Automotive Repair Safety Manual

What Should an Automotive Repair Safety Manual Include?

The contents of an Automotive Repair Safety Manual should reflect the shop’s actual operations.

A general mechanical repair shop may require a different combination of programs than a tire shop, dealership service department, fleet-maintenance facility, transmission shop, or business servicing hybrid and electric vehicles.

Depending on operations, the manual may address:

• Automotive lifts.
• Jacks and jack stands.
• Tire servicing.
• Brake and clutch work.
• Battery service.
• Hybrid and electric vehicles.
• Fuel systems.
• Vehicle exhaust.
• Hand and power tools.
• Welding and hot work.
• Compressed air and gases.
• Hazardous chemicals.
• Personal protective equipment.
• Fire prevention.
• Vehicle movement.
• Emergency procedures.

Programs should be selected according to the work actually performed and applicable requirements.

Automotive Repair Safety Program

An effective Automotive Repair Safety Program establishes responsibilities and procedures for identifying shop hazards, inspecting equipment, servicing vehicles safely, protecting employees, and correcting unsafe conditions.

Management should provide the equipment, training, and resources necessary to perform automotive work safely.

Managers and supervisors should:

• Identify shop hazards.
• Ensure employees receive appropriate training.
• Maintain service equipment in safe condition.
• Establish procedures for higher-hazard work.
• Ensure required inspections are performed.
• Provide appropriate PPE.
• Correct unsafe conditions.
• Investigate incidents and near misses.
• Follow up on corrective actions.

Employees should follow established procedures, use required PPE, inspect equipment before use, report defects, and perform only work for which they have appropriate training and authorization.

Automotive Shop Inspections

Automotive shops should be inspected periodically to identify unsafe conditions and verify that established safety procedures are being followed.

Inspection topics may include:

• Automotive lifts.
• Jacks and jack stands.
• Tire equipment.
• Hand and power tools.
• Electrical equipment.
• Compressed air.
• Welding equipment.
• Gas cylinders.
• Chemical storage.
• Flammable liquids.
• Fire protection.
• Walking surfaces.
• Emergency equipment.
• PPE.

Deficiencies should be documented and corrected in a timely manner.

Job Safety Analysis (JSA/JHA)

A Job Safety Analysis or Job Hazard Analysis can be used to evaluate higher-hazard automotive tasks.

JSAs/JHAs may be appropriate for:

• Raising vehicles.
• Working beneath vehicles.
• Tire servicing.
• Battery replacement.
• Hybrid and electric vehicle work.
• Fuel-system repairs.
• Welding and cutting.
• Brake and clutch work.
• Vehicle recovery.
• Heavy component removal.
• Road testing.

The analysis should identify task steps, hazards, and controls necessary to perform the work safely.

Vehicle Movement and Shop Traffic

Moving vehicles can expose technicians, customers, and other employees to struck-by and caught-between hazards.

Shops should establish procedures for:

• Entering and exiting service bays.
• Backing vehicles.
• Pedestrian traffic.
• Parking.
• Vehicle keys.
• Spotters when appropriate.
• Customer access.
• Vehicle staging.

Drivers should verify that the path is clear before moving a vehicle.

Securing Vehicles Before Service

Before service begins, employees should prevent unintended vehicle movement.

Depending on the work, this may include:

• Placing the transmission in the appropriate position.
• Setting the parking brake.
• Turning the ignition off.
• Removing or controlling keys.
• Using wheel chocks.
• Following lift or jack procedures.

Additional precautions may be necessary when engines must remain running for diagnosis or testing.

Automotive Lift Safety

Automotive lifts can expose employees to severe crushing and struck-by hazards if a vehicle is improperly positioned, a lift is overloaded, safety locks are not engaged, or equipment is defective.

Only trained and authorized employees should operate automotive lifts.

Employees should follow manufacturer instructions and established procedures for the lift being used.

Lift Operator Training

Employees who operate automotive lifts should receive training appropriate to the equipment.

Training should address:

• Lift controls.
• Rated capacity.
• Vehicle positioning.
• Manufacturer-recommended lifting points.
• Adapters.
• Safety locks.
• Vehicle stability.
• Raising and lowering.
• Work beneath elevated vehicles.
• Emergency procedures.
• Equipment defects.

