Shop rules to go by.

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!