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Instructions for labor protection during vehicle maintenance. Full document

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

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 work that is subject to increased safety requirements - a 20-hour program);
• electrical safety training in the workplace.

Persons who have completed training under a special program and have a certificate of qualification, who do not have medical contraindications for this profession, are allowed to perform the duties of vehicle maintenance personnel.

1.2. Vehicle maintenance personnel must:

• repeated briefing on labor safety at the workplace at least every three 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);
• dispensary medical examination according to the order of the Ministry of Health of Ukraine.

1.3. Vehicle maintenance personnel must:

• comply with the internal labor regulations established at the enterprise;
• 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 labor protection in 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 the assigned work and not transfer it to others without the permission of the foreman or head of the workshop;
• 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. Vehicle 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.

1.7. If any malfunctions of equipment, fixtures, tools and other shortcomings or hazards are found in the workplace, immediately inform the foreman or head of the workshop. You can start work only with their permission after the elimination of all deficiencies.

1.8. If a fire is detected or in the event of a fire:

• turn off the equipment;
• inform the fire brigade and administration;
• start extinguishing the fire with the primary fire extinguishing equipment available in the workshop in accordance with the fire safety instructions.

If there is a threat to life, leave the premises.

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

1.10 During vehicle maintenance, personnel may be exposed to the following production hazards:

• posted car or its units;
• hot water and steam;
• flammable substances;
• toxic gases;
• leaded gasoline;
• equipment, tools, fixtures;
• personnel falling as a result of their careless actions when leaving the cabin and moving around the territory.
• collision and collision with people by intrashop transport;
• hot engine surfaces, cooling systems.

1.11 For failure to comply with the safety requirements set forth in this manual, the worker is liable in accordance with applicable law

1.12. In accordance with the "Norms for the free issuance of personal protective equipment to workers and employees", personnel during vehicle maintenance must use PPE: a cotton suit, combined gloves, leather boots, goggles.

When working with leaded gasoline additionally: rubberized apron, rubber gloves.

For outdoor work in winter, additionally: a cotton jacket with an insulating lining, cotton trousers with an insulating lining.

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

• to the place of work and from work to pass only by specially established routes, marked with signs "Service Passage";
• 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.

2. Safety requirements before starting work

2.1. Make sure that it is in good condition and put on special clothes, fasten it with all buttons, put your hair under a headdress.

2.2. Check whether the aisles and the workplace are blocked by foreign objects. 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.

2.3. Cars sent to maintenance and repair posts must be washed, cleaned of dirt and snow. Putting cars on the posts of technical maintenance repair is carried out under the guidance of a responsible person.

2.4. After setting the car to the post, it is necessary to slow it down with a parking brake, turn off the ignition, set the gear lever to neutral position, put at least 2 special shoes under the wheels.

2.5. A sign should be hung on the steering wheel with the inscription "Do not start the engine - people are working." On vehicles with a backup device for starting the engine, a similar plate must be posted for this device.

2.6. 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.

2.7. If it is necessary to perform work under the car, outside the inspection ditch, lift, overpass, workers must be provided with sunbeds.

2.8. The surface of the workbench should be smooth, upholstered with sheet steel. Safety nets or shields at least 1 meter high must be installed on the workbench.

2.9. Check the necessary tools and fixtures for the job and make sure they are in good condition. Remove defective tools and devices from the workplace. Carry the working tool in a special bag or box.

2.10. It is possible to start the average and major repairs of the car only after the release of gas tanks and gasoline pipelines from gasoline residues.

2.11. Familiarize yourself with the upcoming work, think over the order of its implementation.

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. Inspection ditches and overpasses must have flanges.

2.16. Cars running on gas fuels can enter the maintenance and repair posts only after they have been switched 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.

2.19. Before the delivery of vehicles running on gas fuel for overhaul, the gas from the cylinders must be completely drained, and the cylinders themselves degassed. If necessary, cylinders together with gas equipment can be removed and handed over for storage to a warehouse.

3. Safety requirements during work

3.1. When performing maintenance operations requiring engine operation, 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 fix the car on it, drain the fuel from the fuel tanks and liquid from the cooling system and fuel from the fuel tanks, liquid from the cooling system and other systems, tightly close the engine oil filler neck and remove the battery.

