Discovery 2. Manual — part 3

GENERAL INFORMATION

03-5

Checklist
Always adhere to the following.

Electricity and heating:

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keep doors and windows closed in the winter;

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switch off machinery or lights when not needed;

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use energy efficient heating systems;

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switch off computers and photocopiers when
not needed.

Fuel:

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don't run engines unnecessarily;

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think about whether journeys are necessary and
drive to conserve fuel.

Water:

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don't leave taps and hose pipes running;

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mend leaks quickly, don't be wasteful.

Compressed air:

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don't leave valves open;

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mend leaks quickly;

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don't leave the compressor running when not
needed.

Use of environmentally damaging materials:

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check whether a less toxic material is available.

Handling and storage of materials:

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have the correct facilities available for handling
liquids to prevent spillage and wastage as listed
above;

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provide suitable locations for storage to prevent
frost damage or other deterioration.

Waste Management
One of the major ways that pollution can be reduced
is by the careful handling, storage and disposal of all
waste materials that occur on sites. Legislation
makes it illegal to dispose of waste materials other
than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what
the waste materials are, but also to have the
necessary documentation and licenses.

Handling and storage of waste
Ensure that waste materials are not poured down the
drain or onto soils. They should be stored in such a
way as to prevent the escape of the material to land,
water or air.

They must also be segregated into different types of
waste e.g. oil, metals, batteries, used vehicle
components. This will prevent any reaction between
different materials and assist in disposal.

Disposal of waste
Disposal of waste materials must only be to waste
carriers who are licensed to carry those particular
waste materials and all the necessary
documentation must be completed. The waste
carrier is responsible for ensuring that the waste is
taken to the correct disposal sites.

Dispose of waste in accordance with the following
guidelines.

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Fuel, hydraulic fluid, anti-freeze and oil: keep
separate and dispose of to specialist contractor.

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Refrigerant: collect in specialist equipment and
reuse.

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Detergents: safe to pour down the foul drain if
diluted.

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Paint, thinners: keep separate and dispose of
to specialist contractor.

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Components: send back to supplier for
refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
ordinary waste.

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Small parts: reuse any suitable parts, dispose
of the remainder in ordinary waste.

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Metals: can be sold if kept separate from
general waste.

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Tyres: keep separate and dispose of to
specialist contractor.

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Packaging: compact as much as possible and
dispose of in ordinary waste.

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Asbestos-containing: keep separate and
dispose of to specialist contractor.

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Oily and fuel wastes (e.g. rags, used spill kit
material): keep separate and dispose of to
specialist contractor.

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Air filters: keep separate and dispose of to
specialist contractor.

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Rubber/plastics: dispose of in ordinary waste.

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Hoses: dispose of in ordinary waste.

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Batteries: keep separate and dispose of to
specialist contractor.

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Airbags - explosives: keep separate and
dispose of to specialist contractor.

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Electrical components: send back to supplier
for refurbishment, or disassemble and reuse
any suitable parts. Dispose of the remainder in
ordinary waste.

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Electronic components: send back to supplier
for refurbishment, or disassemble and reuse
any suitable parts. Dispose of the remainder in
ordinary waste.

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Catalysts: can be sold if kept separate from
general waste

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Used spill-absorbing material: keep separate
and dispose of to specialist contractor.

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Office waste: recycle paper and toner and ink
cartridges, dispose of the remainder in ordinary
waste.

GENERAL INFORMATION

03-6

General Fitting Instructions

Component removal
Whenever possible, clean components and
surrounding area before removal.

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Blank off openings exposed by component
removal.

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Immediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or
plugs to prevent loss of fluid and ingress of dirt.

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Close the open ends of oilways exposed by
component removal with tapered hardwood
plugs or conspicuous plastic plugs.

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Immediately a component is removed, place it in
a suitable container; use a separate container
for each component and its associated parts.

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Clean bench and provide marking materials,
labels and containers before dismantling a
component.

Dismantling
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
serious malfunction if trapped in these systems.

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Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
'O' rings used for sealing are correctly replaced
or renewed, if disturbed during the process.

