FIELD MAINTENANCE OF SURFACE MACHINERY

MODULE NUMBER 12OFINSTRUCTION GUIDE NUMBER 43

ON-THE-JOB TRAINING MODULESFORSURFACE METAL AND NONMETAL MINES

FIELD MAINTENANCE OF SURFACE MACHINERY

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This module describes the basic job steps, potential hazards or accidents, andrecommended safe job procedures for field maintenance of surface metal and nonmetalmining machines.

Good preventive maintenance and repairs are essential to the safe, productive, andeconomical operation of surface machinery. Many maintenance and repair operations canbe performed at the job site, without the necessity of removing the machine to a shop.

Field maintenance is performed by such personnel as mechanics, electricians, and theirhelpers; and by greasers or oilers, and the operators of various machines.

Maintenancelrepair work may involve:

1. Inspecting, troubleshooting, evaluating condition

2. Towing3. Deenergizing, securing, releasing pressure

4. Removing and replacing guards or safety devices5. Lubrication

6. Manual or powered materials handling

7. Use of hand and power tools

8. Welding and cutting

9. Changing component parts

10. Inspecting and testing completed work

Maintenance work is hazardous in comparison to other surface mining jobs. Mechanicsand helpers have among the highest, if not the highest, rate of nonfatal injuries at surfacemines. Common types of accidents involve material handling, suspended loads, hand andfinger injuries, fallng material, caught by moving or fallng equipment, flying objects,slipping or broken tools, and caught between objects.

The underlying causes of maintenance accidents involve both the nature of the work andthe attitudes and circumstances surrounding the work. If machines are inoperative andproduction must cease until repairs are made, there may be pressure (either conscious orsubconscious) to take shortcuts and work hurriedly. Sometimes machine operators orothers may attempt repairs they are not qualified to perform. Poor communication with co-workers, and assuming too much about what co-workers wil or wil not do, cause manymaintenance accidents. Maintenance workers should be the first to admit they don'tunderstand something, and should not hesitate to ask machine operators, or others, forhelp. Experienced maintenance workers must guard against overconfidence. Having

gotten away with taking a chance in the past is no indication that good luck wil continue.

Hazards inherent in maintenance work include a great deal of material handling, bothmanual and powered. Maintenance personnel must wear protective equipment and utilzeproper lifting and moving procedures to prevent manual handling injuries. They must know

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and exercise safe inspection and operational procedures for any powered handlingequipment they may be using, such as truck cranes. Improperly used and poorlymaintained hand and power tools cause many maintenance injuries. Maintenance peoplemust inspect, maintain, and properly use their tools as well as the larger equipment theywork on. Without proper tools, repairs are more diffcult and the risk of injury is increased.

Unsafe position is a cause or contributing factor in many maintenance accidents. Thesafest way in which to position oneself during various steps of the job is not alwaysobvious. Certainly one should not position any part of the body under suspended or raisedloads which are not properly blocked or mechanically secured. Each maintenance orrepair situation requires thought, however, as to what could slip, shift, break, or otherwisemove and in what direction the movement could occur. Then a conscious effort is requiredto remain out of line of potential movement or pinch points.

Field maintenance operations are so numerous and varied that it is impossible for thismodule to contain specific procedures for each task. Instead, an attempt is made toinclude general procedures and precautions which may be applied to most maintenancetasks.

The basic job steps included in this module are:

1. Travel to machine in need of repair or maintenance.

2. Be sure machine is properly parked and secured.

3. Evaluate condition.

4. Tow machine (or have towed) if necessary.5. Get on and off mobile equipment.

6. Perform repairs.

7. Remove and replace component parts as needed.8. Perform routine maintenance and lubrication.9. Replace all guards and shields and restore all safety devices.10. Inspect and test completed work.