Employees should understand that different vehicles may require different lifting configurations.

Pre-Use Lift Inspections

Automotive lifts should be visually checked before use.

Depending on the lift, employees should look for:

• Hydraulic leaks.
• Damaged arms.
• Worn pads.
• Damaged cables or chains.
• Defective locks.
• Loose components.
• Unusual movement.
• Damaged controls.
• Missing components.

Conditions that could affect safe operation should be reported and the lift removed from service when necessary.

Periodic Lift Inspection and Maintenance

Automotive lifts should receive periodic inspection and preventive maintenance consistent with manufacturer instructions and applicable facility procedures.

Inspection and maintenance records should be retained as appropriate.

Repairs should be performed by persons qualified to perform the work.

Safety devices should not be removed, defeated, or bypassed.

Vehicle Positioning and Lifting Points

Vehicles should be properly positioned before lifting.

Employees should:

• Identify appropriate lifting points.
• Position lift arms correctly.
• Use appropriate adapters.
• Verify contact before fully raising the vehicle.
• Consider vehicle weight distribution.
• Account for unusual loads or modifications.

Removing heavy components may change a vehicle’s center of gravity and stability.

Lift Capacity

The rated capacity of an automotive lift should not be exceeded.

Employees should consider the actual vehicle weight, including cargo, equipment, accessories, or modifications that may significantly affect weight.

When vehicle weight is uncertain, it should be verified before lifting.

Engaging Lift Locks

Where a lift is equipped with mechanical safety locks, employees should ensure they are functioning and properly engaged according to manufacturer instructions.

Employees should not rely solely on hydraulic pressure to support an elevated vehicle when the lift is designed to rest on mechanical locks during service.

Working Under Raised Vehicles

Before employees work beneath a raised vehicle, they should verify that:

• The vehicle is stable.
• Lift contact points are properly positioned.
• Required safety locks are engaged.
• The vehicle is at an appropriate working height.
• The surrounding area is controlled.

Employees should remain alert to activities that can change vehicle stability, including removal of engines, transmissions, batteries, axles, or other heavy components.

Defective Lifts

A lift with a condition that could affect safe operation should not be used.

Defective equipment should be:

• Removed from service.
• Appropriately identified.
• Reported.
• Repaired by qualified personnel.
• Returned to service only when safe.

Employees should not attempt temporary or improvised repairs to safety-critical components.

Floor Jacks

Floor jacks should be selected according to the load and used on firm, stable surfaces.

Employees should:

• Observe rated capacity.
• Position the jack correctly.
• Use designated lifting points.
• Maintain control while raising and lowering.
• Inspect the jack for defects.

A jack should not be relied upon as the sole means of supporting a vehicle while an employee works beneath it.

Jack Stands

Appropriately rated jack stands should be positioned on stable surfaces and placed at suitable vehicle support points.

Before beginning work beneath a supported vehicle, employees should verify that the vehicle is stable.

Improvised supports such as buckets, loose blocks, wheels, or other unsuitable objects should not be used.

Wheel Chocks

Wheel chocks should be used when necessary to prevent unintended vehicle movement.

Chocks should be appropriate to the vehicle and positioned according to the work being performed.

Employees should consider vehicle slope, drivetrain configuration, lifting method, and the wheels remaining on the ground.

Working Beneath Raised Vehicles

Employees should never place themselves beneath a vehicle unless it is supported by equipment designed and positioned to safely support the load.

Before entering beneath the vehicle, employees should verify stability and support.

Work that changes vehicle weight distribution should be evaluated before heavy components are removed.

Tire Service Safety

Tire servicing can expose employees to stored energy, moving machinery, compressed air, heavy lifting, and damaged wheel components.

Employees performing tire service should receive appropriate instruction for the equipment and tires they service.

Procedures should address:

• Tire inspection.
• Wheel inspection.
• Tire-changing equipment.
• Inflation.
• Wheel installation.
• Compressed air.
• Handling.

Special requirements apply to certain rim-wheel servicing operations.

Tire Changing Machines

Only trained employees should operate tire-changing equipment.

