SAFE WORK PROCEDURE, GEM MAINTENANCE

7/30/2019 SAFE WORK PROCEDURE, GEM MAINTENANCE

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Safe Work Procedure General MaintenanceDocument No: 00016Page 1 of 46

Originally Adopted: 9/6/2006

Current Adoption:1.0Due For Revision: 9/6/2007Revoked/Superseded:

Safe Work ProcedureGeneral Maintenance


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PurposeThe purpose of this manual is to provide the operator with the correct information to safely carry out general maintenanceassociated with RC surface drill rigs.

ScopeThis SWP covers the :

Immobilization

General repairs and servicing

Jacking and blocking

Lifting

Welding

Battery maintenance

Oxy and acetylene cutting

Hand tools

Tyre changing and inflationassociated with surface RC drill rigs

Learning OutcomeAt the completion of this training module the operator will be competent to safely carry out general maintenance associated with RCsurface drill rigs.

PPE RequirementsHard Hat, Safety Glasses, Safety Boots, Hearing protection, Gloves


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STEP POTENTIAL HAZARD SAFE WORK PROCEDURE

ImmobilisationProcedure

Unexpected movement ofvehicle

1. Park machine on hard, level ground where possible.2. When immobilising a light vehicle or truck, leave the

transmission in first gear, engage the park brake and turnengine off.

3. Switch off key and turn off isolation switch.4. Tag out machine according to tagging regulations as per Swick

Drilling Australias Isolation Procedures.5. Place chocks under wheels where required.


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General Repairs andServicing Procedure

Manual handling injuries

Eye injuriesCaught in machineryRing avulsion injuries

Slips/falls

Always use the Immobilisation Procedure. Because of the size ofsome of the components, personnel should check the weight of theobject.

1. If it is overly heavy or awkward, then assistance from otherpersonnel should be sought.

2. If it is extremely heavy, then some mechanical means should beused.

At all times, the correct lifting procedure should be used whenremoving any components.

1. Always wear protective glasses and boots when working aroundmachines.

2. Do not wear loose fitting or torn clothing.3. Remove all rings from fingers when working on machines.4. Where possible, ensure the machine is on a level, hard surface.

If jacking is required, follow Jacking and Blocking Procedure.

1. Use steps and grab handles when mounting or dismounting amachine.

2. Clean any mud, oil or debris from steps, walkways or work

platforms before using.3. Always face the machine when using steps, walkways and

ladders.


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General Repairs andServicing Procedure(cont.) Unexpected release of high

pressure airBurns/scolds

Contact with moving parts

Slips/trips/falls from height

All tools used for repairs or servicing should be of the correct typeand in good condition.

1. Relieve all pressure in air, oil or water systems before any lines,fittings or related items are disconnected or removed.

2. To avoid burns, be alert for hot parts on machines which havebeen stopped and hot fluids in lines, tubes and compartments.

3. Ensure all protective devices, including guards and shields areproperly installed and functioning correctly before startingrepair.

4. If a guard or shield is removed before repairs, use extra caution.

5. After service or repair, make sure all protective guards andcovers are secured in place on machine.

6. Make sure the machine deck, walkways and steps are free ofdebris, oil, tools or other items not part of the machine.

When servicing machinery, ensure all oil, water and grease levelsare correct according to specifications as per the manufacturer


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Jacking and BlockingProcedure

Unexpected hydraulicfailure. Crush injury

Stand failure/crush injury

Vehicle slipping off jack.

Crush injury

1. Do not work on any machine that is supported only by lift jacksor hoists.

2. Immobilize machine according to Immobilization Procedures.3. Ensure lift jack is of the correct capacity and height for the job.4. Position the lift jack in an appropriate jacking point and jack

machine up to the required height.5. Install stands in the correct positions and release lift jack slowly

until stands take up all weight of the machine.6. If the top of the stands are not shaped to fit certain machine

components, i.e. flat wooden blocks are to be placed between

the stand and the machine to prevent slipping.


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Lifting Procedure

Failure of lifting devices

1. Immobilise the machine according to ImmobilisationProcedures.

2. Ensure lifting devices are in good condition and are of thecorrect capacity for the job.

3. Check slings for fraying and wear.4. Check chains for stretching, cuts, kinks or any other signs of

damage and check that the certification tags are current.5. Make sure lifting devices are attached correctly to the lift eyes.6. No side loading on eyes during a lifting operation.7. Make sure hooks are positioned correctly.

