Motor Pool and Maintenance

Motor Pool and Maintenance
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Motor Pool and Maintenance Good morning/afternoon. I’m __________________________, the instructor and facilitator for this safety lesson titled Motor Pool and Maintenance Safety. How many of you have worked in a motor pool or maintenance facility or at least visited one? If you have, you realize how dangerous these areas can be in any unit. Soldiers could easily be hurt or killed if procedures are not followed and/or tools are incorrectly used. Although motor pool operations and maintenance areas are dangerous, they are still a necessary part of our military units. Therefore, it is important that these operations are performed more safely and that accident prevention is inherent in all maintenance operations. Safety and Accident Prevention

Maintenance-Related Accidents
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Maintenance-Related Accidents Maintenance-related accidents are responsible for 20 percent of all military on-duty injuries DA PAM 750-1, pg. 24 (6-2) Maintenance-related accidents account for 20 percent of military on-duty injuries. Accidents reduce a unit’s effectiveness, impact adversely on morale and discipline, and degrade operational capabilities. In most cases, the deaths can be attributed to personnel not following standards and not using the required safety equipment or personal protective equipment needed to safely accomplish the mission. Other times, it’s attributed to a failure by leadership to properly train and supervise the individual. Failure to utilize the Composite Risk management process. NOTE: This slide shows an actual accident scene where a Soldier was killed, by a split rim tire, while airing up the tire. The tire was on the vehicle, 50% deflated. The split ring came off the rim and killed the Soldier. There should not be any split-rims left in the Regular Army’s inventory. The Army went to solid rims in Guard and Reserve units might have some in their inventory. (There are two types of vehicles that still have these split rims. HEMMIT, 2 ½ ton and some trailers.) 2

Leaders Safety Course: Motor Pool and Maintenance Facility Safety
References 29 Code of Federal Regulations (CFR) 1910, General Industry Standards AR , The Army Safety Program AR 750-1, Army Material Maintenance Policy DA Pam 750-1, Commanders’ Maintenance Handbook DA Pam 750-3, Soldiers’ Guide for Field Maintenance Operations 29 Code of Federal Regulations (CFR) 1910, General Industry Standards, is the primary source for guidance related to maintenance and shop hazards. This is the standard all federal government facility will follow. DoD and the Army incorporate these standards into their instructions, regulations, and guidance. AR , The Army Safety Program, 23 AUG 07 The AR 750-1, Army Material Maintenance Policy, 20 SEP 07, and DA Pam 750-1, Commander’s Maintenance Handbook, 2 Feb 07, are the primary sources for maintenance shops and motor pools. In addition, DA Pam 750-1, Chapter 2, Provides specific guidance for a unit maintenance program. DA PAM 750-3, Soldiers’ Guide for Field Maintenance Operations, 29 SEP 06 gives guidance that can be applied to any field maintenance operation. 3

Terminal Learning Objective
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Terminal Learning Objective Action: Explain requirements for motor pool and maintenance safety and accident prevention. Conditions: During group discussions regarding motor pool and maintenance operations. Standard: Requirements include responsibilities, standing operating procedures, and safety precautions. 4

Lesson Data Safety Requirements Risk Assessment Environmental Conditions Evaluation Oral questions Participation during class discussions Lesson Data (ensure you inform the students of classroom specifics for each of the following) Safety Requirements: [specific to class location] Risk Assessment: Low [construct Risk Assessment Worksheet] Environmental Conditions [specific to class location] Evaluation Criteria: You will be evaluated based on your participation during class discussions and answers to the Checks-on-Learning. 5

Overview Responsibilities of key maintenance personnel Standing Operating Procedures (SOPs) Precautions for hazards found within or around a motor pool and/or maintenance facility Hazards of specialized equipment and procedures During this block of instruction, we will cover four learning objectives which are: Responsibilities of key personnel regarding maintenance Requirements for maintenance standing operating procedures Precautions for hazards found within or around a motor pool and/or maintenance facility Hazards of specialized equipment and procedures 6

Enabling Learning Objective A
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Enabling Learning Objective A Action: Identify the responsibilities of key maintenance personnel within a unit maintenance program. Conditions: Given the titles of key maintenance personnel Standard: Identification must include a minimum of three responsibilities for each as outlined in AR , AR-750-1, and DA Pam 7

Commander’s Responsibilities
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Commander’s Responsibilities As an Army leader, commander’s responsibilities include: Protecting personnel, equipment, and facilities Establishing accountability for safety and occupational health Implementing safety and occupational health policies AR , paragraph 1-5 c, identifies responsibilities for all leaders. It includes responsibilities such as: Protect personnel, equipment, and facilities under their commands. Establish accountability for safety and occupational health through the performance evaluation system and performance counseling sessions. Implement safety and occupational health policies. 8

Commander’s Responsibilities
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Commander’s Responsibilities Continued Commander’s responsibilities also include: Integrating Composite Risk Management (CRM) process into mission activities Emphasizing the importance of safety and maintenance Continued AR , paragraph 1-5 c, also includes: Integrating CRM into their mission activities. AR 750–1, paragraph 2-17c Emphasize the importance of safety and maintenance and ensure that subordinates are held accountable for the conduct of maintenance operations 9

