Safety program general automotive repair




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SAFETY PROGRAM
GENERAL AUTOMOTIVE REPAIR

SHOPS

SIC CODE 7538

For further information on safety programs developed by the Division of Safety of Florida's Department of Labor and Employment Security, call 904/488-3044 or

800/367-4378 (within Florida).
Material contained in this publication is in the public domain and may be reproduced, fully or partially, without permission of the State of Florida.

May, 1994


PREFACE
How to Use This Manual
To The Employer:

The purpose of this safety manual is to establish standards for an industry-specific safety program for establishments covered under Standard Industrial Classification (SIC code): 7538, General Automotive Repair Shops. This safety program has been developed by the Florida Division of Safety with voluntary input from Florida employers, workers' compensation insurance carriers, labor organizations, trade associations, and other industry leaders.


This manual is intended to serve as the basis for an employer integrated safety and health management program. Implementation of this safety program satisfies the requirements of the Division of Safety. The essential elements of this program include: top management's commitment and involvement; the establishment and operation of safety committees; provisions for safety and health training; first aid procedures; accident investigations; recordkeeping of injuries; and workplace safety rules, policies, and procedures.
If this manual meets the needs of your establishment, it may be used exactly as written. If you have previously established and are maintaining a safety program, you can continue to use your program provided that the essential elements covered in this safety program are also addressed in your program. Use of all or part of this manual does not relieve employers of their responsibility to comply with other applicable local, state or federal laws. In addition, if an employer maintains the OSHA 200 Log to meet federal requirements, then that will meet the log and summary requirements of the LES SAF 200 form in Section VI of this program.
It is intended that this manual be enhanced and continuously improved by the employer. Any section of this manual may be modified by the employer to accommodate actual operations and work practices, provided that the original intent of that section is not lost. For example, if a safety committee meets weekly or quarterly instead of monthly, then Section II of the manual should be amended to accommodate this practice. If there is a safety rule, policy, or procedure appropriate for the work or work environment which has not been included, or if a rule included in Section VII is inappropriately written, then a new safety rule, policy, or procedure should be added to improve the manual. Likewise, if a specific rule in the Safety Rules, Policies, and Procedures section does not apply because the equipment or work operation described is not used, then that specific rule should be crossed out or deleted from the manual. If accidents occur, new safety rules should be developed and incorporated in Section VII of this manual to prevent their recurrence.

TABLE OF CONTENTS

Preface 3

Table of Contents 5


Section I - Management Commitment and Involvement

Policy Statement 1


Section II - Safety Committee

Safety Committee Organization 3

Responsibilities 3

Meetings II.1

Meeting Minutes II.2
Section III - Safety and Health Training

Safety and Health Orientation 1

Job-Specific Training 1

Periodic Retraining of Employees III.1


Section IV - First Aid Procedures

Minor First Aid Treatment 1

Non-Emergency Medical Treatment 1

Emergency Medical Treatment 1

First Aid Training 2

First Aid Instructions 3


Section V - Accident Investigation

Accident Investigation Procedures 1

Investigation Report Form Error: Reference source not found
Section VI - Recordkeeping Procedures

Recordkeeping Procedures 5

First Notice of Injury DWC-1 1

LES SAF 200 Form 2


Section VII - Safety Rules, Policies, and Procedures

Safety Rules, Policies, and Procedures 1


Section I.
MANAGEMENT COMMITMENT AND INVOLVEMENT

POLICY STATEMENT
The management of this organization is committed to providing employees with a safe and healthful workplace. It is the policy of this organization that employees report unsafe conditions and do not perform work tasks if the work is considered unsafe. Employees must report all accidents, injuries, and unsafe conditions to their supervisors. No such report will result in retaliation, penalty, or other disincentive.
Employee recommendations to improve safety and health conditions will be given thorough consideration by our management team. Management will give top priority to and provide the financial resources for the correction of unsafe conditions. Similarly, management will take disciplinary action against an employee who willfully or repeatedly violates workplace safety rules. This action may include verbal or written reprimands and may ultimately result in termination of employment.
The primary responsibility for the coordination, implementation, and maintenance of our workplace safety program has been assigned to:
Name:

Title: Telephone:


Senior management will be actively involved with employees in establishing and maintaining an effective safety program. Our safety program coordinator, myself, or other members of our management team will participate with you or your department's employee representative in ongoing safety and health program activities, which include:
• Promoting safety committee participation;

• Providing safety and health education and training; and

• Reviewing and updating workplace safety rules.
This policy statement serves to express management's commitment to and involvement in providing our employees a safe and healthful workplace. This workplace safety program will be incorporated as the standard of practice for this organization. Compliance with the safety rules will be required of all employees as a condition of employment.