8. When using a forklift for lifting, ensure it is on hard, levelground.9. Make sure the load to be lifted is within the forklifts capacity.10. When using slings do not:

a) exceed SWLb) dragc) drop from heightd) kinke) tie knots inf) join with nut and boltg) place around sharp corners without packing

h) shock loadi) induce angles that exceed the SWLj) store in weatherk) drag from under load.


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Welding Procedure

Battery explosion. Burns

Flash burns

Burns from sparks/slag

Inhalation of fumes

Fire

Explosion of container

Electrocution

1. If welding on a machine, immobilise according to theImmobilisation Procedure.

2. Disconnect batteries.3. Ensure all personnel other than the person performing the

welding are clear of the area so as to reduce the likelihood of aflash incident.

4. Use the correct welding gauntlets, shield goggles, apron andother protective clothing appropriate to the welding job beingperformed.

5. Ensure there is adequate ventilation to remove welding fumesfrom the working area.6. Check there is no flammable material within ten (10) metres of

the welding job.7. Welding diesel containers should be carried out with the diesel

drained and the container filled with water.8. Avoid welding in and around water wherever possible.9. If work must be done in wet conditions, ensure rubber boots are

used and standing on rubber mats, if appropriate.


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Battery Changing andCharging Procedure

Explosion of battery gasBurns from acid/explosion

Batteries give off flammable gases which are explosive. Nosmoking and no naked flames around batteries. Protectivegloves and glasses of the appropriate type should be worn.Immobilise machine according to Immobilisation Procedures.Remove the negative terminal first, then the positive. Removebattery clamps. Remove batteries from machine. This job oftenrequires two people depending on the size and location of thebatteries. Where practicable, mechanical lifting devices shouldbe used. Remove the battery and take to a well ventilated area,free of any ignition sources for charging. Remove battery capsand check that the electrolyte is covering the cells. Ensurecharger is switched off and connect the charger clamps tobattery posts in correct polarity, usually black to negative andred to positive. Check the charger is on the correct voltage forthe battery and that it is on low amps, then switch on. If thetemperature of the battery exceeds 50 degrees Celsius or it isgassing violently or splashing electrolyte, stop charging orreduce the rate. After the battery is charged, switch off powerand disconnect the battery from the charger. Check batterycaps to ensure vent holes are clear and then screw back in.Check that the battery is charged.


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Battery Changing andCharging Procedure.(cont.)

Batteries can be connected so that more than one is charged at

once.

Parallel Charging: Connect the positive of one battery to thepositive of another; negative of one to the negative of the other.The number of batteries which may be connected depends onthe current capacity of the charger. Only batteries of the samecapacity should be charged at once and current will be equallydivided amongst the lot.

Series Charging: Connect the positive terminal of one battery tothe negative of the other. Each battery receives the full current

as shown by the charger. The number of batteries which can beconnected depends upon the voltage rating of the charging

source. Batteries of different capacity can be charged but therate must be set in line with the lowest capacity battery.


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THE USE OF OXYGENAND ACETYLENECUTTING EQUIPMENT

Pinch/crush injuries

PersonnelPersonnel who use oxygen and acetylene must:

a) Be trained to identify the contents of different gascontainers and know their potential hazards from theavailable MSDS sheets.

b) Be trained in the operation and the use of safety andemergency equipment provided (eg. fire extinguishers).

SAFE HANDLING OF OXYGEN AND ACETYLENE

BOTTLES

Equipment

Personnel who regularly move or handle gas cylinders, must beprovided with:

a) stout gloves (eg. leather)b) protective footwear (eg. steel cap shoes)c) trolley or other suitably designed device for transporting

cylinders. There should be provision for securing thecylinder during the moving with a chain.

.


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THE USE OF OXYGENAND ACETYLENECUTTING EQUIPMENT(cont.)

Manual handlinginjuries

Handling TechniquesMost accidents or injuries whilst handling cylinders of compressedoxygen or acetylene occur whilst moving these cylinders. For thisreason, personnel are to:

a) remember the mass of the cylinder (up to 100kg)b) to be aware of trapping fingers between cylinders whilst they are

being movedc) when it is necessary to lift heavy cylinders, to manually to seek

help and observe the lifting postured) to use a trolley or other suitable device for transporting heavy

cylinders, even for a short distance and to ensure that thecylinder is secured

e) to ensure regulator withdrawal equipment is disconnected andthe valve firmly shut when moving

f) to ensure that, when provided, valve protection caps and gas tiedoutlet cap plugs are securely fitted to cylinders whilst they arebeing moved and not in use.


