Guidelines for underground coal mine vehicles

Guidelines for the Operational Use of Free Steered Vehicles in Underground Coal Mines
Guidelines for the operational

use of free steered vehicles in
underground coal mines
MDG 1009
Date of Issue: April 1999
File Reference No.: C98/2510
Disclaimer
The compilation of information contained in this document relies upon material and data derived from a number of
third party sources and is intended as a guide only in devising risk and safety management systems for the
working of mines and is not designed to replace or be used instead of an appropriately designed safety
management plan for each individual mine. Users should rely on their own advice, skills and experience in
applying risk and safety management systems in individual workplaces.
Use of this document does not relieve the user (or a person on whose behalf it is used) of any obligation or duty
that might arise under any legislation (including the Occupational Health & Safety Act 2000, any other Act
containing requirements relating to mine safety and any regulations and rules under those Acts) covering the
activities to which this document has been or is to be applied.
The information in this document is provided voluntarily and for information purposes only. The New South Wales
Government does not guarantee that the information is complete, current or correct and accepts no responsibility
for unsuitable or inaccurate material that may be encountered.
Unless otherwise stated, the authorised version of all reports, guides, data and other information should be
sourced from official printed versions of the agency directly. Neither the Department of Primary Industries, the
New South Wales Government, nor any employee or agent of the Department, nor any author of or contributor to
this document produced by the Department shall be responsible or liable for any loss, damage, personal injury or
death howsoever caused.
Users should always verify historical material by making and relying upon their own separate inquiries prior to
making any important decisions or taking any action on the basis of this information.
It is expected that the appropriate level of probity is exercised when any determination is
made as to the extent that this document is reproduced in any form.
MDG 1009 Document: A/M06 1009.doc
Page 1 of 32 File Number: C98/2510
Issue/Rev: C Date of Issue: April 1999
Prepared By: FSV Committee Authorised by: L. Roberts
TABLE OF CONTENTS
1. FOREWORD............................................................................................................................................... 4
2. SCOPE ......................................................................................................................................................... 5
3. REFERENCES AND STANDARDS......................................................................................................... 5
4. DEFINITIONS ............................................................................................................................................ 6
5. GENERAL................................................................................................................................................... 7
5.1. RISK ASSESSMENT ........................................................................................................................... 7
5.2. NEW OR MODIFIED VEHICLES....................................................................................................... 7
5.3. REVIEW AND AUDIT ........................................................................................................................ 7
6. DESIGN & MAINTENANCE OF ROADWAYS .................................................................................... 8
6.1. GENERAL REQUIREMENTS ............................................................................................................ 8
6.2. DESIGN................................................................................................................................................ 8
6.3. CONSTRUCTION................................................................................................................................ 8
6.4. HOUSEKEEPING STANDARDS ....................................................................................................... 8
6.5. SPECIAL AREAS ................................................................................................................................ 9
6.6. CLEARANCES .................................................................................................................................... 9
6.7. MAINTENANCE ............................................................................................................................... 10
7. CONDITIONS UNDER WHICH VEHICLES MAY BE USED .......................................................... 11
7.1. OBSTACLES...................................................................................................................................... 11
7.2. CABLES ............................................................................................................................................. 11
7.3. PROPERLY VENTILATED ROADS ................................................................................................ 11
7.4. RETURN AIRWAYS ......................................................................................................................... 11
7.5. FAILURE OF MAIN FAN.................................................................................................................. 12
7.6. EXHAUST FUMES............................................................................................................................ 12
7.7. DUST .................................................................................................................................................. 12
8. SAFE OPERATION OF VEHICLES ..................................................................................................... 13
8.1. GENERAL.......................................................................................................................................... 13
8.2. PRE START CHECKS ....................................................................................................................... 13
8.3. BRAKES............................................................................................................................................. 13
8.4. LEAVING VEHICLES WITH THE ENGINE RUNNING ................................................................ 14
8.5. RIGHT OF WAY ................................................................................................................................ 14
8.6. REVERSING OF VEHICLES ............................................................................................................ 14
8.7. TRAVELLING IN CONVOY ............................................................................................................ 14
8.8. PASSING THROUGH DOORS ......................................................................................................... 14
8.9. SINGLE ENTRIES ............................................................................................................................. 15
8.10. PARKING........................................................................................................................................... 15
8.11. EMERGENCY PARKING ................................................................................................................. 15
8.12. TOWING OF VEHICLES .................................................................................................................. 16
8.13. WARNING LIGHTS .......................................................................................................................... 16
8.14. FIRES.................................................................................................................................................. 16
8.15. DEFECTS REPORTING .................................................................................................................... 17
9. TRANSPORTING OF LOADS ............................................................................................................... 17
9.1. GENERAL.......................................................................................................................................... 17
9.2. PACKAGING OF LOADS ................................................................................................................. 17
9.3. LOADING AND UNLOADING ........................................................................................................ 17
9.4. RAIL TRANSFER POINTS ............................................................................................................... 18
9.5. CONVEYANCE OF LOADS ............................................................................................................. 18
9.6. SPECIAL LOADS .............................................................................................................................. 18
10. LIMITS OF VEHICLE OPERATION ................................................................................................... 19

