Unti 1: Shop Facilities, Equipment, and Materials

UNIT 1
Shop Facilities, Equipment, and Materials

Unit Objectives:

After completion of this unit, the student will be able to:

1. Work safely in the shop and in the field.
2. Identify the safety devices used in the shop.
3. Identify and use the different types of shop equipment.
4. Identify and use the cleaning chemicals used in the shop.
5. Explain contamination control processes used in the shop.
6. Identify hazardous materials used in the shop.
7. Properly classify and dispose of hazardous materials.
8. Identify the basic state and federal regulations including
OSHA and EPA.

Unit References:

Safety Is…No Accident (Video) TEVN2746

Shake Hands with Danger (Video) TEVN2619
Fluid Contamination--the silent thief (CD ROM) PERV4632
NOTES
 Lesson 1: Shop Safety Equipment
Lesson 1: Shop Safety Equipment

Introduction:

To work in any type of shop, a person must know how to work

safely in the shop and must also practice safety.
Objectives:

After completion of this lesson, the student will be able to work

safely in the shop and in the field and be knowledgeable in the safety
devices used in the shop.
References:

Safety Is…No Accident (Video) TEVN2746

Shake Hands with Danger (Video) TEVN2619
Unit 1 1-1-2 Caterpillar Service Industry
Lesson 1

Fig. 1.1.1 Eye Wash Stations

Safety
NOTE: The federal government of the United States of America
has many safety laws such as the National Fire Code and the
Occupational Safety and Health Act. Some state and local
governments also have their own additional laws. This has been
written with the United States federal laws in consideration.
Safety laws in your country or state may be different or more
specific than the United States safety laws. When reviewing this
manual consult your local and federal governments for safety
laws that may apply to your facility. Also recognize each
company will have its own set of safety rules.

Eye Wash Station

An eyewash has a pan with drain and two devices, one on each side,
that send water towards the face and eyes. A valve to turn the water
on and off is at the side of the eyewash. This description is of a wall
fastened type. A field type which has its own water source is also
available.
Unit 1 1-1-3 Caterpillar Service Industry
Lesson 1

An eyewash is used to flush foreign material from the eyes. The

primary use is when strong chemicals get in the eyes or on the face.
Large amounts of water flush the eyes and the face, which results in a
reduction in the chemical strength and possible physical damage.
Water temperature and pressure must be safe enough to withstand
extended time under the eyewash.
Water temperature and pressure must not exceed 25 psi (173 kPa).
An injured person must never adjust the eyewash. The time taken to
adjust the eyewash may result in further injury.
Keep the eyewash clean and free of dirt and oil. Check the operation
of the valve regularly. Keep the water temperature and pressure
correct.

Fig. 1.1.2 and 1.1.3 Showers

Shower
There are two types of showers. The first is a stationary showerhead
about 6 1/2 feet high. With this type you get under and direct the
flow of water to the affected area of the body. The second type is a
showerhead on a flexible hose connected to a water source. Some
models of this type are together with eyewashes.
Unit 1 1-1-4 Caterpillar Service Industry
Lesson 1

Emergency showers are used when the body has come in contact with
chemicals that cause injury. It is used to wash any chemical off the
body in an emergency. To wash the chemicals off the body, large
amounts of water fall on the body. Safe water temperature and
pressure must be kept to make sure that a worker with an injury can
withstand the shower for extended times.
Water temperature must be kept at a safe range. The earlier a worker
gets to the shower, the more effect it will have to keep the injury to a
minimum. Areas around the shower must be kept clean.
Keep the shower free of dirt and oil. Test the shower regularly for
temperature, correct flow, leaks and valve operation.

