2. Maintenance
The process of keeping something in useable
condition by checking or repairing it on regular
basis.
3. Practice
Actual doing of something rather than ideas
Wayof doing something
Doing an activityor training on regular basis to
improveskills
Habit orCustom
5. Why this subject?
Prime objective of an AMP is to maintain an aircraft in
airworthy condition so that it can fly safe and reach its
destinationwith all its passenger safely.
If there is an error in maintenance or ignorance of
maintenance procedure by maintenance personnel
then the life of passengers and crews and machine is at
stake.
So it is important that the persons involved in
maintenance of aircraft must have properknowledge
of procedures and practices involved inmaintenance
of aircraft
6. Safety Precautions-Aircraft and
Workshop
Safety Precaution-Aircraft andWorkshop
Workshop Practices
Tools
Operation, Function and Use of Electrical GeneralTest
Equipment
Fits and Clearances
Weight and Balance
7. Safety Precaution
An action taken in advance to
possible danger,
protect against
failure, orinjury.
Maintenance Practice-1
8. Aircraft
Any machine which can derive support in the
atmosphere from reactions of theairother than
reactions of the air against the earth's surface
and includes balloons whether fixed or free,
airships, kites, gliders and flying machines.
(source: Aircraft Rules 1937)
Anyvehicledesigned to be supported by air,
heavier or lighter than air, mechanically or
non-mechanicallydriven
9. Workshop
A roomorshopwherework is done
It includes
-Aircraft hanger maintenancebays
-Mechanical and electrical bays
-Machineshops
-Cleaning plants
-Batteryrooms
-Basic bench tool workareas
Maitenance Practice-1
10. Accident
An unfortunate incident that happens unexpectedly
and unintentionally, and may result in injury ordeath
of peopleand/ordamage toequipmentsor facilities
Accident always have acause.
That cause maybe
-unsafe humancondition
-unsafe environmental condition (Humans are
responsible for choosing or creatingunsafe
condition )
11. Hazard
anything that has the potential to create danger
and thus harm.
Most hazards aredormant or potential, with only a
theoretical risk of harm; however, once a hazard
becomes "active", it cancreate an emergency
situation.
12. Hazard
Hazardsoccursasa resultof day-to-dayactivities
in and around the workplace.e.g.
Slippery floor
Defective tools
Spilled chemicals
Overconfidence
Fatigue
Stress
Lack of fitness
Inappropriate or incorrectly worndresses
13. Risk
‘risk is the likelihood/chance thata person may be harmed
or suffersadverse health effects if exposed toa hazard.’
The level of risk is often categorised upon the potential
harm or adverse health effect that the hazard may cause,
the numberof times persons areexposed and the number
of persons exposed.
Exposure to airborne asbestos fibres will always be
classified as high because a single exposure may cause
potentially fatal lung disease, whereas the risk associated
watching a television for a short period could be
considered to bevery low as the potential harm oradverse
health effects areminimal.
14. Risk and Hazard
The terms Hazard and Risk are often used
interchangeably but this simpleexampleexplains the
difference between thetwo.
If there was a spill of water in a room then that water
would present a slipping hazard to persons passing
through it. If access to that area was prevented by a
physical barrier then the hazard would remainthough
the risk would beminimised.
So, Risk and Hazard collectively leads toAccident.
15. Risk Assessment for Safety
A risk assessment would involve identifying a
hazard and then evaluating the risk in the light of
precautions to reduce thedangerorremove it.
First hazard must be recognized; then they must be
assessed; and finally, if necessary, they must be
controlled.
19. Airport
An airport is a location where aircraft such
as fixed-wing aircraft, helicopters, and
blimps take off and land. Aircraft may be
stored or maintained at an airport. An
airport consists of at least one surface such
as a runway for a plane to take off and land,
a helipad, or water for takeoffs and landings,
and often includes buildings such as control
towers, hangars and terminal buildings.
20. Airside and Landside
Airports are divided into landside andairside
areas.
Landside areas include parking lots, public
transportation train stations andaccess roads. It is
the area accessible to normalpublic.
Airside areas include all areas accessible to
aircraft, including runways, taxiways and ramps.
Access from landside areas to airside areas is
tightly controlled at mostairports.
25. APRON
Tarmac: Though commonly used to describe the area
where planes park, tarmac isn’t officially a place. That
word is the name of a product produced by a British
company that produces a surface coating that is
applied to roads andairfields.