Note: Refer to Module 13, "Welding and Cutting"; Module 14, "Inspecting and ReplacingWire Ropes (Cables)"; Module 16, "Manual Handling of Materials"; and Module 17,"Prevention of Slip and Fall Accidents" as needed during OJT of maintenance personneL.

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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,snug fitting clothing appropriate for weather conditions, hearingprotection where needed

SEQUENCE OFBASIC JOB

STEPS

1. Travel to

machine inneed of repairor maintenance.

POTENTIALACCIDENTS OR

HAZRDS

1. A) Slipping or

tripping, flying

objects such asdirt or splashedfluids, caught inpinch points.

B) Collsions, loss ofcontrol.

C) Being struck or runover by heavy

machines, caught

in movingmachinery.

D) Being struck or runover by heavy

machines,runaway vehicle.

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RECOMMENDED SAFE JOBPROCEDURES

1. A) Conduct a pre-shiftinspection of the vehicle toinclude slipping and trippinghazards, tires and wheels,surrounding area for peopleor obstructions, enginecompartment, fluid levels,leaking or broken hoses andlines, fire extinguisher,steps, cab, windows andmirrors, seat belts,instruments and gauges,horn, engine operation,wipers and lights, andbrakes and steering.

B) Follow traffic rules andadjust speed for conditions.

C) Be sure machine operator isaware of your presence byvisual contact, radio, or othermeans.

D) Park welt in the clear ofoperating machines. Setparking brake. If on a grade,block wheels or turn intobank.


STEPS

2. Be sure

machine isproperly parkedand secured.


HAZRDS

.2. A) Caught by rollngmachine, crushed

by fallng buckets,etc.

B) Machine rollngduring repair,operationsdisrupted.

C) Rock fall or slide.

D) Caught by rollngmachine.

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2. A) See that buckets, bowls, etc.are lowered. Verify thatparking brake is set andcontrols are in the neutral orshutdown position.

B) Select a safe and easily

accessible location (ifpossible). Mobile equipmentthat can be moved should berepaired on level ground outof the way of otheroperations. Advise others ofyour intentions.

C) Reposition machine asnecessary to avoid workingbetween machine and the pitwall or bank where escapemay be hindered.

D) Block wheels securely,especially if on a grade or ifmaintenance operation couldpossibly cause release ofbrakes, transmission, etc.Keep yourself to the sidewhen installng and removingwheel blocks.


STEPS

2. (Continued)


HAZRDS

E) Struck by fallngequipment, fallngfrom raisedequipment, inade-quate blocking.

F) Shock,

electrocution,caught in movingparts if equipmentis started.

G) Someone startingmachine whilerepairs areunderway.

H) Slips and falls,rock falls or slides,fires.

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E) Lower any raised partswhich can be lowered. Ifnecessary to perform workon top of, under, around, orfrom a raised piece of equip-ment, block or mechanicallysecure the equipment toprevent accidental rollng,fallng, or lowering. Goodblocking materials for mostpurposes include solidbanks, berms, wooden cribblocks, solid concreteblocks, or specially designedlocking devices, pins, etc.Cinder blocks are

inadequate for manypurposes.

F) Power switches must be

locked out and taggedbefore electrical ormechanical work is to bedone on electrically poweredequipment.

G) Place warning tags onsteering wheel or otherprominent location, andremove ignition key.

H) Visually inspect work areafor potential hazards.Remove debris andcombustible material fromjob site.


STEPS

2. (Continued)

3. Evaluate

condition.


HAZRDS

I) Struck by moving

machine, caught inmoving parts.

3. A) Being struck by or

caught inmachinery.

B) Loss of control,striking others withmachine, machinedamage.

C) Caught in movingmachinery, shock,

electrocution.

D) Caught in movingmachinery, shock,

electrocution.

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i) If equipment must be running

or moving to evaluate condi-tion, or to complete certainportions of the repair,exercise extreme cautionand have good com-munications with everyoneinvolved.

3. A) If watching machine inoperation, have goodcommunications withoperator and stay in a safeposition.

B) Do not operate machineunless you are properlytrained and qualified to doso.