Fig. 1.1.4 and 1.1.5 First aid kits

First Aid Kit

A first aid kit is normally kept in a hinged metal box, generally blue
in color. These boxes come in different sizes according to the
quantity of supplies. Inside the box are supplies used for immediate
first aid. Supplies including bandages, medications, and tools such as
scissors and knife. Larger kits may have more supplies.
The first aid kit is used when injuries such as small cuts and burns
need to be treated. The kit is designed to be used by a person who
has no training in first aid. The first aid kit is to be used before being
treated by acceptable first aid personnel. First aid kits must be hung
in clear view on a wall at a short distance from all personnel.
Unit 1 1-1-5 Caterpillar Service Industry
Lesson 1

Fig. 1.1.6 and 1.1.7 Stretchers

Stretcher
A stretcher is a lightweight unit used to move or transport a person
with an injury. The stretcher is made up of two wood or aluminum
poles with a heavy duty piece of cloth centered between the poles.
The poles stick out at each end of the cloth to make handles for two
persons to carry the stretcher. Stretchers also have straps to hold the
user on the stretcher.
A stretcher is used to transport a person with an injury from the
accident location. It must be done in a way that the person is not
injured more. Always make an inspection of the injured person
before he is moved, to find out if any movement will cause more
injury.

Fig. 1.1.8 and 1.1.9 Fire blankets

Fire Blankets
Fire blankets come in different sizes. The blanket is generally a dark
color and made of a cloth material that has been treated with
aluminum or other special materials. Some types are the throwaway
types. Others must be treated with fire resistant material after each
use. Fire blankets are generally found in red hinged boxes hung on a
wall, or in a container case with a stretcher.
Fire blankets have two different purposes. The first is to put out
small fires, generally flammable liquids. The second use is to cover
an injured person with the blanket to keep him warm. An added use
is to cover a person whose clothes are burning, to extinguish the fire.
Unit 1 1-1-6 Caterpillar Service Industry
Lesson 1

Fig. 1.1.10 Chemical Fire Extinguisher

Chemical Fire Extinguisher

The normal chemical fire extinguisher is the cylinder type with a
tank and valve equipment. The average unit weighs almost 40
pounds (18 kg), according to the size of the cylinder. The cylinder is
charged to 400 pounds per square inch (2760 kPa) pressure. Most
fire extinguishers are red in color, but other colors are also used.
Listed on the side of the cylinder is the kind or classes of fire the
extinguisher will put out along with other information. Extinguishers
are generally found hung on a wall or in a wall recess.
The purpose of a chemical fire extinguisher is to put out small fires
or stop fires from getting larger. The types of chemicals in fire
extinguishers differ, but all four types of fires can be put out with
chemicals of some type. Most chemical fire extinguishers will put
out Class B and C fires. These fires take in flammable liquids (Class
B) and electrical fires (Class C). Class A fires are those where
normal materials such as paper and wood burn. Class D fires are
flammable metal fires. These take special chemicals to extinguish.
Whenever using any fire extinguisher point at the base of the fire.
Never use a fire extinguisher on a fire that is too large for the
extinguisher. Chemical fire extinguishers are to be used on small
fires and to slow down larger fires. Never point the extinguisher at a
person when in operation. Because the cylinder of a fire extinguisher
is under pressure, do not keep it near a high heat source.
Unit 1 1-1-7 Caterpillar Service Industry
Lesson 1

At monthly intervals, chemical fire extinguishers must be inspected

and charged (if needed). This is to keep the extinguisher in condition
for safe operation. Along with each extinguisher will be a list, which
gives earlier maintenance information. The extinguisher must be
given a hydrostatic test if it shows signs of corrosion or mechanical
injury.

