Seguridad y Proteccion Contra Incendios en Talleres

00:01-02
Issue 13
en-GB
Safety and fire protection in

service workshops
1 585 267
Scania CV AB 2012, Sweden
Contents
Contents
Introduction
Preconditions for safety............................................ 3

Safety requirements .................................................. 6
Personal safety.......................................................... 7
Safety around the vehicle
General safety precaution ......................................... 8

Tilting the cab........................................................... 8
Working under vehicles.......................................... 10
Heavy equipment.................................................... 12
Several mechanics working on one vehicle............ 13
Mechanical work
Noise....................................................................... 14
Vibrations ............................................................... 15
Dust......................................................................... 16
Rotating components and tools .............................. 18
Fragments from tools.............................................. 20
Flying parts............................................................. 21
Tensioned springs................................................... 22
Airbag and belt pretensioner .................................. 24
Fluids and gases
Risk of fire and explosion....................................... 25

Pressurised fluids or gases...................................... 27
Solvents .................................................................. 28
Ethanol.................................................................... 30
Vehicle gas ............................................................. 33
Coolant ................................................................... 36
Refrigerant.............................................................. 37
Air pollution ........................................................... 38
Electricity
General ................................................................... 40
Electric motors........................................................ 41
Generator set........................................................... 42
00:01-02
Introduction
Introduction
Preconditions for safety
The 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

information
The 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
Introduction
Observe warnings
The 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.
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.
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.
00:01-02
Introduction
Incidents
An 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.
Feedback
Report 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
Introduction
Safety requirements
Laws and local regulations
Most countries have laws and local regulations
that are intended to prevent damage, injuries
and accidents at work. These regulations must
be followed.
Safety instructions
Take note of any existing safety instructions
before commencing work involving a risk of
damage or injury.
Knowledge
Scania 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.
Attention
The 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.
Caution
There 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.
00:01-02
Introduction
Personal safety
Jewellery
Remove necklaces, rings and bracelets.
Jewellery can conduct current, cause electric
arcs, get caught in machines, etc., and
consequently cause serious injury.
Hair
Long 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.
Clothing
Make sure all clothing is intact.
Remove loose clothing such as ties and
scarves. Never wear clothing with wide sleeves
or legs.
00:01-02
Safety around the

vehicle
General safety precaution
The 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.
Tilting the cab

Instructions, tilting the cab
The work descriptions for tilting the cab in the
inspection information must always be
followed.
00:01-02
WARNING!
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
Working under vehicles

Working under the chassis
A 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.
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.
Working underneath bodywork

Raised bodywork must always be supported.
Working under vehicles with air

suspension
Always 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.
10
00:01-02
Working under the cab

Make 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.
Risks
Mechanical 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
11
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.
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.
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
will be necessary.
12
Stands must lock automatically (braking

device or irreversible screw).
00:01-02
Several mechanics
working on one vehicle
Inadvertent 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
13
Mechanical work
Mechanical work
Noise
Being 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
14
Use ear defenders. Make sure the ear

defenders have been tried and tested for the
relevant noise level.
Limit exposure to noise with soundabsorbing screens (also use soundabsorbing materials in ceilings and walls).
00:01-02
Mechanical work
Vibrations
The 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
15
Mechanical work
Dust
Brake and clutch linings
Brake 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
The SCR catalytic converter contains
vanadium, which is hazardous to health.
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
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.
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.
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.
SCR catalytic converter and

silencer
Safety 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.
16
00:01-02
Mechanical work
Safety precautions
An 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.
You should not eat, drink or smoke while

working.
00:0254
A vacuum with microfilter should be used to

remove dust in order to minimise exposure.
Make sure you clean your hands after working

with an SCR catalytic converter.
Grinding
Lead can enter the bloodstream through skin
contact and cause lead poisoning.
Risks
Dust 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.
00:01-02
17
Mechanical work
Rotating components and

tools
Examples of rotating components and
tools:
Cooling fan
Drive belts
Injection pump coupling
Propeller shafts
Drilling machines
Lathes, grinders
Risks
18
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.
00:01-02
Mechanical work
Safety 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
19
Mechanical work
Fragments 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
20
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.
00:01-02
Mechanical work
Flying parts
Rubber 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
21
Mechanical work
Tensioned springs
Examples 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
22
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.
00:01-02
Mechanical work
Safety 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
23
Mechanical work
Airbag and belt

pretensioner
Cut the power to the vehicle before starting

repairs in order to avoid the uncontrolled
discharge of airbags and belt pretensioners.
00:0254
Airbags 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.
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".
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.
24
A scrapped module must be marked with a

label for non-mountable materials,
Bn 1947, and returned to the supplier.
00:01-02
Fluids and gases
Fluids and gases

