Workshop Safety & Tools

1.1. Introduction

- The number one priority of any business is the healthy and safety of its employees.
- The employer is responsible for safety training for each employee and for providing a safe
working environment.
- According to federal law, each shop will have a safety-training program.
- Accidents that occurs in an automotive shop often happen because safety consideration are
not as obvious when repairing automobile as they are in such trades as rooting or carpentry.
-A person who caused the accidents often suffers from guilt from the harm they have caused
another.
-Injured persons often suffer from shock and should not be left unattended.
-Every shop should have some one trained to handle emergencies.

1.2.General personal safety

- A first-aid kit contains items for treating some of the small cuts and abrasions.
- Gloves , goggles and respirators or called personal protective equipment or PPE.
- Wearing eye protection will prevent most eye injuries , so when using machinery eye
protection is mandatory.

1.3.eye protection safety

- rotating tools can throw pieces of metal or grit , causing eye injuries.
-safety goggles or a face shield should be worn when using shop tools and equipment .
-prescription safety glasses are an advantage because the user always wears them.
-face shield are convenient because they can stay with the piece of equipment .
-eye protection must be worn :
 wherenever working around moving parts and machinery ( grinding, cutting ,drilling ,
washing )
 when blowing off parts with compressed air.
 when blowing under the vehicle .
 when working on air conditioning.
 when flame- cutting or welding.

-if your eye Is accidentally contaminated with a dangerous liquid, flush thoroughly in an
eyewash fountain or other water source.
1.4.Back protection.

 following safe lifting procedures will prevent most back injuries.

 the following are safety precautions to used when lifting.
-be sure to get when moving heavy item. the normal tendency is to say that items are not that
heavy and you hate to ask somebody for help.
-if an item is too heavy to lift, use the appropriate equipment.
before moving a heavy item, plan the route that the item will be carried and how it is to be set
back down you get there.
-lift slowly.
-do not jerk or twist your back. shift your feet instead.
-bend your knees and lift with your leg, do not your back. also, keep your lower back straight
when lifting. think about thrusting your stomach out.

1.5.clothing and hair

 clothing (shirt tails) or hair that hangs out can get caught in morning machinery or under a
creeper.
 keep long hair tied or under a cap.
 shirts tails should be tucked in or shops clothing can be worn over the shirt.
1.6.shoes or boots

 leather shoes or boots offer much better protection than sport shoes or sandals.
 shoes are available that resist shipping and one resistant to damage from petroleum product.

2.1. shop habits

 greasy, oily tools and hands should be wiped clean, preventing the mess from being spread
around the rest of the shop.

 oil and solvent spills can be cleaned up with an absorbent material, such as vice hull ash or kitty
litter greases weep.

 greases weep is swept up and reused until it becomes too wet.

 one of the result of environmental regulation is that greases weep is classified as hazardous if it
is used to soak up used motor oil.

2.2.hot tank safety

 always wear gloves and face protection when working around (caustics) .
 if caustic contact your skin, rinse immediately and seek medical attention.
 if caustic get into an eye , the caustic must be flushed from the eye immediately or blindness
may results. be sure to lift the eyelid and flush under it with water for 15 minutes . continue
repeated 15- minutes washing while medical attention is sought .
 articles should be lifted from the tank with lifting device . people have fallen into large hot tanks
while trying to retrieve objects by hand.
2.3. cleaning solvent safety

 cleaning solvents are used extensively in auto repair.

 their use is generally safe provided the user has knowledge of hazard associated wih them.
 standard solvent has a relatively high flash point, but fire can still result.

2.4. skin care safety precaution

 dermatitis can result from exposure.

 if hands are burned or swollen from solvent contact , seek medical attention :-
 do not put hand creams on the skin as treatment.
 be sure the gloves you use do not allow penetration by the solvent being used.
 do not mix other chemical with cleaning solvent . to aid in cleaning hands, burrier cream
are often rubbed on the skin prior to working in a greasy environment.

