This module describes the basic job steps, potential hazards or accidents, and · 2019-08-11 ·...

This module describes the basic job steps, potential hazards or accidents, andrecommended safe job procedures for front-end loader operation.

Front-end loaders are probably the most versatile machines utilized at surface metal andnonmetal mines. The front-end loader can be used for many purposes, including: loadinghaulers, pushing material, grading, hauling material, and working stockpiles or spoil areas.Front-end loaders, typically with 14-16 cubic yard buckets, are sometimes used for strippingoverburden. The most common use at surface mines is for loading waste rock haulers andore haulers.

This module is designed primarily for use in the initial training of front-end loader operators.The content deals with the loading of haulers or bins and hoppers, but can be applied toother jobs performed by a loader. The material should be used by the trainer as asupplement to practical knowledge and specific mine conditions.

Many surface metal and nonmetal miners are injured or kiled each year in loaderaccidents. Loader accidents frequently occur when tramming an unloaded machine at highspeed. Accidents also result from collsions with other machines, a person getting caughtin pinch points, and spilage of material while tramming or loading. Numerous otherhazards exist, and loader operators must be aware at all times of hazards that can causeinjury.

Self-propelled machines that wil be used during a shift must be inspected by the machineoperator before operation. Particular attention should be given to the steering and brakingsystems, in order to ensure proper working order. Headlights, horns, and backup alarmsystems must function properly at all times. Seat belts must be provided and worn.

The basic job steps included in this module are:

1. Conduct walk-around check of loader.2. Mount loader and check cab.

3. Start loader and complete pre-shift examination.

4. Tram loader to work area.5. Load bucket.

6. Tram to dump area.

7. Dump materiaL.8. Tram back to loading area.9. Refuel and park.

10. Perform repairs and maintenance.

The operator's manual provided with the machine, and the mine's operating procedures,should also be used in training machine operators.

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The following safe job procedures wil help minimize incidents which may cause injuries andadversely affect production:

Required and/or recommended personal protective equipment

Hard hat, safety shoes, safety glasses with side shields, gloves, clothingappropriate for weather conditions, hearing protection where needed

SEQUENCE OFBASIC JOB

STEPS

POTENTIALACCIDENTS OR

HAZRDS

RECOMMENDED SAFE JOBPROCEDURES

1. Conduct walk- 1. A) Frostbite, 1. A) Dress to suit weatheraround check hypothermia, conditions.of loader. sunburn, heat

stroke, heatcramps, heatexhaustion.

B) Struck by B) Check to be sure loader bucketmoving loader is lowered to ground, and, ifor other parked on a grade, wheels aremachines. blocked and/or turned into a

bank. Be alert for nearbymachines.

C) Slips or trips, C) Conduct walk-around inspec-struck by flying tion of loader. Avoid slick spotsobjects such as and keep area free of slippingdirt or splashed or tripping hazards. Befluids, caught in especially careful of ruts,pinch points. uneven ground, and frozen

ground. Use suitable access ifnecessary to mount anddismount loader to checkengine or other area ofmachine.

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STEPS

1. (Continued)


HAZRDS

C) (Continued)


Check:1) Tires and wheels for lug nuts,

cracked rims, cuts, tire pressure.2) Area around loader for people or

obstructions.3) All bolts, guards, covers, and

mechanical components ofloader to make sure they are inplace.

4) Engine compartment for dirt,debris, oily rags, tools. Graspengine covers firmly whenremoving. Avoid over-reaching.Get help if needed.

5) Fluid levels. Wear safetyglasses with side shields andgloves. Remove tank caps orcovers carefully.

6) Hydraulic oil and coolant lines

and hoses for breaks, leaks,rubbing lines or loose fittings,especially in the pivot area.

7) Fire extinguisher (if on outside of

machine) to make sure it's inplace and fully charged.

8) Loader linkage for loose pins orcracks in lift arms, bucketattachment and bucket itself.

9) Ladders and steps for brokenrungs, loose bolts, breaks,cracks, missing parts, or bentand twisted steps.

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STEPS

1. (Continued)

2. Mount loader

and checkcab.


HAZRDS

D) Sludge deposits,or ice, whichmight preventvalve operation -tank rupture fromexcessivepressure.

