Battery Disconnection

All service workshops are a source of potential danger and repair work should only be performed by technically trained staff following procedures detailed in this manual. A safety conscious approach to the performance of all service procedures must be observed at all times. Statutory requirements governing all aspects of health and safety at work including directives for the proper use of materials and equipment must be implemented.

The following contains a list of particular safety precautions which should be observed; it is not intended to be exhaustive.

Battery Disconnection

When a service manual procedure requires the vehicle battery to be disconnected - always physically disconnect the vehicle battery earth (Negative) lead.

Do not use the ‘Battery Disconnect Switch’.

After reconnecting the vehicle battery the following items will have to be reset or re-learnt:

• Radio pre-sets
• Windows
• DTCs will be lost

Air Conditioning (A/C) System

Do not break into the A/C refrigeration system until the refrigerant has been evacuated using the procedure detailed in this manual. Do not disconnect any A/C refrigerant system pipes unless trained and instructed to do so. The refrigerant used can cause blindness if allowed to contact your eyes.

Chemical Handling and Storage

Chemicals used in the servicing of motor vehicles include acids, adhesives, antifreeze, brake fluids, coolants, grease, oil, paint, resin and solvents. Exposure to certain chemicals through direct contact or inhalation can be fatal.

Potential hazards may also be present through the incorrect use, storage and handling of chemicals causing a fire risk.

The following precautions should be observed.

• Strictly adhere to handling and safety information found on containers and labels.
• Do not store chemicals in unlabelled or incorrectly labelled containers.
• Containers used for storing chemicals should not be left open; there is a risk of spilling, or evaporation of fumes which may be inflammable or toxic.
• Do not mix chemicals unless instructed to do so following manufacturers guidelines.
• Do not inhale chemical materials to determine identity, they may be toxic.
• Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin.
• Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages.

• Chemicals based on solvents such as paint should not be sprayed in a confined space; work areas used for such operations should be well ventilated and fume extraction equipment should be utilised.

• Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.

F1 DO NOT SMOKE IN THE VICINITY OF VOLATILE DE-GREASING AGENTS.

WARNING FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE, WHITE SPIRIT, SBP3, METHYLENE CHLORIDE, PERCHLORETHYLENE.

• Avoid splashing the skin, eyes and clothing.
• Clean chemicals from the skin and clothing as soon as possible after soiling.
• Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other corrosive and toxic substances.

Electrical Equipment

• Ensure that electrical equipment is in safe working order before use.
• Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed.
• Ensure that electrical equipment is protected by a fuse of the correct current rating.
• Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine or when working beneath the vehicle.

Exhaust Fumes

Engines should not be run in confined spaces as exhaust fumes contain harmful and toxic substances including carbon monoxide which can prove fatal if inhaled. Engines must only be run where there is fume extraction equipment in operation or where there is adequate ventilation.

Fire Precautions

• Ensure that a suitable form of fire extinguisher is conveniently located near the work area.
• Keep oils, solvents and combustible materials away from naked flames and other sources of ignition.
• Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be present and ensure that the warnings are strictly observed.
• Ensure that dry sand is available to soak up any spillage of fuel or other flammable solutions.
• Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours.
• All personnel should be aware of the fire drill procedures and precautions.