2.5. carburetor cleaner safety precautions.

 carburetor cleaner is highly cocentrated and dangerous to skin, eye and clothing.
 if is dangerous to breathe and can be absorbed through the skin , so protective glove are worn
when handling.
2.6.breathing safety

 there are many source of breathing hazard.

 there include paints, cleaning chemical, burned wire insulation , grinding dust, asbestos , vehicle
exhaust and battery gas.
 exausts gas can contain large amounts of carbon monoxide.
 protect yourself and others from exaust gas by using an exaust system.

2.7.Electric shock

 12-volt direct current (DC) electrical system, like the one used in automobiles, do not cause
serious electrical shock.
 shop equipment , however is powered by either 110v or 220v alternating current, which can be
very dangerous.
 do not stand in water when using electric tools.
 be sure that a tool is turned off before plugging it in so that a spark does not jump from the
outlet to the plug.

 electrical wall outlets should be properly grounded.

 3-wires electrical tools are the best choice for commercial work. the extra terminal is for ground .
if you use a homeowner- type with 2 wire plug it should be double insulated.
 be sure to observe electrical wire colour-coding when repairing or replacing power cords on
electric tool.

2.8. cooling fan safety

 the fan that draws cool air across the radiator can be driven by either a belt or electricity.
 some are controlled by an automatic switch and can start unexpectedly.
 electric cooling fans should be disconnected when working around them.
 visually inspect fan blade for damage. a damaged fan blade will probably be out of
balance , making it prone to fly apart.
 keep hair and clothing away from fans and fan drive belts.
2.9 coolant burns

 the most likely ways to be burned in an automotive shop are with engine coolant or by the
exaust system.
 if the hose is hard and feels like it is full of coolant , the coolant level is acceptable.
 if the hose collapses , the coolant is not under pressure but steam can still cause a burn.

3.1. battery safety

 as a battery charges it gives off explosive hydrogen gas.

 spark must be avoid around batteries, which accasionally explode.
 a battery explosion can cause :-
 damage your skin (from acid thrown by the explosion )
 permanent or temporary hearing loss.
 blindness.
3.2 battery safety procedure

1. always wear eye protection when working around batteries.

2. unplug the charger before connecting or disconnecting any of the cables

3. be sure to shut of the battery charge before unplugging its 110 v power cord , or a spark
could happen when the electricity tries to jump from the outlet to the plug.
3.4. jump-starting a car

 when jump-starting a car, follow the proper procedures and wear eye protection
 a battery that has been charging normally ( the host vehicle) could have tapped
hydrogen gas under its cell caps the battery terminal.
 always connect the dead battery last and hook up the ground cable to the engine block
away from the battery.

3.5. battery acid safety

 battery acid (electrolyte) is a chemical combination of sulfuric acid and water.

 battery acid can harm the skin, eye and clothing.
 boiling soda can be used to neutralize battery acid.
 after carrying or servicing a battery , keep your hands out of your pockets.
 the acid from your hands will cause holes to develop in your pockets after yours clothes
are washed.
3.6. refrigerant safety

 refrigerant is used in automotive air condition.

 when pressure is removed from it ( such as when you disconnect one of the air
conditioning lines )it boils vigorously as it turns into a vapors.
 when working around refrigerants :
 wear around to protect your skin .
 wear goggles to protect you eyes.

before a test drive.

 before driving a customer’s car, remember to check the operation of the brakes and look
at the condition of tires.
 do not test drive a car with obvious safety hazard until they corrected.
4.1. fire safety

2 major item should be considered when dealing with fires:-

 if the fire is burning so dangerously, that your personal safety is jeopardized, leave the area
immediately and call for help.
 if you can safely remove the source or fuel or heat to a fire.

4.2.fire extinguishers

 a fire extinguisher is portable tank that contains water or foam , a chemical , or a gas.
 4 type of fire extinguisher:-
-A = for wood,papers, cloth, rubber, plastic, rubbish and upholstery.
-B = for gasoline, oil, grease, paint and lighter fluid
-C = for motor, appliances , wiring, fuse box and switchboards
-D = for aluminium , magnesium, potassium, sodium, titanium and zirconium.

 fire extinguisher in business establishments are periodically inspected by the local fire
department or a fire extinguisher service company, but be save to check the gauge on the
extinguisher or regular basis.
 locate and check the type of fire extinguisher in your shop.
 if a fire began there, you would not be able to get the extinguisher.
 locating fire extinguisher on both sides of a common work area is a good idea.
draw workshop plan and fire extinguisher area.