10.1. VEHICLE DESIGN ............................................................................................................................ 19
10.2. GRADES............................................................................................................................................. 19
10.3. LOADS ............................................................................................................................................... 19
10.4. ROADWAY SPEEDS ........................................................................................................................ 19
10.5. SIGNS ................................................................................................................................................. 19
11. TRANSPORT OF PERSONNEL ............................................................................................................ 20
11.1. DRIVER RESPONSIBILITY ............................................................................................................. 20
11.2. CARRIAGE OF EQUIPMENT .......................................................................................................... 20
11.3. TRANSPORT OF INJURED PERSONS............................................................................................ 20
12. ACCESS TO TRANSPORT ROADS ..................................................................................................... 21
12.1. WORKING ALONG TRANSPORT ROADS .................................................................................... 21
12.2. PEDESTRIAN ACCESS .................................................................................................................... 21
12.3. USE OF WARNING DEVICES ......................................................................................................... 21
13. MAINTENANCE OF VEHICLES.......................................................................................................... 22
13.1. SHIFT CHECKS................................................................................................................................. 22
13.2. GARAGES.......................................................................................................................................... 22
13.3. REPORTING OF DEFECTS .............................................................................................................. 23
13.4. MAINTENANCE ............................................................................................................................... 23
13.5. OVER HEATING ............................................................................................................................... 23
14. INCIDENT INVESTIGATION ............................................................................................................... 24
14.1. INVESTIGATION.............................................................................................................................. 24
15. TRAINING ................................................................................................................................................ 25
15.1. VEHICLES ......................................................................................................................................... 25
15.2. SURFACE........................................................................................................................................... 25
15.3. UNDERGROUND.............................................................................................................................. 25
15.4. REFRESHER...................................................................................................................................... 25
15.5. CERTIFICATION .............................................................................................................................. 25
16. SPECIFIC VEHICLES ............................................................................................................................ 26
16.1. LOAD HAUL DUMP (BUCKET) MACHINES ................................................................................ 26
16.2. LONGWALL ROOF SUPPORT TRANSPORTER ........................................................................... 27
16.3. LONGWALL SHEARER TRANSPORTER...................................................................................... 27
16.4. SHUTTLE CARS................................................................................................................................ 28
16.5. RAMCAR ........................................................................................................................................... 29
16.6 DESIGNATED TRANSPORT VEHICLES ....................................................................................... 29
16.7. MPV’S ................................................................................................................................................. 29
16.8 MINESMOBILES............................................................................................................................... 30
16.9. PETS ................................................................................................................................................... 30
16.10. POWERTRAMS................................................................................................................................. 30
16.11. GRADERS.......................................................................................................................................... 31
16.12. BICYCLES ......................................................................................................................................... 31
17. SURFACE VEHICLES ............................................................................................................................ 32
17.1. GENERAL ................................................................................................................................................ 32

1. FOREWORD
MDG 1009 provides generic information to assist mine management, in the process of risk
reduction and risk management in the use of free steered vehicles in underground coal mines.
Advancement in technology and management systems too often outstrip the ability of experts
to provide exacting community standards (guidelines) for the safe and effective operation of
management systems and equipment. Inherent hazards associated with technology and
management of technology within the use of free steered vehicles requires guidelines to be
utilised in association with a process not only to reduce hazards to an acceptable level but
also produce management systems appropriate for the business. This demands the adoption of
a structured process for the identification of hazards and evaluation and control of work
related risks associated with the free steered vehicles.
This is assisted with an existing comprehensive legal framework under the Occupational
Health and Safety Act, 1983 and Coal Mines Regulation Act, 1982 requiring organisations to
manage their activities in such a manner as to anticipate and prevent circumstances which
may result in occupational injury or death. This guideline when used in conjunction with
MDG 1010 offers a process to meet such requirements. It is envisaged such an approach may
be integrated with the management of other aspects of business performance with expected
outcomes as minimising the risk to employees and others and improving business
performance.
The preparation of this document through a working committee involved the input and
support from the following persons and organisations: John Smith, Powercoal, Brian
Connolly, Powercoal, Gary Brown, United, Ian Cribb, Cumnock, Ron Stothard, CFMEU, G.
Cowan, DMR & Chairperson, G. Jervis, DMR, and D. Nichols, DMR. Their contribution is
gratefully acknowledged. Any additions or alterations you feel could add value to this
document will be gratefully appreciated. Comments on any aspect of this guideline should be
submitted in writing to:
Mr L Roberts
Manager Technical Services
Division of Mine Safety and Environment
Department of Mineral Resources
PO Box 536
ST LEONARDS 1590
Fax: (02) 9901 8584
N.Sneddon
ASSISTANT DIRECTOR SAFETY OPERATIONS

2. SCOPE
2.1. Section 101 (1) of the Coal Mines Regulation Act, 1982, as amended, requires
the manager of a mine to make rules with respect to the use of vehicles at the
mine.
2.2. Clause 6 of the Coal Mines Regulation (Transport - Underground Mines)

Regulation 1984, prescribes certain matters which shall be included in the
“Transport Rules”.
2.3. The following guideline is intended to help managers in preparing their

“Transport Rules”. The information supplied is based on accident and incident
experience together with best practice from other sources.
These guidelines do not generally give quantitative information, as it is not the

intent to restrict managers to specific parameters.
2.4. This guideline does not in any way negate the requirements of the NSW Coal
Mines Regulation 67/1982 nor the Occupational Health and Safety Act, 1983,
No. 20.
3. REFERENCES AND STANDARDS

The following references and standards are referred to in this document:
3.1 ACARP Project C3026 - Operator Underground Roads Manual - Construction

and Maintenance by Coffey Partners international Pty Ltd.
3.2 CMRA - Coal Mines Regulation Act, 1912 and associated Regulations.
3.3 MDG 1 - Mechanical Design Guideline No. 1
3.4 OH & S - Occupational Health and Safety Act
3.5 Safe Operation of Free Steered Vehicles in Underground Coal Mines. Third
Mechanical Colliery Engineering Safety Seminar Date: 6 April, 1993

4. DEFINITIONS
APPROVED: Approved by the Chief Inspector of Coal Mines in accordance with the
Coal Mines Regulation Act 1982.
DMR: Department of Mineral Resources (NSW)
FSV COMMITTEE: A committee formed to improve safety and operational aspects

of free steered vehicles for use in underground coal mines. The committee
includes multi-disciplinary personnel from the Department and Coal Mining
Companies.
LHD: Load Haul Dump Machine
MDG: Mechanical Design Guideline
MPV: Multi Purpose Vehicle
OEM: Original Equipment Manufacturer
RISK ASSESSMENT: The overall process of risk analysis and risk evaluation.
RISK MANAGEMENT: Refer to MDG 1010.
SHALL: Means that the requirement is highly recommended if it is applicable to the

type of equipment under consideration unless it is used in association with a
legislative requirement then it is mandatory.
SHOULD: Means that the requirement is recommended.
Note: If any of the parameters as recommended under a “shall” or “should”

instruction are not adhered to, the manager shall justify the alternative to the
recommendation through a process of technical assessment, risk assessment
and risk management.
VEHICLE: A rubber tyred or caterpillar tracked vehicle propelled by electric or

mechanical means and used for the purpose of transporting persons, materials,
coal or stone, whether by carrying, towing or otherwise and includes a shuttle
car.

