Haul Truck Operations

Haul Truck Operations
Resource Manual
Table of Contents
1 Session Preliminaries.............................................................................................................9
1.1 Purpose of this Resource Manual...............................................................................................9
1.2 Safety Requirements....................................................................................................................9
1.3 Training Requirements...............................................................................................................9
1.4 Assessment Requirements...........................................................................................................9
1.5 Prerequisite..................................................................................................................................9
1.6 Getting Help...............................................................................................................................10
2 Introduction..........................................................................................................................11
2.1 Scope...........................................................................................................................................11
2.2 Haul Truck Types and Specifications......................................................................................11
2.2.1 Overview............................................................................................................................ 11
2.2.2 Body Type......................................................................................................................... 12
2.2.3 Drive Type......................................................................................................................... 13
2.3 Identifying the Truck’s Main Components and Functions...................................................15
2.3.1 Front View......................................................................................................................... 15
2.3.2 Right Side View................................................................................................................. 16
2.3.3 Left Side View.................................................................................................................... 17
2.3.4 Rear View.......................................................................................................................... 18
2.3.5 Operator Cabin Instruments and Controls.........................................................................19
2.4 Operating Authority..................................................................................................................21
3 Operate Haul Truck.............................................................................................................23
3.1 Introduction...............................................................................................................................23
3.2 Identifying Safe Operating Practices.......................................................................................24
3.3 Identifying Personal Injury Hazards.......................................................................................25
3.4 Pre-Start Procedure..................................................................................................................26
3.4.1 Overview............................................................................................................................ 26
3.4.2 Driver Changeover............................................................................................................ 26
3.4.3 Operator’s Inspection Form............................................................................................... 27
3.4.4 Walk-Around Inspection..................................................................................................... 28
3.5 Start Up Procedure....................................................................................................................34
3.5.1 Final Pre-Start Checks....................................................................................................... 34
3.5.2 Start Up Process............................................................................................................... 34
3.5.3 Post Start Up Checks........................................................................................................ 35
3.5.4 Braking Systems Tests...................................................................................................... 35
Printed copy is UNCONTROLLED. The training web site has the latest version of this document
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3.5.5 Continuing Checks............................................................................................................ 36

3.6 Moving Off Procedure...............................................................................................................37
3.7 Emergency Procedures..............................................................................................................38
3.7.1 Under Inflated and Flat Tyres............................................................................................ 38
3.7.2 Tyre Failure....................................................................................................................... 38
3.7.3 Tyre Fires.......................................................................................................................... 40
3.7.3.1 Introduction................................................................................................................ 40
3.7.3.2 Suspect or Burning Tyres.......................................................................................... 41
3.7.4 Truck Fires......................................................................................................................... 43
3.7.5 Electric Truck Grid Box Fire............................................................................................... 44
3.7.6 Loss of Steering or Brakes................................................................................................ 44
3.7.7 Immobilised Haul Truck..................................................................................................... 44
3.7.8 Loss of Traction................................................................................................................. 45
3.7.8.1 Overview.................................................................................................................... 45
3.7.8.2 Rear Wheel Skid........................................................................................................ 46
3.7.8.3 Front Wheel Skid....................................................................................................... 47
3.7.8.4 All Wheel Skid........................................................................................................... 48
3.7.9 Breakdown on a Gradient.................................................................................................. 49
3.7.10 Haul Truck Rollover......................................................................................................... 50
3.7.11 Electrical Conductors....................................................................................................... 51
3.7.11.1 Overhead Conductor Clearances............................................................................51
3.7.11.2 Fallen Conductors on Equipment............................................................................52
3.7.11.3 Trailing Conductors................................................................................................. 52
3.8 Driving the Haul Truck.............................................................................................................53
3.8.1 Dash Indicators and Warnings...........................................................................................53
3.8.2 Visibility.............................................................................................................................. 54
3.8.3 Clearances........................................................................................................................ 55
3.8.4 Horn Signals...................................................................................................................... 56
3.8.5 Ramp Speed Limits........................................................................................................... 56
3.8.6 Trailing Distance................................................................................................................ 56
3.8.7 Turns................................................................................................................................. 57
3.8.8 Stopping and Parking........................................................................................................ 57
3.8.8.1 Parking...................................................................................................................... 57
3.8.8.2 Routine Stopping and Parking...................................................................................57
3.8.8.3 Stopping with the Secondary Brake System..............................................................57
3.8.8.4 Short Term Parking................................................................................................... 58
3.8.8.5 Long Term Parking.................................................................................................... 59
3.8.8.6 Fundamentally Stable Parking...................................................................................61
3.8.8.7 Braking...................................................................................................................... 62
3.8.8.8 Braking Systems........................................................................................................ 62
3.8.8.9 Emergency Braking................................................................................................... 64
3.8.9 Retarder Controls.............................................................................................................. 66
3.8.9.1 What is a Retarder?................................................................................................... 66
3.8.9.2 Retarder Operation in a Mechanical Drive Haul Truck..............................................66

3.8.9.3 Retarder Operation in an Electric Haul Truck............................................................69
3.8.10 Hill Starts......................................................................................................................... 71
3.8.10.1 Mechanical Haul Trucks..........................................................................................71
3.8.10.2 Electric Haul Trucks................................................................................................. 71
3.8.11 Uphill Driving................................................................................................................... 71
3.8.12 Reversing........................................................................................................................ 72
3.8.13 Wet Road Conditions....................................................................................................... 72
3.8.14 Fuel Consumption........................................................................................................... 73
3.8.15 Tyre Wear........................................................................................................................ 73
3.8.15.1 Speed...................................................................................................................... 73
3.8.15.2 Manoeuvring............................................................................................................ 73
3.8.16 Minimising Equipment Damage and Wear.......................................................................74
3.8.17 Spotting........................................................................................................................... 75
3.8.17.1 Day time from Ground............................................................................................. 75
3.8.17.2 Night........................................................................................................................ 75
3.8.18 Maintenance Workshop Areas.........................................................................................76
3.8.18.1 Driving in and around Workshops............................................................................76
3.8.18.2 Spotting at the Workshops.......................................................................................76
3.8.19 Efficient Operations......................................................................................................... 77
4 Load, Haul and Tip Materials............................................................................................79

4.1 Essential General Information.................................................................................................79
4.1.1 Loading Area Movements.................................................................................................. 79
4.1.2 Loading Area Signals......................................................................................................... 79
4.2 Haul Truck Cycle Times and Operating Efficiency...............................................................80
4.2.1 Overview............................................................................................................................ 80
4.2.2 Cycle Time......................................................................................................................... 80
4.2.3 Loading Efficiency............................................................................................................. 81
4.2.4 Hauling Efficiency.............................................................................................................. 81
4.2.5 Tipping Efficiency.............................................................................................................. 82
4.3 Queuing.......................................................................................................................................83
4.3.1 Queuing Safety.................................................................................................................. 83
4.3.2 Queuing Procedure........................................................................................................... 83
4.4 Loading Techniques..................................................................................................................84
4.4.1 Overview............................................................................................................................ 84
4.4.2 Loading Precautions.......................................................................................................... 84
4.4.3 Overloading....................................................................................................................... 84
4.4.4 Oversize Rock Loading Precautions..................................................................................85
4.4.5 Positioning a Truck for Loading.........................................................................................85
4.4.6 Loading with Loading Units................................................................................................ 89
4.4.6.1 Overview.................................................................................................................... 89
4.4.6.2 Onside Loading......................................................................................................... 89
4.4.6.3 Offside Loading......................................................................................................... 90

4.4.6.4 Single-Sided Loading................................................................................................ 90
4.4.6.5 Double-Sided Loading............................................................................................... 91
4.4.6.6 Modified Drive-By Loading.........................................................................................92
4.4.7 Loading with Front-End Loaders........................................................................................ 93
4.4.7.1 Overview.................................................................................................................... 93
4.4.7.2 Onside Loading......................................................................................................... 93
4.4.7.3 Offside Loading......................................................................................................... 94
4.4.8 Loading with Excavators.................................................................................................... 95
4.4.8.1 Overview.................................................................................................................... 95
4.4.8.2 Top Loading............................................................................................................... 97
4.4.8.3 Top loading at 45 Degrees........................................................................................ 98
4.4.8.4 Top loading at 90 Degrees........................................................................................ 99
4.4.8.5 Bottom Loading....................................................................................................... 100
4.4.8.6 Bottom Loading 45 Degrees....................................................................................101
4.4.8.7 Bottom Loading 90 Degrees....................................................................................102
4.4.8.8 Drive-By Loading..................................................................................................... 103
4.5 Hauling.....................................................................................................................................104
4.6 Tipping Techniques.................................................................................................................105
4.6.1 Overview.......................................................................................................................... 105
4.6.2 General Tipping Guidelines............................................................................................. 105
4.6.3 Operating the Tray........................................................................................................... 106
4.6.3.1 Tray Hoist Control.................................................................................................... 106
4.6.3.2 Tipping a Load......................................................................................................... 107
4.6.3.3 Tipping Safety Procedures......................................................................................108
4.6.4 Tipping at Tip Heads........................................................................................................ 109
4.6.4.1 Tipping under Normal Conditions............................................................................109
4.6.4.2 Soft Tipping............................................................................................................. 112
4.6.5 Special Tipping Requirements.........................................................................................113
4.6.5.1 Tipping in Crushers................................................................................................. 113
4.6.5.2 Back Filling Pits Containing Water...........................................................................115
4.6.5.3 Free (Block) Tipping................................................................................................ 116
4.6.5.4 Tipping in Corners................................................................................................... 117
4.6.5.5 Tipping for Dozers to Build a Tip Head....................................................................118
4.6.6 Managing an Overloaded Haul Truck..............................................................................119
4.6.6.1 Special Tipping Area............................................................................................... 119
4.6.6.2 Return to Loading Unit............................................................................................. 119
4.6.6.3 Partially raised Tray................................................................................................. 119
5 Perform Post-Operational Procedures.............................................................................121

5.1 End of Shift...............................................................................................................................121
5.2 Maintenance.............................................................................................................................121
5.2.1 Preventative Maintenance............................................................................................... 121
5.2.2 Defect Reporting.............................................................................................................. 122
5.2.3 Breakdowns..................................................................................................................... 123
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5.2.4 Fluid Levels..................................................................................................................... 123