Signature of CEO/President Date



Section II.
SAFETY COMMITTEE
Safety Committee Organization
A safety committee has been established as a management tool to recommend improvements to our workplace safety program and to identify corrective measures needed to eliminate or control recognized safety and health hazards. The safety committee employer representatives will not not exceed the amount of employee representatives.
Responsibilities

The safety committee will be responsible for assisting management in communicating procedures for evaluating the effectiveness of control measures used to protect employees from safety and health hazards in the workplace.


The safety committee will be responsible for assisting management in reviewing and updating workplace safety rules based on accident investigation findings, any inspection findings, and employee reports of unsafe conditions or work practices; and accepting and addressing anonymous complaints and suggestions from employees.
The safety committee will be responsible for assisting management in updating the workplace safety program by evaluating employee injury and accident records, identifying trends and patterns, and formulating corrective measures to prevent recurrence.
The safety committee will be responsible for assisting management in evaluating employee accident and illness prevention programs, and promoting safety and health awareness and co-worker participation through continuous improvements to the workplace safety program.
Safety committee members will participate in safety training and be responsible for assisting management in monitoring workplace safety education and training to ensure that it is in place, that it is effective, and that it is documented.

Management will provide written responses to safety committee written recommendations.


Meetings

Safety committee meetings are held quarterly and more often if needed and each committee member will be compensated at his or her hourly wage when engaged in safety committee activities .


Management will post the minutes of each meeting (see page 5) in a conspicuous place and the minutes will be available to all employees.
All safety committee records will be maintained for not less than three calendar years.

SAFETY COMMITTEE MINUTES



Date of Committee Meeting: Time: Minutes Prepared By: Location:


Members in Attendance

Name Name Name






Previous Action Items:


Review of Accidents Since Previous Meeting:


Recommendations for Prevention:


Recommendations from Anonymous Employees:


Suggestions From Employees:


Recommended Updates To Safety Program:


Recommendations from Accident Investigation Reports:

Safety Training Recommendations:
Comments:



Section III.
SAFETY AND HEALTH TRAINING
Safety and Health Orientation
Workplace safety and health orientation begins on the first day of initial employment or job transfer. Each employee has access to a copy of this safety manual, through his or her supervisor, for review and future reference, and will be given a personal copy of the safety rules, policies, and procedures pertaining to his or her job. Supervisors will ask questions of employees and answer employees' questions to ensure knowledge and understanding of safety rules, policies, and job-specific procedures described in our workplace safety program manual.

All employees will be instructed by their supervisors that compliance with the safety rules described in the workplace safety manual is required.


Job-Specific Training
• Supervisors will initially train employees on how to perform assigned job tasks safely.

• Supervisors will carefully review with each employee the specific safety rules, policies, and procedures that are applicable and that are described in the workplace safety manual.


• Supervisors will give employees verbal instructions and specific directions on how to do the work safely.
• Supervisors will observe employees performing the work. If necessary, the supervisor will provide a demonstration using safe work practices, or remedial instruction to correct training deficiencies before an employee is permitted to do the work without supervision.
• All employees will receive safe operating instructions on seldom-used or new equipment before using the equipment.
• Supervisors will review safe work practices with employees before permitting the performance of new, non-routine, or specialized procedures.

Periodic Retraining of Employees


All employees will be retrained periodically on safety rules, policies and procedures, and when changes are made to the workplace safety manual.
Individual employees will be retrained after the occurrence of a work-related injury caused by an unsafe act or work practice, and when a supervisor observes employees displaying unsafe acts, practices, or behaviors.

Section IV.


FIRST AID PROCEDURES
EMERGENCY PHONE NUMBERS
Safety Coordinator Poison Control

First Aid Fire Department

Ambulance Police

Medical Clinic

Clinic Address
Minor First Aid Treatment

First aid kits are kept in the front office and in the employee lounge. If you sustain an injury or are involved in an accident requiring minor first aid treatment:


• Inform your supervisor.

• Administer first aid treatment to the injury or wound.

• If a first aid kit is used, indicate usage on the accident investigation report.

• Access to a first aid kit is not intended to be a substitute for medical attention.

• Provide details for the completion of the accident investigation report.
Non-Emergency Medical Treatment

For non-emergency work-related injuries requiring professional medical assistance, management must first authorize treatment. If you sustain an injury requiring treatment other than first aid:


• Inform your supervisor.

• Proceed to the posted medical facility. Your supervisor will assist with transportation, if necessary.