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

3.4. Before working with lifting devices (hoists), check their serviceability and make sure that the brake, slings and chain are reliable by lifting the load to a small height.

3.5. When repairing or maintaining a car, hang a sign on the steering wheel: "Do not start the engine! People are working!"

3.6. When repairing, put the car on the trestle and make sure that they are securely installed. When working under the car outside the inspection ditch, overpass or lift, use sunbeds.

3.7. Carry out all repair or maintenance work on the vehicle with the engine stopped, with the exception of adjusting the carburetor, checking the electrical equipment and the brake system.

3.8. When lifting the car, place the jack 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 car only after installing it on the tragus.

3.9. It is possible to drain oil and water from vehicle units only into a special container.

3.10. When performing welding work on a car and near it, close the gas tanks with asbestos covers.

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

3.12. For safety reasons, when placing the car at the service station or repairing the car, brake the car using the parking brake system and turn on the first gear, turn off the ignition, place at least two special stops (wedges, shoes) under the wheels.

3.13. 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.

3.14. When working with an electric hoist, follow the labor protection instructions for persons using floor-operated hoisting machines and having a certificate.

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

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

3.17. Before performing work related to turning the crankshaft and cardan shaft, check whether the ignition and fuel supply are turned off (for diesel vehicles), put the gear lever in neutral position, and release the parking brake system. After completing the work, tighten the parking brake lever and engage first gear again.

3.18. It is forbidden:

• work lying on the floor (ground) without a lounger;
• perform any work on a car hung out only on one lifting mechanism, except for stationary ones;
• put wheel rims, bricks and other random objects under the posted car 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 the car 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 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, as well as with faulty tools and fixtures;
• 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;
• carry out repair work under the raised body of a dump truck without first releasing it from the load;
• rotate the cardan shaft with a crowbar or mounting blade;
• blow off dust and sawdust with compressed air.

3.19. During the repair and maintenance of buses and trucks, workers must be provided with scaffolds and ladders. Ladders are not allowed.

3.20. 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.

3.21. 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.

3.22. 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.

3.23. 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.

3.24. When repairing and maintaining vehicles with a high body, use ladders with steps at least 150 mm wide.

3.25. Before repairing a car installed on an inspection ditch, you must:

• check the correct location of the wheels in relation to the guides;
• put the car on the brakes and place spacer pads under the wheels;
• make sure that there is free access to the ditch, that the floor grate in the ditch is in good condition.

3.26. While in the inspection ditch, inspect and repair the car in protective glasses.

3.27. Tighten the fan belt, check the fastening of the water pump and tighten the oil seals only when the engine is stopped.

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

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

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

3.31. It is forbidden:

• 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.

3.32. Work at diagnostic and other posts with a running engine is allowed with local exhaust ventilation turned on.

3.33. 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.

3.34. Replace the springs only after unloading them and placing the car on stands

3.35. Before inflating tires after mounting them on the wheel, make sure that the locking ring is installed in the groove of the disc. In order to avoid injury from a flying disc, the wheel should be inflated with a safety fork or in a special cage.

3.36. When replacing axles and springs, place special stands under the raised end of the frame.

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

3.38. Avoid spilling fuel and lubricants (gasoline, diesel fuel, oil, grease, etc.). Drain water and oil only into a special container, preventing them from spilling onto the floor.

3.39. To drive the car to the parking lot and check the brakes on the go, call the duty or main driver of the car.

4. Safety requirements in emergency situations

4.1. In case of loss of stability of the units and assemblies of vehicles during repair work, they should be stopped and the foreman or work manager should be informed about the incident. After that, locksmiths must take part in preventing arbitrary movement of machine parts.

4.2. In the event of a fire, it is necessary to stop work, take part in extinguishing the fire (with fire extinguishers, asbestos blankets, sand or a strong stream of water), and if it is impossible to eliminate the fire, call the fire brigade by phone 01 and notify the management.

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 components from the car to a special workshop for verification.

5. Safety requirements at the end of work

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

4.2. Check the reliability of the installation of the car on the trestle. It is not allowed to leave the car raised by a jack.

4.3. Inform the foreman or foreman about the work performed, the shortcomings noticed that were identified in the process of work.

4.4. Remove and put special clothes in the closet, wash hands and face with soap and water, take a shower. Do not use chemicals for washing.

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