Before use, employees should:

• Inspect the machine.
• Verify proper setup.
• Follow manufacturer instructions.
• Keep hands clear of pinch points.
• Use appropriate tools.
• Control inflation.

Employees should not bypass equipment safeguards.

Tire Inflation

Employees should inspect tires and wheels before inflation and follow safe inflation procedures.

Employees should not exceed appropriate inflation pressure or position themselves unnecessarily in a potential trajectory area.

Damaged tires, wheels, or components should be removed from service when necessary.

Wheel and Rim Safety

Wheels should be inspected for conditions that could affect safe use, including:

• Cracks.
• Severe corrosion.
• Distortion.
• Damaged mounting surfaces.
• Damaged fasteners.

Specialized rim-wheel assemblies should be serviced only by employees trained for those systems and using required equipment and procedures.

Compressed Air

Compressed air should be used carefully and only for appropriate purposes.

Employees should not direct compressed air at themselves or other persons.

Compressed-air equipment should be maintained in safe condition, and employees should use appropriate eye and other protection according to the task.

Brake Service Safety

Brake servicing can expose employees to dust, chemicals, sharp components, compressed springs, and other hazards.

Employees should follow procedures designed to control brake dust and prevent unnecessary airborne exposure.

Dry cleaning methods that can disperse potentially hazardous brake dust should not be used where prohibited.

Brake and Clutch Dust

Brake and clutch components may contain or be contaminated with hazardous materials.

Employees should not assume that a replacement component is asbestos-free based solely on appearance.

Work practices should minimize generation and dispersal of dust.

Applicable asbestos-control procedures should be followed when required.

Asbestos and Brake/Clutch Work

Automotive brake and clutch inspection, disassembly, repair, and assembly may be subject to specific OSHA asbestos work-practice requirements.

Applicable procedures may include approved HEPA-vacuum or low-pressure/wet-cleaning methods, equivalent methods, or the permitted wet method for qualifying low-volume facilities.

Employees performing covered work should receive appropriate instruction and follow the company’s established brake and clutch procedures.

Automotive Battery Safety

Automotive batteries can expose employees to corrosive electrolyte, electrical energy, hydrogen gas, heavy lifting, and ignition hazards.

Employees should:

• Wear appropriate eye and face protection.
• Avoid shorting terminals.
• Keep ignition sources controlled.
• Use appropriate lifting methods.
• Inspect batteries for damage.
• Follow manufacturer procedures.

Damaged or leaking batteries require additional precautions.

Battery Charging

Battery-charging areas should be appropriately maintained and ventilated according to the equipment and batteries involved.

Employees should control ignition sources and follow procedures for connecting and disconnecting charging equipment.

Charging equipment and cables should be maintained in safe condition.

Jump Starting

Employees should follow manufacturer-approved procedures when jump starting vehicles.

Before connecting equipment, employees should:

• Identify battery type and voltage.
• Inspect for damage.
• Verify correct polarity.
• Control ignition sources.
• Follow the correct connection sequence.

Damaged or frozen batteries should not be jump started unless the manufacturer permits the procedure.

Battery Acid

Employees handling batteries containing corrosive electrolyte should use appropriate PPE.

Facilities should provide suitable means for responding to foreseeable eye or skin exposure as required.

Spills should be handled according to established chemical and spill-response procedures.

Hybrid and Electric Vehicles — When Applicable

Hybrid and electric vehicles may contain high-voltage electrical systems and large energy-storage batteries that present hazards beyond conventional automotive electrical systems.

Shops servicing these vehicles should establish procedures appropriate to the vehicles and work performed.

Employees should be able to recognize high-voltage components and understand which tasks they are authorized to perform.

High-Voltage Vehicle Systems

High-voltage systems can retain hazardous electrical energy even when a vehicle is turned off.

Procedures should address:

• System identification.
• Vehicle shutdown.
• Isolation.
• Verification.
• Stored energy.
• High-voltage cables and components.
• Required PPE and tools.
• Re-energization.

Manufacturer-specific procedures should be followed.

Qualified Employees for EV Work

Employees should not perform high-voltage vehicle work beyond their training and authorization.

The company should establish clear boundaries between:

• General service work.
• Work near high-voltage systems.
• High-voltage diagnosis.
• De-energization.
• High-voltage component repair.

