Shop Safety

and Operations
Objectives
After reading t h i s chapter, you should be able t o
Explain the special notations in the text labeled SHOP TALK, CAUTION, and WARNING.
ldentify the basic procedures for lifting and carrying heavy objects and materials.
Explain the role of personal protective equipment in providing for the technician's personal safety.
Describe other personal safety warnings as they relate t o work area safety.
ldentify the different classifications of fires and the proper procedures for extinguishing each.
Operate the various types of fire extinguisher based o n the type of extinguishing agent each uses.
ldentify the four types of hazardous wastes and their respective hazards t o people's health and to the
environment.
Explain laws regulating hazardous materials, including both the "Right-To-l<now" and employee/
employer obligations.
ldentify which types of records are required by law to be kept o n trucks involved in interstate
shipping.
Discuss the ever-increasing role of computers in the administration, accounting, and record-keeping
functions of heavy-duty truck operations.

I<ey Term List parts requisition

Resource Conservation and Recovery Act (RCRA)
corrosive
reactive
dispatch sheet
Right-To-Know Law
Federal Motor Vehicle Safety Standard (FMVSS)
solvents
flammable
spontaneous combustion
hazardous materials
toxic
Occupational Safety and Health Administration
Vehicle Identification Number (VIIV)
(OSHA)

Shop safety should be the utmost concern for all
technicians, forepersons, managers, and shop and
fleet owners. Safety rules and regulations must be
followed to prevent injuries to yourself, to fellow
employees, and to the public. Carelessness and the
l a c k of g o o d safety h a b i t s c a u s e a c c i d e n t s .
Accidents have a far-reaching effect, not only on the
victim, but also on the victim's family and society in
general. More important, accidents can cause seri-
ous injury, temporary or permanent, or even death.
Therefore, it is the obligation of all shop employees
and the employer t o develop a safety program to
protect the health and welfare of those involved.
Throughout this book, the text contains special
notations labeled SHOP TALK, CAUTION, and
WARNING. Each one has a specific purpose. SHOP
18 Chapter Two -

TALK &ves added ;r~format;or~that w;ll help the

technician t o complete a particular procedure or
make a task easier. CAUTION is given to prevent the
technician from making an error that could damage
the vehicle. WARNING reminds the technician to be
especially careful of those areas where carelessness
can cause personal injury. The following text con-
tains some general warnings that should be followed
when working in a truck service facility.

1 2.1 PERSONAL SAFETY

Personal safety refers to the steps you take to pro-

tect yourself from injury. It involves wearing protec-
tive gear, dressing for safety, and handling tools and
equipment correctly.
B
EYE PROTECTION
The eyes are sensitive to dust, vapors, metal shavings,
and liquids. Grinding and machining generates tiny
particles that are thrown off at high speeds. Gases
and liquids escaping a broken hose or fuel line fitting
can be sprayed great distances under great force. Dirt
and sharp bits of corroded metal can easily fall into
your eyes when working under a vehicle.
Eye protection should be worn whenever you are
exposed to these risks. It is good practice to wear
-
safetv, glasses at all times in the shop. There are
many types of eye protection available ( ~ i ~ u 2-1).
re FIGURE 2-1 (A) Safety glasses; [B) splash goggles;
The lenses must be made of safety glass and must and (C) face shield. (Courtesy of Goodson Shop
offer some sort of side protection. Regular prescrip- Supplies)
tion glasses will not suffice. Select safety glasses
that fit well and feel comfortable. Make a habit of
~uttin - a
eve
, , protection on and leaving
- it on.
If chemicals such as battery acid, fuel, or solvents
enter your eyes, flush them continuously with clean
water until you can get medical help.

CLOTHING
Clothtng should be durable, comfortable, and well-
fitted. Loose, baggy clothing can get caught on mov-
ing parts and machinery. Neck ties should not be
worn. Many service technicians prefer to wear cover-
alls or shop coats to protect their personal clothing
(Figure 2-2). Cut-offs and short pants are not satis-
factory for shop work.

SHOES
Service work involves the handling of many heavy
objects that could be accidentally dropped onto feet FIGURE 2-2 Shop coats can be worn to protect
and toes. Always wear steel-toe safety shoes with clothing.

nonslip soles. Athletic shoes, street shoes, and san-
dals are inappropriate in the shop.
GLOVES
Good hand protection is often overlooked. A scrape,
cut, or burn can seriously impair your ability to work
for many days. A well-fitted pair of heavy work
gloves should be worn during operations such as
grinding and welding, or when handling caustic
chemicals or high-temperature components.
EAR PROTECTION
Exposure to very high noise levels for extended peri-
ods of time can lead to ear damage and hearing loss.
Air wrenches, engines run on dynamometers, and
vehicles running in enclosed areas can all generate
annoying and harmful levels of noise. Simple ear
plugs or earphone-type protectors (Figure 2-3)
should be worn in constantly noisy environments.
HAIR A N D JEWELRY
Long hair and hanging jewelry can create the same
type of hazard as loose-fitting clothing. They can
become caught on moving engine parts and machin-
ery. Tie up long hair securely behind your head or
cover it with a cap. Bump caps (similar to construc-
tion helmets) are recommended when working in pits
or under overhead hoists.
Remove all rings, watches, bracelets, and neck
chains. These items can easily be caught on moving
parts, causing serious injury.
LIFTING A N D CARRYING
Knowing the proper way t o lift heavy materials is
important. You should always lift and work within
your ability and seek help from others when you are
FIGURE 2-3 Typical (A] ear muffs and /BJ ear
plugs. (Courtesy of Dalloz Safety)
Shop Safety and Operations 19
not sure you can handle the size or weight of the
material or object. Even small, compact auto parts
can be surprisingly heavy or unbalanced. Always
examine the lifting task before beginning. When lift-
ing any object, follow these steps.
1. Place your feet close to the load and prop-
erly positioned for balance.
2. Keep your back and elbows as straight as
possible. Bend your knees until your hands
reach the best place for getting a strong grip
on the load (Figure 2-4).
3. If the part or component is stored in a card-
board box, be certain the box is in good
condition. Old, damp, or poorly-sealed
boxes will tear or otherwise fail. A heavy
object could tear through the side or bottom
of the container, causing injury or damage.
4. Grasp the object close to your body and lift
by straightening your legs. Use your leg
muscles, not back muscles.
5 . When changing direction of travel, do not
twist your body. Turn your whole body,
including your feet.
6. When p l a c i n g t h e o b j e c t o n a shelf or
counter, d o not bend forward. Place the
edge of the load on the surface and slide it
forward. Be careful not to pinch your fingers.
7 . When placing a load down, bend your knees
and keep your back straight. Do not bend
forward-this strains the back muscles.
8. Use blocks t o protect your fingers when
picking up or lowering heavy objects to the
floor.
POSITION BODY
OVERLOAD. a
BENT
FIGURE 2-4 Use your leg muscles, never your
back, when lifting any heavy load.
20 Chapter Two