5. GENERAL
5.1. RISK ASSESSMENT
5.1.1. A risk assessment should be carried out of the mine’s transport system.
5.2. NEW OR MODIFIED VEHICLES
5.2.1. Before a new or modified vehicle is placed into operation, a risk

assessment should be carried out and implemented into the appropriate
management system.
5.2.2. OEM’s conditions shall be incorporated into the Transport Rules where
appropriate.
5.3. REVIEW AND AUDIT
5.3.1. The Transport Rules shall include a system for review and audit.
5.3.2. At a specified time period, an external review or audit of the system

shall be conducted.

6. DESIGN & MAINTENANCE OF ROADWAYS

6.1. GENERAL REQUIREMENTS
6.1.1. Managers should refer to the ACARP Project C3026 conducted by

Coffey Partners International Pty Ltd. titled ‘Operator Underground
Roads Manual - Construction and Maintenance’
6.1.2. The manager should provide a plan at suitable locations around the
mine indicating which roads can used for each type of vehicle. Such
plan shall be update as required by the Transport Rules.
6.2. DESIGN
6.2.1. The Manager should specify the minimum dimensions of a roadway

inclusive of any supports or installations that is required for each
vehicle to operate in.
6.2.2. Where possible, transport roads should be on the rise side of any
conveyor or services roads.
6.2.3. No water lines or such should be incorporated in any transport roads.
6.2.4. Where possible, all conveyors and air crossings should be elevated into
the roof over the roadway to allow the roadway to maintain its normal
horizon. This will reduce the possibility of loads being dislodged or
trapped.
6.2.5. Where conveyors cross a transport road, the area should be concreted
to allow for use of cleaning and the control of water build up.
6.3. CONSTRUCTION
6.3.1. Transport roads should be driven on surveyed sights.
6.3.2. Miner drivers should be made aware of the importance of driving the
roads to the correct horizon.
6.4. HOUSEKEEPING STANDARDS
6.4.1. The manager shall set minimum standards for transport roads.
6.4.2. Roads, which are subject to rib spall, shall be properly supported.
Barricades shall be erected around fixed installations in transport roads.

6.5. SPECIAL AREAS
6.5.1. ROAD JUNCTIONS
6.5.1.1. All major intersections should have either mirrors or traffic

lights to assist with traffic flow.
6.5.1.2. The Transport Rules should include the circumstances under

which horns are used.
6.5.2. CROSS MEASURE DRIFTS OR MAJOR INCLINES
6.5.2.1. All inter seam drifts or major inclines should have traffic lights
or similar devices to limit access from either direction at the
same time.
6.5.2.2. The Transport Rules should include rules for when the signally
system is not operating correctly.
6.5.3. VENTILATION DOORS
6.5.3.1. Ventilation doors, which require FSV’s to pass through, should

be positioned where possible on level ground.
6.5.3.2. Sufficient distance should be allowed between the doors to

allow the whole of the vehicle to enter the area with the doors
being closed.
6.6. CLEARANCES
6.6.1. The manager should specify the dimensions of each vehicle and the
minimum clearances required for each vehicle and load.
6.6.2. Clearances should take into account the purpose that a roadway is to be
used for e.g. type of vehicle, speed at which vehicles will travel.
6.6.3. Clearances should be checked before any roadway is commissioned for

FSV use and thereafter at intervals as specified in the Manager’s
Transport Rules.
6.6.4. Any obstacles such as excess protruding roof bolts or damaged straps
should be removed prior to a road being used by vehicles.
6.6.5. Clearances should equally apply to ventilation door frames and other
obstacles as well s roof and sides.
6.6.6. Corners of intersections should be such to allow adequate clearances to

be maintained.
6.6.7. Clearance guides should be available at the portal as well as at specific

sites underground to allow the movement of material from panel to
panel.
6.6.8. All obstructions or restrictions in roadways should be illuminated or

have reflective markings.
6.7. MAINTENANCE
6.7.1. After using fill material on a roadway, the overall dimensions of the
roadway could result in reduced clearances being available.
6.7.2. The Transport Rules should indicate the inspection interval and criteria
for roadways.
6.7.3. The manager should have an appropriate standard to which roads are
maintained.

7. CONDITIONS UNDER WHICH VEHICLES MAY BE USED

7.1. OBSTACLES
7.1.1. Drivers should NOT deliberately drive over or around items such as
props, pipes, drums, hoses, etc.
7.1.2. Drivers should stop and make the road safe.
7.1.3. Drivers shall report any changed roadway condition to an immediate

supervisor.
7.2. CABLES
7.2.1. Drivers shall not drive over cables
7.2.2. Drivers should not attempt to drive under cables, which are not
properly secured, to the roof.
7.2.3. The manager should have a system in place to protect and support any
cables which cross a transport road or intersection.
7.3. PROPERLY VENTILATED ROADS
7.3.1. A diesel vehicle shall not be stood in an unventilated dead-end.
7.3.2. A diesel vehicle shall only be operated on roads, which are positively
ventilated.
7.3.3. The manager should devise a system such that each ventilation split in
the mine has an indication of the maximum number and type of diesel
vehicles which can operate in it at any one time taking into account the
requirements of Underground Mines Regulation.
7.4. RETURN AIRWAYS
7.4.1. A driver shall not drive a diesel into a return airway unless it is
equipped with an approved automatic methane detector and a senior
mining official has inspected the area.
7.4.2. In the event of the methane detector being activated, the driver of a
diesel vehicle shall immediately stop the vehicle and engine. The driver
should place an out of service tag on the vehicle and any necessary
warning devices on the roadway. The driver should remove the
methane detector and carry it with him and report immediately to a
mining official the circumstances.
7.4.3. In the event of the methane detector being activated, the driver of a
battery vehicle shall immediately remove the vehicle to intake air. The
driver shall report immediately to a mining official.

