TRADE OF VEHICLE BODY REPAIR
Contents
1. The following pages show a variety of Safety Signs that are commonly found in a workshop Vehicle Body Repair Phase 2 11 Revision 2 0 January 2014 Module 1 Unit 2 Art nr 99788 Vehicle Body Repair Phase 2 12 Revision 2 0 January 2014 Module 1 Unit 2 CAUTION Dangerous chemical CAUTION Overhead hazard Vehicle Body Repair Phase 2 13 Revision 2 0 January 2014 Module 1 Unit 2 3 7 Symbol Signs e The sign will sometimes include an explanatory text that is intended to provide additional safety information e Some signs are designed to convey a personal safety message These signs suggest the use of safety glasses or hearing protection when in the area e Insymbol signs a pictorial message appears alone or is combined with an explanatory text This allows the safety message to be conveyed to people who are illiterate or who do not understand the local language Vehicle Body Repair Phase 2 14 Revision 2 0 January 2014 Module 1 Unit 2 Eve protection Foot protection must be worn must be worn Ear protectors Respirators must be worn must be worn in this area in this area eite i must be used Hand protection beworn Vehicle Body Repair Phase 2 15 Revision 2 0 January 2014 Module 1 Unit 2 3 8 Wall Chart Signs DANGEROUS SUBSTANCE PACKAGING amp LABELLING ATTENTION AND ASSESSMENT Recognise potential hazards HARMFUL 1 Wear suitable protective clothing ey2. o D class fire is fuelled by combustible metals magnesium potassium turnings and metal shavings They are not as common as A B or C class fires o E class fires need electricity to feed the fire This class includes wiring damaged appliances circuit breakers and fuse boxes Once the electrical supply has been disconnected the fire changes to the class of fuel it is burning 3 14 Fite Extinguisher Types e There are four types of fire extinguisher Each type can be used for one or mote classes of fire o Water extinguishers contain water pressurized by an inert gas or compressed air The water quenches the heat from the fire to below its vaporization point They should only be used on class A fires o Carbon dioxide fire extinguishers are most effective when used against B C and E class fires The gas is heavier than air and provides an inert blanket that smothers the fire A carbon dioxide fire extinguisher will spray small ice particles with the gas This is normal Vehicle Body Repair Phase 2 25 Revision 2 0 January 2014 Module 1 Unit 2 o Dry Powder fire extinguishers contain a fine powder usually sodium bicarbonate held under pressure by an inert gas The extinguisher smothers the fire with a fine powder These extinguishers are good to fight any fuel or liquid fire o Foam fire extinguishers contain a chemical that forms a soft foam that floats over the target area and smothers the fire These are ef
3. Unit 2 1 3 Specialist Skills Motor vehicle re finishing Steering geometry and alionment Estimating Chassis alignment and jigging Sunroof fitting Windscreen door glass fitting and sealing Rust proofing 1 4 Vehicle Body Repair Operations Damage assessment removal of body sealers and deadenerts dismantling and assembly of motor vehicles dismantling and assembly of motor vehicle wiring roughing out planishing metal finishing lead loadings filling hot and cold shrinking chassis and body alignment panel alignment body and seam sealing windscreen and door glass spray painting steering alignment mig welding oxy acetylene brazing and mig brazing 1 5 Common Skills Use and care of hand tools use and care of measuring equipment use and care of machinery general house keeping use of plastic use of glass storage and care of materials Jointing Selection and use of Oxy acetylene brazing proper hand tool and Mig welding materials in the use of Spot welding riveting Plastic welding Soldering Various adhesives Spray Identification and Feathering painting selection of materials Sanding used for spray painting Spray painting techniques Safety procedures Vehicle Body Repair Phase 2 5 Revision 2 0 January 2014 Module 1 Unit 2 2 0 Skills 2 1 Core Skills The range of skills and knowledge which are specific and are required by all craft workers of the trade 2 2 Specialist Skills Those skills which
4. supetvisor assessor An assessment specification and a detailed workplace assessment checklist are provided in each of the on off job phases Only those apprentices who can demonstrate achievement of the relevant industry standards in both on the job competence assessment and off the job modular assessment will be awarded a Fetac Advanced Diploma certification Vehicle Body Repair Phase 2 3 Revision 2 0 January 2014 Module 1 Unit 2 1 0 Vehicle Body Rcpair 1 1 Trade Descr pt on A vehicle body repairer is a skilled worker within the motor trade which involves the repair and or replacement of damaged panels due to collision or corrosion chassis replacement or straightening jigging Preparation and the respray of panels total resprays carry out all glass and glazing requirements rust proofing steering geometry and estimating crash repairs 1 2 Core Skills Safe use of the following machinery and tools Power and treadle guillotine Box pan folding machine Bending rolls Grinding machine Pedestal drill Vacuum sanders Metal nibblers Spray booth oven Alignment jigs Steering geometry gauges Mig welding plant Spray painting equipment Hoists and lifts Body jacks Vehicle body repair tools Body dozer Porto power Ait compressor Spot welders Plastic hot gun Brazing and spot welding Riveting grinding sanding Filing safety procedures rust repairs Vehicle Body Repair Phase 2 4 Revision 2 0 January 2014 Module 1
5. A readily accessible supply of drinking water must be available e Accommodation for clothing worn only at work must be available e Suitable and sufficient First Aid equipment must be available EA SS and adeguately marked 3 ae QO cher k end AAST conti it tor Mos fessin e Areas for rest and consumption of food must be provided need 0 00 IO amp iO Provide your employees with hearing protectors and make sure 7 E they use them property Identify hearing protection zones areas where the use of hearing a io protection is compulsory and mark them with signs if possible Provide employees with training and information on how i P to use and care for hearing protectors EMPLOYEES DUTIES I Co operate in helping your employer to do what is needed to protect your hearing Make sure you use properly any noise control devices eg noise enclosures and follow any working methods that are put in place Wear any hearing protection you are given Wear it properly you should be trained how to do this and make sure you wear it all the time doing noisy work and when you are in hearing protection areas Taking it off even for a short while means that your hearing could still be damaged ft QO Report any problems with your hearing protection or noise control devices straight away EXCLUSIONS I O Let your employer or safety representative know if trouble Exploration extraction sites Agricultural or forestry lan
6. are identified with an industry trade and are applied in specialist sectors within that industry trade Mastery of these skills allows craft workers to specialize in particular areas of industry as key personnel 2 3 Personal Skills The skills which apply to all trades and incorporate the practical application of abilities such as e Communications e Customer Relations e Adaptability e Ability to work as a team member e Ability to work independently e Initiative e Problem Solving e Planning e Information Gathering e Quality e Language e Report Writing Mastery of these skills enables craft worker to enrich their relationships with their colleagues and clients and is essential for progression to higher levels of responsibility promotion and job satisfaction Vehicle Body Repair Phase 2 6 Revision 2 0 January 2014 Module 1 Unit 2 3 0 Health Safety Fire Drill and Behaviour Guidelines 3 1 Introduction Learning Outcome Describe the health safety responsibilities of all personnel fire drill procedures and course participant personal behaviour guidelines that apply to the Training Centre premises Describe the structure of the Phase 2 Apprentice Vehicle Body Repair training centre Because of the unique nature of each Training centre this element of the course will be delivered in accordance with the local conditions and rules governing health and safety local safety statement and identification of haz
