1.
AUTOMOTIVE SHOP SAFETY
GENERAL SHOP PRACTICES
Module I - Automotive Shop Safety
Safety means protecting yourself and others from possible danger and injury.
When everyone obeys the rules, the shop is much safer place in which to work than at
home.
Shop Safety Rules
Personal Safety
Some people say, “Accident will happen”. But safety experts dis-agree, they say,
“Accidents are caused”. They are caused by careless actions. They are caused by
inattention to the job and by using damaged or incorrect tools.
To help prevent accident, follow these safety rules.
01.) Work quietly and give your full attention on the job you are doing.
02.) Keep your tools and equipment under control.
03.) Keep jack handles out of the way and stand the creeper against the wall when not in
use.
04.) Never include in horseplay or other foolish action. You could cause someone to get
serious hurt.
05.) Never put screwdriver or other sharp objects in your pocket. You could cut or stab
your self. or you could damage the upholstery in a car.
06.) Make sure your clothes and shoe are right for the job. Dangling sleeves or ties can
get caught and machinery and cause serious injury.
07.) Do not wear any rings, bracelet, or watches when working around moving
machinery or electrical equipment.
08.) Wipe oil and grease off your hands and tools. You need a good grip on tools parts.
09.) If you spill oil, grease, or any liquid on the floor, clean it up. Help prevent injury
from slips and falls.
10.) Never use compressed air to blow dirt from your clothes. Nor never point a
compressed – air blow gun at another person.
11.) Always wear eye protection when liquid spray or particles are flying about. Safety
glasses, safety goggles, or face shield should always be available. Always wear eye
protection when using a grinding wheel.
12.) Watch out for the spark flying from a grinding wheel or a welding job. The sparks
can set hair or clothes on fire
13.) When using solvents or other chemicals, wear goggles to protect your eyes if you
get a chemical in your eyes, flush them with water at once. Then go to the school
nurse, a doctor, or a hospital emergency room.
14.) Always observed safety pre-caution in using the floor jack, position it properly - it
must not slip out. Never lift a vehicle while someone is working under it! People
have been killed when the jack slipped and the vehicle fell on them. Always put
safety stands in place before going under a vehicle.
15.) Always used the right tool for the job. The wrong tool could damage the part you
are working on or could hurt you.
16.) Keep you hands away from the engine fan an accessory drive belts when the engine
is running. Your hand could get caught in the fan or between a belt and pulley. You
could be badly cut or even lose fingers.
17.) Do not stand directly in line with the engine fan when it is turning or the engine is
running. Some fans, especially fans with flexible blades, have thrown off a blade
while spinning.
Work Area Safety
SAFETY PRECAUTIONS IN SERVICE OPERATIONS
01.) Do not operate the engine for an
extended period of time without proper
exhaust ventilation.
Warming-up the Engine With-Out Proper Exhaust
Ventilation Will Produce Carbon Monoxide
02.) Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels
to prevent the vehicle from moving. After jacking up the vehicle, support the
vehicle weight with safety stands at the points designated for proper lifting and
towing before working on the vehicle.
Wheel Chocks or Tire Blocks
Example of a Hydraulic Jack
Support Stand
03.) When removing a heavy component such as the engine or transaxle / transmission,
take care not to lose your balance and drop it. Also, do not allow it to hit against
adjacent parts, especially brake tube and brake cylinder.
Correct Body Position in Lifting an Object
04.) Before starting repair, which does not require battery power, always turn off the
ignition switch, then disconnect the ground cable from the battery to prevent
accidental short circuit.
Ignition Switch in Disconnected Ground
OFF status Cable
05.) To prevent serious burns, avoid contact with hot metal parts such as the radiator
exhaust manifold, tail pipe and muffler. “Do not remove the radiator cap when the
engine is hot”.
Illustration Showing the Action of the Driver/Technician
Once Radiator Cap is Open at High Temperature
06.) To prevent scratches and soiling, protect fenders, upholstery and carpeting with
appropriate covers before starting servicing. “Take caution that keys, buckets, or
buttons do not scratch the paint”.
Fender Cover
The Technician Doing Gasoline Engine Tune-up
07.) Clean all dis-assembled parts in the designated liquid or solvent prior to inspection
or assembly.
Spraying the Dis-assembled Engine Parts
08.) Arrange the dis-assembled parts in accordance with their assembled locations and
sequence.
Arranged Valve Lifter
Arranged Push Rod
Sample of Arranged Engine Parts after its Dis-assembling
09.) Use approved bonding agent, sealants or their equivalents when required.
Example of Approved Bonding Agent
10.) Replace oil seals, gaskets, packing, o-rings, locking washers, cotter pins, self-
locking nuts, etc. as instructed and discard used ones.
Example of an Old/Damaged Lock Rings
11.) Tapered roller bearings and needle bearings should be replaced as a set of inner and
outer races.
Dis-assembled Installation of the
Bearing new bearing
Example of a new
Bearing
12.) Use only the lubricants specified in the applicable section or those indicated under
“Recommend fuel and lubricants”.
Viscosity Rating
Service Rating
Recommended Oil for Gasoline & Diesel Engines
13.) Do not touch the terminals of electrical components which utilize microcomputers
such as electronic control units. “Static electrical charges stored in your body may
damage internal electronic components”.
14.) After disconnecting vacuum hose or air hose, attach tag, which indicates the proper
connection to prevent in correct connection.
15.) The use of the proper tools and recommended essential tools should be used where
specified for proper, safe and efficient service repair.
16.) When effecting repairs on the fuel, oil, water, vacuum or exhaust systems, make
certain to check all affected lines for leaks.
17.) Dispose drained oil or used solvent for cleaning parts in an appropriate manner.
2. FIRE EXTINGUISHER
Classifications of fire
Class A fires:- fires involving freely or ordinary burning materials. Eg. Paper,
plastic….etc.
Class B fires:- fires involving flammable, combustible liquids. Eg. Gasoline, diesel,
kerosene…
Class C fires:- fires involving flammable gasses (e.g. butane and propane) and energized
electrical equipment’s ( e.g. switches, panel boxes, power tools
appliances)
Class D fires:- fires involving flammable metals ( sodium, lithium, magnesium) and
electrical apparatus.
Types of fire extinguisher
1. Water fire extinguisher:- the cheapest and most widely used fire extinguisher. It is
used for class A fire. Not suitable for class B (liquid) and where electricity is involved.
2. Foam fire extinguisher:- more expensive than water and used for class A and class B
fires. Not for fires involving electricity.
3. Dry powder fire extinguisher:- termed as multi purpose and used for class A, B, & C
fires. It is best for class B(liquid) fires. Special powders are
available for class D (metal) fires.
4. CO2 fire extinguisher:- fires involving for electrical apparatus. It will also extinguish
class B liquid fires.
Color code of fire extinguisher
Water Foam Dry powder Carbon Dioxide
Red Cream Blue Black
How to use fire extinguisher?
To use a fire extinguisher simply remember the word PASS which means,
P – pull the pin
A – nozzle to the fire
S – squeeze the lever
S – swipe the nozzle on the fire (right to left)
Nozzle Pin
Lever
Cylinder
Hazardous materials
A typical shop may contain many potential hazards for those works in it. This hazard can
cause injury, sickness, health impairments, discomfort and even death. Hazards can be
classified as;
a. Chemical hazards:- caused by high concentration of vapors, gases or solids in
the form of dust.
b. Waste hazard:- are due to substances that are the result of a service.
c. Physical hazard:- excessive noise, vibration, pressure and temperature.
d. Ergonomic hazard:- due to human comfort designs.