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THE USE OF OXYGENAND ACETYLENECUTTING EQUIPMENT(cont.)

Breakage of valve assyUnexpected release of highpressure gas

Storing Oxygen and Acetylene CylindersCylinders in storage must be:

a) stood upright and properly secured to prevent toppling overto protect cylinder valve from damage

b) kept with supplied valve protection cap or guard or gas typevalve outlet cap/plug securely in place

c) segregated in the storage area according to the variouscategories (eg. flammable - oxygen; non-flammable -poison, etc.)

d) segregated in the storage area according to content (ie. full

or empty)e) manage to ensure that the older stock is used first

check periodically for general condition - severe rusting, leaks, etc


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SAFE TRANSPORT OFCOMPRESSEDCYLINDERS

OF OXYGEN ANDACETYLENE

Explosion/fire from leakinggas

Breakage of valve assyUnexpected release of highpressure gas

Checks Prior to Transport

Gas containers must always be checked prior to transport toensure:

a) the valves are closed and not leakingb) the valve outlet sealing plug or cap nut, where supplied, is

fitted and tightened using an appropriate tool. This deviceprovides a seal on the valve outlet in the event of the valvebeing opened by mistake and is particularly important fortoxic gases.

c) the valve protection cap or guard, where supplied, iscorrectly fitted. This provides protection for the valveagainst mechanical damage, eg. if a gas container isdropped, or falls over.

d) the cylinder or container is correctly labelled in accordancewith the Australian Dangerous Goods Code.

Type of Vehicle

Vehicles used for transporting cylinders of pressurised gas must

have a well ventilated load area (closed vehicles, eg. private cars,small vans) must never be used to transport toxic gasses andonly with added precautions for other gasses. Vehicles carryinggas containers should be equipped with a fire extinguishersuitable for fighting fire or engine fires.


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SAFE TRANSPORT OFCOMPRESSEDCYLINDERS

OF OXYGEN ANDACETYLENE (cont.)

Load Security Safetya) the load on a vehicle must be adequately secured to

prevent movement during transport and it is important tobear in mind the mass of the gas containers when securingthem to the vehicle

b) particular care should be taken when securing small gascylinders as experience has shown that these can easily belost. They are best carried in special ventilated cage, butnote, they must never be placed in the driverscompartment.

c) unattended vehicles carrying gas cylinders should only beparked in proper parking places, preferably those which aresecure and away from the general public

d) cylinders must not protrude outside vehiclese) liquefied gasses, especially liquefied flammable gas, ie.

LPG, must always be transported vertically to ensure themandatory safety relief device is always in contact with thegas space. This is a legal requirement.


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THE SAFE USE OFCOMPRESSEDOXYGEN ANDACETYLENE

Fire/explosion from gas buildup

Gas Usage AreaThese should be:

a) generally well ventilatedb) Cylinders should be arranged so as to minimise fire risk in

the vicinity of the gas containers. It may also benecessary to eliminate ignition sources. For example,where flammable gasses are used, when non-combustionapplications and where there is a risk of leakage.

c) The area must be provided with appropriate safety andemergency equipment and information (eg. fire

extinguishers, eye protection, emergency disposal systemand the necessary MSDS sheets).

Gas Handling/Control Equipment

It is important to use the correct pressure flow controlequipment. The choice of suitable pipework, fittings andequipment is dependent upon the gas operating pressure. Thechemical and physical properties of the gas, the gas purity, andother user requirements

Special Consideration

Always use a pressure regulator. Do not pipe at cylinderpressure. Installations handling oxygen must be free offlammable materials (eg. oil and grease).


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THE SAFE USE OFCOMPRESSEDOXYGEN ANDACETYLENE(cont.)

