POWER SHOVEL OPERATION

MODULE NUMBER 8OFINSTRUCTION GUIDE NUMBER 43

ON-THE-JOB TRAINING MODULESFORSURFACE METAL AND NONMETAL MINES

POWER SHOVEL OPERATION

This module describes the basic job steps, potential hazards or accidents, andrecommended safe job procedures for power shovel operation.

Power shovels are used at surface metal and nonmetal mines for overburden removal andfor ore loading. Many different sizes of shovels may be used, depending on the type ofoperation and application.

Accidents relating to shovel operation most often result from slips and falls, becomingcaught in or struck by moving mechanisms, and standing or walking near the machinewhile it is in operation.

Slips and falls occur most often during maintenance,' repair, or cleanup, and whenmounting and dismounting the machine. Miners are most often struck by movingmechanisms during greasing or oiling, or when performing maintenance or repair. Injuriesto persons standing or walking near the machine often occur when the person is in thearea and the shovel operator is unaware of their location.

The basic job steps included in this module are:

1. Conduct walk-around inspection of shovel and work area.

2. Mount and dismount.3. Conduct on-board inspection.

4. Generaloperation.5. Shutdown procedure.6. Perform repairs and maintenance.

Several of these proce~ures apply to the oiler and ground man as well as the shoveloperator.

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:

Reguired and/or recommended personal protective eguipment:

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

SEQUENCE OFBASIC JOB

STEPS

1. Conduct walk-

aroundinspection ofshovel andwork area.

POTENTIALACCIDENTS OR

HAZRDS

1. A) Personal injury,unsafe equipmentor work area.

B) Electrocution.

C) Rock falL. Strikingpersonnel, or

damagingmachinery withshoveL.

RECOMMENDED SAFE JOBPROCEDURES

1. A) Visually inspect machine andwork location for defectiveequipment and/or unsafeconditions prior to operation.Report any unsafe conditions toyour supervisor and correct alldefects.

B) Visually inspect trailng cable forcuts, abrasions, and otherdamage (electric powershovels). If inspection requireshandling the cable, power mustbe off at switch house, or properprotective equipment (insulatedhooks, tongs, ropes, or slings)must be used.

C) Inspect highwall, spoil and pitconditions in your work area.Know traffic patterns, andcommunicate with fellowworkers before operatingshoveL. Warning signs arerecommended to prohibitunauthorized persons fromcoming near the shoveL.

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STEPS

1. (Continued)

2. Mounting and

dismounting.


HAZRDS

D) Fallng material,improperoperation.

E) Slips and falls.

F) Machine damage,rope failure.

NOTE: IG 43 Module 14,contains detailedprocedures forinspecting wire rope andrelated items.

G) Splashed fluids,burns.

2. A) Slips, falls, caughtbetween shoveland othermachine.

B) Struck by orthrown fromladder.


D) Inspect bucket dipper teeth andadapters for tightness. Inspectlatch bar for wear and properadjustment.

E) Be especially careful of ruts,uneven ground, and frozenground. Make sure all steps,ladders, handrails, handholds,and walkways are in goodcondition and free from oil,grease, mud, snow, and ice.

F) Check for oil leaks, gear wear,seized bearings, loose ordamaged crawlers or rollers,lubrication of gears and rollers~Check ropes and boomstructural strands (to the extentpossible).

G) Check fluid levels. Wear safetyglasses with side shields andgloves. Remove tank caps orcovers carefully. It is importantto know if gear cases are hot orcold.

2. A) Use caution when mounting or

dismounting. Do not get on oroff until the operator is notified.

B) Do not get on or off while theshovel is in motion.

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STEPS

2. (Continued)

3. Conduct on-

boardinspection.


HAZRDS

C) Slips and falls.

D) Rock fall, caughtbetween shoveland othermachines.

E) Clothing caughton control leversor otherprojections, slipsand falls.

F) Ladder failure.

3. A) Equipment

movement and/orfailure, stuck orinoperativecontrols, poorvisibility.

B) Caught in, orstruck by, movingparts.


C) Use steps, ladders, handholds,etc., provided for mounting andmake sure they are in goodcondition. Keep both handsfree for climbing.

D) Never walk or stand betweenthe shovel and the bank,highwall, spoil, or other nearbymachines while mounting.

E) Wear snug fitting clothing andkeep boots, steps, ladders, etc.,free from oil, grease, mud, etc.NOTE: Slip resistant flooring isrecommended in walkwayzones.