OTHER PERSONAL
SAFETY WARNINGS
Never smoke while w o r k i n g o n any vehicle or
machine in the shop. Tilt the cab with care (Figure
2-5).
Proper conduct can help prevent accidents.
Horseplay is not fun when it sends someone to the
hospital. Such things as air nozzle fights, creeper
races, or practical jokes do not have any place in the
shop.
A welding helmet or welding goggles with the
proper shade lens must be worn when welding
(Figure 2-6). These will protect the eyes and face
from flying molten pieces of steel and harmful light
rays. Never use welding equipment unless thor-
oughly instructed in its use.
To prevent serious burns, avoid contact with hot
metal parts such as the radiator, exhaust manifold,
tail pipe, and muffler.
When working with a hydraulic press, make sure
that hydraulic pressure is applied in a safe manner. It
is generally wise to stand to the side when operating
the press. Always wear safety glasses.
Store all parts and tools properly by putting them
away neatly where people will not trip over them.
This practice not only cuts down on injuries. it also
2-6 ,A, Welding helmet and ,B,welding
reduces time wasted looking for a misplaced part or
goggler,
tool.

2.2 WORI< AREA SAFETY

It is important that the work area be kept safe. All

FIGURE 2-5 The tilting of a hood must be done
with care. Make sure there is adequate clearance in
front of the vehicle and that the area is free of peo-
ple and all objects. Do not tilt a cab with the engine
running. T~ltrngthe cab could engage the transrnis-
sion. If the engine is running, the vehicle could
move, causing an accident that could result in
personal injury or property damage.
surfaces should be kept clean, dry, and orderly. Any
oil, coolant, or grease on the floor can cause slips
that could result in serious injuries. To clean up oil,
be sure to use a commercial oil absorbent. Keep all
water off the floor. Remember, water is a conductor
of electricity. Aisles and walkways should be kept
clean and wide enough for safe clearance. Provide
for adequate work space around any machines. Also,
keep workbenches clean and orderly.
Another important safety requirement for any work
area is proper circulation of air, or ventilation. While
diesel engines produce less carbon monoxide (CO)
fumes than gasoline engines, their exhaust pipes
must be connected to an operating shop exhaust
system because of the harmful particulates they pro-
duce. Space heaters used in some shops can also
be a serious source of deadly CO and therefore must
be periodically inspected to make sure they are ade-
quately vented and do not become blocked. Proper
ventilation is very important in areas where flamma-
ble chemicals are used.
 Shop Safety and Operations 2 1

Keep a list of up-to-date emergency telephone

numbers clearly posted next to the telephone. These
numbers should include a doctor, hospital, and fire
and police departments. Also, the work area should
have a first-aid kit for treating minor injuries. Facilities
for flushing the eyes should also be in or near the
shop area.
Gasoline is a highly flammable liquid. Flammable
liquids are very easily ignited and burn very quickly.
For this reason, always keep gasoline or diesel fuel in
an approved safety can and never use it to wash
hands or tools. Oily rags should also be stored in an
approved metal container. When these oily, greasy,
or paint-soaked rags are left lying about or are
stored improperly, they are prime candidates for
spontaneous combustion; that is, fires that start by FIGURE 2-8 Store combustible materials in
themselves. approved safety cabinets. (Courtesy of the
Check to be sure that all drain covers are snugly Protectoseal Company)
in place. Open drains can cause toe, ankle, and leg
injuries.
Handle all solvents (solvents are substances that explosion. Discard or clean all empty solvent con-
dissolve other substances) w i t h care t o avoid tainers. Solvent fumes in the bottom of these con-
spillage. Keep all solvent containers closed, except tainers can start a fire or explosion. Do not light
when pouring. Extra caution should also be used matches or smoke near flammable solvents and
when moving flammable materials from bulk storage chemicals, including battery acids. Solvents and
(Figure 2-7). Otherwise, static electricity can b u ~ l d other combustible materials must be stored in
up enough to create a spark that could cause an approved and designated storage cabinets or rooms
(Figure 2-8). Storage rooms should have adequate
ventilation.
Storage of flammable material and combustible liq-
uids should never be near exits, stairways, or areas
normally used for the safe movement of people.
GROUND
T O PIPE
FIRE SAFETY
Familiarize yourself with the location and operation of
the fire-fighting equipment in the work area. Keep in
3 0 N D WlRE mind that all fires are classified in the following manner:

