9.1: Auto Lab
Reflection: Auto Safety
One of our first activities and responsibilities as adults is learning the safe use and operation of a car. Cars on the roads are expected to be safe and in good condition. While the requirements for motor vehicle safety fall under the Department of Transportation and Highway Safety there are often many workers on the 'clock' traveling on our highways at all times of the day. OSHA requires motor vehicles as transportation and equipment for conducting work related activities to be safe. Automotive shops operated commercially and as part of a company's business operations serve an important safety function, however, those same places we rely on to keep our vehicles in good working order can be very hazardous for auto technicians.
Take a moment to reflect on just one of the automotive shop hazards discussed below and identify a walking-working surfaces standard that would complement a safety rule and control the associated hazard. Using the hierarchy of controls identify what type of control the standard represents. Elimination, substitution, engineering, work practice?
Automotive Shop Hazards
Every year, thousands of technicians are accidentally injured or killed on the job. Most of these accidents resulted from a broken safety rule. The injured persons learned to respect safety rules the hard way-by experiencing a painful injury. You must learn to respect safety rules the easy way-by studying and following the safety rules given in this section. While working, constantly think of safety. Look for unsafe work habits, unsafe equipment, and other potentials for accidents.
Some areas in the automotive repair shop are more dangerous than others. Areas where dangerous equipment is used or toxic chemicals are stored are often identified by brightly colored floor markings or signs to alert employees to the potential hazards. When working in these marked safety areas, take extra precautions to prevent injury.
Evacuation routes shall be posted in prominent areas throughout the shop. These routes show you how to quickly exit the building in case of a fire, gas leak, or other emergency. Always study the evacuation routes and be aware of your location in relation to these routes whenever you are working in the shop. Being able to quickly exit the building during an emergency could save your life.
When working in an auto shop, you must always remember that you are surrounded by other technicians. This makes it even more important that you concentrate on safety to prevent injury to yourself and to others in the shop.
Types of Accidents
Basically, you should be aware of and try to prevent six kinds of accidents:
- Fires
- Explosions
- Asphyxiation (Airborne Poisons)
- Chemical Burns
- Electric Shock
- Physical Injuries
If an accident or injury occurs in the shop, notify your instructor immediately.
Fires
Fires are terrible accidents capable of causing severe injury and permanent scar tissue. Therefore, every precaution must be taken to prevent fires in the automotive shop. There are numerous combustible substances (gasoline, oily rags, paints, thinners) found in an auto shop. Gasoline is by far the most dangerous and underestimated flammable substance in an auto shop. Gasoline has astonishing potential for causing a tremendous fire. Just a cupful of gasoline can instantly engulf a car in flames.
A few gasoline safety rules include:
- Store gasoline and other flammable substances in approved, sealed containers.
- Never use gasoline as a cleaning solvent.
- When disconnecting a vehicle's fuel line or hose, wrap a shop rag around the fitting to keep fuel from squirting or leaking.
- Wipe up gasoline spills immediately. Do not place oil absorbent ( oil-dry) on gasoline because the absorbent will become highly flammable.
- Keep any source of heat away from open or exposed fuel system parts.
- Disconnect the battery or HV battery pack before working on a fuel system.
Oily rags can also start fires. Soiled rags should be stored in an approved safety can. Paints, thinners, and other combustible materials should be stored in a fire cabinet. Also, never set flammable substances near a source of sparks (grinder), flames (welder or water heater), or heat (furnace, for example).
Electrical fires can result when a "hot wire" (wire carrying current to component) touches ground (vehicle frame or body). The wire can heat up, melt the insulation, and burn. Then, other wires can do the same. Dozens of wires could burn up in a matter of seconds. To prevent electrical fires, always disconnect the battery when told to do so in a service manual. If possible, keep the battery disconnected during repairs.
It you have been trained and authorized to use a fire extinguisher locate the fire extinguishers in your shop and use for an incipient stage fire only should one occur.
Always use the recommended type of extinguisher. Using the wrong extinguisher can actually cause the flames to spread. Multipurpose fire extinguishers can be used for a variety of fires. The most common type of multipurpose extinguisher is an A, B, C, dry-chemical fire extinguisher. To use a fire extinguisher, use the PASS technique,a pull the safety pin from the handle. Aim the nozzle at the base of the flames and squeeze the extinguisher handle while sweeping from left to right
Figure \(\PageIndex{1}\): Fire Safety-Extinguisher and fire classification. (Source; Greg Ling-Long Beach City College)
Explosions
An explosion is the rapid, almost instant, combustion of a material that causes a powerful shock wave to travel through the shop. Several types of explosions are possible in an auto repair facility. You should be aware of these sources of sudden death and injury. Hydrogen gas can surround the top of a car battery that is being charged or discharged (used). This gas is highly explosive. The slightest spark or flame can ignite the hydrogen gas, causing the battery to explode. Battery acid and pieces of the battery case can blow into your eyes and face. Blindness, facial cuts, acid burns, and scars can result. Always wear eye and face protection when working around a battery.
