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Instructions on labor protection during the maintenance of machines and mechanisms. Full Document

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

Introduction

This instruction has been developed on the basis of a standard labor protection instruction for personnel during vehicle maintenance, labor protection instructions for personnel servicing tractors and mechanisms.

This instruction applies to all specialist employees performing service work, maintenance of machines and mechanisms, their repair, testing and commissioning.

1. General safety requirements

1.1. Persons at least 18 years of age who have passed:

• induction training;
• fire safety briefing;
• initial briefing at the workplace;
• training in safe working methods and techniques for at least a 10-hour program (for jobs that are subject to increased safety requirements);
• electrical safety training.

1.2. During the maintenance of machines and mechanisms, personnel must undergo:

• repeated briefing on labor safety at the workplace at least once every six months;
• unscheduled and targeted briefings when changing the technological process or labor protection rules, replacing or modernizing production equipment, fixtures and tools, changing working conditions and organization, in case of violations of labor protection instructions, breaks in work for more than 60 calendar days (for work, which are subject to increased security requirements - 30 calendar days);
• medical examination once a year.

1.3. Maintenance personnel must:

• comply with the internal labor regulations established at the enterprise where the work is carried out and the personnel manual of Vostochnaya Tekhnika LLC;
• comply with the requirements of this manual, fire safety instructions, electrical safety instructions;
• comply with the requirements for the operation of equipment;
• comply with the rules on road transport;
• use for its intended purpose and take care of the issued personal protective equipment;
• be able to provide first (pre-medical) assistance to the victim in an accident;
• know the location of first aid, primary fire extinguishing equipment, main and emergency exits, evacuation routes in case of an accident or fire;
• perform only assigned work and not transfer it to other persons;
• during work, be attentive, not be distracted and not distract others, do not allow persons who are not related to work to the workplace;
• keep the workplace clean and tidy;
• comply with the requirements of prohibiting, warning, prescriptive signs, inscriptions and signals;
• pass through the territory to the place of work along established routes, footpaths, walkways, crossings;
• be extremely careful in traffic areas.

1.4. Maintenance personnel must know and follow the rules of personal hygiene. Eat, smoke, rest only in specially designated areas and places. Drink water only from specially designed installations.

1.5. In carrying out their duties, employees must comply with the following requirements:

• walk only along the established passages, bridges and platforms;
• do not sit down or lean on random objects and fences;
• do not run up and down stairs and walkways;
• do not touch electrical wires, cables of electrical installations;
• do not eliminate malfunctions in the lighting and power networks, as well as starting devices;
• stay out of the reach of lifting machines.

1.6. When moving around the territory, the following requirements must be observed:

• walk on footpaths;
• cross railroad tracks and highways in designated places;
• when leaving the building, make sure that there is no moving traffic;
• follow the instructions for personnel when moving around the territory and production facilities of the company.

1.7. During maintenance, personnel may be exposed to the following production hazardous and harmful factors:

• posted car, machine, tractor, mechanism or its units;
• hot water, steam, coolant;
• flammable substances;
• toxic gases;
• rough surface of equipment, tools, fixtures;
• moving machines mechanisms;
• collision and collision with people by intrashop transport;
• hot surfaces of the engine, cooling systems, exhaust systems, equipment;
• low ambient air temperature;
• insufficient illumination of the working area;
• increased air movement;
• voltage in the electrical circuit.

1.8. Maintenance personnel must use personal protective equipment provided by the employer free of charge:

• cotton suit one for one year;
• mittens combined six pairs per year;
• leather boots, one for two years;
• goggles to wear out.

When working with leaded gasoline additionally:

• apron rubberized to wear;
• rubber gloves two pairs for one year.

For outdoor work in winter additionally:

• cotton jacket with insulating lining one for two years;
• cotton trousers with insulating lining one for two years.