Using tarmac to describe where planes park is like
calling thearea outsidea building wherecars park “the
concrete” instead of calling it the parking lot. Tarmac®
with acapital “T” is a registered trademark.
26. APRON
Ramp: It’s a common unofficial term that is very much
in use at airports of some American and Asian
countries.
27. APRON
Apron: This is in fact the official term used by both the
International Civil Aviation Organization (ICAO), which
advises on aviation practices worldwide, and the Federal
Aviation Administration (FAA), which regulates aviation in
the U.S., to designate the area at the airport where parked
and serviced atairports.
The apron is a busy place. It’s the part of the airport where
vehicles and airplanes share the same space. The many
movements on the apron are not generally controlled by
the air traffic control tower.
28. ManeuveringArea
Area other than apron, used for the movement
of the aircraft on the ground and for the
taking-off and landing.
31. Runway
A stripof land orwaterfrom which aircraftcan takeoff
and land onairport.
32. Hanger
An enclosed structuredesigned to hold theaircraft in
protectivestorage.
33. Points to be Observed
Apron environment is often a busy one and be
aware of thedanger.
Aware with airport operations instructions
rules.
Entry to the maneuvering arearequireclearance
from local air trafficcontroller.
34. Airport Marking
Airport markings are used to mark structures,and
path so that these can be used by required
personnel orvehicles without confusion.
Both paint and lights are used for marking so
that, markingsarevisible in dayaswell as night.
Vehicle routes – whiteline
Aircraft routes – yellowline
Pedestrian routes – greenline
Delineation between apron and maneuvering
area – double whitelines
35. Aircraft Taxiway
The taxiway centre-line is a single continuous yellow
line, 6 inches (15 cm) to 12 inches (30 cm) in width.
This provides a visual cue to permit taxiing along a
designated path.
Taxiway edge marking are of twotypes:
Continuous: Consist of a continuous double yellow
line, with each line being at least 6 inches (15 cm) in
width spaced 6 inches (15 cm) apart. Theyare used to
define the taxiway edge from the paved surface not
intended for use byaircraft.
36. Aircraft Taxiway
Dashed Markings. define theedgeof a taxiwayor taxi-laneon a
paved surface where the adjoining pavement to the taxiway edge
is intended for use by aircraft. e.g., an apron. Dashed taxiway
edge markings consist of a broken double yellow line, with each
line being at least 6 inches (15 cm) in width, spaced 6 inches (15
cm) apart (edge toedge). These linesare 15 feet (4.5 m) in length
with 25 foot (7.5 m) gaps.
Identified by blueedge light and sometimesgreen centre line
lights.
Also havered stop bar lights atvarious holding points.
40. Runways
A line of lights on an airfield or elsewhere to guide aircraft
in taking off orcoming in to land oran illuminated runway
is sometimesalso known as a Flare Path.
Runway center Line: embedded in surface of runway at 50
ft interval along runway center line. White light is used for
this except last 900 m, alternate white and red for next
600m, and red for last300m.
Runway edge lights: white elevated lights that run the
length of the runway on either side. On precision
instrument runways, the edge-lighting becomes yellowin
the last 2,000 ft (610 m) of the runway, or last third of the
runway, whichever is less.
41. Vehicles
For driving in the movementarea personnel must
require Airfield Driving Permit(ADP).
Aircraft have priorityoverall vehicles in the
airside.
Fireand rescuevehicles on emergencycall out
have priority.
Pedestrian have priority onapron.
42. Vehicles
All vehicles display a roof mounted yellowflashing
obstruction light in movementarea.
Fireand rescuevehicles display a flashing blue
light when emergencycallout.
In apron speed of vehicles restricted to 15mph.
Vehicles use dipped headlight while moving.
Vehicles must not approach aircraft until the
aircraft is choked and engines have been shut
down and anti-collision lights have beenswitched
off.
43. Vehicles
Vehicles have to positioned so that theydo not have to
reverse in order to leave the zone.
45. Noise
Noise from turbineengine can cause temporaryor
long-term damage tohearing.
This noisealso blankets the sound of approaching
vehiclesand will drown outshouted warnings.
Personnel working on airport needs toweartheear
defenders.
46. Engine
Personnel must bealertat the timeof starting of
engine not to stray in front of engine intakes,
propellers or into thejet-blast.
