You're not supposed to be part of a circuit!

Mech, Summer, 2004 by Brian Clark

On numerous surveys, we have found modified equipment, and these unapproved items bring up a serious safety issue. No item stands out as unsafe more clearly than multimeter test leads.

The top photo on this page [and the one in the Good, Bad and Ugly department--Ed.] shows safety wire attached to the leads. It is done in such a way that it presents a clear hazard to personnel, not to mention a potential source of FOD. This item was found in an avionics shop, and another set--just like it--was found in the squadron's tool room.

These test leads are used with the ubiquitous Fluke-77 multimeters. It has a tip that is too large to probe many cannon plugs and test points. A resourceful technician, surely intent on solving his problem and fixing an aircraft, modified it to work. Good on initiative ... bad on safety. Notice how the safety wire extends past the finger guard, creating a convenient opportunity for any technician to become part of the circuit. This loose attachment also could fall off, causing a serious FOD problem.

Does a fix for this problem exist? Sure! The supply system stocks a test-lead set with retractable tips. These points are small enough to probe the small contacts on most cannon plugs and can withstand everyday use. They cost less than $10 a set (NSN 6625-01-172-7860).

Innovative Sailors and Marines can be a great thing, but we must apply some common sense and ORM to keep these ideas safe.

VAW-113 in 211735Z Jun 04 reported a maintainer was shocked because of the same problem mentioned in this story-Ed.

Master Chief Clark is a maintenance analyst at the Naval Safety Center.