7. piece coverall overall or a separate shirt and pants the clothes you work in should be comfortable enough to allow you to move without being loose enough to catch on machinery The material must be flame retardant and strong enough that it is not easily torn A flap must cover buttons or press studs If you wear a long sleeve shirt the cuffs must be close fitting without being tight Pants should be cuff less so that hot debris doesn t become trapped Care of clothing Always wash your work clothes separately from your day to day clothes Start a new working day with clean clothes and change out of contaminated clothing as soon as possible It is a good idea to keep a spare set of work clothes in the workshop in case some toxic flammable or corrosive fluid is spilt on the ones you are wearing WN WARNING You ate not to commence work without fireproof workshop overalls being fitted first you are required to wear them at all times when on the workshop floor Vehicle Body Repair Phase 2 39 Revision 2 0 January 2014 Module 1 Unit 2 5 4 Safety Boots Industrial safety footwear must be worn at all times in the workshop Footwear Always wear safety shoes that comply with the relevant standards for your area The soles must be acid and slip resistant the uppers made from a puncture proof material such as leather and the toes protected by a steel cap Industrial safety shoes must be worn at all times in the workshop
8. points 4 Attach the hoist sling If the engine has lifting eyes attach the sling with D shackles or chain hooks If you need to screw in bolts and spacer washers to lift the engine make sure you use the correct bolt and spacer size for the chain or cable Screw the bolts until the sling is held tight against the engine 5 Attach the hoist hook Attach the hook of the hoist under the center of the sling and raise the hoist just enough to lift the engine an inch or two Double check the sling and attachment points for safety The center of gravity of the engine should be directly under the hook of the hoist and there should be no twists or kinks in the chain or sling 6 Raise the engine Raise the hoist high enough so that the engine is clear of the ground and any obstacles Slowly and gently move the hoist and engine to its new position 7 Lower the engine Lower the engine until it touches the ground Making sure it is positioned correctly You may need to place spacers under the engine to stabilize it Once you are sure the engine is stable lower the hoist remove the sling and any securing fasteners then return the equipment to its storage area Vehicle Body Repair Phase 2 33 Revision 2 0 January 2014 Module 1 Unit 2 4 4 Using a Floor Jack Objective e Lift and secure a vehicle with a floor jack and jack stands Safety check e Make sure the jack and stands you are using are suitable for the job e Never lift a veh
9. 17 o S DRY CO2 POWDER FAB vV USE ON o Al Y USE ON sis Flammable A Wood Paper Liquids LL and Textiles v USE ON FAB v USE ON Live Electrical Flammable Equipment Liquids DO NOT USE ON vV USE ON Wood Paper i Gaseous and Textiles Fires DO NOT v USE ON Hold horn when Live Electrical operating Equipment Vehicle Body Repair Phase 2 18 Revision 2 0 January 2014 Module 1 Unit 2 3 10 Safety in the Workshop Safety equipment includes items such as Hand Rails Machinery Guards Painted Lines Soundproof Rooms Gas Extraction Hoses Doors and Gates o Adequate Ventilation e Large fixed machinery such as repair benches present a hazard to the operator and others working in the area To prevent accidents a machinery guard or a yellow painted line on the floor usually borders this equipment e Machinery guards and yellow lines will prevent people from accidentally walking into the operating equipment or indicate that a safe distance should be kept from the equipment e Soundproof rooms are usually used when a lot of noise is made by operating equipment An example is the use of a chassis dynamometer A vehicle operating on a dynamometer produces a lot of noise from its tires exhaust and engine To protect other workshop users from the noise the dynamometer is usually placed in a soundproof room keeping workshop noise to a minimum e Exhaust gases in workshops are a serious health hazard Whenever
10. E E AE O A 41 OA O O E E ten oe ate A TEE TE E peatanatcyenoeasutas 41 NDE oi a 0 E E OEO EA E eee 44 SEPA O O a E EE A N E E ETATE RA 48 OES Te Lye oi Ho i enn ne en ee ee ee eee ee ee ee ee 51 Vehicle Body Repair Phase 2 Revision 2 0 January 2014 Module 1 Unit 2 INIRODUCTION Structure of Apprenticeship During the period of Apprenticeship each apprentice will undertake alternating phases of on the job and off the job training and development Each Apprentice will spend a maximum of 40 weeks in off the job training in an approved training location The rest of the time will be spent in on the job training and development of the necessary skills PHASE 1 On The Job 22 Weeks Training and Work Experience PHASE 2 Off The Job 20 Weeks Training and Development PHASE 3 On The Job Training and Work Experience PHASE 4 Off The Job 10 weeks Training and Development PHASE 5 On The Job Training and Work Experience PHASE 6 Off The Job 10 Weeks Training and Development PHASE 7 On The Job Training and Work Experience Fetac Advanced Diploma Certification Vehicle Body Repair Phase 2 1 Modular Assessment Competence Assessment Modular Assessment Competence Assessment Modular Assessment Competence Assessment Revision 2 0 January 2014 Module 1 Unit 2 Fetac Advanced Diploma Certification Process Throughout the period of apprenticeship each apprentice will undergo a range of assessments to establish co
11. Falling objects crush toe cap Sole penetrated by sharp object Light weight shoes offer NO protection Steel intersole Stout leather prevents injury to the achilles tendon Industrial Safety Shoe Figure 4 Vehicle Body Repair Phase 2 40 Revision 2 0 January 2014 Module 1 Unit 2 5 5 Headgear It is also good practice to wear a cap to hold longer hair in place and to keep it clean when working under a vehicle 5 6 Hand Protection Wherever possible wear gloves to protect your hands There are many types of gloves available and their applications vary greatly Chemical gloves Heavy duty impervious gloves should always be worn when using solvents and cleaners They should also be worn when working on a battery They should extend up to the middle of your forearm to reduce the risk of liquid spilling into them when your hands are immersed Some chemical gloves are also slightly heat resistant They are suitable for use when removing radiator caps and mixing coolant Vehicle Body Repair Phase 2 41 Revision 2 0 January 2014 Module 1 Unit 2 Leather gloves These will protect your hands from burns when welding and heating or handling hot components You should also use them when removing steel from a storage rack and when handling sharp objects Rubber gloves Light duty rubber and plastic gloves should be used to protect your hands from exposure to greases and oils General purpose cloth g