5.3 Refuelling..................................................................................................................................124
6 Activities..............................................................................................................................126
6.1 Section 3 Operate Haul Truck Activities...............................................................................126
Activity 1................................................................................................................................... 126
Activity 2................................................................................................................................... 126
Activity 3................................................................................................................................... 126
Activity 3................................................................................................................................... 127
Activity 4................................................................................................................................... 127
Activity 5................................................................................................................................... 127
Activity 6................................................................................................................................... 128
Activity 7................................................................................................................................... 128
Activity 8................................................................................................................................... 128
Activity 9................................................................................................................................... 129
6.2 Section 4 Load, Haul and Tip Materials Activities...............................................................130
Activity 1................................................................................................................................... 130
Activity 2................................................................................................................................... 130
Activity 3................................................................................................................................... 130
Activity 4................................................................................................................................... 131
Activity 5................................................................................................................................... 131
Activity 6................................................................................................................................... 131
6.3 Section 5 Perform Post-Operational Procedures Activities.................................................132
Activity 1................................................................................................................................... 132
Activity 2................................................................................................................................... 132
Activity 3................................................................................................................................... 132
Section 1 Session Preliminaries
1 Session Preliminaries
1.1 Purpose of this Resource Manual

The purpose of this Resource Manual is to provide detailed information and instructional
material for the subject matter of this training module. Where appropriate the content covers the
standards, procedures, safety and operational requirements for the workplace and tasks
described.
This Resource Manual is a key document in a suite of documents for the learning and
assessment requirements of this module.
1.2 Safety Requirements

If you demonstrate unsafe behaviour or perform a task without the necessary care or
confidence, the Trainer must direct you to cease work and terminate the training immediately.
1.3 Training Requirements

This Training module is conducted in accordance with the Training and Assessment Standard
and will be delivered in a variety of work situations and conditions appropriate to the role or task
to reinforce the required learning and repeated over a suitable time frame.
The Trainer will explain the training format, process and the progression to the assessment
requirements.
The content of this Resource Manual satisfies the training material requirements for this module.
Although you can keep this manual, the Activities at the end of the manual must be completed
and a copy of the Activities given to the Trainer.
1.4 Assessment Requirements

On completion of this training module an assessment will be conducted, which must be
successfully completed to attain an assessment of Competent for the material covered by this
module.
The assessment requirements are:
 A knowledge based test
 Practical demonstrations to establish a satisfactory understanding of the required
task/s and the associated safety requirements
 Workplace evidence completed by the Participant demonstrating competency in all the
required tasks
1.5 Prerequisite
Completing the training for the Generic Health, Safety and Environment Requirements and
being assessed as Competent, is a mandatory prerequisite for attending the training for this
module.
Information covered in the Generic Health, Safety and Environment Requirements Resource
Manual that is also applicable to haul truck operations is not duplicated in this resource manual.
If necessary, review the HSE manual to assist you with the full understanding required for haul
truck operations.
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Section 1 Session Preliminaries
1.6 Getting Help

See your Line Manager or Supervisor to obtain further assistance with the subject matter in this
training module.
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Section 2 Introduction
2 Introduction
2.1 Scope
This training module is aligned with the requirements of the unit of competency, RIIMPO311A
Conduct haul truck operations.
This Resource Manual discusses generic haul truck operations and is to be used in conjunction
with the relevant Original Equipment Manufacturer (OEM) manual for the specific haul truck
model and type that you will be operating at your mine site.
The topics include planning and preparing for operations, operating the haul truck, loading,
hauling and tipping materials and carrying out post-operational procedures.
There is also relevant information covering the HSE and legislative requirements for the
functions associated with operating a haul truck. This safety information is extremely important
and is discussed in detail with all related subject matter, as required, throughout this manual.
2.2 Haul Truck Types and Specifications
2.2.1 Overview
The haul trucks typically have an engine of over 50 litres capacity. The gross power output
exceeds 1000kWs.
The haul trucks typically have turbocharged, pressurised water-cooled mechanical / electric
power trains, using the diesel engine to drive an AC alternator or DC generator that transfers
electric power to electric motors at each rear wheel, while some use a diesel engine to power a
mechanical power train similar to most road vehicles.
Haul trucks (dump / tip trucks) are strictly used for off-road tasks in the mining industry and
other industries with heavy hauling operations. The heavy payloads that can be carried make
them an efficient means of transporting large volumes of material.
Haul trucks are classified by their:
 Body type
 Drive type
2.2.2 Body Type

The term dump truck is not generally applied to the heavy haul trucks used for surface mines by
the mining industry or by the truck manufacturers. The U.S. term of Haul Truck is used to
identify this type vehicle. The two types of truck are the rigid frame and the articulating frame.
This training module only discusses the rigid frame vehicle.
A haul truck is further classified by the method used to discharge its load from the tray, i.e.
bottom, side or end dump. This training module only discusses the end dump vehicle.
An Example of a Haul Truck with the Body Type used by Leighton
2.2.3 Drive Type

Haul trucks are further classified into two categories based on the truck’s drive train type.
Hauls trucks are driven by a mechanical or electric power train. The driving techniques vary
according to the type of power train in the truck you are operating.
The Diesel / mechanical Haul Truck has a manual and automatic retarder control and a power
shift transmission.
The Diesel / Electric Haul Truck has a dynamic retarder and a propulsion control switch for
forward and reverse.
A Typical Mechanical-Drive Haul Truck Power Train
A Typical Electric-Drive Haul Truck Power Train
An Example of Haul Truck Dimensions using a Caterpillar 789C
Weights and Volumes

The weights and volumes of a typical haul truck usually exceed:
 Gross empty weight: 130,000kg
 Payload capacity: 150 tonnes
 Fuel tank capacity: 3000L
 Cooling system capacity: 650L
2.3 Identifying the Truck’s Main Components and Functions

The following photographs and supporting descriptions provide a general understanding of a
haul truck, its basic configuration and components.
The haul truck example used is the Caterpillar model 789C.
2.3.1 Front View
Cabin Access
Cabin access is provided by fixed steps on the front of the truck. A switch is located near the
bottom of the steps to provide lighting for access during poor light conditions.
Steering System
The haul truck’s front wheel steering system uses the movement of the steering wheel to
operate a hydrostatic steering valve, which directs hydraulic pressure to a twin, double-acting,
steering cylinder. An independent hydraulic circuit prevents cross contamination from other
hydraulic systems. The steering oil tank is located on the upper deck.
2.3.2 Right Side View
Tray
The tray is constructed of high tensile steel with a V shaped bottom to help centre the load,
maintain a low centre of gravity and reduce shock loading.
Transmission
Typical transmissions in haul trucks are Planetary Power shift transmissions providing a high
torque. Planetary transmissions are automatics, in that gears can be changed without use of a
clutch. However, the gear selection is manually controlled by the Operator to maintain the
required engine speed, truck speed and torque required for the operating conditions.
The transmissions provide up to seven forward gears (typically 6) and one reverse gear.
2.3.3 Left Side View
Frame
The main structural frame of a haul truck is constructed of a full box section, on which all other
components of the truck are assembled. The box section is made of mild steel to provide
flexibility to help prevent stress related failures and for good durability.
Body Hoist System

The Body Hoist system consists of twin; two-stage hydraulic cylinders mounted on to the main
frame pivot points and the tray frame attachment points.
The raising and lowering operation is controlled by the Operator using the hoist lever located
near the Operator's seat.
2.3.4 Rear View
Braking Systems
The multi-disc braking assembly provides the primary, secondary, parking and retarding
functions in the same system. If the hydraulic system pressure drops below a specified level,
the secondary system automatically applies the brakes.
The brakes are designed to hold a fully loaded truck on a 15° gradient.
The rear wheels have an Automatic Electronic Traction control system that activates
automatically if excessive wheel spin is detected. The brakes are applied to slow the wheel spin
and transfer torque to the tyres to assist with regaining tyre grip.
The haul truck is equipped with an Operator activated Automatic Retarder Control (ARC)
system. The ARC regulates truck and engine speed when the proper gear is selected. The ARC
activates when the engine speed is between 1850 and 1950 rpm.
The Operator can override the automatic ARC with the retarder lever or by applying the service
brake or the emergency brake. If the Operator suspects that the grade or other conditions could
possibly cause engine over-speed apply the ARC manually.
The ARC function automatically overrides the manual retarder function if engine speed is too
high.
Suspension
The oil-pneumatic suspension cylinder on each wheel can handle a series of shocks
simultaneously. When the shock has passed, the cylinder smoothly returns to its normal
position.
A rear upper sway bar (commonly known as a dog bone) is attached to the frame and
differential housing minimises lateral sway, improves Truck handling and Operator comfort.
2.3.5 Operator Cabin Instruments and Controls
Operator Cabin
The Operator’s cabin provides a safe, healthy working environment while allowing efficient truck
operations. Specific design characteristics are:
 Built-in roll over protective structure (ROPS)
 Cabin suspension to help provide vibration isolation
 Air suspension seat to help isolate the driver from vibration
 Sound suppressed to typically less than 80db
 Heat and air-conditioning
 Tilt-adjustable steering column
Operator Seat
The Operator’s seat provides a fully adjustable cushioned ride for the driver’s comfort and ease
of operation.
The seat’s air adjustment may vary between trucks due to site modifications. Ask if required.
The following image illustrates an example of the types of Operator seats that are fitted to haul
trucks.
Key features include:

 3-point seat belt
 Self-levelling air suspension
 Air height adjustment
 Adjustable vertical shock absorber
 Horizontal isolator
 Integrated pneumatic system (IPS)
dual stage air lumbar with lateral
support
 Suspension quick release
 Horizontal adjustment
 Cushion tilt and length adjustment
 High backrest with integrated head
restraint and adjustment
 Armrests optional
Vehicle Management Systems

Within the console functions is a vehicle parameter’s monitoring system (Known as VIMS in the
Caterpillars) for alerting the Operator of an immediate or impending problem in one or more of
the Truck’s systems. This enables the Operator to take timely corrective action to correct the
problem or stop a function to reduce the risk of damage.
These vehicle management systems recognise abnormal conditions as either Equipment
Events or System Events. The systems consist of:
 An action alarm
 A message centre module
 A keypad module for Operator input
 An alert indicator and action lamp
2.4 Operating Authority

