BACKHOE AND HYDRAULIC EXCAVATOR OPERATION

MODULE NUMBER 5OFINSTRUCTION GUIDE NUMBER 43

ON-THE-JOB TRAINING MODULESFORSURFACE METAL AND NONMETAL MINES

BACKHOE AND HYDRAULIC EXCAVATOR OPERATION

This module describes the basic job steps, potential hazards or accidents, andrecommended safe job procedures for backhoe and hydraulic excavator operation.

Backhoes are used at surface metal and nonmetal mines for various types of applications.Their versatiity makes these machines widely used pieces of mobile equipment.Backhoes were designed basically for ditching and cleanup. Their use has beenbroadened to include removal and loading of ore and overburden material by largebackhoes, known as hydraulic excavators.

Backhoe operators must be aware of some of the same general types of hazards as othermobile equipment operators. Many job procedures and related hazards are common tothe operation of all mobile equipment.

The most common hazards related to backhoe and excavator operation are: slipping andfallng of the machine operator, tipping or overturning of the machine, and contactingenergized power lines with the machine.

Slips and falls occur most often when mounting and dismounting, cleaning windows, orrefueling. Tipping or overturning can occur if the machine is not properly leveled, ifmaterials are lifted or handled improperly, or when traveling or operating without propercare for roadway conditions, grades, clearance, visibility, traffic, etc. Contacting energizedpower lines is most often caused by operating the machine too close to electrical lines orinstallations.

The basic job steps included in this module are:

1. Conduct walk-around check of backhoe or excavator.

2. Mount backhoe or excavator, and check cab and controls.3. Start backhoe or excavator, and complete pre-shift inspection.4. General operation of backhoe or excavator.

5. Park backhoe or excavator.

6. Refuel backhoe or excavator.

7. Perform repairs and maintenance on backhoe or excavator.

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 will 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

POTENTIAL ACCIDENTSOR HAZRDS

1. Conduct walk-

around check ofbackhoe.

1. A) Frostbite,hypothermia,sunburn, heat stroke,heat cramps, heatexhaustion.

B) Struck by fallngequipment.

C) Struck by, or runover by, backhoe orother machine.Slipping, tripping,fallng.

D) Slips or trips, struckby flying objectssuch as dirt orsplashed fluids,caught in pinchpoints.

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RECOMMENDED SAFE JOBPROCEDURES

1. A) Dress to suit weatherconditions.

B) Make sure all raised partsof backhoe are lowered tothe ground.

C) If parked on a grade orincline, make sure wheelsare turned into bank and/orblocked to preventmovement. Be alert fornearby machines.

D) Avoid slick spots and keeparea free of slipping ortripping hazards duringwalk-around. Use suitableaccess if necessary tomount and dismountbackhoe to check engineor other area of machine.

SEQUENCE OF POTENTIAL ACCIDENTS RECOMMENDED SAFE JOBBASIC JOB STEPS OR HAZRDS PROCEDURES

1. (Continued) E) Check for problems E) Examine:

that could cause the 1 ) Tires and wheels forfollowing hazards: lug nuts, cracked rims,1) Loss of control, cuts, tire pressure. If

equipment equipped with tracks,malfunction. check tracks for tight-

ness and rollers, idlers,and sprockets fordamage.

2) Running over 2) Area around backhoesomeone. for people or

obstructions.

3) Caught in 3) All bolts, guards, cov-moving parts. ers, and mechanical

components ofbackhoe to make surethey are in place.

4) Equipment 4) Engine compartmentmalfunction or for dirt, debris, oilydamage, fire rags, tools, and leaks.hazard. Grasp engine covers

firmly when removing.Avoid overreaching.

Get help if needed.

5) Burns, splashed 5) Fluid levels. Wearfluids safety glasses with

side shields andgloves. Remove tankcaps or coverscarefully.

6) Burns, high 6) Hydraulic oil, coolant,pressure fluids. and air leaks, rubbing

lines, cracks or loosefittings.

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1. (Continued)

2. Mount backhoe

and check caband controls.


7) Fire hazard.

8) Equipmentfailure.

9) Slips and falls.

F) Potential hazards notcorrected.