Specialized work should be performed only by appropriately trained employees.

Fuel System Safety

Fuel-system work can expose employees to flammable vapors, liquid fuel, pressure, and ignition hazards.

Before opening a fuel system, employees should follow appropriate procedures to control:

• Pressure.
• Ignition sources.
• Spillage.
• Vapor accumulation.
• Static or electrical hazards.

Fuel should be collected in suitable containers.

Gasoline and Diesel

Gasoline and other fuels should be stored and handled according to applicable flammable- and combustible-liquid requirements.

Employees should avoid using gasoline as a cleaning solvent.

Fuel spills should be controlled promptly.

Flammable and Combustible Liquids

Automotive shops may use or store fuel, solvents, cleaners, paints, and other flammable or combustible liquids.

Procedures should address:

• Approved containers.
• Storage.
• Dispensing.
• Ignition sources.
• Ventilation.
• Spill control.
• Fire protection.

Quantities should be limited and stored appropriately.

Parts Cleaning

Parts-cleaning operations may expose employees to solvents, splashes, vapors, and fire hazards.

Employees should:

• Follow product instructions.
• Keep lids closed when appropriate.
• Use required PPE.
• Maintain ventilation.
• Control ignition sources.

Unapproved solvents should not be substituted for products intended for parts cleaning.

Solvents and Degreasers

Employees should review labels and Safety Data Sheets before using solvents and degreasers.

Products should be selected and used in a manner that reduces unnecessary employee exposure.

Chemical-resistant gloves, eye protection, ventilation, or other controls should be used where required.

Vehicle Exhaust and Carbon Monoxide

Running engines indoors can expose employees to carbon monoxide and other exhaust contaminants.

Shops should minimize unnecessary indoor idling and provide appropriate exhaust removal or ventilation.

Employees should understand that carbon monoxide cannot be reliably detected by smell.

Symptoms such as headache, dizziness, weakness, nausea, or confusion should be taken seriously and reported immediately.

Shop Ventilation

Ventilation should be appropriate for the work performed.

Potential sources requiring evaluation include:

• Vehicle exhaust.
• Welding.
• Solvents.
• Cleaning chemicals.
• Battery charging.
• Grinding.
• Spray products.

Local exhaust ventilation should be used where necessary to control contaminants at their source.

Hand and Power Tools

Automotive technicians use numerous hand and power tools.

Tools should:

• Be appropriate for the task.
• Be inspected before use.
• Be maintained in safe condition.
• Have required guards.
• Be used according to manufacturer instructions.

Defective tools should be removed from service.

Pneumatic Tools

Pneumatic impact wrenches, air ratchets, grinders, and other air-powered tools should be properly connected and maintained.

Employees should:

• Inspect hoses and fittings.
• Use appropriate pressure.
• Keep body parts clear of moving components.
• Disconnect air before certain adjustments or servicing.
• Wear required PPE.

Damaged hoses and fittings should be removed from service.

Impact Tools

Impact tools can expose employees to noise, flying particles, hand injuries, and unexpected movement.

Employees should use appropriate sockets and accessories designed for impact use.

Worn or damaged accessories should not be used.

Grinding Safety

Grinding operations can expose employees to flying particles, sparks, wheel breakage, noise, and fire hazards.

Employees should:

• Inspect wheels and equipment.
• Maintain required guards.
• Use appropriate eye and face protection.
• Control sparks.
• Keep combustibles away.
• Use wheels rated for the equipment.

Damaged grinding wheels should not be used.

Bench Grinders

Bench grinders should have required guards and work rests properly maintained and adjusted.

Employees should not grind on wheel surfaces not designed for that purpose.

The grinder should be secured and maintained in safe operating condition.

Welding and Cutting

Welding and cutting may expose employees to fire, fumes, ultraviolet radiation, burns, compressed gases, and electrical hazards.

Procedures should address:

• Work-area preparation.
• Combustible materials.
• PPE.
• Ventilation.
• Gas cylinders.
• Fire protection.
• Vehicle fuel systems.
• Nearby employees.

Employees should receive appropriate training before performing welding or cutting.

Hot Work

Before performing hot work on or near a vehicle, employees should evaluate nearby:

• Fuel.
• Fuel lines.
• Batteries.
• Upholstery.
• Plastics.
• Flammable liquids.
• Combustible materials.