Fig. 1.1.11 Carbon Dioxide Fire Extinguisher

Carbon Dioxide Fire Extinguisher

The normal carbon dioxide fire extinguisher is the cylinder type, with
a tank and valve equipment. The unit will weight from 5 to 60
pounds (2.3 to 27 kg) according to the size of the cylinder. Each
extinguisher is charged to 350 pounds per square inch (2415 kPa)
pressure. Most fire extinguishers are red in color, but other colors
are also used. Carbon dioxide fire extinguishers and chemical fire
extinguishers are generally very similar except for their contents.
The purpose of a carbon dioxide fire extinguisher is to extinguish
small fires and control larger fires. Carbon dioxide extinguishers will
work only on Class B and C fires. These include flammable liquid
and electrical fires. Carbon dioxide extinguishers are operated by
removal of the lock pin and compression of the handle. Whenever
using a fire extinguisher point at the base of the fire for best results.
Unit 1 1-1-8 Caterpillar Service Industry
Lesson 1

Never use a fire extinguisher on a fire that is too large for the
extinguisher. Fire extinguishers are to be used on smaller fires.
Never point the extinguisher at a person when in operation. Because
the cylinder of a fire extinguisher is under pressure, do not keep it
near a high heat source.
Carbon dioxide fire extinguishers must be inspected two times a year
to make sure they are still fully charged. They also must be inspected
one time a year to look for mechanical damage. Along with each
extinguisher will be a list, that gives earlier maintenance information.
The extinguisher must also be given a hydrostatic test if it shows
signs of corrosion or mechanical injury.

Fig. 1.1.12 and 1.1.13 Hand Pump Fire Extinguisher

Hand Pump Fire Extinguisher

The hand pump fire extinguisher looks similar to other fire
extinguishers but operates in a different way. The extinguisher is
filled with water, but is not under pressure. The extinguisher’s hand
pump is used to pump water towards the fire. They are made in
1 1/2 to 5 gallon capacities. The extinguisher has a 2 foot long hose
used to direct the water towards the fire.
The hand pump fire extinguisher is used on Class A fires only. Class
A fires are those where normal materials such as wood and paper
burn. Do not use on a flammable liquid or electrical fire. The pump
is operated by an up and down movement of the handle. This will
cause water to flow through the hose and out. Hand pump
extinguishers can be used many different times without being filled,
but it is best to refill the tank as soon as it has been used.
Unit 1 1-1-9 Caterpillar Service Industry
Lesson 1

Fig. 1.1.14 Fire Hoses

Fire Hoses
A fire hose is a long, flexible tube used to conduct water to fires.
Fire hoses are made of canvas or strong but light plastics. Most
hoses have a 2 1/2 inch diameter and are 75 feet long. One end of
the hose is connected to a water source and the other end has an
attachment to hold on to and direct water towards the fire. The Hose
is stored in a fixture or in a special wall opening.
The purpose of a fire hose is to put out large Class A fires. The hose
is attached to a water source, and when needed a valve must be
opened to let water flow through the hose. A person who uses the
hose must pull the hose out of the fixture and then open the valve.
Water must be directed to the base of the fire. Only Class A fires
(normal combustible material) can be extinguished with water.
Unit 1 1-1-10 Caterpillar Service Industry
Lesson 1

Fig. 1.1.15 Fire Hydrant

Fire Hydrant
A fire hydrant is a piece of fire equipment used only by firemen with
training. The location of the fire hydrant is generally outside of a
shop. Some special applications can have a hydrant inside the shop,
but this is not common. Fire hydrants stand about 30 inches from the
ground, and are painted variable colors. They have connections for
fire hoses that range from 1 1/2 inches to 3 inches in diameter.
Generally special tools are needed to use them.
Fire hydrants are used to supply large amounts of water to put out
large fires. The hydrants are connected to the water main, so they
supply large volumes of water. When a fire starts, firemen connect
their hoses to the fire hydrants, that supply the water to put out the
fire.
Unit 1 1-1-11 Caterpillar Service Industry
Lesson 1

Fig. 1.1.16 Emergency light

Emergency Light
An emergency light is a unit with the ability to produce light without
use of the building’s electrical system. The body of the unit is a box,
which is hung on a wall in a room. Its contents are batteries and
other electrical components for operation. On top of the box are two
lights similar to those used on vehicles. Other types have only the
lights and are connected to a larger battery or generator, which sends
emergency power to the complete shop. This is the type shown
above. The lights must be directed to give light to most areas.
Emergency lights are used only when normal electricity is off.
Power comes from their own batteries, so it is separate from other
power sources. Emergency lights give limited light in emergency
periods so that first aid, etc., can be made complete. Emergency
lights are automatically activated when there is a failure of regular
lights. These units are generally placed in areas that are used by
most personnel.
Unit 1 1-1-12 Caterpillar Service Industry
Lesson 1