Even at low powersetting hot jet blastcan be left 100ft
behind theaircraft.
At full powersomeengines can even pull a full grown
man into intake. And can throwa truck, if is in the
vicinity of engine’sexhaust.
Soareas coming directly undertheoperationof engine
should beavoided.
49. Fuel Spill
The source of spill should be shutoff.
All sources of ignition should beremoved.
All engines in Ground Power Unitand vehicles in the
area should be turnedoff.
50. Task Lighting
Overhead pylon lights are capable of illuminatingthe
area but this does not help when personnel are
working underaircraft.
Lighting in these area are well below what would
considered adequate for conducting maintenance task.
Hand torches may seem to be an ideal solution but
their batteriesgraduallydepleteand theydo restrict
user to one handed operation.
51. Task Lighting
Ensure that the light being used duringmaintenacne
is of approved flameproof type.
52. Foreign Object Damage (FOD)
Unwanted objectother than objects required aircraft
maintenance and operation are known as Foreign
Object. Cuts of locking wire, split pins, plastic
bags, stones etc.
Can damage the turbine engine.
Can cause serious damage to the moving propeller
blades.
53. Working onA/c
Appropriate clothing and suitable footwear, donot
wear jewellery or looseitems.
Don’t carry means of ignition.
Beaware that it takes time togain fully nightvision
when moving from a brightly lit area to a dark
place.
Always ground aircraft before fueling,de-fueling
or work on oxygensystem.
Approved fire extinguisher should be locatedat
easily accessiblearea.
54. Working onA/c
Aircraft should be correctlychoked, and appropriate
coversand locks should be used when required.
Before moving flight control surfaces ensure that
movement is notobstructed byground equipment,
and don’t posses hazard to personnel.
Specified procedure and must be followed during
removal or installation of aircraft’scomponent.
Don’t use tools carelessly as this may scratch the
aircraft paint finish and will introducecorrosion.
55. Working onA/c
Ensure that aircraft electrical bonding wires and static
discharges are left intact and connected after work has
been completed.
Always take extra care while handling the aircraft
fluids. As there spillage maydamageotheraircraft
parts.
Approach the helicopter in view of the pilot.
Neverapproach a helicoptercarrying anything with a
vertical height that the blades could hit. This could
cause bladedamageand injury to the person.
56. Shop Safety
The highest standards of orderly work
arrangements and cleanliness should be observed
during the maintenance of aircraft.
Where continuous work shifts are established, the
outgoing shift should remove and properly store
personal tools, rollaway boxes, all work stands,
maintenance stands, hoses, electrical cords, hoists,
crates, and boxes that were needed for the work to
beaccomplished.
57. Shop Safety
Signs should be posted to indicate dangerous
equipment or hazardous conditions. There should also
be signs that provide the location of first aid and fire
equipment.
Safety lanes, pedestrian walkways, and fire lanes
should be painted around the perimeter inside the
hangars. This is a safety measure to prevent accidents
and to keep pedestrian trafficoutof work areas.
58. Shop Safety
Technicians and supervisors should watch for their
own safetyand for the safetyof others working around
them.
If other personnel are conducting their actions in an
unsafe manner, communicate with them, reminding
them of theirsafetyand thatof othersaround them.
59. Electrical Safety
It is known that when electricity is applied to the
human body, it can create severeburns.
In addition, the nervous system is affected and can be
damaged ordestroyed.
To safely deal with electricity, the technician must
have a working knowledge of the principles of
electricity, and a healthy respect for its capability to do
both work anddamage.
60. Electrical Safety
Wearing or use of proper safety equipment can provide a
psychological assurance at the same time it physically
protects theuser.
The use of rubber gloves, safety glasses, rubber or grounded
safety mats, and other safety equipment contributes to the
safety of the technician working on or with electrical
equipment.
Two factors thataffectsafetywhen dealing with electricity
are fearand overconfidence. While both acertain amount
of respect forelectrical equipment is healthyand acertain
level of confidence is necessary, extremes of either can be
deadly.
61. Electrical Safety
Lack of respect is often due to lack of knowledge.
Personnel who attempt to work with electrical
equipmentand have no knowledgeof the principlesof
electricity lack the skills to deal with electrical
equipmentsafely.
