Index
Safe Operating Practices
for Mining Equipment Users
Preface
A review of many safety sources including MSHA,
OSHA, ANSI provisions and various individual mine
safety policies was conducted to develop these safe
operating practices recommendations. The purpose of
these recommendations is to assist and support our
customers in their safety efforts in preventing
accidents.
Introduction
P&H shovels and excavators are carefully designed,
manufactured, and tested. When used properly by
qualified operators, they will give safe, reliable service.
T h e r e a r e P & H o f fic e s w o r l d - w i d e t o a n s w e r
anyquestions about P&H products or their safe use.
The World Sales andService headquarters for P&H
Mining Equipment is:
Harnischfeger Corporation
4400 West National Avenue
P.O. Box 310
Milwaukee, WI 53201 USA
Telephone: (414) 671-4400.
Because shovels and excavators are complex and
massive equipment and have the ability to lift and
move heavy loads, they also have a potential for
accidents if safe operating practices are not followed.
This booklet is intended to help prevent accidents
which could result in injury, death, or property damage.
General safe practices for working on machinery must
be followed as well as the safe operating practices. The
following recommendations are provided to
supplement customer/owner, local, or national safety
codes, rules or procedures.
Operator Qualifications
GENERAL. Only the following personnel should be
permitted to operate a shovel or excavator:
1. Appointed qualified operators, who have met the
requirements of the operation tests and physical and
mental condition.
2. Qualified maintenance and test personnel, when
required to do so in the performance of their duties.
3. Inspectors qualified to operate the machinery.
OPERATION TESTS. Every employer should require
that all persons who will be authorized to operate a
shovel or excavator first pass an examination which
accurately measures practical knowledge of the
equipment and proper methods to be used in operating
the shovel or excavator.
PHYSICAL AND MENTAL CONDITION. An operator
must meet the following physical and mental
qualifications:
1. An operator must possess good hearing ability as
well as good vision (corrected or uncorrected). Good
depth perception is also required, especially where
truck loading is critical or must be accomplished at
some distance from the operator.
2. An operator must not be afflicted with any known
health condition or disability which could cause a
sudden inability to react quickly.
3. An operator who is taking medication prescribed by
a doctor must present written assurance from his
doctor that the medication will not affect the operator's
ability to operate the shovel or excavator in a safe
manner.
4. An operator who is known, or suspected, to be under
the influence of alcohol or drugs must not be allowed to
operate equipment under any circumstances.
viii
5. The operator must have a good attitude towards
safety at all times.
Mine Management's Responsibility
Management must ensure that operators are trained,
competent, physically fit and, if required, licensed.
Good vision is required, as are good judgement,
coordination and mental ability. Any person who lacks
any of these qualities must not be allowed to operate a
shovel or excavator.
Management must maintain its equipment in a safe
operating condition and must require the equipment's
operation to immediately stop if an unsafe condition is
found.
Management must ensure that the ground crew have
good vision and sound judgement, know standard
signals and be able to give travel signals clearly. They
must have enough experience to be able to recognize
hazards and signal the operator to avoid them.
Management must assign a job supervisor at the site to
be responsible for overall job safety. Shovel or
excavator operators and crew members must know who
has been assigned this responsibility.
C r e w m e m b e r s m u s t b e g i v e n s p e c i fic s a f e t y
responsibilities and instructed to report any unsafe
conditions to their supervisors.
Management must assign specific people to coordinate
and direct the service, repair, inspection and
maintenance process for the shovel or excavator during
each shift with specific methods to de-energize
equipment before starting the work and to lockout and
tagout equipment until ready for operation.
Management must assign qualified people with proper
tools and protective equipment for specific work
assignments.
Management must maintain a safety program which
includes both instructions and training for employees
on shovel or excavator safety.
Management must ensure that during night operation,
suitable lighting is provided.
Operator's Responsibility
Safety must always be the operator's most important
concern. He must refuse to operate when he knows it
ix
is unsafe and consult his supervisor when safety is in
doubt.
He must read and understand the Operator's Manual,
all instructions and signs on the equipment. He must
see that the machine is in proper order before
operating.
He must be alert, physically fit, and free from the
influences of alcohol, drugs, or medications that might
affect his sight, hearing, or reactions.
He must ensure that people, equipment, and material
are kept out of the work area. He must never operate
the dipper or bucket over people. He must never use
the shovel or bucket to lift or transport people.
A warning signal must be given by the operator prior to
starting, operating, or traveling the shovel or
excavator.
Responsibilities Of All Crew Members
Any unsafe condition or practice must be corrected or
reported to the job supervisor and equipment operator.
Everyone who works around shovels or excavators,
including support people and maintenance personnel,
must obey all warning signs and watch out for their
own safety and the safety of others. Crew members
setting up machines or handling maintenance or
repairs are expected to know proper procedures
including lockout/tagout practices.
Watch for hazards during operations and alert the
operator of dangers such as the unexpected presence of
people, other equipment, unstable ground and bank
conditions or approaching storms.
