Healthy and Safety Precautions Part 2

Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.

Gasoline (petrol) engine
There may not be adequate warning of odour or of irritation before toxic or harmful effects arise. These may be immediate or delayed.

Fibre Insulation
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect.
Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the use of gloves.

Fire
Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or welding processes.
Ensure, before using electrical or welding equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.

First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
Individuals affected by inhalation of gases, fumes etc. should be removed to fresh air immediately. If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not induce vomiting unless this action is indicated on the label.

Foams - Polyurethane
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturer's instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and respiratory protection. Do not remove the respirator immediately after spraying, wait until the vapor/mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames or the use of electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation.

Fuels
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

Gasoline (Petrol)
Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs e.g. through vomiting, is a very serious hazard.
Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe pain.
Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of gasoline vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.
Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious consequences of inhalation in the event of vapor build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth.

Gas - oil (Diesel Fuel)
Combustible.
Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin disorders including skin cancer.

Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation.

Gas Cylinders
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 13.790 kPa, (2000 lb/in2) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition.
Only trained personnel should undertake work involving gas cylinders.

General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required.
Never use tools or equipment for any purpose other than that for which they were designed. Never over - load equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment.
Ensure adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil Test Equipment
Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle, e.g. diesel injector, at the skin as the fluid may penetrate to the under - lying tissue etc., and cause serious injury.

Legal Aspects
Many laws and regulations make requirements relating to health and safety in the use and disposal of materials and equipment in workshops. Some of these laws which apply in the U.K. are listed. Similar laws exist for other territories:
- The Factories Act (1961).
- The Asbestos Regulations (1969).
- Highly Flammable Liquids and Liquified Petroleum Gases Regulations (1972).
- Control of Pollution Act (1974).
- Health and Safety at Work Act (1974).
- The Classification, Packaging and Labelling of Dangerous Substances Regulations (1978, 1981, 1983, 1984).
- Control of Lead at Work Regulations (1980).
- Control of Substances Hazardous to Health (COSHH) Regulations (1989).
- Abrasive Wheels Regulations (1970).
- Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1985 (R1DD02).

Workshops should be familiar, in detail, with these and associated laws and regulations.
Consult the local factory inspectorate if in any doubt.

Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and skin.

Used Engine Oil
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
There are publications describing the problems and advising on precautionary measures. For the UK a typical Health and Safety Executive publication is: SHW 397: Cautionary Notice: Effects of mineral oil on the skin.

Health Protection Precautions
- Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Do not put oily rags into pockets.
- Avoid contaminating clothes, particularly underpants, with oil.
- Heavily soiled clothing and oil - impregnated footwear should not be worn. Overalls must be cleaned regularly.
- First Aid treatment should be obtained immediately for open cuts and wounds.
- Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
- Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanoline replace the natural skin oils which have been removed.
- Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
- If skin disorders develop, obtain medical advice without delay.
- Where practicable, degrease components prior to handling.
- Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

Environmental Precautions
Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. In the UK the heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the appropriate local authority and/or manufacturer of approved appliances.
Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the relevant local authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses.

Noise
Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear protection must be worn.

Paints
Highly flammable, flammable - observe No Smoking policy

One Pack
Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should be carried out only with adequate ventilation.

Two Pack
Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturer's instructions should be followed. See also Resin - based Adhesives and Isocyanate Adhesives and Sealers under Adhesives and Sealers.
Spraying should preferably be carried out in exhausted ventilated booths removing vapor and spray mists from the breathing zone. Individuals working in booths should wear appropriate respiratory protection. Those doing small scale repair work in the open workshop should wear air - fed respirators.

Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy - acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.

Solvents
See also chemical materials, Fuels(Kerosene), Fire
e.g. acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins, thinners etc.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, e.g. paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturer's instructions.

Suspended Loads

CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load e.g. suspended engine, etc.
Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc., are adequate and suitable for the job, in good condition and regularly maintained.

Viton
In common with many other manufacturers' vehicles, some components fitted to the Jaguar range have `O' rings, seals or gaskets which contain a material known as `Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for `O' rings, gaskets and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of 400 degrees C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.
`O' rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky substance.
DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected `O' ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may be Viton or any fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater (calcium hydroxide) solution to neutralize the acid before disposing of the decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding
See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Resistance Welding
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.

