Automotive Shop TOOLS + EQUIPMENT SAFETY

An automotive technician must adhere to the following shop safety guidelines when using all tools and equipment.

Hand Tool Safety

Careless use of simple hand tools such as wrenches, screwdrivers, and hammers causes many shop accidents that could be prevented. Keep in mind the following tips when using hand tools:

• Keep all hand tools grease-free. Oily tools can slip out of your hand, causing broken fingers or at least cut or skinned knuckles.
• Inspect your tools for cracks, broken parts, or other dangerous conditions before you use them.
• Hand tools should only be used for the purpose they were designed for. Use the right tool for the job.
• Make sure the tool is of professional quality.
• Never use broken or damaged tools.
• When using a wrench, always pull it, not push it, toward you.
• Always use the correct size of wrench.
• Use a box-end or socket wrench whenever possible.
• Don’t use deep-well sockets when a regular size socket will work. The longer socket develops more twist torque and tends to slip off the fastener.
• Use an adjustable wrench only when it’s absolutely necessary; pull the wrench so that the force of the pull is on the nonadjustable jaw.
• When using an air impact wrench, always use impact sockets.
• Never use wrenches or sockets that have cracks or breaks.
• Never use a wrench or pliers as a hammer.
• Never use pliers to loosen or tighten a nut; use the correct wrench.
• Always be sure to strike an object with the full face of the hammerhead.
• Always wear safety glasses when using a hammer and/or chisel.
• Never strike two hammer heads together.
• Never use screwdrivers as chisels.
• Be careful when using sharp or pointed tools.
• Don’t place sharp tools or other sharp objects into your pockets.
• If a tool is supposed to be sharp, make sure it’s sharp. Dull tools can be more dangerous than sharp tools.
• Use knives, chisels, and scrapers in a motion that will keep the point or blade moving away from your body.
• Always hand a pointed or sharp tool to someone else with the handle toward the person to whom you are handing the tool.

Power Tool Safety:

CAUTION! Carelessness or mishandling of power tools can cause serious injury. Make sure you know how to operate a tool before using it.

Power tools are operated by an outside power source, such as electricity, compressed air, or hydraulic pressure. Always respect the tool and its power source.

Carelessness can result in serious injury. Also, always wear safety glasses when using power tools. Never try to use a tool beyond its stated capacity.

Electrical Tools--When using an electrically powered tool, make sure it’s properly grounded. Check the wiring for insulation cracks, as well as bare wires, before using it. Also, when using electrical power tools, never stand on a wet or damp floor. Before plugging in any electric tool, make sure its switch is in the off position. When you are finished using the tool, turn it off and unplug it. Never leave a running power tool unattended.

When using power equipment on a small part, never hold the part in your hand. Always mount the part in a bench vise or use vise grip pliers.

When using a bench or floor grinding wheel, check the machine and the grinding wheels for signs of damage before using them. If the wheels are dam aged, they should be replaced before using the machine. Make sure the speed rating of the replacement wheels match the speed of the machine. Be sure to place all safety guards in position. A safety guard is a protective cover over a moving part.

Although the safety guards are designed to prevent injury, you should still wear safety glasses and/or a face shield while using the machine. Make sure there are no people or parts around the machine before starting it. Keep your hands and clothing away from the moving parts. Maintain a balanced stance while using the machine.

Compressed Air Tools--Tools that use compressed air are called pneumatic tools. Compressed air is used to inflate tires, apply paint, and drive tools, such as air ratchets and impact wrenches. Pneumatic tools must always be operated at the pressure recommended by the manufacturer. Before using a pneumatic tool, check all hose connections for leaks. Also check for air line damage.

When using an air nozzle, wear safety glasses and/ or a face shield. Particles of dirt and pieces of metal, blown by the high-pressure air, can penetrate your skin or get into your eyes. Always hold an air nozzle or air control device securely when starting or shutting off the compressed air. A loose nozzle can whip suddenly and cause serious injury. Never point an air nozzle at anyone. Never use compressed air to blow dirt from your clothes or hair. Never use compressed air to clean the floor or workbench. Never spin bearings with compressed air. If the bearing is damaged, one of the steel balls or rollers might fly out and cause serious injury.

+++ A bench grinder with its safety shields in place.

