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Chapter 06: Introduction

Site: CDX Learning Systems
Course: DE Section 2-1: Engine Blocks and Cylinder Heads
Book: Chapter 06: Introduction
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Date: Thursday, 5 November 2026, 7:45 PM

Table of contents

1. Learning Objectives

Shop Safety and Workplace Practices

 

 
  LEARNING OBJECTIVES (LO)  
 

After studying this chapter, you should be able to:

LO 6-1 Identify and describe the major safety hazards associated with engine service and maintenance.

LO 6-2 Explain the purpose of lockout/tagout procedures and regulations associated with the release of hazardous energy.

LO 6-3 Identify and describe the safety hazards associated with high-voltage chassis systems and outline control practices.

LO 6-4 Identify and describe the hazards associated with exhaust emissions and outline control practices.

LO 6-5 Identify and describe the hazards associated with engines as ignition sources and outline control practices.

LO 6-6 Identify and describe the hazards associated with rotating components and outline control practices.

LO 6-7 Outline and describe the legal responsibilities of employees and employers relating to safe working practices.

LO 6-8 Describe the purpose and use of common personal protective equipment associated with engine service.

LO 6-9 Describe the various types of fire suppression systems and explain their use.

LO 6-10 Identify and describe clean care practices.

  
 

 

 
  YOU ARE THE AUTOMOTIVE TECHNICIAN  
 

For a co-op work term placement, you are expected to work at a major fleet maintenance shop servicing over 300 medium- and heavy-duty (HD) tractors and straight trucks. As part of a work term report, you are expected to outline the scope of training and skills development you received through this work experience. In preparation for writing the report, identify your expectations for safety-related skills training and include the following explanations in your answers:

  1. When is safety training expected to begin after you arrive at the facility for work?
  2. Who do you expect will identify the personal protective equipment (PPE) you need?
  3. Create a list of safety hazards you expect to encounter at the facility in bullet form and explain how those hazards are controlled.
  
 

 

©2026 - CDX

1.1. Introduction

Shop Safety and Workplace Practices

 

Introduction

Mechanics in general have above-average death and injury rates compared to all other professions, according to U.S. labor statistics. The importance of identifying potential workplace hazards, and rigorously adopting safety practices to control or avoid hazards, is a matter of life and death. This learning curve is particularly steep for novice workers in an industry where they are reported to be three times more likely to be injured in their first year on the job. According to data from the U.S. Bureau of Labor Statistics, a disproportionate one-third share of nonfatal occupational injuries involving lost work time was encountered by workers with less than 1 year of service. This data, generalized across all occupations, does not capture the increased likelihood of death and injury to apprentices or new workers in skilled trades exposed to many more work hazards involved in servicing heavy vehicles. These threats should not overshadow the value of the work or job satisfaction from careers working in shops maintaining and servicing medium-duty (MD) and HD commercial vehicles. Behind these grim statistics are stories of injuries and accidents that were avoidable with proper training, supervision, correct use of PPE, and personal awareness. Compared to many other workplaces, working in a commercial vehicle repair facility requires greater vigilance and adoption of a larger number of work practices to prevent unique safety hazards from causing life-threatening events. With increased job experience, the likelihood of injury from risks associated with workplace hazards sharply declines.

There are work practices that apply specifically to engine work to prevent injuries to technicians and to protect customers’ vehicles and equipment, including practices that enhance the durability and effectiveness of service work. Many of these engine-specific work habits fall under the topic of clean care practices that are performed to prevent contaminant entry (during service work) into the engine and fuel systems resulting in premature failure and excessive wear Figure 1.

Servicing hybrid and battery electric vehicles presents relatively new hazards in the workplace. With almost no moving parts, the powertrains of high-voltage propulsion systems store large amounts of electrical energy in batteries or generate it through traction motors and have few visible or audible warnings of potential danger. As the number of these vehicles increases, technicians need to quickly become very familiar with safe work practices associated with the presence of these vehicles in the shop. To help technicians develop the skills related to safety and workplace practices associated with engine service and maintenance in commercial vehicles, this chapter surveys important safety-related topics. This chapter supplements other safety information covered in more detail in Fundamentals of Medium/Heavy Duty Commercial Vehicle Systems, Second Edition.

   Fig06_1

FIGURE 06-1: A rebuilt transit bus engine ready for installation. Note the clean shop floor and the sealing of lines and hoses to prevent the entry of contaminants.

 

©2026 - CDX