module 2 dozer operation

MODULE NUMBER 2OFINSTRUCTION GUIDE NUMBER 43

ON-THE-JOB TRAINING MODULESFORSURFACE METAL AND NONMETAL MINES

DOZER OPERATION

This module describes the basic job steps, potential hazards or accidents, andrecommended safe job proceures for dozer operation.This material is designed primarily for use in the initial training of dozer operators atsurface metal and nonmetal mines. The content deals with general operation and clearingand pushing, but this material can be applied to other jobs performed with a dozer. Thismaterial should be used by trainers as a supplement to practical knowledge and specificmine conditions.

Dozers are one of the strongest and heaviest pieces of equipment used at surface mines.Dozers can be used effectively for clearing operations, pushing material, grading work,compacting loose material, etc. The most common uses are for clearing and pushingoperations.

Accidents involving dozers often result in disabling injuries or fatalities, due to the massiveweight of the dozer. Crushing type injuries involving dozers most often result in fatalities.Most of these occur when operators are run over by their own machine. Many otherhazards exist, requiring the dozer operator to remain alert at all times.

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 to ensure proper working order. Headlights, horns, and backup alarm systemsmust 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 dozer.2. Mount dozer and check cab.3. Start dozer and complete pre-shift examination.4. Tram dozer to work area.5. Examine work area.6. Clear materiaL.7. Push materiaL.8. Refuel and park.9. 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 injuriesand adversely affect production:

Required and/or recommended personal protective equipment

Hard hat, safety shoes, safety glasses with side shields, gloves,clothing appropriate for weather conditions, hearing protection whereneeded

SEQUENCEOF BASIC JOB

STEPS

1. Conductwalk-aroundcheck ofdozer.

POTENTIALACCIDENTS OR

HAZRDS

1. A) Frostbite,hypothermia,sunburn, heatcramps, heatexhaustion.

B) Struck bymoving dozer orotherequipment.

C) Slips or trips.Struck by flyingobjects, such asdirt or splashedfluids. Caughtin pinch points.

RECOMMENDED SAFE JOBPROCEDURES

1.A) Dress to suit weather conditions.

B) Check to be sure dozer blade islowered to ground. Be alert fornearby equipment.

C) Conduct walk-around inspection ofdozer. Avoid slick spots, and keeparea free of slipping or trippinghazards. Use suitable access ifnecessary to mount and dismountdozer to check engine or other area ofmachine.

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STEPS

1. (Continued)

2) Mount dozerand checkcab.


HAZRDS1. C) (Continued)

D) Defects andhazards not fixed.

2. A) Slips and falls.Clothingcaught oncontrol leversor otherprojections.


During walk-around inspection, check:1. Area around dozer for people or

obstructions.2. All bolts, guards, covers, and

mechanical components of dozerto make sure they are in place.

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

4. Fluid levels. Wear safetyglasses with side shields andgloves.

5. Hydraulic oil and coolant linesand hoses for breaks, leaks,rubbing lines or loose fittings,

6. Fire extinguisher (if on outside ofmachine) to make sure it's inplace and fully charged,

7. Ladders, steps, hand holds, andhandrails for loose bolts, breaks,cracks or missing parts.

D) Report and, if possible, repairany defects found. Do not useequipment with uncorrectedsafety defects.

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

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STEPS

2. (Continued)


HAZRDSB) Fallng from

machine.

C) ROPS/FOPSfailure in arollover orfallng objectaccident.Missing orinoperative fireextinguisher.

D) Struck by f1yingobjects.Jammedcontrols.Projectingcontrol levers.

E) Accidentcaused by poorvisibility.

F) Improper seatadjustment maynot allowmaximumbrake pedalpressure in anemergency.

G) Thrown againstcab interior, orthrown out ofthe machine.


B) Use belt hooks, pockets, etc., tocarry materials up to cab. Keepboth hands free for climbing. Usehandholds and select firm footing.Avoid haste and projections.

C) Check for any damage torollover/fallng object protectivestructure. Check fire extinguisher(if located at cab).

D) Remove or secure any looseobjects in cab. Avoid projections.

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

F) Be sure seat is properly adjusted.

G) Make sure seat belts are providedand in good condition. BUCKLEUP!

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STEPS

2. (Continued)

3. Start dozerandcompletepre-shiftexamination.


HAZRDSH) Equipment

malfunction.

3. A) Hitting orrunning overpersons orobjects in area.Striking insideof cab if dozermovessuddenly.

B) Engine orauxiliaryequipmentmalfunction.

C) Engine ordeceleratormalfunction.

D) Poor visibility.Poor operation.

E) Loss of control.


H) Check all instruments and gaugesto be sure they are not stuck. Makesure all controls are in neutralposition, and parking brake is set.

3. A) Check equipment for warning tags.Be sure blade is lowered to ground.Check controls to be sure they arein neutral. Sound horn beforestarting or moving. Check backupalarm after start-up.

B) Let engine run at low idle until itreaches normal operatingtemperature. Check gauges andwarning lights again for normalreadings.

