CHAPTER ONE

1
CHAPTER ONE

• Safety and Shop Practices

2
Objectives

• You should be able to
• Explain what OSHA does.
• List shop hazards.
• Describe personal protective items that must be
  worn in the shop.
• List important safety practices that must be
  followed in the shop.

3
Objectives (Contd)

• Explain how to use cleaning and compressed air
  equipment safely.
• Describe the procedures for safely raising a
  vehicle on a lift or jack stands.
• Demonstrate how to lift heavy objects.
• Describe safe hand, power, hydraulic, and
  electric tool operating procedures.

4
Objectives (Contd)

• Describe safe engine lift practices.
• Explain how to safely operate a vehicle in the
  shop.
• Demonstrate how to use special engine tools
  safely.
• Identify hazardous materials and explain the
  Right-to-Know Laws.

5
Objectives (Contd)

• Describe proper handling and disposal techniques
  for hazardous materials.
• Explain how to use shop safety equipment.
• Demonstrate gasoline handling and electrical
  safety procedures.
• Explain how to extinguish a fire.

6
Objectives (Contd)

• Describe the different types of fire
  extinguishers available.
• List employee and employer obligations in the
  shop.
• Describe the ASE certification and testing
  process.

7
OSHA

• The Occupational Safety and Health Act (OSHA)
  regulates working conditions in the United
  States.
• It provides research, information, education, and
  training in the field of occupational safety and
  health.
• OSHA was passed in 1970.

8
Shop Hazards

• Shop hazards include
• flammable liquids and materials
• batteries
• loose drain covers
• caustic liquids
• high-pressure air
• frayed cords on electrical equipment

9
Shop Hazards (Contd)

• hazardous waste material
• carbon monoxide
• loose clothing, jewelry, or long hair
• dust and vapors generated during repairs
• high noise levels
• oil, grease, water, or parts cleaning solution on
  floors

10
Personal Safety

• Always wear proper eye protection in the shop.
• Always wear ear protection in noisy environments.
• Avoid long hair, torn clothing, neckties, or
  dangling jewelry.
• Properly store all tools and parts.

11
Personal Safety (Contd)

• Always wear leather shoes or steel-toed boots in
  the shop.
• Always wear heavy work gloves when grinding,
  welding, or handling high-temperature components.
• Always wear approved gloves when handling caustic
  chemicals.

12
Personal Safety (Contd)

• Always take proper precautions with asbestos or
  toxic substances.
• Never smoke while working on a vehicle or working
  with machines/equipment.
• Avoid horseplay in the shop.
• Beware of hot metal parts.

13
Safety in the Automotive Shop

• To avoid shop hazards, follow all rules with
  regard to
• personal protection
• smoking, alcohol, and drugs in the shop
• electrical and gasoline safety
• general shop and housekeeping safety
• fire safety

14
Compressed Air Equipment Safety

• Pneumatic tools use compressed air.
• Never direct high-pressure air against any part
  of the human body do not use compressed air to
  blow off hair or clothing.
• Do not clean the work bench or floor with
  compressed air.
• Always operate pneumatic tools according to
  manufacturers instructions.

15
Compressed Air Equipment Safety (Contd)

• Always wear eye protection when using compressed
  air.
• Always wear ear protection when using compressed
  air.
• Maintain air line fittings and hoses in good
  condition.
• Never spin bearings with compressed air.

16
Vehicle Lift Safety

• Be sure the vehicle doors, hood, and trunk lid
  are closed before raising the vehicle.
• Do not raise a vehicle with people inside.
• Be sure the lift pads are contacting the
  specified vehicle lift points
• Check the lift pad to lift point contact after
  raising the vehicle a short distance.

17
Vehicle Lift Safety (Contd)

• Be sure the lift locking mechanism is in place
  when the lift is at the desired height
• Before lowering a vehicle, be sure there is no
  person, equipment or tools underneath.

18
Lifting and Carrying

• When lifting or carrying a heavy object
• Always use a back protection device.
• Always lift and work within your ability.
• Ask others for help if you are not sure you can
  handle the size/weight of the object.
• Be sure your path is free from loose parts or
  tools.

19
Lifting and Carrying (Contd)

• Place your feet close to the object and position
  them to maintain good balance.
• Keep your back and elbows straight.
• Bend your knees, so you can get a strong grip on
  the object.
• Firmly grasp the object, and do not change your
  grip as you move the load.

20
Lifting and Carrying (Contd)

• Keep the object close to your body and lift it up
  by straightening your legs.
• Use your leg muscles, not your back muscles.
• To change direction, do not twist your body.
  Instead, turn your whole body, including your
  feet.

