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Safety Manual for Dumper Operator

himanshu bhushan

Safe Code of Practice for Dumper Operator

1. 2. While on duty, he shall wear Safety Gadgets like helmet, shoes, earplugs, dust- caps and uniform. Before starting the dumper, he shall inspect and test the vehicle for its roadworthiness paying attention to Engine, Transmission and Hydraulic oil Levels Radiator water Tyre condition Horn and If the vehicle is operated after day light hours, Lights. He shall take the dumper for use after he is satisfied that it is mechanically sound after ensuring the brake condition. The operator shall keep the cabin glass clean, for clear vision. He shall operate dumper at a speed as specified in the code of traffic rules. He shall negotiate downhill gradients in low gear. On haul road, he shall not drive closely behind a dumper but maintain a 30M distance behind it. He shall not attempt to overtake another vehicle unless he can see clearly for enough ahead to be sure that he can pass it safely. He shall also sound the horn before overtaking. Before crossing a road, he shall reduce speed, look in both directions along the road and shall proceed across the road only if it is safe to do. The operator shall be sure of the clearance before driving under the cable cross over. The operator shall sound horn near turnings. While one dumper is being loaded, the other dumper operator shall not take his dumper for loading spot but shall wait at a safe distance. He shall place the dumper for loading after obtaining signal from shovel operator. He shall leave the loading spot after receiving signal from shovel operator. He shall not reverse the dumper unless he has a clear view of the area behind the dumper. He shall stay at a safe distance from the edge of the dump area and never strike the berm, preferably just touch the berm. He shall apply dump brakes during unloading. After dumping the material he shall lower the bucket, release the brake and proceed forward. While in operation, if the dumper goes under break-down, he shall park the dumper on the left side of the haul road / nearest safe place. Apply wedges to the wheels, fence off the dumper and put on lights in case of night. He shall not allow any unauthorized person to ride on the dumper. After finishing work, he shall bring the dumper to proper parking area/ place, apply parking brakes and run the machine at low idle for 3 to 5 minutes before shutting down the engine.

3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

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Care to be taken during dumper driving

1. He shall not possess contra bands while on duty. 2. Do not jump off a dumper when it is still in motion. 3. Do not stand between the front and rear parts of an articulated dump truck when the engine is running, where there is danger of being crushed. 4. Do not alter tyre pressures in an attempt to improve traction. 5. Be aware of the rear of the dumper with rear wheel steering. 6. Do not drive with skip in tipped position. 7. Always apply hand break before tipping. 8. Do not allow the lip of the skip to strike the ground when tipping. 9. Do not tipped the load while the dumper is moving. 10.Do not use the skip in tipped position as dozer.

Care to be taken at the time of refueling

1. 2. 3. 4. 5. Do not smoke when refueling. Never refuel with the engine running. Replace the fuel caps securely on the engine and fuel container. Wipe up any spillage immediately. Fuel container should be in good condition and leak proof. Do not use dumper in hazardous or explosive atmosphere, or where fuel has been spilt. Don not use machine in a badly ventilated area where exhaust fume can build up. Check that there is no combustible material lying on or against the exhaust system. The exhaust pipe and silencer get very hot.

6.

RIGHT OF WAY (a) Where the main haul road is connected to any road either at the same level or through a ramp, designated parking places shall be provided where the operator of the vehicle shall stop, observe on both sides and then only enter into the main haul road. The parking place shall be on level ground. Whenever any vehicle / Dumper / Water tanker or other heavy vehicle is required to exit from the haul road, the driver / operator shall immediately before exit, ensure through the rear view mirrors that there is no vehicle following him and shall exit giving proper indication by side indicator lights. The exit point shall be on level gradient and well illuminated. At intersection which are not governed by the traffic signs / signals, the vehicle having the right of way shall be given way except. Water tanker / sprinklers, graders, road rollers and Dozers used for repairing and maintaining haul roads have the right of way over all other vehicles.

(b)

(c)

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4 Vehicle flashing emergency lights shall have the right of way over all other vehicles, e.g. Fire Tenders, Ambulance, Vans. Light vehicle shall at the times give way to all dumpers, trucks and other heavy vehicle. The driver of a vehicle having right of way over another vehicle shall not endanger himself or others through insistence on that right if this is likely to cause a collision.