12. TRADE OF VEHICLE BODY REPAIR PHASE 2 Module 1 UNIT 2 Induction Produced by SOLAS An tSeirbhis Oideachais Leanunaigh agus Scileanna Further Education and Training Authority In cooperation with subject matter expert Maurice Stack Some material courtesy of CDX Global and FENC Further Education National Consortium SOLAS 2014 Vehicle Body Repair Phase 2 Revision 2 0 January 2014 Modulel Unit 2 Table of Contents Introduction E ad INN a 40 0 eos ELE cis 011 6 mmmmm m mmm m m m m mm mmmrmrm mrmrm mrmrm mrmrmrmrmrmrmrmrmr rr r rr 1 10 Vehicle Body ReDALLneonnanan nanaoeanaaeaah aneaiahaiheaaaieaa N errr erent eee er rere Tree 4 IS Med ocho log Bl Sail mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmk 4 Wee CSO ER AEAEE E OEE AE OEN AIEN EE E E E E 4 Bo e E E E A E I AT SEE 5 1 4 Vehicle Body Repair Operations sssssssesessssssesesssesesesesestseststsesesreresesttsesesenentneseeeeeseeeses 5 Meg A ONC A INS P E E E E E T EE E E E N 5 bai lt lt ee E E E ee A ee E eee 6 De Nee IIS A EA A E T A ET E E E T N 6 P E as I E E E E A nm 6 Os NSIS a E mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmma 6 3 0 Health Safety Fire Drill and Behaviour Guidelines iiiiieereeeneneneeneneneenennsnen 7 O E O Ea R E EO A EAA E 7 E R E Be E A E E A E E E E 8 Po UG E E E E E E A E E E 8 VC mmmmmmmmmuwwvwvwvwvvuwmwwvwvvwuwwvwwvwvuw
13. a vehicle s engine is running toxic gases are produced from its exhaust To prevent an excess of gas build up a well ventilated work area is needed as well as some method of extracting the toxic gases e The best way to get rid of these gases is with a suction hose that fits over the vehicle s exhaust pipe The hose is attached to an extraction pump that vents the gas to the outside e Doors and gates are used for the same reason as machinery guards and painted lines A doorway is a physical barrier that can be locked and sealed to separate a hazardous environment from the rest of the workshop or a general work area from an office or specialist work area e In the day to day operation of a workshop there is often a reason to temporarily separate one work bay from others If a welding machine or an oxyacetylene cutting torch is in use it may be necessary to place a temporary screen or barrier around the work area to protect other workshop users from welding flash or injury O O O O Vehicle Body Repair Phase 2 19 Revision 2 0 January 2014 Module 1 Unit 2 Step by step instruction 1 Workshop Layout Familiarize yourself with your workshop There are special work areas that are defined by painted lines These show the hazardous zone around certain machines and areas If you are not working specifically on the machines you should stay outside the marked area Observe warning signs Study the various warning signs aro
14. ards The fire alarm sound will be demonstrated as part of the fire drill in the particular centre where the course is located Emergency exit route designated safe areas location and function of Safety Statements are all specific to the location and will be coveted in the induction programme for the centre where the course is located Demonstrate the location and use and limitations of the appropriate fire extinguisher for an identified fire incident Describe the procedures to be followed in accident or emergency events Demonstrate the operation and safety controls of the automotive workshop fixed equipment Describe the vehicle parking arrangements of the training centre workshop that comply with emergency fire evacuation procedutes Assemble in location for VBR Identification of hazards their removal and reduction are all part of an on going process in each training location Copies of hazard statements are located in the training areas and will be brought to the attention of the apprentices during the induction programme Vehicle Body Repair Phase 2 i Revision 2 0 January 2014 Module 1 Unit 2 3 2 Information Covered e Code of Behavior Booklet e Booklet on Noise e Booklet on Safety and Hygiene e Fire Instructions Evacuation Plan and Layout e Information Trainees Apprentices based in Training Centre e Suggested Reading e DVD Video 3 3 Activity By the end of this unit each apprentice will be ab
15. ark state No 9 10 11 12 13 when the arc welding starts e The lens automatically returns to a light state when the arc stops e Infinite shade adjustments can be made between 9 and 13 whilst welding e Match your welding application to the shade indicated on the shade chart e This helmet is good for MIG TIG SMAW Plasma Arc and Air Carbon Arc cutting e Increased welding productivity and quality because hands are free at all times e Protection from harmful UV and IR radiation at all times in darkened or clear state e The lens contains two sensors to detect the light from the welding arc and darken the lens Vehicle Body Repair Phase 2 44 Revision 2 0 January 2014 Module 1 Unit 2 Gas welding goggles Gas welding goggles can be worn instead of a welding mask when using Of assisting a person using an oxyacetylene welder The eyepieces are heavily tinted but not as much as those in an electric welding mask allowing you to see the welding task There is no ultraviolet radiation from an oxy acetylene flame so the full face shield is not required Welding mask Wear a welding mask when using or assisting a person using an electric welder The light from a welding arc is very bright and contains high levels of ultraviolet radiation For this reason the viewing aperture has heavily tinted glass to reduce the intensity of the light from the welding tip so you can see what you are doing and the remainder of th
16. d other than buildings Transport The Upper Exposure Action Value is a daily or weekly exposure of 85 The Exposure Limit Value the legal limit on noise exposure is a daily sound pressure of 14008 es Vehicle Body Repair Phase 2 1 6 Revision 2 0 January 2014 Module 1 Unit 2 FIRST AID gt BASIC RULES DO NOT move the patient if the patient is unconscious and not breathing follow the instructions below If breathing place in the recovery Position as shown in 5 below Keep patient warm and covered DO NOT give the patient food drink or allow to smoke Loosen any tight clothing Reassure the patient If you have any doubts about the injury call an ambulance BURNS e Cool the skin immediately with running water and continue this treatment for at least 10 minutes Remove any restrictive jewellery Apply a clean dressing BLEEDING Raise the wound Apply pressure to the wound with your hand or a clean dry cloth until the bleeding has stopped Apply a clean dressing EMERGENCY RESUSCITATION ARTIFICIAL RESPIRATION KISS OF LIFE Mouth to Mouth method 1 SAFEGUARD YOURSELF If patient collapses due to an ELECTRIC SHOCK switch off the current or break the circuit Use or stand on some DRY non conducting material to REMOVE THE CASUALTY from contact with the cable or source of electricity Remove any obvious obstruction including broken or displaced dentures from the
17. e and personal safety procedures when carrying out the following tasks If you are unsure of what these are ask your instructor Vehicle Body Repair Phase 2 22 Revision 2 0 January 2014 Module 1 Unit 2 Points to note e Each workshop will have a firefighting procedure There should be a workshop fire warden and fire officers Understand clearly the firefighting policy for your workshop e Fire extinguishers will be located in easily accessible places Do not block access to fire extinguishers with workshop equipment and clutter e Fire extinguishers either smother or quench a fire A fire extinguisher that smothers a fire does not remove heat Keep a watch over the fire Even though the fire may seem to be out it may restart e Workshops will have various firefighting tools fire hoses fire buckets fire blankets and fire extinguishers Each has a specific application and method of use Familiarize yourself with each of these tools e Fire blankets are manufactured from fire retardant material and have multiple uses They can be used to smother a fire in a cleaning station or wrap around clothing that has caught on fire They may be used to shield people from fire when evacuating a building or be used as a stretcher to carry injured or unconscious people e Never use water on a fuel based fire The fuel will float on the water and spread further e The only exception to this is in the case of a fire fuelled by methanol Met