1.9. When on the railway tracks, the personnel must comply with the following requirements:

• to the place of work and from work to pass only specially established routes, marked with signs and prescribed in the technological documentation;
• walk along the tracks only on the side of the road;
• cross the tracks only at a right angle, after making sure that there is no moving train in this place;
• cross the track occupied by the rolling stock, using only the brake pads of the wagons, making sure that the handrails, steps are in good condition and that there are no locomotives and wagons moving along the adjacent track;
• when leaving the wagon brake platform, hold on to the handrails and position yourself facing the wagon;
• bypass groups of wagons or a locomotive standing on the way at a distance of at least 5 m from the automatic coupler;
• pay attention to the indications of enclosing traffic lights, sound signals and warning signals.

1.10. For non-compliance with the safety requirements set forth in this instruction, the employee is liable in accordance with the current legislation of the Russian Federation.

2. Safety requirements before starting work

2.1. Put on serviceable special clothes and shoes, fasten it with all buttons, tie it so that there are no hanging ends.

2.2. Check if the aisles and the workplace are cluttered with foreign objects, prepare the workplace for the upcoming work.

2.3. Make sure that the workplace is well lit so that the light will not dazzle your eyes. The voltage of local lighting should not exceed 42 V, and portable electric lamps 12 V.

2.4. Machines, mechanisms sent to maintenance and repair posts must be washed, cleaned of dirt and snow. Arrangement for maintenance and repair posts is carried out under the guidance of a responsible person.

2.5. After placing the equipment on the post, it is necessary to slow it down with a parking brake, turn off the ignition, set the gear lever to the neutral position, put at least 2 shoes specially designed for this type of equipment under the wheels, tracks.

2.6. A sign must be hung in the control cabin with the inscription "People do not start the engine." On mechanisms that have a backup device for starting the engine, a similar plate should be posted near this device.

2.7. Before carrying out work related to turning the crankshaft and cardan shaft, it is necessary to additionally check the ignition is turned off (switching off the fuel supply for diesel vehicles), the neutral position of the gear lever, and release the parking brake lever.

2.8. If it is necessary to perform work under machinery, equipment that is outside the inspection ditch, lift, overpass, workers must be provided with sun loungers.

2.9. Check the necessary tools and fixtures for the job and make sure they are in good condition. It is forbidden to use faulty tools and devices in work. Carry the working tool in a special bag or box.

2.10. It is possible to start medium and major repairs of equipment only after the tanks and wires are freed from fuel residues.

2.11. Get acquainted with the upcoming work, think over the order of its implementation, do not rush.

2.12. Before removing the components and assemblies of the power supply, cooling and lubrication system of the car, when liquid leakage is possible, it is necessary to first drain the fuel, oil and coolant from them into a special container, preventing them from spilling.

2.13. Before starting work with a power tool, check the presence and serviceability of grounding. When working with a power tool with a voltage above 42 V, it is necessary to use protective equipment (rubber gloves, galoshes, rugs, wooden dry racks).

2.14. Before using a portable lamp, it is necessary to check whether there is a protective grid on the lamp, whether the cable and its insulation are in good condition.

2.15. Inspection ditches, trenches and tunnels must be kept clean, not cluttered with details and various objects. Sturdy wooden gratings should be installed on the floor of the ditch.

2.16. Equipment running on gas fuel can enter the maintenance and repair posts only after they switch to work on gasoline.

2.17. Before entering, it is necessary to check the gas supply system for leaks at a special post.

2.18. The gas from the cylinders of a car on which welding, painting work is to be carried out related to the elimination of malfunctions of the gas system or its supply or its removal must first be completely drained in a specially designated place, and the cylinders must be purged with compressed air, nitrogen or other inert gas.

3. Safety requirements during work

3.1. When performing maintenance operations that require the operation of the engine, the exhaust pipe must be connected to the exhaust ventilation, and in its absence, measures must be taken to remove exhaust gases from the room.

3.2. When working on a turntable (tilter), it is necessary to first securely fasten the equipment on it, drain the fuel from the fuel tanks, liquid from the cooling system, liquids from other systems, tightly close the engine oil filler neck and remove the battery.

