Handout Activity: HA975

Transcription

1 Basic safety introduction HA975-2 Handout Activity: HA975 Student/Intern information: Name Date Class Basic safety introduction Summary Just because it so commonplace, it is sometimes easy to overlook the many potential risks involved in vehicle servicing and repair. Motor vehicle servicing is a universal activity Motor vehicle servicing is one of the most common work activities worldwide. Hundreds of thousands of workshops service millions of vehicles every day. Don t underestimate the dangers Just because it so commonplace, it is sometimes easy to overlook the many potential risks involved in vehicle servicing and repair. Thousands of injuries are reported to local health and safety authorities, but many more go unreported. Accidents and injuries can happen at anytime Here are just a few examples: Fires and explosions are a constant hazard wherever there are flammable fuels Page 1

2 Basic safety introduction HA975-2 Electricity can kill you very quickly, as well as cause painful shocks and burns Heavy equipment and machinery can easily cause broken bones or crush fingers and toes Hazardous solvents and other chemicals can burn or blind as well as contribute to many kinds of illness Trips and falls can be caused by things such oil spills, and by tools left lying around Poor lifting and handling techniques can cause chronic strain injuries, particularly to your back Page 2

3 Basic safety introduction HA975-2 Accidents and injuries are avoidable Your workplace will be a much safer place if YOU : Learn and follow all of the correct safety procedures - every time Always wear the right protective clothing Stay alert and aware of what is happening around you Think about how what you are doing could affect others Know what to do in an emergency Document and report all accidents and injuries whenever they happen, and do everything you can to make sure they never happen again. Safety is the responsibility of everyone in the workplace - including you Make sure that you understand and follow all the regulations and safety procedures that apply in your own workplace Page

4 Basic safety introduction HA and report all accidents and injuries whenever they happen, and do everything you can to make sure they never happen again. 2. Fires and are a constant hazard wherever there are flammable fuels 3. Hazardous and other chemicals can burn or blind as well as contribute to many kinds of illness Score / 3 Supervisor/Instructor information: Name Signature Date Page 4

5 Identifying hazards Engines: Motive Power Types: Handout Activity: HA107 HA107-2 Student/Intern information: Name Date Class Identifying hazards Summary A workshop is a hazardous environment. The objective of this procedure is to show you how to follow workplace procedures for hazard identification and avoidance. Part 1. Preparation and safety Objective Follow workplace procedures for hazard identification and avoidance. Personal safety Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection such as rubber gloves and barrier cream Respiratory equipment such as face masks and valved respirators If you are not certain what is appropriate or required, ask your supervisor. Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor. Points to note A workshop is a hazardous environment. To make people more aware of specific workshop hazards, legislative bodies, such as the International Safety Organization (ISO), have developed a series of safety signs. These signs are designed to give adequate warning of an unsafe situation. Each sign has four components: Signal word Background color Text Pictorial message Page 1

6 Identifying hazards Part 1. Preparation and safety continued HA107-2 There are three signal words: Danger: This indicates an immediately hazardous situation, which, if not avoided, will result in death or serious injury. Danger is usually indicated by white text with a red background. Warning: This indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. The sign is usually in black text with an orange background. Caution: This indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. This is usually in black text with a yellow background. The sign will sometimes include an explanatory text that is intended to provide additional safety information. Some signs are designed to convey a personal safety message. These signs suggest the use of safety glasses or hearing protection when in the area Page 2

7 Identifying hazards Part 1. Preparation and safety continued HA107-2 In symbol signs, a pictorial message appears alone or is combined with an explanatory text. This allows the safety message to be conveyed to people who are illiterate or who do not understand the local language. Workshop safety equipment includes items such as: Hand Rails Machinery Guards Painted Lines Soundproof Rooms Gas Extraction Hoses Doors and Gates Adequate Ventilation Large, fixed machinery such as lathes and milling machines present a hazard to the operator and others working in the area. To prevent accidents, a machinery guard or a yellow painted line on the floor usually borders this equipment. Machinery guards and yellow lines will prevent people from accidentally walking into the operating equipment or indicate that a safe distance should be kept from the equipment. Soundproof rooms are usually used when a lot of noise is made by operating equipment. An example is the use of a chassis dynamometer. A vehicle operating on a dynamometer produces a lot of noise from its tires exhaust and engine. To protect other workshop users from the noise, the dynamometer is usually placed in a soundproof room, keeping workshop noise to a minimum. Exhaust gases in workshops are a serious health hazard. Whenever a vehicle s engine is running, toxic gases are produced from its exhaust. To prevent an excess of gas build-up, a well-ventilated work area is needed as well as some method of extracting the toxic gases. The best way to get rid of these gases is with a suction hose that fits over the vehicle s exhaust pipe. The hose is attached to an extraction pump that vents the gas to the outside. Doors and gates are used for the same reason as machinery guards and painted lines. A doorway is a physical barrier that can be locked and sealed to separate a hazardous environment from the rest of the workshop, or a general work area from an office or specialist work area. In the day-to-day operation of a workshop, there is often a reason to temporarily separate one work bay from others. If a welding machine or an oxyacetylene cutting torch is in use, it may be necessary to place a temporary screen or barrier around the work area to protect other workshop users from welding flash or injury Page

