Information Sheet 1.

1-1
OH&S REGULATIONS
Introduction
Because the work takes place around potentially dangerous machinery, tools and
chemicals, automotive repair poses certain dangers to mechanics. You might never make
your service area completely free of danger, but you can significantly reduce the risk of
injury by providing regular training and requiring that technicians follow basic safety
procedures on the job.
Occupational Health and Safety (OH&S)
Is a cross-disciplinary area concerned with protecting the safety, health and welfare
of people engaged in work or employment. The goals of occupational safety and health
programs include fostering a safe and healthy work environment.
Occupational Health and Safety
Occupational safety and health can be important for moral, legal, and financial
reasons. Moral obligations would involve the protection of employee's lives and health.
Legal reasons for OSH practices relate to the preventative, punitive and compensatory
effects of laws that protect worker's safety and health.
"Occupational health” should aim at:
1. The promotion and maintenance of the highest degree of physical, mental and social
well-being of workers in all occupations;
2. The prevention amongst workers of departures from health caused by their working
conditions;
3. The protection of workers in their employment from risks resulting from factors
adverse to health;
4. The placing and maintenance of the worker in an occupational environment adapted
to his physiological and psychological capabilities; and,
5. To summarize, the adaptation of work to man and of each man to his job.
Hazard
Hazard is a situation that poses a level of threat to life, health, property, or
environment. Most hazards are dormant or potential, with only a theoretical risk of harm;
however, once a hazard becomes "active", it can create an emergency situation. A hazard
does not exist when it is not happening. A hazardous situation that has come to pass is
called an incident. Hazard and vulnerability interact together to create risk. Work place
hazards can come from a wide range of sources, example of hazards in driving laboratory
and practical work are:
Example of hazards Example of harm caused
Electricity Electric shock
Wet floor Slips, falls
Electrolyte Burn skin
Brake fluid Irritate skin
Fuel Explosion
Risk
Riskis the chance or probability that a person will be harmed or experience an
adverse health effect if exposed to a hazard. It may also apply to situations with property or
equipment loss.
PERSONAL SAFETY RESPONSIBILITIES
  Observe all the safety precautions related to your work or duty.
 Report any unsafe conditions or any equipment or material you think might be
unsafe. Don’t just walk by an open manhole or turn in a broken tool without saying
anything about it. Report it!
 Warn others of hazards that exist.  If you see someone knowingly, or unknowingly,
place him or herself or others in danger, say something.
 Report   any   injury   or   ill   health   to   your trainer. Take an action if there is
injury don’t let the injured person be infected.
 Wear protective clothing whenever appropriate or required. If you’re issued boots,
wear them.
 Be safety conscious.  Always remain alert to danger that may exist.
 Always   inspect   equipment   and   associated attachments for damage before you
use them.  Make sure the equipment you are using is suited for the job. Check the
safety precautions that pertain to each piece of equipment.
SAFETY
The word safety refers to your freedom from danger, injury and damage, and to your
personal security. The word safety has been used so often that many of you may think of it
as a "Preaching Word", or a word that forces you to alter your ways or change bad habits.
Instead, when you hear the word safety, think of it as a word that applies to the way you do
everything in life. Think of it as a procedure to keep you from harm.
Personal Protective Equipment and Dress
Student’s attire should consist of long sleeve shirts and long pants that help protect
arms and legs from cuts, scrapes and burns. Avoid loose clothing that could get caught in
machines or equipment. Require that trainee’s tie back any long hair and remove body
jewelry before working with machinery. Make all appropriate protective equipment available
to students, including safety glasses, goggles, chemical-resistant gloves and kneepads.
Ensure that students use safety equipment when it is required.
Chemical, Electrical and Fire Safety
All chemicals used in the shop should be properly labeled with safety information.
Keep safety data sheets for all chemicals present. The shop should have a functioning eye-
wash station in case of emergency.
Ensure that all students know the location of the electrical shut-off, as well as how to
operate it. Repair or discontinue the use of any electrical equipment with frayed cords to
prevent electrocution and electrical fire.
Make sure all fire extinguishers are marked, charged and checked monthly for expiration.
Train students on the proper use of fire extinguishers and the proper techniques for
combating different types of fires. Make sure an evacuation plan is posted and understood
by all students. Exits should be clearly marked.
Workplace Habits
Safe workplace habits can greatly reduce the potential for injury in the automotive
repair industry. Provide regular safety training and equipment training. Only allow trained
and certified technicians to repair vehicles. Keep the shop floor free of clutter to minimize
the risk of tripping, and use "wet floor" signs after cleaning or spills. When a tool or piece of
equipment is in need of repair, tag it with a sign or sticker so employees don't use it by
accident. Do not allow workers to smoke on or near the shop floor.