PersonnelPersonnel who use compressed gasses such as oxygen andacetylene should be trained in:

a) the identification of the gas container contents and thepotential hazards. They should also have access to theappropriate material safety data sheets.

b) the operation and use of the safety and emergencyequipment, where provided (eg. fire extinguishers, eyeprotection, hand protection, etc.)

c) the handling and use of the gas container and its valve

d) the correct operation of the gas flow and controlequipment

e) the importance of ensuring that the gas container is notcontaminated

f) what emergency procedures to institute should a problemoccur


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Compressed Gas Cylinder Pre-Use ChecksPrior to connecting equipment and using gas from cylinders:

a) check to see if they contain the correct gas for theintended usage by reference to the gas name label,reading the instructions or warnings

b) secure properly to prevent toppling over or othermovement which would fracture the connecting pipeworkor damage control equipment

c) remove by hand the disposable plastic plug initially fittedto the cylinder valves after filling

d) check for cleanliness of the cylinder valve outlet asfollows, particularly on subsequent use for fire and matterwhich may harm equipment and be hazardous:

for Class 2.2/5.1 oxidising gasses (eg. oxygen), crackedcylinder valve (open and quickly shut) to remove waterand dust. Do not use compressed air or cleaning clothswhich may lead to ignition due to oily residues

for Class 2.1 flammable (eg. acetylene), use compressedair or a clean brush to remove water or dust. Do notcrack the cylinder valve


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Damage to cylinder/valve assy

Explosion/fire

Care of the Cylindera) Do not drop cylinders from a height or allow cylinders to

fall over.b) Secure cylinders against falling whilst in use, storage or

transport.c) Do not allow naked flames to impinge on cylinders.d) Do not allow any form of heating that would artificially

raise the temperature of the cylinder above 45 degreesCelsius.

e) Do not use cylinders as rollers or supports for plates.

f) Protect cylinders from impact damage from passingvehicles.g) Protect cylinders from paint spray, acids, alkalies,

prolonged water contact.h) Do not strike electrical arcs on cylinders.i) Do not cover up or repair signs of damagej) Do not repair cylinder valves.k) Keep cylinders, particularly the valves, clean. Do not use

cylinders with dirty valves. Do not attempt to clean valvesl) Close cylinder valves when the cylinder is not in use.

Also when the cylinder is empty. Refit any supplied valve

cap or gas tied outlet cap or plug.


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BurnsExplosions

EMERGENCY PROCEDURES WHEN DEALING

WITH FIRE SITUATIONS OR FLAMMABLECOMPRESSED GASSES

In general:

a) if possible, immediately isolate the gas supply so that itdoes not continue to flow into the affected area

b) Fire threatening compressed gas cylinders. If there is arisk of rupture, explosion of cylinders subjected toprolonged heating (such as in a fire), such cylindersshould be moved to a protected place before they becometoo hot, or if this is not possible, cooled with water hosedfrom a protected position, a safe distance away.

c) Any cylinder that has been involved in a fire, must beclearly marked as such the supplier must be notifiedaccordingly to prevent hazards to people who refillcylinders. Never cover up a fire damaged cylinder.

d) Ignited flammable gas leak: If possible, isolate the gassupply. If this is not possible, DO NOT extinguish theflame. Try to ensure the flammable gas burns in ascontrolled a manner as possible. It does not ignite

anything else and it does not impinge upon anypressurised gas containers, equipment or pipelines. Ifpossible, keep surrounding area equipment cooled byspraying with water from a protected and safe distance.


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CARE AND USE OFHAND TOOLS

Material flying off hammer facePuncture injury

Loose hammerhead projectile

Common Sense Rules When Using Hand Tools

1. Select the right tool for the job

2. Use it in the correct manner3. Make sure it is in good condition4. Store it safely

Remember hand tools will not abuse you unless you abusethem.

HammersHammer FaceIt is important that the hammer face is keep clean and free ofgrease as these cause the hammer to slip possibly resulting inan injury. Never hit any items such as files that are harder than

the hammer as this produces pitting of the face which in turncan cause slippage or twisting of the hammer during use.Check the face of the hammer for these defects and get themcleaned or refaced.

Safety Checks on Hammers1. Before using a hammer, check that it is safe to use.2. Check that the hammer head is firmly attached to the

handle.3. Check that the holding wedges are tight. Never use nails

as holding wedges.

4. Check that the hammer handle is free from cracks, splitsand splinters.

5. Check that the face is free from oil and grease or othersubstances and free of pit marks.


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CARE AND USE OFHAND TOOLS(cont.)

Foreign body in eyes

If any of the above items are found to be faulty, do not use the

hammer, but replace it as soon as possible.