8 Identifying hazards Part 2: Step-by-step instruction HA Workshop layout Familiarize yourself with your workshop. There are special work areas that are defined by painted lines. These show the hazardous zone around certain machines and areas. If you are not working specifically on the machines, you should stay outside the marked area. 2. Observe warning signs Study the various warning signs around your workshop. Understand the meaning of the Signal Word, the colors, the text and the symbols or pictures on each sign. Ask your supervisor if you do not fully understand any part of the sign. 3. Identify exits Find out where every door, window and gate is, and whether they are usually open or locked. Plan your escape route, should you need to exit in a hurry. 4. Check air quality Check for air quality. There should be good ventilation and very little chemical fumes or smell. Locate the extractor fans or ventilation outlets and make sure they aren t obstructed in any way. Locate and observe the use of the exhaust extraction hose, pump and outlet that s used on the vehicle s exhaust pipes. 5. Identify fire fighting equipment Check the location and types of fire extinguishers in your workshop. Be sure you know when to use each type, and how. 6. Identify flammable hazards Find out where flammable materials are kept, and make sure they re stored properly. 7. Identify hazards - Compressed air Check the hoses and fittings on the air compressor for any damage or excessive wear. You have to be particularly careful when troubleshooting air guns. Never pull the trigger while inspecting it severe eye damage can result. 8. Identify hazards - Corrosives Find out which liquids will burn or corrode parts, metals or skin. Identify caustic chemicals and acids associated with activities in your workshop. 9. Personal protection Be aware that YOU could be a hazard in the workshop, if you don t wear mandatory protective gear when working on hazardous machines. 10. Equipment hazards Ask your supervisor for information on any special hazards in your particular workshop, and any special avoidance procedures, which may apply to you and your working environment Page 4

9 Identifying hazards HA rooms are usually used when a lot of noise is made by operating equipment. 2. Locate and observe the use of the exhaust hose, pump and outlet that s used on the vehicle s exhaust pipes. 3. Familiarize yourself with your workshop. There are special work areas that are defined by lines. 4. Each sign has four components: Signal word Background color Text message 5. Check for air quality. There should be good and very little chemical fumes or smell. Score / 5 Supervisor/Instructor information: Name Signature Date Page 5

10 Evacuating in an emergency Engines: Motive Power Types: Handout Activity: HA108 HA108-2 Student/Intern information: Name Date Class Evacuating in an emergency Summary The objective of this procedure is to show you how to carry out an emergency evacuation procedure remembering to always follow the emergency procedures that apply in your workshop. Part 1. Preparation and safety Objective Carry out emergency evacuation procedures. Personal safety Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection such as rubber gloves and barrier cream Respiratory equipment such as face masks and valved respirators If you are not certain what is appropriate or required, ask your supervisor Page 1

11 Evacuating in an emergency Part 1. Preparation and safety continued HA108-2 Safety check Make sure you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor. Points to note Emergency evacuation procedures are designed for the specific requirements of your workshop and region. If there are no evacuation procedures in your workshop, consult your local police and fire departments for specific information. Evacuation procedures will also vary depending on the nature of the emergency. In the case of a building fire, the procedure will involve leaving a building and moving to an assembly point outside. The emergency procedure for a hurricane or cyclone warning, however, requires you to take cover inside a designated shelter. Other evacuation procedures provide action for emergencies such as: Bomb Threats Civil Unrest Chemical Spills Bushfire/Wildfire If you have any questions about evacuation procedures, contact your national health and safety authority. If your supervisor assigns you a task, like assisting in an evacuation, it is because he or she believes you are capable of fulfilling that role. Once you have completed that task, notify your supervisor. Part 2: Step-by-step instruction 1. Don t panic! The first Rule when you have an emergency, or if you hear the alarm at your workshop is: DON T PANIC! Follow the emergency procedures that apply in your workshop. 2. Who s in charge? Determine WHO s in charge. He or she should have a list of all personnel who are working in the area. Follow their directions and evacuate the area by the nearest emergency exit. 3. Secure your workplace If you have time, turn off the electrical supply to all operating equipment. Turn off the taps and put lids on any containers of flammable liquids. Check small rooms, such as offices or rest rooms to make sure nobody is in them. If you are the last one out of an area, close all doors and windows on your way out. 4. Assemble and count Once you have all met at the appropriate assembly point, count your co-workers and report anyone missing to your supervisor. Report the emergency to the appropriate authorities. That may be police, fire, ambulance or other regional emergency body. Be aware that emergency vehicles or personnel may be arriving on site and may need direction. If this is not your task, stay out of the way Page 2

