Part 2

Health and Safety Precautions

Gasoline (Petrol)
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 vapor 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/in2) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight. Fuel gases, 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 product 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 minimized, 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 minimize 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 license to operate the plant. If such a license 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.
- Tires: Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of tires 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
For example acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, for example paints, adhesives, and metal coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.

Suspended Loads

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

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

Welding
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

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

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

CAUTION: Some of the components installed to the vehicle e.g. the interior cross beam and underbonnet cross member are manufactured from magnesium alloy. On no account should any welding operations be attempted on these components.


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

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