Safety Officer/NCO Responsibilities
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Safety Officer/NCO Responsibilities Responsibilities include: Serving as principal advisor to the commander in all safety / occupational health related matters related to mission Advising and assisting the commander in ensuring CRM is an integral part of the unit’s operations and training Assisting with hazard identification and assessment tools AR , paragraph 1-5d. Safety director (officer) and safety staff. The safety director (officer) and safety staff will— (1) Serve as principal advisor to the commander in all safety and occupational health related matters of mission execution pertaining to this regulation, safety and occupational health regulatory and statutory requirements. (2) Execute the commander’s safety and occupational health program. (3) Communicate best practices and share lessons learned. DA Pam 385-1, Small Unit Safety Officer/NCO Guide, 10 November 2008, paragraphs 3-1 & 3-4 It is the responsibility of the ADSO/NCO to advise and assist the commander in ensuring CRM is an integral part of the unit’s operations and training. The ADSO/NCO plays a key role in all phases of the CRM process, advising the commander on hazards, risks, and controls associated with the mission. Additionally, the ADSO/NCO does his or her best to ensure that CRM is integrated into unit planning, processes, and procedures and assists in developing hazard identification and assessment tools tailored for the unit mission. 10

Supervisor’s Responsibilities
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Supervisor’s Responsibilities A supervisor’s responsibilities include: Maintaining a safe and healthful workplace Inspecting the work area for hazards Using CRM during planning, preparation, and execution of all operations Preventing accidents AR , paragraph 1-5 c, identifies responsibilities for supervisors. It includes responsibilities such as: (1) Maintain a safe and healthful workplace. (2) Inspect the work area for hazards. (4) Be responsible for use of CRM during planning, preparation, and execution of all operations. (5) Be responsible for accident prevention to the same extent that they are responsible for production, service, and mission accomplishment. 11

Supervisor’s Responsibilities
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Supervisor’s Responsibilities Continued A supervisor’s responsibilities also include: Attending, leading, and supervising preventive maintenance operations Checking and updating SOPs Enforcing Army Maintenance Standards Training operators and crews to operate equipment and perform PMCS properly Enforcing safety DA PAM 750-1, paragraph 2–6, includes: The unit’s supervisors provide the leadership link to the operators and crews and support the achievement of the Army Maintenance Standard by— a. Attending, leading, and supervising preventive maintenance operations. b. Checking and updating SOPs. c. Enforcing the Army Maintenance Standard for the equipment for which they are responsible and ensuring that the desired sense of “ownership” applies to subordinate supervisors, leaders, crews, and operators/users. d. Training operators and crews to operate equipment and perform PMCS properly. e. Enforcing safety. 12

Operators’ and Crews’ Responsibilities
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Operators’ and Crews’ Responsibilities Operator and crew responsibilities include: Detecting and reporting malfunctions Operating equipment properly and safely Knowing their responsibility in achieving the Army Maintenance Standard Performing Preventive Maintenance Checks and Services (PMCS) DA Pam 750-1, paragraph 2–5, states: To have a successful unit maintenance program that supports mission accomplishment, leaders must start with their operators and crews. Operators and crews must know how to detect and report malfunctions as well as operate equipment properly and safely. An atmosphere of pride and “ownership” of equipment on the part of operators and crews enables that to happen. A disciplined routine and self-motivated pursuit of excellence help to ensure operators and crews perform PMCS to achieve the Army Maintenance Standard. Let’s talk more about PMCS 13

Performing PMCS Cornerstone of the Army Maintenance System Required by all printed, electronic, and interactive electronic technical manuals (TM) Must be performed from the applicable TM Faults detected that violate a safety directive must be corrected AR 750-1, paragraph 3-9 – Operator/crew performing PMCS from the applicable TM XX–10 series is the cornerstone of the Army Maintenance System NOTE: DA Pam 750-1, paragraph 1-10: a. Observation by the equipment operator or user of equipment performance and condition is necessary for an Army maintenance program. Observation of equipment performance and condition is the basis of the Army PMCS. Utilization of PMCS is crucial to the success of unit maintenance operations and is required by all printed equipment TMs, electronic technical manuals (ETMs), and interactive electronic technical manuals (IETMs) for the before, during, and after equipment operation checks. Through observation, an operator compares equipment performance and condition against an established technical standard and reports problems before they become catastrophic. The operation and maintenance standards found in the TM XX–10 and TM XX–20 series specify the technical standards that apply to all Army equipment. 14

Enabling Learning Objective B
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Enabling Learning Objective B Action: Describe the requirements for maintenance standing operating procedures (SOPs). Conditions: During group discussions. Standard: Requirements must include the description for the need of SOPs and at least 10 areas that should be addressed in detail as specified in DA Pam DA Pam 750-3, Soldiers’ Guide for Field Maintenance Operations Let’s look at the need for SOPs 15

Why have a Maintenance Standing Operating Procedure (SOP)?
Required by AR which states: “SOPs will be established and maintained by all Army organizations and activities performing maintenance operations.” Purpose To formally describe the way a unit performs maintenance AR 750-1, paragraph 3–7b states: “Standing operating procedures will be established and maintained by all Army organizations and activities performing maintenance operations.” DA Pam 750–3, paragraph 2–2 states the purpose.