+++ Typical lifting points: The correct ones for a vehicle are given in the service manual for that vehicle. Drive-on lift Frame engaging lift Two-post suspension lift; Don’t lift or support on track bar; Drive-on lift; Frame engaging lift; Two-post suspension lift

Lift Safety: Always be careful when raising a vehicle on a lift or a hoist. Adapters and hoist plates must be positioned correctly on twin post- and rail-type lifts to prevent damage to the underbody of the vehicle.

There are specific lift points. These points allow the weight of the vehicle to be evenly supported by the adapters or hoist plates. The correct lift points can be found in the vehicle's service manual. +++ - typical locations for unibody and frame cars.

These diagrams are for illustration only. Always follow the manufacturer's instructions. Before operating any lift or hoist, you should already have been trained on the proper use of the lift. Always follow the recommended instructions for operating a particular lift.

Once you feel the lift supports are properly positioned under the vehicle, raise the lift until the sup ports contact the vehicle. Then, check the supports to make sure they are in full contact with the vehicle.

Shake the vehicle to make sure it’s securely balanced on the lift, then raise the lift to the desired working height.

! WARNING! Before working under a car, make sure the lift's locking device is engaged.

The Automotive Lift Institute (ALI) is an association concerned with the design, construction, installation, operation, maintenance, and repair of automotive lifts. Their primary concern is safety.

Every lift approved by ALI has the label shown. It’s a good idea to read through the safety tips included on that label before using a lift.

+++Automotive lift safety tips.

Jack and Jack Stand Safety: A vehicle can be raised off the ground by a hydraulic jack. A handle on the jack is moved up and down to raise part of a vehicle and a valve is turned to release the hydraulic pressure in the jack to lower the part. At the end of the jack is a lifting pad.

The pad must be positioned under an area of the vehicle's frame or at one of the manufacturer's recommended lift points. Never place the pad under the floorpan or under steering and suspension components, because they can easily be damaged by the weight of the vehicle. Always position the jack so that the wheels of the vehicle can roll as the vehicle is being raised.

! WARNING! Never use a lift or jack to move something heavier than it’s designed for. Always check the rating before using a lift or jack. If a jack is rated for 2 tons, don’t attempt to use it for a job that requires a 5-ton jack. It’s dangerous for you and the vehicle.

Safety stands, also called jack stands, are supports of various heights that sit on the floor.

They are placed under a sturdy chassis member, such as the frame or axle housing, to support the vehicle.

Once the safety stands are in position, the hydraulic pressure in the jack should be slowly released until the weight of the vehicle is on the stands. Like jacks, jack stands also have a capacity rating. Always use a jack stand of the correct rating.

Never move under a vehicle when it’s supported by only a hydraulic jack. Rest the vehicle on the safety stands before moving under the vehicle.

The jack should be removed after the jack stands are set in place. This eliminates a hazard, such as a jack handle sticking out into a walkway. A jack handle that is bumped or kicked can cause a tripping accident or cause the vehicle to fall.

Chain Hoist and Crane Safety:

Heavy parts of the automobile, such as engines, are removed by using chain hoists or cranes. Another term for a chain hoist is chain fall.

Cranes often are called cherry pickers.

To prevent serious injury, chain hoists and cranes must be properly attached to the parts being lifted.

Always use bolts with enough strength to support the object being lifted. After you have attached the lifting chain or cable to the part that is being removed, have your instructor check it. Place the chain hoist or crane directly over the assembly. Then, attach the lifting chain or cable to the hoist.

+++ Jack stands should be used to support the vehicle after it has been raised by a jack.

+++A heavy-duty engine hoist.

+++ A solvent-based parts washer.

+++ Typical hydraulic jack.

Cleaning Equipment Safety:

Parts cleaning is a necessary step in most repair procedures. Cleaning automotive parts can be divided into three basic categories.

Chemical cleaning relies primarily on some type of chemical action to remove dirt, grease, scale, paint, or rust. A combination of heat, agitation, mechanical scrubbing, or washing may be used to help remove dirt. Chemical cleaning equipment includes small parts washers, hot/cold tanks, pres sure washers, spray washers, and salt baths.