7.5. FAILURE OF MAIN FAN
7.5.1. The Transport Rules shall indicate the procedures to be followed in the
event of the stoppage of the main fan.
7.5.2. If a driver parks a vehicle underground because of the stoppage of the

main fan, the driver shall inform an official of the mine of the position
of the parked vehicle.
7.6. EXHAUST FUMES
7.6.1. Vehicles should never be operated in an unventilated stub or roadway.
7.6.2. The Transport Rules should include the circumstances under which the
testing of diesel vehicles exhaust gases is carried out in accordance
with the regulations.
7.7. DUST
7.7.1. The manager should make rules regarding the system for minimising
the problem of dust on transport roads.

8. SAFE OPERATION OF VEHICLES

8.1. GENERAL
8.1.1. The OEM’s have a responsibility under the OH & S Act to provide
documentation as to the required inspection, testing and examination of
the equipment provided.
8.1.2. The manager should ensure that the OEM is in agreement with the
intended use of the vehicle and the conditions under which it is to
operate.
8.2. PRE START CHECKS
8.2.1. The Transport Rules should indicate the pre-start checks for all
vehicles and should at least include the following:
8.2.1.1. Lights working
8.2.1.2. Fire Extinguisher
8.2.1.3.Warning Devices
8.2.1.4. Reversing Alarm Operation
8.2.1.5. Exhaust Conditioner and Radiator Water Levels and refill

where necessary
8.2.1.6. Brake and Transmission areas are free from oil and dust
accumulations
8.2.1.7. Forward and Reverse Controls
8.2.1.8. Wheel Nuts Look Visually Tight
8.2.1.9. Guards and Covers in Operators Cabin are properly secured
8.2.1.10. Operation of all brakes, including emergency brakes, where

fitted
8.2.2. Any defects should be report to an appropriate official and vehicle not
used until the defect is fixed. The mine “Out of Service” Tag system
should be used.
8.3. BRAKES
8.3.1. The Transport Rules should provide for situations which require the
testing of the foot brake and should include the following situations:
8.3.1.1. Immediately after starting the vehicle.
8.3.1.2. After driving through water.

8.3.1.3. Prior to driving down major grades.
8.3.2. The Transport Rules should provide the safe braking distances for
vehicles under their normal operating conditions, which prevail at the
mine including the towing of trailers.
8.4. LEAVING VEHICLES WITH THE ENGINE RUNNING
8.4.1. The Transport Rules should designate the circumstances under which a
driver can leave the driver seat with the engine running and which
could include the following:
8.4.1.1. During brief stops which are part of the normal operation of
the vehicle e.g. Whilst opening and closing ventilation doors.
8.4.1.2. While the vehicle or exhaust gas are being tested.
8.4.1.3. During operations involving the vehicle’s hydraulic power

take-off.
8.4.1.4. For maintenance purposes.
8.4.2. The Transport Rules should include a definition of “Unattended”.
8.5. RIGHT OF WAY
8.5.1. Vehicles travelling out bye should have right of way.
8.5.2. Vehicles towing trailers or other equipment should have right of way
at all times.
8.6. REVERSING OF VEHICLES
8.6.1. No vehicle should be reversed more than 1 cut through or a distance

designated by the Transport Rules unless the driver is facing the
direction of travel whilst properly seated.
8.6.2. Provision shall be made in the mine for the turning around of trailers to
limit the need for excessive reversing.
8.7. TRAVELLING IN CONVOY
8.7.1. The manager should include in the Transport Rules the circumstances
under which vehicles can travel in convoys and the safe distance,
which should be maintained, between vehicles.
8.7.2. Supply vehicles should not travel in convoys.
8.8. PASSING THROUGH DOORS
8.8.1. The Transport Rules should include a procedure for passing through
single and double doors.
8.8.2. Any procedure should include the reminder of applying the hand brake
prior to leaving the vehicle.
8.8.3. If the grade is such that there is any likelihood that the vehicle could
move in the direction of the doors, a warning notice should also be
displayed outlining the procedure to be used.
8.9. SINGLE ENTRIES
8.9.1. Only vehicles, which can be driven in either direction with the driver
properly seated, should be used in single entry roadways.
8.9.2. Appropriate barriers should be installed in single entries to limit the

danger of run aways.
8.9.3. The Transport Rules should include the rules relating to pedestrian
access whilst vehicles are using the single entry.
8.10. PARKING
8.10.1. The manager should designate set parking areas or standards for
parking a vehicle.
8.10.2. All parked vehicles should be angled into the ribs to prevent runaways.
8.10.3. Vehicles should not be parked on the rise side of area where people
congregate, such as crib areas, unless a suitable barrier is placed
between the vehicle and the people.
8.10.4. The driver shall activate the park brake before leaving the vehicle.
8.11. EMERGENCY PARKING
8.11.1. The Transport Rules should indicate the system to be incorporate when
a vehicle breaks down on a travelling road which should include the
following:
8.11.1.1. Informing a mine official and repair personnel of the

breakdown and the location of the vehicle.
8.11.1.2. The driver to remain with the vehicle unless otherwise

instructed.
8.11.1.3. The mine official is to notify the surface for adits or drift
inset to enable some form of notification to be prominently
displayed specifying the location of the broken down vehicle.
Such notification should be removed upon the vehicle being
repaired or moved.
8.11.2. Warning triangles or similar devices should be carried on all vehicles

and the use of such should be documented.