Motor Pool and Shop Safety SOPs
DA Pam specifies Every unit SOP will address safety Motor pool operations and field maintenance are linked with safety DA Pam 750–3, paragraph 2–4 and 2-5

Minimum Areas to Address in SOP
Duties/responsibilities for key unit personnel How the maintenance platoon is organized The Army Maintenance Management System (TAMMS) information not covered in DA Pam 750-8 DA PAM 750–3, paragraph 2–3 describes the minimum required areas to address in standing operating procedures As a minimum, the following areas [17 areas from a through q] of the SOP should be addressed in detail: a. Maintenance related duties and responsibilities for key unit personnel. b. How the unit’s (or FSC’s) field maintenance platoon/section is organized. c. The Army Maintenance Management System (TAMMS) (Note: This addresses minor deviations or procedures not covered in DA Pamphlet 750–8). 18

Continued Preventive maintenance checks and services (PMCS) Procedures for scheduled Field PMCS Army Oil Analysis Program (AOAP) Calibration of tools and Test, Measurement, and Diagnostic Equipment (TMDE) DA PAM 750–3, paragraph 2–3 describes the minimum required areas to address in standing operating procedures (continued) d. Preventive maintenance checks and services (PMCS) are as follows: (1) Procedures to be followed by personnel during scheduled Field PMCS periods (2) Procedures to be followed by all unit personnel associated with Field PMCS (scheduled services). (3) Army Oil Analysis Program (AOAP). (4) Calibration of tools and Test, Measurement, and Diagnostic Equipment (TMDE). 19

Continued Tool accountability and control procedures Safety requirements to include: All applicable safety guidance associated with equipment maintenance HAZMAT and PPE Lifting and holding device servicing Chemical Agent Resistant Coating (CARC) DA PAM 750–3, paragraph 2–3 describes the minimum required areas to address in standing operating procedures (continued) e. Tool accountability and control procedures. f. Safety requirements as follows: (1) All applicable safety guidance associated with equipment maintenance. (2) SOP/SOUM. (3) Environmental/proper handling and disposal of hazardous chemicals (HAZMAT). (required PPE) (4) Lifting and holding device servicing. (5) Arc welding/cutting. (6) Chemical Agent Resistant Coating (CARC). 20

Continued Unit maintenance training programs and requirements Motor pool security Readiness reporting Publications Work order management DA PAM 750–3, paragraph 2–3 describes the minimum required areas to address in standing operating procedures (continued) g. Unit maintenance training as follows: The unit’s program for operator/crew and mechanic sustainment training. (Training for operator/crew, mechanic on complicated and dangerous tasks). (2) Procedures required to obtain a Government equipment operator’s license (DA Form 5984–E (Operator’s Permit Record)/OF 346 (U.S. Government Motor Vehicles Operator’s Identification Card)). (3) The unit driver/mechanic awards program. (4) Single-/multi-piece rims and wheels training. h. Motor pool security i. Readiness reporting. j. Publications. k. Work order management 21

Continued Equipment classifications Battlefield damage assessment and repair/recovery (BDAR/R) Repair parts (Class IX) management Warranty Management Program DA PAM 750–3, paragraph 2–3 describes the minimum required areas to address in standing operating procedures (continued) l. Equipment classifications m. Battlefield damage assessment and repair/recovery (BDAR/R) n. Repair parts (Class IX) management as follows: (1) Product Quality Deficiency Report (QDR) preparation/reporting. (2) Involvement in equipment dispatch, scheduled services, command inspections. (3) Development of Shop Supply List (SSL)/Authorized Stockage List (ASL). (4) Battery management program. (5) Recoverables management. (6) Scrap material management (non-HAZMAT). (7) Tire/track/road/wheel management. o. Warranty Management Program. 22

Continued Army Record Information Management System (ARIMS) filing system Equipment winterization/extreme climate program DA PAM 750–3, paragraph 2–3 describes the minimum required areas to address in standing operating procedures (continued) p. Army Record Information Management System (ARIMS) filing system. q. Equipment winterization/extreme climate program 23

SOP Development Considerations
Maintenance Operations Safety and protection plans such as: Fire Prevention Plan Ground Pre-accident Plan Past accidents Lessons learned Preventive measures To develop or revise an SOP, you may start by reviewing maintenance operations to determine information to add to the SOP. Then review the protection plans that must be in place and ask questions such as: What information needs to be added to the SOP? What safety plans should practiced with drills and how often? Review past accident that happened in the unit, Are they maintenance related? What lessons learned can be gleaned from reviewing the accidents? Look at preventive measures. 24

Motor Pool and Shop Safety Sample SOPs
Army Knowledge Online (AKO) U.S. Army Combat Readiness/Safety Center DA Pam 750–3, paragraph 2–5

Enabling Learning Objective C
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Enabling Learning Objective C Action: Recommend precautions for hazards found within or around a motor pool and/or maintenance facility. Condition: During group discussions and viewing photographs of maintenance areas. Standard: Recommended precautions must be feasible and effective. 26

Recognize Motor Pool and Maintenance Facility Hazards
Walk around outside areas of the facility to notice: Surface conditions Use of ground guides Use of wheel chocks Protective railings Hazardous substances 27

Poor Surface Conditions
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Poor Surface Conditions Does the motor pool have dangerous pot holes? What about oil separators, are they being used as designed and periodically cleaned out? Where does water run after a heavy rain? Are spilled POL products being cleaned up immediately or allowed to sit around. 28

Ground Guides Required when wheeled and tracked vehicles are: Backed Moved within an assembly area or motor pool AR , paragraph 11-4 h. Use of ground guides. Ground guides are required when wheeled and tracked vehicles are backed, or when moved within an assembly area or motor pool. 29

Ground Guides Will be properly trained FM 21-60 Visual Signals
Leaders Safety Course: Motor Pool and Maintenance Safety Ground Guides Continued Will be properly trained FM Visual Signals FM Manual for the Wheeled Vehicle Driver TC , Tracked Combat Vehicle Driver Training 30 30

Ground Guides Continued Tracked vehicle movement within an assembly area requires ground guides front and rear Tracked vehicle movement within an assembly area requires ground guides front and rear. 31