Use of HammersThere are a few safety rules associated with the use of a

hammer.1. Keep hands and fingers clear of the object being struck if

possible.2. Place the hand at the base of the handle, ie do not choke

the hammer. The free end can strike objects and put yourswing off.

3. When chipping at metal using chisels, wear safety glasses- eyes cannot be replaced.

4. Do not use the side of the hammer head to strike objects.Use only those faces designed for striking.

5. Do not use hammers that are faulty or damaged in anyway.

Spanners

Spanners vary considerably in shape and size to provide easeof operation and provide ease of operation under differentconditions.

There are four basic types:1. open end spanner incorporating shifting spanner2. tube or box spanners3. socket spanners4. ring spanners


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Contact with injuries

Slips/falls

The choice of spanner for use on any particular job is one that:

1. fits exactly2. allows room for use3. allows the job to be done in the shortest possible time

Safe Use of Spanners1. Exert effort on open end or ring spanners by pulling.

Pulling is the safest as there is less chance of hittingknuckles if the spanner or nut gives suddenly.

2. Use both hands on big spanners.3. Keep yourself balanced and brace to avoid slipping in the

event that the spanner or nut giving suddenly.4. Hold onto some support if there is any chance of falling.5. Use two hands when turning tubular box spanners.

Normal spanners have a length that is approximately ten timesthe width of the jaw opening. The correct pull on the end of theshank will produce the required turning effect on the nut. Neverexert excessive pull on a spanner, particularly by using a pipe toextend the length of the spanner.

Excess turning effect could:

1. strip the thread2. shear the bolt3. strain the jaws of the spanner4. make the spanner slip and cause an accident


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Importance of Correct FitIt is important not to use a spanner that does not fit correctly. Itcould result in injury to you and damage to the spanner and thenut. To fit exactly, a spanner must be the correct size, placedcorrectly on the nut and in good condition. Never use a spannerfrom one thread system on another thread system. Spannershave there jaws slightly wider than the width of the nut so theycan be placed into position with ease. However, any more than1/500th of a millimetre clearance causes the spanner to slipunder pressure. Place the spanner so that the jaws bear fully

on the flats of the nut. Failure to thrust the spanner fully on thenut is liable to damage the spanner and the nut. Only when thelower jaw makes contact with the outer edge of the flat, is amaximum turning effect on the nut produced. In the correctposition shown, the spanner should pivot about the tip of thelower jaw, springing open the jaws and bearing the edge of theflat. This could possibly result in injury to the user.


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Adjustable SpannersMost common types of adjustable spanners are similar to openend spanners but they have one moveable jaw. The openingbetween the jaw of a typical 250mm spanner can be adjustedfrom 0 to 28mm. Adjustable spanners are convenient for usewhere a full kit of spanners cannot be carried as for example, onmaintenance work. They are not intended to replace fixedspanners which are more suitable for heavy work. Keepadjustable spanners clean and oil moving parts occasionally.Inspect for damage before use. If the moveable jaw or knurled

screw are cracked or worn, replace them with spare parts.When using adjustable spanners, it must be remembered thatthe length of the handle was designed to suit the maximum jawopening. Therefore, with smaller nuts, a smaller effort shouldbe applied to the handle, otherwise shearing of the bolt canresult.When using adjustable spanners, it must be rememberedthat the length of the handle was designed to suit the maximum

jaw opening. Therefore, with smaller nuts, a smaller effortshould be applied to thehandle, otherwise shearing of the boltcan result.


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The Stillson

These wrenches are used primarily for turning pipes with a widerange of diameters. Fixed to the handle is a jaw with outwardfacing teeth. Attached to this handle by a pivot pin is a springloaded casing that carries a knurled adjusting nut. Thisengages with a thread on the adjustable arm of the jaw withinward facing teeth. Once the jaws are adjusted, the springloading keeps them in contact with the work and the toggle

action causes the hardened teeth to bite into the work. Use twohands to set it on the work. Centre the work against the fixedjaw. Use the left thumb to push the adjusting nut around toclose the jaws. When the grip is tight, pull the handle with theright hand. When changing grip, use the left hand to keep theadjusting nut steady and thereby the jaws are in the correctposition. The jaws will mark the surface of the work, thereforenever use Stilton wrenches on polished or plated work. Nevergrip hardened materials as this will damage the teeth. Stillsonwrenches should never be used on nuts or bolt heads unlessthat nut is so damaged, it has to be discarded.


