student reference

AutomotiveTechnologyCurriculum

AutomotiveTechnologyCurriculum

Module 1: Introduction toAutomotive Technology

Module 1: Introduction toAutomotive Technology

70-1801-S

2006 EditionStudent

Reference

IntroductIon to AutomotIve technology

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Automotive Technology

Module 1: Introduction to Automotive Technology

Student Reference

ProducedbytheInstructionalMaterialsLaboratory1400RockQuarryCenter

UniversityofMissouri-ColumbiaColumbia,MO65211

(800)669-2465

2006Edition

Catalogno.70-1801-S©2006.TheCuratorsoftheUniversityofMissouri.

AllRightsReserved.

TechnicalConsultants:

KenEstesRobinFerguson

SteveReese

ProjectCoordinator:EricaKassel

Editor:JanisLevsen

GraphicArtists:

ChrisBenedictJacquelineCraig

AutomotIve technology

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ACKNOWLEDGMENTS

The2006revisionofIntroduction to Automotive TechnologyrepresentstheInstructionalMaterialsLaboratory’scommitmenttothecontinualimprovementoftheAutomotiveTechnologyCurriculum.Introduction to Automotive Technologyis the first in the nine-module series. The other modules are as follows:

Module2 Electrical SystemsModule3 Engine Performance, Section 1: Ignition SystemsModule3 Engine Performance, Section 2: Fuel and Exhaust SystemsModule3 Engine Performance, Section 3: Emission Control SystemsModule4 Engine RepairModule5 Steering and Suspension SystemsModule6 BrakesModule7 Manual Drive Train and AxlesModule8 Automatic Transmissions and TransaxlesModule9 Heating and Air Conditioning

AllmodulesarebasedontheNationalAutomotiveTechniciansEducationFoundation(NATEF)tasklist.ForyearstheNationalInstituteforAutomotiveServiceExcellence(ASE)hassettheprofessionalstandardsforautomotivetechnicians.AstrongNATEForientationmakestheninecurriculumguidesaneffective tool for preparing students to enter the technologically advanced field of automotivetechnology.

IML gratefully acknowledges the important contribution of the advisorycommittee:

RogerDonovan,IllinoisCentralCollege,EastPeoria,ILKenEstes,GrandRiverTechnicalSchool,Chillicothe,MORobinFerguson,KirksvilleVocationalTechnicalSchool,Kirksville,MOSamJeanrenaud,Lee’sSummit,MOKeithKendrick,JohnA.LoganCollege,Carterville,ILSteve Reese, Lewis and Clark Vocational Technical School, St. Charles, MORon Tuetken, Lewis and Clark Community College, Godfrey, ILJohnWalker,HannibalAreaVocationalTechnicalSchool,Hannibal,MORodneyWolken,EldonCareerCenter,Eldon,MO


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TABLE OF CONTENTS

Introduction ................................................................................................................ i

TitlePage............................................................................................... i

Acknowledgments.............................................................................iii

Components.......................................................................................vii

References.........................................................................................viii

Unit I Careers in the Automotive Field ..................................................S 1

Lesson1:TheAutomotiveTechnologyCareer.......................... S5Unit II Safety ...............................................................................................S 11

Lesson1:ProtectingYourselfandOthersintheShop............ S15

Lesson2:ShopSafetyFeaturesandEmergency Procedures...................................................................................... S35

Lesson3:RaisingandSupportingVehiclesSafely.................. S41

Lesson4:FederalandStateHazardousMaterial Regulations..................................................................................... S49

Unit III Chemicals and Their Use ............................................................S 59

Lesson1:Solvents,Soaps,andCleaningSolutions................. S63

Lesson2:LubricantsandSpecialtyChemicals......................... S71

Lesson3:Gases,AsbestosDust,andBatteryAcid.................. S79

Unit IV Basic Hand Tools ..........................................................................S 85

Lesson1:TypesofWrenches...................................................... S89

Lesson 2: Types of Screwdrivers and Pliers.............................. S97

Lesson3:TypesofHammers,Punches,andChisels............. S103


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Unit V Specialty Tools, Fasteners, and Measuring Tools ................S 107

Lesson1:SpecialtyTools........................................................... S111

Lesson2:Fasteners..................................................................... S119

Lesson3:MeasuringTools........................................................ S129

Unit VI Power Tools and Shop Equipment ..........................................S 135

Lesson 1: Power Tools................................................................ S139

Lesson2:ShopEquipment........................................................ S151

Unit VII Vehicle Information ...................................................................S 161

Lesson1:ServiceInformationandVehicle Identification................................................................................. S165Unit VIII Customer Service ........................................................................S 169

Lesson1:CustomerService,WorkOrders,and VehiclePreparation..................................................................... S173


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COMPONENTS

I. Objectives —Eachunitisbasedonobjectivesthatstatethemeasurableunit and specific behavioral or performance objectives that the student is expectedtoachieve.Becausetheobjectivesoftheunitprovidedirectionfortheteaching-learningprocess,theteacherandstudentneedacommonunderstandingoftheintentoftheobjectives.

II. Information Sheets —Presentedinoutlineformat,theinformationsheetsprovide content essential for meeting the cognitive (knowledge) objectives intheunit.Thestudentshouldstudytheinformationsheetsbeforeanyclassdiscussionorcompletionoftheassignmentsheets.ThecorrespondingStudentReferencepagenumbersappearintheuppercorneroftheInstructorGuide.

III. Assignment Sheets — The assignment sheets allow the student to respond to cognitive questions in writing.

IV. Job Sheets —Thejobsheetsaredesignedtoguidethestudentthroughvariouskeytasksandprovideameansfortheinstructortoevaluateastudent’sperformanceofthetask.

V. Unit Tests — The unit tests evaluate the student’s knowledge of the material.

VI. Student Workbook and Student Test Packet Tracking Sheets —Theseprovide the instructor with an effective way to track student progress on theassignmentsheets,jobsheets,andunittests.


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rEFErENCES

Alliance of Automobile Manufacturers. www.autoalliance.org.

“AqueousPartsCleaning.”Best Environmental Practices for Auto Repair,November1999.EnvironmentalProtectionAgency.

Automotive Lift Institute. www.autolift.org

“Battery Safety.” National Ag Safety Database (NASD). www.cdc.gov/nasd.

Chrysler. www.chrysler.com.

Dodge. www.dodge.com.

Duffy,JamesE.ModernAutomotiveTechnology.TinleyPark,IL:TheGoodheart-WillcoxCompany,Inc.,2000.

“FloorCleanup.”Best Environmental Practices for Auto Repair,November1999.EnvironmentalProtectionAgency.

Ford Motor Company. www.ford.com.

General Motors. www.gm.com.

NationalAutomotiveTechniciansEducationFoundation(NATEF).www.natef.org.

National Institute for Automotive Service Excellence (ASE). www.asecert.org.

Occupational Outlook Handbook, 2006–07 Edition.UnitedStatesDepartmentofLabor. Bureau of Labor Statistics. www.bls.gov/oco.

Screw Drive Systems. Sizes.com. www.sizes.com.

Sunkin,Ed.“TrendsandTraitsofToday’sTechnicians:The2001ProfessionalAutomotiveTechniciansSurvey.”Underhood Service,March2001.

Tobolt,WilliamK,LarryJohnson,andW.ScottGauthier.AutomotiveEncyclopedia.TinleyPark,IL:TheGoodheart-WillcoxCompany,Inc.,2000.

UnitedStatesDepartmentofLabor,OccupationalSafetyandHealthAdministration. www.osha.gov.

United States Environmental Protection Agency. www.epa.gov.

www.autoalliance.org

www.autolift.org/

www.cdc.gov/nasd

www.chrysler.com

www.dodge.com

www.ford.com

www.gm.com

www.natef.org/

www.asecert.org

www.bls.gov/oco

www.sizes.com

www.osha.gov

www.epa.gov


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UNIT I: careers IN The aUTomoTIve fIeld

coNTeNTs of ThIs UNIT

I. Unitobjective

II. Lessonplan

A. Lesson1:TheAutomotiveTechnologyCareer

1. Informationoutline

2. AssignmentSheet

a. AS1-L1-UI:AutomotiveTechnologyField

III. UnitITest


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Aftercompletingthisunit,studentswillbeabletoidentifysomeoftheopportunities in the automotive field and various facts about the automotive technologycareer.Studentswilldemonstratemasteryofthematerialbycompletingtheassignmentsheetandachievingascoreof_____ontheUnitITest.

sPecIfIc oBJecTIves

Aftercompletingthelessoninthisunit,studentsshouldbeableto:

Lesson 1

I. Identify some of the opportunities in the automotive field.

II. Identifytheimportanceoftrainingandhowautomotivetechniciansandtraining programs are certified.

III. Identify job prospects in the automotive technology field.

IV. Identifycommonmethodsusedtopayautomotivetechnicians.

V. Identifyotherfactsaboutworkingasanautomotivetechnician.

VI. Complete the assignment sheet on the automotive technology field (AS1-L1-UI).


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lessoN 1: The aUTomoTIve TechNology career

I. Opportunities in the automotive field

A. AccordingtostatisticsfromtheU.S.DepartmentofLabor,over800,000peopleintheUnitedStatesareemployedasautomotiveservicetechniciansandmechanics.

1. Mostareemployedinthefollowingbusinesses:

a. Automotiverepairandmaintenanceshops

b. Automobiledealers

c. Retailersandwholesalersofautomotiveparts,accessories,andsupplies

2. Othersworkinthefollowingbusinessesororganizations:

a. Gasstations

b. Homeandautomotivesupplystores

c. Automotiveequipmentrentalandleasingcompanies

d. Federal,state,andlocalgovernments

3. Over16%owntheirowntheirownbusiness.

B. Manyjobopportunitiesareavailablethatrelatedirectlyandindirectlyto the automotive technology field.

Automotive technology

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1. Opportunitiesdirectlyrelatedtoautomotivetechnology

a. Automotivetechnician

b. Automotivetechnician’sapprentice

c. Repairshopsupervisor

d. Exhaustandemissionstechnician

e. Tune-uptechnician

f. Servicewriter

g. Mechanicalunitrepairer

h. Technicianinautomotivemanufacturingplants i. Airconditioningtechnician

j. Enginetechnician

k. Teacherortrainer

NOTE: Manygraduatesofautomotivetechnologyprogramsqualifytopursueacareerasateacherortrainerwithlittleornoextratrainingrequiredforanentry-levelposition.

l. Dieseltechnician m. Businspector

n. Tractortechnician

o. Partssalvager

2. Opportunitiesindirectlyrelatedtoautomotivetechnology

a. Farmequipmenttechnician

b. Aircrafttechnician

c. Officeequipmentservicetechnician/servicerepresentative

d. Machinistapprentice


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e. Airconditioningandheatingserviceapprentice

f. Industrialmachinemaintenancetechnician

g. Smallenginetechnician

h. Marineequipmenttechnician

i. MotorcycletechnicianII. Training and certification

A. Repairingandmaintainingtoday’ssophisticatedvehiclesrequiresknowledgeinmanydiversesystemsandtechnologicallyadvancedareas.

1. Thedaysofgettingajobbasedonperformingautomotiverepairasahobbyortinkeringinthegaragearegone.

2. Mostjobopportunitiesrequireformaltraininginautomotivetechnologyinhighschoolorapostsecondaryschoolorcollege.

B. Certifyingorganizations

1. AsstatedontheirWebsite,theNationalInstituteforAutomotive Service Excellence (ASE) is a nonprofit organization thataimsto“improvethequalityofvehiclerepairandservicethrough the testing and certification of repair and service professionals.“

a. Automotive technicians can be certified in one or more of theeightareasbelow.

• Brakes

• Electrical/electrical systems

• Engineperformance

• Suspensionandsteering

• Automatictransmissionandtransaxle

• Enginerepair

• Heatingandairconditioning


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• Manualdrivetrainandaxles

b. To be certified, technicians must have at least 2 years of experienceandpassanASEwrittenexamination.Theymustretaketheexamevery5yearstomaintaintheircertification.

2. TheNationalAutomotiveTechniciansEducationFoundation

(NATEF),anarmofASE,reviewstrainingprogramstoensuretheyaremeetingASEstandardsandstayingup-to-datewiththecontinuouslychangingautomotivetechnologyandrepairmethods.

a. Trainingprogramsrequestthereviewprocessonavoluntarybasis.Ifaprogrampassesthereview,NATEFrecommends it to ASE for certification. Programs must be reviewed again every 5 years to be recertified.

b. InASE’sautomobilespecialty,trainingprogramscanbecertified in the eight areas listed in 1a.

C. To stay current with changes and advancements in the field,

automotivetechnicianswillneedtoattendtrainingclassesthroughouttheircareers.Techniciansmayreceivetrainingattheirworkplaceormayneedtoattendclassesatatechnicalschoolorcollege.


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III. Job prospects in the automotive technology field

A. Prospectsareverygoodforindividualswithtrainingandskillsindiagnosis,problemsolving,electronics,andmathematics.Knowledgeinelectronicshasbecomecrucialbecausemostvehicleconcernsinvolveworkingwithoranalyzingtheelectricalsystem.AccordingtotheAllianceofAutomobileManufacturers,“electronicsnowcontrolmorethan86%ofallsystemsinatypicalvehicle.”

B. Manyemployersintheindustryhavereportedthatthereisashortageof automotive technicians and they have difficulty hiring individuals witheducationandexperienceintheareasdesired.

C. AccordingtotheOccupational Outlook Handbook,publishedbytheU.S.DepartmentofLabor,jobopportunitiesforautomotivetechniciansareexpectedtoincrease9%to17%throughtheyear2014.Thegrowthwillbeduetotheincreasednumberofvehiclesontheroadandthelossoftechniciansbecauseofretirementoradvancementtospecializedpositions.

D. Workforautomotivetechniciansisgenerallysteadythroughouttheyearandnotverysensitivetochangesineconomicconditions.Therefore,layoffsarenotabigconcern.

IV. Commonmethodsusedtopayautomotivetechnicians

A. Hourly–Thetechnicianispaidforthetimeheorsheputsin.

B. Salary–Asalaryisasetamountofmoney,usually40hoursperweek,regardlessofthevolumeofworkperformed.

C. Flatrate–Thetechnicianispaidhisorherhourlywagemultipliedby the time listed for a specific job in a factory flat-rate manual or anaftermarketlabortimeguide.Theseguidesaresometimescalledpartsandlaborestimatingguides.Techniciansrefertotheseas“bookhours.” The technician is paid this flat rate regardless of the time spentonajob.

D. HourlyplusapercentageoflaborandpartsV. Otherfactsaboutworkingasanautomotivetechnician

A. Automotivetechnician’susemanydifferenttoolsandequipment,includingthoseinthefollowinglist.Techniciansusuallypurchasetheirownhandtools,whereastheshopprovidesthemoreexpensivepowertoolsandequipment.


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1. Commonhandtools

2. Powertools

3. Machinetools

4. Weldingandoxyfuelcuttingequipment

5. Liftsandjacks

6. Computerstoperformadministrativetasksandaccessserviceinformation

7. Computerizeddiagnosticequipment

8. Measuringtools

9. Testinstruments

10. Otherspecialtytools,dependingontheautomotivetechnologyarea

B. Someshopsareunionized,whichmeansthattechniciansemployedtherearesubjecttounionrulesregardingpayandotherissues.Forexample,thetechnicianmayberequiredtoworkfor2yearsasanapprenticebeforeadvancingtothejourneylevel.Theunionalsofunctionstohelpemployeesnegotiatewiththeiremployersregardingsalariesandworkingconditions.


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UNIT II: safeTy


I. Unitobjective

II. Lessonplans

A. Lesson1:ProtectingYourselfandOthersintheShop


2. Assignmentsheet

a. AS1-L1-UII:WorkSafetyintheShop 3. Jobsheet

a. JS1-L1-UII:IdentifyVehiclesEquippedWithaSupplementalRestraintSystem(SRS)andAntilockBrakeSystem(ABS)

B. Lesson2:ShopSafetyFeaturesandEmergencyProcedures


2. Assignmentsheets

a. AS1-L2-UII:SafetyFeaturesandEmergencyProceduresintheShop

b. AS2-L2-UII:ShopSafetyInspectionChecklist

C. Lesson3:RaisingandSupportingVehiclesSafely


2. Assignmentsheet

a. AS1-L3-UII:LiftandSupportVehicles 3. Jobsheet

a. JS1-L3-UII:LiftaVehicle


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D. Lesson4:FederalandStateHazardousMaterialRegulations


2. Assignmentsheet

a. AS1-L4-UII:HazardousMaterialRegulations

III. UnitIITest


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UNIT II: safeTy

UNIT oBJecTIve

Aftercompletingthisunit,studentsshouldbeabletoidentifyvarioussafetyrulesforpersonalsafetyintheshop,liftingandsupportingavehicle,andworkingwithhazardousmaterials.Theyshouldalsobeabletoidentifysafetyfeaturesandemergencyproceduresintheshop.Studentswilldemonstratemasteryofthematerialbycompletingtheassignmentsheets,successfullyperforming specific tasks on the job sheets, and achieving a score of _____ on the UnitIITest.

sPecIfIc oBJecTIves

Aftercompletingthelessonsinthisunit,studentsshouldbeableto:

Lesson 1

I. Identifywhoisresponsibleforsafetyintheshop.

II. Identifyfederalagenciesandguidelinesforsafepractices.

III. Identifygeneralshopsafetyrules.

IV. Identifygeneralsafetyrulesforhandlingtoolsandequipment.

V. Identifyrulesforelectricweldingsafety.

VI. Identifyrulesforoxyacetyleneweldingandcuttingsafety.

VII. Identifyrulesforliftingheavyobjectssafely.

VIII. Identifythepersonalprotectiveclothingandequipmentthatisusedintheshop.

IX. Identifytheimportanceofpropergroomingandhygiene.

X. Identifyrulesforusinghazardousmaterialssafely.

XI. Identifysafetyprecautionsforsupplementalrestraintsystems(SRSs)andantilockbrakesystems(ABSs).

XII. Completetheassignmentsheetonworksafetyintheshop (AS1-L1-UII).


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XIII. Demonstratetheabilityto:

A. Identifyvehiclesequippedwithasupplementalrestraintsystemandantilockbrakesystem(ABS)(JS1-L1-UII).

Lesson 2

I. Identifythesafetyfeaturesandequipmentintheshop.

II. Identifytheimportanceofmaintainingcleanlinessandorderintheshop.

III. Identifyemergencyproceduresusedintheshop.

IV. Completetheassignmentsheetonsafetyfeaturesandemergencyproceduresintheshop(AS1-L2-UII).

V. Completetheassignmentsheetonashopsafetyinspectionchecklist (AS2-L2-UII).

Lesson 3

I. Identify terms and definitions associated with lifting vehicles.

II. Identifycommonliftingdevices.

III. Identifycommonsupportdevices.

IV. Identifyprinciplesofliftingandsupportingvehicles.

V. Completetheassignmentsheetonliftingandsupportingvehicles (AS1-L3-UII).

VI. Demonstratetheabilityto:

A. Liftavehicle(JS1-L3-UII).

Lesson 4

I. IdentifytherequirementsinOSHA’shazardousmaterialregulations.

II. IdentifytherequirementsintheEPA’shazardousmaterialregulations.

III. Completetheassignmentsheetonhazardousmaterialregulations (AS1-L4-UII).


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UNIT II: safeTy

lessoN 1: ProTecTINg yoUrself aNd oThers IN The shoP

I. Responsibilityforsafety

A. Safetyintheautomotiveshopistheresponsibilityofeveryone.Safetymeansprotectingyourselfandothersfrominjuryatalltimes.Workingintheshoprequirestheuseofalargevarietyoftools,materials,andequipmentthatcaninjuretheworkerandothersintheshopifnotproperlyhandled.

B. Safetyintheshopincludestheitemslistedbelow.

1. Followingfederalguidelinesforsafepractices

2. Keepingtheshopfreeofhazards

3. Usingprotectiveclothingandequipment

4. Handlingandusingmaterialscontainingpotentiallyharmfulchemicalscorrectly

5. Usinghandtools,powertools,andequipmentcorrectly

6. FollowingweldingsafetyrulesII. Federalguidelinesforsafepractices

A. Twofederalagenciesissueguidelinesandoverseesafetyintheworkplace.

1. OSHA(OccupationalSafetyandHealthAdministration)issuesguidelinesconcerningsafetyfortheworker.

2. TheEPA(EnvironmentalProtectionAgency)issuesguidelinesconcerningsafetyfortheenvironment.

B. OSHAguidelinesandEPAguidelines

1. EachschoolwillhaveacopyofOSHAandEPAguidelinesthatmustbefollowed.DuetothechangingnatureofOSHAandEPAguidelines,theinstructorwillgoovercurrentguidelineswithstudents.AllstudentsarerequiredtofollowOSHAandEPAguidelines.


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2. OSHAguidelinesconcernthecorrectlabelingofhazardouscomponentsofequipment,thecorrectstorageofequipmentandmaterials,theuseofprotectiveclothingandequipment,theplacementofwarningandsafetysigns,andgeneralsafetypractices.

3. EPAguidelinesconcernproperhandling,storage,anddisposalofhazardousmaterials.Theycoveranymaterialsthatmaybehazardousifreleasedintotheenvironment,includingtheenvironmentoftheshop.

4. SeeLesson4formoreinformationabouttheseagencies. III. Generalshopsafetyrules

A. Duringthecourseofworkingintheshop,anautomotivetechnicianmovesfromoneareaoftheshoptoanother,movingpartsandequipmentaroundtheshopandperformingvariedtasks.Itisimportant that the shop floor be free of hazards that could cause technicianstosliportrip.

B. Inawidevarietyofshoptasks,wastematerialsareproducedthatcancausedangeroussituationsunlessthewastematerialsaredisposedoforstoredproperly.

C. Alwaysbesurethatshopexitsarewell-markedwithan“EXIT”signandareclearofobstructions.

D. Forpersonalsafetyandtohelpkeeptheshopfreeofhazards,alwayscomplywiththefollowingsafetyrules.

1. Workquietlyandfocussolelyonthejobathand.

2. Do not leave creepers laying on the floor. Always stand them againstthewall,wheelsoutward,whennotinuse.

3. Donotindulgeinhorseplayintheshop.Immatureandimproperbehaviorintheshopcancauseseriousaccidents.

4. Beforeperformingatask,considertherelevantsafetyprecautionsrelatedtothetaskandformulateapreventionplanforeachhazard.

5. Alwayswearprotectiveclothingandequipmentinanysituationwhereitisnecessary.


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6. Wearprotectiveeyewearatalltimesintheshoparea.