Wheel Chocks Army vehicles will be equipped with properly sized chocks when: Vehicles are parked on an incline Maintenance is being performed Vehicle is parked and a trailer is attached This should be a daily check in your motor pools, even when you think the ground is level, be especially careful in maintenance bays. Ensure where the chock block is placed will stop the vehicle if it starts to roll. You could prevent a Soldier from being crushed. AR 385–10 paragraph 11–4g(5). Army motor vehicles, except non–tactical vehicles, will be equipped with properly sized chock blocks for use when parked on sloping terrain, while maintenance is being performed, or when a vehicle is parked and a trailer is attached. Your command could make more stringent, ex. Chock blocks will be used when vehicle is parked. 32

Proper Wheel Chock? Slope What is wrong with this picture? Will this stop this trailer from rolling? Let’s look at the “chock” on the next slide Wheel Chock? 33

This is wrong -- why? 34

Protective Railings Elevated platforms (4 feet and above) should be equipped with proper railings and work platforms 29 CFR ( C ) 4 ft and above Elevated platforms should be equipped with proper railings and work platforms. The picture depicts the correct Occupational Safety and Health Administration (OSHA) required platform and railings. Correct OSHA required platform and railings 35 29 CFR General Industry

Report this Hazard to be Corrected
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Report this Hazard to be Corrected 29 CFR ( C ) 4 ft and above Elevated platforms should be equipped with proper railings and platforms to work from. Someone should put in a work order to correct this, or maybe no one has died here as yet. 36 29 CFR 1910 General Industry

Hazardous Substances Ensure: Proper storage, storage containers, and markings Inventory listing of all hazardous materials Material Safety Data Sheets (MSDS) are located in area Signs are posted Next, check what's stored in storage containers. Ensure combustibles and flammables are separated. Properly mark containers containing hazardous materials to make fire fighters aware of dangers in case of fire. Inventory all hazardous materials. Are signs posted to prohibit eating, drinking, and smoking in that area? 37

Material Safety Data Sheets (MSDS)
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Material Safety Data Sheets (MSDS) Must be maintained in the work area where hazardous chemicals are stored or used Post an inventory list of all chemicals on-hand and MSDS 29 CFR 1910 General Industry Material Safety Data Sheets are required for all hazardous substances. An inventory list must be posted that shows what hazardous substances are available. An MSDS must be available for each substance. MSDSs will explain the hazard, outline protective measures and prescribe personal protective equipment to be used or worn. 38

Know What’s Stored Secondary containment needed? Hazardous substance? What's in this 5 gallon can? The personnel assigned to the shop where it was found also did not know what was contained in the can. 29 CFR Hazard Communications, requires leaders to identify and label all hazardous chemicals. If the substance is unknown, it should be considered hazardous until it can be identified or disposed of. (soldiers should wear some kind of PPE until it is clear what substances are present) POL should always have secondary containment. Some hazardous substances when mixed together will ignite or explode. 39

Recognize Motor Pool and Maintenance Facility Hazards
Walk around inside areas of facility to notice hazards associated with: Roof leaks Exhaust/Carbon Monoxide Bay areas Mezzanine storage areas Noise exposure Electrical Housekeeping and general requirements 40

Roof Leaks May be common, yet still present a multitude of problems Slippery work surfaces Electrical hazards Health hazards Pests Roof leaks are common but must be dealt with as soon as possible. Leaking water offers too many sources of hazards. Electrical, work slips, health hazards from mold, and invites pests. Submit work orders. 41

Exhaust / Carbon Monoxide
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Exhaust / Carbon Monoxide Carbon monoxide poisoning may result from exhaust gases Avoid operating vehicles in a maintenance facility Use ventilation system Conduct annual carbon monoxide tests Refer to AR , 11-4k (1) Vehicle engines will not be operated in a maintenance facility longer than needed to move the vehicle in or out. If vehicles must be operated in a maintenance facility, an exhaust ventilation system that adequately exhausts vehicle engine gases will be used. (2) Maintenance facilities and other enclosed areas used for vehicles will be ventilated adequately at all times to prevent overexposure to exhaust gases from vehicle engines or space heaters. (3) Sleeping in parked vehicles with the engine heater, or externally mounted generator running is prohibited. Carbon monoxide poisoning may result from exhaust gases entering the vehicle. (4) When the power train, cooling, and exhaust systems are separated from the crew by engine access panels, the operator will ensure that the panels seal properly to prevent carbon monoxide from entering the crew compartment. Commanders of organizations that have vehicles of this type will ensure annual carbon monoxide tests are conducted, under full working conditions, by trained personnel using calibrated test equipment. Commanders should coordinate with their local preventive medicine office for support. Any vehicle that fails the annual carbon monoxide test will be considered non-mission capable until the vehicle satisfactorily passes the test. AR , 11-4k 42

Bay Areas Pits must be fully covered when not in use An opening can be no larger than one (1) inch 4-ft hole is still considered a pit 29 CFR (a) (9). Pits must be fully covered when not in use. There cannot be an opening larger than 1 inch. 4-ft hole, considered a pit. 43

Bay Areas When the cover is not in place
Leaders Safety Course: Motor Pool and Maintenance Safety Bay Areas Continued When the cover is not in place Opening must be constantly attended by someone Or be protected by removable standard railings 29 CFR (a) (5). When the cover is not in place, the opening must be constantly attended by someone or shall be protected by removable standard railings. 44 44