Fuel tanks, even seemingly empty ones, can explode. A drained fuel tank can still contain fuel gum and varnish. When this gum is heated and melts, it can emit vapors that may ignite. Keep sparks and heat away from fuel tanks. When a fuel tank explodes, one side will usually blow out. Then, the tank will shoot across the shop as if shot out of a cannon. You or other workers could be killed or seriously injured.
Asphyxiation
Asphyxiation is caused by breathing toxic or poisonous substances. Mild cases of asphyxiation will cause dizziness, headaches, and vomiting. Severe asphyxiation can cause death. The most common cause of asphyxiation in an auto shop is the exhaust gases produced by an automobile engine. Exhaust gases are poison. If a vehicle must be operated in an enclosed shop, connect the vehicle's tailpipe to the shop's exhaust ventilation system. Also, make sure the exhaust ventilation system is turned on. If a shop exhaust system is not available use large portable fans to push air outdoors through garage doors. As discussed in related chapters, other shop substances are harmful if inhaled. A few of these harmful substances include asbestos (brake lining dust, clutch disc dust), parts cleaners, and paint spray. Wear appropriate PPE when handling these parts or materials.
Respirators (filter masks) should be worn when working around any airborne impurities. Dust masks are made of treated paper and will only stop large particles from entering your body. Cartridge respirators provide good respiratory protection when potentially hazardous fumes are present in the shop. An air-supplied respirator must be worn when catalyzed paint products are applied in the shop.
Chemical Burns
Solvents (parts cleaners), battery acid, and various other corrosive shop substances can cause chemical burns to the skin. Always read the directions on all chemical containers. Also, be sure to wear proper protective gear when handling solvents and other caustic materials. Throttle body cleaner (decarbonizing type), for example, is very powerful and can severely burn your skin in a matter of seconds. Wear rubber gloves and a full face shield when using a decarbonizing throttle body cleaner. If a skin or eye burn occurs, follow label directions.
Electric Shock
Electric shock is a result of electric current passing through parts of your body, causing injury or death. It can occur when using improperly grounded electric power tools. Never use an electric tool unless it has a functional ground prong (third, round prong on plug socket). This prevents current from accidentally passing through your body. Also, never use an electric tool on a wet shop floor.
Hybrid Safety
Hybrid vehicles use a high-voltage motor/generator and an HV battery pack that operates on approximately 300-600 volts. This is enough electrical energy to cause serious injury or even electrocution! Voltage levels and hybrid service procedures vary. Therefore, it is important to follow the vehicle manufacturer's instructions and safety rules when working on a specific make and model hybrid. Always wear rubber electrician's gloves (rated for 1000 volts) when working on a high-voltage hybrid drive train system. The thick rubber gloves will prevent electric shock if you accidentally touch a conductor carrying high voltage and current. You must also use fully insulated tools to service the high-power cable connections on the battery. Most hybrids have a main power cutoff switch, or high-voltage disconnect, near the output cables of the battery pack. This switch allows you to electrically disconnect the battery pack from the rest of the hybrid drive train system. It should be turned to the off or disabled position before servicing a hybrid drive train system.
Physical Injury
Physical injuries such as cuts, broken bones, strained backs can result from many situations in an auto shop. As a technician, you must evaluate every repair technique. Decide whether a particular operation is safe and take action as required. For instance, if you are pulling on a hand wrench as hard as you can and the bolt will not turn, stop! Find another wrench that is larger. A larger tool has more leverage and is, therefore, safer. This approach will help prevent injuries and improve your mechanical abilities.