C) Do not perform repairs ormaintenance until the poweris of and the machinery islocked out and tagged andblocked against motion,

except where machinerymotion is necessary fortrouble-shooting, or to makeadjustments.

D) Lock out and block againstmotion before guards orcovers are removed frommoving parts or electricalcircuitry.


STEPS

4. Tow machine

(or have towed)if necessary.


HAZRDS

4. A) Runaway machine,

loss of control.

B) Loss of control.

C) Loss of controlafter machine isreturned toservice.

D) Failure of towingattachment,runaway machine.

E) Tow bar failure,equipmentdamage.

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4. A) Obtain assistance as neededfor towing. Be sure thevehicle used is large enoughand powerful enough tohandle the job.

B) Do not operate any towingmachine you are not trainedand qualified to operate.

C) When towing requiresdisabling any failsafe brakesystems or other safetydevices, be sure they arerestored to operativecondition before the machineis returned to service.

D) If a machine must be towed,a properly sized tow bar orequivalent must be used.Unless steering and brakingare under the control of anoperator on the towedmachine, a suitable safetychain or wire rope must beused along with primaryrigging. Use properconnecting links to attachtow bar. Connections shouldbe of soft (not brittle) steelwhich wil bend or stretch,rather than break, uponimpact.

E) Use a smooth, steady pullwhen towing. Do not snatchand jerk machine.


STEPS

4. (Continued)

5. Getting on andoff mobileequipment.


HAZRDS .

F) Loss of control,machine damage.

5. A) Slips and falls.

B) Fall from higherlevel, clothingcaught on controllevers or otherprojections.

C) Fallng to sameleveL.

D) Falls, strains.

E) Falling whileclimbing ladder.

F) Fall from higher

leveL.

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F) Watch contour of groundcarefully when towing. Useof makeshift towingequipment should beavoided.

5. A) Maintain access areas,

ladders, etc. free of excessoil and grease.

B) Wear personal protectiveequipment (proper footwear)and snug fitting clothing.Keep steps and boots free ofmud, ice, snow, grease, andoiL.

C) Do not get on and off movingequipment.

D) Use proper techniques formounting and dismounting.

E) Use belt hooks, pockets, etc.to carry material up laddersand keep both hands free forclimbing. Ropes can beused to hoist bulkier items.Face ladder and use threepoints of contact whenclimbing (two hands and onefoot, or two feet and onehand, in contact with ladderat all times). Use handholdsand select firm footing.Avoid haste and projections.

F) Do not use machinery as

work platform.


STEPS

5. (Continued)

6. Perform repairs.


HAZRDS

G) Equipment failure.

6. A) See Job Step No.

2.

B) Personal injuryfrom improperprocedure.

C) Whipping ofpressurized hoseswhendisconnected,burns from hothydraulic fluid,mechanicalmovement causedby release of

pressure.

D) Fall to a lowerleveL.

E) Injury orequipmentdamage from useof improper tools.

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G) Report and/or repair damageto access components.

6. A) Be sure machine is properlyparked and secured (see

Job Step No.2).

B) Machine operators shouldnot attempt repairs ormaintenance they do notunderstand and are nottrained to do.

C) Ensure that pressure isrelieved from air andhydraulic systems beforeany attempt to disconnect orrepair hoses, cylinders,motors, etc.

D) Use safety belt or harnessand line where there is adanger of falling (when workmust be done at an elevatedlocation unprotected byrailngs).

E) Select, inspect, and use theproper tools for the job. Donot use tools withmushroomed heads, loose orcracked handles, etc.


STEPS

6. (Continued)


HAZRDS

F) Persons below

being struck byfallng objects,

trips and falls.

G) Strains, sprains,dropping parts.

H) Machine damage,personal injury.

i) Premature failure

of machinery.

J) Dirt falling into

electrical boxes ormechanical parts.