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Allen KeysThese are hexagonal section bars of tool steel bent into an Lshape. They used to turn set screws having internal hexagonalsockets and are available in sets ranging in size from 1.5mm to25mm. When using these socket wrenches, make sure socketand wrench are clean before use. Use the correct size andinsert to the full depth. Discard those wrenches with worn androunded edges as these are liable to slip


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Screw DriversScrew drivers are designed to tighten or loosen screws andshould not be used for any other purpose. Hand-held screwdrivers include standard types with tips to suit screw slots.Special types (Philips) with tips to recessed head screws.

Standard Screw Drivers

Standard screw drivers are made with tips to turnscrews with slotted heads, blades of hardenedand tempered carbon steel. Usually handles aremade of metal, wood or moulded insulatedmaterial, shaped to give a good grip for turning.

Standard Shaped TipsA correctly shaped standard tip on a screw driver should ensurethat it engages the screw slot efficiently, is almost as thick asthe slot, exerts its turning moment at the bottom of the slot, hasa width not less than three quarters the length of the slot, and itturns the screw with a minimum of downward pressure. If theincorrect screw driver is used, this may result in damage to the

screw driver, damage to the workplace or injury to the hands.Prior to use, screw drivers should be inspected and if the bladeis not of a uniform taper, then it should be removed andreplaced.


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Selecting The Correct Sized Tip

It is most important when using a screw driver that the correctsize of the tip is selected. The width of the tip should bealmost equal to the length of the bottom of the slot. Toowide a tip and damage the workplace whereas toonarrow a tip can damage the head of the screw. Tipsthat are too narrow exert turning force too close to thescrew axis. Under these circumstances, the turningpressure tends to damage the screw driver tip or thescrew head rather than turn the screw. The thickness ofthe tip should almost equal the width of the slot. If, on

the other hand, the tip is too thick, the tip cannot beinserted into the slot without causing damage to thescrew head. Find out the range of screw drivers that best

suit your work and always use the correct one.


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Pierce injuries

Using a Screw DriverAfter deciding which size tip is required for any particular job,select the longest suitable screw driver with that size tip.Ensure that the handle of the screw driver and your hands aredry and free of grease and oils. Hold the screw driver with itsaxis in line with the axis of the screw. Guide the blade with theleft hand. Apply just sufficient pressure with the right hand tokeep the tip in the slot and twist firmly and steadily. Alwaysbrace small work against the bench or other firm support beforeusing a screw driver. Never hold small work in your left whileusing a screw driver as it could slip and pierce your hand. To

turn large screw, use a screw driver with a square blade using aclose fitting spanner on the blade to give extra turning force.Never use pliers to apply twisting force to square blade of thistype of screw driver. Impact screw drivers are also available forthis class of work.


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Special Type of Screw Drivers for Recessed Head ScrewsA wide variety of recessed head screws are used inmanufactured articles. It is important that the correct form ofscrew driver is used on these screws as in the case of PhilipsHead screws. Remember - right tool, right job.

Using a Screw Driver

After deciding which size tip is required for any particular job,select the longest suitable screw driver with that size tip.Ensure that the handle of the screw driver and your hands aredry and free of grease and oils. Hold the screw driver with itsaxis in line with the axis of the screw. Guide the blade with theleft hand. Apply just sufficient pressure with the right hand tokeep the tip in the slot and twist firmly and steadily. Alwaysbrace small work against the bench or other firm support beforeusing a screw driver. Never hold small work in your left whileusing a screw driver as it could slip and pierce your hand. Toturn large screw, use a screw driver with a square blade using aclose fitting spanner on the blade to give extra turning force.Never use pliers to apply twisting force to square blade of thistype of screw driver. Impact screw drivers are also available for

this class of work.


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Special Type of Screw Drivers for Recessed Head ScrewsA wide variety of recessed head screws are used inmanufactured articles. It is important that the correct form ofscrew driver is used on these screws as in the case of PhilipsHead screws. Remember - right tool, right job.


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Pliers

Pliers, tongs and cutters are from the one family of tools. Theyhave a pair of legs, joined by a pivot, each leg consists of a longhandle and a short jaw and thus applies the principles of leversto gain mechanical advantage. Small pressure on the handlesgives great pressure on the jaws.