F) Raise boarding ladder (ifprovided) and be sure it issecured.

3. A) Check operator's cab. Makesure all controls are in theneutral position, brakes set, andbucket lowered to the ground.Make sure cab is free fromdebris, etc., and windowsclean.

B) Make sure all guards and safetydevices are in place and ingood condition.

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STEPS

3. (Continued)


HAZRDS

C) Slips, trips, falls,fire hazard.

D) Fire hazard.

E) Fire and/orexplosion hazard.

F) Electrocution,

burns, equipmentfailure.

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C) Check decks and house areafor uncovered openings,slipping, or tripping hazards,and accumulations of flammableor combustible material orliquids. Practice goodhousekeeping.

D) Know location and operation offire extinguishers, and makesure they are fully charged andoperable. Don't smoke or useopen flame sources aroundcombustible or flammableliquids or materials.

E) Keep all compressed gascylinder tanks secured, andkeep covers in place. Keep allcompressed gas cylinders,hoses, torches, and regulatorsfree of grease and oiL. Do notstore this equipment in thesame enclosed area whereflammable or combustibleliquids are stored.

F) Be sure all electrical equipment(switches, breakers, controls,panels, guarding, etc.) is inproper operating position and ingood condition. Never perform

any electrical work or enter anyenergized electrical panels orcabinets unless you are aqualified electrician. Be sure tolock out and tag the equipmentor circuit.


STEPS

3. (Continued)


HAZRDS

G) Boom or gantryfailure, ropefailure caused bysheave failure,excessive rope

wear.

H) Rope failure.

I) Trips and falls.

J) Potential hazards

that remainuncorrected.

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G) Inspect boom, boom pockets,and gantry for cracks, breaks,structural damage, excessivewear, missing parts, etc. Checkpoint sheaves and saddleblocks for damage or excessivewear.

H) Check both the running ropesand the boom structural strandsfor broken strands and loosesockets. Periodic

nondestructive testing ofsockets is recommended.

i) Check all steps, ladders,handrails, platforms, andwalkways for cracks, corrosion,damage, or any deterioration.

J) Report and, if possible, repairany defects or hazards foundduring walk-around or on-boardinspections. Do not usemachine with safety defects. Ifthe shovel is unsafe andremoved from service, tag it toprohibit further use until repairsare completed.


STEPS

4. General

operation.


HAZRDS

4. A) Striking or

catching otherpersonnel.

B) Personal injurydue to lack ofcommunication.

C) Machine or controlmalfunction.

D) Personal injury,inefficientoperation.

E) Unsecured raisedequipment, injuryfrom suddenmachinemovement whenpower is restored,equipmentdamage.


4. A) Sound an audible horn prior tostarting shovel in motion, afterrepairs or after being idle.

B) By visual observation or verbalcommunication, make certainmachine crew (oiler/groundman) and all otherpersons and machines are clearbefore starting. Be sure themachine crew reports to youthroughout the shift, so that youhave a general idea of wherethey are at all times.

C) Make sure air pressure is atproper operating range. Checkout motions of machine and allcontrols, limits, and warningdevices. Check all brakesystems. Stop machine if youfeel or see any unusualresponse or hear any abnormalsounds.

D) Clearly understand any workassignment before starting.Make certain machine crew andothers know and understand allsignals.

E) In the event of a power failure,move all brake switches to setposition, place other controls inthe neutral position, and securethe machine's position untilpower is restored.

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STEPS

4. (Continued)


HAZRDS

F) Personal injury,machine damage.

G) Injury orequipmentdamage from fallof materiaL.

H) Equipmentdamage,overturning.

I) Fall of material

and/or bucket.

J) Ground failure,rock fall.

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F) When operating and/or movingshovel, be alert for pitelevations, highwall, spoil,trenches, faults, clearances,traffic, machine crew, otherworkers, sump holes, andtrailing cables. Keep shovel ongood sound footing.

G) Never swing bucket overworkers, vehicles, machines, ortrailng cable. When loadinghaulers, don't swing over cab.Be sure of clearance overhauler bed and position bucketbefore tripping.

H) Never suddenly set brakes

while swinging, except in anemergency. Avoid jerking andabrupt motions.

I) Do not suspend a loaded or

empty bucket in the air, with thebrakes set, for long timeperiods. Lower to ground whennot in use.