4.3.Fuel fire

 gasoline is a major cause of automotives.

 gasoline vapors are havier than air, so they can collect in low places in the shop.
  rubber-coated bulb, which are available , will reduce the chance of scattering glass if the bulb is
broken. But recommended style of shop light to be used around automobiles is the one
enclosed in a plastic tube or an ordinary flashlight.
 to be extinguisher a fuel fire must first have its source shut off.
 the fire will go out if the source of oxygen, is removed or if the temperature is lowered below
the fuel’s flash point.

4.4.Gasoline safety

 gasoline should be stored only in an approved safety container and never in a glass jar
 never use gasoline to clean floor or part .
 careless cigarette smoking or falling to immediately and thoroughly clean gasoline spills can
contribute to a dangerous situation
 people get used to working around gasoline and then begin to ignore how dangerous it can be.
 do not attempt to siphon gasoline with your mouth . accidental breathing of gasoline into the
lungs can be fatal.
4.5.Electrical fires

 Electrical fires are prevented by disconnecting the battery before working on the electrical
system or around electrical components such as the stater or alternator.

 if there is an electrical fire , the battery must be disconnected as fast as possible so the fire can
be put out.

 another advantage to removing the ground cable is that an electric cooling fan cannot
accidentally come on while working near it.

5s
Tools

1. wrench

 most screw or bolt head are hexagonal (having six sides). The wrench size used on hex
heads will almost always be either standard or metric.
 Wrench are typically organized in rack so they can be easily located.
 open end wrench

 adjustable wrench

 box wrench
  combination wrench.

2. screwdriver.

 Screwdriver are available with several different style of head.

 The two most common screwdrivers are the standard flat tip and the Philips head.
 Be sure to selected a screwdriver that is the correct thickness and width for the slot in
the screw.
 using a screwdriver with the wrong size blade can ruin the head of screw.
 the blade on the standard screwdriver should fill up the slot in the screw head.
3. plier

 pliers come in many types and size . it is not uncommon for the same tool to have more
than one name, including the one from tool company that originally developed the tool.
 example of this are the rib joint plier , called channel- locks and locking pliers, called
vise grips.
 pliers are often misused for tightening and fasterner. the result is most often a rounded-
of fastener head.
 the proper use of pliers is ditacted by its design. most often a pliers is for cutting ,
bending , or positioning a part( such as a cotter pin) or for stripping an electrical wire .
the use of too small pliers for the size of the job can result in damage to pliers’s jaws.
4. pullers

 there are many type of pullers used in automotive work, ranging from small to large.
 pullers are used to remove or install pressed- fit gear, bushing, bearing or other parts
from shafts.
 pullers can be either hydraulic or manual.
 manual puller have a bridge yoke or a bar-type yoke.
 a slide hammer or a pressure screw is threaded through the yoke.
 many puller, the jaws can be turned around to accommodate inside and outside pull.
 jaws of different lengths and size can be installed to make the puller more versatile.

5.puller safety

 wear eye protection

 when heating a part to help free it, do not heat the jaws of the puller. this could change
the temper of the metal.
 be sure the pressure screw is clean and lubricated before using an impact wrench.
 be sure the removable point is installed in the puller shaft tip.
 be sure the puller is aligned so it is perpendicular to the part being pulled.
 do not use a puller with damaged or worn part.
 use the correct size puller so overloading is avoided.
 use a 3-jaws puller instead of 2-jaws puller when possible.
6.battery charger

 this battery charger can be used to charged batteries as well as to help car’s battery
start the engine.
 some battery charges have instruction that recommended against using the unit for
starting the car.
 be sure to check the instruction for the unit you are using and be sure the cables are
clamped to the proper battery terminal.

7.soldering tools

 a soldering gun is used to melt solder when joining electrical wires.