To operate a haul truck under any circumstances you must:
 Have a current full drivers licence issued by the transport authority of an Australian
State or Territory
 Be at least 18 years of age
 Complete the relevant site induction/s
 Must be trained and deemed competent to operate by site training requirements
If you have committed a traffic offense resulting in the suspension or loss of your State or
Territory Drivers Licence, you cannot operate a haul truck (or any other site vehicle) until your
Drivers Licence has been reinstated.
If you are unsure about your authority to operate or what authorisation is required, seek advice
from your Supervisor.
Section 3 Operate Haul Truck
3 Operate Haul Truck
3.1 Introduction
Operating a truck is a skilled task that requires significant training and an on-going discipline to
manage and drive this highly specialised and unique vehicle.
While driving the vehicle, there are critical parameters for speed and braking that must be
strictly adhered to, with constant monitoring of systems and surrounds for alarms and
hazardous situations.
It is part of the Operator’s responsibility to help improve the general appearance, standard of
roadworthiness and operating efficiency of the truck. This is achieved by following the required
operating procedures.
These procedures are:
 Taking part in shift change-over procedures
 Conducting walk-around inspections and pre-start checks
 Reporting defects in or on the truck using approved defect-reporting forms or
procedures
 Operating the truck safely and productively
 Operating the truck with due care, so as not to reduce its service life or cause
unnecessary damage to it or to other machinery
 Parking the truck in secure locations or designated areas
 Observing shutdown procedures
 Ensuring the truck is available for use whenever it is required
 Ensuring that preventative maintenance is performed when scheduled
 Ensuring that high standards of housekeeping are maintained
 Keeping the truck clean
The truck must be operated with headlights on during truck operations to assist with mine site
safety. This is mandatory.
If you correctly perform all checks and drive within prescribed handling parameters, the
operation of the truck is always a safe task.
The Operator’s truck care responsibilities may vary depending on site regulations.
3.2 Identifying Safe Operating Practices

You must perform frequent pre-operational and operational checks and inspections on the haul
truck. The purpose of these inspections is to discover and locate any adjustments that may be
required before operating the truck and to find any defects before they become significant
problems that may cause injury and equipment or environmental damage.
Ensure a high level of truck maintenance, safety and operating standards by:
 Carrying out quality walk-around inspections
 Performing the required pre-start checks at the beginning of each shift and before
starting the truck after a shutdown
 Only operate the controls while the engine is running as damage to some components
can occur and / or leave some functions in an unsafe setting causing unexpected
movement when systems are powered up
 Detailed and conscientious reporting of defects
 Ensuring all routine servicing and any other preventative functions are carried out as
scheduled
 Operating the haul truck within its limits in a safe manner
 Ensure that the haul truck will not be damaged or made unsafe by any actions that
you may take
 Never drive a haul truck into an area that is suspected of being unsafe or where vision
is restricted
Notify a Supervisor and have the area inspected or get assistance.
 Keeping the haul truck clean
Warning : Do not operate the haul truck if you believe it is in an unsafe condition. Report
your concern and either get it cleared as safe to operate or report it for repair.
Monitoring the truck’s operational status includes regularly checking:

 Temperature gauges
 Fluid level gauges
 All controls and switches
 Pressure gauges
 Alarms and indicator lights
 Steering
 Braking systems
 Hydraulic systems
Always include safety in your operating plan by:

 Monitoring personnel and equipment in the haul truck operating area
 Constantly inspecting ground conditions around the truck, with particular attention to
windrows and edges
 Moving the truck by driving forwards wherever possible to avoid visual problems and
potential strain injuries to your neck and back
3.3 Identifying Personal Injury Hazards

Although you are operating the truck from inside a secure cabin, sitting on a suspended seat
with a seat belt, there are still occasions during normal operating conditions when you can
sustain an injury if you are not fully aware of some situations around you.
Back, neck and other limb injuries can occur by some operating conditions severely throwing
you around despite the wearing of a seat belt. Always remain aware of your operating
environment as Operators have sustained injuries while belted in the seat.
Potential injury situations include the following conditions.
Rough ground
When driving over rough ground slow down and ensure that you are correctly supported in the
seat to minimise the jolting and sideways motions that can cause injuries.
Loading Oversized Material

This can severely rock the truck around. If you chose to stay in the cabin, sit securely and
squarely in the seat to avoid being jolted around and potentially hitting something in the cabin.
Lowering the Tray

Do not allow the tray to fall heavily as this can cause a severe jolt that can cause injury if you
are twisted around and not supported correctly in the seat.
Load Movement
Load movement can change the handling of the truck and affect your stability in the seat. If you
unexpectedly have to make any quick recovery actions while driving or braking this can cause
injuries due to the tense nature of your body during the jolting and recovery movements.
3.4 Pre-Start Procedure
3.4.1 Overview
The primary reasons for a pre-start walk-around truck inspection are to identify any
maintenance concerns before they become serious problems and to identify any potential safety
issues before they become serious hazards.
A walk-around inspection must be performed:
 At the beginning of every shift
 Before operating any other truck during a shift
 After a hot seat changeover occurs
Perform a brief walk-around inspection whenever the opportunity arises, i.e. after refuelling.
Before starting the inspection, ensure that the:
 Haul truck is parked on stable, level ground in an appropriate place
 Park brake is on and the transmission is in neutral
 Tray is down and empty
Note : As required and after checking site-specific procedures, refer to OEM, SWI,
CBP, JSEA and Risk assessment documents. Complete a Take 5.
3.4.2 Driver Changeover

Observe the following procedure for a hot seat driver changeover.
1. Incoming and outgoing Operators communicate to initiate the changeover.
2. Incoming Operator observes that the outgoing Operator follows the park-up procedures.
3. Incoming Operator observes that the outgoing Operator has dismounted the truck.
4. Incoming Operator approaches the truck and meets the outgoing Operator at either the left
side front wheel or at the foot of the boarding ladder in front of the truck.
5. The outgoing Operator briefly mentions any concerns regarding the truck or site conditions
as necessary.
6. Incoming Operator ensures that the outgoing Operator is clear of the area.
The incoming Operator is now ready to start the walk-around procedures.

The hot seat driver changeover may vary according to site regulations.
3.4.3 Operator’s Inspection Form

The Operator’s pre-start safety inspection checks form must be completed during the
walk-around to record any faults or damage to the truck before commencement of your shift.
The information you record on this form can also protect you against being accountable for any
previous damage to the truck.
The following image is an example of the typical pre-start inspection forms used for
driver-operated heavy equipment at Leighton’s mine sites. The form used at your site may not
be exactly the same.
The forms typically have three fault categories.

1. Do Not Operate – Report the fault to your Supervisor for repairs.
2. Authorisation Required – Report the fault to your Supervisor and obtain authority to
operate.
3. Corrective Action Required – Report the fault to your Supervisor and if the fault is not
corrected before the end of the shift, it must be recorded in the backlog defect list.
Note : All fire extinguishers on the truck must be operational and you must have at
least one operational hand held fire extinguisher available before operating the
truck.
3.4.4 Walk-Around Inspection

Introduction
The Caterpillar 789C is used as an example to describe the required pre-start checks. The
location of some functions and items may vary on some of the haul trucks at your site. However,
the important factor is that all points specified for inspection on your haul truck are checked.
Truck Footprint
Warning : A walk-around inspection of an empty truck must be conducted outside the

footprint of the vehicle. However, it is acceptable to enter inside the footprint to
place Isolation after a Take 5 is conducted.
If the truck is loaded, inspect the truck at a distance determined by a personal risk assessment
or tip the load off the truck, park it in a safe position and then conduct the inspection.
Walk-Around Direction and Inspection Start

The following diagram illustrates the preferred walk-around inspection direction for haul trucks at
Leighton mine sites.
Commence walk-around by:
1. Starting at position 1 (diagram below)
2. Isolating the engine
3. Walking anticlockwise around the truck to perform the following inspections
A walk-around inspection can be performed in either direction around the truck provided the
procedure you use is methodical and complete.
The tray is not shown to provide a clear view of all the inspection checkpoints around the truck.
1. Front and isolation point 2. Left side 3. Rear

4. Right side 5. Service platform 6. Operator cabin
Under the Truck – All Around

As you walk around the truck check for:
 Leaks
 Hanging hoses or control cables
 Build- up of mud that could break away and cause injury
 Obvious damage
1. Front
Check:
 Radiator for build-up of dirt or rubbish, leaks and damage
 Air intakes are clear of debris
 Access steps and ladders for security and damage
 Working lights for cleanliness and damage
 Structure for cracks and damage
 Underneath for leaks and damage
 Fire extinguishers for correct pressure, security and damage
 Isolation panel for security and damage
2. Left Side
Check:
 Tyres for correct inflation, cuts, damage to side walls or tread face, rocks trapped
between tyres and valve security
 Wheels for hub leaks, loose locking rings, loose or missing wheel nuts and damage
 Underside for leaks and damage
 Tray particularly around ribs for cracks and damage
 Hoist cylinder for leaks and damage
 Hoist cylinder trunnions for cracks, security and damage
 Fuel tank for leaks and damage
 Fuel tank indicator for fuel quantity
 Indicator light for cleanliness and damage
3. Rear
Check:
 Tail, brake and hazard lights for cleanliness, security and damage
 Lubrication lines for leaks and damage
 Differential for oil leaks
 Rear suspension cylinders for correct inflation, leaks and damage
 Tray and tailgate for cracks and damage
 Tray pivot points for security and damage
 Tray attachment points for cracks and damage
 Rock ejectors for security of pivot pin and damage
 Tyres for rocks trapped between tyres
4. Right Side
Check:
 Rear tyres for correct inflation, cuts, damage to side walls or tread face, rocks trapped
between tyres
 Rear wheel for hub leaks, loose locking rings, loose or missing wheel nuts and
damage
 Underneath the haul truck for leaks and damage
 Tray particularly around ribs for cracks and damage
 Hoist cylinder for leaks and damage
 Hoist cylinder trunnions for cracks, security and damage
 Hoist, torque converter and brake oil tank for correct levels on sight gauge
 Hoist, torque converter and brake oil tank for leaks and damage
 Transmission oil for correct level
 Transmission oil tank for leaks and damage
 Turn indicator light for cleanliness and damage
 Front wheel for hub leaks, loose locking rings, loose or missing wheel nuts and
damage
 Front tyre for correct inflation, cuts, damage to side walls or tread face and valve
security
 Main frame around front strut mount for cracks and damage
 Front suspension strut for correct height, leaks and damage
 Steering cylinders and hydraulic lines for leaks and damage
 Engine bay inspection doors are secured
 Engine exhausts for cracks, security and damage
 Engine for leaks and damage
5. Service Platform
Check:
 After-cooler and radiator coolant level via appropriate sight gauges
 Air filter restriction devices
 Steering system tank for leaks and damage
 Steering system tank sight gauge levels
 Auto-grease system for security, general condition and damage
 Primary air tank for leaks, security and damage
 Exhaust muffler for security and damage
 Fire extinguishers for charge and security
 Fire suppressant cylinders for charge and security
 Batteries for leaks, security and damage
 Service deck for cracks and damage
 Service deck rails for security and damage
 Right side rear vision mirror for cleanliness, security and damage
6. Operator Cabin
Check:
 Doors for security, damage and correct operation
 ROPS for cracks and damage
 Windscreen and windows for cleanliness, cracks, damage
 Windscreen wiper blades for damage
 Windscreen washer reservoir for level
 Left side rear vision mirror for cleanliness, security and damage
 For out of service, danger or information tags
 Cabin seats and seat belts for cleanliness, security and damage
 Instruments and controls for cleanliness, damage and correct operation
Missing Wheel Nuts