18. e face and glove protection oe st ah 2 In the event of contact with skin wash immediately with plenty of water y health risk if ingested inhaled 3 In the event of contact with eyes wash immediately with plenty Or absorbed through the skin of water and seek medical advice 4 in case of accident or if you feel unwell seek medical advice immediately Understand unfamiliar handling operations Know how to use handling aids Use personal protective equipment properly IRRITANT Appreciate environmental factors contributing to safety Do not breathe dust or spray or vapour with the skin of inhaled Be a good housekeeper TOXIC VERY TOXIC Wes he protective clothing eye face and glove protection Realise your own capability Very low low quantities cause in th contact with skin wash immediately with plenty of water death or severe health risk if in the event of contact with eyes wash immediately with plenty ingested ahaled or absorbed ol water and seek medical aois CHECK THE FOLLOWING through the skin In e of accident or if you feel unwell seek medical advice immediately DANGERS Are there any sharp corners projecting nails points etc Wear suitable protective clothing eye face and glove protection CORROSIVE Remove mmeciaiety all contaminated clothing BALANCE May cause bums or destruction In the event of contact with skin wash immediately with plenty of water of living tissue on contact with In the event of contact with eye
19. e mask is made from a durable material that blocks any other light from reaching your face Vehicle Body Repair Phase 2 45 Revision 2 0 January 2014 Module 1 Unit 2 Safety glasses The most common is a pair of safety glasses It is good practice to wear these whenever you are in a workshop They are designed to protect your eyes from direct impact or debris damage The only time they should be removed is when you are using other eye protection equipment Prescription safety glasses are also available Full face shield When using solvents and cleaners epoxies and resins or when working on a battery it is necessary to use a full face shield The clear mask allows you to see all that you are doing but will protect yout whole face from chemical burns should there be any splashes or battery explosions You should also use a full face shield combined with safety gogeles when using a bench or angle grinder Vehicle Body Repair Phase 2 46 Revision 2 0 January 2014 Module 1 Unit 2 Safety goggles Safety gogeles provide much the same eye protection as safety glasses but with the added protection from any harmful gas that may find its way behind the lenses Safety goggles must be worn when servicing air conditioning systems or any other system that contains pressurized gas Vehicle Body Repair Phase 2 47 Revision 2 0 January 2014 Module 1 Unit 2 5 8 Ear Protection Ear Protection should be worn once sound le
20. e the vehicle gently to confirm that it is stable on the hoist Vehicle Body Repair Phase 2 28 Revision 2 0 January 2014 Module 1 Unit 2 6 Raise the vehicle completely Once you are sure the vehicle is safely positioned on the hoist lift it to the working height 7 Engage safety device With the vehicle at the correct height you should now lock the hoist in place and engage whatever safety device is used with it 8 Lower the vehicle Before the hoist is lowered remove all tools and equipment from the hoist area and wipe up any spilled fluids Remove the safety device or unlock the lift before lowering it Make sure nobody is near the vehicle on the hoist before lowering it Once the vehicle is on the ground you can remove the lifting arms and drive it away from the hoist 4 2 Operation of a Four Post Hoist Using a tour post hoist Objective e Lift a vehicle using a four post hoist Safety check e Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks If you are unsure of what these are ask your instructor Points to note e Four post hoists allow the vehicle to be positioned and lifted easily They are often used to lift a vehicle for wheel alignment services and brake repairs e Some four post hoists are fitted with attachments that allow the vehicle to be raised in a wheels free position Refer to the operations manual for the correct operati
21. erate Check which way to hold the extinguisher you ve chosen e Stand about 2 8 m 8 ft away from the fire and SQUEEZE the handle to discharge the fire extinguisher e Remember that if you release the handle on the extinguisher it will stop discharging e SWEEP the nozzle from side to side at the base of the fire Watch the fire Although it may appear to have gone out it may re ignite e If the fire is indoors you should be standing between the fire and the nearest safe exit If the fire is outdoors you Vehicle Body Repair Phase 2 24 Revision 2 0 January 2014 Module 1 Unit 2 should be standing facing the fire with the wind on your back so that the smoke and heat are being blown away from you Again make sure that you have a means of escape should the fire get out of control e When you are quite sure that the fire is out report it to your instructor Also report what actions you took to put out the fire e Once the circumstances of the fire have been investigated and your instructor or the fire brigade has given you the all clear clean up the debris and submit the used fire extinguishers for inspection and re filling 3 13 Fite Classifications e There are 5 classes of fire o A class fires involve wood paper cloth rubber and trash o B class fires involve flammable liquids such as oil paint gasoline grease and tar o C class fires involve flammable gases such as LPG Natural Gas Acetylene etc
22. ers Designated assembly point Vehicle Body Repair Phase 2 56 Revision 2 0 January 2014 Module 1 Unit 2 11 Ask an instructor or dial the main switchboard Call first aid person and inform the instructor Vehicle Body Repair Phase 2 57 Revision 2 0 January 2014 SOLAS An tSeirbh s Oideachais Lean naigh agus Scileanna Further Education and Training Authority 27 33 Upper Baggot Street Dublin 4
23. fective fighting liquid gaseous paper or wood fires 3 15 Fire Extinguisher Suitability e You will often see more than one symbol on a fire extinguisher This identifies the extinguisher as suitable for more than one class of fire e Class A B and C fire extinguishers have a numerical rating These are used to determine the extinguisher s potential to fight a fire This rating is expressed as a number from 1 to 40 for Class A fires and from 1 to 640 for Class B and C fires It will appear on the extinguisher e g 1A or 20B or 4A 20B C A larger number means a larger fire extinguisher Vehicle Body Repair Phase 2 26 Revision 2 0 January 2014 Module 1 Unit 2 4 0 Use of Fixed Equipment The major items of fixed equipment in the garage are the two and four post hoists The following notes indicate the safety procedures to be observed in operating these items of equipment 4 1 Using a Two Post Hoist Objective e Lift a vehicle using a two post hoist Safety check e Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks If you are unsure of what these are ask your instructor Points to note e Before lifting any vehicle make sure the frame is structurally sound If you see rust or signs of major repair lifting the vehicle with a hoist may cause damage to the vehicle or may be dangerous to you e The lifting capacity of the hoist you are usin