Risk of fire and explosion
Examples 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
25
Fluids and gases
Safety precautions
Special cases
Diesel
The 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 gearbox
The 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.
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.
Battery charging
When 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.
26
Hot work
Hot 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.
00:01-02
Fluids and gases
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.
Safety precautions
Wear protective gloves and goggles.
Risks
Working on the following components may

involve a risk of injury:
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.
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

poisoning.
00:01-02
27
Fluids and gases
Solvents
Fluids 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
28
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.
00:01-02
Fluids and gases
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.
00:01-02
00:0254
Safety precautions
29
Fluids and gases
Ethanol
Risks
Great 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.
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.
Keep the tank well sealed and away from

sources of ignition. Smoking is prohibited.
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).
151 973
Regulations
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.
30
00:01-02
Fluids and gases
Safety 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.
Illustration 1. Display signs as in the example

above during work requiring ethanol handling in
the workshop.
00:01-02
31
Fluids and gases
Procedures for all work in the

workshop
After work in the workshop
IMPORTANT!
Start the vehicle and check for ethanol

leaks. The recommended method is to leak
test the fuel system using measuring
instrument 588 875.
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.
Environment
Help 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 fireextinguishing equipment in the engine
compartment, cut the power to the vehicle by
disconnecting the battery connections.
During work in the workshop
32
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.
00:01-02
Fluids and gases
Vehicle 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
33
Fluids and gases
Safety precautions
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.
318 265
Working with
highly flamma ble
fuels in p rogress
Illustration 1. Display signs as in the example

above during work requiring ethanol handling
in the workshop.
34
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
temperatures as the gas pressure will
increase as it warms up.
00:01-02
Fluids and gases
Fire prevention requirements

Always 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.
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.
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.
Shut off the gas supply at the gas tanks.
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.
00:01-02
35
Fluids and gases
Coolant
Coolant 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
36
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.
00:01-02
Fluids and gases
Refrigerant
Refrigerant 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
37
Fluids and gases
Air pollution
Air 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 from certain oils can cause skin

problems such as pimples, boils and eczema.
Fuming sulphuric acid is corrosive and can

damage the respiratory system.
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, anticorrosive 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
38
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.
00:01-02
Fluids and gases
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 shortstop heater is used.
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.
Isocyanates
Isocyanates 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
such work is being carried out. Personnel
should normally use respiratory protection with
a supply of fresh air when carrying out this
type of work.
00:01-02
39
Electricity
Electricity
General
Remember 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 charging
Explosive 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
00:01-02
Electricity
Electric 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 wipers
Even 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 motor
The 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
41
Electricity
Generator set
A 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
42
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.
00:01-02
Electricity
Connecting electrical consumers
Electrical 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.
Installation, commissioning, operation

and inspection of the generator set may
only be carried out by trained and
qualified personnel.
Electrical consumers may only be

connected by trained and qualified
personnel authorised to carry out this
work.
WARNING!
WARNING!
WARNING!
The connection of electrical consumers

must be in full compliance with national
or local regulations.
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 remotecontrolled 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.
00:01-02
43
Electricity
Electric shock
Noise
A generator set without a canopy can cause
noise levels above 105 dBA.
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.
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.
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.
44
00:01-02
Electricity
Lifting the generator set
Warning stickers
A generator set can be lifted in various ways

depending on its equipment.
The 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.
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! The generator set can be remotelycontrolled 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
45

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00:01-02

Safety and fire protection in

Scania CV AB 2012, Sweden

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

Safety around the vehicle

General safety precaution ......................................... 8

Fluids and gases

Risk of fire and explosion....................................... 25

Scania CV AB 2012, Sweden

That inspection information instructions

That local laws and regulations are

That the mechanic carries out the work in a

Using the inspection

Scania CV AB 2012, Sweden

Note: Used when an incorrect action could

Used when an incorrect action could result in

Used when an incorrect action could result in

Warnings in the inspection information do not

Scania CV AB 2012, Sweden

Scania CV AB 2012, Sweden

Scania CV AB 2012, Sweden

Scania CV AB 2012, Sweden

Safety around the vehicle

Safety around the

Tilting the cab

Scania CV AB 2012, Sweden

Safety around the vehicle

Danger of crushing when working on cab

Working on the cab tilting mechanism disables

Scania CV AB 2012, Sweden

Safety around the vehicle

Working under vehicles

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

A levelling valve is operated when the

Working underneath bodywork

Working under vehicles with air

Always use axle stands to support the vehicle

Scania CV AB 2012, Sweden

Safety around the vehicle

Working under the cab

Use reliable and correctly dimensioned

Stands and struts must be sturdy.

Lifting tools must have been inspected and

Scania CV AB 2012, Sweden

Safety around the vehicle

Unsuitable lifting straps could break or

Equipment being lifted in a stand may start

Equipment being lifted with an overhead

Use gloves. They usually offer good

Use protective shoes with steel caps.

Use a jack with fixture as instructed in the

Use approved lifting tools or other aids,

If it is still necessary to lift without aids:

Stands must lock automatically (braking

Scania CV AB 2012, Sweden

Safety around the vehicle

A wheel being rotated on a driving axle

Working on axle suspension (springs and

Operations controlled from the driver area,

Be aware of the risks involved when more

Make colleagues aware of the work being