8.12. TOWING OF VEHICLES
8.12.1. Towing of vehicles which are inoperable shall be as recommended by

the OEM and provisions to be made should include the following:
8.12.1.1. The towing attachment should be designed to a minimum

safety factor of 2.5 times the maximum rated towing capacity
of the towed plant
8.12.1.2. Provision should be made for crossed slings to be fitted for

towing.
8.12.1.3. The maximum towable weight (gross load) for a towed plant
to be as per the towing vehicle manufacturer’s
recommendation.
8.12.1.4. A means of releasing brakes without having to go beneath the

vehicle.
8.12.1.5. A means of steering or guiding the towed vehicle.
8.12.1.6. A means of adequately braking the towed vehicle. Brake

indication lights should operate.
8.12.1.7. Documentation of limitations and requirements of the towing

system.
8.12.1.8. Direct communication between operators of towing

equipment and towed equipment should be installed (on an as
required basis).
8.12.2. The Transport Rules should indicate the proper method for towing each
vehicle including the equipment to be used.
8.13. WARNING LIGHTS
8.13.1. Drivers should not drive a vehicle with a warning light indicating a
problem unless instructed to do so by a senior official of the mine.
8.14. FIRES
The manager should make rules regarding the fighting of fires on vehicles
including the reporting of and the statutory obligations of not moving
the vehicle.

8.15. DEFECTS REPORTING
8.15.1. The manager should provide each driver with means of reporting
defects or problems. Such reporting system should be in a written form
with a duplicate copy remaining with the driver. The reporting system
should at least cover:
8.15.1.1. Machine Number and Type.
8.15.1.2. Driver’s Name and shift.
8.15.1.3. Defects with the machine.
8.15.1.4. Defects with the roads.
8.15.1.5. Any accidents or near misses.
8.15.1.6. Any potential safety problems.
9. TRANSPORTING OF LOADS
9.1. GENERAL
9.1.1. Many incidents occur because a load slips or catches when being
transported.
9.1.2. Drivers are responsible for the loads being transported and should not
move a vehicle if they are not satisfied that it can done safely.
9.2. PACKAGING OF LOADS
9.2.1. Secure packaging of supplies would reduce the risk of injury when
unloading or transferring.
9.2.2. Where possible, all loads should be designed as packaging and not
single item handling.
9.3. LOADING AND UNLOADING
9.3.1. The Transport Rules should define the system for loading and securing
loads.
9.3.2. Poorly positioned or failure to designate loading or unloading stations

often mean slippery or untidy areas being used which often results in
incidents.
9.3.3. Many inbye destinations have no load handling facilities as used on

the surface. Many incidents have occurred when loads are removed by
driving the vehicle or trailer from under the load and allowing the load
to fall to the floor.

9.3.4. The use of purpose design equipment to unload vehicles would reduce
a majority of injuries especially with strained back and trapped fingers.
9.3.5. Stumbling, falling or slipping incidents generally occur when stepping

on or off vehicles or trailers while manually transferring material loads.
9.3.6. Where possible, all designated loading or unloading area should be

well illuminated.
9.3.7. Suitable restraints should be used in tying down loads.
9.4. RAIL TRANSFER POINTS
9.4.1. The Transport Rules should define the system of loading and unloading
vehicles or trailers onto rail flat-tops.
9.4.2. All rail transfer points should be designed to allow straight access onto
the flat-top.
9.4.3. All ramps should be properly designed and constructed.
9.4.4. The area should be well lit and properly supported.
9.4.5. No person should be allowed access to the area unless they are actively
involved in the operation.
9.5. CONVEYANCE OF LOADS
9.5.1. The carrying and towing capacity of each vehicle should be

prominently marked on the vehicle.
9.5.2. Each trailer should have the maximum carrying capacity prominently
displayed.
9.5.3. All loads should be properly secured before moving.
9.5.4. All loads should be contained within the designated envelope of the
vehicle or trailer.
9.5.5. Any dislodged or spilled loads must be re-secured immediately if

possible or removed from the transport road. Where it is impossible to
re-secure the load, the driver should immediately notify a mining
official of the circumstances prevailing.
9.5.6. For some loads, the design of the vehicle or trailer might need
modification to allow the load to be safely transported.
9.6. SPECIAL LOADS
9.6.1. The Transport Rules should designate the conditions under which, if
any, loads that exceed the minimum required clearances could be
moved.
10. LIMITS OF VEHICLE OPERATION

10.1. VEHICLE DESIGN
10.1.1. Managers should make reference to MDG 1
10.1.2. All vehicles should be fitted with an illuminated Speedo, which does
not rely on the drivers cap light to read.
10.1.3. Suitable windscreens should be provide in vehicles together with some

means of cleaning them, to enable the driver to clearly see the roadway
whilst travelling at speed.
10.2. GRADES
10.2.1. The maximum grade on which vehicles can safely operated should be
indicated on the vehicle for both for loaded and unloaded situations.
10.2.2. The maximum cross grade on which vehicles can be safely operated
should be indicated on the vehicle for both for loaded and unloaded
situations.
10.3. LOADS
10.3.1. The maximum load which a vehicle can safely carry should be
indicated on the vehicle for both level conditions and a range of grades
10.4. ROADWAY SPEEDS
10.4.1. All speeds should be quantitative e.g. 5 kph max.
10.4.2. The mine roadways should be divided into sections and each section
should have a designated speed for each type of vehicle to use it.
10.4.3. A plan of the mine should be prepared for each type of vehicle showing
which roadways are accessible for that vehicle and the speeds at which
the vehicle can travel.
10.4.4. The maximum speed at which vehicles travel should take into account
the state of the roadway, the grade, clearances available, load being
carried and comfort of any passengers.
10.5. SIGNS
10.5.1. Speed signs should be quantified.
10.5.2. Directional signs should be utilised to control the flow of traffic.
10.5.3. Safety signs should be used to indicate grades, blind corners, major
intersections, etc.
10.5.4. All grades steeper than 1 in 14 are to be specified with signs e.g. 1:8.
11. TRANSPORT OF PERSONNEL

11.1. DRIVER RESPONSIBILITY
11.1.1. The driver shall have full and total control of the passengers and the
vehicle.
11.1.2. The driver shall ensure that no more than the number of passengers
approved to be carried by the vehicle are allowed to ride in the vehicle.
11.1.3. The driver shall ensure that all passengers are properly seated before
and during the journey.
11.1.4. The vehicle shall be only operated at such speed as permits the driver
to have total control at all times.
11.2. CARRIAGE OF EQUIPMENT
11.2.1. No equipment, other than hand tools, crib bags, survey or scientific
equipment or spares which can be easily carried by one person maybe
carried in the same vehicle as passengers.
11.2.2. Other equipment can be carried if the vehicle has a specially designed
compartment for the carriage of such equipment.
11.3. TRANSPORT OF INJURED PERSONS
11.3.1. The manager should include in the Transport Rules conditions under
which injured persons should be transported in the mine.
11.3.2. The rules should include the following:
11.3.2.1. The speed at which vehicles are to driven whilst transporting

an injured person.
11.3.2.2. The method to be used for the transporting of stretchers in

various vehicles.
11.3.2.3. The system of alerting other vehicles that an injured person

is being transported.

