CHAPTER ONE

Safety and Shop Practices

ObjectivesYou 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.

Objectives (Cont’d)• 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.

Objectives (Cont’d)• 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.

Objectives (Cont’d)• 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.

Objectives (Cont’d)• Describe the different types of fire

extinguishers available.

• List employee and employer obligations in the shop.

• Describe the ASE certification and testing process.

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.

Shop HazardsShop hazards include:

• flammable liquids and materials

• batteries

• loose drain covers

• caustic liquids

• high-pressure air

• frayed cords on electrical equipment

Shop Hazards (Cont’d)• 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

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.

Personal Safety (Cont’d)• 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.

Personal Safety (Cont’d)• 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.

Safety in the Automotive ShopTo 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

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.

Compressed Air Equipment Safety (Cont’d)

• 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.

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.

Vehicle Lift Safety (Cont’d)

• 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.

Lifting and CarryingWhen 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.

Lifting and Carrying (Cont’d)• 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.

Lifting and Carrying (Cont’d)• 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.

Lifting and Carrying (Cont’d)• 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.

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.

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.

Power Tool Safety (Cont’d)• 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.

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.

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.

Engine Lift Safety (Cont’d)

• 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.

Vehicle OperationWhen 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.

Vehicle Operation (Cont’d)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.

Vehicle Operation (Cont’d)• Place transmission in park (automatic

transmissions) or neutral (manual transmissions).

• Set the emergency brake.

• Never stand directly in front of or behind the vehicle.

Vehicle Operation (Cont’d)

• 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.

Cleaning Equipment SafetySome 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.

Cleaning Equipment Safety (Cont’d)

• To prevent accidents, walk carefully in the cleaning equipment area, and keep the floors clean.

• Follow the equipment manufacturer’s recommendations when cleaning aluminum components in caustic solutions.

Cleaning Equipment Safety (Cont’d)

• 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

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.

Engine Rebuilding Safety Concerns (Cont’d)

• 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.

Engine Rebuilding Safety Concerns (Cont’d)

• 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.

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

Hazardous Materials (Cont’d)• 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

Hazardous Materials (Cont’d)• 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

Hazardous Materials (Cont’d)• 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.

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.

Work Area Safety and Shop Safety Equipment (Cont’d)

• 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.

Work Area Safety and Shop Safety Equipment (Cont’d)

• 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.

Work Area Safety and Shop Safety Equipment (Cont’d)

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.

Work Area Safety and Shop Safety Equipment (Cont’d)

• Class C: electrical equipment such as wires, motors, and switches.

• Class D: metal chips, turnings, and shavings

Work Area Safety and Shop Safety Equipment (Cont’d)

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.

Work Area Safety and Shop Safety Equipment (Cont’d)

• 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.

Work Area Safety and Shop Safety Equipment (Cont’d)

• 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.

Work Area Safety and Shop Safety Equipment (Cont’d)

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

Work Area Safety and Shop Safety Equipment (Cont’d)

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.

Employer Obligations• Employer responsibilities include

providing:– Wages and fringe benefits– A clean, safe place to work – Instruction, supervision, and training– Opportunity– Fair treatment

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

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.

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.

Summary (Cont’d)• 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.

Summary (Cont’d)• 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.

Summary (Cont’d)• 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.