2. A) Slips and falls,clothing caughton control leversor other projec-tions.

B) Fallng from

ladder.

C) Sudden machinemovement onsome loaders(even withengine off,fallng fromloader.


D) If loader has air brakes, bleedthe air lines to release anycondensation that might haveaccumulated, and trip thepressure relief to be sure it'soperable.

2. A) Wear snug fitting clothing. Keepladders and boots free of mud,ice, snow, grease, and oiL.

B) Use belt hooks, pockets, etc., tocarry materials up ladders, andkeep both hands free forclimbing. Ropes can be used tohoist bulkier items. Face ladderand use three points of contactwhen climbing (two hands andone foot, or two feet and onehand, in contact with ladder atall times). Use hand holds andselect firm footing. Avoid hasteand projections.

C) Do not use steering wheel as agrab point.

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STEPS

2. (Continued)

3. Start loader

and completepre-shiftexamination.


HAZRDS

D) ROPS failure in arollover, canopyfailure in a fallngobject accident.Missing or

inoperative fireextinguisher.

E) Struck by flyingobjects, jammedcontrols,projecting control

levers.

F) Accident causedby poor visibility.

G) Thrown againstcab interior, orthrown out of themachine.

H) Machinemalfunction.

3. A) Hitting or running

over persons orobjects in area.Striking steeringwheel or otherparts of cab ifloader movessuddenly.


D) Check for any damage torollover protective structure orfallng object protective

structure. Check fireextinguisher.

E) Remove or secure any looseobjects in cab. Avoid projec-tions.

F) Inspect and clean windows andmirrors. Adjust mirrors ifnecessary.

G) Make sure seat belts areprovided, and are in goodcondition. Seat belts must beworn by the operator.

H) Check all instruments andgauges before start-up to besure they aren't stuck. Makesure all controls are in neutralposition, and parking brake isset.

3. A) Check machine for warning tags.Be sure bucket is lowered toground. Check controls to besure they are in neutral. Soundhorn before starting or moving.Check backup alarm after start-up.

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STEPS

3. (Continued)


HAZRbs

B) Engine or

auxiliaryequipmentmalfunction.

C) Engine

malfunction.

D) Poor visibility.Poor operation.

E) Emergencysteering failure.

F) Loss of control.

G) Potential hazardsnot corrected.

H) Hearing loss.


B) Let engine run until it reachesnormal operating temperature.Check all gauges, indicators,and warning lights again fornormal readings.

C) Check engine for smooth idleand unusual smoke or noise.

D) Check wipers and lights. Checkhydraulic controls.

E) Check emergency steering, ifequipped and if recommendedby manufacturer.

F) Check brakes and steering aftermoving a short distance. Brakesmay also be checked againstpartial engine power beforemoving, according to companypolicy or manufacturetsrecommendations. Checktransmission operation.

G) Report and, if possible, repairany defects found. Do not usemachine with uncorrected safetydefects. If the loader is unsafeand removed from service, tag itto prohibit further use untilrepairs are completed.

H) Use ear protection whennecessary.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOBBASIC JOB ACCIDENTS OR PROCEDURES

STEPS HAZRDS

4. Tram loader to 4. A) Personal injury. 4. A) Do not allow anyone to ridework area. outside the cab for any reason.

No one shall ride with theoperator unless safe seating

facilties are provided.

B) Running over B) Sound horn before starting tosomeone. tram.

C) Poor visibility, C) Observe travel area. Adjustpoor stability, speed for conditions. Tram withoverturning bucket low (15 to 20 inches offloader, striking the ground) to increase stability.other machinesor people.

D) Caught in pinch D) Keep doors latched securely.points.

E) Overturning E) Travel in proper gear atloader. acceptable speeds for condi-

tions. Avoid loose material, slickspots, and weak areas. Observeroad hazards, and travel instable areas.

F) Loss of control, F) When carrying a loaded bucketoverturning down a steep grade, travel inloader. reverse.

G) Loss of control, G) Control speed and slow downoverturning carefully if loader starts "road-loader. walking."

H) Loss of steering H) Monitor gauges/indicators.

and/or brakes - Follow traffic rules.collsions.

i) Struck by fallng i) Stay out from under swing ofore or rock. dragline.