(d) (e)

PARKING & STANDING CONDITIONS &PROCEDURES. Parking only at designated place: a) No dumper shall park or stand except at designated places, which shall be flat, well lighted and have proper layout, for sufficient number of dumpers. Road layout shall be demarcated. b) If it is to be parked due to breakdown: (a) A driver shall not park his vehicle in a position that will endanger other traffic in the area. (b) A driver shall not park or stand his vehicle within 30m of the working area of mobile equipment or where his vehicle cannot be clearly observed. (c) A driver shall not park or stand his vehicle within the area of swing of the dragline without obtaining prior permission from the dragline operator. (d) A driver before leaving his parked vehicle, shall ensure that The vehicle is secured. A red flag is displayed at the extreme end of the vehicle and during night the parking lights be switched on. The parking brakes have been applied. All implements have been lowered / emptied / taken out. (e) If circumstances dictate that a heavy vehicle must be parked on a gradient, than The steering shall be turned off-centre. The vehicle shall be kept in the opposite gear of the dip gradient. Red flag to be displayed at the end of the vehicle, during nights and the parking lights shall be switched on.

PROCEDURES FOR OVERTAKING. (a) Overtaking shall not be permitted on haul roads except at designated places. The designated place shall be flat as far as possible, well lighted, well demarcated and shall not have road divider and junction. No dumper shall overtake another dumper. A dumper can overtake water tanker at designated place.

(b) (c)

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5 (d) (e) As far as possible pump truck of SMS/SME shall not be allowed on haul road during haul hours. Overtaking shall be done only after giving designated signal (say, a single long horn.) to the vehicle being overtaken and also after receiving designated acceptance signal (say,two long blast of horn). During nights the overtaking shall be done only after exchange of light signals. The accepted vehicle shall reduce the speed to Zero km/h and give way to the overtaking vehicle before allowing the overtake. The operator shall ensure that adequate clearance is there in the front and on the side, by viewing from both sides of rear view mirrors. Before actual overtaking, the driver / operator of the overtaking vehicle shall also ensure himself of adequate clear space ahead and on the overtake side of the vehicle being overtaken.

(f)

(g)

PROCEDURES FOR REVERSAL.

a) Reversal of dumper or any other vehicle shall be done at designated places, which may be loading and unloading stations of dumpers. b) The designated places shall be flat and well lighted and sufficiently large to accommodate 2/3 vehicle and ensure smooth reversing. c) Dumper, water tanker or any other vehicle shall not be reversed under any circumstances on a haul road. In case a vehicle is required to travel in opposite direction, definite turnout point shall be reversed with forward motion only. d) During reverse mode of operation, the maximum permissible speed shall not exceed 5 km/h. e) The vehicle shall not be reversed unless the driver has a clear visibility of the rear area through mirror. f) In case of doubt about the clear spaces on the rear area for reversing the driver should personally inspect the area before reversing.

Warning /Signal The reversing shall not be done unless sufficient warning has been given. The AVA should be in working condition for communicating adequate warning during reversing. The driver / operator shall not undertake reversing if the AVA is not in working order. Utmost care shall be exercised in reversing during unloading in the dump yard. During reversing at the dump yard the vehicle should be stopped as soon as the rear wheel touches the berm. At the time of hoisting the data of the dumper, Dumper Brake shall be applied and Brake lever shall be kept on position just to avoid rolling. The reversing shall be done by skilled driver/operator duly authorized for the vehicle.