12 Evacuating in an emergency HA Once you have all met at the appropriate assembly point, your co-workers and report any one missing to your supervisor. 2. If you have time, turn off the supply to all operating equipment. 3. In the case of a building fire, the procedure will involve leaving a building and moving to an point outside. Score / 3 Supervisor/Instructor information: Name Signature Date Page

13 Fuel fires HA109-2 Handout Activity: HA109 Student/Intern information: Name Date Class Fuel fires Summary The danger of a gasoline, or petrol, fire is always present in an automotive workshop. Most automobiles carry a tank, often with large quantities of this type of fuel on board, more than sufficient to cause a large and very destructive and explosive fire. The danger of a gasoline, or petrol, fire is always present in an automotive workshop. Most automobiles carry a tank, often with large quantities of this type of fuel on board, more than sufficient to cause a large and very destructive and explosive fire. Fuel vapor Liquid fuel vaporizes rapidly, especially when spilt, and the vapor is extremely easy to ignite. Because fuel vapor is invisible and heavier than air, it can spread unseen across a wide area and a source of ignition can be quite some distance from the original spillage. Fuel can even vaporize from the cloths or rags that are used to wipe up liquid spillages, and these should be allowed to dry in the open air, not held in front of a heater element. Any spark, any naked flame, even a lit cigarette can start an explosive fire. Flammability range Fuel vapor has a wide range of flammability. When mixed with air it will readily ignite if the ratio of fuel is 1.4% - 7.6% of the mixture, so it is especially dangerous at quite low concentrations. Spillage risks Spills frequently occur when technicians remove a fuel tank sender unit, which is often located on the side of the fuel tank, without first emptying the tank safely. Spills also occur when fuel lines are damaged and are being replaced, or when fuel systems are being checked, or when fuel is being drained into unsuitable containers or containers that are too small for the amount of fuel being drained. Draining fuel If there is a possibility of fuel spillage while working on a vehicle then you should first remove the fuel safely. Do this only in a well-ventilated, level space, preferably outside in the open air. Make sure that all potential sources of ignition have been removed from the area, and disconnect the battery on the vehicle. Do not drain fuel from a vehicle over an inspection pit. Make sure that the container you are draining into is made of a suitable fuel-resistant material, and that it is large enough to contain all of the fuel in the system being drained. Use a fuel retriever Always use a fuel retriever, preferably removing the fuel through the filler neck, as this will minimize the chance of sudden gross spillage occurring. You may need to use narrow bore hoses or adaptors to drain fuel lines or to bypass anti-spillage devices. Check your vehicle workshop manual for details on how best to drain the fuel from the vehicle you are working on Page 1

14 Fuel fires HA109-2 Repairing a fuel tank Never weld anywhere near a tank or any kind of fuel line. Hot work on a tank itself is a job for specialists, because an empty fuel tank can still contain vapor and therefore even more dangerous than one full of liquid fuel. Do not attempt to repair a tank yourself. 1. Never anywhere near a tank or any kind of fuel line. 2. Make sure that all potential sources of ignition have been removed from the area, and the battery on the vehicle. 3. Because fuel vapor is invisible and than air, it can spread unseen across a wide area and a source of ignition can be quite some distance from the original spillage. Score / 3 Supervisor/Instructor information: Name Signature Date Page 2

15 Using a fire extinguisher Engines: Motive Power Types: Handout Activity: HA110 HA110-3 Student/Intern information: Name Date Class Using a fire extinguisher Summary Each workshop will have a firefighting procedure. There should be a workshop fire warden and fire officers. Understand clearly the firefighting policy for your workshop. Do not attempt to fight a fire unless you have a fire extinguisher large enough to extinguish the fire. Many small extinguishers empty in 8 to 10 seconds. Never try to extinguish a fire that is spreading rapidly. Do not try to put out a fire unless you know what type of fire is burning. Using the wrong fire extinguisher will make the fire worse. Test the fire extinguisher before you attempt to extinguish a fire. Do not inhale any fumes from a fire. Fire gives off toxic gases. Do not use water on grease fires, electrical fires or fires where electrical wiring is present. If you cannot fight the fire, leave the area and call the fire department. See your local fire department for a demonstration of the appropriate procedure in your jurisdiction. Fighting a fire Three elements must be present at the same time for a fire to occur: fuel, oxygen and heat. These three elements are demonstrated by the fire triangle. The secret of firefighting involves the removal of one of these elements, usually the oxygen or the heat. Know how to operate the extinguisher. Read the instructions when you purchase the extinguisher. You will not have time to read them once a fire has started. Never turn your back on a fire or allow a fire to get between you and a means of escape. If you are fighting a fire outside, always have the wind at your back. If possible, get an assistant to guide you and inform you of the fire s progress. If a fire occurs in your work area, remember the PASS word: Pull, Aim, Squeeze, Sweep PULL out the pin that locks the handle at the top of the extinguisher to prevent accidental use. Carry the fire extinguisher in one hand, and use your other hand to AIM the nozzle at the base, or seat, of the fire. Some fire extinguishers need to be turned upside down to operate. Check which way to hold the extinguisher you ve chosen Page 1