Information Sheet 1.1-2

Identify Appropriate Sealant/Adhesive
Introduction
There are three types of sealants manufacturers commonly use to assemble their
automotive engines. These are RTV or room temperature vulcanizing sealant, anaerobic
sealant, and pipe joint compound. Of the three, pliable silicone sealants like RTV are most
common when repairing or rebuilding an engine. This is due to engine vibrations and
imperfect surfaces on engine parts. RTV sealant is not to be used in areas with high
temperatures like exhaust manifolds. Always use the appropriate sealer recommended by
the engine manufacturer for the specific job.
SealantA substance, such as sealing wax,used to seal a surface to preventpassage of a liqu
id or gas.
Types of Sealant
 Aerobic sealant
 Anaerobic sealant
Silicon based aerobic sealants
RTV or room temperature vulcanizingis used throughout the engine sealing all kinds
of leaks. If you've been a technician for any length of time, you've used RTV. An aerobic
sealant dries in the presence of air and forms a flexible rubber gasket. This sealant along
with the other three mentioned, must be applied to a clean surface. Scrape any old gasket
of the surface with a gasket remover and clean the surface thoroughly for a good leak proof
seal.
Always follow manufacturer’s specifications and procedures when using any sealant
with a sensor or actuator. This sealant may be used in place of a conventional gasket only
in specific applications. Sometimes Teflon tape is a great option to help seal threaded parts.
Anaerobic sealants
Is use on machined surfaces.These sealants dries and hardens in the absence of air,
this is the opposite of aerobic sealant that dries in the presence of air. These sealants are
capable of withstanding temperatures in excess of 300 F. These sealants are more likely to
be found inside of an engine.
Keep these sealants out of bolt holes, they will fill the threaded hole and affect the
torque readings. Like the oil pan in the illustration spread the sealant around the inside of
any bolt holes facing the fluid and the inside of the engine.

Seals and Gaskets

Gasket
A gasket is a thin layer of soft material such as paper, cork, rubber, copper,
synthetic material, or a combination of these. The gasket is preformed or precut to the
desired shape and thickness. Clamping the gasket between two flat surfaces makes a tight
seal.
Oil Seals
Cars and light trucks have up to 15 oil seals, or shaft seals. The seal closes or seals
the space between stationary and moving parts. It protects the bearing and retains the
lubricants, and seals out contaminants.The oil seal acts as a separator that prevents two
different substances from mixing.
TASK SHEET 1.2-1

Title: Sanding The Surface

Performance Objective: After reading this task sheet the trainee’s should be able to
perform sanding the surface properly. Sanding the surface should be performed within
30mins.
Supplies/Materials :
Supplies materials
 Paper
 Pencil
 Solvent
 Sand paper
Equipment :
Equipment/tools/instruments
 Putty knife
 Scraper
 Compressor
 Steel brush
 Paint brush
 Rubber hammer
 Hand tools
Steps/Procedure:
1. Clean the surface
At a minimum, you need to have a CLEAN, dry surface on which to apply your
adhesive. Remove as many surface contaminants as possible from the bond area,
including dust, dirt, and grease. For delicate surfaces, clean off as much as practical,
especially any loose particles or surface films. If you use detergents or liquids to clean
the surface, make sure the surface is dry and void of trace cleaners before applying
adhesives.
2. Degrease/oil
The next step you can do is degreasing the surface. Degreasing is removing all
traces of oil and grease (even relatively clean surfaces have oils from fingerprints). If
possible, use a solvent such as, acetone, or isopropyl alcohol*. Wipe or bathe the
surface clean. We recommend degreasing whenever possible, because surface oil or
grease will get in the way of almost all adhesives and weaken adhesion.
3. Abrade
For the strongest and most durable bonds possible, we also recommend
abrading. Abrading a surface gets rid of surface films, mill scale, paint, and oxides and
also gives a much better area for the adhesive to "grip." We recommend abrading if
practical for the material you are bonding. Use fine grain sand paper (600-1000cc),
emery cloth, steel wool, or grit blasting. Abrade enough just to clean and roughen the
surface. After an abrasion treatment, remember to remove all loose particles before
applying adhesive. Brush the surface or blow with compressed air, and then degrease
to clear away all loose particles and residual oils. Abrading and degreasing is enough
 surface prep for all but the most demanding industrial applications.
4. Surface Alteration
Finally, some materials are simply difficult to bond. These include rubber, and
"polyolefin" plastics (such as polyethylene, polypropylene, and hard nylon). Also, some
metals such as copper, stainless steel, and aluminum are slightly more challenging to
bond than other metals. If you are bonding these materials, you might need to change
the surface properties to get good adhesion. Specifically, these are considered low
surface energy surfaces, and you need to alter the surface to increase the surface
energy. This involves using chemical primers, scorching the surface, grit blasting, or acid
etching the surface. Because all materials are slightly different, consult your material
supplier for the most effective way to treat the material for best adhesion.
* NOTE: Always first determine if a solvent can be used without harming your material,
especially in the case of plastics. Also, organic solvents are highly flammable. Follow all
safety instructions and local regulations when using such solvents.