Class A-Fires in which the burning mater~als

PAINT OR
are ordinary combustibles, such as paper,
SOLVENT wood, cloth, or trash. Putting out this type of
DRUM SPRING CLAMP
fire requires drowning with water or foam solu-
tions containing a high percentage of water, or
PAINT O R a multipurpose dry chemical extinguisher.
SOLVENT Class B-Fires in which the burning material is
DRUM
B O N D WlRE a liquid, such as gasoline, diesel fuel, oil,
grease, or solvents. To extinguish this type of
fire requires a smothering action from foam,
carbon dioxide, or dry chemical type extin-
SAFETY
CAN guisher. Do not use water on this type of fire.
It will cause the fire to spread.
Class C--Fires in which the burning material is
"live" electrical equipment: motors, switches, gen-
FIGURE 2-7 Safe methods of transferring flammable erators, transformers, or general wiring. To extin-
materials from bull<storage. (Courtesy of DuPont Co.) guish this type of fire requires a nonconductive
22 Chapter Two

action, such as carbon cl~oxid~

Sil'ii;tll~r'i~~~~ or dvy
chemical extinguisher. Do not use water on this
type of fire.
Class D-Fires in which the burning materials
are combustible metals. Special extinguishing
agents are required to put out this type of fire.
Following are some general tips for operating the
various types of portable extinguishers based on the
type of extinguishing agent they use (Figure 2-9):
r Foam-Don't spray the stream into the burning
liquid. Allow the foam to fall lightly on the fire.
Carbon dioxide-Direct discharge as close to
fire as possible, first at the edge of the flames
and gradually forward and upward.
Soda-acid, gas cartridge-Direct stream at the
base of the flame.
Pump tank-Place foot on footrest and direct
the stream at the base of the flame.
Dry chemical-Direct at the base of the flames.
In the case of Class A fires, follow up by direct-

Typical
Class of Fire Fuel Involved Type of Extinguisher

Class A Fires

I
For Ordinary Combustibles
Put out a class A fire by lowering
i B temperature or by coating the
burrling con~bustibles.
Wood
Paper
Cloth
Rubber
Plastics
water*'
Foam*
Multipurpose dry chemical4

(green) 1 1 Rubbish 1
Upholstery
For Flammable Liquids Gasoline Foam*
Put out a class B fire by smothering Oil Carbon dioxideS
Class Fires it. Use an extinguisher that gives Grease Halogenated agent6
a blanketing, flame-interrupting Paint Standard dry chemical2
I effect; cover whole flaming liquid 1 Lighter fluid 1 Purple K dry chemical3
(red) surface. Multipurpose dry chemical4
- -

For Electrical Equipment Motors Carbon dioxides

Class

0 (blue)
Fires
Put out a class C fire by shutting off
power as quickly as possible and by
always using a nonconducting
extinguishing agent t o prevent
electric shock.
For Combustible Metals
I
Appliances
Wiring
Fuse boxes
Switchboards

Aluminum
Halogenated agent6 -
Standard dry chemjcalL
Purple K dry chemical3
Multipurpose dry chemical4

Dry powder extinguishers and

Class

x(yellow)
Fires
Put out a class D fire of metal chips,
turnings, or shavings by smothering
or coating w i t h a specially designed
extinguishing agent.
Magnesium
Potassium
Sodium
Titanium
Zirconium
agents only

'Cartridge-operated water, foam, and soda-acid types of extinguishers are no longer manufactured. These extinguishers should be removed
from service when they become due for their next hydrostatic pressure test.
Notes:
(I) Freezes in low temperatures unless treated with antifreeze solution, usually weighs over 2 0 pounds (9 kg), and is heavier than any other
extinguisher mentioned.
(2) Also called ordinary or regular dry chemical. (sodium bicarbonate)
(3) Has the greatest initial fire-stopping power of the extinguishers mentioned for class B fires. Be sure to clean residue immediately after
using the extinguisher so sprayed surfaces will not be damaged. (potassium bichbonate)
( 4 ) The only extinguishers that fight A, B, and C classes of fires. However, they should not be used on fires in liquefied fat or oil of appreciable
depth. Be sure to clean residue immediately after using the extinguisher so sprayed surfaces will not be damaged. (ammonium phosphates)
(5) Use with caution in unventilated, confined spaces.
(6) May cause injury to the operator if the extinguishing agent (a gas) or the gases produced when the agent is applied to a fire is inhaled.