• Provide details for the completion of the accident investigation report.
Emergency Medical Treatment

If you sustain a severe injury requiring emergency treatment:


• Call for help and seek assistance from a co-worker.

• Use the emergency telephone numbers and instructions posted next to the telephone in your work area to request assistance and transportation to the local hospital emergency room.

• Provide details for the completion of the accident investigation report.


First Aid Training

Each employee will receive training and instructions from his or her supervisor on our first aid procedures.

FIRST AID INSTRUCTIONS

In all cases requiring emergency medical treatment, immediately call, or have a co-worker call, to request

emergency medical assistance.
WOUNDS:
Minor: Cuts, lacerations, abrasions, or punctures

• Wash the wound using soap and water; rinse it well.

• Cover the wound using clean dressing.

Major: Large, deep and bleeding

• Stop the bleeding by pressing directly on the wound, using a bandage or cloth.

• Keep pressure on the wound until medical help arrives.


BROKEN BONES:
• Do not move the victim unless it is absolutely necessary.

• If the victim must be moved, "splint" the injured area. Use a board, cardboard, or rolled newspaper as a splint.

BURNS:
Thermal (Heat)

• Rinse the burned area, without scrubbing it, and immerse it in cold water; do not use ice water.

• Blot dry the area and cover it using sterile gauze or a clean cloth.

Chemical


• Flush the exposed area with cool water immediately for 15 to 20 minutes.
EYE INJURY:
Small particles

• Do not rub your eyes.

• Use the corner of a soft clean cloth to draw particles out, or hold the eyelids open and flush the eyes continuously with water.

Large or stuck particles

• If a particle is stuck in the eye, do not attempt to remove it.

• Cover both eyes with bandage.

Chemical

• Immediately irrigate the eyes and under the eyelids, with water, for 30 minutes.

NECK AND SPINE INJURY:
• If the victim appears to have injured his or her neck or spine, or is unable to move his or her arm or leg, do not attempt to move the victim unless it is absolutely necessary.
HEAT EXHAUSTION:
• Loosen the victim's tight clothing.

• Give the victim "sips" of cool water.

• Make the victim lie down in a cooler place with the feet raised.

Section V.
ACCIDENT INVESTIGATION

Accident Investigation Procedures
An accident investigation will be performed by the supervisor at the location where the accident occurred. The safety coordinator is responsible for seeing that the accident investigation reports (see page Error: Reference source not found) are being filled out completely, and that the recommendations are being addressed. Supervisors will investigate all accidents, injuries, and occupational diseases using the following investigation procedures:
• Implement temporary control measures to prevent any further injuries to employees.
• Review the equipment, operations, and processes to gain an understanding of the accident situation.
• Identify and interview each witness and any other person who might provide clues to the accident's causes.
• Investigate causal conditions and unsafe acts; make conclusions based on existing facts.
• Complete the accident investigation report.
• Provide recommendations for corrective actions.
• Indicate the need for additional or remedial safety training.
Accident investigation reports must be submitted to the safety coordinator within 24 hours of the accident.

ACCIDENT INVESTIGATION REPORT

REPORT #
COMPANY: ADDRESS:

1. Name of injured: S.S. #:

2. Sex [ ] M [ ] F Age: Date of accident:

3. Time of accident: a.m. p.m. Day of accident:

4. Employee's job title:

5. Length of experience on job: (years) (months)

6. Address of location where the accident occurred: 7. Nature of injury, Injury type, and Part of the body affected:

8. Describe the accident and how it occurred: 9. Cause of the accident:

10. Was personal protective equipment required? [ ] yes [ ] no Was it provided? [ ] yes [ ] no

Was it being used? [ ] yes [ ] no If "no", explain.

Was it being used as trained by supervisor or designated trainer? [ ] yes [ ] no If "no", explain.

11. Witness(es):







12. Safety training provided to the injured? [ ] yes [ ] no If "no", explain.



13. Interim corrective actions taken to prevent recurrence:



14. Permanent corrective action recommended to prevent recurrence:





15. Date of report 19

Prepared by:
Supervisor (Signature) Date:

16. Status and follow-up action taken by safety coordinator:




Safety Coordinator (Signature) Date:
INSTRUCTIONS FOR COMPLETING THE ACCIDENT INVESTIGATION REPORT

An accident investigation is not designed to find fault or place blame but is an analysis of the accident to determine causes that can be controlled or eliminated.