Overconfidence leads to risk taking. The technician
whodoes not respect thecapabilitiesof electricitywill,
sooner or later, become a victim of electricity’s
awesomepower.
62. Fire Safety
Anytimecurrent flows, whetherduring generation or
transmission, a byproduct of that flow is heat. The
greater the current flow, the greater the amount of
heatcreated.
When this heat becomes too great, protective coatings
on wiring and other electrical devices can melt,
causing shorting, which leads to more current flow
and greater heat. This heat can becomesogreat so that
metals can melt, liquids vaporize, and flammable
substances ignite.
63. Fire Safety
Toprevent electrical fires:
- keep the area around electrical
equipment clean, uncluttered,
work or electrical
and free of all
unnecessary flammablesubstances.
- Never place wires or cords where they will be walked
on orrun over byotherequipment
64. Compressed Gas
Storage room for Gas cylindershould be well ventilated
Cylinders should not be exposed tosunlight.
Gas cylinders should not be laid on dampground.
Lightning for stores containing combustible gascylinder
should be flameproof.
Breathing oxygen and welding oxygen should besegregated
and properly labeled to avoidconfusion.
Grit, dirtand oil should be prevented from entering the
cylindervalves.
Acetylene cylinder should be storedvertically.
65. Compressed Gas
Compressed air, likeelectricity, is an excellenttool as
long as it is undercontrol.
Inspectair hoses frequently for breaks and worn spots.
Unsafe hoses should be replacedimmediately.
Keepall connections in a “no-leak condition.”
Airused forpaintspraying should be filtered to
remove oil andwater.
Neverusecompressed air toclean handsorclothing.
Pressure can force debris into the flesh leading to
infection.
66. Compressed Gas
Air hoses should bestraightened, coiled, and properly
stored when not inuse.
Many accidents involving compressed gases occur
during aircraft tire mounting. Toprevent possible
personal injury use appropriate lifting andmounting
devices in mounting orremoving heavy aircraft tires.
67. Welding Safety
Welding should be performed only indesignated
areas.
Any part to bewelded should be removed from the
aircraft, if possible.
A welding shop should be equipped with proper
tables, ventilation, tool storage, and fireprevention
and extinguishing equipment.
Welding on an aircraft should be performed outside, if
possible.
68. Welding Safety
If welding in the hangar is necessary, observe these
precautions:
During welding operations, there should be no open
fuel tanks, and no work on fuel systems should be in
progress.
No painting should be inprogress.
Noaircraftare to be within 35 feetof thewelding
operation.
No flammable material should be in thearea around
the weldingoperation.
69. Welding Safety
Onlyqualified welders should be permitted todo thework.
Fire extinguishing equipment of a minimum rating of 20B
should be in the immediatearea with 80B rated equipment
as a backup.
Aircraft being welded should be in towable condition, with
a tug attached, and the aircraft parking brakes released. A
qualified operator should be on the tug, and mechanics
available toassist in the towing operation should it become
necessary to tow theaircraft. If theaircraft is in the hangar,
the hangar doors should beopened.
70. Fire Protection
Rapid oxidation, accompanied by a noticeable release
of heatand light, is called combustionor burning.
Requirements for Fire ToOccur:
Fuel: something that will, in the presence of heat,
combinewith oxygen, thereby releasing more heatand
as a resultreduces itself tootherchemical compounds;
Heat: accelerates thecombining of oxygen with fuel, in
turn releasing moreheat
Oxygen: theelementwhich combines chemicallywith
anothersubstance through the processof oxidation.
71. Fire Protection
Classification of Fires:
For commercial purposes, the National Fire Protection
Association (NFPA) has classified fires into three basic
types: Class A, Class B, and ClassC.
Class A fires occur in ordinarycombustible materials,
such as wood, cloth, paper, upholstery materials, and
so forth.
Class B fires occur in flammable petroleum products
of other flammable or combustible liquids, greases,
solvents, paints, and soforth.
72. Fire Protection
Class C fires occur involveenergized electrical wiring
and equipment.
Class D fire Class D fires are not commercially
considered by the National Fire ProtectionAssociation
to be a basic type or category of fire since they are
caused by a Class A, B, or C fire. Usually Class D fires
involve magnesium in the shop or in aircraft wheels
and brakes, or are the result of improper or poorly
conducted welding operations.