The following series of diagrams illustrate the Truck’s operating limits for missing wheel nuts.
3.5 Start Up Procedure
3.5.1 Final Pre-Start Checks

Prior to entering the haul truck to start your shift, ensure that any issues found during the
pre-start inspection are resolved and that the appropriate signatures have been obtained.
When you are cleared to enter the truck:
 Check the immediate area to ensure that personnel and equipment are clear of the
truck
 Ensure the access steps are raised and locked
After entering the cabin:

 Adjust the seat and mirrors
 Fasten the seatbelt
 Turn on the two-way radio and check that it is operating correctly
 Ensure the fire suppression system is active
 Check that the doors and windows are secure
3.5.2 Start Up Process

Use the following sequence to start the haul truck.
1. Use the key to turn on the ignition.
The truck’s management system performs a self-test. If a fault is detected, have the system
checked and rectified before starting the engine.
2. Set the park brake.
3. Check that the transmission lever is in Neutral and the retarder lever is in the off position.
4. Ensure that the hoist lever is in Float position.
5. Sound one horn blast to indicate an intention to start – wait five seconds to ensure all
personnel are clear.
6. Turn the ignition key to Start and release once the engine has started.
7. Check the management system for any system faults.
3.5.3 Post Start Up Checks

Complete the following checks after the engine starts.
1. Keep engine at low idle until the engine oil pressure indicator lamp goes out.
Warning : If the engine oil pressure indicator is still illuminated after 15 seconds, stop the
engine immediately and investigate.
2. Allow the engine to warm up at low idle for five minutes.

3. Ensure that the accumulator pressures for the steering and brakes are normal
4. Observe all other gauges, warning and service light panels for irregularities.
Gauges should register in the correct range and all warning and service indicators should
be off.
5. Cycle through the controls to ensure correct operation.
3.5.4 Braking Systems Tests

Before all brake tests move the truck a short distance from the park up area to level ground - if
possible to a dry area.
Note : If the truck moves during any of the brake tests report the problem and do not operate
the truck until it has been cleared for operation.
Park Brake Test

Test the park brake using the following procedure sequence.
1. Engage the park brake.
2. Move the transmission direction and speed control lever to the first speed forward position.
3. Gradually increase the engine speed to 1200 rpm - the truck should not move.
4. Reduce the engine speed to low idle.
5. Move the transmission direction and speed control lever to the neutral position.
6. Leave parking brake engaged.
Service Brake Test

Test the service brakes using the following procedure sequence after system pressures are
normal.
1. Apply service brake control.
2. Release park brake.
Secondary Brake Test

Test the secondary brake system using the following procedure sequence.
1. Apply secondary brake control.
2. Release park brake.
Retarder Control Test

Test the retarder control using the following procedure sequence.
1. Apply the retarder.
2. Release the park brake.
8. Release the retarder.
3.5.5 Continuing Checks

Throughout start-up and operation of the haul truck you need to continue your checking and
safety vigilance by using all your senses to monitor the truck’s performance. This approach can
be summarised as follows.
Look: for unusual occurrences, e.g. oil or coolant leaks, obstructions, poor road
conditions, deterioration of components
Listen: for unusual noises, e.g. bearing failures, engine over-speed, warning alarms,
transmission and drive train failures
Smell: for burning and overheated oils, electrical equipment, engine or transmission
Feel: for unusual vibrations, from engine, transmission, drive train, bearings and
hydraulic controls
3.6 Moving Off Procedure

After completing all the post start up checks, perform the following moving off procedure in
sequence.
1. Conduct a final check of all instruments, indicators and warning systems.
2. Apply the service brake.
3. Ensure that the area is clear and sound the horn twice to indicate your intention to move.
Sound the horn three times before reversing.
4. Move the park brake switch to the off position.
5. Move the transmission selector to the required gear.
6. Release the service brake.
7. Press the accelerator pedal to start the haul truck rolling.
8. Test the steering and brake controls for correct operation.
3.7 Emergency Procedures
3.7.1 Under Inflated and Flat Tyres

Under inflated tyres heat up very fast due to excessive flexing of the tyre walls, leading to the
possibility of tyre fires or blowouts.
The other, and perhaps most dangerous, situation is when a haul truck is travelling loaded while
one of the rear tyres is flat. This means that the tyre next the flat one is carrying the weight of
two tyres. Its walls bulge and rub against the flat tyre generating a lot of heat.
This situation creates extreme potential for a tyre fire. All personnel, particularly loading unit
Operators and dozer Operators at tip heads, must immediately notify the truck Operator by radio
when seeing a haul truck with an under inflated or flat rear tyre.
The driver of the affected truck must park in a safe area, notify the Supervisor and follow their
instructions.
Warning : Never continue to drive on a flat or under inflated tyre and always advise your
Supervisor.
Loads that are required to be tipped are to be tipped a minimum of 10 metres from any tip
head / windrow.
Warning : Never tip on a tip head with a flat tyre – always tip short.
3.7.2 Tyre Failure

If a sudden tyre failure or blowout occurs, attempt to bring the haul truck to a stop as quickly and
safely as possible. Apply the retarder / brakes smoothly while attempting to steer the truck
against the forces generated by the flat tyre.
Regardless of which tyre is affected, there are several factors that must be considered when
attempting to stop the truck.
These include:
 Haul road surface
 Weather conditions
 Travelling up or down inclines
 Loaded or empty
 Speed
 Other vehicles in the vicinity
After the haul truck has been stopped:

 Reduce the engine to idle
 Place the transmission selector to park
 Apply the park brake
 Turn the ignition key off
 Notify your position and problem over the two-way radio
 Evacuate the area if a tyre is burning or displaying evidence of fire
When the haul truck is parked after work, there can be a potential risk of fire or explosion from
an overheated tyre, wheel or brake component. If the tyres have a hot or burning smell or if
smoke is present, follow the site hot tyre procedure.
If you suspect that a tyre is overheated, do not bring the truck into the workshop. Park the truck
in a safe or designated area, well away from mine infrastructure and other equipment, and notify
your Supervisor.
Ensure that an exclusion zone of 500 metres is marked with barriers around the truck for a
period of 24 hours until the tyre has cooled down.
Warning : Do not attempt to extinguish the tyre if it is burning, as the risk of the tyre
exploding is extremely high.
Overheated tyres exploded
3.7.3 Tyre Fires
3.7.3.1 Introduction
Tyre fires and explosions are a major hazard. A truck fire can also cause a tyre to explode.
When excess heat is developed in or applied to a tyre, a chemical reaction may occur within the
tyre’s material components and cause a build-up of flammable gases. If these internal gas
concentrations and temperatures exceed a critical level, the tyre explodes.
Heat in tyres can be caused by:
 Brake Problems – The over-use of service brakes can cause over-heating in tyres
 Under-inflation – Insufficient air in the tyres or too much load on the tyre can cause
separation of the tread
 Flammable liquids on Tyres – Oil or fuel soaked tyres become fire hazards when
exposed to heat
The following image illustrates how a tyre fire can also cause the loss of a truck.
3.7.3.2 Suspect or Burning Tyres

If the circumstances suggest there is a danger of a tyre fire or explosion:
 Move the truck to a remote area, as directed by the Supervisor, provided it can be
done without endangering the Operator or other personnel in the area
 Advise Pit Control where the truck has been parked
 If possible, drive the truck to the tyre fire area
 Park the truck
 Shutdown operation
 Do not attempt to use a hand-held extinguisher on a smouldering or burning tyre
 Exit the truck and move away keeping the vehicle between you and the burning tyre -
avoid passing in front of the suspect tyre when leaving the truck
For tyres that have not burnt or exploded, allow at least 24 hours for the tyre to cool before
approaching to inspect the truck.
If it is absolutely necessary to approach a truck with a suspect tyre, approach it from the front or
rear and use a large bulldozer blade as a shield in front.
If there is evidence of brake fire or smell of burning rubber, do not go near the truck.
Warning : Stay at least 500 metres from a truck with a burning or suspect tyre.
Tyre Explosion Danger Area
Warning : Never approach a burning tyre under any circumstances. The timing of a tyre
explosion is not predictable. Explosions can be immediate or occur anytime up
to 24 hours.
Burning tyres emit toxic fumes and are extremely difficult to extinguish. Dealing
with them is a job for the Fire Crew.
Result of a Tyre Fire Explosion
3.7.4 Truck Fires

If there is a fire on the haul truck, use the following procedure to stop, apply fire-fighting
equipment, obtain help and ensure personal safety.
1. Bring the haul truck operation to a stop as quickly as possible.
2. Turn the steering wheel to full lock towards a windrow or wall if possible.
3. Shut down the engine using the emergency stop – this stops the flow of fuel, air and
electrical energy helping to reduce the spread of the fire.
4. Apply the long term parking procedure.
5. Remove tamper tag / pin on the actuator and depress firmly to activate the on-board fire
suppression system – press button down hard.
6. Use the two-way radio to call, emergency, emergency, emergency and state your name,
location, nature of the emergency, assistance required and any injuries.
7. Leave the Operator cabin and dismount at the safest exit point.
8. ONLY use the hand-held fire extinguisher to help control the fire if it does not to place you
in any personal danger.
9. Once the extinguisher is discharged, move away from the haul truck to a safe location.
3.7.5 Electric Truck Grid Box Fire