Planning the Job
Most accidents can be avoided by careful job planning.
The person in charge must have a clear understanding
of the work to be done, consider dangers or hazards,
develop a plan to do the job safely, and then explain the
plan to all concerned. Factors such as the following
should be considered:
• How can the shovel tail cable be safely moved at the
work site?
• Is there other equipment, power lines or structures
which must be moved or avoided during movement of
the shovel?
• Is the surface strong enough to support the machine
and load?
• How and where will the removed materials be
unloaded?
• What steps will be taken to keep unnecessary people
and equipment at a safe distance from the work
area?
These factors are not meant to be exhaustive, but only
a starting point. Each job must be individually
considered.
Operator's Functional Checks
The operator must make a safety check before starting
to work each shift to see that the machine is in proper
order. Some things to check are:
• Check for warning tags or lockout tags on the starting
controls; do not operate the controls until the tag has
been removed by the person who placed it there, or
by a qualified person.
• Check with mine maintenance and operations
management to see that periodic maintenance and
inspections have been performed and all necessary
repairs made.
• Consult with mine management that scheduled
inspection of load carrying members such as wire
rope (dipper trip lines, hoist rope, suspension lines),
boom, dipper handle and dipper has been conducted.
• Check that all equipment guards are in place and all
inspection and cover plates are closed and locked.
• On hydraulic shovels, check for evidence of hydraulic
oil leaks.
• Look inside, outside and underneath the shovel or
excavator to make sure everything is clear before
starting or energizing the machine.
• After starting the shovel or excavator, check all
gauges and indicators for proper readings and
operation.
• Test all controls for proper operation and control
ability before machine operation or travel including
a check of brakes.
• Check audible warning devices and alarms used for
backup warning for proper operation.
• During operation, be alert for unusual noises or
vibrations; look and smell for unusual smoke or
fumes.
Operating Instructions
1. Determine the load bearing capacity of the ground or
other surface on which machines will be operating. Be
sure the machine is adequately supported. Avoid soft
or unstable ground, areas with high water tables, and
partially frozen ground. When machines are working
near benches, the benches should be shored or sloped
by appropriate equipment to prevent cave-ins or slides.
2. Shovels or excavators should never be used to lift
people. Use ladders, scaffolds, elevated work platforms
or other equipment designed to lift people.
3. Prior to servicing or repairing the shovel or
excavator, follow lockout and tagout procedures. Both
OSHA and MSHA regulations require lockout/tagout
procedures. Injury, death, and damage can occur if the
shovel or excavator is started before servicing is
finished. Never start or operate the equipment if
lockouts or tagouts are on the controls. Look inside,
outside, under and around the equipment to be sure
everyone is clear.
4. Always start and stop swing movements smoothly
and swing at speeds that will keep the dipper load from
spilling. Rapid swings, sudden starts or sudden stops
can cause the load to spill and damage swing
machinery.
5. Keep windows clean. Do not operate if you cannot
see clearly enough to operate. Dirty windows,
darkness, bright sunlight, fog, rain, and other
conditions can make it difficult for the operator to see.
6. Carelessness in getting on and off equipment can
result in serious injuries. Always wait until the
operator has been notified and the shovel or excavator
has stopped all movement before attempting to climb
onto the shovel or excavator. Do not jump on or off. Use
both hands and make sure you have good footing.
7. Keep the machine clean and dry. Slippery floors and
steps, tools, trash, or other loose items can cause slips
and falls.
8. As with all heavy equipment, care must be taken
when shovels or excavators are moved around the job
site. Watch for people, other equipment, low or narrow
clearances, ground bearing limits, and steep hills or
uneven terrain. Use a signalman when traveling.
Know the height, width, and weight of the machine.
Always secure equipment before traveling. Do not
x
travel with people riding on the outside of the machine
or inside the machinery house.
9. Leaving a shovel or excavator unattended can be
very dangerous unless proper precautions are taken.
At night, or conditions of poor visibility, lights, flares, or
other warning devices must be posted to identify the
parked shovel's location for other traffic. Before leaving
his seat, the operator must take the following steps to
prevent the shovel or excavator from moving:
• Lower the dipper to the ground.
• Return all controls to the neutral position.
• .Set all brakes.
Before leaving the shovel or excavator, in addition to
the previous steps required by the operator, the
following should be done:
• Shut off the master control power switch on
electrically-powered shovels or excavators.
• Verify that all electrical cabinets are closed and
locked and that all electrical components guards are
installed.
• Disengage the engine clutch and shut off the engine
on engine-powered shovels or excavators.
10. Wire rope running over drums and through sheaves
create pinch points. Do not use your hands to guide
wire rope onto drums. Use rope guides or prescribed
procedures. Keep clothing and all parts of the body
away from running rope and the machinery that moves
the rope.
11. Rocks too large to be handled safely must be broken
before loading to avoid the hazard of falling and
ricocheting rocks.
12. Shovels or excavators with electric tail cables can
break the cable connection or crush the cable when
traveling. Maintain cable slack while operating and
traveling. Use signalmen during traveling to prevent
damaging to the cable or cable connection.
