© 2012 delmar, cengage learning shop safety chapter 3

© 2012 Delmar, Cengage Learning

Shop Safety

Chapter 3

© 2012 Delmar, Cengage Learning

Objectives• Use shop tools and equipment safely• Understand safety rules

© 2012 Delmar, Cengage Learning

Introduction• Number one priority of any business is the

health and safety of its employees– Employer is responsible for safety training and

for providing a safe working environment

– Employee is responsible for his or her own safety and the safety of others

– Accidents often the result of carelessness, lack of experience, and taking shortcuts

• Injured persons should not be left unattended– American Red Cross offers first-aid training

© 2012 Delmar, Cengage Learning

General Personal Safety• Important points

– Wear safety goggles or a face shield to protect eyes

– Follow safe lifting procedures

– Wear ear protection when loud tools are used

– Keep long hair tied or under a cap

– Tuck in shirt tails or wear shop clothing

– Leather shoes with a reinforced toe protect better

– Use correct gloves when working with chemicals

© 2012 Delmar, Cengage Learning

© 2012 Delmar, Cengage Learning

Fire Safety• Common sense is important

– If personal safety jeopardized• Leave the area• Call for help

– If you can safely remove the fuel to a fire, do so• Shut off fuel• Disconnect electrical source

© 2012 Delmar, Cengage Learning

Fire Extinguishers• Four kinds of fires and four kinds of fire

extinguishers– Class A fire can be put out with water

– Class B fire contains flammable liquids

– Class C is electrical

– Class D is a flammable metal (e.g., magnesium)

• Carbon dioxide or dry chemical extinguishers can be used on Class B and C fires

• Gauge on top of extinguisher tells if it is charged

© 2012 Delmar, Cengage Learning

Flammable Materials• Greasesweep and oil-soaked rags should be

stored in covered metal containers• Saturated greasesweep must be disposed using a

licensed waste hauler

© 2012 Delmar, Cengage Learning

Fuel Fires• Gasoline is a major cause of automotive fire

– Vapors collect in low places and ignite

• Incandescent lights are a fire hazard– Florescent bulb enclosed in a plastic tube is

recommended

– Ordinary flashlights also acceptable

• Gasoline safety– Never use gasoline to clean parts

– Do not smoke carelessly

– Do not siphon gasoline with your mouth

© 2012 Delmar, Cengage Learning

Electrical Fires• Disconnect the

battery before working on the electrical system– Unbolt the

ground cable

– Ground cable is bolted to the engine block

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Shop Habits• Precautions

– Use a shop towel while working

– Greasy tools and hands should be cleaned

– Shop towels may have metal burrs

– Spills should be cleaned when they happen

– Oil and solvent spills can be cleaned with greasesweep

– Waste disposal companies offer a service to soak up spills with superabsorbent cloths

– Newer products have microbes that “eat” oil or fuel and convert it to CO2 and water

© 2012 Delmar, Cengage Learning

Shop Habits (cont'd.)

© 2012 Delmar, Cengage Learning

Electrical Safety Precautions• Twelve-volt DC systems don’t cause serious

shock– Shop equipment powered by 110V or 220V

alternating current can be very dangerous

• Do not stand in water when using electric tools• Turn off tools before plugging in

– Wall outlets should be properly grounded

• Three-wire electrical tools are preferable– Observe wire color coding when replacing cords

© 2012 Delmar, Cengage Learning

© 2012 Delmar, Cengage Learning

Cooling Fan Safety• The fan that draws cool air across the radiator

can be driven by either a belt or electricity– Fans controlled by electric switch can start

unexpectedly

• Precautions– Disconnect electric cooling fans before working

near them– Visually inspect fan blades for damage

• Unbalanced blades may fly apart

– Keep hair and clothing away from fans and fan drive belts

© 2012 Delmar, Cengage Learning

Coolant Burns• Most burns are

caused by coolant or exhaust systems

• Coolant level is acceptable if hose is hard

• If hose collapses, steam may still burn

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General Hand Tool Safety• Using hand tools properly prevents cuts• Precautions