2. A) Slips and falls.

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7) Fire extinguisher (if on

outside of machine) tomake sure it's securedin place and fullycharged.

8) Machine for any

physical damage,hydraulic cylinders andhoses for leaks and/ordamage, boom or liftarms for cracks ordamage.

9) Ladders, steps, and

hand holds for brokenrungs, loose bolts,breaks, cracks, ormissing parts.

F) Report and, if possible,repair any defects found.Do not use machine withuncorrected safety defects.

2. A) Wear snug fitting clothingand keep steps, mountingladders, and shoes freefrom mud, dirt, snow, ice,grease, and oiL. On trackmounted backhoe, makesure cab is positionedcorrectly for mounting andwalkways around engineand hydraulic enclosuresare free from debris andslipping or stumbling haz-ards. Make sure grab railsor hand holds are providedand in good condition.


2. (Continued)


B) Fallng while

climbing up or down,clothing caught oncontrol levers or

other projections.

C) Struck by flying ob-jects, jammedcontrols, ROPS orFOPS failure in anaccident, poorvisibilty.

D) Personal injury,missing orinoperative fireextinguisher.

E) Thrown out of cab oragainst cab interior.

F) Equipment failure orrollng out of control.

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B) Keep both hands free forclimbing. Use hand holdsand select firm footing.Avoid haste andprojections.

C) Inspect cab forhousekeeping (extraneousmaterials) and FOPS orROPS damage. Makesure windows and mirrorsare clean and in goodrepair.

D) Check fire extinguisher iflocated at cab. Make surestarting fluid is not storedinside cab.

E) Check seat belts to be surethey are in good condition.Always wear them whenoperating equipment.

F) Check all instruments,gauges, and controlsbefore starting engine toensure they are not stuckor malfunctioning. Allcontrols should be inneutral position and theparking brake set.


3. Start backhoeand completepre-shiftinspection.

4. General

operation.


3. A) Operating with safety 3.

or mechanicaldefects, struck bymoving parts, orbacking over person.

B) Engine or auxiliaryequipmentmalfunction.

C) Poor visibility.

D) Loss of control.

4. A) Personal injury.

B) Personal injury,fallng hazard.

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A) Check equipment forwarning or out of servicetags. Sound horn before

starting or movingmachine. Check backup

alarm after starting. Besure all persons andobjects are clear beforestarting or moving.

B) After starting engine, idleuntil normal operatingtemperature is reachedand check gauges andwarning lights again fornormal readings. Checkengine for smooth idle andunusual smoke or noise.

C) Check lights and wipers.

D) Check brakes (includingswing brake) and steering.Don't operate machine withuncorrected safety defects.

4. A) Allow no one to ride

outside the cab for anyreason. No one should

ride with the operatorunless safe seating isprovided.

B) Never use basket or otherattachment as a stagingplatform for workers.


4. (Continued)


C) Overturning and/or

collsion.

D) Loss of control.

E) Bystanders may not

consider the swingradius at the rear oflarger machines.

F) Tipping and/or

overturning.

G) Fall of material,overturning machine.

H) Collsion.

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C) Keep machine under

control at all times. Useprudent operating speedsconsistent with conditions.

D) Never attempt to operatebackhoe from outsideoperator's compartment.

E) Be sure all persons andobstacles are clear beforeswinging or movingmachine in any direction.Always have adequateclearance before swinging

machine.

F) Avoid fast swings, hoists,or sudden braking. Besure of the working rangeand lifting capacity of themachine at all times. Moveloads carefully. Be alertfor trenches, open cuts,sump holes, coal rib,clearances, grades, etc.Keep machine as level aspossible when operating.

G) Observe highwall, pit,and/or travel conditions.Stay away from edge ofbanks, pits, and highwalls.Stay clear of overhangsand slide areas. Neverundercut the machine.

H) Know traffc patterns of thejob location and obeyflaggers, road signals, andsigns.


4. (Continued)


I) Electrocution.

J) Propert damage,

fire or explosion,electrocution.

K) Dropping material onhauler operator orbystanders,damaging hauler,excessive spilage.

L) Backing over person.

