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Most important Health & Safety (H & S) regulation
1974) Health And Safety At Works Act (HASAWA) =
- This regulation covers everyone involved/affected by work
...

- Aims to involve employees through better information
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- Creates a framework for developing & updating safety laws
...

- Equipment must be safe to use, regularly maintained & inspected regularly by qualified
personnel
...

- Employer is responsible for scheduling sufficient breaks
...

– Give information in its use
- For head, eye, body, foot and high Vis clothing
...

- Employers must carry out risk assessments with the help of 5 or more employees taking
notes on the significant findings
...

– know what a Jack, engine crane, hoist, chains, sling & wire ropes
...


Other H & S regulations
1996) Consultation with employees regulations =
- Employers must consult employees of H & S (Health & Safety) matters when introducing
new work systems or equipment
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- Give information on about any risks or dangers
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- Planning and organising H & S training
...
g
...

1995) Reporting Injuries, Disease & Dangerous Occurrence Regulations (RIDDOR) =
- Day-to-day injuries (cuts, bruises etc
...

- ill health at work must be reported to allow enforcing authorities to identify how risks can
arise
...

1990) Environmental Protection Act (waste disposal of materials) =
- Remove and transfer waste to a licenced site for disposal
...
(You can be prosecuted if you put a
hazardous substance down a drain)
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- Employers must carry out assessments and surveys of materials hazardous to health
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- Keep posters to inform
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- Employer is responsible for displaying information like RPM (Revolutions Per Minuit of
engine) and training them to use it
...
5 bars e
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air condition refrigerant, compressors & air lines
...

1989) Noise At Work Regulations (NAWR) =
- Noise exposure during work, should be 85dbA (decibels) at max
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- Employers must designate ear protection zones and require all who enter these zones to
wear ear protection
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– Indicate its safe working load (SWL)
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– Apply safety measure
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- Arranging for a competent person to assist with compliance of safety laws
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- Take measure to reduce risks
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1996) Safety signs & signals regulations =
- Employer must display safety signs indicating hazards e
...
where hands should be
cleaned, substance disposed of etc
...
) must be recorded in an incident book
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- Absence due to illness must be reported
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- Or In-house treatment & discharge via foul sewer
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2002) Control Of Substances Hazardous to Health (COSHH) regulations =
- Provide protection to those working with hazardous substances
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- There must be data sheets for all materials to identify its risks to health
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1982) the safety in industry (Abrasive wheels) regulations =
- This regulation covers the use of abrasive wheels to cut down harp metal components
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1989) Pressure Systems & Transportable Gas Containers Regulations =
- Covers use, maintenance and repair of tools which use steam, gas or other fluids under
pressure greater than 0
...
g
...

1989) Electricity at Works Regulations =
- Requires electrical equipment safety by ensuring equipment is tagged, tested and
maintained by a qualified electrician every year
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Personal H & S in automotive
People that can be affected in the business:
- Employers
- Employees/Work personnel
- Customers
- Contractors
- Suppliers (People you buy your tools from)

People in business
Employers

Employees

Inspectors (HSC & HSE)

Responsibilities
- Written safety policy
- Safe working environment
- Safe working system
- Providing safe tools & equipment
...

– Corporate fines
- Personal fines
- Loss of production
- Loss of income
- Bad publicity in the media
- Prohibition (forbid) Notice

H & S signs that must be in the work shop
- Fire & emergency exit signs
- “Action in event of fire/emergency…” signs
- H & S instructions signs
- Use of H & S equipment signs