24. front of each ramp to prevent the vehicle from being driven off the front of the hoist At the back there will be ramps that allow the vehicle to be driven up and on to the hoist These will lift up when the hoist is raised and prevent the vehicle from rolling off 3 Position the vehicle Drive the vehicle slowly and carefully onto the hoist and position it centrally If the vehicle has front wheel restraints drive the vehicle forward until the wheels lock into the brackets Get out of the vehicle and check that it s correctly positioned on the platform If it is apply the emergency brake and select first gear or park 4 Raise the vehicle Make sure the hoist area is clear Move to the controls and lift the vehicle until it s reached the appropriate work height 5 Lock safety device Most 4 post hoists will have an automatic locking mechanism If the hoist has a manual safety mechanism you should lock it in place to engage whatever safety device is used Vehicle Body Repair Phase 2 30 Revision 2 0 January 2014 Module 1 Unit 2 6 Lower the vehicle Before the hoist is lowered remove all tools and equipment from the hoist area and wipe up any spilled fluids Remove the safety device or unlock the lift before lowering it Make sure that nobody is near the vehicle or the hoist Once the hoist is fully lowered you can drive the vehicle off the hoist Other non fixed equipment deserves special mention 4 3 Using an engine hois
25. g must be rated for a vehicle weight greater than that of the vehicle you are intending to lift Check the hoist rating and compare it with the weight given in the vehicle service manual e Make sure you know exactly how to operate the hoist Take particular care that you know exactly where the stop control is so that you can use it quickly in an emergency Refer to the operations manual for the correct procedure e Be sure the hoist is fully lowered before positioning the vehicle over it Check the amount of clearance under the vehicle Driving a low slung vehicle over the lifting mechanism may result in damage to the underside of the vehicle e The lifting points on a vehicle are typically located under the jacking points Check the vehicle service manual if you are not sure where the lift points are The lifting arms must be positioned under the center of the lift points so that the weight of the vehicle is distributed evenly Vehicle Body Repair Phase 2 al Revision 2 0 January 2014 Module 1 Unit 2 Make sure that there will be adequate headroom above the vehicle after it has been raised Taller vehicles especially those fitted with roof racks may need more headroom than you think The hoist should be raised so you can comfortably work under it Lock the lift in place before moving underneath or working on the vehicle Step by step instruction 1 Read instructions Read the safety instructions that are provided with
26. g the lifting chain or sling have a tensile strength that is in excess of the weight of the engine e Leave enough length in the sling so that when the engine is hanging the angle at the top of the sling is close to 45 degrees and not exceeding 90 degrees e If removing an engine from an engine bay once it is lifted free and away from the vehicle lower the engine so that it is close to the ground If the engine 1s lifted high in the air the hoist will be unstable e When moving a suspended engine move the hoist slowly Do not change direction quickly because the engine will swing and may cause the whole apparatus to tumble Part 2 Step by step instruction 1 Position the hoist Make sure the weight rating of the lifting crane is greater than the weight of the object you re lifting In this case you ll be lifting and moving an engine Lower the lifting arm and position the lifting end and chain over the center of the engine 2 Inspect the lifting attachments Inspect the chain steel cable or sling and bolts to make sure they are in sound condition They must be strong enough to support the weight of the engine The sling should be long enough so when you lift the engine the angle at the top of the sling is about forty five degrees Vehicle Body Repair Phase 2 oy Revision 2 0 January 2014 Module 1 Unit 2 3 Locate the lifting points Look carefully around the engine to determine if it has lifting eyes or other anchor
27. hanol is heavier than water and burns with an invisible flame Use a water extinguisher on a methanol fire e Fire buckets contain sand that can be thrown over a fire to smother it Do not be too quick to empty all the sand in one throw You may not completely cover the fire the first time Vehicle Body Repair Phase 2 23 Revision 2 0 January 2014 Module 1 Unit 2 3 12 Fighting a Fire e Three elements must be present at the same time for a fire to occur fuel oxygen and heat These three elements are demonstrated by the fire triangle The secret of firefighting involves the removal of one of these elements usually the oxygen or the heat The Fire Triangle Oxygen e Know how to operate the extinguisher Read the instructions when you purchase the extinguisher You will not have time to read them once a fire has started e Never turn your back on a fire or allow a fire to get between you and a means of escape If you are fighting a fire outside always have the wind at your back e If possible get an assistant to guide you and inform you of the fire s progress e Ifa fire occurs in your work area remember the PASSword o Pull Aim Squeeze Sweep e PULL out the pin that locks the handle at the top of the extinguisher to prevent accidental use e Carry the fire extinguisher in one hand and use your other hand to AIM the nozzle at the base or seat of the fire Some fire extinguishers need to be turned upside down to op
28. heels were on the ground When you ve finished working under the vehicle make sure you ve removed all tools and equipment before you attempt to lower it Raise the vehicle off the stands Use the jack to raise the vehicle off the safety stands Slide out the safety stands from under the vehicle Lower the vehicle Turn the valve on the jack handle counter clockwise very gently to lower the vehicle to the ground Do not allow the vehicle to drop quickly or you may cause serious damage Return the floor jack the safety stands and the wheel wedges to their storage area before you continue working on the vehicle Vehicle Body Repair Phase 2 36 Revision 2 0 January 2014 Module 1 Unit 2 5 0 Personal Safety and Protection 5 1 Personal Protection Equipment PPE During the Delivery of each unit and module of the course the Personal Protection Equipment may change however the following notes and guidelines cover most of the standard issue protective personal equipment necessary for safe working Figure 2 THINK SAFE ACT SAFE BE SAFE Vehicle Body Repair Phase 2 37 Revision 2 0 January 2014 Module 1 Unit 2 Figure 3 Always use the correct and safe equipment for the job at all times when in the workshop Vehicle Body Repair Phase 2 38 Revision 2 0 January 2014 Module 1 Unit 2 5 2 Personal Protection Protective Clothing 5 3 Outerwear Always wear appropriate work clothing Whether this is a one
29. icle that is heavier than the jack s rated capacity e Always use matched pairs of jack stands e Never support a vehicle on anything other than jack stands e Do not use wood or steel blocks to support the vehicle They may slide or split under the weight of the vehicle e Do not use bricks to support the vehicle They will shatter under the weight of the vehicle e Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks If you are unsure of what these are ask your instructor Points to note e There are three types of workshop jacks hydraulic pneumatic and mechanical e Hydraulic and pneumatic jacks are the most common They can be mounted on slides or on a wheeled trolley Vehicle Body Repair Phase 2 34 Revision 2 0 January 2014 Module 1 Unit 2 e The size of jack you use will be determined by the weight of the vehicle you want to lift Most workshops will have a jack that has a lifting capacity of about 2 2 tons tonnes If the vehicle is heavier than that or if the vehicle is loaded you will need to use a jack with a larger lifting capacity e Always check the vehicle service manual or owner s manual to determine the best position to support a vehicle Some vehicles require special attachments to be fitted before they can be lifted e Do not jack or support a vehicle under any independent suspension components They are not strong enough