13. Make sure that the shovel or excavator house or
bucket does not hit obstructions when swinging.
Establish clearances for the machine after each
relocation with job site procedures.
14. Cave-in can occur when excavating in a pit or along
a high wall. Do not undercut the bank but remove the
uppermost material first or take other appropriate
precautions.
xi
15. People can be pinched, entangled or crushed by
moving machinery. Personnel should not place any part
of their body or clothing on or near any rotating
machinery, gears, pinions, ropes, cables or crawlers
while the machine is in operation.
Maintenance Work Precautions
Inspection, service and maintenance are essential
elements in the proper operation and performance of
s h o v e l s a n d e x c av a t o r s. The following
recommendations are provided to supplement past
experience, knowledge and common sense of a
serviceman concerning potential hazards associated
with inspection, service and maintenance.
1. Prior to undertaking any work on the equipment, the
personnel performing the work shall notify the
operator about the nature and location of the job.
Appropriate lockout and tagout procedures must be
determined and followed by all individuals involved to
guard against potential hazards.
2. Before maintenance or service is attempted, the
operator must park the machine in a location to avoid
hazards such as falling rocks and unstable ground.
After parking the machine, the operator shall:
• Set the dipper on the ground.
• Set all brakes.
• De-energize control functions.
• Comply with lockout and tagout procedures.
3. Injury, death, and damage can occur if the machine
is started before servicing is finished. Never start or
operate the equipment if lockouts or tagouts are on the
controls. Prior to starting the machine, look under,
within, and around the equipment to be sure everyone
is clear.
4. Specific inspection, service and maintenance
instructions for P&H shovels or excavators are
available from product manuals and the P&H service
network. Always read and follow instruction manuals
and use the P&H service network for assistance.
5. On hydraulic shovels, release system pressure before
attempting to make adjustments or repairs. Pressure
in hydraulic systems can be retained for long periods of
time. If not properly released before maintenance
people attempt to work on the hydraulic system, this
pressure can allow machinery to move or cause hot oil
and hose ends to shoot out at high speed.
6. Maintenance and service can involve the handling of
heavy parts or components which can injure personnel.
Use lifting and handling equipment along with
blocking to remove, support, and install heavy parts.
7. Make sure both ends of booms or cylinders are
supported and the boom suspension lines completely
slacked off before removing pins. Never stand on,
inside, or under booms during erection or disassembly.
Pin-connected booms may fall if not properly supported
when removing or installing pins.
8. In regard to inspection and retirement of wire rope
used on surface mining machines:
• Mine management shall provide and appoint
qualified personnel to inspect, prepare and retain
written reports on wire rope inspections.
• An inspection procedure should be established by
Mine Management for each wire rope application on
their mining shovels or excavators.
• Unless instructed otherwise, the frequency of
inspections shall be established based upon
operating shifts, days, weeks or months depending
upon anticipated rope life and working conditions.
• An average wire rope life shall be established based
upon the number of operating cycles, volume of
material handled or weight of material handled.
Replacement is determined from this established
rope life analysis.
9. MSHA procedures require all wire rope be inspected
daily to determine whether it should be replaced.
As a minimum, wire rope replacement should be
performed when any of the following conditions exist:
• Severe abrasion, scrubbing, peening, or kinking, or
broken outer wires.
• Crushing, or other damage that distorts the rope's
structure.
• Severe reduction of rope diameter or an observable
increase in rope lay.
Index
• Bird-caging or other distortion indicating uneven
distribution of load between rope strands.
• Evidence of severe corrosion, particularly in the
vicinity of attachments.
• Uneven stretch of multiple ropes.
• Heat damage from any source.
• A rapid increase in the number of broken wires.
10. Wire rope end connections must be installed
properly and inspected daily.
• Wire rope secured with a wedge socket should be
installed so that the load line is in a straight line pull
with the eye of the socket; and the loaded part of the
rope is not kinked where it leaves the wedge. The
rope end should always protrude at least 6 to 9
inches beyond the socket. Attach a short piece of wire
rope to the rope end with two wire rope clips to
prevent the rope end from slipping out of the wedge
socket.
11. Electrically powered shovels or excavators operate
using high voltage wiring, components and systems.
This voltage can kill or seriously injure people
servicing, repairing or working on the machines.
Inspection, maintenance or service of any electrical
component must be done by qualified personnel. All
people working on or around the equipment should
read and obey hazard signs and always use lockout and
tagout procedures.
12. All guards, signs, warning devices and guarding
devices must be in place and in working conditions
before the shovel or excavator is placed back in
operation after inspection, service and maintenance.
13. Loose or missing hardware, bolts, or nuts should be
properly tightened or replaced with the manufacturer's
specified hardware. Refer to P&H Service and Parts
sources for replacement parts.
14. If there is not enough wire rope on the drum, the
rope can be pulled off. Allow for at least two full wraps
of wire rope on drums when replacing the rope.
xii