3.3. When hanging a piece of equipment with lifting mechanisms (jacks, hoists), except for stationary ones, you must first put special stops under the non-lifting wheels, tracks, then hang the transport, put the tragus under the hung part and lower the transport on them.

3.4. Before working with lifting devices (hoists), check their serviceability, make sure that the brake is reliable, that the sling and chain are reliable, lifting the load to a small height of not more than 0,3 m.

3.5. All work on repair or maintenance of equipment should be carried out with the engine stopped, with the exception of work requiring engine operation, checking electrical equipment and the brake system.

3.6. When lifting equipment, the jack must be placed on a solid and stable wooden lining. The height of its rise must correspond to the required height of the vehicle and its components. You can work under the equipment only after installing it on the tragus.

3.7. It is possible to drain oil and water from the vehicle units only into a special container, taking special care to prevent liquids from getting into the eyes and onto the skin.

3.8. When carrying out welding work, it is necessary to comply with the technology of welding production, be guided by the fire safety rules used in this area at this time.

3.9. The body of the dump truck must be pre-strengthened with a stop rod when performing work with the body raised.

3.10. Disassembly and assembly of wheels should be carried out on a stand or on a flat, clean area. It is not allowed to inflate the wheel tires in the safety device, upset the retaining ring at this time with a hammer or sledgehammer.

3.11. When working with an electric hoist, you should follow the labor protection instructions for persons using hoisting machines controlled from the floor and have a certificate for the right to operate these machines, a slinger's certificate.

3.12. When working on drilling, grinding machines, you should follow the labor protection instructions for persons using this equipment and having a certificate.

3.13. Use special clamping devices when replacing, disassembling and assembling springs, springs. Check the alignment of the holes with a beard or mandrel.

3.14. It is forbidden:

• work lying on the floor (ground) without a lounger;
• perform any work on equipment hung only on one lifting mechanism, except for stationary ones;
• put wheel disks, bricks and other random objects under the posted equipment instead of traguses;
• remove and install springs on cars of all designs and types without first unloading them from the mass of the body by hanging the body with the installation of trestles under it or the car frame;
• carry out maintenance and repair of equipment with the engine running, with the exception of certain types of work, the technology of which requires starting the engine;
• lift, hang out the car by the towing devices by grabbing them with cables, a chain or a hook of the lifting mechanism;
• lift loads weighing more than what is indicated on the plate of this lifting mechanism;
• remove, install and transport units when mooring them with a cable or ropes;
• lift the load with an oblique tension of the cable or chains;
• work on faulty equipment, mechanization means, as well as with faulty tools and devices;
• leave the tool and parts at the edges of the inspection ditch;
• work under a raised body of a dump truck, without a special additional stop;
• use random coasters and pads instead of a special stop;
• work with damaged or incorrectly installed stops;
• start the engine and move the car with the body raised;
• rotate the cardan shaft with a crowbar or mounting blade;
• blow off dust and sawdust with compressed air;
• connect the power tool to the network in the absence or malfunction of the plug;
• carry an electric tool by holding it by the cable, as well as touch the rotating parts with your hand before installing them;
• direct a stream of air at yourself or others when working with a pneumatic tool;
• install a gasket between the jaw of the key and the edges of the nuts and bolts, as well as increase the key with other levers.

3.15. During the repair and maintenance of large and high equipment, workers must be provided with scaffolds and ladders. Ladders are not allowed.

3.16. In the area of ​​maintenance and repair of vehicles is prohibited:

• wipe the car and wash the units with flammable liquids;
• store flammable liquids and combustible materials, acids, paints, calcium carbide in quantities greater than replacement needs;
• fill the car with fuel;
• store clean cleaning materials with used ones;
• clutter up the passages between the racks and exits from the premises;
• store used oil, empty containers from fuel and lubricants.

3.17. When carrying out maintenance and repair work on gas-fuelled vehicles, it is necessary:

• raise the hood for ventilation;
• carry out work on the removal, installation and repair of gas equipment only with the help of special devices;
• check the tightness of the gas supply system with nitrogen, compressed air;
• protect gas equipment from pollution and mechanical damage;
• fasten the hoses to the fittings with clamps.