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Use marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could
initiate cracks or distortion in marked
components.

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Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).

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Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.

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Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.

Cleaning components
Always use the recommended cleaning agent or
equivalent. Ensure that adequate ventilation is
provided when volatile degreasing agents are being
used. Do not use degreasing equipment for
components containing items which could be
damaged by the use of this process.

General inspection
All components should be inspected for wear or
damage before being reassembled.

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Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an
incipient failure.

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When a component is to be checked
dimensionally against recommended values,
use the appropriate measuring equipment
(surface plates, micrometers, dial gauges etc.).
Ensure the measuring equipment is calibrated
and in good serviceable condition.

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Reject a component if its dimensions are
outside the specified tolerances, or if it appears
to be damaged.

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A part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition. Use 'Plastigauge' 12
Type PG-1 for checking bearing surface
clearances.

GENERAL INFORMATION

03-7

Ball and Roller Bearings

General
When removing and installing bearings, ensure that
the following practices are observed to ensure
component serviceability.

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Remove all traces of lubricant from bearing
under inspection by cleaning with a suitable
degreasant; maintain absolute cleanliness
throughout operations.

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Conduct a visual inspection for markings on
rolling elements, raceways, outer surface of
outer rings or inner surface of inner rings. Reject
any bearings found to be marked, since marking
in these areas indicates onset of wear.

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Hold inner race of bearing between finger and
thumb of one hand and spin outer race to check
that it revolves absolutely smoothly. Repeat,
holding outer race and spinning inner race.

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Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation. Reject bearing
if action is not perfectly smooth.

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Lubricate bearing with generous amounts of
lubricant appropriate to installation.

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Inspect shaft and bearing housing for
discoloration or other markings which indicate
movement between bearing and seatings.

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Ensure that shaft and housing are clean and
free from burrs before fitting bearing.

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If one bearing of a pair shows an imperfection, it
is advisable to replace both with new bearings;
an exception could be if the faulty bearing had
covered a low mileage, and it can be
established that damage is confined to only one
bearing.

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Never refit a ball or roller bearing without first
ensuring that it is in a fully serviceable condition.

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When hub bearings are removed or displaced,
new bearings must be fitted; do not attempt to
refit the old hub bearings.

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When fitting a bearing to a shaft, only apply
force to the inner ring of the bearing. When
fitting a bearing into a housing, only apply force
to the outer ring of the bearing.

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In the case of grease lubricated bearings (e.g.
hub bearings) fill the space between bearing
and outer seal with the recommended grade of
grease before fitting seal.

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Always mark components of separable bearings
(e.g. taper roller bearings) when dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring; always fit a complete new
bearing assembly.

GENERAL INFORMATION

03-8

Oil Seals

General
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly). NEVER use
a seal which has been improperly stored or handled,
such as hung on a hook or nail.

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Carefully examine seal before fitting to ensure
that it is clean and undamaged.

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Ensure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.

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Protect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.

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Lubricate the sealing lips with a recommended
lubricant before use to prevent damage during
initial use. On dual lipped seals, smear the area
between the lips with grease.

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If a seal spring is provided, ensure that it is fitted
correctly. Place lip of seal towards fluid to be
sealed and slide into position on shaft. Use
fitting sleeve where possible to protect sealing
lip from damage by sharp corners, threads or
splines. If a fitting sleeve is not available, use
plastic tube or tape to prevent damage to the
sealing lip.

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Grease outside diameter of seal, place square
to housing recess and press into position using
great care, and if possible a 'bell piece' to
ensure that seal is not tilted. In some cases it
may be preferable to fit seal to housing before
fitting to shaft. Never let weight of unsupported
shaft rest in seal.

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Use the recommended service tool to fit an oil
seal. If the correct service tool is not available,
use a suitable tube approximately 0.4 mm
(0.015 in.) smaller than the outside diameter of
the seal. Use a hammer VERY GENTLY on drift
if a suitable press is not available.

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Press or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant
to be retained if the housing is shouldered, or
flush with the face of the housing where no
shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.