30. ld be a hazard in the workshop if you don t wear mandatory protective gear when working on hazardous machines Vehicle Body Repair Phase 2 20 Revision 2 0 January 2014 Module 1 Unit 2 10 Equipment hazards Ask yout instructor for information on any special hazards in your particular workshop and any special avoidance procedures which may apply to you and your working environment Vehicle Body Repair Phase 2 21 Revision 2 0 January 2014 Module 1 Unit 2 3 11 Using a Fire Extinguisher Objective e Locate workplace fire extinguishers and identify applications and operating procedures Safety check e Do not attempt to fight a fire unless you have a fire extinguisher large enough to extinguish the fire Many small extinguishers empty in 8 to 10 seconds e Never try to extinguish a fire that is spreading rapidly e Do not try to put out a fire unless you know what type of fire is burning Using the wrong fire extinguisher will make the fire worse e Test the fire extinguisher before you attempt to extinguish a fire e Do not inhale any fumes from a fire Fire gives off toxic gases e Do not use water on grease fires electrical fires or fires where electrical wiring is present e Ifyou cannot fight the fire leave the area and call the fire department e See your local fire department for a demonstration of the appropriate procedure in your jurisdiction e Make sure that you understand and observe all legislativ
31. le to State the attendance safety fire drill procedures that apply to the training establishment Select correct tool type sizes for different applications Identify various workshop layouts and machine type State the recommended fire extinguisher type for the use with the following fires carbonaceous liquid fuel and electrical 3 4 Outcomes e Training centre layout Location of evacuation assembly points e Location and use of fire fighting equipment e Attendance and time keeping procedures e Safety procedures e Identification of basic workshop equipment e Accident reporting e Tools types and sizes e Workshop cleaning routine cleaning roster e Identification and marking engraving tool kit e Care of tools and equipment e Location and identification of special tools equipment and consumables e Booklet on noise safety and hygiene and fire instructions e General information for trainees based in training Vehicle Body Repair Phase 2 6 Revision 2 0 January 2014 Module 1 Unit 2 3 5 Identifying Hazards ratte AN ns Sa gt e She Poh ei sag DE fp A RIL Figure 1 Suggested Exercise Identify unsafe workshop practices Vehicle Body Repair Phase 2 9 Revision 2 0 January 2014 Module 1 Unit 2 3 6 Preparation and Safety Objective e Follow workplace procedures for hazard identification and avoidance Safety check e Make sure that you u
32. loves Wear these in cold temperatures particularly during winter so that cold tools do not stick to your skin Vehicle Body Repair Phase 2 A Revision 2 0 January 2014 Module 1 Unit 2 Barrier cream This prevents chemical being absorbed into your skin and should be applied to your hands before you commence work Even the slightest exposure to some chemicals can lead to dermatitis a painful skin irritation Cleaning your hands When cleaning your hands use only specialized hand cleaners which protect your skin not solvents such as gasoline or kerosene as they remove the natural oils Vehicle Body Repair Phase 2 43 Revision 2 0 January 2014 Module 1 Unit 2 5 7 Eye Protect on Auto Darkening Welding Mask e Always read the instructions before use e This helmet is not designed for laser or laser cutting or gas welding e Designed to protect your eyes and face from sparks splatter and harmful IR and UV radiation e Will not protect you from explosive devices or corrosive liquids e Never operate this helmet without lens cover properly installed e Keep front lens cover and light sensors clean for proper operation e Replace auto darkening lens if it is cracked scratched or pitted to avoid serious personal injury e Use only replacement parts specified in this manual Welding with the Auto Darkening Welding Mask e Will automatically change from a light state shade No 4 to a d
33. mouth by sweeping a finger around the inside of the mouth SES When the casualty is breathing place in the recovery position this prevents choking on the tongue and allows fluids to drain 2 IMMEDIATELY start artificial respiration and send for MEDICAL AID 3 METHOD see diagrams 1 to 4 Lay casualty on back if possible on a table or bench Kneel or stand by the casualty s head chin lift Pinch the casualty s nostrils together with your fingers Open the airway by head and NY a M Open the mouth wide and take a deep breath Seal your lips around His Her mouth Blow into casualty s mouth until the chest rises Remove your mouth allow the chest to fall Continue at a rate of 10 breaths a minute until normal breathing is restored or until medical aid arrives In the event of an accident however small it must be reported to vour instructor immediatel who will take the correct course of action Vehicle Body Repair Phase 2 17 Revision 2 0 January 2014 Module 1 Unit 2 3 9 Fire Signs Th sella ime acl SIEMENS Cerberus Division Siemens Building Technologies LTD 1 Sound the alarm im AAA 2 Call the fire brigade dial 999 Email info siemenscerberus ie 3 Switch off electrical switches machines ag j on ga nena 4 Close doors and windows Ea at alfmoon Lane South Douglas Road Cork 5 Evacuate premises Phone 021 436 2177 Fax 021 436 27
34. mpetence monitor progress and identify areas requiring additional skill development On successful completion of the required assessments each apprentice will be awarded the Fetac Advanced Diploma Assessment and Certification Model SOLAS has established a national system for apprenticeship training assessment and certification The system is based on standards derived from industry and surveys carried out by SOLAS Two types of assessment will be used to form the basis of certification e Fetac Modular Assessment e Competence Assessment Fetac Modular Assessment Fetac Modular Assessment will be carried out during the off the job phases It involves coursework assessment and standardized and supervised practical multi choice and short answer tests Coursework assessment consists of exercises and projects carried out with access to all available resources The Assessment Programmes for each Phase are set out in a separate manual and will be implemented by the off the job training providers Vehicle Body Repair Phase 2 2 Revision 2 0 January 2014 Module 1 Unit 2 Competence Assessment Competence Assessment will be carried out during the on the job phases Competence is defined as the application of skills knowledge and attitudes in order to perform tasks or combinations of tasks to industrial and commercial standards under operational conditions The workplace assessment will be carried out by the workplace
35. nderstand and observe all legislative and personal safety procedures when carrying out the following tasks If you are unsure of what these are ask your instructor Points to note e A workshop is a hazardous environment To make people more aware of specific workshop hazards legislative bodies such as the International Safety Organization ISO have developed a series of safety signs These signs are designed to give adequate warning of an unsafe situation e Each sign has four components o Signal word o Background color o Text o Pictorial message e There are three signal words DANGER Danger This indicates an immediately hazardous situation which if not avoided will result in death or serious injury Danger is usually indicated by white text with a red background Vehicle Body Repair Phase 2 10 Revision 2 0 January 2014 Module 1 Unit 2 Warning This indicates a potentially hazardous situation which if not avoided could result in death or serious injury The sign is usually in black text with an orange background Caution This indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices This is usually in black text with a yellow background Read all safety signs carefully and follow their instruction The signs must be kept in good condition at all times Replace any missing or damaged signs