If smoke or flames are observed from the grid box, use the following procedure to stop, apply
fire-fighting equipment, obtain help and ensure personal safety.
1. Turn off the Retard Speed Control (RSC).
2. Use the service brakes for emergency braking procedure.
3. Park the vehicle in a safe position with wheels turned towards a windrow or wall if possible.
4. Apply long term parking procedures.
5. Shut down the engine using the emergency stop – this stops the flow of fuel, air and
electrical energy helping to reduce the spread of the fire.
6. Do not isolate.
7. Use the two-way radio to call, emergency, emergency, emergency and state your name,
location, nature of the emergency, assistance required and any injuries.
8. Advise Pit Control / Supervisor of circumstances and location – they notify relevant
personnel including the water truck.
9. Exit vehicle.
10. Retreat to a safe location away from the vehicle.
11. DO NOT attempt to fight the fire.
Warning : Activating the engine fire suppression systems does not extinguish a Grid Box
fire.
3.7.6 Loss of Steering or Brakes

It is imperative that an Operator is competent in all aspects of haul truck operations.
Operator’s experiencing malfunctions such as loss of steering or brakes must use the correct
procedures for the type of haul truck being operated. It is imperative that the Operator acts as
quickly as possible to ensure the haul truck can be brought to a complete stop to avoid possible
injury to personnel and damage to equipment.
Refer to the haul truck’s OEM instructions for handling a loss of steering or brakes emergency.
3.7.7 Immobilised Haul Truck

If the haul truck is bogged or is unsafe to move due to a mechanical fault, immediately contact
your Supervisor. The Supervisor takes the appropriate actions to ensure that the haul truck is
recovered in the correct and safe manner.
Warning : Do not attempt to recover an immobilised haul truck on your own, as the risk of
serious injury or damage is high.
3.7.8 Loss of Traction
3.7.8.1 Overview
During wet weather (or where ramps have been over-watered), trucks can sometimes break
traction and begin to spin the rear wheels.
Skidding and sliding occur when the front or rear wheels lose traction with the ground. It occurs
more frequently in wet conditions, and is more likely to happen in conjunction with the following
bad driving practices:
 Swerving
 Excessive speed
 Rapid slowing
 Sudden and / or excessive braking
 Excessive acceleration
 Transmission change downs on wet roads in mechanical trucks
The three types of skidding are:

 Rear wheel skidding
 Front wheel skidding
 All wheel skidding
3.7.8.2 Rear Wheel Skid

This occurs when the rear of the truck tries to catch up with the front, which can result in the
truck turning completely around and facing the other direction.
To control rear wheel skidding:
1. Release foot off the accelerator
2. Simultaneously turn front wheels into the direction of the skid and reduce braking.
3. Take care not to over correct.
4. When the truck comes back into line, gently accelerate and steer in the required direction
3.7.8.3 Front Wheel Skid

This causes loss of steering by either excessive speed or excessive braking.
If caused by excessive speed:
1. Release foot off the accelerator
2. Apply retarder / dynamics sufficiently to regain steering control
3. Steer into intended direction
If caused by excessive braking:

1. Remove foot from accelerator
2. Straighten front wheels
3. Momentarily remove foot from brake and allow the wheels to start turning again
4. Reapply the brakes with gradual pressure
3.7.8.4 All Wheel Skid

If the truck starts to slide sideways due to over-acceleration, road camber or rear wheel lock up:
1. Reduce acceleration
2. Steer in the direction of the slide
3. Stay close to the left hand windrow
If the truck starts to slide sideways while braking:

1. Release the brake
2. Steer into the direction of the slide
3. Gently accelerate making the rear wheels turn at the truck’s ground speed and increase
tyre to road friction giving more control
4. Brake again more gently
Note : Always report excessive loss of traction on haul roads to the Supervisor.
3.7.9 Breakdown on a Gradient

Operator must assess situation, perform a haul truck risk assessment if necessary and follow
the breakdown procedure.
1. Turn wheels into windrow or high-wall.
2. Apply the long-term park-up procedures.
3. For electric trucks stop the engine with the shutdown button. Do not use the key to
turn off the engine, as this bleeds the emergency brake and steering accumulators.
4. Operator informs Supervisor and all other road users of the breakdown situation.
5. Supervisor ensures adequate safety controls are in place for personnel and
equipment.
6. Operator uses the cabin two-way radio or a designated spotter to direct traffic flow
until bund building equipment is in place.
7. While construction of bund wall is taking place, all traffic flow on ramp is to cease.
8. Truck maybe positioned against high wall or bund if deemed safe by Supervisor to
ensure fundamental stability.
9. After the truck is secured, maintenance personnel gain permission from the
Supervisor to approach broken down truck.
10. Supervisor assesses the status of situation and acts accordingly.
Bund-wall Construction
There must be positive communication between all parties involved with the construction of the
bund-wall. The wall is constructed on the down side of broken down truck.
A spotter is used to oversee the material being pushed up to tyres of the truck.
The material must be pushed to the tyre from a 45° angle. When an adequate amount of
material has been placed in front / behind the truck it is then pushed up against the tyres from
directly in front / behind.
If an emergency ladder is fitted to the truck, it is only to be used for an emergency. If required,
release the ladder and dismount using 3-point contact.
3.7.10 Haul Truck Rollover

When haul trucks are operated correctly, the chances of a rollover are minimal. However, there
is no room for complacency because rollovers have and can occur with reduced awareness.
There are several conditions either, separately or in combination, that can cause rollovers.
These are:
 Flat tyres
 Rocks
 Rough ground
 Excessive speed
 Uneven load distribution
 Tipping at an angle – should never occur
In the event of a rollover, follow the recommended precautions and procedures as much as
practicable in an attempt to prevent or minimise injury.
Brace firmly in the Operator’s seat with both feet firmly on the floor to minimise body movement
during the rollover. You should already be wearing your seat belt.
When the haul truck has stopped moving, if there is no immediate danger, exit the cabin if you
can do it safely. If there is a possibility of the haul truck moving again remain in the cabin until
assistance arrives.
Warning : Never attempt to jump clear while the truck is moving in a rollover situation.
At the earliest opportunity:

 Shut down the engine
 Radio for assistance
 Shut down all electrical systems
Note : Always maintain a high standard of housekeeping in the cabin as serious injury
can occur from loose objects during a rollover.
3.7.11 Electrical Conductors
3.7.11.1 Overhead Conductor Clearances

Power line contact during heavy equipment operations can be fatal. If problems exist with power
line clearance or location, take the time to plan your work around the lines to avoid electrical
hazards.
Note : When it is necessary to work in the vicinity of the 10-metre corridor for
overhead power lines, the safe clearance height must be established before any
work can commence.
Warning : Electricity may jump the gap (arc) between the conductor and the truck if you
work too closely to high voltage lines.
Always ensure you operate the haul truck outside the minimum clearance specified for a
particular voltage power line.
Signs are posted on main roads to warn Operators of the power lines and safe clearance.
Wherever possible, equipment is to travel under these conductors at designated crossings.
Prior to crossing under or working in the vicinity of overhead lines in non-signposted areas,
check with your Supervisor to determine whether a JSEA procedure needs to be carried out or
permit to travel under the power line is required.
Always note the safe clearance distance on every danger sign as this can vary. The higher the
voltages, the greater are the safe distance to avoid power arcing to you or your equipment.
Voltage Clearance Required at Maximum Height of Equipment – including Aerials

Line’s Lowest Point Assumes Lines are 12 Metres of the Ground
33kv 2.3 Metres 9.7 Metres

220kv 4 Metres 8 Metres
3.7.11.2 Fallen Conductors on Equipment

If you are in a vehicle that comes into contact with an electrical conductor and the vehicle is
immobilised:
 Use mine emergency procedures
 Warn all personnel to stay clear, if you can do it safely
 Do not touch any conductive material in the vehicle
 Stay in the vehicle until directed to leave
 Do not step onto the ground
 Do not touch any electrical conductor
 Do not operate the controls
 Wait until power has been isolated and you are instructed to step down
3.7.11.3 Trailing Conductors

Driving equipment or vehicles over electrical cables is strictly prohibited unless cable crossover
mats are used.
3.8 Driving the Haul Truck
3.8.1 Dash Indicators and Warnings

Operators need to be familiar with all the indicators on the dash as this allows you to take timely
corrective action for any problems while operating and to report all the information required by
maintenance crews for repair.
The following diagram illustrates, as examples, a comprehensive set of symbols for the
Caterpillar and Komastu haul trucks.
Always refer to the relevant OEM manual for your truck model and type, as the dash indicators
may be different.
3.8.2 Visibility
When driving the haul truck remain totally aware of your surroundings and concentrate fully on
the safe operation of the truck.
Be constantly aware of the height of the haul truck, (especially with the tray raised) to avoid
contact with overhead obstructions.
Remember to be constantly aware of the truck’s blind spots to help prevent accidents.
The shades areas in the above diagram illustrate the locations and size of the blind spots in a
typical haul truck with the Operator seated in the normal position in the cabin.
As with driving most vehicles, with a slight movement of your head and body, you can see
around the door pillars and rear view mirrors. However, the areas immediately in front, directly
behind and most of the right side of the truck are always blind.
When driving, you have full visibility of the areas that become blind spots as the truck moves
forward. However, if you are not fully concentrating some areas can become blind spots without
you being aware if the area is clear or if the road condition immediately in front is safe.
As you can see from the diagram, visibility awareness is very critical when reversing. The care
and attention required will constantly test your driving skills and experience. You can never
afford to be over confident.
The need to be fully alert and safety conscious all the time cannot be overstated.
3.8.3 Clearances
It is the Operator’s responsibility to ensure the truck has sufficient clearance whenever it is in
operation.
Be aware of clearances when:
 Reversing
 Parking
 Turning – slow down and avoid making contact with bund walls / windrows
 Tipping
 Operating in tight areas around other equipment, overhead power lines, near cables,
lighting plants and park up areas
If in doubt when entering into an area for the first time, seek clarification and guidance from the
Supervisor.
The following photographic example shows that the haul truck driver cannot see any of the other
vehicles, due to blind spots, when seated in an upright position with seat belt applied.
In relation to visibility from vehicles, a blind spot is defined as a line of sight obscured by a
window column or other obstruction.
3.8.4 Horn Signals

Operators of mobile equipment in the pit areas use horn signals to indicate the three main
vehicle actions.
These are:
 1 blast indicates the equipment is about to start
 2 blasts indicate the equipment is going to move forward
 3 blasts indicate the equipment is going to reverse
3.8.5 Ramp Speed Limits

The traffic regulations reflect the safety requirements for haul trucks at your mine site.
Speed limits vary according to location, conditions and each mine site. The typical speed limits
for haul trucks are shown in the following table.
Speed Limit Maximum kph Location
16 At the crest of a ramp