8.welding equipment

 there are two main types of welding equipment : electric and gas.
 in both types, metal is melted into a puddle, which is moved by the operator to
complete the weld. this is a mechanical skill and requires some practice.
 MIG welding is very popular type of welding in automotive shop.
 MIG stands for metal inert gas.
 A MIG welder has a spool of wire that automatically fed through the positive end of the
torch.
 when aluminium wire used, this kind of welding can be used on aluminium.
 aluminium cannot be welded using ordinary arc welding.
 MIG welding is especially popular for welding sheet metal body panels.

8.1. welding safety

  welding can result in splatter of molten metal. Be sure to wear appropriate protective
gear.
 cutting with a torch can result in a great deal of flying molten metal. Be sure that
flammable materials are not in the area.

9.Hydraulic floor jacks (service jack ) safety.

 Hydraulic floor jacks (service jacks) are used extensively in automotive repair.
 Cars are often serviced while raised on a portable service jack, but this is a dangerously practice.
 Follow there safety precautions when using a hydraulic floor jack.:
 A hydraulic service jack should be used to raise and lower a vehicle only.
 Always use vehicle support stands (jackstand)
 Use support stand in pairs.
 Be sure to use support stand only a level concrete surface. On a hot day, the legs can dig
into asphalt and cause an accident.

Shop Crane (Engine Hoist Safety)

 When using a shop crane ( cherry picker) , several precaution are necessary.
 Its is important that the centre of gravity be observed.
 when the engine is removed from the car , it is usually raised 3-4 feet off the ground to clear the
radiator grill.
 It is very dangerous to move the shop crane with the canter of gravity this high because the
crane can tip over easily.
  It is very important that the bolts that the bolts that hold the engine sling to the engine
block are not too short. The amount of thread on the bolt that enters te block should be
of an amount that’s is at least 1 ½ timesthe diameter of the screw thread (Usually about
6 turns) .
 Bolt used to attach a lifting fixture to heavy part must be firmly tightened against the
device . use space if necessary .
 Be sure to lower the engine as soon as possible before attemting to roll the crane to a
different location when an engine has been removed from a vehicle be carefull when
raising the vehicle in the air when on a frame-contact lift . the vehicle will be rear-end
heavy when the weight of the engines is removed from it. the result can be that the
vehicle falls off the lifts.

workshop equipment – Lifts

 hydraulic equipment is used for lifting vehicle and heavy parts.

 it is a portable equipment (hydraulic floor) is used in all automotive shops.
 ALI or called, Automotive Lift Institute is a trade association that promotes the safe design,
construction , installation, operation, maintenance and repair of automotive lift.
 AL also called hoist or rack.
 2 main categories. “in-ground lift’ and ‘ above ground lift”.
9.1 lift types

 it consist of 2 categories:
- frame-contact lift
-wheel-contact lift
 another type of lift is in ground-lift called axle engaging lift and pad lift.
 The advantage of the above mentioned lift types is wheel hang free, which makes it easier to
perform tire, brake and suspension work.

9.2. lift safety

 lift have an excellent safety record but, unfortunately , vehicle occasionally fall off them.
 when a vehicle comes down by accident, this is usually due to carelessness, misuse or neglected
maintenance.
 ANSI and ALZ have set American National Standard (ALOIM-1994) for automotive lift.
 this standard lifts safety requirement for operation, inspection and maintenance of lifts.

9.3. centre of gravity.

  the centre of gravity is the point between the front and the rear wheels where the weight will
be distributed evenly.
 according to the automotive lift institute:

 on rear wheel drive ( RWD) cars, the centre or gravity is usually below the driver’s seat .
 on front wheeldrive (FWD) cars, the centre of gravity is usually slighty in front of the
driver’s seat, beneath the steering wheel.
 on 1 or 2-post lifts, position the vehicle’s centre of gravity over the posts, on 4 post models,
position the car equally between the front and rear.