F I G U R E 2-9 G u i d e to fire extinguisher selection


ing the dry chemicals at the remaining material
that is burning.
I f a fire extinguisher is used, report it to your
instructor or service manager so that it can be imme-
diately recharged.
1
2.3 SHOP TOOL SAFETY
Understanding the proper use of nonpower-driven
hand tools, portable electric power tools, pneumatic
power tools, and stationary equipment will help elim-
inate many accidents. Observe the following:
Select the proper size and type of tool for the job.
Use tools only for the purpose for which they
are designed.
Keep tools in safe working condition.
Store tools safely when not in use.
Report any breakage or malfunctions to your
instructor or service manager.
Make sure that cutting tools are properly sharp-
ened and in good condition.
Do not use tools with loose or cracked handles.
Never use tools unless you know how to oper-
ate them.
Shop tool safety depends mainly on the person
who uses the tool. Knowing what a tool is designed
to do and how to use it correctly is the key. Because
of the importance of this, Chapter 3 is devoted to
safe use of the tools used by the heavy-duty truck
service technician.
1 1
2.4 HAZARDOUS
MATERIALS
Heavy-duty truck repair work involves use of many
materials classified as hazardous by both state and fed-
eral governments. These materials include such items as
solvent and cleaners, paint and body repair products,
adhesives, acids, coolants, and refrigerant products.
Hazardous materials are those that could cause
harm to a person's well-being. Hazardous materials
can also damage and pollute land, air, or water.
There are four types of hazardous waste:
Flammable-Materials that will easily catch fire
or explode.
Corrosive-Corrosive materials are so caustic
that they can dissolve metals and burn skin and
eyes.
Shop Safety a n d Operations 23
Reactive-Reactive materials will become
unstable (burn, explode, or give off toxic
vapors) if mixed with air, water, heat, or other
materials.
Toxic-Materials that can cause illness or
death after being inhaled or contactiqg the skin.
LAWS REGULATING
HAZARDOUS MATERIALS
The Hazard Communication Regulation-commonly
called the Right-To-Know Law-was passed by the
federal government a n d is administered by
Occupational Safety and Health Administration
(OSHA). This law mandates that any company that
uses or produces hazardous chemicals or sub-
stances must inform its employees, customers, and
vendors of any potential hazards that may exist in
the workplace as a result of using the products.
Most important is that you keep yourself informed.
You are the only person who can keep yourself and
those with whom you work protected from the dan-
gers of hazardous materials. These are some of the
highlights of the Right-To-Know Law:
You have a right to know what hazards you
may face on the job.
You have a right to learn about these materials,
and how to protect yourself from them.
You cannot be fired or discriminated against for
requesting information and training on how to
handle hazardous materials.
You have the right for your doctor to receive
the same hazardous material information that
you receive.
Employee/Employer Obligations
An employer or school that uses hazardous materials
must
Provide a safe workplace.
Educate employees about the hazardous mate-
rials they will encounter while on the job (Figure
2-1 0 ) .
Recognize, understand, and use warning labels
and Material Safety Data Sheets (MSDSs)
(Workplace Hazardous Material Information
Systems-WHMISs).
Provide personal protective clothing and equip-
ment and train employees to use them properly.
You, the employee or student, must
Read the warning labels on the materials.
Follow the instructions and warnings on the
MSDS or WHMIS.
Take the time to learn to use protective equip-
ment and clothing.
24 Chapter Two --- --

Vulcan
CHEMICALS
V
MATERIAL SAFETY DATA SHEET
24 Hour Emergency Phone (316) 524-5751
D ~ v ~ s ~o o
f Vulcan
n Materials Company I P 0. Box 530390 Birmingham, AL 35253-0390
~ ~ ~ - - - -- - - - - -

I - IDENTIFICATION
--
CHEMICAL FORMULA MOLECULAR WEIGHT
S d m thidroxide Solution NaOH L0.W
TRACE NAME
&ustic SoQ, 73%, 50% and Weaker Solutions
-~ --
SYNONYMS DOT IDENTIFICAT~ON4 0 .
Liquid Caustic, Lye Solution, Caustic, Lye. SoQ Lye UN 1824

1
FNFNTII) C ~ E M C A LNAME
11- PRODUCT AND COMPONENT DATA
CAS REGISTRY WO O/o
--
(M) Approx OSHA PEL

S&wi Hydroxide 73, 50 2 rng/d

a d less Ceiling
Note: ?his Material Safety Data Sheet is also valid
f o r caustic soda solutions weaker than 50%. ?he
b o i l k g pint,vapor pressue , and -specific gravity
will be different from those l i s t e d .

* Denotes chemical su3jecl to reponlng requiremenls of Section 313 01 Title Ill o l the 1986
Superfund Arnerdmenls and Reauthortzation Act (SARA) and 40 CFR Pan 372 I

Ill - PHYSICAL DATA

- - -- - --
--- - 7 S P E C l F l C G R A V l r Y - -
50% Solution: 1 . 5 3 @ 60"F/60°F
73% - -
VAPOR DENSITY IN AIR (Atr

1 50%Solution: 293°F (145°C) 1 N/A 1

-
% VOLATILE BY VOLUNE
- - --

STABILITY I CONDITIONS TO AVOID

-
IV REACTIVITY DATA I
Mixture .with water, acid o r inconqjatible mterials can cause
I
Stable l a t t e r i n g and release of large ammts of heat ( k f e r t o Section VIII). W i l l
-.
e a c t xith scns r1~t2.l~ forming f l m m b l e hydrogen gas. -
IIUCOhiP4TIBILITY (Matevals to avold)
Cnlorirlated 3nd fluorinated h y d r o c a h n s ( i . e . chloroform, difluoroethane) , acetaldehyde, acrolein, almimn
chlorire t r i f l u o r i d e , l y d r o q u i m ~ ,m l e i c anhydride, phosphorous pentoxide a d tetrahydrofuran.

FIGURE 2-1 0 Typ~calMaterial Safety Data Sheet. (Courtesy of Vulcan Materials Company)
 Shop Safety and Operations 25

V - FIRE AND EXPLOSION HAZARD DATA

FLASHPOINT (Method used) FLAMMABLE LIMITS IN AIR

None None
EXTINGUISHING AGENTS
N/A NFPA Hazard Rat-: Health 3 ; FLarnnability 0; Reactivity 1
UNUSUAL FlRE AND EXPLOSION HAZARDS
Firefi$ters should wear s e l f - c o n a d positive pressure breathing apparatus, d avoid skin
contact. Refer to Reactivity Data, Section IV.

VI -TOXICITY AND FIRST AID

EXPOSURE LIMITS (When exposure to this product and other chemicals is concurrent, the exposure limit must be defined in the workplace.)

ACX;M: 2 mg/d Ceiling

2 mg/d Ceiling

LDLH: 250 mg/d

Effects described In this section are believed not to occur if exposures are maintained at or below appropriate TLVs.
Because of the wide variation In individual susceptibility, these exposure l~mltsmay not be applicable to ail persons and those with medical conditions listed below.
MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE
May aggravate existing skin and/or eye conditions on contact.

I*currTOXIClW Primary route@)of exposure: a lnhalat~on a Sk-in Ingestion

Inhalation: Inhalation of solution mist can cause mild irritation a t 2 mg/n?. More severe bums d
tissue damge a t the upper respiratory tract, can occur a t hi&r cmentrations. Pnemnitis can result
fran severe q s u r e s .