20 – must use 2nd gear Travelling down a ramp loaded
40 Travelling down a ramp unloaded
Mechanical trucks have to select the appropriate gear for the conditions.
The use of the Auto Retard Control is recommended for both electrical and mechanical trucks
when descending ramps.
3.8.6 Trailing Distance

The trailing distance for all haul trucks is no closer than 50m.
3.8.7 Turns
Turns with the haul truck are usually conducted at either low speed with a small turn radius or at
operational speed with a large turn radius as normally encountered on the haul road.
Always use indicators and allow enough time for other vehicles in the vicinity to stop or avoid
the indicated path of travel.
The rate or speed of entry into a turn together with the truck weight and the distribution of that
weight over the drive and steering axles determine how the haul truck steers.
3.8.8 Stopping and Parking
3.8.8.1 Parking
Mine site rules for parking are:
 Parking is not permitted on a haul road
 Utility vehicles and other personnel transport vehicles must park at least 50 metres
away from heavy equipment
 Light vehicles must be parked in an easily visible position from operating equipment
 Trucks must be parked in designated park up bays with the front tyre in the V drain
 If parking on an incline, prevent uncontrolled movement by turning the front wheels
toward the embankment or windrow
 Chocks are to be used where a V drain is not present – Empty trucks only
3.8.8.2 Routine Stopping and Parking

When stopping and parking the haul truck, perform the following procedures in sequence.
1. Use the retarder to slow and bring the haul truck to a stop in a safe or designated area with
sufficient clearance on each side.
2. Move the transmission selector to the Neutral position.
3. Set the park brake switch to on.
4. Move the retarder lever to the off position.
5. Switch off all lights and electrical service.
6. After five minutes idle period, switch off the engine ignition and remove the key.
7. Report any known defects.
3.8.8.3 Stopping with the Secondary Brake System

The secondary brake is used to provide emergency braking if the low air pressure alarm
sounds, the indicator illuminates and the service brakes are inoperative.
Depress the secondary brake pedal and hold it down until the haul truck stops.
Note : After an emergency stop, do not operate the haul truck until a complete check
has been made of the entire braking system and any necessary repairs have
been completed.
Emergency braking and parking is discussed under the heading, Driving the Haul Truck later in
this manual.
3.8.8.4 Short Term Parking

When parking for a short term, i.e. at the loading unit or tip, your truck must be at least one truck
length behind, slightly to the left and stop in the line of vision of the rear view mirror on or offside
of the truck in front.
You must remain in the seat in the cabin with load / wheel brake lock applied.
Note : If you can see one of the mirrors of the truck in front then you can be seen.
3.8.8.5 Long Term Parking

Operator out of cab park brakes must be applied.
Trucks are to be parallel parked next to each other at the designated park up or as per site
procedures.
There must be at least a 3-metre space between parked trucks.
Many park up areas have a V drain for the front wheels of the truck to provide extra security
against uncontrolled truck movement.
Reverse Park Up Area – Aerial View
The numbers in the above image indicate the reverse parking sequence of the trucks. This
ensures that a truck previously parked is visible to the truck being parked.
Do not reverse park when trucks are parked on your blind side.
Reverse Park Up Area – Normal View
Forward Park Up Areas

Many park up areas allow for driving forward to park and driving forward to leave the area. This
is the preferred parking method where possible due to greater visibility when moving in and out
of the park up areas.
3.8.8.6 Fundamentally Stable Parking

It is sometimes necessary to park a truck due to a fault with the truck or an emergency. In these
instances it may not be possible to apply the standard short or long term parking procedures.
However, it is necessary when parking the truck to ensure that it is always parked in a
fundamentally stable state. This is defined as a state in which the truck cannot roll in either
direction.
The test for fundamental stability is stopping the truck on flat level ground wherever possible
and applying all brakes with the engine still running. Place the truck in neutral and release all
brakes. If the vehicle is in a fundamentally stable state it will not roll when the brakes are
released.
After testing for stability, return the truck to a safe state by reapply all long term parking brakes.
Warning : Do not use the retarder for parking.
Fundamental stability can be achieved by:

 The truck’s front or rear wheels being driven into a ditch
 The truck being parked at a designated park up
 Parking the truck against a windrow
 Using wheel chocks – this only applies when the truck is empty and the truck is parked
on level ground
Warning : Chocks do not hold a loaded truck or a truck parked on an incline.

Under these circumstances the Operator must remain with the truck, in the cab,
until a stabilising windrow has been tipped in front of or behind the truck as
required and a test for fundamental stability has been successfully completed.
Except in an emergency or a breakdown, trucks should not be parked on inclines. In these

circumstances fundamental stability can sometimes be achieved by parking up against a
windrow or by having a suitable amount of material pushed up to hold the truck, i.e. a bund-wall.
When parking against windrows ease the truck tyre against a windrow and ensure the windrow
is substantial and free of tyre damaging material.
Warning : When parking a truck in an emergency situation do not turn off the ignition or
electrical power.
3.8.8.7 Braking
3.8.8.8 Braking Systems

Haul trucks have four separate systems used for braking.
These are:
 Retarder
 Service
 Secondary
 Parking
Mechanical Haul Trucks

The above four braking systems generally applies the brakes to all four wheels.
Electric Haul Trucks

The following illustrations show how the various braking systems act on the truck’s wheels.
3.8.8.9 Emergency Braking

If an emergency situation occurs requiring the haul truck to be stopped immediately, perform the
following procedures.
Mechanical Haul Truck

Apply the service brakes. If this does do not stop the truck, apply the secondary brake until the
truck comes to a complete stop.
Electrical Haul Truck

Apply service brake with one firm application until the truck comes to a complete stop.
Parking After an Emergency Stop

When the truck has come to a complete stop:
 Turn wheels left hand down into the windrow or high wall
 Apply brakes for long-term parking, i.e. wheel brake lock, load brake and park brakes
 Ensure truck is fundamentally stable
 Activate hazard lights
 Notify your position and emergency details using the two-way radio
Emergency Windrow Parking – Down Hill
The haul truck is shown with the front wheels turned towards the windrow.
Emergency Windrow Parking – Up Hill
The haul truck is shown with the front wheels turned towards the windrow with the rear wheels
also towards the windrow.
3.8.9 Retarder Controls
3.8.9.1 What is a Retarder?

A Retarder is a complex braking mechanism use to slow the haul truck in a controlled and
sustained manner using the truck’s brake system / power train to maintain engine speed at a
constant rpm to protect the engine from over-speeding.
3.8.9.2 Retarder Operation in a Mechanical Drive Haul Truck

Mechanical haul trucks are equipped with manual and automatic retarder controls and power
shift transmissions.
3.8.9.2.1 Approaching a Downgrade

Before approaching a downgrade, especially with a loaded truck, select the transmission gear
range that limits the truck’s speed to a point where the retarder can be safely applied. This
prevents over-speeding of the power train and excessive use of the service brakes.
When selecting a gear range to descend a grade, remember that the retarder is most efficient
when the converter is in direct drive (lockup).
Select a gear range that allows the converter to go into direct drive before the retarder is
applied. This may not always possible, but it is the most efficient method of using the retarder.
When a grade is descended, select the appropriate gear range and move the retarder lever to
the full-on position to produce the most effective braking action. Hold the lever in the full on
position until the downhill speed of the truck has been reduced to a safe speed.
Note : The transmission can be up-shifted or downshifted with the retarder fully or
partially activated. However, when downshifting, the converter must not be in
direct drive (lockup).
3.8.9.2.2 Calculating the Gradient

To select the appropriate gear range, the downgrade percentage must be considered.
The following chart illustrates the grade percentages and the recommended gear changes.
Using an example from the chart, a truck approaching a 13-16% grade is in first gear range and
the retarder fully activated. This allows you to maintain control of the truck.
This chart is a guideline only. Variations in road construction, road conditions, traffic, weather
and other factors may make it necessary to select a different gear range than the chart
recommends.
The retarder may be applied in any range. However, the lower the range the greater the braking
affect. If a grade less than 13% is encountered, select the second gear range with the retarder
fully activated and the service brakes used intermittently, if necessary, to maintain control of the
unit.
A grade of more than 20% is extremely hazardous and must be approached with extreme
caution.
Warning : The retarder control lever is to be always in the off position whenever the truck
is operating on a level road, going up a grade, or is at a standstill with the
engine running.
3.8.9.2.3 Downgrade Retarding

Always keep the transmission in gear. Transmission controls prevent shifting from forward gear
to neutral or reverse at ground speeds greater than 5 km/h.
If you attempt to stay in a lower gear on a long downgrade by retarding you may be
unsuccessful because engine speed may reach the up-shift point. The resulting lower engine
speed reduces brake cooling oil flow and may cause brake overheating.
The transmission up-shift point is raised to a higher rpm than the normal shift point whenever
the service brake or retarder is applied.
Remember to closely monitor the retarder temperature and reduce road speed by shifting to the
next lower gear if the temperature rises above the normal operating range.
3.8.9.2.4 Automatic Retarder Control

The Automatic Retarder Control is activated by moving the control switch to the on position.
This allows the transmission to up-shift to the gear selected by the transmission selector lever.
The automatic retarder control governs the engine speed in the selected gear. When the engine
speed is between 1850 and 1950 rpm, the ARC applies the brakes, as necessary, to maintain
the engine speed.
The brakes are not to be applied when the engine speed is below 1800 rpm.
The Automatic Retarder Control can be overridden at any time by depressing the accelerator
pedal, applying the manual retarder lever or pressing on the service brake pedal.
Note : For correct operation of the Automatic Retarder Control, the switch remains on
during all normal operation. Select the correct gear for the grade, load and
ground condition.
3.8.9.2.5 Slowing
The correct procedure for slowing the haul truck is by using the retarder and downshifting in
coordinated movements. The throttle must not generally be used while the retarder is engaged.
However, in attempting to control the haul truck under slippery conditions (in case of a slide) it is
acceptable to use service brakes. Constant use of power against service brakes can result in
excessive brake wear.
The service brakes are capable of absorbing the large amounts of power required to slow the
haul truck, but only for a very short period of time. This braking capacity is reserved for
emergency situations and usually results in a rapid temperature rise in the brake cooling
system.
Judgement of distance and speed and anticipation of what the truck does before an emergency
situation arises must be mastered quickly.
3.8.9.2.6 Transmission Selection