9.4. lift operation safety.

 if there are any problem with the lift, do not use it. see your supervisor immediately. do not take
chances.

 when lifting , first raise the vehicle until its wheel are about 6 off ground. then , jounce the
vehicle and double check the contact between the adapter and the frame to be sure the vehicle
is safely engaged.

 be certain that all four lift pads are contacting their lift points and bearing a load. it is not
unusual for three lift arms to be touching the car with the fourth one free to move. if a lift arm
can be moved after the car is in the air, the car is unevenly loaded. lower the car reposition the
arm.

 if a lift arm is position improperly, lower the vehicle slowly to the ground and reposition the arm.

 when performing vehicle repairs on a vehicle on a frame contact lift, do not use a large prbar or
do anything else that might knock the vehicle off the adapters. when tight bolts are
encountered , it is best to use an air impact wrench on them.

 be sure that the lift contact points on the vehicle are good condition and that there is no oil or
grease on them.

 some lifts have different length arms in the front than they do in the rear. these are called
asymmetrical arms. be sure to consult the manufacturer’s instruction before using this type of
 lift.

 some lift have a safety locking device that hold the post should a hydraulic failure occur . be sure
it is not equipped with a safety device, use 4 high reach supplementary stands.

 the lift area should be clean . there should be no grease or oil on the floor. hoses, extension
cords, and tools should be in the places where they belong.

 insurance companies usually prohibits customer from being in the lift area. do not allow the
customer to drive his/her own car onto the lift.

 be sure that the lift has adequate capacity to lift the weight of the vehicle . if the vehicle
contains any load inside, in the trunk, or in the bed of pickup, the centre of gravity will be
affected and the vehicle will be unsafe to lift.

 be sure that the lift is all of the way down before attempting to drive a car into or out of it.
 before lowering a vehicle ,be sure to alert anyone nearby. be certain that’s no tools or
equipment are below the car. all of the car’s door should be closed.

10. Compressor size

 Compressed air are used to power tools in the shop in much the same way that’s shop in much
the same way that electricity is used.
 One of the advantages is no danger of electrical shock, especially in auto body work where
water is sometimes used when sanding.
 Air compressor resemble small engine
 They have one or more piston and one-way check values.
  Size is an important consideration, when shopping for as air compressor.
 each air tools consumes a certain amount of air during use.
 air compressor are equipped with pressure switches to shut the compressor off when the
receiver tank reaches a set pressure.
 An air compressor is operating at its maximum practical capacity when it runs for 7 out of every
10 minutes.
 this is referred to as a 70% duty cycle.
 the best measurement of useful capacity is free air delivery , measured in standard cubic feet
per minutes (SCFM)
 most small air tools are designed to run at 90 psi, so it is necessary to know the air pressure at
which the free air delivery was measured.

10.1. Air Compressor Tank.

 the correct receiver tank for an air compressor is an important consideration.

 a large tank takes longer to fill initially, but the compressor will not need to run as often to refill
it.
 the compressor is often installed outside of a bulding or in a storeroom where noise will not be
a factor.

10.2.compressor motors

 permanently installed air compressor used in most shops are driven by 5 to 10 hp motors.
 large compressor usually require a 220-volts electrical supply
 portable compressors under 5hp that run on 110 volt power are also available.

10.3 air lines

 when lines are too small, the pressure must be raised to compensate.
 raising the pressure heat the air, which is hard on tools and cause the compressor to work.
 each output line from the air feed system is called a drop.
 a small line act as an orifice, dropping pressure at the tool.
 this also happens when someone mistakenly installs an air regulator that’s is to small.
10.4.air compressor maintenance

 water is produce as outside air is condensed by the compressor into the receiver tank.
 the tank requires periodic bleeding , or blow-down to drain the water that accumulates.
 the oil level in the compressor should be checked regularly especially if it appears that there is
oil leakage.
 it is important that the compressor breathes lean air, much the same as with an internal
combustion engine.
 check the drive belts regularly for sign of wear or looseness. a loose belt will slip and wear the
pulley.

Measuring tools

In this part , student will learn about common measuring instrument and system of measurement used
in repairing automobiles. The two system of measurement that an automotive technician must
understand are the british imperial (U.S) System and Metric System.

American manufacturers are slowly changing their tooling to the metric system to be competitive in the
rest of the world, which uses the metric system.