16 Using a fire extinguisher Engines: Motive Power Types: Stand about 2.8 m (8 ft) away from the fire and SQUEEZE the handle to discharge the fire extinguisher. Remember that if you release the handle on the extinguisher, it will stop discharging. SWEEP the nozzle from side to side at the base of the fire. Watch the fire. Although it may appear to have gone out, it may re-ignite. HA110-3 If the fire is indoors, you should be standing between the fire and the nearest safe exit. If the fire is outdoors, you should be standing facing the fire with the wind on your back, so that the smoke and heat are being blown away from you. Again, make sure that you have a means of escape, should the fire get out of control. When you are quite sure that the fire is out, report it to your supervisor. Also report what actions you took to put out the fire. Once the circumstances of the fire have been investigated, and your supervisor or the fire brigade has given you the all clear, clean up the debris and submit the used fire extinguishers for inspection and re-filling. Fire classifications There are 5 classes of fire. A class fires involve wood, paper, cloth, rubber and trash. B class fires involve flammable liquids, such as oil, paint, gasoline, grease, and tar. C class fires involve flammable gases, such as LPG, Natural Gas, Acetylene, etc. D class fire is fuelled by combustible metals - magnesium, potassium turnings and metal shavings. They are not as common as A, B, or C class fires. E class fires need electricity to feed the fire. This class includes wiring, damaged appliances, circuit breakers and fuse boxes. Once the electrical supply has been disconnected, the fire changes to the class of fuel it is burning. US fire classifications There are 5 classes of fire: A class fires involve ordinary combustibles such as wood. B class fires involve flammable liquids or gaseous fuels. C class fires involve electrical equipment. D class fires involve combustible metals such as sodium, titanium and magnesium. K class fires involve cooking oil or fat. UK / Australian fire classifications There are 6 classes of fire: A class fires involve ordinary combustibles such as wood, paper, cloth, rubber and trash. B class fires involve flammable liquids, such as oil, paint, gasoline, grease, and tar. C class fires involve flammable gases, such as LPG, Natural Gas, Acetylene, etc. D class fire is fueled by combustible metals - magnesium, potassium turnings and metal shavings. They are not as common as A, B, or C class fires. E class fires need electricity to feed the fire. This class includes wiring, damaged appliances, circuit breakers and fuse boxes. Once the electrical supply has been disconnected, the fire changes to the class of fuel it is burning. F class fires involve cooking oil or fat. US fire extinguisher types There are no official standards in the US for the color of extinguishers. Extinguishers are marked with pictograms depicting the types of fires that the extinguisher is approved to fight. Fire class A - Green triangle Page 2

17 Using a fire extinguisher HA110-3 Fire class B - Red square Fire class C - Blue circle Fire class D - Yellow pentagram Fire class K - Black hexagon UK fire extinguisher types Water Signal red extinguisher. This extinguisher is best for A class fires. Foam Red with cream panel. This extinguisher is best for A, B, & E class fires. Dry powder Red with blue panel. This extinguisher is best for A, B, C & E class fires. Carbon dioxide Red with black panel. This extinguisher is best for B & E class fires. Wet chemical Red with canary yellow panel. This extinguisher is best for A & F class fires. Class D powder Red with blue panel. This extinguisher is best for D class fires. Australian fire extinguisher types Water Solid red extinguisher. This extinguisher is best for A class fires. Foam Red with a blue band.. This extinguisher is best for A and B class fires. Dry chemical (powder) Red with a white band. This extinguisher is best for A, B, C & E class fires. Carbon dioxide Red with a black band This extinguisher is best for A, B, C, E, & F class fires. Vaporizing liquid (not halon) Red with a yellow band This extinguisher is best for A, B, C, E class fires. Halon Solid yellow extinguisher This extinguisher is best for A, B & E class fires. Wet chemical Red with an oatmeal band This extinguisher is best for A & F class fires 1. E class fires need to feed the fire. 2. If the fire is indoors, you should be standing the fire and the nearest safe exit. 3. Three elements must be present at the same time for a fire to occur: fuel, and heat. 4. the fire extinguisher before you attempt to extinguish a fire. Score / 4 Supervisor/Instructor information: Name Signature Date Page 3