12. ACCESS TO TRANSPORT ROADS

12.1. WORKING ALONG TRANSPORT ROADS
12.1.1. All persons working on transport roads should wear reflective

garments.
12.1.2. Working areas should be designated by the use of flashing lights or

similar warning devices.
12.2. PEDESTRIAN ACCESS
12.2.1. The Transport Rules should indicate the maximum speed at which any
vehicle can pass a pedestrian.
12.2.2. Wherever practical, pedestrians should be kept clear of roads where

FSV vehicles are operating.
12.3. USE OF WARNING DEVICES
12.3.1. The manager shall include in the Transport Rules the conditions under
which drivers can proceed pass a warning device.
12.3.2. No vehicle should proceed pass a warning device unless the obstruction
has been personally examined by the driver on foot and has found it
safe to pass.
12.3.3. The Transport Rules should specify the distances and position that
warning devices should be placed from a hazard.
12.3.4. Anybody who is working on a broken down vehicle or obstruction

shall attach danger tags to the warning devices.
12.3.5. Anybody working in or adjacent to a roadway should attach danger

tags to the warning devices.
12.3.6. No vehicle should drive pass a warning device with danger tag attached
unless it is done under the supervision of the person attaching the
danger tag.
12.3.7. Where a grader or similar device is being used on a section of roadway,

appropriate warning devices should be displayed with the Transport
Rules specifying the means of carriage through this area.

13. MAINTENANCE OF VEHICLES

13.1. SHIFT CHECKS
13.1.1. All operational diesel vehicles shall be checked at least once a shift in
accordance with the OEM instructions but should at least include the
following:
13.1.1.1. Fuel
13.1.1.2. Low Water Shutdown
13.1.1.3. Radiator Water
13.1.1.4. Oil Level (Engine and hydraulic)
13.1.1.5. Security of Wheel Studs
13.1.1.6. Tyres are correctly inflated
13.2. GARAGES
13.2.1. The Underground Mines Regulations requires the manager to

nominated places for the means of inspection, maintenance, repair,
refuelling and charging of vehicles at the mine. Such places could be
on the surface or underground.
13.2.2. In relation to the underground garages, the following items should be

addressed:
13.2.2.1. A distance should be maintained at the entry to any garage

where no vehicle may be parked and which is to remain
unobstructed.
13.2.2.2. The number of ‘Vehicle Service Bays’ should be specified

and this should be the maximum number of vehicles that may
be located in the garage without an operator at the controls.
13.2.2.3. The speed of vehicles in the area of the garage should be

restricted.
13.2.2.4. Some form of barrier should be installed across the entrance

to any service bay.
13.2.2.5. The garage area should be protected from the flow of any
mine water.
13.2.2.6. Communication should be provided between the

underground garage and the surface.

13.3. REPORTING OF DEFECTS
13.3.1. The manager should provide each person carrying out maintenance
with means of reporting defects or problems. Such reporting system
should be in a written form with a duplicate copy remaining with the
person. The reporting system should at least cover:
13.3.1.1. Machine Number and Type.
13.3.1.2. Person’s Name and shift.
13.3.1.3. Defects with the machine.
13.3.1.4. Defects with the equipment.
13.3.1.5. Any potential safety problems.
13.3.2. Any defects should be report to an appropriate official and vehicle not
used until the defect is fixed. The mine “Out of Service” or “Danger”
Tag system should be used.
13.3.3. The defect should still be reported even if the defect has been fixed.
13.4. MAINTENANCE
13.4.1. The manager should instigate a system which requires ‘Safe Work
Procedures’ to be written for each job.
13.4.2. A Risk Assessment maybe required prior to writing the Safe Work
Procedures.
13.4.3. Where access on to or off a vehicle is required, the dangers associated

with such should be highlighted especially in relation to slips, trips and
falls.
13.5. OVER HEATING
13.5.1. The driver should immediately stop a vehicle in a safe place when the
temperature gauge indicates a heating problem.
13.5.2. The driver should not attempt to remove a radiator cap from an
overheated vehicle until a specified time has lapsed if there is a danger
of steam or burns.

14. INCIDENT INVESTIGATION

14.1. INVESTIGATION
14.1.1. The Transport Rules should include a system of investigating all defect
or accident reports.
14.1.2. The investigation system should be a closed loop system that reports
the findings of any investigation back to the person who initiated the
original report.

15. TRAINING
15.1. VEHICLES
15.1.1. Differences between similar types of vehicles should be recognised and

highlighted.
15.1.2. Vision surveys as detailed under Section 4.7 on Page 14 of MDG 1

should be carried out for all vehicles, which have not had such
information, supplied by the OEM. The results of this information
should be supplied to all relevant drivers.
15.2. SURFACE
15.2.1. All drivers should undergo initial training on the surface for all
vehicles to be carried out by an appropriate training officer.
15.2.2. All drivers should be made aware of the vision limitations of each
machine, especially in relation to their own statute.
15.3. UNDERGROUND
15.3.1. All drivers should undergo underground training under the direction of
a competent driver.
15.3.2. A minimum period of instruction should be required.
15.4. REFRESHER
15.4.1. All drivers should undergo refresher instruction as specified in the

manager’s Transport Rules.
15.4.2. Refresher training enables skill levels to be enhanced, bad practices to

be identified and eliminated and safe practices to be updated.
15.4.3. All drivers should undergo refresher training whenever the Transport
Rules are updated or altered.
15.5. CERTIFICATION
15.5.1. Driver under going training should be issued with a limited

appointment.
15.5.2. Supervisors and instructors should provide written reports on a driver’s

ability prior to final assessment.
15.5.3. An independent third party should examine drivers as to their

competency.