Required fire-prevention measures should be established before work begins.

Compressed Gas Cylinders

Compressed gas cylinders should be:

• Properly secured.
• Protected from damage.
• Stored appropriately.
• Kept away from excessive heat.
• Handled using suitable equipment.

Valve-protection caps should be used where required.

Oxygen and fuel-gas equipment should be maintained according to applicable requirements.

Hazard Communication

Automotive repair shops that use hazardous chemicals should maintain an applicable Hazard Communication Program.

The program should address:

• Chemical inventory.
• Container labeling.
• Safety Data Sheets.
• Employee information and training.
• Non-routine tasks.

Employees should know how to obtain hazard information before using a chemical.

Automotive Chemical Safety

Automotive chemicals may include:

• Brake cleaner.
• Carburetor cleaner.
• Solvents.
• Degreasers.
• Coolants.
• Refrigerants.
• Lubricants.
• Adhesives.
• Sealants.
• Fuel additives.
• Battery electrolyte.

Employees should follow product labels, Safety Data Sheets, and company procedures.

Used Oil and Waste Fluids

Used oil, coolant, brake fluid, transmission fluid, fuel, and other waste liquids should be collected and stored appropriately.

Containers should be:

• Suitable for the material.
• Kept in good condition.
• Properly identified.
• Protected against spills.

Waste streams should be managed according to applicable environmental and disposal requirements.

Spill Prevention and Response

Automotive shops should establish procedures for foreseeable spills involving oils, fuels, coolants, chemicals, and other fluids.

Employees should understand:

• Reporting requirements.
• Spill-kit locations.
• PPE.
• Cleanup procedures.
• Disposal.
• When evacuation or specialized response is necessary.

Employees should not respond to releases beyond their training and assigned responsibilities.

Hazardous Waste — When Applicable

Some automotive waste may be regulated as hazardous waste depending on its characteristics, contents, and applicable environmental requirements.

Potential waste streams should be evaluated appropriately.

Employees responsible for handling regulated waste should receive appropriate instruction.

Personal Protective Equipment

PPE should be selected according to the hazards associated with each task.

Depending on operations, PPE may include:

• Safety glasses.
• Goggles.
• Face shields.
• Gloves.
• Protective footwear.
• Hearing protection.
• Welding PPE.
• Chemical-resistant clothing.
• Respiratory protection.

Employees should inspect and properly use assigned PPE.

Eye and Face Protection

Eye injuries can result from grinding, drilling, compressed air, batteries, chemicals, dust, fluids, and flying particles.

Appropriate eye protection should be worn whenever an eye hazard exists.

Face shields should supplement rather than replace required primary eye protection where both are necessary.

Hearing Conservation — When Applicable

Impact tools, grinders, compressed air, engines, and other shop equipment can generate significant noise.

Employee noise exposure should be evaluated where warranted.

Where applicable, the company’s Hearing Conservation Program should address exposure monitoring, hearing protection, training, and audiometric testing.

Respiratory Protection — When Applicable

Engineering controls and work practices should be used to control airborne hazards where feasible.

Where respirators are required, the company should maintain an applicable Respiratory Protection Program addressing:

• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Cleaning.
• Storage.

Employees should not use required respirators without satisfying applicable program requirements.

Manual Lifting and Material Handling

Automotive employees may lift and move:

• Tires.
• Wheels.
• Batteries.
• Parts.
• Tools.
• Engines.
• Transmissions.
• Drums and containers.

Mechanical assistance should be used where practical for heavy or awkward loads.

Employees should obtain assistance when a load cannot be safely handled alone.

Ergonomics

Automotive work can involve kneeling, reaching overhead, bending into engine compartments, working beneath vehicles, repetitive tool use, and handling heavy components.

Ergonomic controls may include:

• Vehicle positioning.
• Lift adjustment.
• Mechanical lifting devices.
• Creepers and stools.
• Tool selection.
• Improved work height.
• Task planning.

Employees should report recurring discomfort or ergonomic concerns.

Shop Housekeeping

Automotive shops can quickly accumulate tools, parts, hoses, cords, fluids, packaging, and waste.