Mezzanine Storage Areas
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Mezzanine Storage Areas Structure must be approved by a building official Post sign showing the load limit and date inspected Hazard: Non approved structure. Citation: (d)(1). Suggested Solution: Structure must be either approved by a building official or removed. If approved, an engineer for DPW will need to load test the structure and a sign/plate will need to be affixed to the side of the structure showing the load limit and date inspected. Non-approved structure 45

Unsafe Overhead Mezzanine 29 CFR (d) (e). Stairway railings, mid rails, toe boards and guards Here is an example of an overhead mezzanine, identified during a safety survey which was being used to store equipment. The storage area had not been load tested, did not have a sign or plate affixed that depicted load bearing weight. Also notice the absence of top railings, mid railings and toe boards. Proper railings and proper stairways will need to be installed. OSHA requires a top rail, a mid rail, and a toe board for any area where personnel may be walking below. The top rail must be able to withstand a top rail pressure of 200 lbs. 46

Noise Exposure Surveillance Program
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Noise Exposure Surveillance Program When noise equals or exceeds an 8-hour time-weighted average of 85 decibels, the employer shall: Develop and implement a monitoring program Establish and maintain an audiometric testing program (g) Occupational noise exposure TB 385-4, 6.4 When noise equals or exceeds an 8-hour time-weighted average of 85 decibels, the employer shall develop and implement a monitoring program. The employer shall establish and maintain an audiometric testing program as provided in this paragraph by making audiometric testing available to all employees whose exposures equal or exceed an 8-hour time-weighted average of 85 decibels. 47

Electrical No Cover Broken Cover Any open blanks must be covered to prevent personnel from inadvertently putting their finger in the empty space. Any electrical system that has exposed wiring must be covered. Replace broken switches and plug covers. Exposed Wiring 48

Electrical Panels Each circuit on the panel must be clearly identified and prominently labeled TB 385-4, 3.11 Each circuit on the panel must be clearly identified and prominently labeled. 49

Electrical Ground Protection
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Electrical Ground Protection Symbol for double insulated , (g) Grounding If power tools have the symbol for double insulation, which is a square inside a square, they will not be required to have a ground prong on the plug end. Ground fault circuit interrupters can also be used and are required for any operation where electrical appliances, tools are used in a damp location. Areas that use steam cleaners powered by electricity must have GFCI. TB 385-4, Grounding Metal Frames. Metal frames of electric equipment and tools, such as handheld power tools, must be connected to a grounding conductor, i.e., they must contain a three wire power cord and plug. Portable tools that are protected by an approved insulation system (listed by Underwriter's Laboratory, or equivalent) need not be grounded. Plug with ground prong 50

Housekeeping and General Requirements
Leaders Safety Course: Motor Pool and Maintenance Safety Housekeeping and General Requirements Take a look at this picture and tell me some of the violations you notice. Violations result in hazards 51 51

Must provide quick, safe egress
Leaders Safety Course: Motor Pool and Maintenance Safety Exits Must provide quick, safe egress UNSAFE!! Ensure clear routes of egress – exit routes must be clear. If exit doors have locks, they must be unlocked during duty hours. Panic hardware is a good way to allow exit but provides security too. Don’t forget lighted exit signs in rooms without exterior light. Also, do not block emergency eyewash stations, electrical panels, or safety board. 52 52

Hard to Reach Safety Board
Leaders Safety Course: Motor Pool and Maintenance Safety Hard to Reach Safety Board Do not block safety board and ensure it is accessible to everyone in the section. 53 53

Blocked Emergency Eyewash Station
Leaders Safety Course: Motor Pool and Maintenance Safety Blocked Emergency Eyewash Station Again, don’t allow personnel to block emergency eyewash stations. 54 54

Blocked Again eyewash station 55
Leaders Safety Course: Motor Pool and Maintenance Safety Blocked Again eyewash station An obstructed eyewash station . Should be on an unobstructed path between the workstation and the hazard. (Workers should not have to pass through doorways or weave through machinery or other obstacles to reach them.) 55 55

Requirements for Emergency Eyewash Stations
Leaders Safety Course: Motor Pool and Maintenance Safety Requirements for Emergency Eyewash Stations Work areas that may require Emergency Eyewash Stations include: Battery charging areas Spraying operations High dust areas Dipping operations Hazardous substances dispensing areas 56 56

Eyewash Stations Accessibility
Leaders Safety Course: Motor Pool and Maintenance Safety Eyewash Stations Accessibility Locate as close to the hazard as possible Be on the same floor as the hazard Not separated by a partition from the hazardous area Easily seen by workers Ensure path is unobstructed between the workstation and the hazard Eyewash stations should: Be located as close to the hazard as possible and not be separated by a partition from the hazardous work area. Be on an unobstructed path between the workstation and the hazard. (Workers should not have to pass through doorways or weave through machinery or other obstacles to reach them.) Be located where workers can easily see them - preferably in a normal traffic pattern. Be on the same floor as the hazard (no stairs to travel between the workstation and the emergency equipment) and be located near an emergency exit where possible so that any responding emergency response personnel can reach the victim easily. Be located in an area where further contamination will not occur Provide a drainage system for the excess water (remember that the water may be considered a hazardous waste and special regulations may apply). Not come into contact with any electrical equipment that may become a hazard when wet, and be protected from freezing when installing emergency equipment outdoors. 57 57

Work Surfaces – Water on Floor
Leaders Safety Course: Motor Pool and Maintenance Safety Work Surfaces – Water on Floor CFR (a)(2) Water run-off or drains are recommended so the water does not create a slipping hazard when used or tested. If it cannot be installed, water must be mopped up immediately after use or test. Hazardous 58 58

