipment such as

which can give toxic effects if inhaled. Respiratory

jacks, hoists, axle stands and slings are adequate and

protection may be necessary.

suitable for the job, in good condition and regularly

Solder spillage and filings should be collected and

maintained.

removed promptly to prevent general air

contamination by lead.

Transmission Brake Bands

High standards of personal hygiene are necessary in

See Asbestos.

order to avoid ingestion of lead or inhalation of solder

dust from clothing.

Underseal

See Corrosion Protection.

Solvents

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

Viton

For example acetone, white spirit, toluene, xylene,

In common with many other manufacturers vehicles,

trichloroethane.

some components fitted to the Ford range have

Used in cleaning and dewaxing materials, paints,

O-rings, seals or gaskets which contain a material

plastics, resins and thinners.

known as ‘Viton’.

Some may be highly flammable or flammable.

Viton is a fluoroelastomer, that is a synthetic rubber

type which contains Fluorine. It is commonly used for

Skin contact will degrease the skin and may result in

O-rings, gaskets and seals of all types. Although Viton

irritation and dermatitis following repeated or

is the most well known fluoroelastomer, there are

prolonged contact. Some can be absorbed through

others, including Fluorel and Tecmoflon.

the skin in toxic or harmful quantities.

When used under design conditions fluoroelastomers

Splashes in the eye may cause severe irritation and

are perfectly safe. If, however, they are exposed to

could lead to loss of vision.

temperatures in excess of 400

°C, the material will not

Brief exposure of high concentrations of vapours or

burn, but will decompose, and one of the products

mists will cause eye and throat irritation, drowsiness,

formed is hydrofluoric acid.

dizziness, headaches and, in the worst

This acid is extremely corrosive and may be absorbed

circumstances, unconsciousness.

directly, through contact, into the general body

Repeated or prolonged exposure to excessive but

system.

lower concentrations of vapours or mists, for which

O-rings, seals or gaskets which have been exposed to

there might not be adequate warning indications, can

very high temperatures will appear charred or as a

cause more serious toxic or harmful effects.

black sticky substance.

Aspiration into the lungs, for example through

DO NOT, under any circumstances touch them or the

vomiting, is the most serious consequence of

attached components.

swallowing.

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100-00-12 General

Information 100-00-12

DESCRIPTION AND OPERATION (Continued)

Enquiries should be made to determine whether Viton

Gas Welding (and Cutting)

or any other fluoroelastomer has been used in the

Oxy-acetylene torches may be used for welding and

affected O-ring, seal or gasket. If they are of natural

cutting, and special care must be taken to prevent

rubber or nitrile there is no hazard. If in doubt, be

leakage of these gases, with consequent risk of fire

cautious as the material may be Viton or any

and explosion.

fluoroelastomer.

The process will produce metal spatter and eye and

If Viton or any other fluoroelastomers have been

skin protection is necessary.

used, the affected area should be decontaminated

The flame is bright, and eye protection should be

before the commencement of work.

used, but the ultra-violet emission is much less than

Disposable heavy duty plastic gloves should be worn

that from arc welding, and lighter filters may be used.

at all times, and the affected area washed down using

The process itself produces few toxic fumes, but such

wire wool and a limewater (calcium hydroxide)

fumes and gases may be produced from coatings on

solution to neutralise the acid before disposing of the

the work, particularly during cutting away of damaged

decomposed Viton residue and final cleaning of the

body parts, and inhalation of the fumes should be

area. After use, the plastic gloves should be discarded

avoided.

carefully and safely.

In brazing, toxic fumes may be produced from the

Welding

metals in the brazing rod, and a severe hazard may

arise if brazing rods containing cadmium are used. In

See also Fire, Electric Shock, Gas Cylinders.

this event particular care must be taken to avoid

Welding processes include Resistance Welding (Spot

inhalation of fumes and expert advice may be

Welding), Arc Welding and Gas Welding.

required.

Resistance Welding

Special precautions must be taken before any welding

or cutting takes place on vessels which have

This process may cause particles of molten metal to

contained combustible materials, for example boiling

be emitted at a high velocity, and the eyes and skin

or steaming out of fuel tanks .

must be protected.

Warning Symbols on Vehicles

Arc Welding

Decals showing warning symbols will be found on

This process emits a high level of ultra-violet radiation

various vehicle components.

which may cause arc-eye and skin burns to the

operator and to other persons nearby. Gas-shielded

These decals must not be removed. The warnings are

welding processes are particularly hazardous in this

for the attention of owners/operators and persons

respect. Personal protection must be worn, and

carrying out service or repair operations on the

screens used to shield other people.

vehicle.

CONTACT LENS WEARERS ARE ADVISED TO

The most commonly found decals are reproduced

REVERT TO ORDINARY SPECTACLES WHEN ARC below together with an explanation of the warnings.

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 the metals being welded, 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

1. Components or assemblies displaying the caution

anticipated. In extreme cases or confined spaces

triangle and open book symbol advise

where adequate ventilation cannot be provided,

consultation of the relevant section of the owners

air-fed respirators may be necessary.

handbook before touching or attempting

adjustments of any kind.

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