21
Lifting and Carrying (Contd)

• When placing the object on a shelf/counter, do
  not bend forward. Place the edge of the load on
  the shelf and slide it forward, being careful not
  to pinch your fingers.
• To set down a load, bend your knees and keep your
  back straight -- do not bend forward.

22
Hand Tool Safety

• Keep tools clean and in good condition.
• Use the proper tool for the job.
• Be careful when using sharp or pointed tools.
• Tool tips that are intended to be sharp should be
  kept sharp.

23
Power Tool Safety

• Power tools are operated by an outside source of
  power, such as electricity, compressed air, or
  hydraulic pressure.
• Always wear safety glasses when using power
  tools.
• Make sure electrically-powered tools are properly
  grounded.

24
Power Tool Safety (Contd)

• Before use, check wiring for cracks in insulation
  and for bare wires.
• Never use electric power tools when standing on a
  wet or damp floor.
• Disconnect the power source before performing any
  service on a power tool.
• Be sure the power switch is off before plugging
  in the tool.

25
Jack and Jack Stand Safety

• Be sure the hydraulic jack is lifting on the
  specified vehicle lift point.
• Be sure the jack lift pad is securely positioned
  on the lift point.
• Always lower the vehicle securely onto jack
  stands before working under the vehicle.

26
Engine Lift Safety

• Be sure the lifting sling is securely attached to
  the engine.
• Be sure the lifting sling attachment bolts are
  strong enough to lift the engine.
• Be sure the lifting sling attachment bolts are
  threaded far enough into the engine.

27
Engine Lift Safety (Contd)

• Be sure the lift legs and lift boom are properly
  adjusted to prevent lift tipping.
• Stand clear of the engine when lifting or
  lowering the engine.
• When the engine is out of the vehicle, lower it
  to the floor, or install it on an engine stand.

28
Vehicle Operation

• When moving a vehicle into the shop
• First, check the brakes.
• Next, put on your safety belt.
• Finally, drive carefully in and around the shop,
  making sure no one is near and that your path is
  clear.

29
Vehicle Operation (Contd)

• When road-testing a vehicle
• Always obey all traffic laws.
• Drive only as far as is necessary to check the
  vehicle.
• If the engine must be running while working on
  the vehicle
• Block the wheels to prevent movement.

30
Vehicle Operation (Contd)

• Place transmission in park (automatic
  transmissions) or neutral (manual transmissions).
• Set the emergency brake.
• Never stand directly in front of or behind the
  vehicle.

31
Vehicle Operation (Contd)

• Run the engine only in a well-ventilated area to
  avoid carbon monoxide.
• Carbon monoxide is a poisonous gas.
• Use an exhaust ventilation system or use a hose
  and direct the exhaust out of the shop.

32
Cleaning Equipment Safety

• Some cleaning solutions are caustic, so avoid
  skin or eye contact with these solutions by
• Always wearing eye protection and face shields
  when using cleaning equipment.
• Always wearing protective gloves when using
  cleaning equipment.

33
Cleaning Equipment Safety (Contd)

• To prevent accidents, walk carefully in the
  cleaning equipment area, and keep the floors
  clean.
• Follow the equipment manufacturers
  recommendations when cleaning aluminum components
  in caustic solutions.

34
Cleaning Equipment Safety (Contd)

• Used cleaning solution is considered a hazardous
  waste and must be handled according to
  environmental regulations.
• The four basic categories of automotive parts
  cleaning are
• chemical, thermal, abrasive, steam

35
Engine Rebuilding Safety Concerns

• Use proper procedures for lifting heavy objects.
• Keep the work area clean.
• Use an engine hoist to lift the engine out of the
  vehicle.
• Do not get under the engine, and do not place
  arms or legs under the engine.

36
Engine Rebuilding Safety Concerns (Contd)

• Do not pour gas into the carburetor or throttle
  body -- use a squirt can for priming.
• If the engine comes loose, get out of the way and
  let it fall.

37
Engine Rebuilding Safety Concerns (Contd)

• Prior to starting an engine, make sure all fuel
  lines, electrical connectors, and belts are
  properly connected.
• Have a fire extinguisher next to the vehicle.