Work areas should be kept orderly.

Employees should:

• Clean spills promptly.
• Store tools.
• Route hoses and cords safely.
• Remove waste.
• Maintain clear aisles.
• Keep exits and fire equipment accessible.

Good housekeeping helps prevent slips, trips, fires, and vehicle movement hazards.

Walking-Working Surfaces

Floors and other walking-working surfaces should be maintained in safe condition.

Employees should report:

• Oil.
• Grease.
• Coolant.
• Water.
• Damaged flooring.
• Obstructions.
• Poor lighting.

Temporary hazards should be controlled until corrected.

Slips, Trips and Falls

Common automotive shop trip and slip hazards include:

• Air hoses.
• Electrical cords.
• Creepers.
• Tools.
• Parts.
• Oil.
• Coolant.
• Water.

Employees should maintain clear travel paths and clean up spills promptly.

Electrical Safety

Employees should inspect portable electrical equipment and cords and report damage.

Electrical equipment should be suitable for the environment in which it is used.

Employees should not perform electrical work beyond their training and authorization.

Lockout/Tagout — When Applicable

Automotive shops may contain equipment subject to hazardous-energy control requirements during servicing or maintenance.

Examples may include:

• Shop machinery.
• Compressors.
• Vehicle-washing equipment.
• Parts-cleaning systems.
• Mechanical equipment.
• Other powered shop equipment.

Applicable energy-control procedures should be followed before covered servicing work begins.

Fire Prevention

Automotive shops may contain fuels, oils, solvents, welding operations, batteries, electrical equipment, and other potential fire hazards.

Fire-prevention procedures should address:

• Ignition-source control.
• Flammable-liquid storage.
• Hot work.
• Housekeeping.
• Battery charging.
• Electrical equipment.
• Fire extinguishers.
• Emergency exits.

Employees should know how to report a fire and follow the shop’s emergency procedures.

Emergency Action Plan

Automotive repair businesses should establish emergency procedures appropriate to their operations.

Potential emergencies may include:

• Fire.
• Serious injury.
• Chemical release.
• Fuel spill.
• Vehicle incident.
• Severe weather.
• Medical emergency.

Employees should understand alarm systems, evacuation procedures, emergency contacts, and assembly locations.

First Aid

First-aid supplies should be readily available according to workplace hazards and applicable requirements.

Employees should know how to obtain emergency medical assistance.

Emergency washing facilities should be provided where required by corrosive chemical exposures.

Bloodborne Pathogens — When Applicable

Automotive employees may occasionally encounter blood following vehicle accidents, workplace injuries, or contaminated vehicles.

Where employees have reasonably anticipated occupational exposure, applicable Bloodborne Pathogens requirements should be addressed.

Other employees should understand procedures for avoiding and reporting unexpected biological contamination.

Driving and Road Testing

Employees may drive customer vehicles for diagnosis, verification of repairs, delivery, or road testing.

Drivers should:

• Be appropriately licensed and authorized.
• Wear seat belts.
• Avoid distracted driving.
• Obey traffic laws.
• Adjust mirrors and controls before driving.
• Evaluate obvious vehicle safety concerns.

Vehicles should not be road tested when a known defect makes driving unsafe.

Customer and Visitor Safety

Customers and visitors should be restricted from hazardous service areas unless appropriately authorized and escorted.

Controls may include:

• Signs.
• Barriers.
• Designated waiting areas.
• Marked walkways.
• Employee escorts.

Customers should not stand beneath raised vehicles or enter active repair areas unnecessarily.

Auto Body and Refinishing — When Applicable

Automotive businesses performing collision repair, sanding, body work, spray painting, refinishing, or similar operations may have significant additional hazards.

These can include:

• Paints and coatings.
• Isocyanates.
• Solvents.
• Sanding dust.
• Spray operations.
• Respiratory hazards.
• Welding and cutting.
• Fire and explosion hazards.

Businesses performing substantial collision repair or refinishing should maintain safety programs appropriate to those specialized operations.

Automotive Repair Safety Training

Employees should receive training appropriate to their assigned work and hazards.