Skin: Major potential hazard - contact with the skin can cause severe bums with deep ulcerations.
I - with solution or mist can cause d t i p l e burns with t q m r a r y l o s s of hair a t burn s i t e . Solu-
Contact
tions of 4% may m t cause irritation a d burning for several hours, h i l e 25 to 50%solutions can cause
these effects in less than 3 minutes.

Eves: Major potential hazard - Licpid in the eye can cause severe destruction and b l ~ s s .lhese
effects can occur rapidly effecting all parts of the eye. Mist o r &st can cause irritation with high
concentrations causing destructive bums.

I Ilxzestion: Ingestion of sodim hydroxide can cause severe burning and pain in l i p s , m t h , tongue, I

Inhalation: Move person to fresh a i r . If breathing stops, adninister a r t i f i c i a l respiration. Get

rnedical attention imrediately .

I
Skin: Rerrwe contaminated clothing imrediately and wash skin thoroughly for a minimm of 15 mimtes with
large quantities of water (preferably a safety shower). Get wdical attention imrediately.
-
e : Wash eyes imrediately with large m u n t s of water (preferably eye wash fountain), lifting the
upper d lower eyelids and rotating eyeball. Continue washing for a minirnrm of 15 mimtes. Get mdical
attention inmediately .

Iwestion: I f person i s conscious, give large quantities of water to dilute caustic, Do m t i d x e

vomiting. Get medical attention irmediately. Do m t give anything by mouth t o an ~mcious prson.
26 Chapter Two .

CHRONIC TOXICITY

No h chronic effects

Carcino~enicity: No studies were identified relative to sodim hydroxide and carcinogenicity.

Sodim hydroxide i s not l i s t e d on the IARC, NI'P or OSHA carcinogen l i s t s .

- -

VII - PERSONAL PROTECTION AND CONTROLS 1

Lhere concentrations exceed or are likely to exceed 2n1&1? use a NIOSH/%HA approved hi&-efficiercy
particulate f i l t e r with full facepiece or self-contaired breathing apparatus. Follow any applicable
respirator use standards and regulations.

As necessary to rnaintain conc.entration in a i r below 2 "g/d a t a l l t i r e s .

Wear moprew, WC, or rubber gloves; WC rain s u i t ; rubber boots with pant legs over b a t s .

I Chemical goggles which are splashproof and faceshield. I

_ _ _ _ p - p p _ _ p _ _ p p

WYGENE

Avoid contact with skin and avoid b r e a t h n g mist. Do m t e a t , drink, or m k e i n work area. Wash hards
prior to eating, d r m k q , or using restroom. Any protective clothing or shoes which b e c m con-ted
with caustic should be rermved imnediately and t h o r o @ & 4 a ~ b & ~ - ~ - ~ .
OTHER CONTROL MEASURES

Safety shower and eyewash station n u t be located i n M d i a t e work area. To determiile the exposure
level(s) , monitoring should bf p e r f o m d regularly.
NOTE: Protective equipwnt and clothing should be selected, used, and m i n t a i w d according to
applicable standards and regulations. For further informtion, contact the clothing or e q u i p n t
manufacturer or the Vulcan Chemicals Technical Sellrice Departxlent. I
I
 --- Shop Safety and Operations 27

VIII - STORAGE AND HANDLING PRECAUTIONS

Follow protective controls s e t forth i n Section VII when handling this p r h t .

Store in closed, properly labeled tanks or containers. Do r n t r a v e or deface labels or tags.
When diluting with water, slowly add caustic solution t o the water. Heat w i l l be prodxed during dilution.
nil1 protective clothing, goggles and faceshield should be worn. Do r n t add water to caustic because
excessive heat f o m t i o n will cause boiling and spattering.
Contact of caustic soda cleaning solutions with food and beverage p r o d x t s ( i n e ~ l o s e dvessels or
spaces) can pr&e l e M concentrations of carbon rmmxide gas. Do m t enter confined spaces such as tanks
or p i t s without following proper entry procedures as required by 29 CFR 1910.146.

SARA T i t l e I11 Hazard Categories: h d i a t e Health.

I
-
IX SPILL, LEAK AND DISPOSAL PRACTICES
--
STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED

Cleanup personnel mt w e a r proper protective e q u i p n t (refer to Section VII). Gmpletely contain

spilled material with dikes, sardbags, e t c . , and prevent run-off into g o d or surface waters or sewers.
Recover as material as possible into containers for disposal. Remaining material may be diluted with
water and neutralized with dilute hydrcchloric acid. Neutralization products, both liquid and solid, rmst be
recovered for disposal. Reportable @amity (RQ) is lOCO lbs. Notify Natiorml Response Center (800/424-8802:
of wxontained releases to the ernirorrrent in excess of the RQ.
----
WASTE DISPOSAL METHOD

Recovered solids or liquids may be sent to a licensed reclaimr or disposed of i n a pennitted waste mula-
g m n t f a c i l i t y . C o d t federal, s t a t e , or local disposal authorities for approved procedures.