(Items 1-6) Identification: This section is self-explanatory.
(Item 7) Nature of Injury: Describe the injury, e.g., strain, sprain, cut, burn, fracture. Injury Type: First aid -injury resulted in minor injury/treated on premises; Medical - injury treated off premises by physician; Lost time -injured missed more than one day of work; No Injury - no injury, near-miss type of incident. Part of the Body: Part of the body directly affected, e.g., foot, arm, hand, head.
(Item 8) Describe the accident: Describe the accident, including exactly what happened, and where and how it happened. Describe the equipment or materials involved.
(Item 9) Cause of the accident: Describe all conditions or acts which contributed to the accident, i.e.,

a. unsafe conditions - spills, grease on the floor, poor housekeeping or other physical conditions.


b. unsafe acts - unsafe work practices such as failure to warn, failure to use required personal protective equipment.
(Item 10) Personal protective equipment: Self-explanatory
(Item 11) Witness(es): List name(s), address(es), and phone number(s).
(Item 12) Safety training provided: Was any safety training provided to the injured related to the work activity being performed?
(Item 13) Interim corrective action: Measures taken by supervisor to prevent recurrence of incident, i.e., barricading accident area, posting warning signs, shutting down operations.
(Item 14): Self-explanatory
(Item 15): Self-explanatory
(Item 16) Follow-up: Once the investigation is complete, the safety coordinator shall review and follow-up the investigation to ensure that corrective actions recommended by the safety committee and approved by the employer are taken, and control measures have been implemented.
Section VI.


RECORDKEEPING PROCEDURES

Recordkeeping Procedures
The safety coordinator will control and maintain all employee accident and injury records. Records are maintained for a minimum of three (3) years and include:
• Accident Investigation Reports, see page Error: Reference source not found;
• Workers' Compensation Notice of Injury Reports DWC 1, see page 1; and
• Log & Summary of Occupational Injuries and Illnesses LES SAF 200, see page 2.

notice of injury

saf 200


Section VII

GENERAL AUTOMOTIVE REPAIR SHOPS

SAFETY RULES, POLICIES, AND PROCEDURES

The safety rules contained on these pages have been prepared to protect you in your daily work. Employees are to follow these rules carefully, review them often and use good common sense in carrying out assigned duties.

ALL EMPLOYEES

General Safety Rules 2

Electrical Safety 2

Office Safety 2

Lifting Procedures 4

AUTO REPAIR TECHNICIANS

Shop Safety 6

Vehicle Safety 10

Tire Service 7

Tubeless Tires - Demounting 10

Tubeless Tires - Mounting 8

Tube Type Tires - Demounting 10

Tube Type Tires - Mounting 10

Wheel Mounting/Demounting on Vehicles 12

Tire Handling VII.9

Electrical Tool Safety 14

Hand Tool Safety 14

Grinders VII.10

Automotive Lifts 16

ALL EMPLOYEES
General Safety Rules

1. Do not block or obstruct stairwells, exits or accesses to safety and emergency equipment such as fire extinguishers or fire alarms.

2. Straighten or remove rugs and mats that do not lie flat on the floor.

3. Use a ladder or step stool to retrieve or store items that are located above your head.

4. Use the handle when closing doors, drawers and files.

5. Obey all posted safety and danger signs.

6. Use caution signs/cones to barricade slippery areas such as freshly mopped floors.

7. Do not run on stairs or take more than one step at a time.

8. Do not block your view by carrying large or bulky items; use a dolly or hand truck or get assistance from a fellow employee.

9. Do not tilt the chair you are sitting in on its back two legs.

10. Use handrails when ascending or descending stairs or ramps.

11. Do not stand in front of closed doors.

12. Walk around wet, icy, slick or oily areas if possible.

13. If required to cross a slippery surface, walk slow and flat-footed. Hold onto a handrail or solid object, if present, to maintain balance.

14. Use provided aisles, walkways or sidewalks. Do not take shortcuts.

15. Clean shoes of ice, water, mud, grease or other substances that could cause a slip or fall.

16. Pull merchandise carts through areas of restricted visibility.

17. Use a flashlight, turn on lights or take time for eyes to adjust when entering a dark room or dim surroundings.

18. Do not move faster than conditions allow on slippery surfaces or in congested areas.

19. Open one file cabinet drawer at a time.

20. Use a cord cover or tape the cord down when running electrical or other cords across aisles, between desks or across entrances/exits.
Electrical Safety

1. Do not use appliances and extension or power cords that have the ground prong removed or broken off.

2. Do not connect multiple electrical devices into a single outlet.

3. Do not overload electrical circuits with multiple outlets.

4. Turn off electrical appliances and equipment when not in use.

5. Turn off and unplug office machines before adjusting, lubricating or cleaning them.


Office Safety

1. Close drawers and doors immediately after use.

2. Do not kick objects out of your pathway; pick them up or push them out of the way.

3. Put heavy files in the bottom drawers of file cabinets.

4. Store sharp objects, such as pens, pencils, letter openers or scissors in drawers or with the points down in a container.