K) Crushed fingers orhand.

L) Burns, getting

fluids in eyes.

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F) Do not leave tools or otherobjects lying around loosewhere they could fall onsomeone. Rope off area,use screens, etc., ifnecessary, for adequateprotection of those workingor passing below. Do notleave tools or other objectslying around in walkways.

G) Utilize any substantial workstands or platforms availableto minimize reaching andlifting.

H) Follow company andmanufacturer's policy,procedures, and safety rulesfor the specific repair beingmade.

I) Follow manufacturer's

recommendations forreplacement parts, fluids andlubricants, torque values,etc.

J) Clean and inspect cover

plates before removaL.

K) Keep hands, fingers, andother parts of body out ofpinch points.

L) Avoid burns from hot

bearings, hot hydraulic fluid,etc. Allow to cool if possible.Wear gloves where possible.Wear safety glasses.


STEPS

6. (Continued)


HAZRDS

M) Hand injuries,damaging boltheads or threads.

N) Flying objects ineyes.

0) Cuts, scrapes,

bruises.

P) Injuries orunsuccessfulrepairs because oflack ofcommunication.

Q) Struck by movingmachinery orropes.

R) Skin cancer.

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M) When using a wrench, seat itfirmly and use steadycontrolled force. Avoidjerking the wrench.

N) Always wear safety glasseswhen striking objects with ahammer.

0) Wear gloves to handle metalparts and when using tools.

P) Maintain goodcommunication with all co-workers. Tell them whatyou're about to do if it couldcause machine movement orother hazards.

Q) Assume a safe position outof direct line of potentialmotion of parts. Do notposition yourself in theinside radius or in direct lineof wire ropes being used forpullng.

R) Avoid excessive skin contactwith lubricants, especiallypenetrating oiL. Use ofbarrier creams, waterlesshand cleaner, or soap andwater can minimize thishazard.


STEPS

6. (Continued)


HAZRDS

S) Electrocution,

burns, equipmentfailure.

T) Shock, equipmentdamage.

U) Personal injury,equipmentdamage.

V) Electric shock,equipmentdamage orunexpectedmovement.

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S) Be sure all electncalequipment, switches,breakers, controls, panels,guarding, etc., is in properoperating position and ingood condition. Neverperform any electrical workor enter any energizedelectrical panels or cabinetsunless you are qualified. Besure to lock out and tag theequipment or circuit.

T) Use properly sized and ratedmaterial for the job, such asfuses and connectors.

U) Never bridge or jumper outany safety device.

V) Never change wiring fromthe original prints orschematics.


STEPS

6. (Continued)


HAZRDS

W) Struck byexploding lockring or other partsof rim, crushedunder weight ofwheel assembly,

strains, sprains

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W) Use extreme caution whenworking with tires and multi-piece rims.1. Completely deflate tires

by removal of the valvecore:a) before removal from

machine,b) before dismounting.

c) when the tire hasbeen driven under-inflated at 80% orless of its recom-mended pressure,and/or

d) when there isobvious or suspecteddamage to the tire orwheel components.

2) Be sure components are

properly matched andundamaged.

3) Use inflation cages, longinflation hoses,adequate lifting andhandling anddismounting tools.

4) Do not attempt to correctthe seating of side andlock rings byhammering, striking orforcing the componentswhile the tire ispressurized.

5) Stay out of the potentialpath of an explodingwheel assembly asmuch as possible duringyour work.

SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOBBASIC JOB ACCIDENTS OR PROCEDURES

STEPS HAZRDS

7. Remove and 7. A) Strains, sprains, 7. A) Use proper liftingreplace ruptures, procedures (see Module 16,component overexertion. "Manual Handling ofparts as Materials"). Obtain helpneeded. when load may be too

heavy.

B) Failure of lifting B) Carry and use lifting de-device. vices - jacks and hoists - to

the extent possible, to avoidmanual lifting. Inspectthese devices regularly.