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I) Always check for overhead

power lines and be sureyou have adequateclearance if working nearoverhead lines. Keepboom at least 10 feet fromany energized power line.High voltages may dictatedistances up to 35 feet.

J) Learn beforehand as muchabout your work area aspossible. Be sure of thelocation of gas lines, sew-ers, utility lines, buriedcables or lines.

K) Don't load a hauler untilthe driver is in a safeplace. Load the hauler

from the rear or side. Loadhauler evenly to avoidoverloading rear axles andcausing spillage. Don't

drop material into truckbed from unnecessaryheights. Never swingbucket over hauler cab orworkers.

L) Never back up until youhave checked to see thatarea is clear of personneland/or obstructions.


4. (Continued)

5. Parking.


M) Tipping, over-turning, collsion.

N) Cable damage,shock or burns.

0) Loss of control.

P) Loss of control,machine damage.

5. A) Collsion, personal

injury, traffcobstruction.

B) Struck by equipment.

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M) Use caution when workingon, or crossing, sidehils,ridges, ditches, slopes, etc.Cross at an angle and atreduced speed. Except forshort distances, position

boom in direction of travel.Always face the directionof travel.

N) Don't cross power and/ortrailing cables unlesssuitable crossovers orcross-unders are provided,or the cable is properlytrenched.

0) Always set swing brake

and/or lock boom when tra-veling to or from a job site.

P) Always keep your machineunder control and in safeoperating condition at alltimes.

5. A) Always park in designated

parking area if provided orselect a safe parking area.Don't park on haul roads oractive work areas. If youmust park in anemergency, pick the safestplace and use warningsignals, flares, or barriers.

B) If necessary to park on anincline, block againstmotion and/or turn towardembankment.


5. (Continued)

6. Refueling.


C) Struck by machine,material, orattachment.

D) Run over or struckby machine.

E) Engine damage.

F) Trips, slips and falls,clothing caught oncontrols or

projections.

G) Hazards due to lackof communication.

6. A) Collsion, runaway

equipment, traffcobstruction.

B) Slips, trips and falls,clothing caught.

C) Fuel on skin or ineyes.

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C) Never leave the operator's.cab with the enginerunning or with a load orbucket suspended.

D) Place all controls inparking position. Setswing lock or brake andparking or traction brake orlock to prevent machinemovement.

E) Idle engine a short periodbefore shut down.

F) Dismount machine. Pay

attention to travelways.

G) Always inform appropriatepersonnel of any abnormalconditions, defects,changes made in machineand/or job procedure orcondition.

6. A) If refueling, park at fuelstation and follow parkingprocedure (See JobProcedures 5. A-G).

B) If necessary to mountbackhoe to refuel, useladder, steps, rails, orhand holds (See JobProcedures 2. A-B).

C) Wear safety glasses.Remove fuel cap slowly.


6. (Continued)

7. Performing

repairs andmaintenanceÒ(ifapplicable).


D) Fire or explosionhazard.

E) Slips, trips, falls.

F) Fuel spilage or

discharge, firehazard.

7. A) Personal injury from

improper procedure.

B) Caught or struck bymoving or fallngparts, or movingmachine.

C) Caught in or struckby moving parts.

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D) Avoid fuel spilage atrefueling station and on hotengine parts. Do not

smoke at or near therefueling station.

E) Keep refueling area freefrom extraneous materiaL.

F) Always replace fuel cap onbackhoe and return fuelhose and nozzle to therack.

7. A) Do not attempt repairs ormaintenance you are nottrained to do.

B) Do not attempt any repairsor maintenance until thepower is off, the machineryis blocked against motion,and all raised equipmentlowered. If necessary toperform work on a raisedpiece of equipment,securely block in place.Remove ignition key toprevent backhoe frombeing started while work isperformed.

C) Replace all guards andother safety devices beforestarting or using backhoe.

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 willbe 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 office for the first part of the training. Anygeneral theory or knowledge training, as well as the initial explanation of the job procedure, maybe best done in an office/classroom setting; especially when noise levels, or other conditionsat the job site, make communication diffcult. A complete series of job steps could be presentedthrough the use of slides developed at the mining operation.

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BACKHOE AND HYDRAULIC EXCAVATOR OPERATION

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