16. SPECIFIC VEHICLES

16.1. LOAD HAUL DUMP (BUCKET) MACHINES
16.1.1. Persons should only ride in approved seating.
16.1.2. The machine should not be operated unless an approved door is fitted.
The door should be closed at all times during the vehicle operation.
16.1.3. The vehicle load should not exceed that designated by the sign on the
vehicle.
16.1.4. The bucket should be carried in the lowered position when moving.
16.1.5. Where possible the bucket should be trailing the vehicle when
travelling.
16.1.6. Always travel on inclines or declines with the front of the vehicle
(bucket) pointing downhill where possible. The bucket can be lowered
and dug into the ground to stop the vehicle in case of emergency.
16.1.7. When the vehicle is operated in areas where people are working or
passing, the driver shall ensure that:-
16.1.7.1. He is aware of persons working in the area.
16.1.7.2. No persons stand between the vehicle and rib or other

structures whilst the vehicle is being manoeuvred.
16.1.7.3. The vehicle is stopped immediately he becomes aware

that a person is standing in an unsafe position.
16.1.8. A person shall NOT work out of the bucket. An approved work
platform must be used.
16.1.9. Where a person or persons is working on a work platform
16.1.9.1. The driver of the LHD must remain at the controls whilst
any person is on the platform
16.1.9.2. The vehicle is only to be moved with persons on the

platform if it is a requirement of the specific task.
16.1.9.3. The driver shall ensure that all persons on the platform are
aware that the vehicle is about to be moved.
16.1.9.4. The driver shall ensure the lowest gear in the direction of
travel must be used.
16.1.10. The vehicle shall not be articulated with an elevated, loaded

bucket.

16.1.11. Always park the vehicle with the bucket or attachment on the
ground and the vehicle articulated to steer towards the rib.
16.1.12. Do not allow any person to stand or work under the bucket
unless the bucket is secured with a support.
16.2. LONGWALL ROOF SUPPORT TRANSPORTER
16.2.1. The driver of the transporter shall have full control of his vehicle and
not operate the vehicle unless he is seated within the driver’s
compartment.
16.2.2. The vehicle shall only be operated at such speeds that permits the
driver to have total control at all times with due regard for load, grade
and road conditions.
16.2.3. The driver shall ensure that all headlights and clearance lights are
operating before moving the vehicle.
16.2.4. The driver shall ensure that the roof support is properly secured before
moving the vehicle.
16.3. LONGWALL SHEARER TRANSPORTER
16.3.1. No person other than the driver shall ride on the support carrier.
16.3.2. The driver shall not operate the vehicle unless he is completely within
the driver's compartment.
16.3.4. The driver shall ensure that the shearer is correctly loaded and secured
on the transporter before moving the vehicle.

16.4. SHUTTLE CARS
16.4.1. The manager shall supply written instructions of the methods to be

used in securing a shuttle car anchor including its positioning.
16.4.2. The driver of electric shuttle cars shall ensure that trailing cable is
safely and securely anchored with an approved anchor using the
accepted method of securing the anchor.
16.4.3. The driver shall ensure that the car has sufficient cable to satisfy the
full shift’s production. The driver shall bring to the attention of a mine
official if insufficient or excess cable exists.
16.4.4. The driver shall ensure that where he is required to pass under any
cable, pipe or other structure, that there is sufficient clearance to do so
safely.
16.4.5. The manager shall specify the period required for the cleaning of the
cable reel compartment and drivers cabin taking into account the
roadway conditions that the car will operate in.
16.4.6. The driver shall ensure that the headlights are on in the direction of
travel when proceeding along a roadway.
16.4.7. The shuttle car conveyor chains shall not be operated whist any person
is within the body of the shuttle car.
16.4.8. Before moving the shuttle car, the driver sound an audible warning and
shall ensure that all personnel are clear of the trailing cable and outside
the area swept by the cable when passing the anchor point.
16.4.9. The driver should face the direction of travel when the vehicle is
moved.
16.4.10. The driver of a shuttle car shall prior to using the shuttle car
walk along the wheeling roadway on which the vehicle is to
travel to ensure that it is safe to proceed.
16.4.11. The driver shall not leave the machine whilst the car is
operating.
16.4.12. No person other than the driver shall ride in, or on, a shuttle car.
16.4.13. The driver shall not operate the machine unless he is

completely within the driver’s compartment.
16.4.14. The vehicle shall only be operated at such speeds as permit the
driver to have full control at all times.
16.4.15. The driver shall ensure that the machine is not overloaded.

16.5. RAMCAR
16.5.1. No person other than the driver shall ride on a ramcar.
16.5.2. No person(s) shall be carried in the body of the machine.
16.5.3. The driver shall not operate the machine unless he is completely within
the driver’s compartment.
16.5.4. The vehicle shall only be operated at such speeds as permit the driver
to have full control at all times.
16.5.5. The driver shall ensure that the headlights are on in the direction of
travel when proceeding along a roadway.
16.5.6. The driver shall ensure that the machine is not overloaded.
16.5.7. The driver shall ensure that where he is required to pass under any
cable, pipe or other structure, that there is sufficient clearance to do so
safely
16.6 DESIGNATED TRANSPORT VEHICLES
16.6.1. The driver shall ensure that no more than the approved number of
passengers displayed on the vehicle are carried in the vehicle.
16.6.2. The driver shall have control over his vehicle and passengers
16.6.3. The driver shall not operate the vehicle unless he is completely within
the driver’s compartment.
16.6.4. The vehicle shall only be operated at such speed as permits the driver
to have total control at all times.
16.7. MPV’s
16.7.1. No person other than the driver shall ride on an MPV unless it is fitted
with approved seating or is set up for man transport.
16.7.2. The driver should ensure that the maximum number of persons which
the vehicle is approved to carry is not exceeded.
16.7.3. The driver shall ensure that all the passengers are completely seated
within the designated area before moving the vehicle.
16.7.4. The driver shall ensure that warning device are correctly fitted when
using the vehicle as a man transport.
16.7.5. The maximum load to be carried shall not exceed that specified by the
manufacturer.