Some of the more popular types of pliers used are:

1. multi-grip pliers2. engineers or combination pliers3. side cutters

Multi-Grip Pliers

Multi-grip pliers are slip joint pliers having a sharp pivot whichcan fit into a number of openings in the legs. This gives a rangeof jaw openings allowing parallel gripping by the jaws in anumber of position. The longer handles on multi-grip pliersallow a very strong jaw grip to be obtained. However, care mustbe taken not to exert too much pressure as this could damagethe shaped pivot pin.


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Foreign body in eyes

Engineers or Combination PliersA standard engineers or combination pliers as they are calledshould have:

1. a serrated flat jaw grip for general gripping2. a serrated pipe grip jaw for gripping cylindrical objects3. side cutting blades for cutting small diameter soft wires4. shear cutters for cutting steel wire5. bear or insulated handles.

When using combination pliers for cutting short endsfrom wire, the same precautions as described inthe use of side cutters, should be observed. SideCutters

These should have:

1. jaws set at an angle2. a single cutting blade jaw

Side cutting pliers are used for cutting small diameter wires,cutting wires close to flush surfaces. Care should be exercisedwhen cutting short ends of wire, especially steel wire, as theyare liable to fly when cut. Cut with the free end pointing awayfrom you and wear safety spectacles if necessary


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Using Pliers Safely

There are some basic safety rules to be observed when usingpliers. Not only will the observance of these rules help toprevent the user from receiving injury, but will also extend thelife of the tool.

1. always use the correct size and type of pliers2. do not try to cut material that is too large or too hard for the

cutting jaws as this could deform or break them3. never try to put extensions on the handles as this could

break them4. never use pliers to turn nuts - use the correct size spanner5. when gripping an object, pull towards you to turn it. There is

less danger of slipping6. never use unprotected pliers to grip a hardened, polished or

plated surface.7. keep the pliers clean. Wash in a suitable solvent and dry

regularly8. oil the pivot pin to keep it free moving and reduce wear9. inspect the pliers regularly. Worn tools can slip and damage

your hand and the work piece.

10. replace damaged insulating covers on the handles ofelectricians pliers.

11. never subject pliers to heat as this can ruin them12. worn out pliers can be used as tongs for holding hot work

when they are useless for anything else. Always weargloves for this operation.


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HacksawsMost hand hacksaws have frames that are adjustable to takeseveral different lengths of blade. Set screw enables the bow tobe set in different positions and the handle to facilitate this. Thetension in the blade holding pieces has square shanks to allowthem to be set in any one of four positions, from the flats ofthese pieces hardened steel pins projected at a slight angle tohold the blade. A wing nut it provided to apply the correcttension to the blade. Hacksaw frames should be well balancedand rigid when tension. When not in use, it is most importantthat the tension should be removed from the frame by loosening

the blade. Clean and oil the tension piece and wing nut fromtime to time. To make cuts greater than the depth of the bow, itis necessary to set the blade at right angles to the plane of theframe. This can only be achieved if the work piece is sufficientlynarrow to clear the frame.

Choice of Hacksaw Blades

When performing any work where a hacksaw is to be used, theselection of the blade is of the utmost importance. The followingnotes may help you in deciding which hacksaw blade is required

for the particular job in hand.Hacksaw blades are identified by the pitch of the teeth and thenumber of teeth per inch (tpi). The size of the teeth is directlyrelated to the pitch - the finer the pitch, the smaller the teeth.


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Avoiding Damage to the BladeObeying some simple common sense rules will help extend thelife of your hacksaw blade.

1. never allow the teeth to strike a sharp edge or straddle thickwork as this causes complete teeth to be broken out

2. limit the downward pressure on the blade when there areonly a small number of teeth in contact with the work.Excessive pressure will crack the blade or break the pointsof the teeth

3. keep the correct tension on the blade

4. keep the frame upright so that the blade does not tilt in thecut5. keep cutting straight so that the sideways thrust does not

twist the blade6. normally, blades are pulled through the work by the front of

the frame, but if they jam in the cut, thrust from the back ofthe frame causes the blade to buckle and break

7. always inspect the blade before starting a cut8. replace blades that are worn, cracked or have missing teeth


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CHANGING TYRES

Unexpected movement ofthe vehicleInteraction with othervehicles

Procedure for changing a tyreEnsure the truck is parked on a level flat hard surface.Ensure ignition is off.If on the road, ensure hazard lights are switched on and safetytriangles (if available) are placed in the appropriate position.Ensure a wheel, other than the one being jacked, is chocked onboth sides.Safety glasses and steel toe shoes are worn.Locate jack.Remove spare wheel from carrier and place beside flat tyre.