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6 SIGNS (a) Every place having Change of direction, Speed or any other instruction supposed to be followed at any place in the opencast workings regarding traffic control, a clear and distinct signal shall be provided. Clear and distinct signal shall be provided where a possibility of collision of a dumper with other dumper or structure or even berm/ driver etc. exists. Every signal shall be clearly visible from a distance of more than 30m. They shall be made with fluorescent paints of adequate thickness. The signal post shall not be in the direct path of the dumper. All signs are to be obeyed as read. If the intent or validity of a sign is in doubt the manager / assistant manager shall be contacted. Temporary or any sign shall be removed as soon as possible after need for them ceases to exist. Warning signs, including the blasting time, are to be displayed. SPEED LIMIT OF VEHICLES. Maximum Speed: a) As per the guidelines/instructions issued by the manager temporarily or permanently, to a place the speeds of different vehicles shall be followed. b) During water spraying on haul- roads or in poor visibility conditions, the driver / operator shall reduce the speed of his vehicle and it shall not exceed 20 KMPH. c) At all turnings the speed of dumpers / other vehicles shall be reduced to 25 KMPH. Overtaking prohibited at the turnings (with mud/slush). d) Maintain safe distance (30Mtrs) between dumpers or Dumper to other vehicle. e) While coming / going out /into the parking yard the speed of any vehicle shall be reduced to 5 KMPH. f) On the haul-roads, on which dividers are not provided (level roads & ramps), the speed shall not more than 20 KMPH. g) Reduce the speed at cable crossovers. Maximum Speed near Dump Yard: a) Dumpers approaching dump yard from main haul road and main junctions shall not travel at a speed more than 20 Kmph. b) Dumpers reversing for final dumping operation shall not travel at a speed more than 5 Kmph and shall move slowly close to the berm c) Maximum Speed at or near Parking area: a) Dumper entering / coming out of the parking area shall not travel at a speed more than 5 kmph. Maximum Speed at Poor Visibility : a) Where visibility or road conditions are poor, a driver shall reduce the speed of his vehicle to extent necessary to effectively control the vehicle and in no case speed exceeds 20 Kmph. Maximum Speed at Downgradient: a) While going downhill, the speed of the dumper shall not be more than 30 Kmph (empty) and 20 Kmph (load) However in the adverse gradient the operator shall use retarder to restrict the speed himanshu bhushan

b)

c) d) e)

Why SEAT BELTS The chance of surviving an accident is greater when a seat belt is worn. In fact, the safest place to be during an accident is in the cab with a seat belt fastened. Nearly onehalf of all mobile mining equipment fatalities occur to operators who are not wearing seat belts, or who take them off in a futile attempt to jump clear of the equipment. Staying with the machine is almost always better than attempting to jump out. A number of needless fatalities can be prevented by the simple act of wearing a seat belt and remaining within the cab.

Backing Over tbe Edge Operators must STAY ALERT when operating their haulage trucks near the crest of a stockpile. They must know where their rear tires are in relation to the slope edge. A surprising number of stockpile accidents occur when a haulage truck is simply backed over the edge of a pile. When operators are end dumping over the crest of a stockpile, they must make sure that they are in a designated area with adequate berms or other impeding devices. Mirrors must be clean and properly adjusted. If dumping at night there should be adequate lighting to see the edge. Brakes must be tested to ensure they are working properly. himanshu bhushan

8 Operators should back slowly to ensure there is adequate time to react and stop before contacting the berm. BERMS CANNOT BE RELIED ON TO STOP A TRUCK. When a spotter is used, the spotter should stand where his signal can be clearly recognized. Spotters should use signal lights at night and when visibility is limited. Berms Backing through or over a berm is a common cause of stockpile accidents. A normal rule of thumb is that berm height should be equal to mid-axle height of the largest truck using the dump site also requires that berms be equal to axle height of the largest truck at the work site. The berms should be constructed strong enough to survive a moderate impact. However, they should not be used to stop a truck. Berms should be used as a visual indicator of where the truck should be stopped, or to provide a "feeling" of the berm as the rear tires contact it. A BERM SHOULD BE USED FOR SPOTTING ONLY! TRUCK DRIVERS MUST MAKE SURE

THAT THEY ONLY DUMP WHERE A BERM OR IMPEDING DEVICE IS PROVIDED.

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Backing Orientation
When backing at an angle to the slope edge one set of rear duals will reach the edge before the other. If the rear tyre on the side of dumper opposite the operators compartment reaches the slope edge first, the chance of accident increases. This happens when the operator is watching his side of truck and unexpectedly contacts the berm with other side. The far side tyre contacts the berm too hard and dumper either goes through or over the berm. It is important for driver to back their dumper square to the edge of the slope or at a slight angle that places the operators side closer to the slope edge. Drivers should primarily use the mirrors on the operators side of the dumper when backing.

If there is confusion where to dump stop and ask to supervisor

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