5. Keep floors clear of items such as paper clips, pencils, tacks or staples.

ALL EMPLOYEES
Office Safety (Continued)

6. Carry pencils, scissors and other sharp objects with the points down.

7. Do not use extension or power cords that have the ground prong removed or broken off.

8. Point the ejector slot away from yourself and bystanders when refilling staplers.

9. Do not connect multiple electrical devices into a single outlet.

10. Do not throw matches, cigarettes or other smoking materials into trash baskets.

11. Keep doors in hallways fully open or fully closed.

12. Use a staple remover, not your fingers, for removing staples.

13. Turn off and unplug office machines before adjusting, lubricating or cleaning them.

14. Do not use fans that have excessive vibration, frayed cords or missing guards.

15. Do not place floor type fans in walkways, aisles or doorways.

16. Do not use frayed, cut or cracked electrical cords.

17. Do not store or leave items on stairways or walkways.

18. Clean up spills or leaks immediately by using a paper towel, rag or a mop and bucket.


Lifting Procedures

1. Plan the move before lifting; remove obstructions from your chosen pathway.

2. Test the weight of the load before lifting by pushing the load along its resting surface.

3. If the load is too heavy or bulky, use lifting and carrying aids such as hand trucks, dollies, pallet jacks and carts or get assistance from a co-worker.

4. If assistance is required to perform a lift, coordinate and communicate your movements with those of your co-worker.

5. Position your feet 6 to 12 inches apart with one foot slightly in front of the other.

6. Face the load.

7. Bend at the knees, not at the back.

8. Keep your back straight.

9. Get a firm grip on the object with your hands and fingers. Use handles when present.

10. Never lift anything if your hands are greasy or wet.

11. Wear protective gloves when lifting objects with sharp corners or jagged edges.

12. Hold objects as close to your body as possible.

13. Perform lifting movements smoothly and gradually; do not jerk the load.

14. If you must change direction while lifting or carrying the load, pivot your feet and turn your entire body. Do not twist at the waist.

15. Set down objects in the same manner as you picked them up, except in reverse.

16. Do not lift an object from the floor to a level above your waist in one motion. Set the load down on a table or bench and then adjust your grip before lifting it higher.

17. Slide materials to the end of the tailgate before attempting to lift them off of a pick-up truck. Do not lift over the walls or tailgate of the truck bed.

18. When practical, push objects into position for lifting, do not pull.

AUTO REPAIR TECHNICIANS


Shop Safety

1. Follow these steps when handling hot automotive parts that have been removed from vehicles:

a) Pick up the part using gloves, heat resistant pads or dry rags.

b) Place hot parts such as loose pipes, mufflers and shocks in metal containers that are labeled "Hot Metal Parts Only".

2. Wear safety glasses when working in the shop area.

3. Use a flexible exhaust hose to vent engine exhaust to the outside when the shop bay doors are closed.

4. Remove dust and shavings from drum lathes with a dust pan and broom or vacuum cleaner on a daily or job by job basis. Do not use your bare hands.

5. Dump gasoline and other liquid chemical waste into containers labeled "Flammable Waste" from containers labeled "Flammable".

6. Attach the pressure reducing nozzle that is labeled "Reduces Pressure to 30 psi" to the air hose when using compressed air to clean. Wear safety goggles when using compressed air to clean.

7. When lifting batteries or other heavy objects from the engine compartment of a vehicle, use the following procedures:

1) Press your thighs against fender by leaning into vehicle.

2) Grasp the object by lifting with both hands.

3) Keep the object close to body, with elbows close to body.

4) Turn body using feet, not twisting at waist.

5) Move the object to work bench and lower onto bench. Use arms to lower and do not bend at waist.

8. When examining under the dash, use inspection mirrors. Do not twist your body or maintain an awkward posture when trying to look under the dash.

9. Drape a shop rag over the radiator cap before venting or removing the cap from the radiator.

10. Wear gloves, safety goggles and a rubber apron when working in the battery charging area.

11. Direct engine hand tools away from rotating fan blades when the engine is running.

12. Before "running" the vehicle for an engine analysis, engage the parking brake and use wheel blocks to "chock" the wheels of the vehicle.