18 Using an MSDS Engines: Motive Power Types: Handout Activity: HA111 HA111-2 Student/Intern information: Name Date Class Using an MSDS Summary Material Safety Data Sheets provide information about handling, use and storage of chemicals that may be hazardous. The objective of this procedure is to show you how to identify and define information found on an MSDS. Part 1. Preparation and safety Objective Identify and define information found on an MSDS. Personal safety Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection such as rubber gloves and barrier cream Respiratory equipment such as face masks and valved respirators If you are not certain what is appropriate or required, ask your supervisor. Safety check A Material Safety Data Sheet (MSDS) plays an important part in maintaining personal and workshop safety. It is your responsibility to be aware of any dangers and hazards when using chemicals Page 1

19 Using an MSDS Part 1. Preparation and safety continued HA111-2 Points to note Material Safety Data Sheets provide information about handling, use and storage of chemicals that may be hazardous. They also alert you to symptoms you will experience if you are exposed to the chemical, and provide basic first aid procedures. All suppliers produce an MSDS for the product they manufacture and it should be provided when the product is purchased. The MSDS should always be clearly visible and located near the product s storage area. Ask your supervisor to show you the MSDS location in your workshop. Familiarize yourself with their for mat and the information they contain. Part 2: Step-by-step instruction 1. Locate the appropriate MSDS Once you have studied the information on the container label, find the Material Safety Data Sheet, or MSDS, for that particular material. 2. Check the revision date Always check the revision date to ensure that you re reading the most recent update. 3. Material and manufacturer ID Note the chemical and trade names for the material, who manufactures it, and the emergency telephone number to call. 4. Hazardous ingredients Find out why this material is potentially hazardous. It may be flammable, it may explode or it may be poisonous if inhaled or touched with your bare skin. Check the threshold limit values or TLVs. The concentration of this material in the air you breathe in your workshop must not exceed these figures. There could be physical symptoms associated with breathing harmful chemicals. 5. Health hazard data Study the TLV, and find out what will happen to you if you suffer overexposure to the material, either through breathing it in, or coming into physical contact with it. This section will help you take safety precautions, such as eye, face or skin protection, wearing a mask or respirator while using the material, or washing your skin afterwards. 6. Fire and explosion data Note the flash point for this material so that you know at what temperature it may catch fire. Also note what kind of fire extinguisher you would use to fight a fire involving this material. The wrong fire extinguisher could make the emergency even worse. 7. Mixing or reacting with other materials Study this section to identify the physical conditions or other materials that you should avoid when using this material. It could be heat, moisture or some other chemical. 8. Special precautions The last two sections will show you what special precautions you should take when working with this material. This will include personal protection for your skin, eyes or lungs and storage and use of the material. 9. Refresh your knowledge Be sure to refresh your knowledge of your MSDS sheets from time to time. Be confident that you know how to handle and use the material, and what action to take in an emergency, if one should occur Page 2

20 Using an MSDS HA Check the threshold limit values or TLVs. The of this material in the air you breathe in your workshop must not exceed these figures. 2. Always check the revision date to ensure that you re reading the most update. 3. The MSDS should always be clearly and located near the product s storage area. 4. Note the and trade names for the material, who manufactures it, and the emergency tele phone number to call. Score / 4 Supervisor/Instructor information: Name Signature Date Page

21 Removing toxic dust Engines: Motive Power Types: Handout Activity: HA112 HA112-2 Student/Intern information: Name Date Class Removing toxic dust Summary Never cause dust from vehicle components to be blown into the air. It can stay floating for many hours, meaning that other people can breathe the dust unknowingly. The objective of this procedure is to show you how to clean hazardous brake and clutch components and safely treat and dispose of toxic dust. Part 1. Preparation and safety Objective Clean hazardous brake and clutch components and safely treat and dispose of toxic dust. Personal safety Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection such as rubber gloves and barrier cream Respiratory equipment such as face masks and valved respirators If you are not certain what is appropriate or required, ask your supervisor. Safety check Some vehicle components contain asbestos, which while having very good heat properties is very toxic. Asbestos dust causes lung cancer. Complications from breathing the dust may not show for decades after exposure Page 1