First gear (torque converter drive) is engaged when the transmission selector lever is moved
from neutral to first (or any desired higher speed) with the haul truck stopped and the engine at
low idle.
As the engine is accelerated and ground speed increases, the transmission automatically
up-shifts. The lockup converter activates on each gear change.
Shifting is governed by ground speed. Therefore, moving the transmission selector lever to a
higher gear while in motion does not force an up-shift. When ground and engine speed are
reduced, by increased load or deceleration, the transmission automatically downshifts one gear
at a time to select the correct gear. A downshift inhibitor prevents forced downshifts.
Accidentally moving the transmission selector lever to a low gear while travelling, does not force
a sudden downshift.
Note : The haul truck must be stopped and the engine at low idle before changing
direction. After moving the shift lever, do not accelerate until the transmission
clutches engage.
The haul truck is equipped with a reverse transmission neutraliser that prevents reverse from
engaging with the hoist in the raised position. If the hoist lever is moved to the raised position
when the transmission is in reverse, the transmission returns to the Neutral position. If this
occurs:
 Depress the service brake
 Move the transmission selector lever to neutral
 Return the transmission selector lever to reverse
3.8.9.3 Retarder Operation in an Electric Haul Truck
3.8.9.3.1 Dynamic Retarder

Electric trucks have electrically operated dynamic retarders. This means the degree of
retardation can be directly controlled by the pressure applied on the retarder pedal.
Activate the retarder lever 10 to 14 seconds before the grade is descended to allow enough
time for the retarder to become fully activated. It might also be necessary to accelerate the
engine momentarily to remain in direct drive and maintain a constant speed while descending
the grade.
Increased pressure on the pedal increases retardation. When the retarder is applied an amber
caution light alerts oncoming traffic that the truck is in retarding mode and may decelerate.
When the retarder is applied the engine rpm automatically goes to a minimum of 1250 rpm and
maximum 1650 rpm.
A retarder grade speed chart decal is attached to the cab instrument panel as a guideline to
appropriate downgrade operation of a loaded truck.
You must become familiar with the chart to operate the retarder correctly and safely.
An example of a standard grade speed chart is illustrated below.
Before approaching a downgrade, especially with a loaded truck, adjust the Retarder Speed
Control (RSC) to a range that limits the truck’s speed to a point where the retarder can be safely
applied. This prevents over-speeding of the wheel motors and damage to the wheel motor
components.
It is good practice to apply the retarder at least 10 seconds before the downgrade is reached.
This maintains good control of the truck.
Warning : Do not try to control the truck speed by partially applying the service brakes, as
this leads to overheating of the brakes with a high potential of a brake fire. This
situation allows the truck to go into a dangerous overshoot condition.
You can safely control the truck on a downhill grade if the retarder is used effectively. It should
not be necessary to use the service brakes.
A grade of more than 20% is extremely hazardous and must be approached with extreme
caution.
3.8.9.3.2 Operating the Retarder Speed Control (RSC)

Engage the RSC by turning on and pulling out the yellow mushroom head switch on the shift
console on the 730E and 830E trucks and on the instrument panel on the 630E.
A light beside the switch or on the overhead console illuminates when the RSC is switched on. It
is recommended that the RSC be on at all times.
A rotary dial on the RSC panel provides decent speed control on a gradient. The RSC panel
monitors each wheel motor for wheel slip and automatically controls retarding to prevent
skidding and fish tailing. Experience will dictate the optimum dial settings for the various load
and speed conditions.
When switched on, the RSC can be controlled by the accelerator pedal. Releasing the pressure
engages the RSC and increased pressure disengages it.
The RSC can be switched on or off and the rotary dial can be adjusted at any time while
operating the truck.
3.8.10 Hill Starts

Hill starts need to be performed using caution, as Operators must avoid rollback regardless of
the type of truck being driven.
3.8.10.1 Mechanical Haul Trucks

The start process is:
 Pull down the retarder lever
 Apply the service brakes
 Release the park brake
 Engage forward or reverse
 Slowly release the retarder and increase the throttle (engine speed)
When you move the transmission control lever from neutral to any forward speed, first gear is
engaged. At low ground speeds, the truck is in torque converter drive.
When the engine accelerates and the ground speed increases, the transmission automatically
shifts up. During higher ground speeds of first gear and of other forward gears, the lockup clutch
engages placing the truck in direct drive. During gear shifting, the truck is in torque converter
drive.
3.8.10.2 Electric Haul Trucks

The start process is:
 Apply the service brakes
 Engage forward or reverse
 Push the override button
 Increase engine revs to around 1200 to 1300 rpm
 Slowly release the brake and use the throttle to increase engine speed
 When the truck is moving and the brakes are fully released, release the override
button
Note : Always refer to the OEM manual for your type and model of haul truck for
specific operating instructions.
3.8.11 Uphill Driving

The haul truck is capable of developing high power, but that power is only useful if the drive
wheels do not lose traction or spin. Therefore, the useable power is limited to the traction effort
that can be developed depending on the haul truck’s weight and the grade of the incline.
Some models of Caterpillar haul trucks are equipped with a Traction Control System (TCS) that
electronically monitors and controls wheel slippage. The TCS prevents the wheel spin that can
otherwise occur if low gears and high rpm are used when driving uphill.
However, increased performance can be obtained when driving up an incline by selecting the
highest possible gear to maintain a ground speed that is suitable for the surface conditions.
3.8.12 Reversing
General Guidelines
Reversing is a necessary operation that can be dangerous due to restricted visibility and blind
spots. Mirrors and back-up alarms provide some level of protection and having a spotter
working with the driver also decreases the potential for backing accidents.
Sound the horn three times to indicate that the truck is about to reverse.
Extreme care must be exercised and it is the driver’s responsibility to ensure that the area they
intend to reverse into is clear.
Reversing without the aid of a spotter is only permitted at crushers, tip heads, loading units and
designated park ups.
Before attempting to reverse, check through left and right rear vision mirrors, if in any doubt
physically check that the area into which the truck is to be reversed is clear of personnel and
equipment.
If you are required to reverse into a confined area, maintain a minimum clearance on the onside
of the truck where there is greatest visibility. You can then be confident that there is sufficient
clearance on the offside of the truck. During the reversing operation, continually monitor the off
side mirror to ensure that no obstructions are present.
You must become proficient in judging distance and accurately positioning the haul truck under
the loading unit or excavator using the rear-vision mirrors.
Note : When reversing outside normal operations a Spotter must be used.
Retarding in Reverse
Retarding effort is severely limited and must not be relied upon when reversing the truck. Keep
reversing speed in the service brake range of 5 km/h.
Reversing Over a Distance

There may be occasions when the haul truck is required to reverse for some distance into a
tight load-out area.
Usually the path in is reasonably straight, but where a straight run is not possible, you may have
to negotiate bends and obstacles. Maintain minimum clearance with the near side (Operator
side) so that you can be confident that there is sufficient clearance on the offside of the haul
truck.
Continually check the offside mirror when performing this manoeuvre to ensure that no
obstructions are present.
3.8.13 Wet Road Conditions

Warning : Mechanical Trucks – Applying the retarder on a slippery road can cause the
wheels to lock up and the transmission to down shift. This can cause serious
damage to the power train.
Gradually apply the retarder control lever on slippery roads to prevent the
wheels from locking and the transmission from down shifting.
3.8.14 Fuel Consumption

Some simple causes of high fuel consumption are:
 Driving faster than is necessary
 Heavy acceleration when starting off, particularly when loaded
 Incorrect use of the braking system
 Excessive revving when tipping
3.8.15 Tyre Wear
3.8.15.1 Speed
Excessive speed, particularly when loaded:
 Causes heat build-up in the tyres, leading to ply separation that contributes to a
reduction in the tyre’s serviceable life
 Increase in the possibility of a tyre overheating and catching fire
 Requires heavier braking leading to increased tyre wear, possible damage and a
reduced tyre life cycle
3.8.15.2 Manoeuvring
When travelling straight, a loaded haul truck’s weight is distributed evenly over all wheels.
However, in a turn, weight is transferred to the outside steer tyre, e.g. When turning right, the
left steer wheel carries more weight.
The weight transfer to the truck’s tyres increases with tight turns and higher speeds. This
causes the tyres to distort, the outer walls to bulge and become more exposed to stones, which
can either cut or bruise the tyre walls causing internal fractures. A tyre with internal fractures
heats up quickly under load with a greater potential for failure.
If you identify a haul truck with a flat tyre, you must immediately notify the haul truck Operator of
the situation by radio. The haul truck Operator must park the truck in a safe area and advise the
Supervisor that assistance is required with a tyre problem.
3.8.16 Minimising Equipment Damage and Wear

Steady and consistent driving maintains an acceptable level of operating safety, production
efficiency and care for the haul truck.
To minimise undue wear and possible damage to the haul truck, where possible, avoid the
following operating conditions.
Excessive speed
This causes:
 Increased fuel consumption
 Heavier braking
 Increased tyre wear
 Increased vibration and strain on the truck
Violent Manoeuvring
This causes increased:
 Tyre wear
 Strain on the steering and suspension components
 Risk of load spillage
Excessive acceleration from stationary

Especially when loaded this causes:
 Tremendous strains on the transmission and final drive components
Over Revving the Engine

This causes:
 Increased engine wear
When operating the hoist, over revving places tremendous strain on the hoist ram glands and
seals when they reach the limit of travel under full power.
Heavy Braking
This causes:
 Increases tyre wear
 Tremendous loads on suspension components
 A high risk of tyre damage, suspension and body damage, especially when driving
over dirty ground
Mechanical Trucks – Changing from Forward to Reverse while in Transit

Ensure the truck is completely stopped and the engine is at low idle before moving the
transmission lever between the forward and reverse directions.
After moving the shift lever, do not accelerate until after hearing or feeling the transmission
clutches engage.
If the transmission is in forward gear and reverse is selected, the truck remains in forward gear
until 8 km/h is achieved when the transmission selects neutral. When the road speed is below
3km/h, reverse is engaged.
Electric Trucks - Changing from Forward to Reverse while in Transit

If the propulsion control switch is used to change from a forward to a reverse direction while in
transit, an electrical contractor flashover occurs inside the cabinet. To prevent this from
happening, the haul truck must first come to complete stop and only then can the direction
switch change from a forward to a reverse direction.
3.8.17 Spotting
Refer to site procedures for specific spotting practices. The following information is typical, but
may vary across sites.
3.8.17.1 Day time from Ground