38
Hazardous Materials

• Be familiar with hazardous materials in the shop.
• A material is hazardous if it is
• on the EPA list
• reactive
• corrosive
• toxic
• ignitable

39
Hazardous Materials (Contd)

• The EPA publishes a list of hazardous materials.
• Follow all federal and state laws with regard to
  safe handling and disposal of hazardous
  materials.
• Be familiar with the Right-to-Know Laws and the
  RCRA

40
Hazardous Materials (Contd)

• Know where the Material Safety Data Sheets (or
  the WHIMS) are located in the shop.
• Examples of hazardous waste include
• used oil
• used batteries
• used brake and transmission fluids

41
Hazardous Materials (Contd)

• Be familiar with the proper way to handle
  environmental emergencies.
• Never pour anything down a drain without ensuring
  it is safe and legal to do so.
• Never throw anything in the trash without
  ensuring it is safe and legal to do so.

42
Work Area Safety and Shop Safety Equipment

• Keep the work area clean and safe.
• Wipe up water immediately and maintain good
  ventilation in the shop.
• Keep emergency numbers and first aid kits handy.
• Have an eyewash fountain in your shop.

43
Work Area Safety and Shop Safety Equipment
(Contd)

• Gasoline is very volatile and must be stored in
  approved containers.
• Never use a welder or grinder near flammable
  liquids or materials.
• Keep spark sources away from batteries that are
  being charged.

44
Work Area Safety and Shop Safety Equipment
(Contd)

• Solvents are flammable and must be handled with
  care and properly stored in an approved
  container.
• Oily, greasy, or paint-soaked rags must be stored
  in an approved container and not thrown in the
  trash.

45
Work Area Safety and Shop Safety Equipment
(Contd)

• Types of fires
• Class A ordinary combustible materials such as
  wood, paper, clothing, or textiles.
• Class B flammable liquids such as gasoline,
  oil, paint, solvents, or grease.

46
Work Area Safety and Shop Safety Equipment
(Contd)

• Class C electrical equipment such as wires,
  motors, and switches.
• Class D metal chips, turnings, and shavings

47
Work Area Safety and Shop Safety Equipment
(Contd)

• Fire extinguisher selection
• Foam-type fire extinguishers
• - Use on class A or B fires.
• - Do not use on class C fires.
• - Direct stream into the burning liquid.

48
Work Area Safety and Shop Safety Equipment
(Contd)

• Carbon dioxide-type fire extinguisher
• Use on class B or C fires.
• Do not use on class A fires.
• Direct stream as close as possible to the fire.
• Direct stream at the edge of the flames, and
  gradually move stream forward and upward.

49
Work Area Safety and Shop Safety Equipment
(Contd)

• Multi-purpose dry chemical-type extinguisher
• Use on class A, B, or C fires.
• Direct stream at the base of the flames with a
  rapid left-to-right motion.

50
Work Area Safety and Shop Safety Equipment
(Contd)

• Soda-acid-type extinguisher
• Use on class A fires.
• Do not use on class B or C fires.

51
Work Area Safety and Shop Safety Equipment
(Contd)

• Using a fire extinguisher
• Pull the pin from the handle.
• Aim the nozzle at the base of the fire, or as
  required by the class of fire.
• Squeeze the handle.
• Discharge the extinguisher stream as required by
  the class of fire.

52
Employer Obligations

• Employer responsibilities include providing
• Wages and fringe benefits
• A clean, safe place to work
• Instruction, supervision, and training
• Opportunity
• Fair treatment

53
Employee Obligations

• Employee responsibilities include
• Productivity and quality
• Teamwork and positive attitude
• Honesty and loyalty
• Responsibility, punctuality, and regular
  attendance
• Adherence to directions, and federal and state
  regulations

54
ASE Certification

• There are eight basic areas of certification.
• Each certification test contains 40 to 80
  questions.
• Two years of relevant work experience are also
  required.
• Schooling can be substituted for some of the
  experience requirement.

55
Summary

• OSHA provides safe and healthful working
  conditions for employees.
• Shop hazards must be avoided.
• Personal protective items must be worn in the
  shop to prevent personal injury.
• All important safety practices must be followed
  in the shop.

56
Summary (Contd)

• All instructions and safety guidelines must be
  followed when using cleaning and compressed air
  equipment.
• All procedures for safely raising a vehicle on a
  lift or jack stands must be followed.
• Always use the proper procedure for lifting heavy
  objects.

57
Summary (Contd)

• Always follow safe operating procedures for
  power, hydraulic, electric, and special engine
  tools.
• Always follow safe engine lift and vehicle
  operation procedures.
• Be sure to identify hazardous materials and
  understand the Right-to-Know Laws.

58
Summary (Contd)

• Always handle and dispose of hazardous materials
  properly.
• Be sure to understand how to use shop safety
  equipment, such as fire extinguishers.
• Always follow all gasoline handling and
  electrical safety procedures.