Arc Welding
This process emits a high level of ultra - violet radiation which may cause arc - eye and skin burns to the operator and to other persons nearby. Gas - shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.

Gas Welding (and Cutting)
Oxy - acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultra - violet emission is much less than that from arc welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.

Warning Symbols on Vehicles
Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service or repair operations on the vehicle.
The most commonly found decals are reproduced below together with an explanation of the warnings.







1. Components or assemblies displaying the warning triangle and open book symbol advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind.







2. Components or assemblies displaying the warning triangle with the electrified' arrow and open book symbol give warning of inherent high voltages. Never touch these with the engine running or the ignition switched on.







3. Jaguar vehicles and replacement parts which contain asbestos are identified by this symbol.







4. Components or assemblies displaying this symbol give warning that the component contains a corrosive substance.







5. Vehicles displaying the caution circle with a deleted lighted match symbol, caution against the use of naked lights or flames within the immediate vicinity due to the pressure of highly flammable or explosive liquids or vapors.

Safety Precautions

WARNING:
- WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOR BEING PRESENT IN THE ATMOSPHERE. FUEL VAPOR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHILST WORKING ON THE FUEL SYSTEM. ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:
- DO NOT SMOKE IN THE WORK AREA.
- DISPLAY NO SMOKING SIGNS AROUND THE AREA.
- DISCONNECT THE BATTERY BEFORE WORKING ON THE FUEL SYSTEM.
- DO NOT CONNECT/DISCONNECT ELECTRICAL CIRCUITS, USE ELECTRICAL EQUIPMENT OR OTHER TOOLS OR ENGAGE IN WORKING PRACTICES WHICH IN ANY WAY MAY RESULT IN THE PRODUCTION OF SPARKS.
- ENSURE THAT A CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.
- ENSURE THAT DRY SAND IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
- EMPTY FUEL USING SUITABLE FIRE PROOF EQUIPMENT INTO AN AUTHORIZED EXPLOSION PROOF CONTAINER.
- DO NOT EMPTY FUEL WHILE WORKING IN A WORKSHOP OR A PIT.
- ENSURE THAT WORKING AREA IS WELL VENTILATED.
- ENSURE THAT ANY WORK ON THE FUEL SYSTEM IS ONLY CARRIED OUT BY EXPERIENCED AND WELL QUALIFIED MAINTENANCE PERSONNEL.
- ENSURE THAT FUME EXTRACTION EQUIPMENT IS USED WHERE APPROPRIATE.
- FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE, WHITE SPIRIT, SBP3, METHYLENE CHLORIDE, PERCHLORETHYLENE. DO NOT SMOKE IN THE VICINITY OF VOLATILE DEGREASING AGENTS.

Whenever possible, use a ramp or pit whilst working beneath a vehicle, in preference to jacking. Position chocks at the wheels as well as applying the parking brake. Never rely on a jack alone to support a vehicle. Use axle stands, or blocks carefully placed at the jacking points, to provide a rigid location. Check that any lifting equipment used has adequate capacity and is fully serviceable. Ensure that a suitable form of fire extinguisher is conveniently located. When using electrical tools and equipment, inspect the power lead for damage and check that it is properly earthed. Disconnect the earth (grounded) terminal of the vehicle battery. Do not disconnect any pipes of the air conditioning refrigeration system unless you are trained and instructed to do so. A refrigerant is used which can cause blindness if allowed to come into contact with the eyes. Ensure that adequate ventilation is provided when volatile degreasing agents are being used.

Adhere strictly to handling and safety instructions given on containers and labels. Keep oils and solvents away from naked flames and other sources of ignition. Do not apply heat in an attempt to free seized nuts or fittings; as well as causing damage to protective coatings, there is a risk of damage from stray heat to electronic equipment and brake lines. Do not leave tools, equipment, spilt oil etc. around the work area. Wear protective overalls and use barrier cream when necessary.

Environmental Protection
In some countries it is illegal to pour used oil onto the ground, down sewers or drains, or into water courses. The burning of used engine oil in small space heaters or boilers is not recommended unless emission control equipment is fitted. Dispose of used oil through authorized waste disposal contractors, to licensed waste disposal sites or to the waste oil reclamation trade. If in doubt, contact the Local Authority for advice on disposal facilities.