Defender. Manual — part 7
Highly flammable - OBSERVE NO SMOKING POLICY.
Swallowing gasoline (petrol) can result in mouth and throat irritation and absorption from the stomach can result in
drowsiness and unconsciousness. Small amounts can be fatal to children. Inhalation into the lungs, through vomiting, is
a very serious hazard.
Gasoline (petrol) dries the skin and can cause irritation and prolonged or repeated contact may cause dermatitis; if it is
allowed to enter the eyes, it will cause severe smarting. Wash affected area with copious amounts of water and SEEK
IMMEDIATE MEDICAL ATTENTION.
Gasoline (petrol) may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentration of
vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache,
depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.
Make sure there is adequate ventilation when handling and using gasoline (petrol). Great care must be taken to avoid
the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline (petrol) storage tanks.
Gasoline (petrol) should not be used as a cleaning agent. It must not be siphoned by mouth.
Gas-oil (Diesel Fuel)
Combustible.
Prolonged skin contact with high boiling point gas oils (diesel fuel) may cause serious skin disorders including skin
cancer.
Inhalation into the lungs will cause internal bleeding - SEEK IMMEDIATE MEDICAL ATTENTION.
If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable - OBSERVE NO SMOKING POLICY.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid
aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from
kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and
make sure there is adequate ventilation.
If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.
Gas Cylinders
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 138 bar
(13800 kPa) (2000 lbf/in!) and great care should be taken in handling these cylinders to avoid mechanical damage to
them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight. Fuel gases,
for example acetylene and propane should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.
Only trained personnel should undertake work involving gas cylinders.
General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used
where required.
Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment
such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately
apparent and may result in a fatal failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A
damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.
Make sure there is adequate ventilation to control dusts, mists and fumes.
High Pressure Air, Lubrication and Oil Test Equipment
Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the underlying
tissue and cause serious injury.
Jacking
Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.
When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake is
applied and wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack has
sufficient load capacity for the weight of the vehicle.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety
stands.
Ensure that hoists have sufficient load capacity for the weight of the vehicle.
Legal Aspects
There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment in
a workshop.
For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and
skin.
Used Engine Oil
Prolonged and repeated contact with engine oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
Health Protection Precautions
Avoid prolonged and repeated contact with oils, particularly used engine oils.
Wear protective clothing, including impervious gloves where practicable.
Do not put oily rags into pockets.
Avoid contaminating clothes, particularly underpants, with oil.
Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.
First Aid treatment should be obtained immediately for open cuts and wounds.
Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help).
Preparations containing lanoline replace the natural skin oils which have been removed.
Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice without delay.
Where practicable, degrease components prior to handling.
Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or face
shields; in addition an eye wash facility should be provided.
Environmental Precautions
This section provides general information which can help to reduce the environmental impacts from the activities carried
out in workshops.
Emissions to air
Many of the activities that are carried out in workshops emit gases and fumes which can contribute to global warming,
depletion of the ozone layer and/or the formation of photochemical smog at ground level. By considering how the
workshop activities are carried out, these gases and fumes can be minimised, thus reducing the impact on the
environment.
Exhaust fumes
Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to atmosphere.
However, the amount of time engines are running and the position of the vehicle should be carefully considered at all
times, to reduce the release of poisonous gases and minimise the inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based and will evaporate rapidly to atmosphere if used carelessly, or if
containers are left unsealed. All containers must be firmly closed when not required and solvent should be used
sparingly. Wherever possible, solvents having a low toxicity and flammability should be selected. Always follow the
instructions supplied by the solvent manufacturer. Similarly, many paints are solvent based and the spray should be
used in such a way as to reduce emissions to a minimum.
Refrigerant
It is illegal to release any refrigerant into the atmosphere. Discharge and replacement of these materials from air
conditioning units should only be carried out using the appropriate equipment.
Discharges to water
Most workshops will have two systems for discharging waste water - storm drains and foul drains. Storm drains should
only receive clean water i.e. rainwater. Foul drains will accept many of the normal waste water i.e. washing water,
detergents and domestic type waste BUT NOT oil, petrol, solvent, acids, hydraulic fluid, antifreeze and similar fluids. If in
doubt, always consult the local authority or water company.