Information Sheet 1.3-1

Safe Handling of Sealant/Adhesive

HEALTH & SAFETY

Work, Health and Environmental Protection When Using Adhesives and
Sealants
The handling of raw materials and products in a responsible way throughout their
lifecycle, namely from their manufacture via the usage stage right through to recycling and
disposal, is nowadays a generally recognized principle.

In many countries, including the US and Western Europe, the development and
manufacture of adhesives and sealants has been carried out following theResponsible
Care®guidelines promulgated by chemical trade associations worldwide, including
the Adhesive and Sealant Council and FEICA. A significant contribution to sustainable
development, Responsible Care® is the chemical industry’s global voluntary initiative under
which companies, through their national associations, work together to continuously
improve their health, safety and environmental performance, and to communicate with
stakeholders about their products and processes.

This specifically means that health protection and environmental compatibility

considerations are taken into account when developing and manufacturing new products.
This has consequences for the composition of the adhesives and sealants, product design,
recommendations for the application of the adhesive or sealant, and the purpose of use and
for the recycling of the product after it has been used.

Health Protection: 
The aim of health protection is to protect people against hazards and exposure.
“Work protection” is used to describe protection in commercial and industrial work
environments while “consumer protection” refers to private users.

Work Protection: 
Industrial and commercial users of adhesives require special protection because
they work on daily basis with adhesives, often for many hours a day. In addition to hazards
associated with the physical properties of adhesives such as flammability, explosiveness
and burns when using hot melts, it is in particular chemical effects such as toxicity, skin
irritation, acid burns and allergies which have to be avoided.
This is achieved by equipping the workplace with properly designed air
replenishment and ventilation systems, providing workers with personal protection
equipment (e.g. work clothing, gloves, and safety glasses) and ensuring that hygiene regula-
tions are adhered to (e.g. thorough washing of the skin before breaks and at the end of
work; refraining from eating, drinking and smoking in the workplace). Safety officers
monitor compliance with these safety measures. Personnel who work with adhesives
undergo regular training on matters relating to work safety and environmental protection.

Consumer Protection: 
 In a professional work environment, possible hazards can be efficiently managed
using suitable protective measures, even in situations where there is long-term use, but the
situation is different for private individuals using adhesives at home where no special
protective measures are taken. Different requirements are put on these adhesives. This is
because private users, unlike industrial users, generally have no knowledge of the
properties and potential hazards of products. That is why only relatively few of all the
known types of adhesives are available to private users, and even then only small amounts
are made available in the form of tubes, cartridges and tins.
On the other hand, private users do not use adhesives every day, but rather only
occasionally and then only in limited quantities and for limited periods of time. As such, the
protective measures described for industrial users are generally neither possible nor
necessary. It is nevertheless essential that the safety information given on the small
packages is observed, as well as basic principles of work hygiene.

Health Risks: 
The area of toxicology is concerned with issues relating to the effects of chemical
compounds and mixtures of chemicals. Assessing the health risk is a multi-step process.
The first step is sound assessment of possible undesirable properties of substances based
on recorded data. In the second step, the quantities of material involved and the nature and
degree of any possible contact are determined. It is then investigated whether an undesired
effect of a material can be caused as a result of this contact. There is no health risk for
people if there is no contact with the undesired material. The risk assessment determines
whether, and to what extent, there is a health risk to people as a result of the relevant
hazard potential of the substance and the nature and degree of exposure.