Fig. 1.1.17 Safety Glasses

Safety Glasses
Safety glasses are used over the eyes to give protection to them.
They are made up of two round shaped pieces of clear glass (lenses)
in a frame. Two ear pieces hold the glasses to the head. Some safety
glasses have side shields which give protection to the eyes from the
side. Glasses must feel good but fit right. They must not get in the
way of the users actions. The glasses must also be easily cleaned.
Safety glasses give protection to the eyes from accidents where
foreign material can come in contact with the eye. When there is
danger to the eyes from the side, guards can be fitted to the ear pieces
to give protection from the side. Safety glasses must be used at all
times while in the shop. For this reason a good fit is needed. A
person with training must fit the glasses. Glasses to correct the sight
(vision) of the eyes are also available in safety glass.
Never use standard glasses for safety glasses. Standard glasses will
break at a much lower impact than safety glasses. Side shields must
be used if there is eye danger from the side.
Unit 1 1-1-13 Caterpillar Service Industry
Lesson 1

Fig. 1.1.18 and 1.1.19 Safety Shoes

Safety Shoe
A safety shoe looks like a normal shoe. Most are made of leather and
come in many types for men and women. A steel toe box is made
into the toe of the shoe. Other types of safety shoes are metal-free
shoes for use where there are electrical dangers. Shoes with
reinforcement of flexible metal in the inner soles to give protection
from sharp materials. Metatarsal guards (shown) are often used in
addition to safety shoes. The guards, made of metal covered with
leather, are fastened to the toe of the shoe and extended over the top
of the foot to the leg.
Safety shoes give protection to the foot against dropped material, or
if a foot is run over by a heavy pipe or truck wheels, and accidents
where sharp material is contacted. Safety shoes must be used when
there is danger like those listed above. Metatarsal guards give
protection to the front of the foot between the toes and the bottom of
the leg. Shoes with insulation are used to give protection against
electric shock.
Unit 1 1-1-14 Caterpillar Service Industry
Lesson 1

Fig. 1.1.20 Shin guards

Shin Guards
Shin guards are shaped guards, which cover the leg from foot to
knee. They have an extra piece at the bottom to give protection to
the top of the foot. The front part has reinforcement to give impact
protection. This type is generally made of plastic, aluminum, or
fiberglass. One other type called leggings, are made of leather or
asbestos. Shin guards either give protection all the way around the
leg or only cover the front of the leg and fasten in the back.
Shin guards are used for protection against impact from dropped parts
or accidents when there is contact with sharp materials. They also
will give protection against hot metals, sparks, and chemicals, which
will burn the skin. Use shin guards or leggings when there is a
possible danger from any of these items.
Unit 3 1-1-15 Caterpillar Service Industry
Lesson 2

Fig. 1.1.21 Safety Hat

Safety Helmet
The most common material safety hats are made of is hard plastic,
shaped under high pressure. Safety hats come in two types, full
brimmed and brimless (cap type). A brim extends out from the
bottom of the hat and gives the best protection, but where the brim is
in the way the cap type is used. Metal hats are available. These are
generally made of aluminum. They are lighter weight than plastic
but do not have as much impact resistance. The suspension is an
important part of the hat. It gives impact distribution to the hat. The
suspension adjusts to give the user a good fit. Safety hats are also
divided into groups by their shock resistance ability.
Safety hats give protection to the worker from impact and shock
from dropped materials and limit electric charges. When work is
near electric dangers the hat gives protection to the head from
electric charges. Check the specifications of the hat for what
voltages it will give protection against. The suspension takes up
much of the impact when the hat is hit. The suspension must be
adjusted so the hat is at a minimum of 1 1/2 inches from the head.
Be sure the hat is rated for the correct voltage if work is near
electricity. Never use a metal safety hat around electric work. To
have more effect, the hat must fit good and have a minimum of 1 1/2
inches clearance between the hat and the head.
General inspection on the hat must be done regularly. Cracks and
suspension defects are the most important items to look for. Do not
repair the cap part of the hat. If it has been broken, it must have a
Unit 1 1-1-16 Caterpillar Service Industry
Lesson 1