Training may include:

• Automotive lift safety.
• Jack and jack-stand safety.
• Tire servicing.
• Brake and clutch procedures.
• Battery safety.
• Hybrid and EV safety.
• Hand and power tools.
• Chemical safety.
• PPE.
• Welding and hot work.
• Emergency procedures.

Employees should receive required training before performing tasks requiring specific knowledge, qualification, or authorization.

New and Short-Service Employees

New and inexperienced automotive employees may be unfamiliar with shop equipment, procedures, vehicle hazards, and chemical exposures.

Orientation should address applicable hazards before employees begin work.

New employees should not operate lifts, tire equipment, welding equipment, or other specialized equipment until required instruction and authorization have been completed.

Supervision should reflect the employee’s experience and familiarity with the work.

Automotive Repair JSA/JHA

JSAs/JHAs can be developed for recurring or higher-hazard automotive tasks.

Useful topics may include:

• Automotive lift operation.
• Raising vehicles with jacks.
• Tire servicing.
• Battery replacement.
• Brake service.
• Hybrid and EV servicing.
• Fuel-system work.
• Welding and cutting.
• Engine or transmission removal.
• Road testing.

The JSA/JHA should reflect the actual vehicle, equipment, task, and shop conditions.

Automotive Toolbox Talks

Short safety meetings can reinforce hazards associated with current shop operations.

Useful topics may include:

• Automotive lifts.
• Jack stands.
• Tire inflation.
• Battery safety.
• Brake dust.
• Hand tools.
• Grinding.
• Chemical safety.
• PPE.
• Housekeeping.
• Vehicle exhaust.
• Fire prevention.

Toolbox talks supplement formal training but should not replace training required for specialized equipment or hazardous tasks.

Additional Automotive Safety Programs

Depending on the services performed, equipment used, and employee exposures, additional programs may include:

• Asbestos Awareness.
• Battery Safety.
• Bloodborne Pathogens.
• Chemical Safety.
• Compressed Air Safety.
• Compressed Gas Cylinders.
• Driving and Fleet Safety.
• Electrical Safety.
• Emergency Action Plan.
• Ergonomics.
• Fire Prevention.
• First Aid.
• Flammable and Combustible Liquids.
• Hand and Power Tools.
• Hazard Communication.
• Hazardous Waste Management.
• Hearing Conservation.
• Lockout/Tagout.
• Machine Guarding.
• Manual Lifting and Material Handling.
• Personal Protective Equipment.
• Respiratory Protection.
• Spill Prevention and Response.
• Slips, Trips and Falls.
• Vehicle Maintenance Safety.
• Welding, Cutting and Hot Work.
• Walking-Working Surfaces.

Programs should be selected according to actual operations rather than automatically included simply because a company performs automotive repair.

Building an Automotive Repair Safety Manual

The most useful Automotive Repair Safety Manual is based on the services employees actually perform.

Consider whether employees:

• Operate automotive lifts.
• Use jacks and jack stands.
• Service tires.
• Repair brakes and clutches.
• Service batteries.
• Work on hybrid or electric vehicles.
• Repair fuel systems.
• Operate engines indoors.
• Use pneumatic and power tools.
• Weld, cut, or grind.
• Handle compressed gases.
• Use hazardous chemicals.
• Handle used oil and waste fluids.
• Road test vehicles.
• Perform collision repair or refinishing.

These activities help determine which individual safety programs should be included.

A small general repair shop should not receive a manual filled with specialized programs for spray refinishing or high-voltage EV repair if those operations are not performed. Likewise, a large dealership or full-service repair facility may require numerous specialized programs in addition to core workplace safety procedures.

Customized Automotive Repair Safety Manuals

Companies can request a customized Automotive Repair Safety Manual containing programs selected according to the vehicles serviced, repair operations, shop equipment, chemicals, and employee exposures.

Manuals can be developed for independent auto repair shops, dealership service departments, fleet-maintenance facilities, tire shops, mechanical repair businesses, specialty automotive shops, and other vehicle-service operations.

Applicable programs can be selected for automotive lifts, jacks, tire service, batteries, brake and clutch work, hybrid and electric vehicles, tools, welding, chemicals, PPE, fire prevention, vehicle movement, and other automotive repair hazards.

Individual safety programs can also be selected when a company needs to add or update a particular program within an existing safety manual.