3.18. Adjustment of gas supply system devices directly on the vehicle should be carried out in a separate specially equipped room, isolated from other rooms by partitions.

3.19. When carrying out maintenance and repair of vehicles running on gas fuel, it is prohibited:

• tighten threaded connections and remove parts of gas equipment and gas pipelines under pressure from the car;
• release compressed gas into the atmosphere or drain liquefied gas to the ground;
• twist, flatten and bend hoses and tubes, use oily hoses;
• install handicraft gas pipelines;
• use wire or other objects to fasten the hoses.

3.20. While in the inspection ditch, inspect and repair with protective glasses.

3.21. When working with a pneumatic tool, it is allowed to supply air after the tool is in its working position.

3.22. Pneumatic tool hoses may be connected and disconnected after the air supply has been turned off.

3.23. Blowtorches and pneumatic tools are allowed to be issued to persons who have been instructed and who know the rules for handling them.

3.24. Pressing out and pressing bushings, bearings and other parts with a tight fit is carried out using special tools, presses and hammers with copper strikers.

3.25. When cutting, chasing and similar work, wear protective goggles.

3.26. Avoid spilling fuel and lubricants (gasoline, diesel fuel, oil, grease, etc.).

3.27. Be careful when performing various maintenance and diagnostic operations in hard-to-reach places, as you can injure your hands on the sharp edges of bolts, nuts, cotter pins, and equipment.

3.28. Avoid contact with oil and fuel, as this may cause skin irritation. Remember that it is more difficult to hold the tool in oily hands.

3.29. When diagnosing, removing and installing injectors of diesel engines, determining the quality of atomization of fuel by an injector with a compressionmeter, be careful, as fingers are often injured during these operations, and in the process of diagnosing, beware of fuel getting on your face and body parts.

3.30. When cleaning the battery from dirt, adding electrolyte to it, be careful not to get the electrolyte on the skin to avoid burns.

3.31. When controlling at idle the correct operation of the individual mechanisms of the machine after adjustment operations, make sure that there are no people in the path of its possible movement and the gear lever is in the neutral position.

3.32. During maintenance, lower the attachment to the ground, fix the moving parts of the machines in a fixed position.

3.33. Work must be carried out in safe ways, not in a hurry, think over all upcoming operations, in cases of difficulty in performing the operation, it is necessary to consult with the manager, start work after making a safe decision to perform the work.

4. Safety requirements in emergency situations

4.1. In case of loss of stability of units and assemblies of equipment during repair work, they should be stopped and the cause should be eliminated. If the cause of the loss of stability cannot be eliminated, then measures must be taken to prevent arbitrary movement of parts of the equipment.

4.2. In the event of a fire, it is necessary to stop work, inform the manager and start extinguishing the fire using primary fire extinguishing equipment (fire extinguishers, asbestos blankets, sand), and if it is impossible to eliminate the fire, the fire brigade should be called.

4.3. In case of any malfunction of the high and low pressure reducers, the electromagnetic shut-off valve, it is necessary to close the supply and main valves, and send the faulty units for verification to a special workshop.

4.4. In case of detection of malfunctions of equipment, devices, tools and other shortcomings or hazards in the workplace, immediately inform the manager. You can start work only with their permission after the elimination of all deficiencies.

4.5. In case of an accident, provide the victim with first (pre-medical) aid, immediately report the incident to the manager and the ambulance, take measures to preserve the situation of the incident (equipment condition), if this does not create a danger to others.

5. Safety requirements at the end of work

5.1. Tidy up your workspace. Wipe tools and accessories and put them in the place provided for them.

5.2. Check the reliability of the installation of equipment on the tragus. It is not allowed to leave the equipment raised by the jack.

5.3. Report to the manager about the work performed, the shortcomings noticed that were identified in the process of work.

5.4. Remove and put away special clothes, shoes in a place specially designated for these purposes, wash hands and face with soap and water, take a shower. It is forbidden to use chemicals (gasoline) for washing.

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