Information Sheet 1.3-2

Procedures in Sealant/Adhesive Application

INTRODUCTION
This application procedure outlines general requirements for installing Sealants. By
following these procedures closely, you will help ensure good sealant performance. To be
eligible, these procedures must be followed. Sealants are applied in many different
environments and situations, these procedures are not intended to be a complete and
comprehensive quality assurance program

SEALANT APPLICATION PROCEDURE

It is critical that the sealant fill the entire joint or cavity, and firmly contact all
surfaces intended to receive sealant. If the joint is improperly filled, good adhesion will not
be achieved, and sealant performance will be weakened.
To obtain full adhesion, sealants require a clean, dry, frost-free surface. Although silicone
sealants have excellent wide temperature gun ability, the practical application temperature
can be dictated by frost formation on the joint edges, which can begin to occur below -4°C.
To assist in the drying of a frost-contaminated joint, a water-soluble solvent such as IPA
should be used.

Sealant should be applied as follows:

1. Masking tape should be used to keep excess sealant from contacting
adjacent areas where it is not intended to ensure an aesthetically pleasing job.
2. Apply the sealant in a continuous operation using a caulking gun or pump. A
positive pressure, adequate to fill the entire joint width, should be used. This can be
accomplished by pushing" the sealant ahead of the application nozzle. Care must be
taken to ensure complete fill of the sealant cavity,

JOB SHEET 1.3-2

Title: Applying Sealant/adhesive

Performance Objective: After reading this job sheet the trainee’s should be able to
apply adhesive properly. Applying sealant should be performed within 30mins.

Supplies/Materials :
Supplies materials
 Form in place gasket
 Ribbon sealer
 Sealant (aerobic and anaerobic)
 Silicon body sealer
Equipment :
Equipment/tools/instruments
 Putty knife
 Scraper
 Steel brush
 Paint brush
 Compressor
 Hand tools
 Rubber hammer
PPE includes:
 Gloves
 Apron
 Safety shoes
 Goggles
 Gas mask
Steps/Procedure:
1. Preparation – Gather all the materials,tools needed, place near in the area that
are accessible.
2. Sanding the surface –the surface should be clean and free from dirt and other
contaminants.
3. Squeeze a bead of plastic sealant from a tube onto one of the mating surfaces.
Typical surfaces include valve cover, cylinder head,thermostat, water pump.
4. On preformed gasket,or precut gasket, apply the sealant on both sides and
assemble immediately.
5. After the gasket is assembling,tighten the bolts to prevent leaking of fluid other
liquid.
6. Re-checks your work.
7. Perform 5s – return all the tools and materials in the proper place. And clean
the area.
 Information Sheet 1.4-1
Store/Dispose of Sealant/Adhesive

Introduction
This sheet has been prepared as a general guideto safe handling and storage
procedures for allusers of adhesives and sealants. Specific hazards and precautionary
measures are stated, whererequired, for the various types of adhesives andsealants.
HYGIENE
The possible ingestion of adhesives and sealantsshould be avoided and the
consumption orstorage of food or drink should be prohibited inareas where adhesives are
handled or used.Certain adhesives which emit dust or toxicvapors present a hazard from
inhalation. Suitabledust masks, respirators and/or adequateventilation should be provided
in these instances.Skin contact should be minimized andmanufacturers will advise on
barrier and cleansingcreams appropriate for their products, as well assuitable protective
clothing and eye protectionwhere considered necessary.
STORAGE
The storage of adhesives and sealants should berestricted to 'NO SMOKING' areas
since even fornon-flammable adhesives there is a risk that vapors can be given off which
will be convertedby pyrolysis to toxic products by a burningcigarette.
All flammable adhesives should be stored insuitable flameproof areas according to
theirrequirements of the appropriate authorities.All adhesives and sealants should be
stored in conditions and reasonable temperatures,preferably between 50C-300C.
Warn drums of solvent-based adhesives shouldbe opened slowly and carefully to
allow gradualrelease of internal pressure.
To ensure that the useful shelf life of adhesiveproducts is not exceeded, strict
rotation of stockshould be observed and possible safety hazards from aging avoided.
In all cases, the manufacturer's instructions anddirections printed on the label
should be observed.
SPILLAGE & WASTE DISPOSAL
Spillages of any type should be attended toimmediately. Water-based products can
bewashed away with water before they dry, providedit is permissible to discharge this type
of effluentinto the drains. An alternative method is to soakup the Spillage with an inert
material, which canbe placed in a suitably closed container fordisposal. This technique is
particularly appropriatefor solvent based adhesives, using sand,clay or powdered limestone
as the absorbentmaterial.
Care should be taken in the disposal of full orempty containers for solvent-based
adhesives inorder to avoid a latent explosion and/or firehazard. The empty containers
should be eithercarefully punctured or left open to ensure that nosolvent vapor is trapped
under pressure, takingthe usual precautions concerning flammablematerials.