C) Check engine for smooth idle, andunusual smoke or noise. Checkdecelerator operation.

D) Check wipers and lights. Checkhydraulic controls.

E) Check brakes and steering aftermoving a short distance. Brakesmay also be checked againstpartial engine power beforemoving, according to companypolicy. Check transmissionoperation.

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STEPS

4. Tram dozerto work area.

5. Examinework area.


HAZRDS4. A) Personal injury.

B) Running oversomeone.

C) Poor visibility,poor stability,overturningdozer, strikingotherequipment orpeople.

D) Caught inpinch points.

E) Overturningdozer.

F) Loss of steer-ing and/orbrakes.Collsions.

5. A) Fallng materialfrom highwallor fill. Looseground.

B) Struck bymovingequipment.


4. A) Do not allow anyone to ride outsidethe cab for any reason. No oneshall ride with the operator unlesssafe seating facilities are provided.

B) Sound horn before starting to tram.

C) Observe travel area. Adjust speedfor conditions. Tram with blade low(15 to 20 inches off the ground).

D) Keep doors latched securely.

E) Travel at acceptable speeds forconditions. Avoid loose material,slick spots, and weak areas.Observe road hazards, and travelin stable areas.

F) Monitor gauges/indicators. Followtraffic rules.

5. A) Stop dozer a safe distance awayfrom highwall or fresh excavationswhere loose material could be ahazard.

B) Observe area for other equipment.If leaving dozer, lower blade, setbrakes, and shut-off the engine.

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STEPS

5. (Continued)

6. ClearmateriaL.


HAZRDSC) Slipping/

trippinghazards.

D) Struck byfallng materiaL.

E) Slips and falls.Hypothermia.

6. A) Loss of brakes,equipmentdamage, dozeroverturning,steep slopes,operator error.


C) Select firm footing, avoid slickspots. Be aware and cautious ofmud, snow, ice, loose material andsteep inclines.

D) Inspect working areas for:1. Overhanging material,2. Loose rock,3. Vertical and horizontal cracks,4. Boulders, trees, or other material

which might fall or roll,5. Jagged sections of highwall,6. Undercuts,7. Sliding or fallng material,8. Miscellaneous debris,9. Compliance with standard

procedures for degree of slope,benching, etc.

E) Be aware of weather changeswhich affect ground conditionsincluding rain, snow, freezing, andthawing. Dress for weatherconditions.

6. A) Avoid overheating brakes.Maintain dozer stability. Avoidturning sideways. Frequentlycheck gauges to be sure fluid pres-sures are adequate, preventingengine shutdown and transmissionshifting. Be sure you know locationand use of appropriate controls.

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STEPS

6. (Continued)


HAZRDSB) Dozer over-

turning,ineffcientoperation,equipmentdamage, flyingbrush, caughtin pinch points.

C) Groundpersonnelstruck bydozer, tree,cable, etc.

D) Skidding orsliding, steepslopes, strikingground person-nel, unstableground, poorvisibility.

E) Skidding orsliding.


B) Keep blade down and avoidrunning on downed material, suchas felled trees. Operate in gearconsistent with the area andmaterial being cleared. Keep doorsclosed and securely latched.

C) Frequently check location of anyground personnel to ensure theyare not in path of dozer or in anarea where they could be struck byflying brush, fallng trees, etc.

D) Use extra caution if clearing in rain,snow, ice or other conditions thatcould reduce traction. Be aware oflimited sight distance in fog, rain,dust, or snow; operate at lowerspeeds to allow quicker stops, etc.

E) Rocks, loose material, heavyvegetation, etc., will reduce tractionand cause sliding/ skidding whenbraking. Operate in gear consistentwith material, reduce load that isbeing pushed and operate indirection that will provide mosttraction and best braking surface.

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STEPS

7. PushmateriaL.


HAZRDS7. A) Sliding

equipment.Ground failureunder weight ofdozer.

B) Striking otherequipment orpersons.

C) Skidding orsliding, steepslopes, strikingground person-nel, unstableground, poorvisibility.

D) Falling orslidingmaterial,ineffcientoperation.


7. A) Be alert for ground conditionswhich may cause accidents; loosematerial, large rocks and ice canresult in sliding equipment. Steepslopes, cut out areas, and freeze-thaw cycles can result in weakareas that cannot support theweight of a dozer, causing theground to break under the dozer.Avoid these areas, or repair andcompact prior to beginning work.Wear seat belts at all times.

B) Be aware of other equipmentoperating in the area. Frequentlycheck the location of otherequipment. Keep lights and back-up horns in operating condition.

C) Use extra caution if operating inrain, snow, ice or other conditionsthat could reduce traction. Beaware of limited sight distance infog, rain, dust, or snow; operate atlower speeds to allow quickerstops, etc. Keep in mind thatadverse weather can cause groundconditions to change rapidly, checkfor these changes and adjustoperation accordingly and reportthem to your supervisor.

D) Frequently check highwalls andstorage piles. Keep blade low, andoperate in gear needed for thematerial being worked.