16.8 MINESMOBILES
16.8.1. No person other than the driver shall ride on a minesmobile.
16.8.2. The driver shall not operate the vehicle unless he is completely
within the driver’s compartment.
16.8.3. The vehicle shall only be operated at such speeds as permits the
driver to have full control at all times.
16.8.4. The driver shall use the headlights whenever the vehicle is in
motion.
16.9. PETS
16.9.1. When the vehicle is set up for man transport, the driver should ensure
that the maximum number of persons which the vehicle is approved to
carry is not exceeded.
16.9.2. When the machine is set up for load transport, no person other than the
driver and a person in the approved passenger seat shall ride on the
machine.
16.9.3. The driver shall ensure that all the passengers are completely seated
within the designated area before moving the vehicle.
16.9.4. Drivers should pay particular attention when turning corners or passing
obstacles whilst carrying passengers.
16.10. POWERTRAMS
16.10.1. The manager shall authorise the persons to operate a

powertram.
16.10.2. The powertram should be left at idle for a minimum of 5

minutes prior to shutdown, to allow the turbocharger time to
cool.
16.10.3. The transport rules should specify the type of vehicles, which
can be used to assist a powertram in negotiating a drift.

16.11. GRADERS
16.11.1. The transport rules should specify the conditions under which a
grade can operate including the use of warning devices.
16.11.2. No person other than the driver shall ride on a grader.
16.11.3. The driver shall not operate the vehicle unless he is completely
within the driver’s compartment.
16.11.4. The driver shall use the headlights whenever the vehicle is in
motion.
16.11.5. Prior to using the grader, the operator shall use appropriate
signs to designate a section of roadways is being graded and
any speed restrictions which are to apply.
16.12. BICYCLES
16.12.1. Before using a bicycle underground, the following should be

checked to ensure safe operation:-
16.12.1.1. Tyre Pressure
16.12.1.2. Brake condition
16.12.1.3. Condition of chain

17. SURFACE VEHICLES

17.1. General
17.1.1. The Transport Rules should specify the vehicles and areas that the
surface rules apply to.
17.1.2. No contractor vehicle should be allow onto the surface of the mine
other than the car park without the contractor being made aware of the
transport rules.


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Guidelines for the Operational Use of Free Steered Vehicles in Underground Coal Mines

Guidelines for the operational

3. REFERENCES AND STANDARDS......................................................................................................... 5

10. LIMITS OF VEHICLE OPERATION ................................................................................................... 19

MDG 1009 Document: A/M06 1009.doc

Fax: (02) 9901 8584

MDG 1009 Document: A/M06 1009.doc

2.2. Clause 6 of the Coal Mines Regulation (Transport - Underground Mines)

2.3. The following guideline is intended to help managers in preparing their

These guidelines do not generally give quantitative information, as it is not the

3. REFERENCES AND STANDARDS

3.1 ACARP Project C3026 - Operator Underground Roads Manual - Construction

3.3 MDG 1 - Mechanical Design Guideline No. 1

3.4 OH & S - Occupational Health and Safety Act

MDG 1009 Document: A/M06 1009.doc

DMR: Department of Mineral Resources (NSW)

FSV COMMITTEE: A committee formed to improve safety and operational aspects

LHD: Load Haul Dump Machine

MDG: Mechanical Design Guideline

MPV: Multi Purpose Vehicle

OEM: Original Equipment Manufacturer

RISK MANAGEMENT: Refer to MDG 1010.

SHALL: Means that the requirement is highly recommended if it is applicable to the

SHOULD: Means that the requirement is recommended.

Note: If any of the parameters as recommended under a “shall” or “should”

VEHICLE: A rubber tyred or caterpillar tracked vehicle propelled by electric or

MDG 1009 Document: A/M06 1009.doc

5.2. NEW OR MODIFIED VEHICLES

5.2.1. Before a new or modified vehicle is placed into operation, a risk

5.3. REVIEW AND AUDIT

5.3.2. At a specified time period, an external review or audit of the system

MDG 1009 Document: A/M06 1009.doc

6. DESIGN & MAINTENANCE OF ROADWAYS

6.1.1. Managers should refer to the ACARP Project C3026 conducted by

6.2.1. The Manager should specify the minimum dimensions of a roadway

6.2.3. No water lines or such should be incorporated in any transport roads.

6.3.1. Transport roads should be driven on surveyed sights.

6.4. HOUSEKEEPING STANDARDS

Barricades shall be erected around fixed installations in transport roads.

MDG 1009 Document: A/M06 1009.doc

6.5. SPECIAL AREAS

6.5.1. ROAD JUNCTIONS

6.5.1.1. All major intersections should have either mirrors or traffic

6.5.1.2. The Transport Rules should include the circumstances under

6.5.2. CROSS MEASURE DRIFTS OR MAJOR INCLINES

6.5.3. VENTILATION DOORS

6.5.3.1. Ventilation doors, which require FSV’s to pass through, should

6.5.3.2. Sufficient distance should be allowed between the doors to

6.6.3. Clearances should be checked before any roadway is commissioned for

6.6.6. Corners of intersections should be such to allow adequate clearances to

6.6.7. Clearance guides should be available at the portal as well as at specific

6.6.8. All obstructions or restrictions in roadways should be illuminated or

MDG 1009 Document: A/M06 1009.doc

7. CONDITIONS UNDER WHICH VEHICLES MAY BE USED

7.1.2. Drivers should stop and make the road safe.

7.1.3. Drivers shall report any changed roadway condition to an immediate

7.2.1. Drivers shall not drive over cables

7.3. PROPERLY VENTILATED ROADS

7.3.1. A diesel vehicle shall not be stood in an unventilated dead-end.

7.4. RETURN AIRWAYS

MDG 1009 Document: A/M06 1009.doc

7.5. FAILURE OF MAIN FAN

7.5.2. If a driver parks a vehicle underground because of the stoppage of the