73. Fire Extinguishers
Any type of fire can occur during maintenance on or
around, or operations involving, aircraft. There is a
particular type extinguisher which is most effective for
each type of fire.
Water extinguishers are the best type to use on Class A
fires. Water has two effects on fire: it deprives fire of
oxygen and cools the material beingburned.
Never use water-type fire extinguishers on Class D
fires. Because metals burn at extremely high
temperatures, the cooling effect of water causes an
explosive expansion of themetal.
74. Fire Extinguishers
Carbon dioxide (CO2) extinguishers are used for Class
A, B, and C fires, extinguishing the fire by depriving it
of oxygen.
Additionally, like water-type extinguishers, CO2 cools
the burning material.
Carbon dioxide (CO2) extinguishers are used for Class
A, B, and C fires, extinguishing the fire by depriving it
of oxygen. Additionally, like water-type extinguishers,
CO2 cools the burning material.
75. Fire Extinguishers
Never use CO2 on Class D fires. As with water
extinguishers the cooling effect of CO2 on the hot
metal can causeexplosiveexpansion of the metal.
When using CO2 fire extinguishers, all parts of the
extinguishercan becomeextremelycold, and remain
so for a short time after operation. Wear protective
equipmentor takeotherprecautions topreventcold
injury (such as frostbite) fromoccurring.
Extremecaution must be used when operating CO2
fire extinguishers in closed orconfined areas.
76. Fire Extinguishers
Halogenated hydrocarbon extinguishers are most
effectiveon Class B and C fires. Theycan be used on
Class A and D fires but theyare lesseffective.
Halogenated hydrocarbon, (commonly called Freon™
by the industry) are numbered according to chemical
formulas with Halon™ numbers.
77. Fire Extinguishers
Bromochlorodifluoromethane (Halon1211),
chemical formula CBrClF2,
is a liquefied gas with a UL toxicity rating of 5.
It is colorless, noncorrosive and evaporates rapidly leaving
no residue.
It does not freeze or cause cold burns, and will not harm
fabrics, metals, or other materials itcontacts.
acts rapidly on fires by producing a heavy blanketing mist
thateliminatesoxygen from the firesource.
It has outstanding properties in preventing reflash afterthe
fire has beenextinguished.
78. Fire Extinguishers
Bromotrifluoromethane (Halon1301):
chemical formula CF3Br,
is a liquefied gas with a UL toxicity rating of 6.
It has all the characteristicsof Halon 1211.
The significant difference between the two is: Halon
1211 forms a spray similar to CO2, while Halon 1301 has
avaporspray that is moredifficult todirect.
79. Fire Extinguishers
Dry powder
Stored as a fine powder in a blue colored
extinguisher, pressurized by a CO2 or anitrogen
cartridge.
Suitable for brake fires and class B, C and Dfires.
Has a little cooling effectand fires may re-ignited.
80. Fire Extinguishers
Dry powderextinguishers: whileeffectiveon Class B
and C fires, are the best for use on Class D fires. Dry
powder is not recommended foraircraft use (excepton
metal fires as a fire extinguisher) because the leftover
chemical residues and dust often make cleanup
difficult, and can damage electronic or other delicate
equipment.
81. Fire Extinguishers
Foam:
Twotypes of foam
Fluoroprotein (used on class B fires)
Aqueous film (used on class A & B fires)
Not suitable for class C and Dfires.
Stored in white or cream colored extinguishers
pressurized with CO2
82. Inspection of Fire Extinguishers
Fire extinguishers should be checked periodically
utilizing a checklist. If a checklist is unavailable, check
the following as aminimum:
• Proper location of appropriateextinguisher
• Safety sealsunbroken
• All external dirt and rustremoved
• Gaugeor indicator in operable range
• Properweight
• No nozzleobstruction
• No obviousdamage
83. Identifying Fire Extinguishers
Fire extinguishers should be marked to indicate suitability
for a particular classof fire.
The markings should be placed on the fire extinguisher and
in a conspicuous place in the vicinity of the fire
extinguisher.
When the location is marked, however, extreme caremust
be taken to ensure that the fire extinguisher kept at that
location is in fact the type depicted by the marking. In
other words, if a location is marked for a Class B fire
extinguisher, ensure that the fire extinguisher in that
location is in fact suitable for Class B fires.