X - TRANSPORTATION

Sodium Hydroxide Solution, 8 , UN 1824, PG 11, RQ

~~~~~~~

t Corrosive, 1824, C l a s s 8
LABEL REQUIRED
- -- -- -

Corrosive, Class 8 . Label as required by O M Hazard Comnslication Standard, and any applicable s t a t e
and local regulations.
-----

Medical
- - Emergencies
Call collect 24 hours a day
for emergency toxicological
information 4151821-5338
Other Emergency information
Call 3161524-5751 (24 hours)
DATE QF PREPARATION
For any other information contact:
Vulcan Chemicals
Technical Service Department
P.O. Box 530390
Birmingham, AL 35253-0390
8001873-4898
8 AM to 5 PM Central Time
Monday Through Friday
N o v h r 1 , 1993

NOTICE: Vulcan Chern~calsbelleves that the ~nformationconta~nedon th~sMater~alSafety Data Sheet IS accurale The suggested procedures are based on experience as
of the date of publlcatlon They are not necessarily all-~ncluslvenor fully adequate In every clrcurnstance Also, the suggestions should not be confused w~thnor loilowed n
v~olat~onof appl~cablelaws, regulat~on,rules or insurance requlrernents
NO WARRANTY IS MADE, EXPRESS OR IMPLIED. OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE.
Form 3239-210
28 Chapter Two
llse common sense when working with haz-
ardous materials.
Ask the service manager if you have any ques-
tions about a hazardous material.
Personal Protection
One of the greatest concerns to personal safety is
the effect of long-term exposure to hazardous mate-
rials, particularly solvents, cleaning agents, and paint
products. The importance of this is easily seen in
concerns over asbestos. When first introduced on
the market, asbestos was widely used in brake pads,
shoes, clutches, and other automotive applications.
We now know that asbestos fibers pose a health risk
and that long-term exposure to small amounts of
asbestos can cause health problems. For this rea-
son, asbestos has gradually been phased out of the
automotive and truck parts market in favor of safer
products.
To handle hazardous materials properly, you need
to
Know what the material is.
Know the material is dangerous.
Know the correct safety equipment needed for
worklng with that material.
Know how to use the safety equipment prop-
erly (Figure 2-1 1).
Make sure that the safety equrpment fits prop-
erly and is in working order.
FIGURE 2-1 1 Wear proper safety equipment
when handling hazardous waste. (Courtesy of
DuPont Co.)
Good personal hygiene practices are important in
minimizing exposure to asbestos dust and other haz-
ardous wastes.
Do not smoke.
Wash before eating.
Shower after work.
Change to work clothes upon arrival at work,
and change from work clothes after work. Work
clothing should not be taken home.
HANDLING AND
DISPOSAL OF
HAZARDOUS WASTE
Specific laws govern the disposal of hazardous
wastes. You and your shop must be aware of how
these laws affect shop operation.
These laws include the Resource Conservation
and Recovery Act (RCRA). This law states that after
you have used hazardous materials, they must be
properly stored until an approved hazardous waste
hauler (Figure 2-12) arrives to take them to the dis-
posal site. In addition, your responsibility continlles
until the materials arrive at an approved disposal site
and are processed in accordance with the law.
When dealing with hazardous wastes
1. Consult the MSDS or WHMlS under t h e
"Waste Disposal Method" category.
2. Check with your instructor or service man-
ager for the exact method for correct storage
and disposal.
3. Follow their recommendations exactly.
FIGURE 2-1 2 Many automotive shops hire full-
service haulers for hazardous waste removal.
(Courtesy of DuPont Co.)

WARNING: The shop is ultimately responsible for
the safe disposal of hazardous wastes, even after
the waste leaves the shop. In the event of an emer-
gency hazardous waste spill, contact the National
Response Center (1-800-424-8802) immediately.
Failure to do so can result in a $10,000 fine, a year
in jail, or both.
Never, under any circumstance
Throw hazardous materials into a dumpster.
Dump waste anywhere but into a collection site
of a licensed facility.
Pour waste down drains, toilets, sinks, or floor
drains.
= Use hazardous waste to kill weeds or to keep
dust down in gravel.
2.6 S H O P RECORDS
It is the "law" that certain records must be kept by
the shop's technician if the trucks are involved in
interstate shipping. These records include the follow-
ing:
= ldentification of each vehicle including the com-
pany unit number, model, serial number, year,
and tire size.
A schedule showing the nature and due date of
the various inspections and maintenance to be
performed.
A record of the nature and date of inspections,
maintenance, and repairs made.
= Lubrication record.
Even if the trucks are not involved in interstate
commerce or local heavy-duty truck servicing opera-
tions, these records are important because
They are required by the Department of
Transportation (DOT).
= A study of parts or component failures can alert
the manager to problems or highlight compo-
nents that have performed well.
A service manager cannot develop a good pre-
ventive maintenance (PM) program without the
use of these records (see Chapter 4).
In the event of a serious accident, a vehicle
maintenance file is usually beneficial in the
defense of a lawsuit.
Shop Safety a n d Operations 29
Shop Tall<
Federal Motor Vehicle Safety Standard (FMVSS)
specifies that all vehicles in the United States be
assigned a Vehicle ldentification Number (VIN).
The VIN is located on the left frame rail over the
front axle and on the Vehicle Specification Decal
(see the drivers manual for the location of the
decal). All heavy-duty trucks are assigned a 17-
character VIN (Figure 2-13). Using a combination
of letters and numerals, the VIN codes the vehicle
make, series or type, application, chassis, cab, axle
configuration, gross vehicle weight rating (G VWR),
engine type, model year, manufacturing plant loca-
tion, and production serial number. A check digit
(ninth position) is determined by assignment of
weighted values to the other 16 characters. These
weighted values are processed through a series of
equations designed to check the validity of the VIN
and to detect VIN alteration.
W O R I < O R REPAIR O R D E R
In most shops, the work or repair is the result of col-