C) Struck or caught C) Be sure component beingby component removed is secured orfallng off blocked as last bolts or nutsunexpectedly. are removed.

D) Strains, sprains, D) Before removing a part, becrushed or sure it does not weigh morelacerated fingers. than you can handle. Stand

in close to the part and besure of good footing. Gethelp in advance if you thinkit may be needed.

E) Failure of hoist or E) Stay clear of suspendedrigging. loads.

F) Caught between F) Use taglines when hoistedhoisted load and objects require steadying orstationary object. guidance. Stay out of

confined areas where youcould be caught between aswinging load and astationary object.

G) Crushed hand or G) Keep hands and fingersfingers. clear of pinch points when

lowering or placing parts.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOBBASIC JOB ACCIDENTS OR PROCEDURES

STEPS HAZRDS

8. Perform routine 8. A) Machine damage, 8. A) Perform scheduledmaintenance unscheduled preventive maintenance onand lubrication. downtime. all machinery in accordance

with company policy and/ormanufacturer'srecommendations.

B) Various hazards B) Some items which aredepending on commonly involved inspecific job. routine maintenance and

inspection schedules formobile equipment include:1) engine oil2) tire condition3) windshield washer level

and wipers

4) lights5) fan belts6) coolant level7) battery8) fire extinguisher9) emergency flares10) first aid kit11) all filters12) brake adjustments13) wheel balance and

alignment14) linkages greased15) backup alarm

C) Caught in moving C) Do not lubricate movingmachinery. equipment where any

hazard exists, unlessextended fittings or cupsare provided. Otherwise,

shut it down, lock jt out, andblock against motion.

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STEPS

9. Replace allguards and

shields andrestore allsafety devices.

10. Inspect andtestcompletedwork.


HAZRDS

9. A) Caught in moving

parts, equipmentdamage.

B) Fire hazard,slipping hazard.

C) Losing tools orequipment, tripsand falls, struckby fallng objects.

10. A) Equipment failure,unguardedmachinery,tripping hazards,losing tools.

B) Machine damageif started withblocking inposition.

C) Machine reactingin an unexpectedmanner.

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9. A) Secure all guards, covers,and shields which protectpeople and equipment.

B) Remove any accumulationsof oil and grease.

C) Be sure tools, old parts, orother objects are returnedto proper storage ordisposed of. Be especially

careful not to leave objectsin walkways or at elevatedlocations. Keep tools clean.

10. A) Inspect completed work toensure that all bolts aretightened, guards replaced,tools removed, etc.

B) When job is complete,remove blocks, removelocks and tags, and restorepower.

C) Operator should be at thecontrols of the machine.Other workers or observersshould position themselvesin a safe area before anyoperation of the machine.Once the machine reactionhas been determined,further testing maycontinue.


STEPS

10. (Continued)


HAZRDS

D) Improper

operation,inoperative safetydevices.

E) Recurrence of

preventabledamage orrepairs.

F) Disrupting work

schedule.

G) Machine damagefrom lack ofmaintenance,performingunnecessarymaintenance dueto lack of records.

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D) A final test of properoperation should be givento the equipment, includingproper grounding system ifapplicable, before theequipment is put back intoservice.

E) Discuss potential causes ofthe damage, if applicable,with machine operators orothers to prevent recurringrepairs.

F) Notify other workers andforeman that equipment isrepaired and is returning toservice.

G) Keep proper maintenancerecords.

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 faciltates 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 nee to tailor the materialsomewhat to frt 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: llStructuring 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 whichthe supervisor/trainer coaches (corrects and encourages) the employee, and evaluates whenthe employee is ready to do the job without direct superision.

The first step - explaining the job to the employee - can be done in different ways. Thesupervisorltrainer 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 diffcult. A complete series of job steps couldbe presented through the use of slides developed at the mining operation.

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FIELD MAINTENANCE OF SURFACE MACHINERY

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