replacement and the old cap thrown away. The suspension can be
used again if in good repair. An electrical test must be done on hats
used for electric work. The test is used to find out how high a
voltage the hat will give protection.

Fig. 1.1.22 Face Protector

Face Protector
The face protector is a clear cover for the face and eyes to protect
them from foreign material. The face protector is a piece of clear
plastic, which covers the face around almost to the ears and down
below the mouth. The clear plastic is assembled to a headpiece that
adjusts. The head gear is similar to the suspension of a safety hat.
Some types have no head piece but fasten to the brim of a safety hat.
The face protector keeps the face safe against light impact, chemicals
and hot metal, high heat, and other dangers. Its most common use is
when someone saws, grinds, or sands. The face protector is not the
only protection for the eyes. Safety glasses must be used under the
face protector.
Unit 1 1-1-17 Caterpillar Service Industry
Lesson 1

Fig. 1.1.23 Ear Plugs

Ear Plugs
Ear plugs, also known as insert type ear protection are put into the
ear openings (canals). (The ear canal starts at the outer opening of
the ear.) Ear plugs come in many types that are different in both
style and material. Materials used are rubber, soft plastic, wax and
cotton. The rubber and plastic types are the most common because
they are low cost, easily cleaned, and give good performance. The
wax and cotton type are used very little because they offer very little
protection.
The ear plugs are designed for the reduction of noise that gets to the
ear. A normal ear plug will decrease the noise to the ear by 25 to 30
decibels (measure of noise volume). Being in an area where the
noise level is 90 to 100 decibels for an extended time will cause ear
damage. The plugs generally have a cone shape. The end with the
point is put into the ear canal and pressed in to get a good fit.
Unit 1 1-1-18 Caterpillar Service Industry
Lesson 1

Fig. 1.1.24 Earmuffs

Earmuffs
Earmuffs are the better type of ear protection. Earmuffs have a shape
that covers the entire outside of the ear, to give resistance to noise.
At points of contact between the earmuffs and the head, cushions are
used to give a good fit on the head and added ear protection. Head
bands of spring steel hold the earmuffs to the head.
Earmuffs are used to lower noise to the ear by 35 to 45 decibels.
Earmuffs and ear plugs used together give an added 3 to 5 decibels
more protection. Be sure the correct type of ear protection is used
because efficiency changes with size and shape.
Unit 1 1-1-19 Caterpillar Service Industry
Lesson 1

Fig. 1.1.25 Seat Belts

Seat Belts
Seat belts are belts that fasten around an operator’s waist (middle
section of the body) to keep him in his seat during an accident. Seat
belts are generally made of webbing or leather. Webbing is a type of
mesh, but is made of a strong cloth. Webbing belts are better than
leather because they are much stronger and easier to take care of.
Seat belts are 2 to 3 inches (5 to 7 cm) wide and fasten in the middle.
Buckles (fasteners) are available in many types, but make sure the
buckle is strong and in good condition.
Seat belts are installed on all new vehicles that have a seated
operator. A seat belts purpose is to prevent an operator from being
thrown from his seat during an accident, and possibly get an injury.
The belt is not to be fastened over the soft spot above the waist, but
down below this soft spot. Seat belts also give back support to make
the operator’s job easier.
Unit 1 1-1-20 Caterpillar Service Industry
Lesson 1