laboration between truck driver, service manager,
and technician. The need for a vehicle's service is
noted in the driver's pre- and post-trip report. After
studying the problem, observations are passed on to
the service manager. The service manager then turns
it over to the technician in the form of a work (or
repair) order to correct the situation (Figure 2-14).
Another form that is used in some shops that con-
cerns the technician is the parts requisition. To
order new parts, the technician writes the names of
what part(s) are needed along with the vehicle's VIN
or company's identification folder.
Parts managers or specialists (see Chapter 1)
must fill out forms to keep enough parts in stock.
When the stock gets low, new parts are ordered.
Occasionally it is necessary to order special parts.
Description
Typical identification Number 1
1 -
Decodlng Table Number' 1 1 12 3 4
- --
5A67
Chassis. Front Axle Position. Brakes
Model Series, Cab
Engine Type
Gross Vehicle Welght Rating (GVWR)
Check Dioit
Vehicle Model Year
Plant of Manufacture
Production Number
FIGURE 2-1 3 Typical VIN.
30 Chapter Two

--
- - - - - - __ REPAIR ORDER INFORMATION

I
I, Portland Freightliner, Inc.
REPAIR ORDER N O (
.

--
v v P T i i N I!'

SERIAL LC.
. .

CUSTCMER ACCOlJNT NO
..

-
DELIVERY 3ATE
D E L I V E R Y MILES

YR;MAKE'MODEL
-- --

~
--..- ----

- -- --1
--

-f
NAXlE 1 J N T UO

ADDRESS UNIT DATA i

CITY ENGINE MODEL
I
I PHCNE / E N G I N E s E W A L 10

----=
-- P 0 NO

ESTIMATE
TRAhS MCDEL

T R A N S S E R I A L UO
--
-
I
-1
VILEAGE
--
R A X L E MODEL
4
-----
MEMO 1 R A X L E S E R I A L NO
-- .-
Y E W 0 2 R ~ X L EM O D E L
----- - - ---. --
I R A X L E SER 4 L NO
I COY0 ->Oh

~.
.~~ --
TYPE

5 TYPE

TERMS: STRICTLY CASH, APPROVED ACCOUNT OR CREDIT CARD

I rhe unders~gnedauthorize you t o perform the repairs and furnish the necessary materials. I understand any cosrs verbally quoted are an
es;lmate only and not binding. Your em~loyeesmay operate vehicle for inspecting, testing, and delivery at my r s k . You will not be respon-
sible for loss or damage t o vehicle or artcles left in it. I agree to pay reasonable storage on vehicle left more than 48 hours after notlficatiun
that repairs are completed.
I AGREE T H A T YOU H A V E A N EXPRESS L I E N O N THE DESCRIBED VEHICLE FOR THE CHARGES FOR PARTS AND LABOR
FURNISHED UNDER THIS REPAIR ORDER INCLUDING THOSE FROM A N Y PRIOR REPAIR ORDERS ON THE VEHICLE I F I
F A I L TO PAY SUCH CHARGES, I AGREE T H A T THE VEHICLE M A Y BE H E L D U N T I L CHARGES ARE PAID I N F U L L I N THE
EVENT OF LEGAL ACTION TO COLLECT A N Y SUMS DUE, I AGREE TO PAY COSTS OF COLLECTION AND FEES INCLUDING
REASONABLE ATTORNEY FEES.
I f charges are handled on an approved open account, they are due on the 10th of the month following the purchase. A FINANCE CHARGE
of 11'2% per month (18%per year) will be added to all balances 30 days past due.

ABOVE REPAIRS AUTHORIZED B Y : --

FIGURE 2-1 4 Typical worl< or repair order. (Courtesy of Freightliner Trucks)


In many shops, a dispatch sheet, or work sched-
ule, keeps track of dates when the work is to be
completed. Some dispatch sheets follow the job
through each step of the servicing process. This
information helps the truck dispatcher know the
whereabouts of vehicles in the shop and when it will
be ready for service use again.
Most fleets, large or small, keep a file on each
individual vehicle, whether it be a tractor or a trailer.
'This file includes all the vehicle's maintenance and
repair records, schedule, PM inspection results, and
any other data about that vehicle. All work orders
performed on that particular vehicle are generally
kept in its history folder.
If a shop wishes to maintain a history of individual
component life or performance by a vehicle, a major
component history can be a part of the vehicle file
also. It is a simple matter of updating this record as
each repair order is placed in the file folder. A copy
of invoices covering outside repairs should be placed
in the vehicle file folder. If major components are
involved, the component history records should be
updated.
The Federal Motor Carrier Safety Regulations
require the mandatory records of a vehicle file to be
retained where the vehicle is housed or maintained
for a period of one year. They also require these
records to be kept on hand for six months after the
vehicle leaves the carrier's control. Experience has
shown that it is a good idea to keep work orders in
the vehicle file folder as long as the vehicle is in ser-
vice within a given operation.
The same regulations require that the driver's
vehicle condition report be retained for at least three
months from the date of the report.
COMPUTERS IN THE SHOP
As can be seen, the heavy-duty truck technician's
responsibilities go beyond just inspecting, maintain-
ing, and servicing the vehicles. Helshe must keep
neat and accurate records. Shop computers (Figure
2-15) equipped with bar-code wands can relieve
technicians of the burden of writing legible repair
orders, help shop managers improve the scheduling,
and keep mistakes out of parts department transac-
tions. With the proper software, a computer can turn
the repairlmaintenance process into a "paperless"
operation. (Shop software can best be described as
the programs a computer uses t o perform mainte-
nance shop tasks-a job which used to be accom-
plished with a sharp pencil and someone with a
good head for figures.) Software packages are avail-
able to track every aspect of a vehicle. Here are
some examples:
Shop Safety and Operations 31
FIGURE 2-1 5 A computer makes shop record
Ikeeping a great deal easier.
Vehicle Maintenance Reporting Standards
(VRMS). Developed by the American Trucking
Association, this is a coding system that can be
used at an individual part level up to total oper-
ating systems. Used within a software package,
it can provide information on items such as part
inventory, part usage, part wear rates, warranty
information, and overall cost control.
Parts Inventory Control. A basic inventory
control system should maintain at least the fol-
lowing information on each part: part number,
description, current quantity, and minimum
(reorder) quantity. The goal is to balance maxi-
mum part availability against minimum invest-
ment in inventory.