Spillages
Every precaution must be taken to prevent spillage of oil, fuel, solvents etc., reaching the drains. All handling of such
materials must take place well away from drains and preferably in an area with a suitable containing wall to prevent
discharge into drains or watercourses. If a spillage occurs, it must be soaked up immediately using a spill kit where
provided.
Checklist
Spillage prevention:
Store liquids in a secure area.
Make sure that taps on liquid containers are secure and cannot be accidentally turned on.
Protect bulk storage tanks from vandalism by locking the valves.
Transfer liquids from one container to another in an area away from open drains.
Ensure lids are replaced securely on containers.
Have spill kits available near to points of storage and liquid handling areas.
Spill Kits
Special materials are available to absorb a number of different substances. They can be in granular form, ready to use
and are supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste management.
Land contamination
Oils, fuels and solvents etc. can contaminate any soil with which they come into contact. Such materials MUST never be
disposed of by pouring on to soil and every precaution must be taken to avoid spillage reaching soil. Waste materials
stored on open ground could either leak or have contaminating substances washed off them that would contaminate the
land. Always store these materials in suitable skips or similarly robust containers.
Legal compliance
Some sites may have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is essential to
know the types of effluent which are allowed to be discharged into the drain and to check the results of any monitoring
carried out by the Water Company.
Where paint spraying operations are carried out it may be necessary to apply to the Local Authority for an air emissions
licence to operate the plant. If such a licence is necessary, additional precautions will be necessary to comply with the
requirements and the results of any air quality monitoring must be checked regularly.
Checklist
Always adhere to the following:
Know what legal consents and licences apply to the operations.
Check that the emissions and discharges comply with legal requirements.
Waste Management
Pollution can be reduced by careful handling, storage and disposal of all waste materials that occur on sites. Legislation
makes it illegal to dispose of waste materials other than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what the waste materials are but also to have the necessary
documentation and licences.
Handling and storage of waste
Ensure that waste materials are not poured down the drain or on to soil and are stored in such a way that they do not
escape on to land or soil.
All waste must be segregated into individual types e.g. oils, metals, batteries, scrap components etc. This will prevent
any reaction between different materials and assist in disposal.
Disposal of waste
Dispose of waste in accordance with the following guidelines:
Fuel, hydraulic fluid, anti-freeze and oil: Keep separate and dispose of to specialist contractors.
Refrigerant: Collect in specialist equipment and reuse.
Detergents: Safe to pour down the foul drain if diluted.
Paint, thinners: Keep separate and dispose of to specialist contractor.
Components: Return to supplier for refurbishment or disassemble and reuse any suitable parts. Dispose of
remainder in ordinary waste.
Small parts: Reuse any suitable parts, dispose of the remainder in ordinary waste.
Metals: Can be sold if separate from general waste.
Tyres: Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of tyres by burning.
Components/materials containing asbestos: Keep separate and dispose of to specialist contractor.
Oil and fuel wastes (e.g. rags, used spill kit material): Keep separate and dispose of to specialist
contractors.
Air filters: Keep separate and dispose of to specialist contractors.
Rubber/plastics: Dispose of in ordinary waste.
Hoses: Dispose of in ordinary waste.
Batteries: Keep separate and dispose of to specialist contractors.
Air bags - DANGER EXPLOSIVES: Keep separate and dispose of to specialist contractors.
Electrical components: Return to supplier for refurbishment or disassemble and reuse any suitable
components. Dispose of remainder in ordinary waste.
Catalytic converters: May be sold if kept separate from general waste.
Packaging: Compact/recycle as much as possible and dispose of in ordinary waste.
Office/paper waste: Recycle paper and toner and ink cartridges, dispose of remainder in ordinary waste.
Noise
Car alarm testing, panel beating, running engines, using air tools etc. are operations which invariably produce a large
amount of noise. The location of such activities and also the time of day must be carefully considered having regard to
the proximity of houses schools etc.
Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear
protection must be worn.
Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals
(normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is
used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of these
should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can
give toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from
clothing.
Solvents
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