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STEPS

5. Load bucket.

6. Tram to dumparea.


HAZRDS

5. A) Obstructed work

area.

B) Fallng or slidingmateriaL.

C) Buried at toe ofstockpile byfallng or sliding

materiaL. Failureof ground undermachine weightat top ofstockpile.

D) Fallng or slidingof loose, uncon-solidatedmateriaL.

E) Overturning

loader.

F) Rapid tire wear,slashes andgashes in tireside walls.

6. A) All hazards in

Step 4 apply.


5. A) Clean loose material from

loading area.

B) Work material from toe, or in amanner which eliminateshazardous rollng or sliding ofmateriaL. Shake off excessmaterial before tramming out ofloading area. If working next toa highwall, visually check it on aregular basis for changingand/or hazardous conditions.

C) When loading from stockpile, donot allow hazardous overhangsor excessive slope angle todevelop. Work material from topif necessary to maintainstockpile stability.

D) Avoid digging into loose rock ortailngs banks which are higherthan bucket reach.

E) Watch for "soft spots,"particularly on tailings pondreclamation work.

F) Avoid spinning the wheels,

especially in wet conditions. Ifloader is equipped with avariable torque converter, adjustto a lower setting.

6. A) All procedures in Step 4 apply.

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STEPS

6. (Continued)

7. DumpmateriaL.


HAZRDS

B) Running over

stationaryobjects, otherpersonnel, andvehicles.

C) Reduced stabilityand visibility.

D) Loss of control -overturningloader.

7. A) Spilage.

B) Overturning

loader.

C) Fallng material,equipmentdamage, excessspilage.

D) Excess spilage,overturning,knocking hauleroperator againstsomething.


B) Check before backing, and keepbackup alarm working.

C) Tram at speed consistent withload and area conditions. Keepbucket low off ground formaximum stability and visibility.

D) Travel in reverse only whencarrying a loaded bucket down asteep grade.

7. A) Position haulers perpendicular

to, and backed into, material sothat spilage stays close to pile.

B) Load and dump on the level oruphil for greater stability. Avoidhaving dumping point downhilfrom loading point.

C) Raise bucket while positioningloader, and tilt bucket forward toavoid spilage. Raise bucket

only to height necessary forclearance. Avoid striking hauleror hopper with bucket or loader.

D) Position loader to avoid spilageon the off side. Make motionssmooth. Tilt bucket slowly toreduce shock of sudden drop ofmaterial, and flying materiaL. DONOT swing loads over operatingcompartments of otherequipment.

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STEPS

7. (Continued)

8. Tram back to

loading area.

9. Refuel and

park.


HAZRDS

E) Running over

persons, fallngmateriaL.

F) Poor handling of

hauler becauseof unbalancedload.

G) Ineffcientoperation.

H) Caught inmaterial flow,suffocation.

8. A) Same asSteps 4 and 6.

9. A) Struck by

machinery, fuelspilage, firehazard.


E) Be sure that other workers areclear before positioning ordumping. Have hauler operatorsstay in cabs or clear of dumparea.

F) Distribute load evenly in haulers.

G) Signal hauler operator whenhauler is loaded.

H) If a hang up occurs while

dumping material into a bin orhopper, do not attempt to freethe material yourself unless youare experienced in this type ofwork. If the bin or hopper mustbe entered, the equipment mustbe locked out, and a safety beltand line must be used. Thelifeline must be tended by asecond person, with minimumslack maintained.

8. A) Same as Steps 4 and 6

9. A) Park at refueling station, placecontrols in neutral and setbrakes. No smoking at or nearthe refueling station.

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STEPS

9. (Continued)


HAZRDS

B) Slips and falls.Clothing caughton control leversor otherprojections.

C) Fuel on skin andin eyes.

D) Trips, slips, andfalls. Fire

hazard.

E) Fire hazard, fuelspilage or

discharge.

F) Collsion,

runawaymachine, trafficobstruction.

G) Unsecuredraised equip-ment, runawaymachine.

H) Engine damage.

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B) Dismount loader (see JobProcedures 2.A-C).

C) Wear safety glasses. Take fuelhose from storage rack, removetank cap slowly, and pump fuelinto tank.