Bar Coding. One of the weaknesses of a com-
puter inventory system is human input error.
Bar coding systems reduce the error rate from
one in a 100 to one in a 100 million. Bar coding
used in maintenance shops is similar to that
used in grocery stores, except it uses the 3-of-
9 code instead of the universal product code
(UPC).
ReplaceIRepair Analysis. The ability to keep
track of which parts are being replaced and
repaired.
Preventive Maintenance. A schedule set up in
the computer tells you which vehicle needs ser-
vicing at what time.
Electronic Data Interchange (ED!). A rapidly
growing technology that allows computers of
any type to talk to each other and exchange
data about business transactions that formerly
had to be transmitted on paper or by tele-
phone.
32 Chapter Two
Vehicle Hi3tory. A d3tabase that can provide a
detailed profile on any vehicle in the fleet.
Work Order Generating. The ability to auto-
matically generate a work order when a vehicle
needs servicing.
Cost Tracking. Using databases on parts,
vehicle history, PM scheduling, and warranty
information to keep track of overall costs.
Warranty Information. A database linked with
vehicle history that provides specific informa-
tion on parts warranty. Helpful in obtaining
prompt warranty payments from vendors.
Vehicle and Driver Performance Analysis.
Trip data can be wirelessly downloaded during
or after each trip.
SUMMARY
Personal safety on the job may require eye or ear
protection, or both, and protective clothing and
shoes. Long hair and loose jewelry are hazards.
Lifting and carrying heavy materials the correct
way will protect against injury.
Tilt hoods and cabs with care.
Do not smoke or engage in horseplay in the
shop.
Take care when welding or working with a
hydraulic press. Use protective eyewear. Avoid
contact with hot metal parts.
The work area should be kept clean, dry, and
neat, and flammable liquids and solvents
should be handled and stored carefully.
Emergency telephone numbers and a first-aid
kit should be handy.
Use fire-fighting equipment appropriately: water
or foam on ordinary combustibles; foam, car-
bon dioxide, or dry chemicals on burning liq-
uids: carbon dioxide or dry chemicals on
burning "live" electrical equipment; and special
extinguishing agents on burning metals.
Select, store, use, and maintain shop tools
properly.
Hazardous materials used in heavy-duty truck
repair include flammable, corrosive, reactive,
and toxic materials. Your employer is obligated
to inform you of potential hazards in your work-
place, and you have a right to protect yourself
from them.
Specific laws govern the disposal of hazardous
wastes, including oil, antifreeze/coolants, refrig-
erants: batteries, battery acids, acids and sol-
vents used for cleaning, and paint and body
repair product wastes. Hazardous wastes may
be recycled in the shop or removed by a
licensed disposal hauler.
By law, records must be kept by each shop of
the repair and maintenance of trucks involved
in interstate shipping.
Computers can be useful in the shop for such
tasks as parts inventory control, work order
generating, and cost tracking.
REVIEW QUESTIONS
1. In this book, the sections that contain cautions
about situations that might result in personal
injury are labeled with what special notation?
a. SHOP TALK
b. SAFETY RULES
c. CAU'TION
d. WARNING
2. 'The best way to prevent eye injury is to
a. take care during grinding or other operations
that throw off particles
b. always wear safety glasses
c. always wear a bump cap
d. make sure a source of running water is avail-
able to flush foreign matter out of the eyes
3. Which of the following describes a safe lifting
and carrying practice?
a. Twist your body when changing your direction
of travel while carrying a heavy object.
b. Bend forward to place a heavy object on a
shelf or counter.
c. Lift by bending and then straightening your
legs, rather than by using your back.
d. Position your feet as far as possible from the
load when you begin to lift.
4. Oil on the floor of the work area can be cleaned
up using a pppp-
5. The exhaust pipe of a diesel engine must be
connected to the shop exhaust system to pro-
tect against
a. particulates
b. carbon monoxide
c. carbon dioxide
d. fire
6. Do NOT attempt to put out a Class B fire using
a. foam
b. carbon dioxide
c. a dry chemical type extinguisher
d. water
7. A Class C fire involves
a. ordinary combustibles, such as paper or cloth
b. a flammable liquid
c. live electrical equipment
d. combustible metals

8. To use carbon dioxide to extinguish a fire, direct
the discharge
a. at the top of the flames
b. first at the edge of the fire, then forward and
upward
c. at the base of the flames
d. several feet over the top of the flames
9. What are the four types of hazardous wastes?
10. The "Right-To-Know" law was passed by the
government to
a. require any company that disposes of
hazardous materials to inform their community
b. protect employees, customers, or vendors
from hazards in the workplace caused by
hazardous chemicals
c. require industries to compensate employees
injured by contact with hazardous materials
d. require chemical industries to reveal complete
information about the chemicals they produce
11. Which of the following is covered under the
Resource Conservation and Recovery Act?
a. waste water
b. waste oil
c. cleaning solvents
d. all of the above
Shop Safety and Operations 33
12. Which of the following is an approved way of
disposing of hazardous wastes?
a. washing them down the drain with plenty of
water
b. using them as weed killer
c, recycling them by reusing them in the shop
d. placing them in leak-proof containers and dis-
posing of them in an RCRA approved method.
13. What record must be kept by the shop on trucks
involved in interstate shipping?
a. out-of-service times
b. names of all drivers
c. names of all service technicians
d. nature and date of inspections
14. What information is provided by the first digit of
the VIN of a heavy-duty truck?
a. model year
b. axle configuration
c. manufacturer
d. gross weight rating
15. Bar coding, along with a computer system, can
be used effectively to
a. improve parts inventory control
b. track preventive maintenance
c, provide a detailed profile on any fleet vehicle
d. generate work orders efficiently