NOTE:Thelawrequiresthatprotectiveeyewearbeavailableandwornincareerandtechnicaleducationcourseswherethereisareasonableprobabilityofinjury.

7. Donotwearrings,bracelets,watches,ornecklaceswhenworkingaroundmovingmachineryorelectricalequipment.

a. Jewelrycancatchinmovingmachinerywithseriousconsequences.

• Anecklacecanbecomeentangledinrunningmachinery,whichcouldpullthetechnicianintothemachineryandcausegreatbodilyharm.

• Ifaringorbraceletbecomesentangledorcaught,itcould result in a severed finger or serious injury to theheadorneck.

b. Ifaringorbraceletshouldaccidentallycreateashortcircuitofavehiclebattery,themetaloftheringorbraceletcouldbecomewhite-hotinaninstant,causingaseriousburn.

8. Donotputsharpobjectsintothepocketsofworkclothes.Theycouldcausepersonalinjuryordamagetoavehicle’sinterior.

9. Keephandsfreefromoilandgrease.

10. Wipe up grease and other spills from the shop floor immediately,oratleastputanoil-absorbingcompoundoverthem.

11. When cleaning up flammable liquids, always dispose of the rags in a metal container with a tight-fitting lid.


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12. Donotlookinthedirectionofanotherpersonwhoiswelding.

13. Donotrunavehicleengineinsideaclosedgarageunlessthevehicleexhaustishookeduptoexhaustventilationequipment.Adeadlyamountofcarbonmonoxide,whichispresentintheexhaust,cancollectinaveryshorttime.

14. Donotsmokeintheshop,exceptinanareadesignatedforsmoking.

15. When pumping a flammable liquid from a large container into a small one, be sure to first attach a ground wire between both containers.

16. Alwaysbealertforhazardoussituationsintheshop.Promptlycorrectthem,ifpossible,andinformtheinstructorofthesituation.

17. Ifroadtestingavehicle,alwaysuseseatbelts,evenifonlygoingashortdistance.

18. Disconnectthebatteryasappropriate.Thiseliminateshazardsfromshortsthatcouldoccurduringrepairprocedures.

CAUTION: The vehicle manufacturer’s recommendations must be followed for disconnecting batteries. Some onboard vehicle computer systems can be damaged if the battery is incorrectly disconnected.

19. Whenpartsareremovedfromavehicle,theyshouldbestoredawayfromtheworkarea(onabenchor,iflargeparts,againstawall).


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20. Asbestosparticlescancausecancer.Asbestosisfoundinbrakeshoesandclutches.Therefore,wearaparticlemaskwhendoinganycleaningworkonbrakeorclutchparts.Donotusecompressedairtocleanbrakeorclutchparts.

21. Donotlettheleadsontestingequipmentfallintothefanofavehiclewhiletheengineisrunning.Electricfanmotorscanturnonevenwiththeignitionoff.

22. Do not play with fire extinguishers. Use fire extinguishers only to extinguish fires.

23. Alwaysreadthelabelsonchemicalsandmaterialsandfollowtheinstructions.

IV. Generalsafetyrulesforhandlingtoolsandequipment

A. Donotoperateanypieceofequipmentunlesstrainedintheuseoftheequipment.

B. Evenifinstructedintheuseofapieceofequipment,donotuseitunless given specific permission by the instructor.

C. Selectthetoolorpieceofequipmentthatwillhandlethejobinthesafest and most efficient manner. Use tools or equipment only as recommendedbythemanufacturer.

D. Beforeusingatoolorpieceofequipment,inspectitfordefects,missingorimproperlyadjustedsafetyguards,andanyothermissingormalfunctioningparts.

E. Maintainandstoretoolsandequipmentproperly.Developaregularmaintenancescheduleforshopequipment.Discard,repair,orreplaceworntoolsbecauseworntoolscanbeasafetyhazardandadverselyaffectworkquality.

F. Donotusecompressedairtoblowdirtfromclothesanddonotpointacompressed-airhoseatanotherperson.

G. Whenusingcompressedairforcleaningobjectsintheshop,theairpressuremustnotbemorethan30poundspersquareinch(psi).

H. Keeptools,especiallytoolhandles,freefromoilandgrease.

I. Beforeusingatool,checkthehandletomakesureitissecure.Forexample,ahammerwithaloosehandleisunsafebecausetheheadmay fly off during use.


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J. Whenoperatingelectrictools,usetheproperprecautionstoavoidelectricshock.

K. Beforeinspectingormakingadjustmentstopneumaticorelectrictools,alwaysdisconnectthemfromtheairorpowersupply.

V. Electricweldingsafety

A. Protectionfromelectricshock

1. Makesurethewelderisinstalledandhookedupproperly.

2. Donotuseequipmentthatisdamagedordefective,suchasanelectrodeholderwithdamagedinsulation.

3. Donotputtheelectrodeholderinwatertocoolit.

4. Do not use water to extinguish an electrical fire or any fire near thewelder.

5. Keeptheworkarea,equipment,andclothingdrywhenusingelectricweldersbecauseevenaslightamountofmoisturecanconductenoughelectricitytocauseasevereshock.

B. Protection from burns and fire

1. Make sure the work area is as fire resistant as possible.

2. Donotdragweldingcablesorhosesthroughdirtoroil,anddonotpullonacabletoforceitoveranobstruction.

3. Takeprecautionswhenhandlinghotworkpieces.Usetongsorpliers,nothands,topickuphotmetal.

4. Radiationfromaweldingarcisstrongenoughtosunburnorsometimesblisterbareskiniftheexposureisintenseorforanextendedperiod,sothearms,legs,andtorsoshouldbecoveredwith durable, flame-resistant clothing.

5. Keeptheworkareacleanandfreeoftrash,grease,oil,andotherflammable materials.

6. Keep a fire extinguisher, first-aid kit, and safety equipment withineasyreach.

7. Donotdrapeanelectricweldingcableoveranytypeofgascylinder,anddonotstrikeanarconagascylinder.


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C. Protectionfromarcrays 1. Aweldingarcproducesultravioletandinfraredradiationthat

canseverelyburneyesthatareunprotectedwithapropershadeofprotectivelens.

NOTE: A welding hood or helmet protects the head from flying sparksandtheshadedlensprotectstheeyes.

2. Makesureallothersintheweldingareaarewearingeyeprotectionaswell.

3. Whenusingawelder,enclosetheweldingareatoprotectothersfromthedangersofarcrays.

D. Protectionfromtoxicfumesandvapors

1. Manyweldingactivitiesproducetoxicfumesandvaporsthatarehazardoustobreathe,andeveryworkstationshouldbeequippedwithaventilationorexhaustsystemcapableofsafelyremovingdangerousandirritatingsmokeandcontaminants.

CAUTION: Always position the head to the side of rising fumes.

2. In confined areas where the hazard of toxic fumes is increased, aweldershouldwearanair-suppliedrespiratororaself-contained breathing apparatus, not a filter-type mask that cannotcompensateforoxygendisplacement.

3. Cleanthemetalbeforewelding.Cleaningthemetalhelpsremoveanychemicalthatmightmixwiththefumesproducedbywelding.

VI. Oxyacetyleneweldingandcuttingsafety

A. Protection from burns (from heat or light rays), fire, and explosions

1. Donotallowoilorgreasetocomeincontactwithoxygenunderpressure.


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NOTE: Nolubricationoftheapparatusisnecessary.

2. Donotuseoxygenasasubstituteforcompressedair.

3. Beforestartingtoweldorcut,makecertainthereisnoflammable material nearby.

4. Alwayswearweldinggogglesandheavygloveswhenworkingwithalightedtorch.

5. Wearweldinggogglesandprotectiveclothingthatblocksharmful light from the acetylene flame.

6. Whenusingawelder,enclosetheweldingareatoprotectothersfrom the dangers of acetylene flames.

7. Donotusematchesforlightingacetylenetorches.Asparklighter,heldatanangle,shouldbeusedtolightatorch.

8. Do not relight oxyacetylene flames on a hot work section in a small confined space.

CAUTION: Acetylene gas gathers in one spot.

9. Donotuseacetyleneatapressureabove15psi.

CAUTION: Using acetylene at a pressure above 15 psi may result in hand burns.

10. Useparticularcautionwhenweldingorcuttingindustyordirtylocations.

CAUTION: Dust can explode.

B. Protectionfromtoxicfumesandvapors

1. Manyweldingorcuttingactivitiesproducetoxicfumesandvaporsthatarehazardoustobreathe,andeveryworkstationshouldbeequippedwithaventilationorexhaustsystemcapableofsafelyremovingdangerousandirritatingsmokeandcontaminants.

CAUTION: Always position the head to the side of rising fumes.


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2. In confined areas where the hazard of toxic fumes is increased, aweldershouldwearanair-suppliedrespiratororaself-contained breathing apparatus, not a filter-type mask that cannotcompensateforoxygendisplacement.

CAUTION: Argon is much heavier than air and quickly displaces oxygen, so be especially careful using the MIG process in a confined area, even though the area appears to have adequate ventilation.

3. Cleanthemetalbeforeweldingorcutting.Cleaningthemetal

helpsremoveanychemicalthatmightmixwiththefumesproducedbytheprocess.

4. Someofthematerialsthatgiveoffespeciallytoxicfumesarebrass,bronze,galvanizedmaterials,ironorsteelcoatedwithlead,orpaintcontaininglead.

C. Safehandlingofgascylinders

CAUTION: The acetylene and oxygen cylinders are highly pressurized and may explode if not handled properly.

1. Oxygenandacetylenecylindersmustbestoredinaventilatedareaandmustbekeptseparate.Allowatleast20ftbetweenoxygencylindersandacetylenecylinders.

2. Allgascylindersmustbesecuredinboththestorageareaand

onthewheeledcartwithasafetychainorapprovedlashing.

3. Theprotectivecapsmustbeinplaceanytimethecylindersarenotinuse.

4. Donotmovethecylinderswithoutprotectivecapsinplace.

5. Donotdroporknockcylindersaround.

6. Donottamperwithsafetydevicesormarkingsonacylinder.

7. Donotuseahammerorwrenchtoopenacylindervalve.

8. Do not move a cylinder unless confident in handling it.


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9. Alwaysmoveagascylinderbyusingahandtruckwithasafetychainorbytiltingitslightlyandrollingitonitsbottomedgewithonehandontheprotectivecap.

CAUTION: Do not tilt the cylinder too far over center; it may cause the cylinder to drop.

VII. Liftingsafety

A. Thetechnicianwillencountermanysituationsinwhichheavyobjectsmust be lifted from the floor. Back injuries are common if lifting is notdoneproperly.

B. Alternativestoliftingheavyobjects

1. Avoidlifting,ifpossible.

2. Moveheavyobjectsbypushing,pulling,rolling,orsliding.

3. Usehoists,jacks,carts,andwheeltruckswhenpossible.

C. Toavoidinjurywhenliftingaheavyobject,useamechanicaldeviceorgettheassistanceofanotherperson.


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D. Stepsofproceduretoliftanobject

CAUTION: Do not lift in an area where the floor is wet or greasy.

1. Spreadthefeetslightly,untilcomfortable,withonefootslightlyaheadoftheotherandalongsideoftheobject.

2. Bendtheknees,kneel,orsquat;donotbendtheback.

3. Useblockingunderobjectstogetahandhold.

4. Getagoodgripanduseglovesiftheobjecthassharporjaggedsurfaces.

5. Liftwiththeleg,arm,andshouldermuscles,straighteningthelegsandcomingtoastandingposition.

6. Shiftthefeettoturn;donottwist.

7. Lowertheloadbybendingtheknees,keepingthebackstraightand using leg and arm muscles, and keep fingers and toes clear ofobjects.

8. Use blocking to keep from pinching the fingers when setting the objectdown.

VIII.Personalprotectiveclothingandequipment

CAUTION: Personal protective clothing and equipment should not be considered the first line of defense against injury but rather as backup protection.


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A. Wearprotectiveeyewearatalltimesintheshoparea.

NOTE:Thelawrequiresthatprotectiveeyewearbeavailableandwornincareerandtechnicaleducationcourseswherethereisareasonableprobabilityofinjury.

1. Specialsplash-resistantgogglesarewornwhenthereisapotentialchemicalhazard.

2. Whenwelding,aweldinghoodorhelmetmustbeworntoprotect the head from flying sparks and protect the eyes from burns.

3. Tintedgogglesmayberequiredifweldingisbeingperformedclosetotheworkarea.Consulttheinstructorfortheappropriatetintedgogglesfortheweldingoperation.

4. Properglassesandwiremeshgogglesorplasticspectacleswithsideshieldsarerequiredinimpacthazardareas,suchasgrindingareas.

5. Everyperson,includingvisitors,mustwearindustrial-qualityprotectiveeyewearatalltimesintheshoparea.


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B. Wear a full face shield in situations where sharp flying objects could injuretheface.

C. Respiratoryprotectionissometimesnecessary.Respiratorydevicesconsistofameshthatcoversthenoseandmouth.Weararespiratorymaskwhendoingtasksthatcancreatedust.

D. Noiseintheshopcancausehearingdamage,dependingonthelevelandduration.Wearingearplugsandearmuffshelpsprotecttheearsfromnoisecreatedbyequipmentsuchaspneumatictools,grinders,andengines.

E. Adequatefootwearshouldbewornintheshoparea.Feetcaneasilybecrushed,cut,orpuncturedifnotproperlyprotected.

1. Footwearshouldhaveleatherorrubberoil-resistantsoles.

2. Footwearshouldprovideafullleatherorstrongfabriccoverfortheentirefootuptotheankles.

NOTE: Footwearwithsteel-reinforcedtoesprovidesevenmoreprotection.

3. High-topleatherbootsarerecommendedforweldingoperations.


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F. Protectiveclothingforthebodyandhandsreducesthehazardofinjuryandprotectsstreetclothing.

1. Glovesandhandleathersareimportantpiecesofprotectiveclothing.Differenttasksrequiredifferentmaterials(e.g.,rubberglovesarewornwhenhandlingcausticchemicalsandheavyleathergloveswithgauntletsarewornwhenwelding).

CAUTION: If operating machinery and wearing gloves, the gloves may become entangled in the moving parts.

2. Apronsareusedtoprotectfromsparks,hotmetalsplashes,andsplashingliquids.Thematerialshouldbesuitablefortheintendeduse.

CAUTION: Never wear loose aprons around revolving or reciprocating machinery.

3. Coverallsprotectthebody.Overalls,avariationofcoveralls,donothavesleeves.Fire-resistantcoverallsmadeofcottonorwoolarerecommendedforweldingoperations.

4. Shopcoatsprovideprotectionagainstdirtandgreasethatsoilstreetclothing.Thesealsooffersomeprotectionagainstchemicalsandhotsubstances.

IX. Theimportanceofpropergroomingandhygiene A. Longhaircanbecomecaughtinmovingmachinery,whichcanresult

inaportionofscalpbeinglostorpulledintothemachinery.Keeplonghairoutofmachinerybypinningituporwearingacap.

B. Jewelryshouldnotbewornintheshop.SeesectionIIIinthislessonfor the specific hazards related to jewelry.

C. Havinggreasyhandscancauseslippagewhenworkingwithhandtools.Greasealsosoilsinteriorsandpaint.

D. Havinggreaseonworkshoescanspreadgreaseacrosstheshopfloor, which increases the risk of slipping and falling. Dirty, greasy coveralls/overalls and shoes can ruin vehicle interiors.

E. Having brake fluid and other chemicals on the hands could allow accidentaltransfertopaintedsurfacesandcauseexpensiverepairs.


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F. Protective eyewear that is dirty and scratched is difficult to see through.Protectiveeyewearshouldbekeptclean.Donotplacethelenses down on the floor or table. The soft, plastic coating can easily bescratched.

X. Hazardousmaterialssafety

A. Fivegeneralsafetyrules

CAUTION: Consult the instructor before using an unfamiliar product.

1. Followthemanufacturer’srecommendations.Refertomaterialsafetydatasheets(MSDSs).SeeLesson4forinformationaboutMSDSs.

2. Carefullyreadtheproductlabelforcorrectusesandhazards.

3. Becarefultopreventspills,damagetothevehicle,orunsafesituations/conditions.

4. Properlystorechemicalsandusedrags. 5. Usechemicalsonlyfortheirintendedpurposes.

B. Hazardousmaterialsincludethefollowing:

NOTE: Thefollowinglistincludessomeofthemorecommonchemicalsfoundintheshopandisnotmeanttobeall-inclusive.SeeUnitIIIforthesafetyprecautionsandusesofthesechemicals.

1. Solventsandacids—Part-washingsolvents,chokeandcarburetorcleaner,brakecleaner,gasketremover,

digestive-typecarburetorcleaner,andvehiclebatteryacid

2. Lubricants—Rust-penetratingoil,siliconelubricant,liquidgraphite, motor oil, automatic transmission fluid, power steering fluid, gear lube, hydraulic fluids, various greases, and specialtyadditives(e.g.,oiltreatmentandgastreatment)

3. Gasesanddust—Gasesinengineexhaust,vaporsfromgasoline,refrigerantgas,andasbestosdustfrombrakeandclutchlinings


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C. Safety from skin damage and fire

1. Manychemicalsintheshopposeahazardtotheskinandeyes.Followthesafetyprecautionsontheproductlabel.

2. Keepelectricaldevices,sparks,andanyhotmaterialawayfromflammable chemicals.

D. Safetyfromtoxicfumes

CAUTION: Breathing toxic fumes can cause dizziness, nausea, headaches, unconsciousness, and can even lead to death.

1. Acommonsourceoftoxicfumesintheshopistheexhaustfromarunningengine.Eachtimeavehicle’sengineisrunintheshop,exhaustventilationequipmentshouldbeattachedtothevehicletoproperlyventthecarbonmonoxide,apoisonousgasemittedintheexhaust.

CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

2. Wheneverfumesorvaporsarepresent,besuretoturnontheshop’sventilationsystemassoonaspossibletoremovethem.


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3. Usebreathingprotection,suchasarespirator,whenworkingwithanymaterialsorchemicalsthatcouldbehazardousifinhaled.

XI. Safetyprecautionsforsupplementalrestraintsystems(SRSs)and antilockbrakesystems(ABSs)

NOTE:Techniciansneedtobeawareofspecialsafetyconsiderationswhenworkingonoraroundthesesystems.

A. SRSorairbagsystem

1. Firstappearinginafew1985-modelvehicles,airbagsystemsarestandardequipmentonmostvehiclesontheroadtoday.Aruling by the National Highway Traffic Safety Administration requiredallnewpassengercarstohavedualairbags(oneonthedriver’ssideandoneonthepassenger’sside)by1998andallnewlighttruckstohavedualairbagsby1999.

2. The SRS is designed to inflate when a vehicle collides head-onwithanobjectataspeedofmorethan14mph.Duringthecollision,thedriverandpassengerimpacttheairbagratherthanthesteeringcolumnordashboard.

3. Inadditiontodriver-sideandpassenger-sideairbags,somevehiclesmaybeequippedwithside-impact,window,andrear-seatairbags.

4. Airbagsarerelativelynewdevices.Newsafetyissuesregardingairbagsarecontinuallybeingrecognizedandstudied.

5. Airbagsmustbeusedwithseatbelts,shoulderharnesses,andtheproperheadreststoprovidemaximumprotection.


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NOTE:Itisimportantforeveryoneintheautomotiveindustry,includingautomotivetechnicians,toexplaintothepublicthattheSRSalonedoesnotprovidemaximumprotectioninacollision.

6. Beforeworkingnearavehicle’sairbags,besuretheyaredisabled.

CAUTION: The force of an air bag can break bones and cause other serious injuries.

7. Evenifanairbaghasbeendisabled,theairbagmaydeployifthediagnosticmodule’sreservepowerhasnotbeendepleted.

CAUTION: The diagnostic module keeps the air bag activated for some time after the negative battery cable has been disconnected. Wait until the diagnostic module’s reserve power has depleted before working on or around the SRS. The time can vary from a few seconds to over 30 minutes.

B. ABS

1. AnABShelpsthedrivermaintaincontrolofthevehiclewhenbraking.Ifthewheelslockduringbraking,thevehiclemayslideoutofcontrol.Theantilocksystempreventsthebrakesfrombeingappliedhardenoughtolockthewheels.

2. Evenwhentheantilocksystemclosesdown,normal power-assistedbrakingremains.Awarninglightlocatedinthe

instrumentpanelindicatesproblems.

3. ListedbelowaregeneralprecautionstoobservewhenservicingtheABS.

CAUTION: Failure to observe these precautions may result in personal injury and damage to the ABS.

a. Followtheserviceinformationcarefully.Usetheproperserviceinformationforthevehicle.Usingthewrongsequenceofservicesteps,skippingsteps,orusingthewronginformationleadstounnecessaryreplacementofparts.

b. Some brake parts contain asbestos fibers that can become airborneasdustduringbrakeservice.Followthelatestfederalprocedureswhenworkingwithasbestos.


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CAUTION: Asbestos is a cancer-causing substance. Do not breathe asbestos dust or allow it to escape into the air.

c. ManycomponentsofanABSarenotserviceable;replacethemasanassembly.DisassemblinganABScomponentthatisnotdesignedtobeservicedmaycausepersonalinjuryorsystemmalfunction.

d. ThereisnoonebleedingprocedurethatappliestoallABSs.Proceduresvarygreatlyfromsystemtosystem.TobleedavehiclewithanABS,usethemanufacturer’sspecific bleeding method for the vehicle being serviced.

e. IfusingelectricarcweldingequipmentonavehiclewithanABS,disconnectthebatteryandpowertraincontrolmodule(PCM).

f. AnABSoperatesatveryhighpressures.AlwaysdepressurizetheaccumulatorbeforeservicingtheABS.

g. Toprotectthecontrolmodule,neverdisconnectorconnectanyABSconnectorwhiletheignitionswitchison.

h. PortionsofanABSoperateatverylowsystemvoltages;therefore,neveruseaconventional12-volttestlighttoprobecircuits.Aconventional12-volttestlightcandamagetheantilockcomponents.Alwaysuseahigh-impedancedigitalmultimeter(DMM)toprobethecircuits.

i. WhenworkingwithwiringonanABS,nevertouchtheelectricalconnectionsorpinsorallowthemtocontactthebrake fluid. This kind of contact damages the PCM.

j. Beforetestdrivingavehiclewithabrakeproblem,testthebrakesatalowspeedtobesurethatthecarstopsnormally.

C. ProceduresforidentifyingvehiclesequippedwithanSRSandABS

1. On some vehicles, the vehicle identification number (VIN) indicatesthatthevehicleisequippedwithanSRSandABS.Checkthemanufacturer’sserviceinformationtodeterminewhatdigitsindicatethatthevehicleisequippedwithanSRSandABS.