AUTO REPAIR TECHNICIANS
Vehicle Safety

1. Do not ride in the bed of pick-up trucks.

2. Turn headlights on when driving inside the shop area.

3. Do not drive over 5 miles per hour in the shop area.

4. Shut all doors and fasten your seat belt before moving the vehicle.

5. Obey all traffic patterns and signs at all times.

6. Maintain a 3-point contact using both hands and one foot or both feet and one hand when climbing into and out of vehicle.

7. Drive up the slope or down the slope; not across the slope.

8. Before leaving the vehicle, engage the parking brakes and chock the wheels.

9. Do not approach any vehicle until the vehicle stops and the driver exits.

10. Walk behind the vehicle and remove any equipment, tools or other pathway instructions before getting into the vehicle. Sound the horn to alert nearby coworkers before backing the vehicle.

11. Tie down, lash, or secure all materials and equipment hauled in the bed of vehicles.

12. Stand clear of vehicles in motion.

13. Do not mount or dismount a moving vehicle.





Tire Service

1. Use the positive lock-down device to hold the wheel on the tire machine before you attempt to inflate the tire. If tire is mounted on a machine that does not have a positive lock-down device, perform inflation in a safety cage.

2. Use an extension air hose with an air pressure gauge to check the tire pressure. Do not inflate beyond 40 pounds of air pressure when trying to seat the beads. If both beads are not completely seated when pressure reaches 40 pounds, completely deflate the assembly, reposition the tire and/or tube on the rim, relubricate and reinflate.

3. Inspect both sides of the tire to be sure that the beads are evenly seated.

4. After the beads are fully seated, adjust the tire pressure to meet the operating pressure labeled on the tire sidewall.

5. Replace a tire on a rim with another tire of exactly the same rim diameter designation and suffix letters.

6. Do not mount or use tires, tubes, wheels or rims that are split, cracked, cut or contain signs of other structural defects.

7. Wear leather gloves when removing rocks, glass and other foreign materials from the inside of the tire.

AUTO REPAIR TECHNICIANS
TUBELESS TIRES-Demounting Procedures

1. Place the tire in a horizontal position on the changer with the narrow ledge of the wheel facing up. Remove valve core and allow the tire to completely deflate.

2. Center the wheel and securely fasten it onto the changer with the hold-down cone.

3. Loosen both tire beads from rim flanges. If the beads do not readily separate from the rim flange, do not force or hammer. Use the rubber tire lubricant labeled "Non-Petroleum Based Lubricant" to lubricate the tire, rotate tire to another position and try again. Never use antifreeze, silicones or petroleum-based lubricants.

4. After beads are loosened from rim flanges, lubricate the inside of the wheel and both bead areas of the tire.

5. Use a tire iron to bring the bead of the tire onto the rotating finger of the tire changer. Hold the tire bead in the center wheel well during this operation. Do not use a pipe or a make-shift bar.

6. Start the tire changer to remove the top bead from the wheel.

7. Again use the rubber tire lubricant labeled "Non-Petroleum Based Lubricant" to lubricate the tire beads and bead seat areas of the wheel including the drop-center well of the wheel.

8. Use a tire iron to raise the bottom bead and bring it over the rotating finger of the changer. Use your hip and hand to hold the side of the tire opposite the rotating finger down in the center well of the wheel.
TUBELESS TIRES-Mounting Procedures

1. Do not mount a tire on a wheel rim that has molten metal scars or other signs that it has been repaired by welding or brazing.

2. Remove any oxidized rubber, dried soap solution, rust or heavy paint from the rim flanges and bead ledges (especially hump and radius) using a wire brush. Replace valve stems that are cracked, split, cut or are otherwise visibly damaged.

3. Place wheel on changer with narrow bead-ledge up. Center wheel and securely fasten it onto the changer with the hold-down mechanism.

4. Use the rubber tire lubricant labeled "Non-Petroleum Based Lubricant" to lubricate sides and bases of tire beads, rim flanges and bead ledge areas. Do not use antifreeze, silicones or petroleum-based lubricants.

5. Remove any tools, foreign objects or liquids that may be present inside the tire casing.

6. In mounting the tire, push the bottom bead first in the well of the wheel.

7. Push the top bead down into the center well of the wheel. Hold the tire in this position while the rotating finger runs the bead onto the wheel. Center tire on rim.

8. Install the valve core.

AUTO REPAIR TECHNICIANS


TUBELESS TIRES-Mounting Procedures (Continued)

9. Tighten the hold down cone before inflating the tire. Use an extension air hose with gauge and clip-on chuck to permit operator to stand clear of the tire assembly. Slowly inflate the tire until the beads "pop" on the bead ledge of the wheel. Prior to inflating the tire, loosen the hold down cone so that it and the tire assembly can be removed later. Inflate the tire to operating pressure labeled on the tire sidewall.