Thermal cleaning relies on heat, which bakes off or oxidizes the dirt. Thermal cleaning leaves an ash residue on the surface that must be removed by an additional cleaning process, such as airless shot blasting or spray washing.

Abrasive cleaning relies on physical abrasion to clean the surface. This includes everything from a wire brush to glass bead blasting, airless steel shot blasting, abrasive tumbling, and vibratory cleaning.

Chemical in-tank solution sonic cleaning might also be included here because it relies on the scrubbing action of ultrasonic sound waves to loosen surface contaminants.

Vehicle Operation: When a customer brings a vehicle in for service, certain driving rules should be followed to ensure your safety and the safety of those working around you.

For example, before moving a car into the shop, buckle your seat belt. Make sure no one is near, the way is clear, and there are no tools or parts under the car before you start the engine.

Check the brakes before putting the vehicle in gear. Then, drive slowly and carefully in and around the shop.

When road testing the car, obey all traffic laws.

Drive only as far as is necessary to check the automobile and verify the customer's complaint. Never make excessively quick starts, turn corners too quickly, or drive faster than conditions allow.

If the engine must be kept running while you are working on the car, block the wheels to prevent the vehicle from moving. Place the transmission in park for automatic transmissions or in neutral for manual transmissions. Set the parking (emergency) brake. Never stand directly in front of or behind a running vehicle.

When parking a vehicle in the shop, always roll the windows down. This allows for access if the doors accidentally lock.

Venting the Engine's Exhaust

Whenever you need to have the engine running for diagnosis or service, the engine's exhaust must be vented to the outside. Car bon monoxide (CO) is present in the exhaust. CO is an odorless, tasteless, and colorless deadly gas. Inhaling CO can cause brain damage and, in severe cases, death. Early symptoms of CO poisoning include headaches, nausea, and fatigue.

Most shops have an exhaust ventilation system; always use it. These systems collect the engine's exhaust and release it to the outside air.

Before running an engine in the shop, connect a hose from the vehicle's tailpipe to the intake for the vent system. Make sure the vent system is turned on before running the engine. If the work area does not have an exhaust venting system, use a hose to direct the exhaust out of the building, then disconnect the positive cable.

+++When running an engine in a shop; make sure the vehicle's exhaust is connected to the shop's exhaust ventilation system.

+++ Before doing any electrical work or working around the battery, disconnect the negative lead of the battery.

Electrical Safety: Much of your work on an automobile will be around or with the vehicle's electrical system. To prevent personal injury or damage to the vehicle, you should always take the necessary precautions before working. When possible, you should disconnect the vehicle's battery before disconnecting any electrical wire or component. This prevents the possibility of a fire or electrical shock. It also eliminates the possibility of an accidental short, which can ruin the car's electrical system. Disconnect the negative or ground cable first.

Because electrical circuits require a ground to be complete, by removing the ground cable you eliminate the possibility of a circuit accidentally becoming completed. When reconnecting the battery, connect the positive cable first, then the negative.

Also, remove wristwatches and rings before servicing any part of the electrical system. This helps prevent the possibility of electrical arcing and burns.

When disconnecting electrical connectors, don’t pull on the wires. When reconnecting the connectors, make sure they are securely connected.

Battery Precautions:

Because the vehicle's electrical power is stored in a battery or battery pack, special handling precautions must be followed when working with or near batteries. Hybrid and other electric vehicles have very high voltages; therefore, special precautions apply to these vehicles and are given following the general precautions for batteries.

¦ Make sure you are wearing safety glasses (preferably a face shield) and protective clothing when working around and with batteries.

¦ Keep all flames, sparks, and excessive heat away from the battery at all times, especially when it’s being charged.

¦ Never smoke near the top of a battery and never use a lighter or match as a flashlight.

¦ Never lay metal tools or other objects on the battery because a short circuit across the terminals can result.

¦ All batteries have an electrolyte, which is very corrosive. It can cause severe injuries if it comes in contact with your skin or eye. If electrolyte gets on you, immediately wash with baking soda and water. If the acid gets in your eyes, immediately flush them with cool water for a minimum of 15 minutes and get immediate medical attention.

¦ Lead-acid batteries use sulfuric acid as the electrolyte. Sulfuric acid is poisonous, is highly corrosive, and produces gases that can explode in high heat.