86. Identifying Fire Extinguishers
Markings should be large enough and in a form that is
easily seen and identifiable by the average person with
averageeyesightatadistanceof at least 3 feet.
Where markings are applied to wall panels, and so
forth, in the vicinity of extinguishers, they should be
large enough and in a form that is easily seen and
identifiable by the average person with average
eyesight, ata distanceof at least 25 feet.
88. Using Fire Extinguishers
When using a fire extinguisher, make sure you have the
correct type for the fire. Most extinguishers have a pin
to pull that will allow the handle to activate the agent.
Stand back 8 feet and aim at the base of the fire or
flames. Squeeze the lever and sweep side to side until
the fire isextinguished.
89. Oils
Specified for components on the basis of their
properties in relation to operating conditions of
thecomponent.
High viscosity oil- for heavily loaded component at
high temperature.
Low viscosity oil- for lightly loaded application at
low temperature.
90. Oils
Turbine engineoils
Are low viscous, synthetic ester base formed from
cocktail of chemical compounds.
Type 1- first generation in older type engines
Type 2 – withstand the high temperature of later
engines.
Not compatible with eachother.
91. Oils
Ester based fluid
hygroscopic nature.
Care in dispensing oil and withcontainer.
Aggressive to most of the paintsfinishes.
Polyurethane provides best protection withthem.
92. Oils
Never mix type-1 and type-2.
Wear protective gloves, apron and face shieldwhen
handling.
Wash hands before smoke, eat ordrink.
Use correct dispensingequipment.
Follow the correct replenishmentprocedure.
93. Chemicals
Flammable Chemicals:
Spark, heat ora naked flame may ignite.
At its flash point mayignite.
Like fuels, oils, solvents andpaints.
Prevent them with exposed tosourceof heat.
Adequate ventilation to prevent the vapor
concentration.
Suitablecontainers
Adequate fireextinguisher
Wear gloves and arespirator
94. Chemicals
CORROSIVE CHEMICALS:
Reactwith and attack metalsand burn the skin.
Etching agents, battery electrolyte and corrosionfluids.
Mostly in liquid form butsome be in powder form.
Adequate type of container.
Avoid the contact with sensitivematerial.
Clean the surfaceadequately.
Wearsuitableclothing, gogglesora faceshield, glovesand apron.
Take the precaution for fire flammableortoxicity.
Check the eye washfacility.
95. Chemicals
Toxic Chemicals:
poisonous, can cause injuries or diseases in short
term or long term. (asthma, cancersetc.)
Have number of routes in the body- Breathe in the
vapor, skin can absorb, carry substances onto food
and into drink and ingestthem.
Solid chemical- harmful dust, hazardous fumes.
Required personal protectiveequipment.
96. Chemicals
Reactive Chemicals:
Are those that experience a chemical change when
exposed to otherchemicals.
Reaction may have slowchangeorvoilentexplosion.
Somecreate high temperaturecauses to fire.
Surface treatment- Alchrom, Cd-plating involve
reactivechemicals.
Some create toxic vapors- phosgene, chlorine and
ferro-cyanide.
97. Safety Around Hazardous Materials
A Material Safety Data Sheet (MSDS) is a document that
contains information on the potential hazards (health, fire,
reactivity and environmental) and how to work safely with the
chemical product. It is an essential starting point for the
developmentof acomplete health and safety program.
MSDSs are prepared by the supplier or manufacturer of the
material. It is intended to tell what the hazards of the product
are, how to use the product safely, what to expect if the
recommendations are not followed, what to do if accidents
occur, how to recognize symptoms of overexposure, and what
to do if such incidentsoccur.
98. Safety Around Hazardous Materials
MSDS formatscan vary from sourcetosourcewithin a
country depending on nationalrequirements.
It is intended to provide workers and emergency
personnel with procedures for handling orworking
with that substance in a safe manner, and includes
information such as physical data(melting
point, boiling point, flash point, etc.), toxicity, health
effects, first aid, reactivity storage, disposal,protective
equipment, and spill-handlingprocedures.
99. Safety Around Hazardous Materials
The most observable portion of the Material Safety
Data Sheet (MSDS) label is the riskdiamond.
It is a four color segmented diamond that represents
Flammability (Red), Reactivity (Yellow), Health (Blue),
and special Hazard (White). In the Flammability,
Reactivity, and Health blocks, there should be a
number from 0 to 4. Zero represents little or no hazard
to the user; 4 means that the material is very
hazardous.