Fig. 1.1.26 Respirator

Respirator
Respirators are available in many types. The types generally used by
dealers are the mechanical filter type and the chemical cartridge type.
A cartridge is a short cylinder that has chemicals, which filter dirty
air. Other types such as gas masks, etc. are not common with
dealers. Respirators cover the nose and mouth so that breathing must
be done through the respirator. Some types also extend up to cover
the eyes. Respirators must make a tight fit at all points where the
face and respirator contact each other. Mechanical filters have a
paper, cloth or other type filter to clean dusts, fumes, etc. from the
air. The chemical cartridge type respirator cleans the air with
variable chemicals. The cartridges are cylinder shaped and extend
out from the remainder of the respirator.
Respirators are used to clean dirty air that is not safe for
consumption. They clean the air in many ways. Some filter the air
and others use chemicals to make the air safe. Common applications
are when work is performed around dust, fumes and spray paint.
Dust is the most common reason for use.
Make sure the correct type of respirator is in use. Do not use the
filter or chemical cartridge type respirators where there is not enough
oxygen in the air. Keep the respirators clean and in good order.
Change filters and cartridges according to the specific intervals listed
on the filter or cartridge. If the respirator has not been used for a
long period, change the filter or cartridge before use. Clean the
respirators at regular intervals. It is better to install a new filter or
cartridge than to clean it.
Unit 1 1-1-21 Caterpillar Service Industry
Lesson 1

Fig. 1.1.27 Gloves

Gloves
The most common form of hand protection is the glove. A glove is a
hand cover with separate sections for each of the fingers and the
thumb. Gloves all have the same general shape, but are different in
materials they are made from. Glove selection is done according to
the type of job they are used for. Common materials used to make
gloves are: heat protection, metal mesh, rubber, leather and cloth.
The only difference in the shape of the gloves is that some extend up
the arm higher than others.
Gloves give protection to the hands against many materials and
electric shock. Different gloves give protection against different
materials. Heat protection gloves give protection from being burned
and against high heat. Protection from cuts by sharp materials is
given by metal mesh gloves, and rubber gloves stop electric shock.
Leather gloves give protection against sparks, low heats, etc. but are
generally used when work is with heavy parts. Cloth gloves give
protection against dirt and lighter work such as extended handling of
parts as shown above.
Unit 1 1-1-22 Caterpillar Service Industry
Lesson 1

Fig. 1.1.28 Safety Goggles

Safety Goggles
Safety goggles are a type of eye protection that make a tight fit
against the face around the eyes. Goggles are made of variable
materials according to the job to be done. These include flexible
plastic, rubber, and glass. Shapes are a cup type where each eye is
covered by a separate cup, and the wide visual type where both eyes
are covered by one section. Goggles are generally held on by an
elastic strap.
Goggles are used to give protection to the eyes from foreign
particles, strong chemicals, dust, and the danger of strong light when
welding. They are often used over normal glasses. Different goggles
are used for different operations. Cover goggles protect against
dangers when grinding, sanding, chipping, etc. Chemical goggles
stop contact with corrosive chemicals and welding goggles with filter
lenses are used with some types of welding. These welding goggles
are used only when gas welding or very light arc welding.
Unit 1 1-1-23 Caterpillar Service Industry
Lesson 1

Fig. 1.1.29 Welder's Protective Clothing

Protective Clothing
Protective clothing for welders generally gives some type of body
and arm protection. Coats (clothing that gives body and arm
protection) made of leather and fire resistant cloths are common.
Treated wool is better than other clothes, because it does not burn
easily. Aprons and capes are used also to give protection when
welding. Coats give full arm protection while the apron and cape
give no arm protection. All pockets on welding clothing must have
covers over them or be assembled to the inside of the clothing.
Welders protective clothing is used to keep the welder form being
burned by sparks and hot metal. Protection is especially important
when welding overhead. For additional protection a welder’s hat
should be worn. Make sure there are no places on welder’s clothing
which will hold sparks and hot metal.
NOTES