Common risks/ hazards
- Electrical equip and leads
- air lines and air powered tools
- Fuels and other hazardous substances
- Moving vehicles
- Waste materials
- Lifting, jacking and supporting vehicles
- Inappropriate behaviour
- Failing to use PPE
- Manual handling
- Slip, strips, falls…
- Struck by…
- Machinery
- Other
H & S practises
- immobilising vehicle (removing ignition keys and applying handbrake)
- Use of PPE (Overalls, safety footwear, Gloves, Goggles) & VPE (Vehicle Protective Equipment e
...
seat covers, wing covers, carpet protection)
- Use axle stands
- Location of fire extinguishers
- Follow safety instructions
- Use correct tools and equipment
Good Housekeeping practises
- Identify unsafe tools – damaged
- Identify unsafe equipment e
...
Leaking jacks
- check electrical equipment for damaged cable
- Prompt disposal of waste materials
- cleaning spillages
- Regular cleaning of work areas
- Proper storage of tools & equipment
Common Hazardous substances
- Solids (old components)
- Liquids (petrol, diesels, engine oil, brake fluid)
- Gases (Welding and heating equipment)
Waste materials
- waste oil and filters
- Old units & components
- cleaning materials
- Volatile materials (petrol filters, engine components)
Accidents & First aid
-All accidents are to be reported to the manager
-First aid kits are to be checked weekly
-Do not administer first aid unless you’re trained

FIRE HAZARDS
Automotive organisations is required to organise for fire drills, exits and fire extinguishers
appropriate to its business size
...
e
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and
Deep fat fryers, oil based fryers
Covers the burning fat/oil in fires and also
removes the oxygen in fires
...


Advantages of GHS

Purpose of GHS

Providing enhanced hazard information
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Encourages safe use & transport for chemicals
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Improves worldwide chemical trade
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White background
Red border
Black symbol

Health hazard

Flammable

You can usually find GHS symbols on
labels and safety data sheets
...
Products that
are less dangerous have no signal word
...

Supplier information = at least, it should state:
-name
-address
-phone number
-GHS pictogram

Axle stands
Axle stand type
Tubular type axle stand
Other axle stand

Total service height is adjustable & locked
via aligning the holes & steel locking pin
...
Usually has an extra locking pin
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Axle stands with a jack

Before using an axle stand
1) Always placed under a jacked-up vehicle using a jack just in-case the jack fails, which
the axle stand takes vehicle load
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3) Position axle stand under a load bearing on a car chassis (car base)
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4) If in doubt regarding jacking/support point, consult the workshop manual
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Lowering the vehicle on high axle stands allows
the wheels to hang freely (this is necessary
when working on breaks or suspensions)

How to use the high axle stand & 4-post car lift combination
1) Position axle stand cups on load bearing
...

3) Move vehicle up & down to ensure that it’s stable (Bring vehicle up if unstable & reposition axle stands)
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- Protons = positively charged atom (+ve)
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- Neutron = Atom with no electrical charge
...


Conductors & insulators
Keywords:
- Conductors = Materials offering low resistance to flow of electrons i
...
wires (copper, silver,
gold, steel, carbon)
...
e
...

Conducters:
- Conductors are materials through which electricity can flow, due to them having a lot of free
electrons
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- Vehicle body shell and engine are also used as conductors
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- Atoms of materials have no free electron
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- The electrons of an insulator are closely bonded to the nucleus and consequently do not
easily move from one atom to another
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Units of electricity
Keywords:
- Current (amps) = Flow of electricity (1 amp = 625 trillion electrons
- Voltage (Volts) = Potential difference
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Voltage
- Electrical power in a battery
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- Higher voltage = Higher current flow
...

Current
- Current flow depends on potential difference of battery and resistance in circuit
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Resistance
- Measured using multi-meter
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Thinner wire = higher resistance), Temperature of conductor (Higher
temperature = decrease electron flow)
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- Ammeter = Measures current (amps)
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- Ohmmeter = Measures resistance (ohms)
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Parallel circuit = circuit with multiple paths
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Rotary switch

Connection for measuring voltage & resistance
Connection for measuring current
Red (Positive) probe

Multi-meter
Multi-meter

Ground connection with black (negative) probe
Ammeter
Step 1) to measure Amps, toggle selector switch from
AC Voltage
to direct voltage

Step 2) rotate the rotary switch to “A”
...
Now you
can measure a current of up to 10amps (maximum)
...