– Inspect tools before use

– Maintain tools in safe working condition

– Do not use worn or broken tools

– Do not put sharp tools in your pocket

– Use eye protection when using hammers and chisels

– Regrind mushroomed chisels and punches

– Be sure file has handle installed before use

© 2012 Delmar, Cengage Learning

Vise and Puller Safety• Vise safety

– Do not over-tighten vise when in wide-open position

– Never use a piece of pipe on the vise handle

• Puller safety– Wear eye protection

– Align the puller perpendicular to the part

– Do not use a puller with damaged or worn parts

– Use the correct size puller

– A 3-jaw puller is preferable

© 2012 Delmar, Cengage Learning

Machinery and Electric Drill Safety

• Machinery safety– Do not talk to someone operating a machine

– Do not talk to others when operating a machine

– Be cautious around engines or rotating machinery

• Electric drill safety– Wear eye protection

– Release pressure occasionally

– If the drill grabs the work, shut it off

– Remove chuck key from the chuck before drilling

– Never stand in water while drilling

© 2012 Delmar, Cengage Learning

Grinder Safety• Precautions

– Stand to the side when starting the motor

– Wear face protection

– Position tool rest as close to wheel as possible

– Use the shield installed on the grinder

– Do not grind on the side of the grinding wheel

© 2012 Delmar, Cengage Learning

© 2012 Delmar, Cengage Learning

Wire Wheel and Compressed Air Safety

• Wire wheel safety– Use face protection and leather gloves

– Do not push too hard against the wheel

– Wire wheels can damage soft aluminum surfaces

• Compressed air safety– Wear eye protection

– Do not blow air against your skin

– Hold the air hose when uncoupling an air line

– Bleed off air from an airline before uncoupling

– Rubber-tipped blowguns are not safety regulated

© 2012 Delmar, Cengage Learning

Impact Wrench Safety• Precautions

– Be careful of loose clothing or hair

– Use approved impact sockets

– Be sure the socket is secured to the tool

– Do not turn on the impact wrench unless the socket is installed on a nut or bolt

– When the wrench fails to loosen a fastener use a large breaker bar

© 2012 Delmar, Cengage Learning

Air Chisel Safety• Precautions

– Wear eye protection

– Hold the tool bit against the workpiece before pulling the trigger

© 2012 Delmar, Cengage Learning

Die Grinder/Air Drill and Press Safety

• Die grinder/air drill safety– Use ear protection

– Be sure the wire is rated for high speed use

– Do not remove head gaskets using a wire brush and die grinder or air drill

• Press safety– Use applicable safety guards

– Wear face protection

– Use the fast speed to press parts when possible

– Use extreme caution as pressure is higher

© 2012 Delmar, Cengage Learning

General Lifting Safety• Be sure the lift

contacts the frame at the recommended lift point

• When lifting on a frame-contact hoist, raise the vehicle six inches and shake it

© 2012 Delmar, Cengage Learning

Hydraulic Floor Jack (Service Jack) Safety

• Cars have fallen and crushed people who use jacks that failed– Hydraulic service jack should be used to raise

and lower a vehicle only

– Use vehicle support stands in pairs

– Position support stands in recommended locations on the frame

– Use support stands only on a level, concrete surface

© 2012 Delmar, Cengage Learning

Shop Crane (Engine Hoist) Safety

• The shop crane can tip over easily when removing an engine from a car

• Precautions– Roll the crane in a straight a line

– Be sure bolts are not too short

– Firmly tighten bolts attaching lifting fixture to part

– Lower the engine as soon as possible before attempting to roll the crane to a different location

– Be careful when raising the vehicle in the air while on a frame-contact lift

© 2012 Delmar, Cengage Learning

© 2012 Delmar, Cengage Learning

Transmission Jack Safety• Used when vehicle is raised in the air on a lift

– Safest use is when the vehicle is on a wheel-contact lift

– When a vehicle is on a frame-contact lift, raising the transmission can result in the vehicle being lifted off the adapters on the lift

• If its balance is upset, the vehicle could be knocked off of the lift

© 2012 Delmar, Cengage Learning

Battery Safety• Batteries give off hydrogen gas as they charge

– Hydrogen gas is explosive

• Common cause of battery explosion – Unhooking a battery charger without turning it off