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2. TheschematicsmayalsocomewithvariouswarningsthatthevehicleisequippedwithanSRSandABS.

3. SomevehicleshaveamarkonthesteeringwheelcovertoindicateanSRS.


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UNIT II: safeTy

lessoN �: shoP safeTy feaTUres aNd emergeNcy ProcedUres

I. Observethefollowingguidelinesaboutsafetyfeaturesandequipmentinashop.

A. Walkaroundtheshoptobecomefamiliarwiththevariousareas(e.g.,work bays, management offices, parts department, customer waiting area) and the traffic flow of vehicles coming in and out of the shop.

B. Notethelocationofshopexits,whichshouldbewell-markedwithan“EXIT”sign.Keeptheareaaroundtheexitsfreeofobstructions.

C. Befamiliarwiththeshop’sevacuationroutesandproceduresincaseof fire or other emergencies.

D. Note the location of specific work areas, such as those for welding, painting,andgrinding,whichshouldbeclearlymarked.

E. Knowthelocationandhowtooperatetheeyewashstation,whichisused to flush the eyes in case of a chemical splash.

F. Know where the first-aid supplies are kept and be familiar with the suppliesavailableandhowtousethem.

G. Locatethetelephonesthatcanbeusedforemergenciesandwhereemergencynumbersareposted.

H. Notethelocationofstoragecontainersforhazardouswastesandmaterials.

I. Know the location of the shop’s fire blanket. Every shop must have a 100% wool fire blanket. The fire blanket can be wrapped tightly around a person who is on fire to smother the flames.

1. Avoid using a fire blanket on a burning person wearing syntheticclothing.Doingsocancauseseriousskindamage.Usewatertoextinguishburningsyntheticclothing.

2. Workcoverallsandshopclothingshouldbemadeofcotton.

CAUTION: Do not allow a person on fire to run.


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J. Know where the fire alarm is and how to activate it at the first sign of a fire that has any possibility of getting out of control.

K. Know where fire extinguishers are located and how to use them. It is critical to be familiar with how the fire extinguishers in the shop operate to be prepared if a fire should start.

1. Types of fire extinguishers

a. ClassA—Plainwater

b. ClassBC—Maybecarbondioxide,ordinarydrychemical,orhalon

c. ClassABC—Multipurposedrychemical

d. ClassD—Drypowder

2. Classes of fires and the appropriate extinguisher for each

a. Class A fires include burning paper, wood, rubber, cloth, andothermaterialscommonlyfoundinclassroomsandoffices. These fires may be effectively handled with either a dry-chemical or water fire extinguisher.


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b. Class B fires include burning liquids, gases, grease, and oil. Use only dry-chemical fire extinguishers. Water fire extinguisherscausetheburningliquidtospread.

c. Class C fires are electrical fires. Use only a Class C fire extinguisherthatcontainsdrychemicalsandcarbondioxide. Water or foam-type fire extinguishers can electrocutepeopleinthearea.

d. Class D fires include burning metals, such as magnesium or sodium. Use only Class D fire extinguishers that contain the appropriate dry powder and are identified by a5-pointstarwiththeletter“D”printedwithinthestar.

NOTE: Most shops use multiple-class fire extinguishers that can be used on Class A, B, and C fires.

3. Universal symbols for fire extinguishers

4. General procedure for using a fire extinguisher

CAUTION: Do not operate a fire extinguisher if not trained to do so, if the flames are large or progress beyond their initial stage, or if the fire becomes too hot or smoky. If there is any doubt about being able to extinguish the fire, evacuate the building immediately.

CAUTION: Before attempting to put out a fire with a fire extinguisher, be sure to identify a safe evacuation route.

NOTE: Theinstructorwilldemonstratetheproperoperationof the fire protection equipment available in the shop. Most fire extinguishers operate using the P.A.S.S. method, which is includedbelow.

a. Pull—Pullthepin,ring,clip,etc.fromtheextinguisher’shandle.Thisactionwillbreakthetamperseal.


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b. Aim—Aimtheextinguishernozzleatthebaseoftheflames.

c. Squeeze—Squeezetheextinguisherhandletoreleasethecontents.

d. Sweep—Sweepfromsidetosideatthebaseoftheflames, discharging the extinguishing agent until the fire isout.

II. Theimportanceofmaintainingcleanlinessandorderintheshop

A. Acleanshopenvironmentreducesthehazardsofslippingandsoilingclothing.Italsoprotectsvehiclesfromgreaseorpaintdamage.

B. Anorderlyshopwithclearpathwaysallowsemployeeseasyaccessto exits. Regulations from the EPA and local fire codes empower the local fire marshal to insist on an orderly, uncluttered, and safe shop area.

C. Keeptools,equipment,andsuppliesorganizedtoallowgreaterefficiency. Store tools, equipment, and supplies in their proper place whennotinuse.

D. Acleanandorderlyshopisthemarkofcompetentprofessionalsandpromotesbusinessgrowth.

III. Emergencyprocedures

A. Ifsomeoneisinjuredintheshop,notifytheinstructoratonce.


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B. Do not give first aid to a victim unless trained to do so. However, if properly trained, do not hesitate to give first aid.

C. Ifsomeonecomesintocontactwithelectricalcurrentandreceivesanimmobilizingshock,donottrytomovehimorherifthecurrentisstillonandthepersonisstillincontactwithit.Shutoffthemaincircuit to the shop. Electrical current will flow through whoever touchesthepersonbeingshocked.Notifytheinstructoratonce.

D. General fire emergency procedure

NOTE: Specific procedures for dealing with fire emergencies vary. It is important to know the specific procedures for your shop.

1. If a person is on fire, immediately wrap the person in a fire blanket to smother the flames.

2. For other fires, turn on the fire alarm.

3. Notifytheinstructorassoonaspossible.Theinstructorwilldecide whether or not to attempt to extinguish the fire or to wait foremergencypersonnel.

4. Turnoffanymachinesandpowerintheeventofanalarmiftimeorcircumstancesallow.

5. Followbuildingevacuationproceduresasrequired.


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UNIT II: safeTy

lessoN 3: raIsINg aNd sUPPorTINg vehIcles safely

I. Terms and definitions

A. Jack — A device, such as a hydraulic floor jack, that raises the front, rear,orsideofavehicleofftheground.

B. Lift —Apieceofhydraulicequipmentusedtoliftthewholevehicleofftheground.

C. Lifting —Usingadevicetoraiseavehicleoffthegroundforthepurposeofinspection,service,orrepair.

D. Safety stands —Lightweightframesusedtosupportavehicleafterbeingliftedbyajack.

E. Torque box areas — Thefourcornersofthepassengercompartmentregardlessofwhetherthevehicleactuallyhastorqueboxes.

F. Torque boxes —Locatedineachcornerofthepassengercompartmentanddesignedtominimizedamagetothecompartmentinacollision.

G. Wheel blocks or wheel chocks —Blocksthatareplacedononeormorewheelsbeforeliftingtokeepthevehiclefromrolling.

II. Commonliftingdevices

A. Inordertoinspectorrepairavehicle,itisfrequentlynecessarytogetthevehicleoffthegroundtoprovideaccesstotheunderside.

B. Awidevarietyofequipmentisavailableforliftingvehicles,suchaslifts and hydraulic floor jacks. Most equipment is hydraulic, but there arealsopneumaticlifts.


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C. Hydrauliclift

1. Functions hydraulically to raise the whole vehicle off the floor

2. Allowsforinspectionunderthevehicle

3. Allowsrepairstobedoneatamorecomfortableheightforthetechnician

4. Safety

a. Refertoserviceinformationforpositioningthevehicleontheliftandfollowallsafetyprecautionsforoperatingthelift.

b. Beforeliftingthevehicle,checkforproperclearanceonall

sidesofthevehicleintheliftareasothatthevehicledoesnothitotherobjects.

c. Donotliftvehicleswithpassengersinsideorwiththedoors,hood,orluggagelidopen.

d. Besurethatthelift’slockingmechanismisinthelockedpositionbeforewalkingunderthelift.

e. Befamiliarwithsafetylockreleasemechanismsforsafeloweringofvehicles.


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D. Hydraulic floor jack

1. Usesmechanicalforce,withtheoperatorusingalevertopumpupthejack

2. Ismountedonfourwheelsforportability

3. Usedofteninraisingthefront,rear,orsideofavehicleforplacementonsafetystands

4. Safety

a. Ensurethevehiclebeingliftedisonalevel,solidsurface.

b. Alwaysbesurethereleasevalveiscompletelyclosedbeforeattemptingtoliftavehicle.

c. Refer to service information to find the correct lift point on thevehicletopositionthesaddleofthejack.

d. Nevercrawlunderavehiclehelduponlybyajack,eitherhydraulicorpneumatic.Alwaysusesafetystandstosupportthevehicle.

e. Besurethattheload-capacityratingforthesafetystandsissufficient to safely support the vehicle.

f. Afterpositioningthesafetystandsunderthevehicle,shakethebodyofthevehicletomakesureitisstable.

g. After raising a vehicle with a floor jack, be sure the handle ofthejackispointedstraightup.

h. Donotoperatehydraulicjacksiftheyareleakingbecausetheymayfail.


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i. Donotliftvehicleswithpassengersinsideorwiththedoors,hood,orluggagelidopen.

j. Makesureeveryoneinthevicinityisstandingwellawayfromaraisedvehiclebeforeopeningthereleasevalvetolowerit.Whenloweringavehicle,thereleasemechanismshouldbeopenedalittleatatime,andthenclosed,tolowerthevehiclealittleatatime.

CAUTION: If the release mechanism is opened all the way, it will drop the vehicle to the floor instantly. This may cause injury to the operator and others in the area as well as damage to vehicle.

III. Commonsupportdevices

A. Safetystands

1. Sturdymetaldevicesthatsupportthevehicleafterbeingliftedbyajack

2. Availableindifferentheightsandloadcapacities

3. Placedundersecurepointsonthevehiclesuchastheframeandaxlehousing

NOTE: Refertoserviceinformationandthemanufacturer’sinstructionsforthecorrectpointstoplacesafetystands.


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B. Wheelblocks,alsoknownaswheelchocks

1. Wedge-shapedblocksusedasasafetymeasure,inadditiontosafetystands,tokeepthevehiclefromrollingafterbeinglifted

2. Usedbeforeliftingthevehiclewithajack

3. Placedinthefrontandrearofawheelthatwillremainonthegroundafterlifting

IV. Principlesofliftingandsupportingvehicles

A. Each vehicle has specific lifting points. Consult current service informationortheowner’smanualforeachmodeltodetermineproperliftingpoints.

CAUTION: Identification of proper lifting points is extremely important. Damage caused by improper lifting can be severe. Common sense, along with an understanding of vehicle construction and vehicle supporting techniques, must be used in each repair instance.

B. Thepurposeofraisingthevehicleistogetthevehiclehighenoughintheairtosafelyinspect,service,orrepairtheunderside.

C. Beforeliftingavehicle,checkboththevehicleandequipmentmanufacturer’srecommendations.

D. Ingettingthevehicleofftheground,therearetwoseparatepointstobeconsideredasfollows:

1. Properliftingmethods


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2. Propersupportingmethods

E. Liftandsupportpoints

NOTE: Thecorrectliftandsupportpointsdependonthemodelofthevehicleandthetypeofliftequipmentbeingused.Refertoserviceinformationandthemanufacturer’sinstructions.

1. Torqueboxareasaregenerallyacceptableliftpoints.

a. Theseareasaredesignedtoabsorbtwisting(torque)forcecausedbyacollisionandroutedamageawayfromthepassengercompartment.

b. Thefourtorqueboxareasarelocatedatthecornersofthepassengersection.

c. Evenifthevehicledoesnothaveactualtorqueboxes,thefourcornersofthepassengercompartmentarereferredtoastorqueboxareas.

d. Torqueboxareasaregenerallythestrongestareasofthevehicleforliftingandsupporting.


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2. Thepinchweldareaoftherockerpanel,whichisthefactoryweldthat fuses the bottom flange of the outer rocker panel to the inner rockerpanel,isastrongsupportareaonunibodyvehicles.


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UNIT II: safeTy

lessoN �: federal aNd sTaTe hazardoUs maTerIal regUlaTIoNs

I. OccupationalSafetyandHealthAdministration(OSHA)regulations

A. OSHAisafederalorganizationthatsetsandenforcesworkenvironmentstandardstoprotectthehealthandsafetyoftheindividualworker.AnyemployerorinstitutionthatdoesnotadheretoOSHAstandardsissubjecttoprosecution.

1. Ifemployeesprovidetheirowneyeandfaceprotectiveequipment,OSHArequiresthattheemployermakesuretheequipment meets specific safety standards.

2. OSHArequirestheemployertoprovideaventilationsystem,

masks,andanyothersuchdevicesneededtoprovidereasonableprotectionagainstharmfuldusts,fogs,fumes,mists,gases,smokes,sprays,andvapors.

3. OSHA requires that flammable liquids like gasoline and solvents thatarepackagedorkeptinsmallcontainersbestoredinanapprovedmetalcabinetinquantitiesoflessthan60gal.

NOTE:ThemetalcabinetsmustbeapprovedbytheUnderwritersLaboratoriesInc.(UL).

4. OSHArequiresthatpotentiallyhazardouschemicalsstoredonsitebeclearlylabeled.Safetytrainingforemployeesshouldaddressthecorrectproceduresforchemicalhandling,storage,anddisposal.

5. OSHArequiresthatemployersprovideadequateearprotectionforallworkersexposedtonoiselevelsdeemedharmful.

B. TheHazardousCommunicationStandardorRight-to-Knowlawinformsemployeesaboutthehazardoussubstancesthatareavailableintheirshop.

1. RequirementsoftheRight-to-Knowlaw

a. A specific person or group is responsible for the operation ofthecompany’sRight-to-Knowprogram.


s 50

b. Allhazardoussubstancesandharmfulphysicalagentsmust be identified.

c. Awrittenprogramdescribestrainingactivities,chemicalidentities,andwastedisposal.

d. Allcontainersofhazardoussubstancemustbelabeledwiththenecessaryhealthandsafetyinformation.

e. Employersmustobtainwritteninformationoneachhazardoussubstanceandprovidethemtoemployeesintheformofmaterialsafetydatasheets(MSDS).

f. AllemployeesmustbetrainedinthedetailsoftheRight-to-Knowrequirements.

C. OSHAusescertainbasiccharacteristicstodeterminewhichmaterialsareincludedonitshazardoussubstancelist.

1. Ahazardousmaterialisanysubstancethatcouldcauseinjuryordeathtopeopleorcoulddamageandpolluteland,air,orwater.

2. Tobeconsideredhazardousasubstancemustbeeithertoxic,flammable, corrosive, reactive, or come into contact with the skin.

a. “Toxic”isthetermusedtodescribeamaterialthatcancauseillnessordeathafterbeinginhaledorcomingintocontactwiththeskin.OSHAandtheEnvironmentalProtectionAgency(EPA)haveliststhatincludehundredsofdifferenttoxicchemicals.

b. “Flammable”isusedforanignitablesubstancethatcaneasily catch fire or any material that has a flash point below 200°F.

c. “Corrosive”isusedforasubstancestrongenoughto

dissolvemetal,burnskin,orcauseeyedamage.Acidsandbasesareexamplesofcorrosivematerials.

d. “Reactive”isusedforamaterialthatcanbecomeunstable,burn,explode,orgiveofftoxicvaporsifmixedwithair,water,heat,orothermaterials.


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D. Employeetrainingisrequired.

1. Employersarerequiredtotrainthefollowingpeople.

a. Workerswhoareroutinelyexposedtohazardouschemicalsorhazardouswaste.

b. Workerswhohandlepackagescontaininghazardousmaterials.

c. Anyonethatcouldbeexposedtohazardousmaterialsinaforeseeableemergencyorcouldbeinvolvedifanaccidentoccurs.

d. Newemployeesthatmeettheaboveexamplesmustbetrainedbeforetheybeginworkwheretheycouldbeexposedtohazardousmaterials.

e. Office workers that only encounter hazardous chemicals in isolatedcasesdonotrequiretraining.

2. Thefollowingmustbeincludedinthetraining.

a. Employeesmustbetrainedtorecognizehazardousmaterialsandhowtogatherinformationaboutthosehazardousmaterials.

b. Employeesmustbetrainedinthebasicwaystoprotectthemselvesfromharmfulexposure.

c. EmployeesmustbetrainedintheproperuseoflevelsandMSDSmaterials.

d. Employeesmustbetrainedinwhattodoinanemergencyandhowtouseequipment.

e. EmployersmusteducateemployeesonthedetailsoftheRight-to-Knowprogram.

3. FederalregulationsdonotincludeannualRight-to-Knowtraining,butmanystatesnowrequiresafetytrainingberepeatedonanannualbasis.

E. Employershavecertainresponsibilities.

1. TheremustbeatleastonepersonappointedtoadministertheRight-to-Knowprogram.


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2. Hazardous materials in the workplace must be identified and listed.

3. AnMSDSmustbeobtainedandkeptforeachhazardouschemicalonsite.

4. AwrittenplanmustbedevelopedthatoutlinestherequirementsoftheRight-to-Knowprogram.

5. Employeesmustbetrainedtounderstandthephysicalandhealthhazardsofthechemicals.

6. Theinformationoncontainerlabelsmustbeexplainedandmaintained.

7. Workersmustbeshownhowtoprotectthemselvesfromchemicalhazards.

8. Theremustbeinstructionsonwhattodoinanemergencyandhowtouseprotectiveequipment.

F. Employeeshavecertainresponsibilities.

1. TheymustknowwheretheMSDSsarekept.

2. TheymustknowhowtoreadlabelsandMSDSinformationandhowtofollowthemanufacturer’sinstructionsandwarnings.

3. Theymustknowhowtoobtaininformationandaskquestions.

4. Theymustknowtheproperproceduresfordealingwithhazardousmaterials.

5. Theymustknowtheproperproceduresfordealingwithanemergencythatinvolveshazardousmaterials.

G. MSDSrequirementsincludethefollowing:

1. PerOSHArequirements,chemicalmanufacturersandmaterialimportersmustobtainordevelopanMSDSforeachhazardousmaterialtheyproduceorimport.AsampleMSDSappearsafterthenextpage.

2. EmployersmusthaveanMSDSintheworkplaceforeachhazardousmaterialtheyuse.

3. EachMSDSmustbeinEnglish.


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NOTE: Theemployermaymaintaincopiesinotherlanguages.

4. ChemicalmanufacturersandimporterscanuseanyformforaMSDSaslongasitisincompliancewithOSHAstandardsandcontains the specific following information.

a. Thename,commonname,andcommonnameofanychemicalsusedinthemix

b. Thephysicalandchemicalcharacteristics

c. Physical hazards including the potential for fire, explosion, andreactivity

d. Healthhazardsincludingthesignsandsymptomsofexposureandanymedicalconditionsthataregenerallyrecognizedasbeingaggravatedbyexposure

e. Primaryroutesofentryonthebody,suchasinhalationandskinabsorption

f. TheOSHA-permissibleexposurelimit,theAmericanConferenceofGovernmentalIndustrialHygienists(ACGIH)thresholdlimit,andanyotherexposurelimitsthatareusedorrecommended

g. WhetherornotthechemicalislistedbyOSHAandtheNationalToxicologyProgram(NTP)annualreportoncarcinogensorisconsideredtobeapotentialcarcinogenintheInternationalAgencyforResearchonCancer(IARC)monographs

h. Anyapplicableprecautionsforsafehandlingandusethatareknown

i. Anyapplicablecontrolmeasuresthatareknown

j. Emergency and first aid procedures

k. DateofpreparationoftheMSDSorthedateofthelastchangetotheMSDS

l. Name,address,andtelephonenumberofthechemicalmanufacturer,importer,oremployerthatpreparedtheMSDS

5. Each manufacturer will have specific information about how to readanMSDS.


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II. EPAregulations

A. TheEPAisafederalagencythatwritesandenforcesregulationsonhazardouswasteandisresponsibleforhowthehealthofthepopulationisaffectedbytheenvironment.

B. Federal laws define three categories of hazardous waste generators.

1. AConditionallyExemptSmallQuantityGeneratorgenerates100kgorlessofhazardouswastepermonthandneverstoresmorethan1,000kgatthebusiness.

2. ASmallQuantityGeneratorgeneratesbetween100kgand1,000kgofhazardouswastepermonth.Theamountofhazardouswastestoredonsitemustneverexceeds6,000kg.

NOTE: The typical shop is classified by the EPA as a Small QuantityGenerator.

3. ALargeQuantityGeneratorgenerates1,000kgormorepermonthofhazardouswaste.Thistypeofgeneratordoesnothaveahazardouswastestoragelimitbutcannotstorewasteonsiteformorethan90days.

C. Allcategoriesofgeneratorsaresubjecttothefollowingrequirements.

1. Ageneratormustdeterminewhichmaterialsarehazardous.

2. AgeneratormustobtainanEPAIDnumber.

3. Ageneratormustprepareandstorehazardouswasteasrequiredbylaw.

4. AgeneratormustshipwastesfortreatmentanddisposalonlytocompanieswithproperEPAIDnumbers.

5. Ageneratormustfollowtheproperhazardouswastestoragerulesfortanksanddrums.

a. Drums must be marked with the date the waste was first placedinthedrum.

b. Thecorrectlabelsmustbeused.

c. Theremustbeasecurestorageareatopreventunauthorizedaccess.


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d. Outdoorstoragemustbeshadedfromsunlightifthewastesareignitable.

e. The floor in the outdoor storage area must be curbed and impermeabletocatchandcontainleaksofthewaste.

6. Ageneratormustkeepmanifestsforatleast3years.Exceptionreports are filed if a waste shipment is lost.

7. Thefacilitymustbeoperatedtominimizeaccidentsandbeequippedwithinternalandexternalcommunicationequipment.Local authorities, fire, police, and emergency medical must be familiarwiththelayout,entranceroutes,accessroutes,andthelistofwastesatthefacilityandrelatedlocations.

NOTE: Anyrefusalbythelocalauthoritiestorespondshouldbedocumented.

8. Ageneratormustinspectwastecontainersonaweeklybasis.Containersmustbekeptclosedbetweenuse.Ifthefacilityiseverclosed,allwastemustberemoved.

D. Additionalrequirementsforcategory2and3generatorsareasfollows:

1. Anemergencycoordinatormustbedesignatedforthesite.Thispersonisoncall24hoursadaytorespondtoanyemergency.

2. Thenameandphonenumberoftheemergencycoordinator,thelocation of the fire extinguishers, the location of the spill control equipment, and the fire department phone number must be postedbythetelephone.