36. nufactures guidelines Vehicle Body Repair Phase 2 50 Revision 2 0 January 2014 Module 1 Unit 2 7 0 Self Assessment Questions Module 1 Unit 2 Give the meaning of each of the following safety signs Vehicle Body Repair Phase 2 51 Revision 2 0 January 2014 Module 1 Unit 2 7 List 7 pieces of PPE Personal Protection Equipment 8 What must be worn before work begins in the VBR Workshop Vehicle Body Repair Phase 2 oz Revision 2 0 January 2014 Module 1 Unit 2 9 State the Fire Drill if you discover a Fire 10 Where do you assemble in the event of a Fire 11 How would you find the First Aid Person Vehicle Body Repair Phase 2 53 Revision 2 0 January 2014 Module 1 Unit 2 12 What do you do in the event of an Accident Vehicle Body Repair Phase 2 54 Revision 2 0 January 2014 Module 1 Unit 2 Answers to Questions 1 12 Module 1 Unit 2 This indicates a potentially hazardous situation if not avoided may result in minor or moderate injury Eye protection must be worn Foot protection must be worn Hand protection must be worn Har protection must be worn Vehicle Body Repair Phase 2 55 Revision 2 0 January 2014 Fa Module 1 Unit 2 Respirators must be worn Boots overalls gloves glasses ear muffs respirator and hand protection must be worn Personal Protection Equipment Sound alarm call the instructor evacuate and count co work
37. onal procedure e The lifting capacity of the hoist you are using must be rated for a vehicle weight greater than that of the vehicle you are intending to lift Check the hoist rating and compare it with the weight given in the vehicle service manual Vehicle Body Repair Phase 2 29 Revision 2 0 January 2014 Module 1 Unit 2 e Make sure you know exactly how to operate the hoist taking particular care to know exactly where the stop control is so that you can use it quickly in an emergency Refer to the operations manual for the correct procedure for stopping the hoist e Make sure that there will be adequate headroom above the vehicle after it has been raised Taller vehicles especially those fitted with roof racks may need more headroom than you think e The hoist should be raised so you can comfortably work under it Lock the lift in place before moving underneath or working on the vehicle Step by step instruction 1 Read instructions Read the safety instructions that are provided with the hoist They should be displayed near the lift operating controls Check the hydraulic system for any leaks and the steel cables for any sign of damage Make sure there are no oil spills around or under the hoist 2 Prepare the hoist The hoist should be completely down before you attempt to drive the car on to it The platform may have built in wheel restraints or attachments for wheel alignment equipment A set of bars is mounted at the
38. s rinse immediately PLAN Sa for 15 minutes with water and seek medical advice Is the parcel stable to lift and easily gripped Is your route clear and free from obstructions REST Can you stop and rest if you need to OXIDISING heen Read and use according to instructions Chemicals tat eae con mas opr EASTA i g cook wol woe Coma DESTINATION Have you identified your destination is it safe to unload f ignil and heat i Store a from aaah ane PROTECTION Are you wearing the appropriate protective equipment EXTREMELY FLAMMABLE proof areas 1 Ensure containers are stored away from sources of heat and 1 ignition and keep lids tightly closed STOP THINK 2 Do not breathe spray or vapour and PLAN 3 Take measures to safeguard against static discharges 1 Read and use according to instructions 2 Ensure containers are stored in a cool well ventilated place and keep tightly closed 3 Store away from sources of ignition and heat 4 Ensure this container and it s contents are disposed of in a safe way 1 Ensure containers are stored away from sources of ignition and heat and keep tightly shut 2 Do not breathe spray or vapour 3 Take measures to safeguard against static discharges gases in contact with water or damp air ES Would or might present immediate 1 Ensure containers are kept tightly shut or delayed danger for one or more 2 Take measures to safeguard against release into the environment component
39. s of the environment if release were to occur NOISE AT WHAT YOU SHOULD The Noise Regulations 2005 require employers to prevent exposure to noise at work Employees have dut EMPLOYERS DUTIES __ Assess the risks to employees from noise at work and take action to reduce the noise exposure that produces those risks ie Ensure that the risk assessment has been drawn up by SS br someone who is competent to carry out the task Ensure that the risk assessment is based onadvice and information from people who are competent to provide it EMPLOYERS DUTIES e Maintain all escape routes fire and emergency exits e Maintain a clean and tidy work environment Perform regular maintenance and rectify any faults as soon as is practicable Provide regularly inspect and maintain Safety Equipment EMPLOYEES DUTIES Maintain all escape routes fire and emergency exits 9 Maintain a clean and tidy work environment Report any faults or unsuitable equipment or machinery to his her employer FURTHER REQUIREMENTS e Suitable and sufficient lighting ventilation and temperature e Furniture fittings floors walls and ceilings must be kept clean Necessary safety devices must be fitted to doors and gates Escalators and moving walkways must operate safely Traffic and pedestrian routes must be safely organised and clearly marked Suitable and sufficient sanitary conveniences and washing facilities must be available e
40. t Objective Use an engine hoist and choose the correct attachments to lift an engine Safety check The weight rating of the crane or hoist must be greater than the weight of the object to be lifted Never leave an unsupported engine hanging on a shop crane Secure the engine on an engine stand or on the ground before starting to work on it If using engine stands make sure they are designed to support the weight of the object you are lifting Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks If you are unsure of what these are ask your instructor Points to note Mobile floor cranes are capable of lifting very heavy objects which make them suitable for lifting engines The lifting arm is moved by a hydraulic cylinder and is adjustable for length If the arm is lengthened the lifting capacity of the arm is reduced The weight limit is usually marked on the arm so that the arm or the hydraulic mechanism is not damaged by attempting to lift too heavy a load Make sure the lifting attachment at the end of the lifting arm is strong enough to lift the engine and is not damaged or cracked Vehicle Body Repair Phase 2 31 Revision 2 0 January 2014 Module 1 Unit 2 e When attaching the lifting chain or sling to an engine make sure it is firmly attached and that the hoist is configured to lift that weight Make sure that the fasteners attachin