• Battery explosions cause:– Skin damage

– Permanent or temporary hearing loss

– Blindness

© 2012 Delmar, Cengage Learning

Battery Safety (cont'd.)• Jump-starting a vehicle

– Follow proper procedures and wear eye protection

• Battery acid contains sulfuric acid and water– If battery acid gets on your skin immediately

wash with water for at least 15 minutes

– Baking soda neutralizes battery acid

• Hybrid vehicles require special knowledge– Know what is safe to touch

© 2012 Delmar, Cengage Learning

Refrigerant Safety• Refrigerant is used in air-conditioning systems

– When pressure removed, it boils and vaporizes

• Precautions– Wear gloves

– Wear goggles• Refrigerant can cause instant blindness

© 2012 Delmar, Cengage Learning

General Safety Around Automobiles

• Precautions– Do not leave things on the floor of the shop

– Hydraulic service jacks (floor jacks) should be left with the handle up

– Stand creepers vertically against a wall

– Check brakes before test driving a car

– Be sure that helpers understand what to do

– Take keys out of the ignition before adjusting a fan belt

© 2012 Delmar, Cengage Learning

Hot Tank Safety Precautions• Caustic base solution from a hot tank can also

eat your skin and cause blindness• Precautions

– Wear gloves and face protection

– If contacts skin, rinse immediately and seek medical attention

– If caustic gets into an eye, flush under eyelid for 15 minutes, repeat, and seek medical help

– Lift articles from the tank with a lifting device

– Securely fasten lifting slings to items in the tank

© 2012 Delmar, Cengage Learning

Hazardous Materials and Environmental Safety

• Hazardous materials– Cause illness, injury, or death– Pollute air, water, or land

• Regulated by the: – Environmental Protection Agency (EPA)– National institute of Occupational Safety and

Health (NIOSH) – Department of Transportation (DOT)

• Examples include ignitable, corrosive, reactive, and toxic wastes

© 2012 Delmar, Cengage Learning

Hazardous Materials and Environmental Safety (cont'd.)

• Bloodstream hazards– Hazardous materials enter the bloodstream

through the lungs• Some materials pass through respirators

– Aerosol cleaners are more hazardous

– Skin protects the bloodstream from most hazards

• Skin damage– Protect skin from hazardous materials

• Wear gloves• Clean hands properly

© 2012 Delmar, Cengage Learning

Hazardous Communication Standards

• EPA: outlines regulations for hazardous material disposal– Each hazardous waste generator has an EPA

identification number• Employer labels materials and trains employees

• Label on hazardous material must include:– Manufacturer’s name and address

– Chemical name and trade name

– Safety information about the chemical

© 2012 Delmar, Cengage Learning

Material Safety Data Sheets• MSDS must be available for any hazardous

materials used• MSDS lists:

– Permissible exposure limit

– Threshold limit value

– Short-term exposure limits• Max exposure during 15 minutes in one workday

– Upper and lower explosive limit• Estimates of danger

© 2012 Delmar, Cengage Learning

Hazardous Materials Common to the Automotive Industry

• Solvents – Liquid organic chemicals used to dissolve solids

– Exposure symptoms may be acute or chronic

– May cause skin problems, liver problems, kidney damage, cancer, etc.

– Chronic effects may be from repeated exposure or a single exposure

– Avoid contact altogether

© 2012 Delmar, Cengage Learning

Cleaning Solvent Safety• Precautions

– Use eye protection

– Do not breathe vapors

– Use adequate ventilation and a respirator

– Do not clean with gasoline

– Use nonflammable solvents

– Do not spray solvents near pilot lights

– Use a brass or nylon brush

– Keep solvent tank lid closed

– Do not smoke or weld anywhere near solvent

© 2012 Delmar, Cengage Learning

Skin Care and Safety Precautions

• Dermatitis can result from exposure• Precautions

– Do not use hand cream • They can seal in the solvent

– Be sure gloves do not allow solvent penetration

– Do not mix other chemicals with cleaning solvents

– Barrier creams do not protect against solvent penetration

• Not a glove substitute

© 2012 Delmar, Cengage Learning

Breathing Safety• Many sources of breathing hazards

– Use an exhaust system to avoid breathing exhaust gas

• Asbestos – Can be cleaned using organic solvent, wetting

agent, or HEPA vacuum• Full vacuum filter must be wetted before removal• Wetting agent must flow through the drum before

removal• Wipe all parts clean with a cloth disposed in

approved, labeled container