3. Thegeneratormustensureanddocumentthatemployeeshavebeentrainedinemergencyoperationsandcommunicationssystems.

4. Theemergencycoordinatormustrespondtoanyemergencyandfollowtheemergencyresponseplan.

E. Hazardouswastesmustbestoredproperly.

1. Whenwastesaregenerated,alabeliscreatedwiththestartdate,facilityaddress,EPAIDnumber,thewords“HazardousWaste,“wasteinformation,andshippinginformation.


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2. Awarningstickermayalsobenecessary.Somewasteshavemorethanonehazardandrequireawarninglabelforeachhazard.

3. Containermanagementrequiresthatalogmustbekeptto

recordweeklyinspectionsofdrumsduringstorage.Druminspectionsrequirethedateandinitialsoftheinspector.SeeSectionII,C,5forotherrequirements.

F. EPAregulationsrelatedtothestorageofhazardouswastesinclude

thefollowing:

1. Thedifferenttypesofhazardouswastescannotbemixed.

2. Storagecontainersmustbeinsoundconditionandhavetheproperdesignandcharacteristicsforthetypeofmaterial.

3. Containersmustbeclearlymarkedandstoredawayfromtheshoparea.TheEPAandDepartmentofTransportation(DOT)require specific labels to indicate various types of wastes.

G. EPAregulationsrelatedtothehandlingofhazardouswastesinclude

thefollowing:

1. Employeesmustbetrainedintheproperuseanddisposalofhazardouswastes.

2. Signsandchartsidentifyinganddescribingthehazardousmaterialsmustbedisplayedintheshop.

a. Emergencyproceduresfordealingwithhazardouswasteaccidentsmustbedisplayedintheshop.

b. Thephonenumbersoftheemergencycoordinator,fire department, police, health center, and the national responsecentermustbepostedbythetelephone.

3. Theshopareamustbeunclutteredandexitseasilyaccessible.The local fire marshal determines if the shop is meeting these requirements.

4. The shop operator must have on file precise information on the chemicalscontainedineachproductintheshop.Theoperatorshould also have on file first aid procedures relating to exposure tothesechemicals.


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H. EPAregulationsrelatedtothedisposalofhazardouswastesincludethefollowing:

1. Hazardouswastesmustbecollectedbyanapprovedwastehauler.

2. Ashoprepresentativemustcompleteawastemanifesteachtimeawastehaulerpicksuphazardousmaterial.Thehaulercannotacceptwastewithoutthecorrectforms.

NOTE:Anexceptiontothisruleinvolvestheuseofsolventsthatwillberecycledbythewastehauler.Inthiscase,thepaperworkishandledbythehauler.

3. Theshopmustobtainatwelve-digitcodenumberfromtheEPA.ThisnumberregisterstheshopasaSmallQuantityGenerator.Awastehaulermusthavethiscode.

4. Eachtypeofwastemustbeinasuitablepackageorcontainerand identified with a code name as specified by the DOT.

5. FailuretoobserveEPAregulationsresultsincriminalliabilitytotheshoporwastehauler.

I. Chemicalsorproductsthataredesignatedashazardouswastecanchange.Thefollowingaretwowaysamaterialisjudged“hazardous”andsubjecttoEPAregulations.

1. The EPA has a published list of specific chemicals deemed to be hazardoustohealthandtheenvironment.

2. If an operator believes a material is flammable or corrosive, will reactchemicallywithothermaterials,orwillreleasehazardousmaterials,thematerialcanbedeemedhazardous.

J. Thefollowingarewaysinwhichashopcanreducetheproductionofhazardouswasteandthecostofdisposingofit.

1. Encouragetheconservativeuseofsolventstoreducewastedisposalcostsaswellasthereplacementcostsofsolvent.

2. Useheatersthatburnoil,whichsavesonheatingbillsaswellaswastedisposalcosts.

3. Shipthehazardouswastedirectlytoarecyclingplantthatwillpickthewasteupatnochargeandusuallynotrequireawastemanifest.


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UNIT III: chemIcals aNd TheIr Use


I. Unitobjective

II. Lessonplans

A. Lesson1:Solvents,Soaps,andCleaningSolutions


2. AssignmentSheet

a. AS1-L1-UIII:SolventsandSoaps

B. Lesson2:LubricantsandSpecialtyChemicals


2. AssignmentSheet

a. AS1-L2-UIII:LubricantsandSpecialtyChemicals

C. Lesson3:Gases,AsbestosDust,andBatteryAcid


2. AssignmentSheet

a. AS1-L3-UIII:Gases,Dust,andAcid

III. UnitIIITest


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UNIT oBJecTIve

Aftercompletingthisunit,studentswillbeabletoidentifycommonchemicalsusedintheshop,theirpurpose,andhowtousethemsafely.Thestudentswilldemonstratemasteryofthematerialbycompletingtheassignmentsheetsandachievingascoreof_____ontheUnitIIITest.

sPecIfIc oBJecTIves


Lesson 1

I. Describe the five general rules for using automotive chemicals.

II. Identifythetypesandusesofsolvents.

III. Identifythetypesandusesofsoapsandcleaningsolutions.

IV. Completetheassignmentsheetonsolventsandsoaps(AS1-L1-UIII).

Lesson 2

I. Identifythetypesandusesofoils.

II. Identifythetypesandusesofgreases.

III. Identifythetypesandusesofspecialtyadditives.

IV. Identifythetypesandusesofspecialtychemicals.

V. Completetheassignmentsheetonlubricantsandspecialtychemicals (AS1-L2-UIII).

Lesson 3

I. Identifygasesandthehazardstheypresent.

II. Identifythehazardsofasbestosdust.

III. Identifythehazardsofbatteryacid.

IV. Completetheassignmentsheetongases,dust,andacid(AS1-L3-UIII).


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lessoN 1: solveNTs, soaPs, aNd cleaNINg solUTIoNs

I. Fivegeneralrulesforusingchemicals

CAUTION: Consult the instructor before using an unfamiliar product.

A. Followthemanufacturer’srecommendations.

B. Carefullyreadtheproductlabelforcorrectusesandhazards.

C. Work to prevent spills, damage to the vehicle, or unsafe situations/conditions.

D. Properlystorechemicalsandusedrags. E. Usechemicalsonlyfortheintendedpurposes.

II. Typesandusesofsolvents

A. Parts-washingsolvent(petroleumbased)

1. Thistypeofsolventdissolvesoil,grease,andvarnishfromenginecomponentsandotherpartsofthevehicle.Itisusuallydispensed in a parts-washing tank that filters and recycles the solvent.

2. Thissolventcontainsvolatileorganiccompounds(VOCs)thatgiveofftoxicvaporsandmustbemanagedasahazardouswaste. Parts-washing solvent is not as flammable as some other solvents, but can burn and does present a fire hazard.

a. Keepelectricaldevices,sparks,andanyhotmaterialaway

fromtheparts-washingtank. b. Thesolventtankshouldbeequippedwithasafetylink,

whichwillmeltshouldthesolventignite.Whenthesafetylinkmelts,thelidonthewashertankwillcloseandsmother the fire.

c. Parts-washingsolventpresentsahazardtotheeyesandskin,especiallywhenthesolventisfresh.Breathingsolventvaporsisalsoahealthrisk.Wearpersonalprotectiveequipment(PPE)whenworkingwiththesolvent.


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CAUTION: Some technicians may have a severe allergic reaction to the parts-washing solvent.

3. Petroleum-basedparts-washingsolventcanmeltsomeshoerubberandshouldneverbesplashedorpouredontheshopfloor. If a solvent spill is not immediately wiped up from the floor, it can cause people to slip and fall.

4. Neverputunitssuchaselectricmotorsinthesolventtank.Suchunitsmaysustaininsulationdamage;theymayalsobehardtodryontheinside.

5. Toextendtheusablelifeofthesolventandtopreventcloggingthetank,removemostofthegrease,gasketmaterial,anddirtfrompartsbeforewashing.Neverpourotherliquidsintothesolventtank.

B. Parts-washingsolvent(aqueousbased)

1. Thistypeofsolventisusedforthesamepurposesasthepetroleum-based solvents, but it is typically nonflammable and containslessthan5%VOCs.Besideswater,theingredientsinaqueous-basedsolventsgenerallyincludeadetergent,corrosivesubstance,oralkalineagentandarustinhibitor.

2. Ratherthandissolvinggreaseandsolidswithchemicals,aqueoussolventsuseheat,agitation,anddetergentstocleanautomotiveparts.

3. Specialcleaningequipmentisrequiredthatheatstheaqueoussolventandspraysitwithgreatforce.

a. Spraycabinets,whicharetotallyenclosed,arebestforcleaningheavilysoiledpartsoralargenumberofparts.

b. Sink-topunitsareusedformorelightlysoiledpartsorfewerparts.

4. The life of the solvent can be prolonged by using filters, maintainingthesolvent’sconcentration,andskimminggreasefromthesolution.

5. Aqueoussolventmaybecomehazardouswastethroughuse.Wastedisposalprofessionalsmustanalyzethesolutiontodeterminehowtodisposeofitsafely.


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C. Chokeandthrottlebodycleanerisanaerosolproductthatismoreaggressivethanparts-washingsolventinthecleaningofoil,grease,andvarnishfromcarburetorcomponentsandothersmallprecision-machinedparts.Itisapetroleum-basedproduct.

1. Choke and throttle body cleaner is extremely flammable and presents a dangerous fire hazard. Never spray the cleaner on hot engine parts or around sparks or fire.

2. Thecleanercandamagepaint.Donotspraythecleanernearthebodyofthevehicleorotherpaintedcomponents.

3. Thecleanercandamageeyesandirritateskin.Breathingitsvaporsisalsohazardous.AlwayswearPPE.Spraythecleanerawayfromthebodysothatvaporsarenotinhaledandthecleanerdoesnotcontacttheskin.

4. Observethesafetywarningsonthecleanercan.Donotexpose

thecleanercantoheatunderanycircumstancesbecauseheatwillcausethecleanercantoexplode.

D. Brakecleanerisanaerosolproductthatisextremelyeffectiveinremovinggreaseandoilfrombrakedrums,rotors,andengineflywheels.

1. Brake cleaner is extremely flammable and presents a severe fire hazardbecausethecleanerissprayedfromanaerosolcan.

2. Brakecleanercandamagepaint.Donotspraythecleanernearthebodyofthevehicleorotherpaintedcomponents.

3. Brakecleanercandamageeyesandirritateskin.Breathingitsvaporsisalsohazardous.AlwayswearPPE.Spraythecleanerawayfromthebodysothatvaporsarenotinhaledandthecleanerdoesnotcontacttheskin.

4. Observethesafetywarningsonthecleanercan.Donotstorebrakecleanerinahotarea.Donotexposethecantoheatunderanycircumstancesbecauseheatwillcausethecleanercantoexplode.

E. Gasketremoverisanaerosolproductthatloosensgasketmaterialthatmaybetightlystucktoenginecomponentswithsealersorglue.

1. Gasket remover is extremely flammable and presents a serious fire hazard because the gasket cleaner is sprayed from an aerosol can.


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2. Gasketremovercandamagepaint.Donotspraytheremovernearthebodyofthevehicleorotherpaintedcomponents.

3. Gasketremovercandamageeyesandirritateskin.Breathingitsvaporsisalsohazardous.AlwayswearPPE.Spraythecleanerawayfromthebodysothatvaporsarenotinhaledandthecleanerdoesnotcontacttheskin.

4. Observethesafetywarningsonthegasketremovercan.Donotstoregasketremoverinahotarea.Donotexposethecantoheatunderanycircumstancesbecauseheatwillcausethegasketremovercantoexplode.

F. Digestive-typecarburetorcleanerisanaggressivechemicalagentthatisusuallystoredina1-or5-galloncontainer.Thechemicaldissolvesorganicmaterial,leavingonlycleanmetalthatisthenrinsedwithwater.

1. Digestive-typecarburetorcleanerreactsvigorouslywithorganicmaterial.Itpresentsseverehazardstotheeyesandskin.AlwayswearPPE.

2. Donotsplashdigestive-typecarburetorcleaner.

CAUTION: Digestive-type carburetor cleaner will quickly burn skin that it contacts, so flush afflicted areas immediately with water.

3. Tocleanparts,gentlysubmergethebasketofpartsintothecan.When the solvent has finished cleaning, carry the basket with lid inplacetothesink.Thebasketofcleanpartsshouldbeplacedinthesinkandthepartsrinsedinagentlestreamofwater.

4. Anyspillsmustbecleanedupimmediately.Ragsortowelsusedinthecleanupshouldbediscarded.

5. Becausedigestive-typecleanerreactswithorganicandsomenonorganicsubstances,useitonlyonmetallicparts.

a. Parts made of rubber, fiber, or plastic may be ruined by digestive-typecarburetorcleaner.Thecleanermayevenremoveanodizedcoatingsalongwithpaintandvarnish.

b. Neveruseanyofthesechemicalsforpurposesotherthanthoselistedontheproductcanorcontainer.


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6. Tokeepfumesandevaporationtoaminimum,adda1-inlayerofwaterontopofthecleanerandcoverthecanwithalid.

7. Digestive-typecarburetorcleanerisanexpensivechemical

andshouldbeusedonlytocleansmall,precisioncomponents.Largercomponentscanbecleanedwithothersolvents.

G. Safetywarningaboutgasoline

1. Donotusegasolineasasolvent.Gasolineisintendedforuseasafuelnotasacleanerforautomotiveparts.

CAUTION: Never use gasoline or other chemicals for purposes other than those listed on the product can or container. Consult with the instructor before using any solvent or chemical.

2. Gasolinefumescancausesimilarhealthproblemsascleaningsolventsandcontributetohydrocarbonemissions.Thefumesare also extremely flammable and, if ignited, can cause severe burnsordeath.

3. Prolongedexposuretoliquidgasolinehasbeenshowntocause

cancerinlaboratoryanimals. 4. Gasolineadditivescanleaveharmfuldepositsonimportant

enginecomponents.

III. Typesandusesofsoapsandcleaningsolutions

A. Soapsandcleaningsolutionsarewater-solubleagentsusedforcleaningdirtandgrease.

B. Liquiddetergent,ordishwashingliquid,isamilddetergentthatisconvenienttouse.Liquiddetergentissuitableforwashingengineblocksafterhoningorglazebreaking.

C. Glass cleaner and windshield washer fluid are available in aerosol, pumpspray,orliquidform.Thebestresultsareobtainedwhenglasscleanerisusedwithpapertowelsratherthanshoptowels.Shoptowelsalmostalwaysretaingreaseandleavelint.

CAUTION: When filling the windshield washer fluid reservoir in the winter time, read the label on the solution to see if it contains the necessary antifreeze. Freezing can result in a cracked reservoir tank due to expansion.


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D. Handsoapsthataretypicallyusedcontainanabrasivetohelpcleanground-ingrease.Thesesoapscancauserawnessorcrackingoftheskin.

CAUTION: Never use abrasive hand soaps on vehicle finishes or plastics because scratches can occur.

E. Hand-cleaningcreamsaremoreeffectivethanordinaryhandsoapsongreaseanddirt.Hand-cleaningcreamsarealsoavailablewithabrasivesfortoughcleaningjobs.Thesecanbeusedinconjunctionwithhandsoaps.

F. Hand-protectingcreamsthatareappliedbeforeworkareeffectiveinpreventingdirtandgreasefromstainingthehandsandarms.Useofordinaryhandsoapwillremovethehand-protectingcream.

G. Cleaning methods for shop floors should be as dry as possible to help

preventwaterpollution.

1. AccordingtoEPAguidelines,shopworkersshouldkeepthe shop floor as dry as possible to minimize the amount of wastewaterthatisgenerated.

2. Ways to keep the floor dry and clean include the following:

a. Keep spills off the floor by using dedicated containers for substanceslikeusedoilandantifreeze.

b. Cleanupspillsimmediatelytopreventworkersfromslippinginthesubstanceandtrackingittootherareas.

c. Useragstocleanupsmallspillsanddisposeofthesoiledragsproperly.

d. Useabsorbentpadsormopstocleanlargespillsandwringthesubstancefromthepadsormopsintoadedicatedcontainerforrecyclingordisposal.

e. Use floor sweep (granules that absorb liquids) only when cleaninguphazardouswastespillssuchasgasolineorsolvents.

f. Sweep the floor with a broom every day to prevent the buildupofdirtandcontaminants.


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g. Do not hose down the floor with water or dump mop waterbecausethecontaminantswillgointothestormdrainorsewer,causingpollution.

h. Usewater,amop,andamilddetergentonlyifnecessaryafterthespillhasbeenremoved.Checkwithlocalauthoritiesfortheproperdisposalprocedure.

H. Examplesofspecialtycleaningagents

1. Spotremover

2. Bugandtarremover

3. Velourupholsterycleaner

4. Carpetcleaner

5. Vinylcleanerandconditioner

6. Batterycleaner

7. Wirewheelcleaner

8. Whitesidewallcleaner


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lessoN �: lUBrIcaNTs aNd sPecIalTy chemIcals

I. Typesandusesofoils

A. Oilisapetroleum-basedorsyntheticproductthatlubricatespartsoracts as a hydraulic fluid. When using oil, follow the safety precautions below.

CAUTION: Wear personal protective equipment (PPE) when working with oils.

1. All types of oils can represent a significant fire hazard. Spontaneous combustion, fire initiated without flame, can and doesoccurwithragssoakedinanytypeofoil.Oilmustbestored in a designated area away from heat, flame, or sparks.

a. Oilyragsmustbestoredinametalsafetycontainerwithanairtightlidbuiltforthispurpose.

b. Oilcanigniteatanytemperatureabove0°whenmixedwithpureoxygen.Oilmustneverbeappliedtooxyacetyleneweldingequipment.

c. Immediatelyuseordiscardbottlesandcansthatareleakingoil.

2. If oil is dripped or spilled on the shop floor, clean it immediately topreventslipping.

a. Wipeupsmallspillsordripswithatowel.

b. Largerspillsmayneedtobeabsorbedwithsawdustoroilabsorbentgranulesandthensweptupanddiscarded.Ifnecessary,scrubremainingslicknesswithsoapandwater.

c. Drainpanshelptopreventoilspills.

3. Avoidprolongedcontactwithoils.

a. Short-termcontactcancauseirritation,chapping,ordryingoftheskin.

b. Long-termcontactcancauseavarietyofskindiseasesthat

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B. Lightorpenetratingoilsareaerosolproductsthatincluderust-penetratingoil,siliconelubricant,liquidgraphite,andbeltdressing.

1. Lightoilsareusedtolubricateprecisionpartsbecausethelubricantgetsintotightclearancesanddoesnotattractasmuchdustanddirtasheavieroils.

2. Becausetheycandissolvesomerust,rust-penetratingoilsareusedtoaidintheremovalofrustyboltsandfasteners.

3. Liquidgraphitedriestoaslick,blackcoatingthatdoesnotattractanydustordirt.Thismakesitdesirableforcomponentswithtinymovingparts,suchaslocks.

4. Beltdressingissprayedondrivebeltstopreventslippageandquietbeltsthatdryoutandgetnoisy.

CAUTION: Aerosol cans are pressurized. The can must not be punctured or crushed, even when empty. The can should not be stored near heat or sparks. Never spray these products towards the body.

C. Standard and heavy oils are motor oil, automatic transmission fluid, power steering fluid, and gear lube.

1. Motor oils are used in vehicle engines and classified by viscosity orweight(e.g.,10W-30)andatwo-lettergrade(e.g.,SJandSL).

a. Refertothemanufacturer’srecommendationforthecorrect viscosity and service classification for the vehicle beingserviced.

b. Refertothevehicleserviceinformationfortheproperintervalforchangingthemotoroil.

2. Automatic transmission fluid (ATF) is available in three main types:TypeF,DexronII,andDexronIII.

a. ATFisusedinallautomatictransmissionsandsomemanual-shift,front-wheel-drivetransaxles.

b. Somevehiclemanufacturersrecommendusingonlytheir products that include specific additives. Refer to the manufacturer’srecommendationwhenselectingandusingATF.


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3. Power steering fluid is similar to ATF. Refer to the manufacturer’srecommendationwhenselectingandusingpower steering fluid.

4. GearlubeisthickerthanmotoroilorATFandprovidessuperiorlubricationbetweenthelargeandhighlystressedgearsofmanualgearboxesanddifferentials.

D. Hydraulic fluids include hydraulic jack oil and brake fluid.

1. Hydraulicjackoilisusedinshopequipmentthathasahydrauliccylinder,suchasjacks,enginehoists,liftracks,andforklifts.

CAUTION: Do not add hydraulic jack oil to shop equipment without the permission and supervision of the instructor.

2. Brake fluid is added to the master cylinder reservoir and clutch mastercylinderinahydraulicclutchsystem.

a. In America, brake fluids must be rated at least DOT-3 (Department of Transportation Specification #3).

b. Using the incorrect brake fluid can result in brake fade, the deteriorationofrubberseals,orcompletebrakefailure.

3. Most hydraulic fluids, especially brake fluid, attack and dissolve paint.

NOTE: If you suspect that brake fluid has contacted a painted surface,immediatelywashthatsurfacewithsoapandwater.

a. Cover fenders when adding brake fluid.

b. Thoroughlywashhandsimmediatelyaftercontactwithbrake fluid.

4. Hydraulic fluids, especially brake fluid, must be capped tightly to prevent dirt and moisture from contaminating the fluid.

a. Smallamountsofmoisturecanturntosteamwhenbrakefluid becomes hot during brake application. The steam reducestheeffectivenessofthebrakes.

b. Hydraulic fluids must be stored in a designated area away from heat, flame, or sparks.


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c. Neversubstituteothertypesofoilforhydraulicoil.Nonhydraulicoilmayharmrubbersealsorfailundertheheatgeneratedbythebrakesystem.

II. Typesandusesofgreases A. Greaseisusedwhenalubricantmuststayonpartsforalongperiod

oftimeandendurehighpressure.Whenworkingwithgrease,followthesafetyprecautionsbelow.

CAUTION: Wear PPE when working with greases.

1. Greasyragsarealsosubjecttospontaneouscombustion.Greasyragsmustbestoredinametalsafetycontainerwithanairtightlidbuiltforthispurpose.

2. Greaseproductsmustbestoredinadesignatedareaawayfrom

heat, flame, or sparks. Wipe up grease spills and clean the area immediatelywithsoapandwater.

3. Avoidprolongedcontactwithgreases. a. Short-termcontactcancauseskinirritation,chapping,or

dryingoftheskin.

b. Long-termcontactcancauseavarietyofskindiseasesthatincludescancer.