22 Removing toxic dust Part 1. Preparation and Engines: safety Motive continued Power Types: HA112-2 Airborne dust in the workshop can also cause breathing problems such as Asthma and throat infections. Never cause dust from vehicle components to be blown into the air. It can stay floating for many hours, meaning that other people can breathe the dust unknowingly. Don t use compressed air to clean dust from brake and clutch components. Wear protective gloves whenever using solvents. If you are unfamiliar with a solvent or a cleaner refer to the MSDS for information about its correct use and applicable hazards. Always wash your hands thoroughly with soap and water after performing repair tasks on brake and clutch components. Always wash work clothes separately from other clothes so that toxic dust does not transfer from one gar ment to another. Always wear protective clothing and the appropriate safety equipment. Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor. Points to note Asbestos is non-flammable even at very high temperatures and is extremely flexible and durable. It was used to insulate buildings because of its insulating qualities and in brake and clutch linings because of its ability to operate at very high temperatures. Most countries have banned the use of asbestos because of its toxic qualities. However, always treat brake and clutch faces as though they contain asbestos, because you never know how old the component is. Even though it is a banned substance, components manufactured in some countries may still use small amounts of it. After completing a servicing or repair task on a vehicle there is often dirt left behind. The chemicals pres ent in this dirt usually contain toxic chemicals that can build up and cause health problems. To keep the levels of dirt to a minimum clean up dirt immediately after the task is complete. Another by-product of workshop dirt is toxic dust. The same chemicals present in the dirt find their way into the workshop air by means of cleaning components and sweeping floors. The vigorous action of sweeping causes the dust to rise so when sweeping the floor use a soft broom that pushes, rather than flicks the dirt forward. Create smaller dirt piles and dispose of them frequently rather than creating one large dirt pile that is disposed at the end of the task. Another successful way of cleaning workshop dirt is to a hose. Its advantage is that it wets the dirt, so no dust is created. But, the wastewater must be caught in a sullage pit, not into a storm water drain. One of the more common sources of toxic dust is inside drum brakes and manual transmission bell housings Page 2

23 Removing toxic dust Part 1. Preparation and Engines: safety Motive continued Power Types: HA112-2 Road wheels collect brake dust as brake pads wear. This is seen by the collection of black dust found on wheels. The same precautions that apply to cleaning brake and clutch assemblies apply when cleaning wheels. Do not use a cleaning solvent on brake and clutch components as it can damage the lining material. Water is the best cleaning agent in this case. Do not use Kerosene to clean brake components as it does not clean brake fluid, is absorbed into brake lining material and causes brake seals to swell. There are various tools that have been developed to clean toxic dust from vehicle components. One such tool uses a vacuum cleaner that has a large cone attachment at the nozzle end. The base of the cone is open so the brake assembly can fit into the cone and the cleaner turned on. A compressed air nozzle is also attached to the cone that is used to loosen dirt particles. They are drawn into the cleaner via a very fine filter. Domestic vacuum cleaners are not suitable as their filters are not fine enough to capture very small dust particles. Whenever using an atomizer with solvents and cleaners make sure there is adequate exhaust ventilation. Wear appropriate breathing apparatus and eye protection Page

24 Removing toxic dust Part 2: Step-by-step instruction 1 Prepare to clean brake or clutch components Before performing any cleaning tasks on brake or on clutch components always wear a facemask, gloves and eye protection. 2 Locate the catch tray HA112-2 Position a catch tray to the bottom of the backing plate. When cleaning brakes, remove the brake drum and check for the presence of dust and brake fluid. When cleaning a clutch, locate the catch tray underneath the bell housing. Add a recommended cleaning solution. 3 Clean the components Using a stiff brush, paint the solution over the components to both wet and clean the components and remove the dust. Any toxic dust will be washed down and caught in the cleaning tray. 4 Dispose of the residue safely The solvent will evaporate after a short time. Once the task is complete, empty the contents of the cleaning tray into the waste oil tank. 1. The solvent will after a short time. 2. is non-flammable even at very high temperatures and is extremely flexible and durable. 3. Do not use to clean brake components as it does not clean brake fluid, is absorbed into brake lining material and causes brake seals to swell. 4. Don t use to clean dust from brake and clutch components. Score / 4 Supervisor/Instructor information: Name Signature Date Page 4

25 Lifting equipment Engines: Motive Power Types: Handout Activity: HA1096 HA Student/Intern information: Name Date Class Lifting equipment Summary Almost any time you need to work under a vehicle, you will need to lift it first. Before using this equipment, make sure that the most recent inspection recorded is still within the prescribed time limit, and that the certificate has not expired. Periodic testing of lifting equipment Check the test certificate In some countries, lifting equipment is subject to statutory testing and certification. If that is the case where you work, the test certificate should be attached to, or displayed near the lifting equipment that it refers to. Before using this equipment, make sure that the most recent inspection recorded is still within the prescribed time limit, and that the certificate has not expired. Check the equipment If your lifting equipment is not required by law to be tested and certified, it is good practice anyway to carry out regular periodic checks on the serviceability of all of the lifting equipment in your workplace. Refer to the manufacturer s handbook to find out how often they recommend maintenance tests and make sure that these occur. It is usually every 6 months in the case of hoists and lifts, but may be longer for larger items of lifting equipment Page 1

26 Lifting equipment Engines: Motive Power Types: HA Before using this equipment, make sure that the most recent inspection recorded is still within the prescribed limit, and that the certificate has not expired. 2. Refer to the manufacturer s to find out how often they recommend maintenance tests and make sure that these occur. 3. In some countries, lifting equipment is subject to statutory and certification. 4. If your lifting equipment is not required by law to be tested and certified, it is good practice anyway to carry out regular periodic checks on the of all of the lifting equipment in your workplace. Score / 4 Supervisor/Instructor information: Name Signature Date Page 2