If there are no jack points, place jack under axle as close to the tyreas possible. Jack the vehicle until jack takes the weight of thevehicle. Make sure the jack is capable of lifting and holding theweight.Check for left or right hand thread markings

Loosen wheel nuts without fully removing.Jack vehicle until wheel is free..Safely release pressure from wedge (if fitted) by tapping with wheelbrace.Loosen nuts, studs and wedges with wheel brace and remove.

Remove outer wheelPlace wheel brace under bottom of tyre to take the weight off.Remove tyre wheel and or rim from vehicle taking care not todamage stud threads.Remove tyre and lean it against the truck.Remove spacer and place beside wheel.


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Remove inner wheelPlace wheel brace handle under bottom of tyre to take the weight

off.Use short sharp upward movement with wheel brace.Pull wheel with other hand and slide rim off hub.

Replace inner wheelMake sure all surfaces on hub wheel spacers are clean and withoutdamage.Clean and prepare hub or spider for remounting of tyre wheel rimassembly.Place rim in position lined up with spider, hub or retaining studs.

Ensure the valve faces outwards.Carefully mount wheel rim assembly making sure not to damagestud threads. Make sure that the valve stem is correctly positionedand accessible. Use wheel brace handle to lift tyre, then pushwheel into position.Make sure valve is positioned between the two studs.

Inspect and refit spacer if applicable.

Replace outer wheelEnsure valves are placed for easy access.

Spider and rim assemblies will require correct positioning of lugsand pre-tensioning of nuts so that the

rotating assembly can be checked for lateral runout. When this isachieved and the vehicle is lowered

from the jack, proceed with correct nut tensioning in the right


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sequence.

Replace individual wedges retaining studs and nuts.

Wheel and hub assemblies will be self-centering provided that thenuts have been tightened in the correct sequence and in the correcttorque. Note - make sure that nut and hole contours are correctlymatched.

Tighten nuts in sequence.Lower and remove jack.Securely tighten wheel nuts in sequence and correct torque - spiderrim to 250 and stud wheel hub to 450 to 500.Replace flat tyre in carrier and resecure.Replace tools and jack.Remove chocks, warning sign and turn off hazard lights.Recheck wheel nuts after driving for approximately 50 kilometres.

Correct jacking procedure use jack of sufficient capacity and in good condition

use a base plate and or timber block under the jack to ensure:weight is spread over a larger areareduce the amount ram required beforecontact is made with jacking point

ensure jack is set up as close to vertical as possible and head ofjack is positioned in the centre of the jacking point to prevent

jack falling over or toppling as the load is appliedensure jackrelease screw is in the raise position

ensure handle is clear of obstructions

pump jack until wheel is clear of ground

Avoid being under vehicle while on the jack unless stand orwheel is in place


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WHEEL NUTTIGHTENINGSEQUENCE


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TYRE INFLATIONPROCEDURE

1. Immobilize the machine according to Immobilization Procedure.2. Remove valve core and make sure tyre is completely deflated.3. Always use correct tools and equipment.

4. Remove locking rings and flanges and tyre using correct toolsand equipment.5. Examine all flanges, locking rings and rim gutters.6. Make sure that all components are clean and adequately

lubricated.7. Carefully assemble tyre wheel components.8. Once a wheel rim and tyre have been assembled and before

any inflation, check the position of loose flanges, sleeve andlocking rings for correct seating.

9. Some method of restraining the locking ring must be in placeprior to the tyre being inflated and it must be ensured that the

tyre is properly centred on the rim and that the flange, lockingring and bead are correctly seated.

10. All inflation lines must have a sufficient length of hose so aspersonnel can stand clear during the inflation process.

11. In conjunction with this inflation device must be a valve andgauge so the person operating the inflation device knows whatpressure the tyre is being inflated to.

12. Final inflation of the assembly must be an approvedrestraining device, ie.

a) Cage. This can be used for small tyres and whenavailable;

b) with specially designed chains if available;c) by placing the light vehicle against the rim of the tyre that

is to be inflated. Before releasing the device, the tyremust be visually checked to see that the rim is correctlyseated.

Only trained personnel are to carry out this procedure.


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Documents

SAFE WORK PROCEDURE, GEM MAINTENANCE