J) Observe condition of highwalland spoil banks at all times.When freezing, thawing, rain,etc., have created a potentialhighwall or spoil bank failurecondition, immediately notifycrew, others working in thearea, and your supervisor. Usemachine's audible alarm signalto warn personnel of thisimmediate danger if necessary.


STEPS

4. (Continued)


HAZRDS

K) Ground failure,rock falL.

NOTE: IG 43, Module15, contains moreinformation on groundcontroL.

L) Cab struck byrollng material,

machine damage.

M) Striking othermachines/vehicles with

fallng material or

machine.

N) Fall of materiaL.

0) Electrocution,

burns, cabledamage, strainsand overexertion.

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K) Loose hazardous material mustbe stripped for a safe distance(1 0 feet or more) from the top ofpit or quarry walls, and looseunconsolidated material mustbe sloped to the angle ofrepose. Leave highwall as safeas possible before moving up.

L) When dumping to a higherlevel, be alert for rocks ormaterial rollng down the bank,especially when cab is besidethe bank.

M) After being notified, allowsuffcient time for vehicles ormachines to pass by shovelbefore resuming normaloperations.

N) Do not work between machinesand the highwall or spoil bankwhere your escape from falls orslides may be hindered.

0) Protect trailing cable from

damage. Never carry or movecable with bucket unless slingsare used. If energized cablemust be moved manually, useproper protective equipment(insulated hooks, tongs, ropes,or slings). Keep kinks, twists,and short bends out of trailingcable. Don't pull long lengths at

one time. Take several loops tominimize strain on cable. Don'trun over power cables.


STEPS

4. (Continued)

S. Shutdownprocedure.


HAZRDS

P) Electrocution,

burns, machinedamage.

S. A) Personal injury,equipmentdamage.

B) Fall of equipment,machine damage.

C) Injury orequipmentdamage ifmachine moveswhen energized.

D) Personal injury.

E) Slips, trips, falls,caught betweenladder and othermachine orobstruction.

F) Hazards due to

lack ofcommunication.

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P) Never work or swing boomwithin a minimum distance of 10feet from any energizedoverhead power line.

S. A) Park shovel on firm ground in a

position where it does notcreate a traffc hazard and is notsubject to damage by slides orfalling materiaL.

B) Place bucket on ground firmlyand release cable tension.

C) Place all controls in properposition. Make sure all brakecontrols are in the set position.

D) Do not permit anyone to get onor off the shovel while it is inmotion unless equipped to doso safely.

E) Dismount shovel (see Job StepNo.2).

F) Communicate with fellowemployees and supervisor atend of shift. Notify of anyhazardous conditions, machinemalfunctions, etc.


STEPS

6. Performing

repairs andmaintenance(if applicable).


HAZRDS

6. A) Personal injuryfrom improperprocedure.

B) Caught by, orstruck by, movingor fallng parts, ormoving machine.

C) Fall of person.

D) Fall of hoistedloads or

equipment.

E) Personal injury.


6. A) Do not attempt repairs ormaintenance you do notunderstand and have not beentrained to do.

B) Do not lubricate any movingpart unless guarding, andextended fittings, preventaccess to hazardous movingparts. Do not attempt any

repairs or maintenance until thepower is off, the machinery islocked out and tagged andblocked against motion, and allraised equipment lowered. Ifnecessary to perform work ontop of, under, around, or from araised piece of equipment, blockor mechanically secure theequipment to prevent accidentalrollng, fallng, or lowering.

C) Don't climb boom or gantrywhile shovel is in motion. Usesafety belts with lanyards inelevated positions outside workplatform, or where there is adanger of fallng.

D) Do not overload hoisting orlifting device. On hoistedmaterials that require steadyingand guidance, use taglines.

E) Plan any work to be done andmaintain good communications.Know and observe safe workpractices. Inspect tools andmaintain in good condition.

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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 the industry.The JSA format facilitates uniform basic training in safe job procedures, while requiring only aminimum of time and effort on the part of the trainer. This material is generic to the industry;therefore, each company using this guide wil need to tailor the material somewhat to fit theirparticular requirements. In some cases, the material must be general in nature, and wil notinclude specific details of procedures or equipment that must be 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," 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 of the 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 which thesupervisor/trainer coaches (corrects and encourages) the employee, and evaluates when theemployee 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 ofthe job procedure, maybe best done in an offce/classroom setting; especially when noise levels, or other conditionsat the job site, make communication difficult. A complete series of job steps could be presentedthrough the use of slides developed at the mining operation.

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Documents

POWER SHOVEL OPERATION