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STEPS

7. (Continued)

8. Refuel andpark.


HAZRDSE) Loss of braking

and/orsteering,equipmentdamage,ineffcientoperation.

F) Overturningdozer, or goingover the edge.Operator error.

8. A) Struck byequipment, fuelspilage, firehazard.

B) Slips and falls.Clothingcaught oncontrol leversor otherprojections.

C) Fuel on skinand in eyes.


E) While working, monitor gauges andperformance for proper pressures,temperatures, and possibleequipment damage. Reportdamaged/faulty equipment to yoursupervisor and have repairs madebefore continuing. Operate thedozer for maximum performance atall times.

F) Leave berms along edges ofslopes. Concentrate on work at alltimes. Do not over estimate yourability or the capabilities of thedozer. DO NOT take chances. Besure you know location and func-tion of controls.

8. A) Park at refueling station, placecontrols in neutral, set brakes,lower blade until firmly seated, andshut off engine. No smoking at ornear the refueling station.

B) Dismount dozer (see 2. A-B). DONOT JUMP. Check surroundingarea for loose material and slickspots.

C) Take fuel hose from storage rack,remove tank cap slowly and pumpfuel into tank.

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STEPS

8. (Continued)


HAZRDSD) Trips, slips,

and falls, firehazard.

E) Fire hazard,fuel spilage ordischarge.

F) Collsion,runawayequipment,traffcobstruction.

G) Unsecuredraised equip-ment, runawayequipment.

H) Caughtbetween partsof dozer.

i) Enginedamage.

J) Struck by otherequipment.

K) Slips and falls,clothing caughton controllevers or otherprojections.


D) Avoid fuel spilage and keep areafree of extraneous materials. Ifnecessary to climb on dozer torefuel, use steps, available rails orhand holds. Keep walking orstanding areas free from slippingand/or stumbling hazards. Avoidfuel spilage onto hot engine parts.

E) Shut off fuel, remove nozzle hose,and replace fuel cap. Return hoseto rack.

F) Park only at designated parkingareas and always set brakes.Avoid parking on inclines orhaulroads. If parking on a haulroadis required, pick the safest place.

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

H) Keep yourself and other personnelout of pinch points while dozer isoperable.

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

J) Observe parking area for othermoving equipment before leavingdozer. Make other operators awareof your presence.

K) Dismount dozer (see 2. A-B). DONOT JUMP. Check surroundingarea for loose material and slickspots.

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STEPS

8. (Continued)

9. Performingrepairs andmaintenance(ifapplicable).


HAZRDSL) Hazards due to

lack ofcommunication.

9. A) Personal injuryfrom improperprocedure.

B) Caught by orstruck bymoving orfallng parts, ormovingmachine.

C) Struck bymaterial fallng

from machine.


L) Always inform appropriatepersonnel of any abnormalconditions, defects, changes madein equipment and/or job procedureor condition.

9. A) Do not attempt repairs ormaintenance you do notunderstand and are not trained todo.

B) Do not attempt any repairs ormaintenance until the power is offand the machinery is blockedagainst motion and all raisedequipment lowered. If necessary toperform work on a raised piece ofequipment, securely block in place.Remove ignition key to preventdozer from being started while workis performed.

C) Do not attempt repairs ormaintenance until any materialfrozen to frame, blade, etc., hasbeen removed.

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GENERAL INFORMATION

This module is part of an Instruction Guide that was developed to assist the surface metaland nonmetal mining industry in conducting effective on-the-job training (OJT) of newemployees, or employees reassigned to different jobs. The use of training materials, suchas 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 isgeneric to the industry; therefore, each company using this guide wil need to tailor thematerial somewhat to fit their particular requirements. In some cases, the material must begeneral in nature, and wil not include specific details of procedures or equipment that mustbe taught by 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," Junej1983.

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 of the training, the supervisorshould be present to monitor the training. OJT is conducted at the actual job site where thework wil be done.

The supervisor/trainer should use the training materials (this module, or other materials)while the training is being done, to help ensure that all job steps are covered, and that noimportant safety precautions are omitted. Effective OJT should begin with an explanation(lecture and/or discussion) of the safe job procedure. The explanation should be followedby a hands-on demonstration of the proper job procedure. A good demonstration is,perhaps, the most important part of OJT. The demonstration is followed by supervisedpractice, during which the supervisor/trainer coaches (corrects and encourages) theemployee, and evaluates when the employee is ready to do the job without directsupervision.

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 trainingmodules that are applicable to his/her job. The fact that most of the training is conducted atthe job site does not preclude the use of a classroom or a quiet offce for the first part of thetraining. Any general theory or knowledge training, as well as the initial explanation of thejob procedure, may be best done in an offce/classroom setting; especially when noiselevels, or other conditions at the job site, make communication diffcult. A complete series ofjob steps could be presented through the use of slides developed at the mining operation.

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module 2 dozer operation

Documents

check of dozer

tram dozer

sure dozer blade

loose material

clear material

push material

basic job steps

training machine operators