100. Safety Around Hazardous Materials
The special hazard segment contains a word or
abbreviation to represent the special hazard. Some
examples are: RAD for radiation, ALK for alkali
materials, Acid for acidic materials, and CARC for
carcinogenic materials. The letter W with a line
through it stands for high reactivity towater
103. Safety Around MachineTools
Hazards in a shop’s operation increase when the
operation of lathes, drill presses, grinders, and other
typesof machinesare used. Each machine has itsown
set of safetypractices.
104. SafetyAround Machine Tools
Drill Press: can be used to bore and ream holes, to do
facing, milling, and othersimilar typesof operations.
The following precautionscan reduce thechance of injury:
• Wear eyeprotection.
• Securely clamp allwork.
• Set the proper RPM for the material used.
• Do not allow the spindle to feed beyond its limit of travel
while drilling.
• Stop the machine before adjusting work or attempting to
remove jammed work.
• Clean the area whenfinished.
106. SafetyAround Machine Tools
Lathes: are used in turning work of a cylindrical
nature. This work may be performed on the inside or
outside of the cylinder. The work is secured in the
chuck to provide the rotary motion, and the forming is
done bycontactwith a securely mounted tool.
108. Safety Around MachineTools
Lathes : following precautionscan reduce thechance of
injury:
• Wear eyeprotection.
• Use sharp cuttingtools.
• Allow thechuck to stopon its own. Do not attempt to stop
the chuck by handpressure.
• Examine tools and work forcracks ordefects beforestarting
thework.
• Do not set tools on the lathe. Tools may be caught by the
work and thrown.
• Before measuring thework, allow it tostop in the lathe.
109. Safety Around MachineTools
Milling machines: are used toshapeordress; cut
gear teeth, slots, or keyways; and similarwork.
The following precautionscan reduce thechanceof
injury:
• Wear eyeprotection.
• Clean thework bed prior towork.
• Secure thework to the bed toprevent movement
during milling.
• Select the proper tools for the job.
• Do notchange the feed speed whileworking.
111. Safety Around MachineTools
Grinders: are used to sharpen tools, dress metal, and
perform other operations involving the removal of small
amounts of metal.
The following precautionscan reduce thechance of injury:
• Weareyeprotection even if thegrinder hasa shield.
• Inspect thegrinding wheel fordefects prior to use.
• Do not forcegrinding wheels onto the spindle.
while
• Do not stand in the arc of the grinding wheel
operating, in case the wheelexplodes.
• Do not forcegrinding wheels onto the spindle. They fit
snugly, but do not require force to installthem.
113. Battery Maintenance
Battery is an integralpart of the electrical system in
aircraft.
Two types of batteries are used: Pb-acid and Ni-
Cd.
Charging rooms are potential very dangerousarea.
Hydrogen is vented during every stage of Pb-acid
batterycharging.
114. Battery Maintenance
There must be separate room for Pb-acid and alkaline
battery charging, repair/maintenance and electrical
supply andstorage.
All tools and equipment must be separate and marked
for thepurpose.
All electrolyte and neutralizing agents containers must
be clearlymarked.
Charging rooms – well vented, explosion proof lighted
and with air extractionsystem.
115. Battery Maintenance
Ambient temperature in thecharging rooms must be
maintained within limits. e.g. lead acid- below 27° C
and Ni-Cd 21° C.
Floor – Level, dry, dust free, proof againstacid oralkali
e.g. concrete.
Bench: Height should be 20 inch from floor, to enable
inspection and reduce lifting effort. Should be madeof
latticed panels of waxedwood.
Co2 type fire extinguisher should bestrategically
placed.
116. Battery Maintenance
Battery charging supply is normally D.C. but supplied
from A.C. distributionsystem.
When disconnecting batteries, the cable should be
removed from the battery first and then from the
charging board.
adjacent to each charging point and be
Individual charging boards should be mounted
mounted
adjacent to each charging point and be mounted
directly above and to rear of the bench to minimize the
need for long connectingcables.
117. Battery Maintenance
H2SO4 SPILLAGE- should be washed in solutionof
bicarbonate of soda and fresh water. Other
neutralizing agent Ammonia powder or borax
powder.
Alkaline Solution- washed in saturated solutionof
boric acid (crystal and powder) and freshwater.