Step 3) ensure the red probe is plugged into the
volt/resistance connection
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depending

Step 3) ensure the red probe is plugged into the
volt/resistance connection
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Multi-meter probes & circuits

Black probe (negative)

Negative battery terminal

Battery
Positive battery terminal

Red probe (positive)
This is how you should connect probes to the
terminals on a circuit
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Ohms & Watts triangle laws
Ohms law: current is directly proportionate to voltage, but inversely proportionate to
resistance, in a circuit
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Ohms law triangle

Watts law triangle

Volts (V)
Current (amps)

V
I

x

Watts
Current (amps)

R

W
A

x

V

Volts (V)

Resistance (ohms)
1 Horsepower = 746 Watts
1
...
Calculate the power in watts?
W = V X A Therefore 12 X 2 = 24 Watts

Series, parallel & series-parallel circuit
Keywords:
- Series circuit = circuit with a single path for electricity to flow
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- Series parallel circuit = a circuit that’s both series and parallel
...
e
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- Conductors = wires
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Law 1) current flowing through every point in a circuit will remain the
same
...

Voltage drop: Voltage at different point’s changes as the electromotive
force drops from a potential difference of 12 V as it leaves the battery
to no Voltage as it returns
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Law 1) Total current flow is equal to the current flow through individual
load circuits
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Law 3) Total circuit resistance is always less than the value of the lowest
resistive branch in the circuit
RT = R1 X R2
R1 + R2
2 x resistors

Series parallel circuit

or 1 = 1 + 1 + 1
RT R1 R2 R3
> than 2 resistors

In parallel circuit, current can flow more than one parallel leg at a time
& failure of one component doesn’t affect the components on other
legs of the circuit
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- Capacitors = Stores small amount of DC voltage & absorbs voltage spikes to
prevent short circuiting i
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ECU (it can also called Suppressors or condensers – Unit
value farad)
...
g
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Types of resistors:

Resistor

Fixed resistor = made of carbon/graphite material + resin bonding
agent & is colour coded for easy identifications
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Stepped resistors = resistance ranges from 10 – 1megohms
Rheostat = used in the highlight switch with dimming knob feature for
instrument lights
...
g
...
A thermistor sensor are used to control engine
temperature gauge
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Electro-magnetically operated switch and is operated by a current signal
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Electrical circuits
Keywords:
- Closed circuit = When the switch on a circuit is ON
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- Earth return = Current passes through vehicle chassis/body
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- Fuse = melts when a specified current flow is exceeded
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Note: Current flows from POSITIVE of battery and return to negative side of battery

Earth return

The problem with Earth return is “bad earth connection”, from
battery to earth
...
g
...
If the current exceeds the contact
breaker rating it will interrupt the current by “tripping” then a specified current flow is exceeded

Fuse

Tooling
Tools that should be used in order when emoving a nut or bolt
first
Last
Torque wrench

Double open-ended spanner

Tools
Torque wrench

Breaker bar

Spanners
1) Combination spanner
2) Double open-ended spanner
3) Ring spanner
4) adjustable spanner

Screw drivers
1) Phillips screw driver
2) Slotted crew driver
3) Torx screw driver
4) Security T screw driver
5) Hex screw driver

Mallet
1) Ball-peen mallet
2) Copper mallet

Taps screw
(used to fix worn thread on a nut)

Ring spanner

Note: These tools should
be used in this order to
prevent receding nuts &
bolts

Torque wrench
Keywords:
- Newton = Unit of force
- Torque = Rotational force
- Torque wrench = Tool used to tighten nuts & bolts to a certain torque
Length (Meters) x Force (Newton) = Overall Force (Newton meter)

Example question
You pull on a torque wrench that’s 0
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What is the torque at the end of the torque
wrench?
0
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2) Tighten the nut or bolt with the torque wrench until you hear
a click
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Torque wrench has a locking mechanism that turns either
directions (clockwise or anti clockwise)
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Measuring equipment (Tread depth)
Keywords:
- Tread depth = the deepness of the groves on a tyre
...
6mm)
...