TUBE TYPE TIRES-Demounting Procedures

1. Remove all balance weights from the rim. Place tire in a horizontal position on changer with the narrow ledge of the wheel facing up. Remove valve core and completely deflate the tire.

2. Center the wheel and securely fasten it onto the changer with the hold-down cone.

3. Loosen both tire beads from rim flanges. If the beads do not readily separate from the rim flange, do not force or hammer. Lubricate only with rubber lubricant approved by the manufacturer and rotate tire to another position and try again. Never use antifreeze, silicones or petroleum-based lubricants.

4. After beads are loosened from rim flanges, lubricate the inside of the wheel and both bead areas of the tire.

5. Use a tire iron to bring the bead of the tire onto the rotating finger of the tire changer. Hold the tire bead in the center wheel well during this operation. Do not use a pipe or a make-shift bar.

6. Start the tire changer to remove the top bead from the wheel.

7. Starting at the valve area, remove the tube from the tire by hand.

8. Again lubricate the tire beads and bead seat areas of the wheel including the drop-center well of the wheel.

9. Use a tire iron to raise the bottom bead and bring it over the rotating finger of the changer. Use your hip and hand to hold the side of the tire opposite the rotating finger down in the center well of the wheel.


TUBE TYPE TIRES-Mounting Procedures

1. Use a wire brush to remove any oxidized rubber, dried soap solution, rust or heavy paint from the wheel well, rim flanges and bead ledges (especially hump and radius) so that interior surfaces are smooth and clean. If wheel is spoked, visually inspect drop center well rim strip for rips and cracks. If necessary to replace the strip, use one-inch wide plastic electrician's tape.

2. Place wheel with the narrow bead ledge up on the changer. Center and securely fasten wheel to changer with changer hold-down cone.

AUTO REPAIR TECHNICIANS


TUBE TYPE TIRES-Mounting Procedures (Continued)

3. Insert the tube in the tire and partially inflate to round out tube. Use a brush or cloth to apply a solution of natural vegetable oil soap or rubber lubricant to the tube base and the base of the top and bottom beads. Do not let lubricant run between the tire and tube. Do not use antifreeze, silicones or petroleum-based lubricants.

4. Mount the bottom bead on the wheel, being careful not to pinch the tube against the rim.

5. After aligning the tube valve with the valve stem hole in the rim, insert and center valve stem through stem hole in the rim.

6. Mount top bead of the tire on the rim so that the bead in the valve area will be the last part of the bead to go over the rim flange. Be careful not to pinch or disturb the tube. Recenter the valve stem if necessary, by rotating both tire and tube. Reinstall the valve core.

7. Use an extension air hose with gauge and clip-on chuck to permit operator to stand clear of tire assembly. Inflate slowly to seat tire beads. Do not exceed 40 psi to seat beads.

8. To prevent tube wrinkling or buckling, remove valve core to completely deflate the tube. Reinsert valve core and firmly seat it.

9. Reinflate assembly to the operating pressure labeled on the tire sidewall.


Wheel Mounting/Demounting On Vehicle

1. Position the lift so that the axle hub of the vehicle is about waist height.

2. Position the tire and wheel on the floor so that the inside of the tire faces you and the outside of the tire faces the car.

3. Place hands on the side of the tire with the tire resting against your thigh just above the knee.

4. With a continuous motion, straighten up using your thigh as a pivot point. Rotate the tire until most of the weight is resting on your thigh. The inside of the tire is now facing the car.

5. Continuing the momentum, the tire and wheel goes toward the hub with a little guidance from the hands.

6. Position the wheel and hub hole on the hub and align the lugs with the holes.

7. Reverse this procedure when demounting.



AUTO REPAIR TECHNICIANS
Tire Handling

1. When loading tires onto or unloading tires from a vehicle, do not throw the tires off of the truck; use the following procedure:

a) Bend at knees, grasp tire with two hands, elevate tire to upright position and carry the tire to the end of the truck.

b) Hand tire off to a co-worker.