B. Multipurposegreaseissuitableforlubricatingsuchitemsassteeringlinkagecomponentsandwheelbearings.

1. Multipurposegreasecanalsobeusedasanassemblygluewhenpackingbearingsintoamanual-shifttransmission.

2. Readtheinformationonthelubricationlabelbeforeusing

multipurposegreasetobesurethatitisrecommendedfortheplannedapplication.

C. Wheelbearinggreaseissuitableforsteeringlinkagecomponentsaswellaswheelbearings.Ifpackingwheelbearingsinadiscbrakeorhighheatapplication,useanextreme-pressure(EP)wheelbearinggreasecompatiblewiththediscbrakes.

D. Brakegreaseisappliedinsmallamountstothebackingplateonvehiclesequippedwithdrumbrakes.


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E. Camlubricantissometimesincludedwithanewcamshaft.Thelubricantcanhelpwithbreakinginthecamshaft.

F. Whitelithiumgreaseisageneral-purposelubricantavailableinatubeoraerosolcan.Usesofwhitelithiumgreaseincludehoodhinges,doorhinges,cables,linkage,andshopequipmentmaintenance.

G. Sticklubricantsareusedondoorstrikersbecausetheydonotstainclothes.

H. Somelight-coloredgreases,suchaswhitelithiumgrease,arenotcompatiblewithATFandshouldnotbeusedasanassemblyglueorasaprelubeforinternaltransmissionparts.

CAUTION: If noncompatible grease is used during automatic transmission assembly, components in the valve body of the transmission can become stuck, resulting in shifting problems.

I. Dielectricgrease,availableinatube,isusedtosealelectricalconnectionstopreventvoltageleakageandkeepoutdirt,corrosion,andmoisture.

J. Brakesystemsiliconecompoundisagreaselikelubricantthatcomesinatube.Itisusedtolubricatesliders,rubberparts,orplasticpartsonbrakesystems.

III. Typesandusesofspecialtyadditives

A. Specialtyadditivesincludeoiltreatment,gastreatment,transmissionconditioner,andstartingether.Refertothecontainerlabelforhazardwarningsandhandlingprocedures.

CAUTION: Wear PPE when working with specialty additives.

B. Oiltreatmentsareusedtoraisemotoroilviscosityortofreestickingvalvesorlifters.Raisingthemotoroilviscositycanextendenginelifebyincreasingoilpressure.

NOTE:Addingtoomuchoiltreatmentcanresultinpoorlubricatingpropertiesoroilthatexceedstheproperviscosity,especiallyincoldweather.

C. Gastreatmentisusedtohelpreducemoistureingasolineandeliminatebuildupofcarbon,gum,andvarnishinfuellines.Gastreatmentusuallycontainsalcohol.Excessiveamountsofmethanolcandestroyrubbercarburetororfuelsystemcomponentsanddamagetheliningofthefueltank.


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D. Transmission conditioner is added to automatic transmission fluid to prolong the life of the fluid and improve the shifting performance of worntransmissions.

E. Startingetherissometimesusedtostartanengineinextremecold.Thedirectionsforusingstartingethermustbefollowedcarefully.

CAUTION: Starting ether is extremely flammable and can create an explosion if the engine backfires.

IV. Typesandusesofspecialtychemicals

CAUTION: Wear PPE when working with specialty chemicals.

A. Thetwotypesofsealersarehardeningandnonhardening.

1. Hardeningsealersformahardsealbetweencomponents.They are used to seal permanent assemblies and to fill gaps in irregularsurfaces.

2. Nonhardeningsealersremainpliable.Theyareusedinareasthatareexposedtovibration,expansion,andcontraction.

a. Roomtemperaturevulcanizingsealer(RTV),typicallyavailableinatube,isaspecialrubberthatsetsupatroomtemperatureandformsasealbetweencomponents.RTVisused instead of a rubber or fiber gasket. It is aerobic, which meansitcureswhenexposedtoair.

NOTE: SomeRTVscannotbeusedonenginesinvehiclesequippedwithcomponentssuchasoxygensensorsorautomatictransmissions.

b. Gasketsealers,appliedwithabrushorfromatube,helptoensureagoodsealbetweengasketsandirregularsurfaces.Thesesealersareanaerobic,whichmeanstheywillcureonlyintheabsenceofair.

c. Threadsealantisusedtosealthreadsandboltsthatareexposedtoliquids,usuallyeitherlubricatingoilorcoolant.

B. Lockingandantiseizecompounds

1. Lockingcompoundspreventafastenerfromlooseningbyactingasalockwasher.Lockingcompoundshavevariousstrengthsthatrangefrom“wrenchremoval”to“permanentlybonded.”


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2. Antiseizecompoundspreventthreadedfastenersfrombecomingpermanentlybondedtoanothercomponentandareusedwhenthefastenerismadeofadifferenttypeofmetalfromthecomponenttowhichitisattached.

D. Twocommonadhesivesareweatherstripandgasketadhesiveandrearviewmirroradhesive.

1. Weatherstripandgasketadhesiveisusedtogluegasketstometalandweatherstripstothevehicle’sdoorsandtrunk.

2. Rearviewmirroradhesiveisusedtoglueinsiderearviewmirrorstothewindshield.


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lessoN 3: gases, asBesTos dUsT, aNd BaTTery acId

I. Gasesandthehazardstheypresent

NOTE: Gasesincludethoseemittedfromengineexhaust,vaporsresultingfromevaporatingfuel,andgasesstoredinpressurizedcontainers.

A. Internal-combustiongasolineenginesemitavarietyofgases.Carbondioxide(CO2),watervapor,andsulfurdioxide(SO2)presentfew,ifany,healthrisks.Gasesintheexhaustthatpresentthemostserioushealthrisksarecarbonmonoxide(CO),hydrocarbons(HCs),andoxidesofnitrogen(NOx).

1. COresultsfromincompletecombustionoffuelandairintheengine.

a. Wheninhaled,itdisplacesoxygeninthebloodthatcausesasphyxiationanddeath.COhasnonoticeableodor,whichmakesitparticularlydangerous.

b. ToavoidCOpoisoning,exhaustfumesmustalwaysbeventilatedtotheoutside.Consulttheinstructorfortheproperuseofexhaustventilationequipment.

2. HCscontainhydrogenandcarbon.RawunburnedgasolineisaHC.ExhaustgascontainssmallamountsofHCs.

a. ExcessivelevelsofHCscausesnausea,vomiting,andpossiblyevencancer.


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b. ToavoidinhalingHCs,exhaustfumesmustalwaysbeventilatedtotheoutside.Consulttheinstructorfortheproperuseofexhaustventilationequipment.

3. NOxareproducedduringhighcombustiontemperatures.NOxhasapungentodorandmustbeventilatedtotheoutside.Consulttheinstructorfortheproperuseofexhaustventilationequipment.

B. Fuel vapors, such as gasoline vapors, are extremely flammable and toxic.Gasolinevaporscanbereleasedfromthefueltankorotherstorage tanks and the engine carburetor. To avoid the risks of fire and explosionoffuelvapors,thefollowingstepsmustbetaken.

1. GasolinedestroysmanytypesofcontainersandmustbestoredinUnderwritersLaboratory(UL)approvedcontainers.Thesecontainersmustthenbestoredinametalsafetycabinetawayfromsparksandheat.

CAUTION: Never leave gasoline cans open or uncapped in

the shop area. Fumes can collect and explode.

2. Avoidgasolinespills.Wipeupspillsimmediately.Disconnectandplugthefuellines.Drainorsiphonthefueltankbeforeremovingfromthevehicle.

3. Anemptyfueltankisdangerousbecauseofgasolinefumes.Neverattempttoweldafueltank.Thismustbedoneonlybyexperiencedprofessionals.


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4. Sparksandheatmustbekeptawayfromenginecarburetors.Evenemptycarburetorsmaycontaingasolineresidueandfumes.Nevermakeelectricalgroundconnectionstothecarburetor.

5. Consulttheinstructorfortheproperdisposalprocedureintheshop.Neverpourgasolinedownasinkorintothesewer.Doingsoisaseriousviolationoffederalregulations.

C. Gasesfromthevehicle’sbattery

1. Batteriesproducehydrogengasthatcancollectatthetopofthebattery. The gas can explode if exposed to a spark or flame.

2. Keep sparks and flames away from the battery.

a. Inspectthebatteryindaylight,notwithalamp.

b. Donotwearjewelrythatcouldcontactthebatteryandcreateaspark.

c. Do not smoke or have open flames around the battery.

d. Connectbatterycablesproperlyandusetoolscarefullyaroundthebatterytopreventsparks.

D. Storedgases

1. Propaneishydrocarbongasthatisusuallystoredinmetalcontainersunderpressure.

a. Propaneisusedintorchesduringsomecarburetoradjustments,vacuumleakdetection,andcatalyticconvertertests.

b. Propanetanksmustbestoredawayfromheatandsparks.Thetankmustneverbepunctured.Neverdiscardapropanetankthatstillcontainspressure.


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2. Acetyleneisasynthetichydrocarbongascommonlyusedforthecuttingandweldingofmetal.

a. Acetylene gas is extremely flammable and chemically unstable.Acetylene,inconjunctionwithoxygen,presentsgraveandunusualhazards.

b. Onlyexperiencedtechnicians,whohavehadextensivesafetytraining,shoulduseanoxyacetylenetorchset.

c. Oilpresentsthemostprominentdangerbecauseitcancreateanexplosioninthepresenceofpureoxygen.

CAUTION: Never allow oil to contact any part of an oxyacetylene torch set or use oxygen or acetylene as compressed air.

E. R-12,orFreon,isarefrigerantgasusedinairconditioningsystemspriorto1995.Since1995,theenvironmentallysafeR-134ahasbeenused.

1. Refrigerantshouldnotbedirectlyinhaledorexposedtoopenflame. Refrigerant is stored under pressure and creates extreme coldwhenreleased.

2. Blindnesscanresultifrefrigerantcontactstheeyes.


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3. Theareashouldbewellventilatedandpersonalprotectiveequipment(PPE)mustbeworn.

4. Neverallowarefrigerantcontainertobepuncturedorstored

nearheat.

II. Thehazardsofasbestosdust

CAUTION: Asbestos dust from brake linings and clutch discs is a hazardous material that requires special precautions.

A. Untilrecentlynearlyallbrakeandclutchliningscontainedasbestos,amaterialthatcanwithstandextremelyhightemperatures.Asbestosdusthasbeenshowntocauselungcancer,eveninminutequantities.Forthisreason,specialcaremustbeexercisedduringbrakeandclutchwork.

CAUTION: Some imported brake products may still contain asbestos.

1. Neverusecompressedairtoblowoutbrakesorclutches.

2. Wearadustmaskandusetheproperdustevacuationsystemwhenworkingonbrakesystems.

3. Alloldbrakeliningsandclutchdiscsmustbereturnedtoatight-sealingbox.Neverleavethesepartslyingaroundtheshop.


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III. Thehazardsofbatteryacid

A. Vehiclebatteriescontainbatteryacid,alsocalledelectrolyte,whichisasolutionof40%sulfuricacidand60%distilledwater.Sulfuricacid,madefromsulfurdioxide,isahighlycorrosiveacid.

B. Observethefollowingsafetyprecautionswhencleaningandhandlingabattery.

1. WearPPE(goggles,faceshield,apron,andgloves)wheninspecting,cleaning,orhandlingabattery.

CAUTION: Do not allow battery acid to contact the skin or eyes because it causes serious burns and damage. The acid will burn holes in clothing as well.

2. If battery acid contacts the skin, flush the area immediately with plentyofwater.

3. If battery acid contacts the eyes, flush the eyes with water immediatelyfor30minutesandseekmedicalattention.

4. Avoidrubbingtheeyesorunprotectedskinwhileworkingwithabatterytopreventcontactwiththeacid.

5. Washhandsimmediatelyafterworkingwithabattery.

6. Ifacidspillsintheshop,neutralizetheacidwithamixtureofbakingsodaandwater,wipeupthespill,andrinsetheareawith clear water. If acid gets on clothing, flush the clothing with thebakingsodaandwatermixture.


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UNIT Iv: BasIc haNd Tools


I. Unitobjective

II. Lessonplans

A. Lesson1:TypesofWrenches


2. AssignmentSheet a. AS1-L1-UIV:Wrenches B. Lesson2:TypesofScrewdriversandPliers


2. AssignmentSheet a. AS1-L2-UIV:ScrewdriversandPliers

C. Lesson3:TypesofHammers,Punches,andChisels


2. AssignmentSheet a. AS1-L3-UIV:Hammers,Punches,andChisels

III. UnitIVTest


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UNIT oBJecTIve

Aftercompletingthisunit,studentsshouldbeabletoidentifybasichandtoolsandtheiruses.Studentswilldemonstratemasteryofthematerialbycompletingtheassignmentsheetsandachievingascoreof_____ontheUnitIVTest.

sPecIfIc oBJecTIves


Lesson 1

I. IdentifythedifferencesbetweenmetricandUSCSwrenches.

II. Identifythetypesandusesofcommonwrenches.

III. Identifythetypesandusesofsocketwrenches.

IV. Identifythetypesandusesofotherwrenches.

V. Completetheassignmentsheetonwrenches(AS1-L1-UIV).

Lesson 2

I. Identifythetypesandusesofscrewdrivers.

II. Identifythetypesandusesofpliers.

III. Completetheassignmentsheetonscrewdriversandpliers(AS1-L2-UIV).

Lesson 3

I. Identifythetypesandusesofhammers.

II. Identifythetypesandusesofpunchesandchisels.

III. Completetheassignmentsheetonhammers,punches,andchisels (AS1-L3-UIV).


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lessoN 1: TyPes of WreNches

I. MetricandU.S.CustomarySystem(USCS)wrenches

A. AlltechniciansshouldhaveasetofbothmetricandUSCS(alsocalledSAE)wrenchesforlooseningandtighteningboltsandnuts.

1. Metricwrenchesaresizedperthemeasurementinmillimeters(mm)ofthejawopening,fromfacetoface.Thejawsizeisactuallyalittlelargerthantheboltornutofthesamesizetoallow the jaw to fit around the bolt or nut.

2. USCSwrenchesaresizedperthemeasurementinfractionsofaninchofthejawopening,fromfacetoface.Thejawsizeisactuallyalittlelargerthantheboltornutofthesamesizetoallow the jaw to fit around the bolt or nut.

B. MetricandUSCSwrenchesarenotinterchangeable.Forexample,ifremoving a 14-mm nut, a 9/16-in wrench is close in size but is not the proper size to effectively remove the nut. The 9/16-in wrench may slipandroundoffthesidesofthenut.A14-mmwrenchshouldbeused.

II. Commonwrenches

A. Theopen-endwrenchturnsnutsandboltsthathavealreadybeenloosened.Iftoomuchtorqueorturningactionisapplied,itcanroundoffthecornersofnutsorbolts.Theendsofthewrencharesetata15°angletoreducethedistancethewrenchismovedtogripthenextsideofthehexhead.


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B. Theboxwrenchcompletelyencirclesthenutorbolttogripallthecorners,whichallowsconsiderablymoretorquetobeappliedwithoutstrippingthenutorbolt.Thiswrenchisparticularlyusefulforlooseningtightboltsandnuts.Moretimeisrequiredtoturnlooseboltswiththeboxwrench.

C. Thecombination-endwrenchisacombinationopen-endandboxwrench.Itisafavoriteoftechniciansbecauseofitsmultipleuses.

D. A tubing wrench, or flare nut wrench, has ends with a portion of one sidecutawaysothatthewrenchmaybeslippedoverasteelline.Eachendpartiallyencirclesthehexheadofanutorbolt.Steellinefittings are usually brass and require this type of wrench to loosen a tight fitting without causing damage.

NOTE:Inadditiontothetubingwrench,anopen-endwrenchisusedto firmly hold the fitting while attaching it to the steel line. Do not allowthesteellinetobecometwisted.

E. Maintenance

1. Wrenchesshouldbekeptfreeofdirtandgreaseandstoredinadryplacetopreventrust.

2. Wrencheswithdistortedjawsshouldbediscarded.

F. Safety

1. Alwaysusethepropersizewrench.DonotusemetricwrenchesonUSCSboltsorviceversa.

2. Donotuseawrenchasahammerorprybar.

III. Socketwrenches

A. Thiswrenchissonamedbecauseithasacylindricalsocket(inthesizeof the bolt) that fits down over the bolt, much like a box-end wrench.


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B. Thesocketwrenchisthepreferredtoolofmosttechnicianswhentheyworkwithnutsandbolts.Socketwrenchescanbeusedinplacesthatareinaccessibletocommonwrenchesandarefasteratremovingbolts.

C. Thetwobasicpartsofasocketwrencharethesocketandbarorhandle.

1. SocketscomeinmetricandUSCSsizesandaresizedaccordingto the size of the bolt head they fit and the size of the bar they take.Theyareavailableinfourpointtypes:4point,8point,6point,and12point,withthe6-pointand12-pointsocketsbeingthemostcommonlyused.

a. Ashallow12-pointsocketisusedforturninghexagonal

boltheadsintightplacesbecauseitofferstwiceasmanystartingpositions.

b. Ashallow6-pointsocketisusedforturninghexagonalboltheadsbecauseitoffersbettergripandlesschanceofroundingofftheboltheadwhenexcesstorqueisused.

c. Adeep-well12-pointsocketisusedtoturnnutswhenaboltorstudprotrudesthroughthenutenoughtoprohibittheuseoftheshallowsocket.

d. Adeep-well6-pointsocketisusedinthesamesituationas

describedabove.Itisparticularlyusefulwhenthereisariskofroundingofftightnuts.

e. Swivelsockets,oruniversalsockets,haveauniversaljointbuiltintothesocketdriveendthatallowsboltsandnutstobeturnedwhenitisnotpossibletogetstraightontothehead.


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f. Impactsocketsaredesignedtowithstandthegreattorqueandimpactdeliveredbyairimpacttools.Animpactsockethasthickerconstructionthanastandardsocket.

CAUTION: Do not use standard sockets on air impact

guns because the socket may shatter.

2. Barsandhandlesareusedtoturnthesockets.Thedriveendissquare and available in 1/4-in, 3/8-in, 1/2-in, and 3/4-in sizes.

NOTE: The 3/4-in size is used for large, heavy-duty bolts

that are found in trucks. The 1/2-in size is used on large automotive bolts. The 3/8-in size is the most commonly used by technicians. For very small work, the 1/4-in size is used because ofitscompactness.

a. Thebreakerbarisasturdyhandlethatisusedwhengreattorqueisrequiredtoloosenboltsandnuts.Theendofthebreakerbarcanswingtoallowclearance.

NOTE: Thelengthofthehandleonthebreakerbarprovidessuperiorleveragefortightnutsandbolts.

b. Theratchetisthemostcommonlyusedhandleforturningsockets.Byrotatingbackandforth,theratchetturnsnutsandboltsinareasoflimitedaccesswithoutbeingremovedaftereachpartialturn.

• Theratchetisnotintendedforuseunderextremetorquebecausetheteethontheratchetmechanismmaystrip.

• Someratchetshaveheadsthatswivel,whichallows

clearancewhileturning.


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c. Extensionbarsaidinreachingrecessedboltsandnutsbyextendingtheratchetdriveend.Commonextensionlengthsinclude3in,6in,and12in.Manyotherlengthsarealsoavailable.

d. SpeedhandlesandT-handlesareoccasionallyusedtospeedassembly.Oneadvantageofthesehandlesistheydonotplacesidestressontheextensionandsocket.Thesehandles are not used for the final tightening.

e. Atorquewrenchisaspecialhandlethatindicatestheamountoftwistingforce(torque)thatisbeingappliedintighteningabolt.

• Thiswrenchisnecessarywhenthetorqueofboltsmust meet manufacturer’s specifications.

• Somemodelshaveascaleordialtoindicatetorque.

• Othersclickorreleasemomentarilywhenthepresettorqueisreached.

• Mostrecently,electronicversionsareavailablethathaveeasilyprogrammableandaccessibletorquesettingsandindicatetorquebyvibrating,producinganaudiblesignal,andprovidingadigitaldisplay.

NOTE: Specifications for the torque of bolts are extremely important.Iftoomuchtorqueisapplied,thesurfacesbeing joined or the bolt/nut will be damaged. If too little torqueisapplied,theboltmayworkloose.


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D. Occasionally,thetechnicianmustuseasocketadapteronasockettoeaseboltremoval.

NOTE:Thetorquecapacityofthesocketandratchetmustbeconsideredsothatthetoolisnotdamagedorbroken.

1. Asizeadapterallowsthetechniciantouseadifferentdrivesizesocketontheratchetortorquewrench.

NOTE:Caremustbeexercisedwhenadaptinglargebreakerbarsdowntosmallerdrivesocketsbecausethetorquecapacityofthesmallsocketmaybeexceeded.

2. Auniversaladapteroperatesbestwhenasockethaslimitedaccessthatpreventstheratchetandextensionfromengagingstraightontothesocket.Theseadapterscannotwithstandgreatamountsoftorque.

E. Maintenance

1. Socketsandhandlesshouldbekeptfreeofdirtandgreaseandstoredinadryplacetoavoidrust.

2. Ratchethandlescanbecomewornandshouldbereconditionediftheratchetstartstoslip.

F. Safety

1. Ratchethandlescanturnbothcounterclockwiseandclockwiseand the lever that switches the direction should be firmly and fullyplacedintoitsproperposition.

2. Donotusearatchethandleasahammerorprybar.

3. Theexactsizesocketmustalwaysbeused.Damagedsocketsshouldbediscarded,becausetheycanslipoffabolt.


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a. Whenusingasocketonadamagedbolthead,beespeciallycarefulsothewrenchdoesnotslipoffandcauseaninjurytotheknuckleorhand.

b. Alwaysbesurethesocketiscompletelyoverthebolthead.If the bolt head is so damaged that the socket cannot fit completelyoverthehead,useanothermethodofremoval.

IV. Otherwrenches

A. AnAllenwrenchisusedonhexheadfasteners,whichcontainacavitywithsixsides.Atorxwrenchisusedontorxbolts,whichcontainacavityofsixroundedpoints.Thisdesignreducestheriskofstrippingordisengagingthethreadsofsmallfasteners.

B. Anadjustablewrenchhasascrewthatallowsthejawtoadjusttodifferentsizes.Undernormalcircumstances,techniciansdonotuseanadjustablewrenchforturningnutsandbolts.

1. Ithasthedisadvantageofnotgrippingassolidlyasbox-end

wrenches,andunlessproperlyadjustedandingoodcondition,maynotgripassolidlyasopen-endwrenches.

2. Anadjustablewrenchmaybeusedifthetechniciandoesnothaveimmediateaccesstotheproperwrenchandiftorquerequirementsarenottoohigh.