41. t and high enough to slip under the vehicle once you ve raised it Vehicle Body Repair Phase 2 35 Revision 2 0 January 2014 Module 1 10 Unit 2 Position the jack Roll the jack under the vehicle and make sure the pad or saddle is positioned correctly under the frame or cross member Turn the valve on the top of the jack handle clockwise and begin pumping the handle up and down until the jack pad touches and begins to lift the vehicle Check position of jack Once the wheels lift off the floor stop and check the placement of the jack pad under the vehicle to make sure there s no danger of slipping Double check the position of the wheel blocks to make sure they haven t moved If the vehicle is stable continue lifting it until it s at the height where you can safely work under it Position the safety stands Slide the two jack safety stands underneath the vehicle Make sure they re positioned at a point that can support the weight Both stands should be adjusted to the same height and placed as far apart as practical Lower the vehicle onto the stands Turn the valve on the jack handle counter clockwise and gently lower the vehicle onto the stands When the vehicle has settled onto the stands lower the jack completely and remove it from under the vehicle Repeat this process to lift the other end of the vehicle Be aware that the vehicle is now supported on jack stands and will not be as stable as it would if the w
42. the hoist They should be displayed near the lift operating controls Check the hydraulic system for leaks Make sure there are no oil spills around or under the hoist Prepare the hoist The hoist should be completely down before you attempt to drive the vehicle onto it You should also check the arms and pads for any signs of damage Check under the vehicle to make sure there are no parts which will interfere with the hoist operation and that the vehicle is structurally sound and not badly corroded Check the vehicle s service manual or your workshop service manual and locate the correct contact points for the lifting pads Position the vehicle Carefully drive the vehicle onto the hoist and position it centrally Leave the vehicle in neutral with the emergency brake off You may need to move the car forward or backward to allow the arms to swing under the car Position the lifting pads under the vehicle lifting points Make sure the lifting pads are adjusted to the same height for both sides of the vehicle Raise the hoist to the vehicle Move to the operating controls and raise the hoist just far enough to come into contact with the vehicle Make sure that the lifting pads are positioned centrally under the contact points Raise the vehicle slightly Make sure nobody is near the vehicle and then raise it just far enough for the wheels to be off the floor Check the position of the lifting pads to make sure they have not moved and shak
43. to support the weight of the vehicle e Make sure the vehicle is positioned on a firm level surface e Make sure the jack stands are in good condition before you use them to support the vehicle If they are cracked or bent they will not support the vehicle safely Step by step instruction 1 Position the vehicle Position the vehicle on a flat solid surface Put the vehicle into first gear or park and set the emergency brake Then place blocks in front of and behind the wheels that aren t going to be raised off the ground 2 Inspect the floor jack Before you try to use the jack check for leaks in the hydraulic system Check the pad or saddle and the wheels of the jack They should rotate freely and show no signs of damage Check the manufacturers label on the jack The specifications will tell you the maximum load weight it will bear so it must suit the vehicle you want to raise 3 Check the vehicle handbook Refer to the ownet s manual to find out where you can safely place the jack This is usually a major point on the chassis a cross member or axle unit 4 Select the jack safety stands Before operating the jack select two safety stands of the same type suitable for the weight of the vehicle Check the stands for any cracks and if necessary lubricate the threaded adjusting post with a few drops of engine oil Place one stand on each side of the vehicle at the same point Adjust them so that they are both the same heigh
44. und your workshop Understand the meaning of the Signal Word the colors the text and the symbols or pictures on each sign Ask your instructor if you do not fully understand any part of the sign Identify exits Find out where every door window and gate is and whether they are usually open or locked Plan your escape route should you need to exit in a hurry Check air quality Check for air quality There should be good ventilation and very little chemical fumes or smell Locate the extractor fans or ventilation outlets and make sure they aren t obstructed in any way Locate and observe the use of the exhaust extraction hose pump and outlet that s used on the vehicle s exhaust pipes Identify fire fighting equipment Check the location and types of fire extinguishers in your workshop Be sure you know when to use each type and how Identify flammable hazards Find out where flammable materials are kept and make sure they re stored properly Identify hazards Compressed air Check the hoses and fittings on the air compressor for any damage or excessive wear You have to be particularly careful when troubleshooting air guns Never pull the trigger while inspecting it severe eye damage can result Identify hazards Corrosives Find out which liquids will burn or corrode parts metals or skin Identify caustic chemicals and acids associated with activities in your workshop Personal protection Be aware that YOU cou
45. uvvwvvvwwuvvvuvvvvvvvvv rare os al mm 9 26 TR ea AON and SL mmmmmmmmmmmm m mm mmmmmmr rm rr rr hr 10 Sub hola DH E eer reer rer rr rere tt ee err ter rete Teeter ee 14 Os II Gloine a T E A A E E A E 16 NM 0G TEE A css psec ac E A E ce scsmegadetiasecagiesaeas 18 3 lU Salety ini sole oilc mmmmmmmmmmmmmmmmmmmmmmmmmmmmmHH mas 19 ac Lib a E E SIV ISVS E E E 22 Vehicle Body Repair Phase 2 Revision 2 0 January 2014 Modulel Unit 2 LE pol E e commer err ener ter er rere E rer rer rere cr et ere try eee 24 eM Flies Cs SUC AION G mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm m mmmmmmmmmmmmmmmmmmmmmmmmmi 25 oA saoil Sam E E E E E 25 as 5 Fire exinouis her ba ITS aaaennaaiaaaahaeneinaahiaa a akaieie ieina inkin 26 4 0 Use of fixed SQUID INCI opatenss batrncdeceteess datesetoaiitcnsotns ianeanpisossabyasesossetagdeducsdueutnesdedstuartusetsess 2l AEE a N E A S E E E rem 27 4 2 Operation of a four post hoist a siscrtycacsownestouseussatvncsysaunsessasiuses seseseuosateoeostousessuatenesesoreess 29 So ia a aoi la a nE E EEA EE IEA EAEE A 31 AAL a a OOE a E a E E E T 34 5 0 Personal Safety and Protection esssssssssssssssessesressssrssesssstsseseeseseestesessesseseeseeseseeseeses 37 5 1 Personal Protection Equipment PPE err en eT en eee ene en eer St bf 5 2 Personal protection PLOLE CVC OUT Oras ctiscstsncsindnasnonsicaroncsdeepesopsensynsedeasenesseowensescos 39 i SI A N A E E E E E E 39 S S E E EE O A E A E E T 40 LA E E reed E EA A
46. vels exceed 85 dB when working around operating machinery for any period of time ot when the equipment you or others nearby are using produces loud noise If you have to shout at a person two feet away from you in order to be heard then the sound level is about 85 decibels Ear protection comes in two forms one type covers the entire outer ear and the other is fitted into the ear canal Both types perform the same task and it is a matter of personal preference as to which is the most suitable for you Figure 5 Vehicle Body Repair Phase 2 48 Revision 2 0 January 2014 Module 1 Unit 2 Breathing Devices 2 Seo Always wear an Air Fed Respirator when applying spray paint When working in an environment where dust is present or where the task you are performing will produce dust you should always wear some form of breathing device There are two types disposable dust mask amp respirator Disposable dust mask A disposable dust mask is made from paper with a wire reinforced edge that is held to your face with an elastic strip It covers your mouth and nose and is disposed of at the completion of the task Vehicle Body Repair Phase 2 49 Revision 2 0 January 2014 Module 1 Unit 2 Respirator The respirator has removable cartridges that can be changed accotding to the type of contaminant they are to filter The cartridges should be replaced periodically to ensure their effectiveness Refer to ma
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