¦ Acid from the battery damages a vehicle's paint and metal surfaces and harms shop equipment. Neutralize any electrolyte spills during servicing.

¦ The most dangerous battery is one that has been overcharged. It’s hot and has been, or still may be, producing large amounts of hydrogen. Allow the battery to cool before working with or around it. Also never use or charge a battery that has frozen electrolyte.

¦ Always use a battery carrier or lifting strap to make moving and handling batteries easier and safer.

¦ Always charge a battery in well-ventilated areas.

¦ Never connect or disconnect charger leads when the charger is turned on. This generates a dangerous spark.

¦ Never recharge the battery when the system is on.

¦ Turn off all accessories before charging the battery and correct any parasitic drain problems.

¦ Make sure the charger's power switch is off when you are connecting or disconnecting the charger cables to the battery.

¦ Always double-check the polarity of the battery charger's connections before turning the charger on. Incorrect polarity can damage the battery or cause it to explode.

¦ Never attempt to use a charger as a boost to start the engine.

High-Voltage Systems

Electric drive vehicles (battery-operated, hybrid, and fuel cell electric vehicles) have high-voltage electrical systems (from 42 volts to 650 volts). These high voltages can kill you! Fortunately, most high-voltage circuits are identifiable by size and color. The cables have thicker insulation and are typically colored orange. The connectors are also colored orange. On some vehicles, the high-voltage cables are enclosed in an orange shielding or casing; again the orange indicates high voltage. In addition, the high-voltage battery pack and most high-voltage components have "High Voltage" caution labels. Be careful not to touch these wires and parts. There are other safety precautions that should always be adhered to when working on an electric drive vehicle:

+++ The high-voltage cables on this Civic hybrid are colored orange and are enclosed in orange casing.

¦ Always adhere to the safety guidelines given by the vehicle's manufacturer.

¦ Obtain the necessary training before working on these vehicles.

¦ Be sure to perform each repair operation correctly.

¦ Disable or disconnect the high-voltage system before performing services to those systems. Do this according to the procedures given by the manufacturer.

¦ Any time the engine is running in a hybrid vehicle, the generator is producing high-voltage. Take care to prevent being shocked.

¦ Before doing any service to an electric drive vehicle, make sure the power to the electric motor is disconnected or disabled.

¦ Systems may have a high-voltage capacitor that must be discharged after the high-voltage system has been isolated. Make sure to wait the prescribed amount of time (normally about 10 minutes) before working on or around the high-voltage system.

¦ After removing a high-voltage cable, cover the terminal with vinyl electrical tape.

¦ Always use insulated tools.

¦ Use only the tools and test equipment specified by the manufacturer and follow the test procedures defined by the equipment manufacturer.

¦ Alert other technicians that you are working on the high-voltage systems with a warning sign such as "High-voltage work: Don’t touch."

¦ Always follow the instructions given by the manufacturer for removing high-voltage battery packs.

¦ Wear insulating gloves, commonly called "line man's gloves," when working on or around the high-voltage system. Make sure they have no tears, holes, or cracks and that they are dry. The integrity of the gloves should be checked before using them.

¦ Always install the correct type of circuit protection device into a high-voltage circuit.

¦ Many electric motors have a strong permanent magnet in them; don’t handle these parts if you have a pacemaker.

¦ When an electric drive vehicle needs to be towed into the shop for repairs, make sure it’s not towed on its drive wheels. Doing this will drive the generator(s), which can overcharge the batteries and cause them to explode. Always tow these vehicles with the drive wheels off the ground or move them on a flat bed.

Rotating Pulleys and Belts:

Be very careful around belts, pulleys, wheels, chains, or any other rotating mechanism. When working around an engine's drive belts and pulleys, make sure your hands, shop towels, or loose clothing don’t come in contact with the moving parts. Hands and fingers can be quickly pulled into a revolving belt or pulley even at engine idle speeds.

!WARNING! Be careful when working around electric engine cooling fans. These fans are controlled by a thermostat and can come on without warning, even when the engine is not running.

Whenever you must work around these fans, disconnect the electrical connector to the fan motor before reaching into the area around the fan.

Next: AUTOMOTIVE WORK AREA SAFETY

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