First Aid Kits Ensure safe for use Inspect contents regularly Discard outdated items Refill kit Complete Current Check the dates on the contents of first aid kits and order replacements as necessary. Its common to find outdated items such as this eye dressing. The composition of fluids changes over time and should not be used past the expiration date. Have your medics inspect, refill and discard outdated equipment. Check Exp. Dates 59

Display Signs “A picture is worth a thousand words” Signs are a great way to remind personnel of what safety requirements should be in place. TB 385-4, Safety Signs, Symbols, and Taggings. Safety signs, safety symbols, or accident prevention tags shall be used where necessary to warn employees about electrical hazards which may endanger them. 60

Personal Protective Equipment
Leaders Safety Course: Motor Pool and Maintenance Safety Personal Protective Equipment First-line leaders should be involved in personal protective equipment (PPE) selection for their personnel First-line leaders should be involved in personal protective equipment selection for their personnel. 29 CFR (a), PPE General requirements. Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment, chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact. 61 61

Personal Protective Equipment
Leaders Safety Course: Motor Pool and Maintenance Safety Personal Protective Equipment When PPE is necessary What PPE is necessary How to don, remove, adjust, and wear PPE The limitations of the PPE Proper care, maintenance, useful life and disposal of the PPE 29 CFR (f)(1) The employer shall provide training to each employee who is required to use PPE. Leaders shall provide training to each Soldier who is required to use PPE. Each employee shall be trained to know at least the following: When PPE is necessary What PPE is necessary How to don, doff, adjust, and wear PPE The limitations of the PPE The proper care, maintenance, useful life and disposal of the PPE 62 62

Enabling Learning Objective D
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Enabling Learning Objective D Action: Identify hazards of specialized equipment and procedures. Condition: Given the name and/or photo of equipment or procedure used within maintenance facilities. Standard: Recommendations must be provided with hazard identification. 63

Machine Guarding Recognize and control hazards Protect from exposure to unguarded or inadequately guarded machines to avoid: Amputations Lacerations Crushing injuries Abrasions Death Don’t overlook the tool room when identifying hazards. Start with the power hand tools. All moving blades, discs, etc. should be guarded. 64

Machine Guarding Continued 29 CFR 1910 Requirements When blades of a ventilation fan are less than 7 feet above the floor or working level, the blades will be guarded Guard shall have openings no larger than ½ inch opening 29 CFR 1910 Requirements: When the blades of a ventilation fan are less than 7 feet above the floor or working level, the blades will be guarded. The guard shall have openings no larger than ½ inch opening. 65

Machine Guarding Hazards
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Machine Guarding Hazards Not Guarded Discuss the hazards shown in these pictures. Faulty Guarding 66

Securing Abrasive Wheel Machines
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Securing Abrasive Wheel Machines Must be bolted to a surface area – work bench or floor 29 CFR Abrasive wheel machine must be bolted to the surface, whether it is on a bench or on the floor. 67

Adjusting & Testing Abrasive Wheel Machines
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Adjusting & Testing Abrasive Wheel Machines 29 CFR (4) Adjust tongue guard and work rest as shown. Conduct a ring test to ensure no cracks exist. A dead or dull sound will be heard if cracks are present. Do not stand in front of a wheel when starting it up, in case the wheel explodes or disintegrates. When you can no longer adjust the tongue or rest guards, replace the wheel. Remove any soft metal that may be imbedded in the wheel surface. The soft metal can dislodge and become a projectile. Eye guards are optional because full face shields are to be used along with hearing protection and gloves. NOTE: Full face shields, hearing protection, and gloves must be used 68

Air Compressors Require scheduled maintenance Drain water to help protect relief valve Avoid dangerous pressure levels Locate outside if possible (noise hazard) 29 CFR (2) Air compressors must have a scheduled time to drain the water from the air tank. Unit SOP is a good place for this, with a log. Water can build up due to condensation and cause the relief valve to seize. The pressure can then build to dangerous levels and lead to a possible explosion. Air compressors are also a noise hazard and should be located outside the maintenance facility if possible. 69

Compressed Air Air receiver shall be equipped with an indicating pressure gage Do not allow air pressure to exceed 30 pounds per square inch (PSI) 30 PSI is the maximum for cleaning TB385-4, 6.2.5 Do not allow air pressure to exceed 30 pounds per square inch. 70

Compressed Air Continued Use rubber or other insulating material for hose lines to blow out equipment Do not use compressed air for cleaning floors Do not direct air toward others or self TB385-4, 6.2.5 Compressed Air Blowers. Use either rubber or another insulating material for hose lines for blowing out equipment. Keep air supplies free of water. Keep air pressure to a minimum. Do not use compressed air for cleaning floors. Do not blow compressed air onto any person, including oneself. 71

Lifting Devices Reference: TB Safety Inspections and Testing of Lifting Devices Cranes Hoists Slings Trucks, Forklift Jacks and Stands Inspect every 6 months TB is the reference for inspections and testing of support equipment for maintenance operations. Lifting devices, cranes, hoists, slings, fork lifts and jacks and stands are covered in this standard. This bulletin prescribes responsibilities, procedures, and guidance for implementing the requirements of the OSHAct 1970. ** Periodic Inspections will be performed every 6 months. (PG E-1) 72

Lifting Devices Load Testing
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Lifting Devices Load Testing Load tests will be clearly marked on the device Slings, wire ropes, hooks, etc., used for lifting, must be tagged with due date Load rating shall become a part of the maintenance records Load tests will be clearly marked on the device. NOTE: Stenciling is not required on lifting devices seven or more feet above floor level. TB , pg. 6 note (2). All slings, wire ropes, hooks etc., that are used for lifting, must have a tag that shows the load test and due date. The load rating shall become a part of the maintenance records of the equipment and be recorded IAW TB , pg. 6(e). 73