C. Standardwrenchescannotbeusedonpipesbecauseoftheroundshapeofpipes.Thepipewrenchhasteeththatdiginasthewrenchturnsthepipe.Theriskofscarringthepipecanbereducedbyplacingaleatherstrapbetweenthepipeandthewrenchteeth.


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lessoN �: TyPes of screWdrIvers aNd PlIers

I. Screwdrivers

A. Thestandardscrewdriverhasastraightbladeforturningscrewswithaslotthatisthesamewidthandlengthasthescrewdriverblade.

CAUTION: The standard screwdriver is not intended for use as a

pry bar, chisel, or gasket scraper. These misuses of the screwdriver can damage the tool and injure the technician.

B. The Phillips screwdriver fits the crossed slot of a Phillips screw. One advantagethisscrewdriverhasoverthestandardoneiswhenitisinsertedintheslot,itisself-centering.

1. Phillips screwdrivers are available in various tip sizes (e.g., #0, #1, #2, #3, #4) with the lower number being the smallest.

2. AtechnicianshouldnotattempttouseastandardscrewdrivertoturnaPhillipsscrew.

3. AgooddealofpressuremustbeappliedwhenusingaPhillipsscrewdriverorthetipmaydisengagetheslot,damagingthescreworthetool.

4. IftheslotofaPhillipsscrewisstripped,itwillhavetobedrilledout.


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C. ThePozidrivscrewdriverissimilartothePhillipsinthatitisusedonacross-slottedscrew.However,thePozidrivscrewdriverandscrewheadhavefouradditionalpointsofcontact.

1. MoretorquecanbeappliedwiththePozidrivscrewdriverbecausethebladewillnotslipoutofthescrewheadaseasilyasthePhillipsscrewdriverwill.

2. Although not recommended because of improper fit, a Phillips screwdriverwillturnaPozidrivscrew.APozidrivscrewdriver,however,willnotturnaPhillipsscrew.

D. Thetorxscrewdriverhasa6-pointtipthatisusedontorx-headscrews.

E. Nutdrivershaveahandleandshaftlikeascrewdriverbuthaveasocketattheendoftheshaftthatisnotremovable.Becausenutdriverscanbeoperatedwithgreaterspeedthansocketwrenches,theyareidealforlooseningandtighteningthesmallnutsandboltsfoundonvehicles.

F. Maintenance

1. Keepscrewdriversfreeofdirtandgreaseandstoretheminadryplacetopreventrust.

2. Keeptheheadsingoodcondition,freefromnicks.

G. Safety

1. Therightsizescrewdrivershouldbeusedforeachjob.

a. Thescrewdrivershouldbetherightlengthforaccesstoleverage.


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b. Theheadofthescrewdrivershouldmatchtheheadofthescrew(bothtypeandsizeofthescrew).

2. Donottrytouseanothertool,suchaslockingpliers,tograbthehandleofthescrewdriverandgetmoreleverage.Ifitcannotbeturnedbyhand,anothertoolisneeded.

3. Usescrewdriverswithinsulatedhandlestopreventelectricshock.

4. Donotuseascrewdriverasapunchorchisel.

II. Pliers

A. Standardslip-jointpliersareoneofthemostcommontypesofpliersusedbytechnicians.Thesegripirregularpartsandholdworkduringdrilling.

B. Lockingpliersareverysimilartostandardslip-jointpliers.Byturningaknobandthenclampingthehandlesinplace,thelockingpliersholdworksecurely.

CAUTION: When clamping or removing locking pliers, keep a proper grip on the handles. The handles snap together and snap apart with considerable force.

C. Adjustable-jointpliershavealongslotwithawidevarietyofadjustmentpositions.Theoffsetjawsoftheadjustable-jointpliersofferareachadvantage.


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D. Long-nosepliers,orneedle-nosepliers,areusefulforgrippingtinypinsandpartsduringtheserviceofcarburetorsandothersmallassemblies.

E. Diagonal-cuttingpliersareusedtocutelectricalwireandtapeaswellasavarietyofothermaterial.Diagonal-cuttingpliersarewell-suitedforremovingcotterpinsonfront-endcomponents.

CAUTION: Do not use on live electrical circuits.

CAUTION: Do not cut spring steel with diagonal-cutting pliers because the pliers will be nicked and ruined.

F. Snap-ringplierscomeinmanystylesandtypes.Snap-ringpliersarerequiredforspreadingorcompressingspringysnapringsfoundintransmissions.Snap-ringpliersareavailablethatcanremoveinternalsnaprings,externalsnaprings,orboth.

G. Maintenance

1. Pliersshouldbekeptfreeofdirtandgreaseandstoredinadryplacetopreventrust.

2. Ifthejawsofthepliersareheldbyascrew,thescrewshouldbekeptsnug.


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H. Safety

1. Whenworkingnearelectricalequipment,useplierswithinsulatedhandles.

2. Donotusepliersasahammer.

3. Donothammeronthehandles.


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lessoN 3: TyPes of hammers, PUNches, aNd chIsels

CAUTION: Wear protective eyewear at all times when using a hammer, punch, or chisel to protect the eyes from flying metal chips. Never strike one hammer with another, because hammer heads are very brittle and metal chips can fly off.

I. Hammers

A. Theballpeenhammeristhemostcommonhammerusedfordrivingpunches and chisels. It has a domed head on one side and a flat head ontheother.

B. Ahand-heldsledgehammercanbeusedwhenagreatdealofdrivingpowerisrequired.

C. Asoft-facedhammercanbeusedtoavoiddamagetotheworkbeingdriven.Theheadcanbemadeofbrass,bronze,rubber,orrawhideasthesematerialsdominimaldamagetoironandsteelcomponents.

D. Aplastic-tiphammerisusedwhenlightdrivingpowerisneededandabrasshammercouldcausedamage.

CAUTION: Do not use this hammer to drive punches and chisels.

It will destroy the plastic tip.


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E. Arubbermalletisusefulforinstallingwheelcovers.Alwaysstrikethewheelcoverevenlyaroundtheperimeter.

F. Maintenance

1. Hammersshouldbekeptfreeofdirtandgrease,withthefacessmoothandfreeofallforeignmatter.

2. Hammersshouldbestoredinadryplacetopreventrust.

G. Safety

1. Always be sure the head is secured firmly on the handle.

2. Besurethehandleisingoodcondition.

3. Strike a flat-surfaced hammer flat against the object being struck,notatanangle.

II. Punchesandchisels

A. Punches

1. Ataperorstartingpunchisthemostcommonlyusedpunch.Thispunchisdesignedtodriveoutrivetsaftertheheadshavebeenremoved.Itisalsousedtopunchoutstraightandtaperedpins.

2. Apinpunchisusedwhenasmallrollpinmustbedriventhroughahole.

3. Thecenterpunchisusedtomakeasmalldimpleinmetalpriortodrilling.Thismarkhelpsensurethattheholewillbedrilledintheproperplaceandthatthedrillbitwillnotmove.


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4. Abrassorbronzepunchisusedwheninanareawhereflammable liquid or gasoline is present. This ensures that no sparkswillbecreated.

B. Chisels

1. Thestandardcoldchiselisusedtocutandremovemetal.Theendofthechiselshouldbegroundtoasharppointona60°angle.

2. Differentchiselshapesareavailableforparticularjobs.Theshapesincludetheroundnose,diamondpoint,andhalfround.Thesechiselsareusedtocutorchipmetal.

C. Maintenanceforpunchesandchisels

1. Whentheheadofthepunchorchiselmushrooms,themushroomingmustbegroundoffwithagrindingwheel.

2. Whenthecuttingedgeofthepunchorchiselbecomesdullandchipped,itmustbesharpenedwithagrindingwheel.

3. Afteracertainamountofmaintenancewiththegrindingwheel,thepunchorchiselbecomestooshortortheedgebecomestooblunt.Whenthishappens,itshouldbediscarded.

4. Punchesandchiselsshouldbekeptfreeofdirtandgreaseandshouldbestoredinadryplacetopreventrust.

D. Safetyforpunchesandchisels

1. Alwayswearheavyglovesandsafetyglasseswhenworkingwithpunchesandchisels.


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2. Grinddownamushroomedheadimmediately.Themushroomed metal may fly off and cause injury. Also, the hammerslipsoffofamushroomedheadmoreeasily.

3. Punchesshouldbetappedgentlyratherthanwithbruteforce.Usuallyseverallighthitsontheheadworkbetterforallpurposesthanaheavyhit.

4. Useachiselholdertominimizetheriskofmissingthechiselandhittingahand.


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UNIT v: sPecIalTy Tools, fasTeNers, aNd measUrINg Tools


I. Unitobjective

II. Lessonplans

A. Lesson1:SpecialtyTools


2. Assignmentsheet a. AS1-L1-UV:SpecialtyToolUses

B. Lesson2:Fasteners


2. Assignmentsheet

a. AS1-L2-UV:CommonVehicleFasteners

C. Lesson3:MeasuringTools


2. Assignmentsheet

a. AS1-L3-UV:UseandCareofMeasuringTools

III. UnitVTest


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UNIT oBJecTIve

Aftercompletingthisunit,studentsshouldbeabletoidentifythetypesandusesofspecialtytools,fasteners,andprecisionmeasuringtools.Studentswilldemonstratemasteryofthematerialbycompletingtheassignmentsheetsandachievingascoreof_____ontheUnitVTest.

sPecIfIc oBJecTIves


Lesson 1

I. Identifythetypesandusesofspecialtytools.

II. Completetheassignmentsheetonspecialtytooluses(AS1-L1-UV).

Lesson 2

I. Identifycommonfastenersusedonvehicles.

II. Identifytoolsandmethodsforcuttingthreads,repairingdamagedthreads,andremovingbrokenbolts.

III. Completetheassignmentsheetoncommonvehiclefasteners (AS1-L2-UV).

Lesson 3

I. Identifythetypesandusesofmeasuringtools.

II. Identifytheproceduresfortheuseandcareofmeasuringtools.

III. Completetheassignmentsheetontheuseandcareofmeasuringtools(AS1-L3-UV).


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lessoN 1: sPecIalTy Tools

I. Typesandusesofspecialtytools A. Specialcuttingtools

1. Hacksawscutmetalpartstosizeorshapeandremovedamagedfasteners.

a. Thehacksawcutsontheforwardstrokeonlyandisliftedonthereturnstroke.

b. Hacksawsaresizedaccordingtobladelength.Wheninstallingtheblade,pointtheteethawayfromthehandleandtightlysecuretheblade.

CAUTION: Always wear safety glasses and heavy gloves when using a hacksaw. The blade can break. In addition, be sure to firmly secure the object being sawed.

2. Tubingcutterscutwithoutbending,kinking,orscarringthetubing.

a. Thecutterisplacedonapieceoftubingandtightenedasitisrotated.

b. Tubingcuttersvaryinsizeaccordingtothediameterofthetubetheyaredesignedtocut.


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3. Ahandreamersmoothsorenlargesholes.Bothstraightandtapered reamers are used. Straight reamers may be either fixed in size or adjustable through a specific cutting range.

4. Filessmoothorshapemetal.Filesaredesignedinvariousshapesfordifferenttasksandhavedifferentteethdesignsforfine or rough work.

CAUTION: Use a handle on the file to prevent hand injury. Never hammer on or use a file as a pry bar. Files are brittle and can shatter with dangerous results.

CAUTION: Always wear safety goggles and heavy gloves when working with a file.


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B. Electricalsystemtools

1. Thedigitalmultimeter(DMM)checkstheconditionofelectricalsystemcomponents.

a. Thistestdeviceisavoltmeter,ohmmeter,andammeterallinone.

b. ADMMhastwoleads,oneblackandonered.OneendoftheleadispluggedintotheDMM.Theotherendisaprobe.

2. Ascantoolisusedtodiagnoseelectricalproblems.Thetoolisconnectedtothevehicle’sdatalinkconnector(DLC)toretrievediagnostictroublecodes(DTCs)andenginesensorinformationthataregeneratedbythevehicle’son-boarddiagnosticssystem.


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3. Anoscilloscope,orscope,isavoltmeterthatdisplaysvoltageinrelationtotime,showingvoltageverticallyandtimehorizontally.ItsconnectionsaresimilartoaDMM.

a. Itproducesalineonacathoderaytube(CRT)orliquidcrystaldisplay(LCD)whenconnectedtocircuitvoltage.

b. Acircuitproblemcanbefoundbycomparingtheline“pattern”toaknowngoodpattern.

4. Thecontinuitylightcheckspowerinvariouscircuits.Oneendofthelightisgroundedandtheotherendispressedintotheelectricaldevice.

NOTE: Thecontinuitylightshouldneverbeusedtocheckthe

powersupplyofelectroniccomponents.

5. Atiminglightdeterminesiftheignitionsystemisdeliveringelectricchargetothesparkplugsatthecorrecttime.


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6. Theremotestarterswitchallowsthetechniciantousethestartertocranktheenginewithoutactuallybeinginthevehicle.

C. Batteryspecialtytools

1. Acablepullerremovesthecablefromthebatteryterminalwithoutbreakingthecableorbatteryposts.

2. Terminalandpostcleanerscleanthepostsandterminalends.

3. Abatteryliftingtoolandcarryingstrapliftsandtransportsthebatterysafely.


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D. Lubricationspecialtytools

1. A transmission funnel is a funnel with a long, small, flexible neck that is ideal for adding transmission fluid.

2. An oil filter removing tool is a wrench or socket adapter that fits around an oil filter to remove it.

3. A grease gun forces grease into fittings. Pressure is created by handactiononthegun’slever.

E. Miscellaneousspecialtytools

1. Ablowgunusescompressedairtocleanordryvariousitemsintheshop.


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2. TheC-clampisaholdingdevicethatiscommonlyusedtocompress the calipers on floating caliper disc brake systems.

3. Apullersetfunctionstoremoveobjects(e.g.,gears,bearings)thatarepressedontoashaft,pullobjects(e.g.,retainers,oilseals)fromvariousopenings,andremoveshafts(e.g.,pinionshafts,transmissionshafts)fromanotherobject.

4. Pressure gauges test the air and fluid pressure in various componentssuchasthetires,oilpump,andfuelpump.

5. Vacuumgaugeschecktheconditionoftheengineandvariousvacuum-operatedcomponents.Gaugescomparethepressureinacomponenttoatmosphericpressureatsealevel.


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lessoN �: fasTeNers

I. Commonvehiclefasteners

NOTE:Vehiclesusemanytypesoffastenerstoholdvariouscomponentstogetherandtechniciansneedtobefamiliarwitheachtype.Someofthemorecommontypesofthreadedfastenersincludenutsandbolts,washers,screws,andstuds.Othercommonfastenersincludesnaprings,rivets,andadhesives.

NOTE: Americanautomobilemanufacturershavelargelyswitchedtothemetricsystemofsizingfastenersandthreads.

A. NutsandboltsintheU.S.CustomarySystem(USCS)

1. Bolt diameters come in increments of 1/16 in, starting with 1/4 in.Themeasurementistheoveralldiameteroftheboltthreads.

NOTE: Itiseasiesttomeasuretheunthreadedorshankportionofthebolt.

2. Thelengthofaboltisitseffectivelengthmeasuredfromundertheheadtotheendofthethreads.Boltlengthsusuallycomein 1/4-in increments, starting from 1/2 in. The longest bolts normally used in the field are 6 in.

3. Thread type is either fine or coarse. Do not thread fine-threaded bolts into coarse threads or vice versa.

NOTE: Nuts are very difficult to measure for diameter, so it is usually best to trial fit the nut onto a bolt and then measure the bolt.


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4. Threadsizeisdeterminedbymeasuringthenumberofthreadsperinch.Athreadgauge,availableinbothmetricandUSCS,canbeusedtodeterminethethreadsizeofbolts.

5. Thestrengthofaboltisimportant.Aboltthatisnotstrongenoughcanbreak.Thestrengthorhardnessofaboltisdeterminedbycountingthepointsorslashesontheheadofthebolt.

CAUTION: Never substitute a bolt with one of less strength. A lower strength bolt may break and cause injury and system failure.

a. Grade1or2boltshavenopointsandareunsuitableforautomobileassemblyduetotheirunknownandpossiblylowstrength.

b. Grade5,or3-point,boltshavethreepointsonthehead.Theseboltsarethemostcommoninautomobileassembly.

c. Grade8,or6-point,boltshavesixpointsonthehead.Theseboltsareexpensivebutverystrongandareusedinhigh-stressconditions.Examplesofgrade8boltsincludeharmonic balancer bolts, flywheel bolts, and steering linkagebolts.Neversubstitutealowergradeboltforagrade8.

6. Right-handthreadnutsandboltsarethemostcommonandturnclockwisetotighten.Left-handthreadnutsandboltsalsoareavailablethatturntheoppositeway.Left-handnutsandboltshavenotchescutatthecornersofthehexheadortheletter“L”stampedonthem.


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NOTE: Veryoldautomobiles(builtbefore1960),Chryslerproductsupuntiltheearly1970s,andFordvansupthroughthemid1980shaveleft-handthreadwheellugsonlyonthedriver’sside.

B. Nutsandboltsinthemetricsystem

1. ThediameterofametricboltornutismeasuredinthesamewayasintheUSCS;however,thediameterofametricboltisexpressedinmillimeters.

2. Theboltismeasuredforitseffectivelengthfromundertheheadtotheendofthethreads.

3. Threadsizeinthemetricsystemisdeterminedbymeasuringthe

distancefromthecrestofonethreadinmillimeterstothecrestofthenextthread.

4. Metricboltstrengthisindicatedbyanumberstampedonthe

bolthead.Thisnumberiscalledthepropertyclass.Examplesofpropertyclassnumbersinclude4.6,4.8,5.8,8.8,9.8,and10.9.Thehigherthenumber,thestrongerthebolt.

CAUTION: Never substitute a bolt with one of less strength. A lower strength bolt may break and cause injury and system failure.

C. Washersarefrequentlyusedwiththreadedfasteners.

1. They fit onto a bolt or screw between the surface being fastened andthenut,orundertheboltorscrewhead.

2. Theyhavetwomainfunctions.

a. Improvethefasteningabilitybyincreasingtheareathatisclamped


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b. Preventtheboltornutfromdamagingthepartsurface

D. Manysizesandtypesofscrewsareusedtofastenautomotiveparts.Twoofthemorecommontypesarethefollowing:

1. Machinescrewsareusedinthreadedholestoclampsmallpartstogether.

2. Self-tappingscrews(alsocalledsheetmetalscrews)havehard,taperingthreadsthatmaketheirownthreadswhendrivenintoasurface.

E. Studshavethreadsoneachendandnohead.Somestudshavethreadsthroughouttheirlength.

1. Fasteningwithstudsisaccomplishedbythreadingoneendofthestudintoapart,placinganotherpartoverthestud,andfasteningtheotherendofthestudwithanut.

2. Studsareusefulforachievingaccuratealignmentofparts.

F. Snaprings(alsocalledretainingrings)areusedtoholdcomponentssuchasshafts,bearings,andgearsinplace.

1. Internalsnapringsfitinagrooveinsideanopeningandexternalsnapringsfitinagrooveontheoutsideofapart.

2. Snap-ringpliersarerequiredforinstallingandremovingsnaprings.

introduction to Automotive technology

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G. Arivetisanonthreadedmetalpinwithaheadononeend.Rivetsareavailableindifferentdesignsandaretypicallymadeofcopper,steel,oraluminum.

1. Rivetsareusedtofastenpartsthatarenotusuallytakenapart.

2. Partsarejoinedtogetherwitharivetbyputtingtherivetthroughaholeinthepartsandhammeringtheheadlessendwithaballpeenhammerorhammerandrivetsetuntiltheendisrounded.

3. Rivetsareremovedbycuttingofftheheadwithachiselanddrivingoutthepinwithapunch.

H. Varioustypesofadhesives,orglues,areusedtobondpartstogether.Partsthatmaybegluedincludetrim,moldings,andvariousplasticandrubberparts.

CAUTION: When using adhesives, it is important to follow the manufacturer’s specifications because some adhesives are toxic, flammable, and harmful if inhaled.

II. Cuttingthreads,repairingdamagedthreads,andremovingbrokenbolts

A. Usingataptocutthreadsintoahole

1. Typesoftaps

a. Thetapertapisthemostcommonlyusedtapbecausethetaperallowseasystarting.Itcannotcutthreadstothebottomofablindhole,aholethatdoesnotgocompletelythroughthemetal.

b. Theplugtapcutsthreadspartofthewaytothebottomofablindhole.

c. Abottomingtapcutsthreadsallthewaytothebottomofablindholebutcannotstartthecuttingprocess.Atapertapmustbeusedbeforethebottomingtap.


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d. Themachinescrewtapcutsthesmall-diameterthreadsofnumberedscrewsizes.

2. Thesequenceforcuttingthreadswithatapisshownbelow.

3. Generalprocedureforusingatap

CAUTION: Before drilling a hole to cut threads, choose the correct drill bit size for the thread size. Failure to use the correct drill bit size can result in a broken tap or inadequate thread depth.

a. Firstapplyathreadcuttingoil.

b. Startthehandlewiththetapstraightandthenmakeahalfturn.


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c. Aftereachpartialturn,backthetapoffuntilthemetalchipsbegintobreakloose.

d. Repeatthisprocessuntilalloftheneededthreadsarecut.Addoilasneededduringtheprocess.

B. Usingadietocutthreadsontoarod

1. Aspecialdiestockholdsthedieforthecuttingprocess.

2. Diesareselectedinthesamemannerastaps,butthediecanbeimproperlyplacedinthediestock.Thedieshouldbepositionedinthediestocksothatthetaperedendengagestherodfirst.

3. Generalprocedureforusingadie

a. Firstapplyathreadcuttingoil.

b. Putthetaperedsideofthedieontherod.

c. Startthediestockwiththediestraightandthenmakeahalfturn.

d. Aftereachpartialturn,backthedieoffuntilthemetalchipsbegintobreakloose.

e. Repeatthisprocessuntilalloftheneededthreadsarecut.Addoilasneededduringtheprocess.

C. Proceduresforrepairingdamagedorstrippedthreads

1. Chasingthreadsinvolvesusingastandardtapordietorunthroughexistingthreadsofthesamesize.Thepurposeofthisprocedureistocorrectsmallimperfectionsthatinterferewiththethreadingofthenutorbolt.


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NOTE:Useathreadcuttingoilduringthisprocedure.