Legal minimum of tread depth = 2mm
legal minimum UK tread depth = 1
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Tread depth must be checked regularly
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The tread wear indicators are located in these
main groves
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It should now show you the tyres tread depth

Measuring equipment (Micrometre)
Keywords:
- Tolerance = minimum and max variation you can tolerate of your parts sizes
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Note: Micrometres can expand with heat
when in your hand
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Lock lever
Measuring
spindle

Anvil

Ratchet

Barrel
Heat-insulated handle

How to read the micrometre
1mm

2mm

3mm

4mm

5mm
Zero (0) line

0
...

Bottom scale represents half a millimetre
(micrometre)
...
g
...
3 & 25 = 0
...

2) Add the top scale value (10mm) to the
bottom scale value (0
...
30) you get the width of the object
you’re measuring
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5mm + 0
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80mm

Tolerance question: a measurement is stated as 2 + 0
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What reading is outside tolerance?
A) 2
...
4mm
Answer:
outside
between
C) 1
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5 = 2
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4 1
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5
1
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5 = 1
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9, 2
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4 etc
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- Mig welding = similar to arc welding but requires s mask
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- Rivets = Short metal pin or bolt that holds metals together
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- Non-ferrous metals = not magnetic
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Vernier calliper
Used to measure internal width

Measures objects depth

Used to measure external width

Keywords:
- Malleability = can be hammered into shape
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Spring washer= prevents loosening by suspension force
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Tab washer= prevents loosening via positive locking
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Measuring equipment (Tread depth)
Keywords:
- Tread depth = the deepness of the groves on a tyre
...
6mm)
...

Legal minimum of tread depth = 2mm
legal minimum UK tread depth = 1
...


Tread depth must be checked regularly
...

The tread wear indicators are located in these
main groves
...
It should now show you the tyres tread depth

Measuring equipment (Micrometre)
Keywords:
Tolerance = minimum and max variation you can tolerate of your parts sizes
...


-

Note: Micrometres can expand with heat
when in your hand
...


Lock lever
Measuring
spindle

Anvil

Ratchet

Barrel
Heat-insulated handle

How to read the micrometre
1mm

2mm

3mm

4mm

5mm
Zero (0) line

0
...

Bottom scale represents half a millimetre
(micrometre)
...
g
...
3 & 25 = 0
...

2) Add the top scale value (10mm) to the
bottom scale value (0
...
30) you get the width of the object
you’re measuring
...
5mm + 0
...
80mm

Tolerance question: a measurement is stated as 2 + 0
...
What reading is outside tolerance?
A) 2
...
4mm
Answer:
outside
between
C) 1
...
5 = 2
...
4 1
...
5
D) 1
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5 = 1
...
9, 2
...
4 etc
...

- Mig welding = similar to arc welding but requires s mask
...

- Rivets = Short metal pin or bolt that holds metals together
...

- Non-ferrous metals = not magnetic
...


Vernier calliper
Used to measure internal width

Measures objects depth

Used to measure external width

Vehicle body components

Chassis (vehicle base)
Drum brakes are
usually at the rear
...


Monocoque chassis = thin frame whereby
loads are supported through external skin
of car
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Backbone chassis = uses a body-on-frame
design
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Integrated chassis = used in normal modernday cars (most common)
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Ladder chassis = usually used for heavy
vehicles such as trucks & tractors
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– Front overhang = distance from the front of the vehicle to the center line of the fron wheel
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– Vehicle width = total car width (not includong mirrors)
...

– vehicle height = distance from rpad surfce to vehicle uppet surface
- vehicle ground clearance = distance from road surface to underside of vehicle
Length

Front overhang

Wheel base

Vehicle width

Vehicle ground clearance

Rear overhang

Track width

Vehicle heigth

Vehicle sfafety features
Keywords:
- crumple zone = hollow point at the front of the car that decreases impact
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- seat belts = seat belts have pretensioners that tug back when pulled
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Damper

Damper

Rear wheel suspension
Car body
Front wheel suspension

Dampers dampen compression cycle (when damper is
compressed) &extension cycle (when damper is
pulled out)
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B post = positioned between
the front & rear doors
...

D post positioned in the rear
wing & tailgate door

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