Jack Stands and Floor Jacks
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Jack Stands and Floor Jacks Daily and/or before use inspections Ensure item is safe for use Follow appropriate checklist, technical manual (TM) and other information to ensure safety Periodic inspections every 6-months 74

Fork Lifts Train and certify operators Do not modify or make attachments Examine for defects Know the capacity of the truck Wear seatbelts Ensure reverse alarm works Avoid traveling with elevated load FM and 29 CFR Train and certify all operators to ensure that they operate forklifts safely. Do not modify or make attachments that affect the capacity and safe operation of the forklift without written approval from the forklift's manufacturer. Examine forklift truck for defects before using. Do not handle loads that are heavier than the capacity of the industrial truck. Operators shall always wear seatbelts. Make certain that the reverse signal alarm is operational and audible above the surrounding noise level. Avoid traveling with elevated loads. 75

Welding Requirements Obtain hot work permit before welding operations Area must be deemed safe for welding Place shield to protect those passing by the area PPE includes gloves, apron boots head shield with protective lens 29 CFR (k) Hot work permits will be granted according to requirements of (a) Before welding operations, a hot work permit must be obtained. It is a permit issued by local fire dept or Fire Services that allows you to weld in an area that has been deemed safe for welding. Workers that may be exposed to welding operations must be shielded from the light produced by the operations and from the fumes that are generated by the heated metal. Place some type of shield around them so passers by cannot look directly at the light or inhale gasses. Gloves, apron, boots, head shield with protective lens. 76

Welding Operations Know what materials are being welded Certain metals produce fumes that produce a serious health threat to the welder Wear respiratory protection as needed No contact lens DoD R-2 Certain metals produce fumes that produce a serious health threat to the welder. Know what metals are being welded, so respiratory protection can be provided for those that need it. Do not allow personnel to wear contact lens around welding operations. Cadmium Repeated or prolonged exposure can cause loss of sense of smell, emphysema, kidney damage, or anemia. Inhalation of a sufficient amount of cadmium, even over a short term, can cause death. 77

Improper Procedures Missing PPE for welding Lack of fall protection – No : 3-point stand Guardrail system Guardrail system, or Personal fall arrest system 29 CFR ,(g) (2).1, , DA PAM 385–10, 14–5. Fall protection Purpose. To prescribe policies, procedures, and responsibilities for protecting personnel working in operations that involve the risk of an accidental fall of four feet or more. (b)(15 Walking/working surfaces not otherwise addressed." Except as provided in (a)(2) or in (b)(1) through (b)(14), each employee on a walking/working surface 6 feet (1.8 m) or more above lower levels shall be protected from falling by a guardrail system, guardrail system, or personal fall arrest system.) 78

Compressed Gas Cylinders
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Compressed Gas Cylinders All personnel who work with or handle pressurized gas cylinders will review AR annually Maintenance activities will maintain a record of these reviews Large number of tanks should not be stored in work areas Bundle and secure all tanks. Caps will be installed unless the tanks are mounted on a welding cart. TB385-4, Pressurized Gas Cylinders. Handle pressurized gas cylinders in accordance with Title 29 CFR 1910, Subpart M, and AR All personnel who work with or handle pressurized gas cylinders will review AR annually. 79

Compressed Gas Storage
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Compressed Gas Storage Storage areas must be clearly marked and properly secured Separate cylinders by hazard class Flammable gas Nonflammable gas Poison gas DoD R-2, 5-7 ( c ), Compressed gases shall be segregated by their hazard class or division into three primary groups: flammable gas, nonflammable gas, and poison gas. 80

Cleaning Solvents Use approved, environmental safe cleaning solvents Not highly toxic or flammable Consult applicable TM Ensure MSDS for solvent used is available Wear required PPE What’s wrong with this picture? Posting a sign listing required PPE as well as the MSDS, and having the required PPE close to the solvent tank is a good idea. TB 385-4, Cleaning Solvents. When cleaning equipment, consult the technical manual for recommended type(s) of cleaning solvent. Do not use highly toxic or flammable cleaning solvents that require special ventilation, such as carbon tetrachloride, trichloroethylene, and benzene. Do not use gasoline, benzene, ether, or any other type of flammable fluid to clean any type of electrical equipment. Do not use alcohol unless specified by the equipment technical manual. Flammable materials that do not require special ventilation may be used to clean nonelectrical equipment. Do not use flammable materials in the presence of electrical generators or other equipment that can cause sparks. 81

Asbestos and Ceramic Fibers
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Asbestos and Ceramic Fibers Inhaling asbestos and ceramic fibers can cause serious fibrotic lung disease and lung cancer Some brake shoes, clutch linings, and engine gaskets contain asbestos or ceramic fibers Take precautions to reduce exposure 29 CFR (f) (vi) Many brakes and clutches used in new and recent model automobiles do not contain asbestos. However, it has not been totally eliminated. Some reports have indicated that many mechanics and employees in the automotive repair shops as well as do-it-yourselfers are unaware that asbestos may be present in both old and replacement brakes and clutches. Inhaling asbestos and ceramic fibers can cause serious fibrotic lung disease and lung cancer. The risk of developing lung cancer is ten times greater if you smoke. Not everyone exposed to asbestos gets lung disease. Assume brake pads, clutches, etc have asbestos until you can identify that it does not exist. Take proper precautions to reduce the exposure to asbestos dust. 82