27 Moving & road testing vehicles HA113-2 Handout Activity: HA113 Student/Intern information: Name Date Class Moving & road testing vehicles Summary Only authorized, fully trained, and licensed drivers should be given responsibility to move vehicles. Vehicles often need to be road tested, or simply moved from one place to another in the workshop or immediate environment. Accidents can occur at this time, especially if the driver involved is inexperienced or unqualified. Only authorized, fully trained, and licensed drivers should be given responsibility to move vehicles. Only the most skilled and experienced drivers available should be allowed to test higher performance vehicles. Have someone outside the vehicle supervise any vehicle movement inside the workshop, especially in restricted spaces, when reversing, and when nearing blind corners. Make sure that customers and visiting drivers to your workshop are aware of your rules for moving cars. Keep the keys for all vehicles secure and away from the vehicles when not in use. 1. Only the most skilled and experienced drivers available should be allowed to test higher vehicles. 2. Make sure that and visiting drivers to your workshop are aware of your rules for moving cars. 3. Only authorized, fully trained, and drivers should be given responsibility to move vehicles. Score / 3 Supervisor/Instructor information: Name Signature Date Page 1

28 Running engines HA114-2 Handout Activity: HA114 Student/Intern information: Name Date Class Running engines Summary Sometimes it is necessary to run an internal combustion engine indoors, or in a confined space. If you do this without following the correct safety precautions, concentrations of fumes from exhaust gases can quickly build to toxic levels. Running engines indoors Exhaust fumes are toxic Sometimes it is necessary to run an internal combustion engine indoors, or in a confined space. If you do this without following the correct safety precautions, concentrations of fumes from exhaust gases can quickly build to toxic levels. Exhaust extraction equipment The best solution is to directly couple the vehicle s exhaust pipe to an exhaust extraction equipment hose so that the fumes will be ventilated away from the enclosed space and into the open air. These should be vented to where they will not be drawn back into the same workshop, to a place well away from other people and other premises. Catalytic converters are not enough Do not assume that an engine fitted with a catalytic converter can be run safely indoors, they can t. Catalytic converters are less effective when the exhaust gases are relatively cool - such as when the engine is only idling or being run intermittently. 1. Catalytic converters are effective when the exhaust gases are relatively cool - such as when the engine is only idling or being run intermittently. 2. If you do this without following the correct safety precautions, concentrations of from exaust gases can quickly build to toxic levels. 3. The best solution is to directly couple the vehicle s exhaust pipe to an exhaust extraction equipment hose so that the fumes will be away from the enclosed space and into the open air. Score / 3 Supervisor/Instructor information: Name Signature Date Page 1

29 Used engine oil HA115-2 Handout Activity: HA115 Student/Intern information: Name Date Class Used engine oil Summary Coming into frequent or prolonged personal contact with used engine oil can cause dermatitis and other skin disorders, including some forms of cancer. Used engine oil can damage your skin Used engine oil is a hazardous substance containing many impurities that can damage your skin. Coming into frequent or prolonged personal contact with used engine oil can cause dermatitis and other skin disorders, including some forms of cancer. Wear protective clothing Avoid direct contact as far as possible, by always using protective clothing, which is cleaned or replaced regularly, and by following safe work practices, which minimize the possibility of accidental spills. Keeping a high standard of personal hygiene and cleanliness are important, so that you get into the habit of washing off harmful substances as soon as possible after contact. Inspect your skin If you have been in contact with used engine oil, you should regularly inspect your skin for signs of damage or deterioration. If you have any doubts, see your doctor. 1. Coming into frequent or prolonged personal contact with used engine oil can cause dermatitis and other skin disorders, including some forms of. 2. If you have been in contact with used engine oil, you should regularly your skin for signs of damage or deterioration.. 3. Avoid direct contact as far as possible, by always using protective clothing, which is cleaned or replaced regularly, and by following safe work practices, which the possibility of accidental spills. Score / 3 Supervisor/Instructor information: Name Signature Date Page 1

30 Vehicle valeting hazards HA116-2 Handout Activity: HA116 Student/Intern information: Name Date Class Vehicle valeting hazards Summary When valeting a vehicle always wear appropriate protective clothing including eyewear, and impervious gloves to protect hands and forearms as cleaning products, especially solvents, can be toxic or flammable. Always remember to keep your work area well ventilated. Personal and environmental hazards Cleaning products, especially solvents, can be toxic or flammable, especially when used in high concentrations. Make sure you understand and comply with your local regulations concerning the safe handling and disposal of substances that can be hazardous to health. Wherever possible, use the least hazardous materials available, and in the smallest quantities practical for any given task. Pour only small amounts of fluid onto a pad or cloth and keep the lids of any product containers closed when you are not actually pouring from them. Keep the work area ventilated Using toxic substances in enclosed areas is especially hazardous. Keep your inside work area well ventilated, and when working inside vehicles leave all the doors and the sunroof, if fitted, wide open. When ventilation is poor, it may be necessary to use flexible ducting to remove fumes and vapors from inside vehicles you are working on Page 1