Flash Cards - Key Terms and Definitions
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Video - Auto Shop Safety
Automotive Skills Center Intro and Safety 2
Automotive Shop Safety
Standard Mapping - Identify Overlapping Standards for Automotive Safety
Working in the automotive shop is a hazardous environment which requires safety to avoid injury or possible death. As a technician, you will be working with tools and equipment to service and repair vehicles. In this activity you will map automotive safety standards to specific safety warnings and procedures for working in the automotive shop.
| General Industry Stardard Subpart | Section | Shop Safety Warning, Rule, Procedure, Hazard |
|---|---|---|
| 1910 Subpart E - Exit Routes and Emergency Planning | 1910.34 - Coverage and definitions | |
| 1910 Subpart G - Occupational Health and Environmental Control | 1910.94 - Ventilation | |
| 1910 Subpart H - Hazardous Materials | 1910.106 - Flammable liquids | |
| 1910 Subpart I - Personal Protective Equipment | 1910.132 - General requirements | |
| 1910 Subpart I - Personal Protective Equipment | 1910.133 - Eye and face protection | |
| 1910 Subpart I - Personal Protective Equipment | 1910.134 - Respiratory Protection | |
| 1910 Subpart K - Medical and First Aid | 1910.151 - Medical services and first aid | |
| 1910 Subpart L - Fire Protection | 1910.157 - Portable fire extinguishers | |
| 1910 Subpart L - Fire Protection | 1910.165 - Employee alarm systems | |
| 1910 Subpart M - Compressed Gas and Compressed Air Equipment | 1910.169 - Air receivers | |
| 1910 Subpart N - Materials Handling and Storage | 1910.179 - Overhead and gantry cranes | |
| 1910 Subpart O - Machinery and Machine Guarding | 1910.212 - General requirements for all machines | |
| 1910 Subpart O - Machinery and Machine Guarding | 1910.217 - Mechanical power presses | |
| 1910 Subpart P - Hand and Portable Powered Tools and Other Hand-Held Equipment | 1910.242 - Hand and portable powered tools and equipment, general | |
| 1910 Subpart S - Electrical | 1910.304 - Wiring design and protection |
Case Study – Fatality
Discuss in your group the specifics of the case below. The details are summarized. View the figures in the report showing the layout of the shop, the vehicle, and employee workstation. Discuss in your groups how you would have prevented this incident. Consider creating a JHA to support your case. Next given the following from the incident report:
Recommendation No. 2: All duties and other tasks not involving the driver of the vehicle, should be performed in an area away from or barricaded from contact with vehicles being serviced.
Are there existing standards that mitigate or are a work around for poor shop design? What are they and how would you implement?
Kentucky Fatality Assessment and Control Evaluation (FACE) Program
Release Date: June 30, 2014
Subject: Auto Technician Mistakes Handicapped-Accessible Accelerator
Pedal for Brake Pedal and Fatally Pins Co-Worker
Summary
Monday, January 06, 2014, the Kentucky Fatality Assessment and Control Evaluation program was notified by a local news channel of a fatality at a dealership involving a vehicle and an employee. The local news reported that the employee was struck from behind while sitting at his desk in the bay area, with his back to the service area, where a technician attempted to idle a vehicle to proceed with an oil change. The technician accidently mistook the handicapped accelerator pedal for the brake pedal and the vehicle traveled into the desk area where the victim was sitting. The technician desperately tried to veer to the right when he realized what was happening but was unable to avoid striking the chair where the victim was sitting and shoved the victim into the desk and wall.
Investigation Details
Monday, January 6, 2014, a 50-year-old Master Technician and married father spoke to another technician about work that needed to be done to a 2009 Lincoln MKX that was accessible for a handicapped driver with a left-foot accelerator made for people who have lost the ability to use their right foot. The left foot gas pedal was purchased from Mobility Products & Design and was model number 3545. This model type is easily removable. To remove the left-foot accelerator you lift the key ring on the LFGP (left foot gas pedal) assembly and while lifting and holding the key ring up, slide the lockout base to the left. When the assembly begins to move, release the key ring and continue to slide the assembly left until it can be lifted out of the base. The instructions are easy to follow and should be placed on the dash where other operators are aware of the installation of handicapped equipment. Mobility Products and Design includes a sticker with their products to be installed on the dash board for safety purposes. The sticker was not on the dash as per instructions of Mobility Products and Design.
After agreeing on the work that needed to be completed, the victim moved to his desk area in front of the bay area where the vehicle was going to be serviced. The Master Technician sat at his desk with his back towards the service area. The technician started the vehicle and while idling, he engaged what he thought was the brake. However, it was the handicapped equipped accelerator and it caused the vehicle to travel forward striking the chair of the victim and pinning him between the desk and the vehicle.
Interviews with the employees discovered there was a prior handicapped vehicle that came in for service and the handicapped equipment was removed prior to the technician’s operation of the vehicle. However, this time, the handicapped equipment was not removed even though the technician was not trained to operate handicapped equipment. It is unknown why the handicapped equipment was not removed and a warning sticker was not on the dash board of the vehicle.
Cause of Death
The cause of death was multiple blunt force injuries from being pinned between the car and the desk and wall.