Working with Batteries
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Working with Batteries Army battery program IAW AR 750-1, Paragraph 8-20 Commanders will ensure that all battery shops are operated in an Occupational Safety and Health Organizations/ Environmental Protection Agency compliant manner Note: Army battery program is designed to provide policy guidance on the use and maintenance of military and commercial standard batteries and rechargeable/reusable batteries. 83

Working with Batteries
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Working with Batteries Continued Charge batteries in a well-ventilated, clean, and uncluttered area Wear chemical splash goggles or a full face shield Filling Storage Batteries Wear acid-resistant gloves, chemical-splash goggles, rubber aprons, and rubber boots with non-slip soles If available, use a fume hood TB 385-4, Charging Batteries. The area should be well ventilated, clean, uncluttered, and free from unnecessary tools or conductive materials that could accidentally contact and short-circuit the battery terminals. PPE While Charging. While working around batteries that are being charged, wear chemical splash goggles or a full face shield to protect against sprayed electrolyte Filling Storage Batteries PPE: Wear acid-resistant gloves, chemical-splash goggles, rubber aprons, and rubber boots with non-slip soles when filling storage batteries. If available, use a fume hood. 84

Storing Batteries Batteries must have secondary containment to prevent acid leaks If stored outdoors, they must have overhead cover Batteries must have secondary containment to prevent acid leaks. If stored outdoors, they must have overhead cover. Improper Storage 85

Lockout – Tagout Affixed to energy isolating devices Prevent start up or release of stored energy in order to prevent injury to employees Prevent activating equipment while it is being worked on DA Pam 385–10, paragraph 14–3. Appropriate lockout or tag out devices will be affixed to energy isolating devices, and to otherwise disable machines energization, start up, or release of stored energy in order to prevent injury to employees. 29 CFR (b) Lock-out Tag-out and Stationary equipment that is hard wired instead of plug and cord must have a Lock-out, Tag-out program in place. This keeps personnel from activating the equipment while it is being worked on. Note: required on some tire machines, hose machines, overhead hoists. 86

Painting Vehicles Minor paint operations can be conducted indoors Minor paint operations may be conducted outdoors As long as repeated operations is not more often than once a week and no more than one body panel Use proper PPE 87

Tire Cages Cages should not be bolted down Training and instructions must be provided Correct air hose must be used, that is, use a 10-foot extension with clip on chuck 29 CFR Tire cages must never be bolted to the floor and be at least 3 feet from any other object. Personnel must be trained on the use tire cage equipment. Instruction should be posted near the cage, and 10 foot extension with clip on chuck available for use. TM , paragraph 2-3. Inflation Safety Cages and Restraining Devices. (1) Field fabrication of safety inflation cages is not recommended and should not be used to inflate tires unless they have been certified during construction by a qualified engineer to meet United States Occupational Safety and Health Administration (OSHA) standard 29 CFR, Part (2) Tire safety inflation cages should be free standing and a minimum of 3 feet away from any object. Never permanently mount a safety cage to the floor or near a wall. Mounting an inflation cage to the floor or near a wall prohibits expected deformation of the bottom plate and equal dissipation of energy released in the event of tire explosion. Permanently mounting an inflation cage to the floor or near a wall could result in failure of one or more of the bars, release of rim components or shrapnel and/or an unwanted concentration of energy. (3) When using a safety cage to inflate tires the operator should not stand in the trajectory and ensure that all persons stay out of the trajectory during inflation. (4) Do not stick their hands, feet or any other body part into the safety inflation cage during inflation and until the rim/tire assembly has been inspected to ensure all components have properly seated and locked in place. In-line Inflator Gage Snap-on Air Chuck Extension Air hose, Minimum 10 ft. (5) Tire inflation will be controlled from a minimum of 10 ft (3.05 m) away using an extension air hose, a in-line pneumatic tire inflator-gage and snap-on air chuck. For tire inflation procedures, refer to the procedures for the type of tire being inflated and to the appropriate vehicle TM. 88

Does Not Meet Specifications
Leaders Safety Course: Motor Pool and Maintenance Facility Safety Does Not Meet Specifications 29 CFR (E) (iv) This cage does not meet manufacture's recommendations and is unsafe for use. The chain is welded to the cage and the cage is bent on bottom left (looking at slide). UNSAFE FOR USE! 89

Check on Learning Name a Commander’s responsibilities relating to maintenance facilities. Protecting personnel, equipment, and facilities Implementing safety and occupational health policies Integrating the composite risk management process into their mission activities 90

Check on Learning What must operators know to have a successful maintenance program? Operators must know how to detect and report malfunctions as well as operate equipment properly and safely. We have discussed the roles of some key personnel in the maintenance system. Now we will discuss SOP requirements. 91

Check on Learning What is the objective of the Army’s PMCS program? The objective is the observation of equipment performance and condition. 92

Check on Learning Name requirements regarding an open pit? It must be covered when not in use, constantly guarded by someone, or guarded by removable rails 93

Summary Responsibilities of key maintenance personnel Standing Operating Procedures (SOPs) Precautions for hazards found within or around a motor pool and/or maintenance facility Hazards of specialized equipment and procedures During this block of instruction, we discussed: Responsibilities of key personnel regarding maintenance Requirements for maintenance standing operating procedures Precautions for hazards found within or around a motor pool and/or maintenance facility Hazards of specialized equipment and procedures 94

Conclusion Follow the standards! Protect yourself and others! Get the job done safely! 95

Motor Pool and Maintenance

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