D) Avoid fuel spilage, and keeparea free of extraneousmaterials. If necessary to climbon loader to refuel, use accessladder, steps, available rails orhand holds. Keep all walking orstanding areas free from slippingand/or stumbling hazards. Avoidfuel spilage onto hot engineparts.

E) Shut off fuel, remove nozzlehose, and replace fuel cap.Return hose to rack.

F) Park only at designated parking

areas, and always set brakes.Avoid parking on inclines or haulroads. If necessary to park onan incline, turn wheels into bankand/or block securely. If parkingon a haul road is required, pickthe safest place.

G) Lower bucket to ground. Placecontrols in neutral position.Engage parking brake.

H) Idle engine for a short period oftime and then shut it off.


STEPS

9. (Continued)

10. Performrepairs andmaintenance(if applic-able).


HAZRDS

i) Slips and falls,clothing caughton control leversor projections.

J) Hazards due to

lack of com-munication.

10. A) Personal injuryfrom improperprocedure:

B) Caught by orstruck bymoving or fallngparts, or movingmachine.

C) Struck by

material fallng

from machine.


I) Dismount loader (see JobProcedures 2.A-C).

J) Always inform appropriatepersonnel of any abnormalconditions, defects, changesmade in machine and/or jobprocedure or condition.

10. A) Do not attempt repairs ormaintenance you do notunderstand and are not trainedto do.

B) Do not attempt any repairs ormaintenance until the power isoff, the machinery is blockedagainst motion, and all raisedequipment lowered. Ifnecessary to perform workabove, under, or around araised piece of equipment,block or mechanically securethe equipment to preventaccidental rollng, fallng, orlowering. Remove ignition keyto prevent loader from beingstarted while work is performed.Tag out machine.

C) Do not attempt repairs ormaintenance until any frozenmaterial under machine frame,bucket, etc., has been removed.

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GENERAL INFORMATION

This module is part of an Instruction Guide that was developed to assist the surface metal andnonmetal mining industry in conducting effective on-the-job training (OJT) of new employees,or employees reassigned to different jobs. The use of training materials, such as this module,is an important part of an effective, systematic, OJT program.

This Instruction Guide uses a generic Job Safety Analysis (JSA) of jobs common to theindustry. The JSA format facilitates uniform basic training in safe job procedures, whilerequiring only a minimum of time and effort on the part of the trainer. This material is genericto the industry; therefore, each company using this guide wil need to tailor the materialsomewhat to fit their particular requirements. In some cases, the material must be general innature, and wil not include specific details of procedures or equipment that must be taughtby the trainer.

Recommendations for an overall OJT program are contained in the Mine Safety and HealthAdministration (MSHA) guide: "Structuring Effective On-The-Job Training Programs," June,1983.

TRAINING RECOMMENDATIONS

On-the-job training is usually best done by the employee's immediate supervisor. If thesupervisor relies on another employee to do certain parts ofthe training, the supervisor shouldbe present to monitor the training. OJT is conducted at the actual job site where the work wilbe done.

The supervisor/trainer should use the training materials (this module, or other materials) whilethe training is being done, to help ensure that all job steps are covered, and that no importantsafety precautions are omitted. Effective OJT should begin with an explanation (lecture and/ordiscussion) of the safe job procedure. The explanation should be followed by a hands-ondemonstration of the proper job procedure. A good demonstration is, perhaps, the mostimportant part of OJT. The demonstration is followed by supervised practice, during whichthe supervisor/trainer coaches (corrects and encourages) the employee, and evaluates whenthe employee is ready to do the job without direct supervision.

The first step - explaining the job to the employee - can be done in different ways. Thesupervisor/trainer and the employee can sit down and go through the training materialstogether. It may be advantageous to provide the employee with a copy of the training modulesthat are applicable to his/her job. The fact that most of the training is conducted at the job sitedoes not preclude the use of a classroom or a quiet offce for the first part of the training. Anygeneral theory or knowledge training, as well as the initial explanation of the job procedure,may be best done in an offce/classroom setting; especially when noise levels, or otherconditions at the job site, make communication difficult. A complete series of job steps couldbe presented through the use of slides developed at the mining operation.

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This module describes the basic job steps, potential hazards or accidents, and · 2019-08-11 ·...

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