2. Do not stack tires above your shoulder level.

3. When unstacking tires that are above your shoulder height, use two people to unstack down to shoulder height.

4. Carry tires with your hands. Do not carry more than two tires at a time; Do not roll tires.
Electrical Tool Safety

1. Do not use power equipment or tools on which you have not been trained.

2. Keep power cords away from the path of vacuum cleaners, floor polishers and grinders.

3. Do not carry plugged in equipment or tools with your finger on the switch.

4. Do not carry equipment or tools by the cord.

5. Disconnect the tool from the outlet by pulling on the plug, not the cord.

6. Turn the tool off before plugging or unplugging it.

7. Do not leave tools that are "On" unattended.

8. Do not handle or operate electrical tools when your hands are wet or when you are standing on wet floors.

9. Turn off electrical tools and disconnect the power source from the outlet before attempting repairs or service work. Tag the tool "Out of Service".

10. Do not drive over, drag, step on or place objects on a cord.
Hand Tool Safety

1. Tag worn, damaged or defective tools "Out of Service" and do not use them.

2. Do not use a tool if its handle has splinters, burrs, cracks or splits, or if the head of the tool is loose.

3. Do not use impact tools such as hammers, chisels, punches or steel stakes that have mushroomed heads.

4. When handing a tool to another person, direct sharp points and cutting edges away from yourself and the other person.

5. Do not chop at heights above your head when working with a hand axe.

6. Do not carry sharp or pointed hand tools such as screwdrivers, scribes, aviation snips, scrapers, chisels or files in your pocket unless the tool or pocket is sheathed.

7. Do not perform "make-shift" repairs to tools.

AUTO REPAIR TECHNICIANS
8. Transport hand tools only in tool boxes or tool belts.

9. Wear safety glasses, goggles or face shields when operating grinders.


Grinders

1. Do not use grinding wheels that have chips, cracks or grooves.

2. Do not use the grinding wheel if it wobbles. Tag it "Out of Service".

3. Do not try to stop the wheel with your hand, even if you are wearing gloves.

4. Do not use grinder if it is not firmly anchored to the work bench.

5. Prior to installing a new grinding wheel, inspect the wheel for cracks or other visible damage; tap the wheel gently with a plastic screwdriver handle to detect cracks that are not visible. If the wheel has a dead sound rather than a ringing sound, do not use the wheel.

6. Do not install a grinding wheel whose labeled RPM speed is lower than the rated speed of the grinder.

7. Do not grind on the side of an abrasive wheel labeled "Type 1".

8. Do not clamp a portable grinder in a vise to use it as a bench grinder.
Automotive Lifts

1. Remove all tools, cords, hoses, trash and any other debris from the lift area and wipe up all grease and oil spills before driving a car or truck into the service bay.

2. Position the lift arms, adapters and supports to the center of the lift out of the way of the car's tires before driving the vehicle into the service bay.

3. Do not stand in front of a vehicle being driven into the service bay.

4. Do not use any lift that has cracked contact pads, cracked lift arms or any other visible damage.

5. Do not use wood or concrete blocks as a substitute for an extender.

6. Use wheel blocks to chock the wheels of any vehicle on a runway lift while the vehicle is on the lift.

7. Do not leave the controls unattended while the lift is in motion.

8. Do not block or "tie open" the lift's control while the lift is in motion.

9. Do not use the engine or transmission supports or stands as a substitiute for jack stands.

10. If the vehicle begins to slip off of the lift, run in the opposite direction of the fall, but not toward a wall or work bench that might trap you between the object and the vehicle.

11. Before you lower the vehicle, remove tool trays, jack, engine and transmission stands, and any other obstructions from under the vehicle.

12. Before removing the vehicle from the service bay, position lift arms and supports to the center of the lift away from the wheels of the vehicles.

13. Do not "tie down" or override the air or control valves of the lift.

14. Do not raise vehicle with anyone inside it.

AUTO REPAIR TECHNICIANS


Automotive Lifts

15. When raising a vehicle, use the following procedure:

1) Use the lift to raise the vehicle about one foot off the ground, then moderately push the rear or front bumper of the vehicle to ensure that the vehicle frame is stably mounted on the lift support's contact pads.

2) If the frame of the vehicle is not firmly touching a support contact pad, or is slipping, immediately lower the vehicle and start over.

3) Once the vehicle is secure on the lift, lift the vehicle to the desired work height and visually check those contact points for misalignment before going under the vehicle.

16. As you raise the vehicle, you will hear a "clicking" noise which indicates that the lift's locking device is engaging. If you do not hear the "clicking" noise, stop the lift, fully lower the vehicle and use another lift. Place an "Out of Service" tag on the control switch of the damaged lift and do not use it.

17. If you will be working under a lift that will be positioned at a point below where the lift's locking device engages, place four jackstands under the vehicle's frame or suspension for additional support before working under the vehicle.

18. Wear safety goggles when working underneath vehicles.





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