31 Vehicle valeting hazards Dangers of flammable substances Some solvents are highly volatile and can explode. Remove all sources of ignition from the work area. It is good practice to disconnect the battery. Personal protection Wear appropriate protective clothing including eyewear, and impervious gloves to protect hands and forearms. If you splash solvent onto items of clothing, remove them and hang them in a safe open place to dry out. If you are not sure how hazardous a particular chemical product is, refer to the relevant MSDS (Material Safety Data Sheet). HA Wherever possible, use the least hazardous materials available, and in the quantities practical for any given task. 2. When ventilation is poor, it may be necessary to use flexible to remove fumes and vapors from inside vehicles you are working on. 3. Cleaning products, especially solvents, can be toxic or flammable, especially when used in high. Score / 3 Supervisor/Instructor information: Name Signature Date Page 2

32 Electrical safety Engines: Motive Power Types: Handout Activity: HA117 HA117-2 Student/Intern information: Name Date Class Electrical safety Summary Many people are injured by electricity in workshops. Poor electrical safety practices can cause shocks and burns, as well as fires and explosions. Many people are injured by electricity in workshops. Poor electrical safety practices can cause shocks andburns, as well as fires and explosions. Electricity supply Make sure you know where the electrical switchgear for your workshop is located. All electrical switches and fuses should be clearly labeled so that you know which circuits and functions they control. In the case of an emergency, you may need to know how to shut off the electricity supply to a work area, or to your entire workshop. Keep the switch and distribution covers closed. It is important that you do not block or obstruct access to this installation, so keep equipment and tools well away so emergency access is not hindered Page 1

33 Electrical safety Engines: Motive Power Types: There should be a sufficient number of socket outlets in your work area for all your needs. Do not connect multiple appliances to a single socket with a simple double adaptor. If necessary, use a multi-outlet safety plug board that has a built-in overload cutout feature. Electric socket outlets should be at least one meter above floor level to reduce the risk of igniting spilt fuel or other flammable liquids. HA117-2 Always switch the socket off before connecting or disconnecting any electrically powered device. Portable electrical equipment If you need to use an extension lead, make sure that it is made of flexible cable not the stiffer type of domestic cabling and that it is fitted with an earth wire. The cable should be neoprene-covered as this material resists oil damage. Portable electric tools and hand lamps, particularly those that operate at 240 volts, are often sources of serious shock and burn accidents. Be particularly careful when using these items. Always inspect the cable for damage and check the security of the attached plug before connecting the item to the supply and switching it on Page 2

34 Electrical safety HA117-2 Choose to use 110-volt or lower voltage tools if they are available. If you have to use 240-volt tools, only use double-insulated or all-insulated tools. Never use any high voltage tool in a wet environment. Air operated tools cannot give you an electric shock, so these are safer to use in the wet. Electric hand lamps are a common source of shocks, especially if they are the wrong type for the purpose, or if they are poorly constructed or maintained. All hand lamps should be double-insulated or all-insulated, and the bulb should be completely enclosed in a transparent insulating case, or protected within a robust insulating cage. The bulbs are very vulnerable to impact and must not be used without this protection. Incandescent bulbs present an extreme fire hazard if broken in the presence of flammable vapors or liquids and should not be used in repair shops. Fluorescent bulbs, while still hazardous, are much safer. If available, choose to use hand lamps that operate at lower voltages, such as 110 volts or less. Only totally enclosed hose-proof hand lamps operating at 24 volts or less should be used in a wet environment. Under no circumstances should mains power be used in a lead light application. Even very low voltage hand lamps can still ignite petrol or flammable vapor and must not be used in areas where these may be present, such as an inspection pit or a paint-spraying area. Always inspect the power cable for damage and check the security of the attached plug before connecting a hand lamp to the power supply and switching it on. Always switch off and unplug a hand lamp before changing the bulb. Score / 5 Supervisor/Instructor information: Name Signature Date Page

35 Electrical safety HA The bulbs are very vulnerable to and must not be used without this protection. 2. Electric socket outlets should be at least meter above floor level to reduce the risk of igniting spilt fuel or other flammable liquids. 3. bulbs present an extreme fire hazard if broken in the presence of flammable vapors or liquids and should not be used in repair shops. 4. If you need to use an extension lead, make sure that it is made of flexible cable not the stiffer type of domestic cabling and that it is fitted with an wire. 5. All electrical switches and fuses should be clearly so that you know which circuits and functions they control. Score / 5 Supervisor/Instructor information: Name Signature Date Page 4