This document provides information about shop safety. It defines personal protective equipment (PPE) and discusses common hazards in vehicle shops. Specific injuries are outlined along with proper lifting techniques to prevent strains. The summary also discusses fire extinguisher classifications, material safety data sheets (MSDS), high voltage safety procedures, and always referring to service manuals before working on high voltage hybrid vehicle systems.

2. After this lecture you should be able to:
 Define “Shop Safety”
 Identify P.P.E.
 Discuss hazards present in shops
 Identify the proper fire extinguisher to use
during a fire
 Understand the MSDS
 Correctly “racking” a vehicle

3. Body part % of total
injuries
Injury type Injury
mechanism
Hazards
Hand and fingers 23%
Lacerations and
open wounds
on motor vehicles Sharp objects
Back 20%
Muscle and
tendon sprains
and strains
fitting/removing
tyres
Manual tasks
Eye 10%
Metal fragments
and dust in eyes
using grinders Foreign body
Shoulder 6%
Muscle and
tendon sprains
and strains
lifting, carrying
or fitting car
parts
Manual tasks
Knee 5%
Muscle and
tendon sprains
and strains
getting out of
motor vehicles or
pushing motor
vehicles
Manual tasks
Wrist 5%
Muscle and
tendon sprains
and strains
fitting or working
on parts of motor
vehicles
Manual tasks
Neck 3%
Muscle and
tendon sprains
and strains
motor vehicle
accidents
Plant, machinery
and equipment
Abdomen and
pelvic region
3% Hernia
fitting,
removing,
lifting or
carrying motor
vehicle wheels
and tyres
Manual tasks
Ankle 3%
Muscle and
tendon sprains
and strains
falling or
tripping over
and standing on
objects on the
ground
Slips, trips and
falls
Foot and toes 3%
Contusions,
bruising and
superficial
crushing injuries
dropping car
parts
Falling objects

4. THE BACK THE KNEES
 Lift with your LEGS
Not your EGGS
 Keep things close to the
chest
 Get garden knee pad for
setting racks
 Get out of every car
like:
1. You are modest
2. You have a short skirt on

5.  Safety Glasses
 Shoes
 Nitryl gloves
 Latex Gloves
 Class 0 or above if servicing Hybrid Systems
 Polyester work clothes

7.  Safety Glasses
 Must be worn
at all times!!

8.  If you do get
something in your
eye, flush it out at
the eye wash station
 2 stations in the
shop

9.  Use only Class “0”
gloves.
 Test gloves every 6
months
 Store gloves in canvas
bag when not in use
 Use nitrile gloves while
servicing non high
voltage components
 Safety Glasses at all
times

10.  Ventilation
 Loose clothing and jewelry
 Long hair
 Clean hands
 Un-marked containers
 Asbestos fibers

11.  Put all oily rags in rag
can
 Place all oil mats in
wringer outside

13.  Class A
 Wood, Paper & Cloth
 Use Dry Chemical to blow or
cool fire
 Class B
 Gas, Oil, Grease
 Smothers fire
 Class C
 Electrical fires
 Non conducting agent to
smother fire
 Class D
 Combustible metal
 Multi Class ABC
 Used on all fires except
combustible metals

14. LIFT POINT FOUND IN
MANUAL
PLACE LIFT ARM UNDER
LIFT POINT

16. LIFT & SHAKE
LOWER TO LOCKS
RAISE AND UNLOCK TO LOWER

17.  MSDS for all shop chemicals should be on
premises
 All containers must be marked with content
 Do not cross contaminate refillable containers
 Locate MSDS on line
Brake Clean MSDS

19.  Black conduit-12 to 42 volts. This voltage level
usually does not represent a shock hazard.
 Yellow or Blue- Usually represents a 42 volt
circuit or SRS system. This level could cause an
arc to be maintained if a live circuit is broken or
deploy the air bags.
 Orange conduit- High and dangerous voltage
levels of 144 to 650 volts

22.  Always test before use
 Always use leather
protective gloves
when using
 Have tested every 6
months when in use.
 2 years if still in
sealed package

23.  CAT I - Typically a CAT I meter
is used for low voltage
measurements such as voltage
measurements of batteries. CAT
I range is roughly 1-200 volts.
 CAT II - A higher-rated meter
that would be typically used for
checking voltages at the fuse
panel in the home. Meters with
a CAT II rating are usually rated
at 300 to 600 volts.
 CAT III - The minimum-rated
meter that should be used for
hybrid vehicles. This category
is designed for voltage
measurements at the service
pole transformer. Meters with a
CAT III rating are usually rated
at 600 to 1000 volts.

26.  Every hybrid will
automatically
disconnect the high
voltage (HV) circuits
when the key is
“OFF”.
 To be sure that no
high voltage is
present, disconnect
the HV switch.
 Then to be safe,
disconnect the 12 volt
auxiliary battery.

27.  GM Parallel Hybrid
Truck (PHT)
 Just 42 volts (three
Valve-Regulated
Lead Acid (VRLA)-
Absorbed Glass Mat
(AGM) 12 Volt
batteries in series)

28.  Be sure that the
“Ready” light is out
 Remove the HEV
20A fuse from the
engine compartment
fuse panel. Wait 10
minutes.
 Remove the HV
service plug

30.  Whenever the high voltage system is being
accessed, the following MUST be done:
 Set up cones around the vehicle.
 A fiberglass ten-foot long hook must be available if
needed to grab a person who may be electrocuted.
 A face shield must be worn.
 High-voltage Linesman’s gloves must be worn.

36.  Regardless of make and model
 ALWAYS REFER TO SERVICE MANUAL
BEFORE SERVICING HIGH VOLTAGE
SYSTEMS!
 Never work on HV without proper safety
equipment!