2. Whenthreadsinaholearesoseverelydamagedthattheycannotbeadequatelyrepairedbychasing,ahelicoilcanbeinstalledtorestorethethreadsbacktotheiroriginalsizes.Thebasicstepsforthisprocedureareasfollows:

a. Completelydrillouttheold,damagedthreadswithadrillbitsuppliedinthehelicoilkit.

b. Tapwithaspecialtapfromthekit.

c. Withaspecialhandle,screwinaninsertthatlookslikeaspringorcoil.Theinsideofthiscoilisthesameastheoriginalthreadofthehole.

3. Athreadinsertcanalsobeusedtorepairdamagedthreads.Theinsertisalmostidenticaltothehelicoilbutissomewhatlarger.Itisretainedinplacebydrivingdownfourpinsaroundtheinsert.

4. Threadrepaircementcanbeusedonlow-torqueapplications.Thecementisappliedtothebolt,andtheboltisthenplacedbackintothedamagedhole.Newthreadsaremoldedastheglue-likesubstancehardens.

D. Proceduresforremovingaboltthatisbrokenoffinathreadedholebecauseofovertightening

1. Ascrewextractorcanbeusedtoremovebolts.Thescrewextractorhasflutesorgroovesthatspiralinacounterclockwisedirection.

a. Drillaholeinthecenterofthebrokenbolt.

b. Insertascrewextractorinthehole.

c. Usethetaphandletorotatetheextractorandboltcounterclockwiseandremovethemasaunitfromthebolthole.

2. Removeaboltthatisnotboundtothethreadedhole.

a. Driveasharppunchintothecenterofthebolt.

b. Useplierstoretrievethebolt.


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NOTE: Breakageduetothewrongthreaddesign, across-threadedbolt,oraboltthatisbottomedoutinthe

holecanmakeremovaldifficult.Drillouttheboltandretapthehole.Usethecorrectboltandstartitintotheholewiththefingers.


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lessoN 3: measUrINg Tools

I. Typesandusesofcommonmeasuringtools

NOTE: Somevehiclecomponents,particularlyintheengineandtransmission,containprecisionmachinedpartsthatrequireprecisemeasurementsforinspectionorreplacement.

A. Theoutsidemicrometerisusedwhenanoutsidemeasurementmustbeaccurateto.001inorless.Partsrequiringthesemeasurementsincludecrankshafts,pistons,valves,andcamshafts.

B. Theinsidemicrometerisusedwhenameasurementofthediameterofaholemustbeaccuratetolessthan.001in.Examplesofsuchholesarecylinderboresandmainbearingbores.

C. Thedepthmicrometermakesprecisedepthmeasurementsofholesorcavities.Forexample,itcanbeusedtomeasurethedistancefromthecenterofthecrankshafttothetopoftheengineblock(deckheight)andthedistancefromthetopofthepistontothetopoftheengineblock(pistondeckclearance).


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D. Thedialindicatortoolmeasuresthrust,back-and-forthmovement,andrunout(side-to-sideplay).Thesemeasurementsaremadeon valves, crankshafts, and flywheels. The dial indicator can also measurethebacklashormovementbetweengearteeth.

E. Afeelergaugemeasuresairgapsandclearancebetweenmovingparts and has numerous flat leaves of different specific thicknesses.

F. Adialcaliperisusedforinside,outside,anddepthmeasurements.Oneapplicationismeasuringboltsandsmallmachinedparts.

G. Plastigageisatinystripofclay-likematerialthatmeasuresclearancessuchasbetweenenginebearingsandtheirjournalsandmainbearingsandconnectingrodbearings.Thestripsarecolorcodedaccordingtotheclearancerange.

II. Proceduresfortheuseandcareofmeasuringtools

CAUTION: The proper care and use of precision measuring tools are critical to the accuracy and long life of the tool. An incorrect measurement can result in expensive component failure.


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A. Useanoutsidemicrometer.

1. Beforeusinganoutsidemicrometer,becomefamiliarwithitsparts.Seetheillustrationbelow.

2. Readtheoutsidemicrometer.

NOTE:Theoutsidemicrometerdoesnotreadilydisplaythemeasurement.Someadditionisrequiredinordertoarriveatthemicrometerreading.Thetechnicianmustdevelopafeelfortheoutsidemicrometerinordertoachieveaccurateresults.

a. Placetheobjecttobemeasuredbetweentheanvilandspindleandturnthethimbleuntiltheobjectislightlycontactedbytheanvilandspindle.Lockthespindleandremovethemicrometerfromtheobject.

b. Readthenumberindicatedonthemicrometersleeve(upperscale).Eachnumberrepresentsonetenth(.100)ofaninch.

c. Add25thousandths(.025)ofaninchforeachadditionallineshowingonthesleeve(lowerscale)pastthenumber.

d. Addthenumberofthousandths(.001)ofaninchindicatedonthethimble.

e. Addthenumberofinchesoftheminimumdimensionthatthemicrometercanread0inthrough5in.

B. Readinganinsidemicrometeranddepthmicrometerissimilartoreading an outside micrometer. Be sure to add the correct figure for theminimummeasurement.


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C. Usethedialindicator.

1. Securelyattachthedialindicatorsoitwillnotmoveandgiveinaccuratereadings.Thedialindicatorispositionedwithaclamp-onbaseorwithamagneticbase.

2. Positiontheplungeragainstthepartbeingmeasured.

3. Rotatetheindicatoruntiltheneedleisonzero.Ifmakingathrustmeasurement,theshaftorgearthatistobemeasuredmust first be pried one way.

4. Rotatethepartforrunoutmeasurementsorprythegearorshaftforthrustmeasurements,andnotethereadinginthousandthsofaninchonthedial.

D. Usethefeelergauge.

1. Select a sample leaf and make a trial fit between the two surfaces.

NOTE: Thethicknessoftheleafisprintedontheleaf.

2. Iftheleafistoolooseortootight,tryanotherleaf.

3. Whenthereisaslight,smoothdragasthefeelergaugeisremoved,thecorrectleafhasbeenfound.Thesizeprintedonthefeelergaugeistheclearance.

4. Afteruse,putalittleoilontheleavestopreventrust.

E. Useadialcaliper.

NOTE: Adialcaliperisaccuratetoapproximately+or-0.002in.Whenmoreprecisionisrequired,useamicrometer.


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1. Beforeusingadialcaliper,becomefamiliarwithitsparts.Seetheillustrationbelow.

2. Adjustthedialcaliperwiththerollknobuntilthejawslightlycontactthework.

3. Readthemeasurementonthelinearscaleandaddthereadingonthedial.

F. UsePlastigage.

1. SelectasmallpieceofPlastigagematerial.

2. PlacethePlastigagematerialonthecrankshaftjournal.ThePlastigagepiecemustspanthefullwidthofthejournalandbecenteredwiththebearingcap.

3. Installthebearingcapandtightentothepropertorque. 4. RemovethebearingcapandinspectthePlastigage.Itshould

appearsomewhatsmashed.ComparethewidthtothepapergaugeonthePlastigagepackage.

G. Careofmeasuringtools

1. Adjustprecisionmeasuringtoolscarefully.Forexample,onlyveryslightpressureisneededtotightenthethimbleonamicrometer.Overtighteningcandestroytheadjustment.

2. Donotattempttoadjustmeasuringtoolswiththelockon.

3. Alwaysstoremeasuringtoolsintheircaseorinasafeplacetoprotectthemfromdamage,grease,dirt,andmoisture.


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4. Checkthecalibrationofprecisionmeasuringtoolsfrequently.Consultthemanufacturer’sinstructionsfortheproperprocedure.


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UNIT vI: PoWer Tools aNd shoP eqUIPmeNT


I. Unitobjective

II. Lessonplans

A. Lesson1:PowerTools


2. Assignmentsheet

a. AS1-L1-UVI:PowerToolsandTheirUses

B. Lesson2:ShopEquipment


2. Assignmentsheet

a. AS1-L2-UVI:ShopEquipmentUse

III. UnitVITest


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UNIT oBJecTIve

Aftercompletingthisunit,studentsshouldbeabletoidentifycharacteristicsand the proper use of power tools and equipment used in the automotive field. Studentswilldemonstratemasterybycompletingtheassignmentsheetsandachievingascoreof____ontheUnitVITest.

sPecIfIc oBJecTIves


Lesson 1

I. Identifytheprinciplesofusingvarioustypesofpowertools.

II. Identifythecharacteristicsandsafeuseofpowerdrills.

III. Identifythecharacteristicsandsafeuseofpowerwrenches.

IV. Identifythecharacteristicsofmiscellaneouspowertools.

V. Completetheassignmentsheetonpowertoolsandtheiruses (AS1-L1-UVI).

Lesson 2

I. Identifythecharacteristicsandsafeuseofelectricalequipment.

II. Identifythecharacteristicsandsafeuseofpneumaticequipment.

III. Identifythecharacteristicsandsafeuseofhydraulicequipment.

IV. Completetheassignmentsheetonshopequipmentuse(AS1-L2-UVI).


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lessoN 1: PoWer Tools

I. Principlesofusingpowertools

A. Electrictools

NOTE:Electrichandtoolsarestillinuseinshops,butsomehavebeenreplacedbypneumatic(air-operated)equipment,whichisusuallylighter.

1. Electrictoolsaredrivenbyanelectricmotor.

2. Usingelectricalequipmentisamatterofcommonsenseandusinggoodsafetypractices.

3. Safety

a. Aswithanyelectricaldevices,beawareofthedangersofelectricshock.

b. Donotstandonwetgroundorawetsurfacewhenoperatinganelectrictool.

c. Alwayscheckthatthepowercordwillnotbedamagedbytheoperationoftheequipmentanddonotrunoverpowercordswithanyheavyobject.

d. Alwayscheckthatthepowercordisnotfrayedorworn.

e. Allelectrictoolsmusthaveathree-prongedplugunlessthetoolisdoubleinsulated.Double-insulatedtoolscannotshorttotheoutsidecaseandrequireonlyatwo-prongplug.

f. Donoteliminatethegroundterminalofathree-prongplugbyusinganadapterorclippingtheterminal.


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g. Donotputcordsinwateroracrossmovingmachinery.

h. Wrapupcordscarefullyafteruseandstorethemproperly.

i. Keephandsandclothingawayfromthemovingpartsofelectricalequipment.

j. Wheninspectingormakingadjustmentstoelectrictools,alwaysdisconnectthemfromthepowersupply.

4. Maintenance

a. Checktheservicemanualfortheequipmentbeingused.

b. Electricalequipmentshouldbekeptfreeofdirtandgreaseandshouldbestoredinanareathatisdryandfreeofdust.

B. Pneumatictools

1. Pneumatictoolsarepoweredbycompressedair.

2. Pneumatictoolshaveadvantagesoverelectrictools.Theyarelighterand,unlikeelectrictools,arenotdamagedbyoverloadingorstalling.

3. Althoughtherearedangersassociatedwithcompressedair,thedangersarenotasgreatasthoseassociatedwithelectricity.

4. Safety

a. Operateairtoolsonlyfortheirintendedpurpose.

b. Airimpactguns,airhammers,andairdrillscancreateflying metal chips that are dangerous to the eyes. Wear protectiveeyewearatalltimeswhenworkingwithoraroundairtools.

CAUTION: Wear personal protective equipment (PPE) when flying metal chips are possible.

c. Pneumatictoolsproduceagreatdealofpower.Usinganimproperattachmentorplacingtheattachmentonthetoolincorrectlycanresultinbreakage.Useonlyimpactsocketsonairimpactguns.


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d. Waterandoilcanaccumulateinaircompressors.Theseshouldbedraineddaily.Itispossibleforcompressedairtocarryinfectionevenwithdailydraining.

CAUTION: Do not play with compressed air blowguns or hoses. The high-pressure air stream on the skin can cause severe infection, require the amputation of a limb, and cause death.

e. Pneumatictoolscreateagreatdealofnoise.Wearearplugs,earmuffs,orothertypesofearprotection.

f. Donotlookintotheair-outletvalveornozzleonanypieceofair-poweredequipment.

g. Donotgrabthemovableportionofanair-poweredtoolwiththehandwhenitishookeduptotheairline.

h. Wheninspectingormakingadjustmentstopneumatictools,alwaysdisconnectthemfromtheairsupply.

5. Maintenanceofpneumaticequipment

a. Beforeanynewairtoolisused,threeorfoursquirtsofflushing oil should be applied to the air inlet to flush any dirtormoisturefromtherotorandtolubricatethemovingparts. Do not use flushing oil around an open flame—the flushing oil is flammable.

b. Oilpneumatictoolsregularlyaccordingtomanufacturerrecommendations.

c. Pneumaticequipmentshouldbekeptfreeofdirtandgreaseandshouldbestoredinanareathatisdryandfreeofdust.

d. Careshouldbetakenthatnoforeignmatterentersthenippleopeningofthecouplingsonpneumaticequipment.

6. Basicdesignsofpneumatictools

a. Rotary—Theairdrivesarotor(turbine)thatspinsashaftandprovidesthepower.

b. Reciprocating—Theairdrivesapistonthatisforcedbackandforthbythecompressedair.


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NOTE: Theexceptionstotheabovetwokindsareblowgunsandpaint-sprayingequipment,whichuseadirectstreamofair.

7. Pneumaticcouplings

a. Pneumaticequipmentisconnectedtoairsupplyequipmentthroughquickcouplers.

b. Thequickcouplerisontheendoftheairsupplyhoseandconnectsintoanippleontheequipment.

c. Onsometools,themanufacturerrecommendsattachingashortleaderhosetothetoolandinstallingthenippleattheendoftheleaderhose.

d. Thequickcoupleroperatesbypullingbackacollaronthecoupler,whichallowsthenippletobeinsertedintothecoupler.Whenthecollarisreleased,itlocksthenippleintothecoupler.

C. Cordlesstools

1. Thesetoolsuseabatterycellasthepowersupply,insteadofelectricityfromawalloutlet.

2. Theyareconvenientinshopsduetoportabilityandtheabsenceofpowercords;however,frequentrechargingisnecessary.

3. Safety

a. Alwaysdisconnectacordlesstoolfromitsbatterybeforeinspectingitandmakingadjustmentstoit.

b. Use only the battery specified by the manufacturer for the toolbeingused.

c. Alwaysstorebatterypackssafelysothatnometalcancomeincontactwiththeterminals.Contactingtheterminal can short-circuit the battery and cause sparks, fire, orburns.


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D. Hydraulictools

NOTE: Most hydraulic tools fit in the category of shop equipment, whichisdiscussedinthenextlesson.

1. Hydraulic tools use pressurized fluid within a cylinder to create greatpressure.

2. The fluid is hydraulic fluid, a petroleum product that is much likeoil.

3. Thehydraulicpressurewithinthetooliscreatedbyairpressureorthemanualpumpingofahandle.

4. Commonhydraulictoolsandequipmentusedintheshopincludejacks,lifts,hoists,andpresses.

5. Safety

a. Beforeoperatingahydraulictool,inspectitspartstomakesurenonearedamagedordeteriorated.

b. Keephydraulichosesawayfrompotentialdamagesuchasgrease,oil,sharpobjects,andhotsurfaces.

c. Beforeusingahydraulictool,consultthemanufacturer’sinformationtobesureitisappropriateforthetaskandthatthetaskwillnotexceedthetool’sloadlimit.

d. Checkhydraulictoolsfrequentlyforleaks.Leakscancausethetooltofail,withdangerousresults.

6. Maintenance

a. Checktheservicemanualforthetoolbeingused.

b. Inspecttoolcomponentsandreportanydamage,leaks,ordeteriorationtotheinstructor.


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II. Powerdrills

A. Electricdrillscanbeusedinterchangeablywithpneumaticdrills.

B. Drillsareusedwithdrillbitstodrillholesorwithspecialattachmentstoremoverustorgasketmaterial.

C. Electricdrillsuseanelectricmotortodriveachuck,adevicethatholdsthedrillbitinplaceandalignsitproperly.Pneumatictoolsusearotor,whichdrivesthechuck.

D. Achuckkeyisusedtoloosenandtightenthechuck.Drillsarealsoavailablewithkeylesschucks.

E. Thesizeofthedrillisdeterminedbythemaximumdiameterofthedrill bit shaft that the chuck holds. For example, a 1/4-in drill holds a drill bit with a shaft diameter no larger than 1/4 in. The most popular sizes are 1/4 in, 3/8 in, and 1/2 in.


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F. Drillbits

1. Drillbitscomeinvarioussizesandlengthsandareinterchangeablebetweenelectricandpneumaticdrills.Whenlookingforaparticularsizeofdrillbit,useadrillgauge.

2. Drillbitsaremadeofhigh-gradesteeland,ifusedproperly,theyseldomneedsharpening.

3. Drillbitsaresizedaccordingtothesizeofholetheydrill.DonotusemetricdrillsinplaceofUnitedStatesCustomarySystem(USCS)drillsorviceversa.Ifa12-mmholeisrequired,usea12-mmbit.

G. Safetyforpowerdrills

1. Makesurethebitistightlyseatedinthechuck,securingitbyturningthechuckkeyineachhole.Besuretoremovethechuckkeybeforestartingthedrill.

2. Make sure the work is firmly secured before starting to drill.

3. Keep a firm grip on the drill and be ready to shut it off if it jams. Drillsoftenjamjustastheyareabouttopenetratewhattheyarecutting.

4. Ifanelectricdrilljams,turnthedrilloffandpullitbackout,thenstartitandcontinuetodrillthehole.Thesameprocedureshouldbeperformedforrestartingapneumaticdrill.Suchjammingmaydamageanelectricdrill.

5. Removethebitfromthedrillwhentheworkiscompleted.

III. Powerwrenches

A. Impactwrenches


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1. Thesetoolscanbeeitherpneumaticorelectricandareusedtodriveimpactsocketstoloosenortightennutsandbolts.

2. Theyusesocketsthatarespeciallymadetohavegreaterstrengththanstandardsockets.

3. Thewheeltorquesocket,alsocalledtorquestick,isatypeofsocketcommonlyusedwithimpactwrenches.

a. Torquesticksarelong-shaftedsocketsthatworkincombinationwithanimpactwrenchtoinstalllugnutsonwheels.

b. They are designed to flex when the proper torque is reached,helpingtopreventthedamagethatcanresultfromovertorquing.

c. Thesticksarecolorcodedpersocketdiameterandtorquelimit.

CAUTION: Torque sticks are designed for tightening lug nuts, not loosening them; using torque sticks to loosen lug nuts will damage the sticks.

4. Usingimpactwrenches

a. Abuilt-inregulatorallowsforadjustmentsinspeedandtorque.However,donotrelyontheregulatortoadjusttheamountoftorqueaccurately.Finaltighteningshouldbedonewithatorquewrench.

b. Holdthewrenchwithaslightforwardpressureontheboltornut.

c. Soakrustyboltsandnutswithpenetratingoilbeforeusinganimpactwrenchtoloosenthem.

d. Aswitchcanchangetheimpactwrenchfromcounterclockwisetoclockwiseoperation.


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B. Airratchet

1. Isasmallerversionoftheimpactwrenchandusuallyusesa 1/4-in or 3/8-in drive lug

2. Deliverslessforcethantheimpactwrenchandstandardsocketsmaybeusedwithit

3. Hasaswitchtochangeitfromclockwisetocounterclockwiserotation

NOTE: Anairratchetshouldbeusedonlytosnugabolt.Aconventionalratchetortorquewrenchshouldbeusedtocompletethetighteningofabolt.

C. Airchisel(airhammer)

1. Usesreciprocatingmotiontoproviderapidimpactforce,muchlikearapidseriesofshorthammerblows

2. Attachmentsavailableincludecutters,chisels,andpunches

3. Oftenusedtobreakweldsloose,cutrivets,punchholes,andshearsheetmetal

D. Safetyforpowerwrenches

1. AlwayswearPPEwhenusingpowerwrenches.

2. Whenoperatinganimpactwrench,onlyusesocketsthataremadeforimpactwrenches.Ifastandardsocketisused,itmaybreak or be damaged and fly off of the tool.


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3. Be sure that the chisel in the air chisel is firmly secured and that thecuttingedgeissharp.

IV. Miscellaneouspowertools

A. Heatguns

1. Heatgunsarehand-heldheatersthatuseforcedairpassingthroughheatedcoils.

2. Theyareusedinvariousrepairprocedurestosoften,loosen,andthaw vehicle components. Specific uses include softening vinyl; loosening sleeves/trim and adhesives; thawing frozen locks, wipers,andweatherstrips;andheatingdecalsforeasyremoval.

B. Tireburnishingtool

1. Thetireburnishingtoolisusedfortirerepair.

2. Thewheelmakestherubberontheinsideofthetirerough.Thispreparestherubberfortheapplicationofatirepatch.


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C. Minidiegrinder

1. Aminidiegrinderisusedforcuttingmetal;removinggasketmaterial;andcleaningbrakerotors,backingplates,andpadmounts.

2. Thegrinderillustratedhasaheadangledat90°foreasyaccessandhandling.

D. Blowguns

1. Ablowgunisapneumaticattachmentthatdirectsasmall,powerfulstreamofair.

2. Ablowgunisusedtocleananddrysurfacestobepaintedandtocleandustfromshopequipment.

CAUTION: Only blowguns that have an approved pressure limiter should be used in the shop. A proper blowgun attachment limits the maximum pressure to 30 pounds per square inch (psi).


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lessoN �: shoP eqUIPmeNT

NOTE: Theterm“shopequipment”referstolargeorexpensivepiecesofequipmentortools,whicharegenerallyprovidedbytheshopowner.

I. Electricalequipment

A. Shopsequippedtomounttireshaveawheelbalancer.

1. Manyshopsnowusecomputerizedwheelbalancers.Wheelbalancersareusedtoequallydistributeweightaroundthewheel’scenterline.

2. Safety

a. Consulttheinstructorbeforeusingthewheelbalancer.

b. Aswithanyelectricaldevices,beawareofthedangersofelectricshock.

c. Donotstandonwetgroundorawetsurfacewhenoperatingelectricalequipment.

d. Ensuretheguardsareinplacebeforeoperatingthewheelbalancer.Beawareoftherotatingmassthatcouldcauseinjuryifcontactismade.


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B. Abenchgrinderisacommonpieceofshopequipment.

1. Abenchgrinderisgenerallyusedtomaintaintoolsthathavebecomedullandtogrindsharpedgesfrommetalpieces.

2. Thegrinderismountedtoabenchandispoweredbyanelectricmotor.

3. Inadditiontothegrindingwheel,thegrindercanbeusedwithawirewheelthatcleansrustanddirtoffparts.

4. Safety


b. Alwayswearsafetyglassesandaparticlemaskwhenworkingwithabenchgrinder.Weararespirator,asneeded,forgrindingcertainmaterials.

c. Besurethatclothing,hair,andothercombustiblesintheareaareprotectedfromthesparksgivenoffbythegrinder.

d. Thebenchgrindershouldhaveatoolrestplatforminfrontofeachabrasivewheel,inadditiontoawheelguardandaneyeshield.

e. Donotputexcessivepressureonthewheelbecauseitcouldbreakapart.Donotusewheelsthatarebrokenorworn.

f. Followthebenchgrindermanufacturer’srecommendationsforremovingandreplacinggrindingwheels.Donotovertightenthespindlenut.

g. Whengrindingsmallparts,neverholdthepartsbyhand.Thepartscanbeveryhotandeasilypropelledthroughtheairbythewheel.Usestandardslip-jointplierstoholdsmallparts.


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h. Abrasive wheels are designed for specific types of metals. Donotgrindaluminumongrindingwheelsdesignedforsteel.Aluminumchipswillclogthewheel’ssurface.

C. Someshopshaveadrillpressfordrillingholesinmetalparts.

1. Maintenance

a. Inspectbitsregularly.Sharpbitscutbetterandarelesslikelytobreak.

b. Oilthebitasneededtopreventbinding.

2. Safety


b. Afullfaceshieldandprotectiveeyewearshouldbeworn.

c. Partsdrilledbythepressmustbesecurelyheldbyaviseorstandardslip-jointpliers.Thispreventstheworkfromspinningoutofcontrolandcuttinghands.

d. Whenusingthedrillpress,donotwearlooseclothingorjewelry.Donotallowlonghairtohangfreely.

D. Avarietyofelectricaltestandserviceequipmentcanbefoundintheshop.Eachpieceofequipmenthasitsuniquesafetyconsiderations.Consulttheinstructorbeforeusinganewpieceofequipment.


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E. Generalmaintenanceguidelinesforelectricalequipment

1. Checktheservicemanualfortheequipmentbeingused.

2. Electricalequipmentshouldbekeptfreeofdirtandgreaseandshouldbestoredinanareathatisdryandfreeofdust.

II. Pneumaticequipmentcanbepermanentlyattachedtotheshopaircompressorortemporarilyattachedtothecompressorbyrubberhoses.

A. Anaircompressorprovidesthecompressedairneededtooperatepneumatichandtoolsandequipmentintheshop.

1. Compressorsareusuallyoperatedbyanelectricmotorandarecomposedofthefollowingthreemainparts.

a. Motor

b. Compressor

c. Storagetank

2. Themotordrivesacompressorthattakesintheairaroundit,compressesitintoasmallervolume(thusincreasingpressure),andthenstoresthecompressedairinalargestoragetank.

3. Maintenance

a. Checktheoileachweekandmaintaintheoilattheproperlevel.

b. Drainwaterfromthetankandchecktheair-safetyvalveeachday.

c. Changetheoil,checkthebeltconditionandtension,andcleantheair-intakebreatherpermanufacturer’srecommendations.


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4. Safety

a. Alwaysdisconnectanaircompressorfromthepowerbeforeinspectingormakingadjustmentstoit.

b. Beforeoperatinganaircompressor,inspectitspartstomakesurenonearedamaged.

c. Makesuretheelectricaloutletfortheaircompressorisproperlygrounded.

d. Waterandoilcanaccumulateinaircompressors.Theseshouldbedraineddaily.Itispossibleforcompressedairtocarryinfectionevenwithdailydraining.

CAUTION: Do not play with compressed air blowguns or hoses. The high-pressure air stream on the skin can cause severe infection, require the amputation of a limb, and cause death.

e. Airhosesshouldnotberunoverwithvehiclesor

equipmentandshouldnotbeusedtopulltoolsacrosstheshop floor.

f. Airhosesshouldbekeptfreeofgreaseandoilandneatlycoiledforstorageattheendoftheworkday.

B. Thetiremachineusesgreatforcetomanipulatetires.

1. Itsusesincluderemovingandreinstallingthetireontothewheel and inflating the tire to the proper pressure.


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2. Safety

a. Thetiremachineisoneofthemostdangerouspiecesofshopequipment.Donotusethetiremachinewithoutpropertraining.

b. Trucktiresthatusethesplitrimtypeofmountingarevery dangerous. These must be inflated in a special cage. Consulttheinstructorbeforeattemptingtomountatrucktireoranytypeoftire.

c. Wearprotectiveeyewearwhenworkingwithatiremachine.

C. Apneumaticjackcanraiseavehiclebythebumperoraxle.

1. Specialinstructionisrequiredtouseapneumaticjack.

2. Thevehiclemustbeloweredontosafetystandsbeforeatechniciancanworkunderavehiclesupportedbyajack.

3. Safety

a. Neverworkunderavehiclesupportedonlybyajack.

b. Consulttheinstructorandrepairmanualwhenplacingsafetystandsfortheproperlocationsofthestands.

c. Besurethattheload-capacityratingforthesafetystandsissufficient to safely support the vehicle.

d. Donotliftvehicleswithpassengersinsideorwiththedoors,hood,orluggagelidopen.


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D. Generalmaintenanceguidelinesforpneumaticequipment

1. Consultthemaintenanceinstructionsprovidedbytheequipmentmanufacturer.

2. Keepthepieceofequipmentfreeofdirtandgreaseandstoreitinanareathatisdryandfreeofdust.

3. Careshouldbetakenthatnoforeignmatterentersthenippleopeningofthecouplingsonpneumaticequipment.

III. Hydraulicequipmentdevelopspressureasaresultoftheclosingofavalveandthepumpingofahandleorasaresultofacombinationofairpressureover hydraulic fluid.

A. The hydraulic floor jack has a cylinder that raises the front, rear, or sideofavehiclebypumpingahandle.

1. A floor jack is mounted on four wheels for portability.

2. Itshouldonlybeusedafterthoroughinstruction.Thevehiclemustalsobesupportedbysafetystands.

3. RefertoUnitII,Lesson3forsafetyguidelines.


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B. Aliftraisestheentirevehicleofftheground.

1. Most lifts use air pressure to pressurize hydraulic fluid, which is thenpumpedintooneormorelargecylinders.

2. RefertoUnitII,Lesson3forsafetyguidelines. C. Ahydraulicpressisfoundinmostshops.Itusesapowerfulpushing

forcetopressbearingsandgearsontoandoffofshafts.

1. Pullingahandleonthepressraisesorlowersaram.Therampressesthepartagainstatable.

2. Safety

a. Consulttheinstructorfortheprocedureforproperlysettingupandusingthehydraulicpress.

b. Wearpersonalprotectiveequipment(PPE)whileusingahydraulicpress.


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D. Theenginehoist,orportableenginecrane,isusedtoraiseheavyenginesandtransmissions.Afterturningavalve,ahandleispumpedtoraisethehoist.

1. Ahoistissimplyahydraulicjackthatisdesignedforattachingontothetopofanobjectandpullingitupward,insteadofgettingunderneathofanobjectandpushingitupward.

2. Theenginehoistisnotintendedtosupportanenginewhileitisbeingserviced.Theengineshouldbemountedonanenginestandduringservice.

3. Safety

a. Consulttheinstructorbeforeusingtheenginehoist.

b. Standclearofanyobjectbeingraisedincasethehoistfailsortopples,ortheobjectbeingliftedcomesloose.

c. Whenmovinganobjectthatissuspendedfromthecrane,movethecraneveryslowly.


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d. Donotworkonanyobjectwhileitissuspendedfromthecrane. Lower it to a workbench or the floor (or into an enginestandforamotor).

E. Generalmaintenanceguidelinesforhydraulicequipment

1. Consultthemaintenanceinstructionsprovidedbytheequipmentmanufacturer.

2. Inspectequipmentcomponentsandreportanydamage,leaks,ordeteriorationtotheinstructor.


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UNIT vII: vehIcle INformaTIoN


I. Unitobjective

II. Lessonplan

A. Lesson 1: Service Information and Vehicle Identification


2. Assignmentsheet

a. AS1-L1-UVII: Vehicle Information and Identification

III. UnitVIITest

aUTomoTIve TechNology

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UNIT oBJecTIve

Aftercompletingthisunit,studentsshouldbeabletoidentifythedifferenttypesof service information and vehicle identification. Students will demonstrate masteryofthematerialbycompletingtheassignmentsheetandachievingascoreof_____ontheUnitVIITest.

sPecIfIc oBJecTIves


Lesson 1

I. Identifythedifferentsourcesandformatsofvehicleserviceinformation.

II. Identifyguidelinesforusingamanufacturer’sserviceinformation.

III. Identifythecommonlocationsofvehiclecodesandhowtoreadthecodes.

IV. Complete the assignment sheet on vehicle information and identification (AS1-L1-UVII).


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lessoN 1: servIce INformaTIoN aNd vehIcle IdeNTIfIcaTIoN

I. Vehicleserviceinformation

A. Sources

NOTE: Vehicleshavebecomesotechnologicallyadvancedthatserviceinformationisusedoneveryjob.Thisinformationcontainsdiagnosis procedures, specifications, and service procedures. Techniciansmustknowhowtolocateandusetheinformationthatisavailable.

1. Vehiclemanufacturerspublishserviceinformationforeachmodelyearofthevehiclestheymanufacture.

a. Thisserviceinformationisthemostcomprehensiveandthe best source of information for a specific vehicle.

b. It includes vehicle specifications, diagnostic and repair procedures,partsdiagrams,andspecialtoolsrequired.

c. Becausemanytechnicalchangesoccuraftertheserviceinformationispublished,manufacturersprovidetechnicalservicebulletins(TSBs)toupdatetheinformation.TheinformationintheTSBsalsoappearsinthenexteditionoftheserviceinformation.

2. Professionalgeneralservicemanualsareusedbyindependentrepairshopsbecauseonemanualcancontaininformationformanydomesticorforeigncarsproducedoverseveralyears.Thesebookssummarizethemostimportantinformationanddonot include all the specifics.

3. Aftermarketspecialtymanualsareoftensoldatbookstoresandmaycoveronemodelofvehicleproducedoverseveralyears.Thesemanualsarewrittenforindividualswithandwithoutexperienceintheautomotiverepairprofessionandarepopularwiththe“do-it-yourself”individual.

4. Anowner’smanual,preparedbythevehiclemanufacturer,isprovidedtothepurchaserofthevehicleandisusuallystoredintheglovecompartment.Itincludesbasicinformationaboutthelocationandfunctionofvehicleaccessories,startingthevehicle,andmaintainingthevehicle.


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5. Sites on the Internet are available to find information that a shop maynothaveinitslibrary,suchasmoreup-to-dateinformation,recallinformation,orinformationaboutahard-to-diagnoserepairissue.

B. Formats

1. Besidesprintedmanuals,serviceinformationisavailableforuseoncomputerharddrives,networks,andCD-ROMs.

2. Usingcomputerizedinformationratherthanprintedmaterialssavesspace.Inaddition,accessingtheinformationonacomputeriseasierandsavestime.

II. Usingthemanufacturer’sserviceinformation

A. Getfamiliarwiththecomponentsoftheserviceinformationandhowthey are organized. Doing so will help in finding information quickly.

1. Thegeneralinformationsectionincludesvehicleinformationsuch as identification (e.g., reading the vehicle identification number(VIN)togetdataaboutthevehicle),basicmaintenance,andlubrication.

2. Therepairsections,whichcovereachsystemofthevehicle,have

detailedproceduresfordiagnosing,inspecting,testing,andrepairingthesystems.Thesesectionsalsoincludethefollowingfeatures:

a. Illustrationsofexplodedviewsofpartsorstepsintheprocedure

b. Diagramsshowingthelayoutofhosesorcircuits

c. Diagnosticortroubleshootingchartsforsystematicallyfinding the source of a problem


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B. Beforeperformingaprocedure,readitthroughoncetogetanunderstandingandoverviewofwhatisrequired.

C. Becarefultodoallstepsinaprocedureandperformtheminthecorrectorder.Missingstepsorperformingthemoutofordermaycauseunsuccessfulresults.

III. Locatingandreadingthevehiclecodes

A. In the early 1980s, the National Highway Traffic Safety AdministrationbeganrequiringvehiclemanufacturerstoidentifyeachvehiclemadeforhighwayusewithaVIN.

1. Avehicle’sVINisacodewith17characters(lettersandnumbers) that is permanently affixed to the vehicle.

2. TheVINistypicallyfoundinseverallocationsonavehicle.Someofthemorecommonlocationsarelistedbelow.

a. Dashboardnearthelowerpartofthewindshieldonthedriver’sside

b. Certification label on the driver’s door frame

c. Enginecompartment

3. The VIN uniquely identifies a vehicle and provides a great deal ofinformationaboutthevehicle’soriginandfeatures.SeethesampleVINbelowforabreakdownofthecode.


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4. For help in reading the VIN for a specific vehicle, check the generalserviceinformationsectionoftheserviceinformationforthatvehicle.

B. An engine serial number and identification number or code is generallystampedontheengineblock.

1. Theexactlocationofthesenumbersdependsonthemanufacturer.

2. Engine codes provide technicians with specifications for the vehicle’sengine,suchasthehorsepowerratingandwhethertheenginewasdesignedforamanualorautomatictransmission.


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UNIT vIII: cUsTomer servIce


I. Unitobjective

II. Lessonplan

A. Lesson1:CustomerService,WorkOrders,andVehiclePreparation


2. Assignmentsheet

a. AS1-L1-UVIII:CustomerService,WorkOrders,andVehiclePreparation

3. Jobsheets

a. JS1-L1-UVIII:CompleteaWorkOrderWithConcern,Cause,andCorrection

b. JS2-L1-UVIII:PerformaGeneralDiagnosis

III. UnitVIIITest


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UNIT oBJecTIve

Aftercompletingthisunit,studentsshouldbeabletoidentifyprinciplesofgoodcustomerservice,componentsandfunctionsofworkorders,andhowtoprepareavehiclebeforeandafterservice.Studentswilldemonstratemasteryofthematerial by completing the assignment sheets, successfully performing specific tasksinthejobsheet,andachievingascoreof_____ontheUnitVIIITest.

sPecIfIc oBJecTIves


Lesson 1

I. Identifypropercustomerrelationprocedures.

II. Identifytheproceduresforpreparingavehiclebeforeandafterservice.

III. Identifythefunctionsandcomponentsofaworkorder.

IV. IdentifythethreeC’sandhowtousethemtodiagnoseavehicleproblem.

V. Completetheassignmentsheetoncustomerservice,workorders,andvehiclepreparation(AS1-L1-UVIII).

VI. Demonstratetheabilityto:

A. Completeaworkorderwithconcern,cause,andcorrection (JS1-L1-UVIII).

B. Performageneraldiagnosis(JS2-L1-UVIII).


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lessoN 1: cUsTomer servIce, Work orders, aNd vehIcle PreParaTIoN

I. Propercustomerrelationprocedures

NOTE: Studies have shown that more people are fired for their inability to getalongwithothersthanforalackoftechnicalexpertise.Thebehaviorofthe technician and other workers can jeopardize the financial stability of the shop.

NOTE: Theamountanddegreeofcustomercontactrequiredinanautomotivetechnicianpositionwillvarydependingonshoporganizationandpolicy.

A. Allemployeesintheshopshouldgreetthecustomerwhenappropriateandactinafriendly,courteousmanner.Refertothecustomerbyusing“Mr.”or“Ms.”andtheperson’ssurname.

B. Listencarefullyandpatiently.Afterthecustomerhasexplainedtheproblem,askquestionsthatmayhelpinthediagnosis.Peoplecommunicateatdifferentpacesandindifferentstyles.

NOTE: Thecustomerislikelytobeupsetthatthevehicleheorshedependsonisunavailableandthattherepairmaybeexpensive.

C. Itisimportanttoverifythecomplaint.Somecustomersunknowinglygiveafalsediagnosis.

D. Givethecustomeranestimate.Acustomerwilllikelybeveryupsetifpresentedwithalargerepairthatwasnotexpected.Obtainthecustomer’sphonenumberandcallthecustomerbeforebeginningtherepairs.

E. Lookforpotentialproblemsotherthanthosedescribedbythecustomer.Explainanynewproblemstothecustomerinaprofessionalmanner.

NOTE: In most shops, the service manager/writer usually has the

responsibilityofcallingthecustomer.

F. Performtherepairinaprofessionalmanner.Rememberthatthecustomerispayingforarepair.Theoutcomeofthejobperformedmakesastatementtothecustomerandemployeraboutthetechnician’sskillsandprofessionalism.


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G. Verifytherepair.Oneofthemostcommoncomplaintsofvehicleownersisthattheypaidtohavearepairperformedonlytoexperiencethesameproblemaftertherepairwastohavebeenmade.

II. Preparingavehiclebeforeandafterservice

A. Anotherimportantpartofcustomerserviceismakingsureeachcustomer’svehiclestayscleanandfreeofdamageduringitstimeintheshop.

1. Placefendercoversonthefenders,frontgrille,andotherareasasneededtoprotectthevehiclefromgrease,scratches,anddents.

2. Use floor protectors to ensure dirt and grease from technicians’ shoesdonotsoilthecarpet.

3. Useseatcoverstoensurethatdirtyorgreasyhandsandclothingdonotsoiltheseats.

4. Coverthesteeringwheelwithasteeringwheelcovertoprotectit from greasy hands and fingerprints.

B. Afterservice,followtheshop’spolicyonpreparingthevehicletoreturnittothecustomer.

1. Someshopsmayrequirethatallprotectivecoversareremoved,whereas others may want covers such as the floor protectors left in.

2. Ensurethatthecustomer’svehicleisascleanaswhenheorshedroppeditoff.Cleanoffanydirtorgreasethatmayhavegottenonthevehicle’sexteriororinterior.

III. Theautomotivetechnicianshouldbefamiliarwiththefunctionsandcomponentsofaworkorder.

NOTE:Asampleworkorderappearsinthissection.

A. Theworkorderservesseveralfunctions.

1. Itemizestherepairsbylistingthecostofpartsandlabor

2. Canbeusedtoauthorizetherepair

3. Hasthenecessaryinformationonhowtocontacttheownerandservesasdocumentationforfuturereference


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4. Mayalsospecifylimitedwarrantiesandliabilitiesoftheshop

5. Mayserveasareferenceforrecentservicehistoryforwarrantyorlegalpurposes

B. Aworkordertypicallyhasthefollowingcomponents.

1. Customername,address,andphonenumber(homeorworkwithextensionnumber)

2. Date

3. Invoicenumber

4. Year, make, model, vehicle identification number (VIN), and mileageofthevehicle

5. Name/initials of the service writer and technician

6. Customerauthorizationsignaturetoallowrepairs

7. Descriptionofcustomerconcern

8. Vehicleservicehistoryinformation

9. Relatedtechnicalservicebulletins(TSB)

10. Technician’snotesthatincludesdiagnosticproceduresperformed,theresultsofdiagnosis,andanyimportantobservationsorremarks

11. Componentorsystemdefectresponsiblefortheconcern

12. Serviceperformedtosuccessfullycorrecttheconcern

13. Laborproceduresandcostsbasedonthepartsandlaborestimationguides

14. Outsidelaborproceduresandcoststhatincludeifashopsentaparticularpartouttoanothershopforrepairs

15. Listingofeachpartthatincludesname,description,andcost

16. Salestax,whichisusuallycalculatedonpartsonly

17. Total that represents the final price that the customer will pay forallchargesrelatedtotherepair


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Smith’s Automotive Repair

Customer’sName: Tom Steffensmeier Date:3/24/2006 Invoice #: 5463874093

Address:601 N. Ann St., Macon, MO 63552 Phone:(660) 442-1577

Year/Make: 2000 Ford Model: Taurus VIN:1FAFP538BYA145471 Mileage:67, 349

ServiceWriter: F. Smith Technician:F. Smith

CustomerAuthorizationSignature:Tom Steffensmeier CustomerConcern:Front brakes are making grinding noise

VehicleServiceHistoryInformation:Routine maintenance performed 12/14/05

RelatedTechnicalServiceBulletins:

DiagnosticProceduresPerformed:Inspected front brakes and rotors and rear drums

Cause:Worn brake pads

Correction:Replaced front brake pads, machined front rotors, and adjusted rear drums

Labor Procedures and Costs Estimated ActualBrake Repair 85.00 70.00Drum Repair 10.00 10.00

Outside Labor Procedures and Costs

Total Labor Costs 95.00 80.00Parts CostsQuantity Part # Description

1 1U2-5680 Kit – Brk Friction 49.95 49.95

Total Parts Costs 49.95 49.95Labor Total 95.00 80.00Parts Total 49.95 49.95

Sales Tax 11.16 10.01GRAND TOTAL $156.11 $139.96


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C. Workordersmaybehandwrittenorpreparedbyenteringcodesinacomputerterminalandthenprinted.

D. Dependingonthepart,thefollowinginformationmayberequiredfororderingrepairparts.

1. Make,model,andmodelyear(foundonthedriver’ssidedoorjamb)ofthevehicle

2. VIN

3. Engineinformationthatincludesenginesize,incubicinchesorliters,thenumberofcylinders,andthetypeoffuelsystem

4. Wheelbase

5. Numberofdoors IV. UsethethreeCs(concern,cause,andcorrection)todiagnosethevehicle

problem.

A. Identify the concern. If possible, ask the owner/driver the following questions.

1. Underwhatconditionsdoestheproblemoccur?

2. Arethereunusualsounds?

3. Howlonghastheproblemexisted?Isitgettingworse?

B. Testdrivethevehicleundertheconditionsthattheproblemhasbeenobserved.

CAUTION: Always obtain instructor’s approval before conducting a road test. Conduct the road test in an area with little or no traffic. Never exceed the legal speed limit during the road test. Always wear safety belts. An assistant should record all observations made during the road test. Do not attempt to drive and record results at the same time.

C. Isolatethecauseoftheproblem.

1. Locate and interpret vehicle and major component identification numbers.

a. VIN


s 17�

b. Vehicle certification labels

c. Calibrationdecals

2. Researchapplicablevehicleandserviceinformation.

a. Applicablecomponentsandtheiroperation

b. Vehicleservicehistory

c. Serviceprecautions

d. Technicalservicebulletins

3. Performavisualinspectionoftheapplicablesystem.

a. Lookfordamagedorbrokencomponents.

b. Lookforwornormisalignedcomponents.

c. Check fluid levels.

d. Inspectrelatedelectricalsensors,corrector,controls,andwiring.

4. Testthesystemsandcomponentsthatcouldcausetheproblem.Eliminategoodcomponentsuntilthecauseisfound.

D. Determinethenecessaryactionandcorrecttheproblem.

student reference

Documents

automotive technologyis

automotive field

s129unit vipower tools

s79unit ivbasic hand

s97 lesson3

s71 lesson3

s119 lesson3

s63 lesson2