Spotting from ground is only to be carried out when absolutely necessary due to the danger of
falling rocks and tyre bursts or explosions.
The Spotter instructs the truck driver of his requirements either by radio or in person. The
Spotter must be in clear view of the truck driver at all times or the truck must stop immediately
vision is lost.
The Spotter must ensure adequate distance is kept from the truck to avoid injury from falling
rocks. The Spotter uses a hand stop signal to stop the truck.
3.8.17.2 Night
At Night the Spotter must be in a position to be seen clearly by the truck driver and must have
an operational torch and reflective clothing.
The Spotter indicates to the truck driver to keep reversing slowly by swinging the torch light
beam in a back and forth motion on the ground alongside his / her body.
The Spotter indicates to the truck driver to stop by changing the motion of the light beam
movement to back and forth across his / her body.
If for any reason the torch goes out, the driver must stop immediately.
The torch beam must not be shone into the truck mirror as a signal to stop.
Note : If you cannot see the Spotter, stop immediately until the Spotter is sighted.
3.8.18 Maintenance Workshop Areas
3.8.18.1 Driving in and around Workshops

When driving in and around workshops:
 Trucks must be at low idle (below 8kph) entering the truck shop at all times
 Always use horn signals around workshop areas
 Obey the speed signs and drive to conditions
 Do not enter or exit truck bays unless guided in and out by a Spotter
 Always use the service brake and not the dynamic retarder when inside the truck shop
 Apply long-term parking, idle truck down and chock the wheels when in position
3.8.18.2 Spotting at the Workshops

A spotter is required to assist the haul truck Operator when manoeuvring around and in and out
of the maintenance workshops due to visibility restrictions.
It is important when you are manoeuvring the haul truck under the guidance of a spotter that
you only accept hand signals from one person.
Prior to any movement, you and the spotter must discuss the process that will be used and have
a full understanding of the task. A risk assessment can be completed if required.
Note : When guiding a haul truck in and out of the workshop, the spotter has the
authority. If there is any confusion, you are to stop the operation immediately.
This diagram illustrates the required positioning of the spotter in relation to the haul truck cabin
when entering and exiting the maintenance workshop.
Haul Truck Leaving Workshop
3.8.19 Efficient Operations

Efficient operations contribute to overall productivity while maintaining safety.
When operating the haul truck:
 Show initiative – maintain safety standards while maximising productivity
 Be alert for hazards while operating the haul truck
 Act promptly on instructions, e.g. in queue lines
 Monitor the truck operating system and react to hazards promptly
 Anticipate problems and act before problems occur
 Cooperate with personnel involved in your work program
 Be proactive – recommend and act on improvements to your work procedures
 Act professionally at all times
Section 4 Load, Haul and Tip Materials
4 Load, Haul and Tip Materials
4.1 Essential General Information
4.1.1 Loading Area Movements

When approaching and leaving a loading unit it is important to be aware of:
 On-foot personnel
 Other vehicles, e.g. light vehicles, dozers and trucks
 Cable boats and mats
 Spillage, e.g. large rocks
 Lighting plants
 Lasers
Whenever possible approach the loading area in a clockwise direction. When a clockwise
direction approach is not possible communicate the change in direction to all vehicles within the
vicinity.
All trucks are to follow the same loading area entry and existing pattern.
As the front truck moves under the loading unit, the next truck in the queue moves up to occupy
the vacant position.
Be aware that a loaded truck has increased:
 Instability
 Stopping distances
 Truck lean and tyre roll when cornering
4.1.2 Loading Area Signals

Operators of loading units direct the movement of haul trucks in the loading area by sounding
their horn.
The following signals are used:
 One short blast – Stop the truck under the loading unit bucket – indicates that the
truck is in the right position
 One long blast – Indicates that the truck is loaded
 Two long blasts – Indicates that the truck is in the wrong position
4.2 Haul Truck Cycle Times and Operating Efficiency
4.2.1 Overview
Efficient operation of a haul truck requires teamwork based on:
 Site operating procedures
 Understanding of each truck’s role
 Effective communication
Efficient haul truck cycling has a direct impact on mine production. A small saving in time
equates to a major savings over the course of a shift or longer period of operation.
A Competent operation minimises safety concerns, damage and downtime while contributing to
high mining efficiency.
4.2.2 Cycle Time

Cycle time is the time required to load a haul truck, travel to the tip head or crusher, tip the load,
and travel back to the loading point and position for loading under the loading unit.
The number of haul trucks operating from a loading unit is determined by the:
 Tonnes per hour the loading unit can load
 Cycle time for the haul trucks
 Haul truck load capacity
Where the lead (distance) to the tip point is short, the cycle time is reasonably short, so only a
small number of trucks are required to keep up with the loading capability of the loading unit.
If there is a long lead to the tip point or a long slow climb out of a pit, the cycle time is much
longer requiring more trucks to keep up with the loading unit.
The loading unit sets the pace at which the haul trucks can be loaded. An efficient haul truck
Operator travels to the tip point and return to the loading unit just in time to be loaded again.
Loading Area Cycle
4.2.3 Loading Efficiency

The time it takes you to react to an instruction is very important to maximising cycling efficiency.
The following statistics indicate how important this concept is during loading. If you save 5
seconds per load by being alert to the instructions of the loading Operator to approach the
loading position, you save:
 5 seconds x 120 loads per 8 hour shift = 10 minutes per 8 hour shift
 10 minutes per shift x 3 shifts per day = 30 minutes per day
 30 minutes per day x 7 days per week = 3.5 hours per week
 3.5 hours per week x 4 weeks per month = 14.0 hours per month
 14 hours per month x 12 months per year = 7 days per year
If the digger excavates 20bcm per day, this equals 140bcm per year.
(bcm is Bank Cubic Metre – a cubic metre of rock or material in situ before it is extracted.)
4.2.4 Hauling Efficiency

For efficient haul truck operations, the key words to remember are STEADY and CONSISTENT.
All haul trucks are to be travelling steadily, evenly spaced out and circulating consistently
without bunching up. Operators must avoid situations where the loading unit is sitting idle.
Considering that a loading unit’s capacity is hundreds of tonnes per hour, the amount of lost
production is significant every time the loading unit sits idle waiting for a haul truck.
A skilled haul truck driver takes into account the activities of all equipment in the group;
communicates with them and varies cycle times in order to maintain a steady and consistent
operation so the loading unit does not become idle.
If possible, refuelling should be timed during the return haul trip, in slow periods or on
instructions from your Supervisor.
Delays do occur from time to time, e.g. when dozers are cleaning up loading areas or
maintaining tip heads.
Note : It is a mistake to believe that it is efficient to drive a haul truck from the loading
unit to the tip head and back as fast as possible. This simply results in the haul
truck ending up in a queue at the loading unit (i.e. under trucking) and / or tip
(i.e. over trucking). Both situations are counter-productive.
4.2.5 Tipping Efficiency

The ideal target time for tipping is one minute. This includes an additional margin for safe
operation in hazardous or difficult tip areas. You can improve your tipping efficiency by:
 Manoeuvring as close as possible to the tip head to tip the load
 Avoiding short tipping at the tip head
 Positioning the truck in the correct tipping position at the first attempt
 Adjusting to the properties of the material being tipped. This could be:
 Shaley material – easy to tip but tends to slump at the tip edge, posing a tip
hazard
 Blocky material – forms a good base for tipping and a solid tip edge
 Clay – sticks in the truck body, therefore is difficult to tip, especially if wet – Clay
forms a slippery surface when wet and may be hazardous at the tip edge
 Wet material – not to be tipped over tip heads because it sticks to the tray and
slumps at the tip edge
 Minimising the use of the clean-up dozer at the tip site by ensuring that the full load is
tipped over the tip head
4.3 Queuing
4.3.1 Queuing Safety

The safety points that must be followed when the haul truck is in a queue are:
 Park clear of high walls
 Park clear of the loading unit’s swing range
 Loaded trucks are to be parked with hazard lights on
 Only park on level areas
 Always check the immediate area before moving off
4.3.2 Queuing Procedure

The queuing procedures for haul trucks at all times are:
 The haul truck at the front of the queue must keep as far to the right as possible
 Queuing haul trucks are to line up slightly to the left of the haul truck in front and a
minimum of one haul truck length behind
This allows the Operator in front to observe any haul trucks that have queued behind.
 Maintaining the arrangement in the queue by moving forward and right as haul trucks
move off to be loaded
 If haul trucks cannot safely queue by lining up behind one another, the haul trucks are
to be positioned parallel to each other and slightly ahead of the truck on the left
Positive communications must be adhered to between loading unit Operator and truck Operator.
If a truck Operator is required to reposition, a positive two-way communication between the
loading unit Operator, truck Operator and any other trucks that are queuing including ancillary
equipment in the exclusion zone, must be made.
If the truck needs to reposition positive communication must be made prior to returning to the
back of the queue.
Warning : Never reverse the haul truck while in a queue.
4.4 Loading Techniques
4.4.1 Overview
Loading is carried out by front-end loaders, excavators or loading units. All loading methods
follow an established circuit in the mining area and are designed to ensure maximum
productivity, efficiency and safety when loading.
Some of the preferred methods are using the double-sided loading system and the modified
drive-by loading system.
Loading can be carried out from either side of the truck and are defined as:
 On-side loading
 Off-side loading
4.4.2 Loading Precautions

The precautions to be observed when conducting loading operations are:
 Remaining inside the Operator cabin during loading operations
 Ensuring that window is up
 Leaving the seat belt fastened
 Watching the payload indicator at all times
 Not exceeding the truck’s rated capacity
 Not moving off until signalled to do so
 Keeping a lookout for rocks and spillage that can damage tyres – if necessary have
the area cleared
 Avoid churning up the loading area with sharp turns and spinning wheels, especially
when the ground is wet
 Using your mirrors constantly during reversing procedures
4.4.3 Overloading
Productivity cannot be increased by overloading the truck. Overloading adversely affects the
operation of the truck in a number of areas including suspension, retarding ability, braking
capacity and general truck performance.
The small gain made with increased load is usually lost with the reduction in truck performance.
It also adds to fuel costs and increases maintenance costs.
Tyre performance and service life are particularly impacted by overloading. Earthmoving tyres
are rated by the manufacturer at a maximum tonne - kilometre per hour rating, which is a rating
of the level of heat build-up a tyre can sustain before heat related failures such as separation of
the plies occur.
4.4.4 Oversize Rock Loading Precautions

The excavator Operator notifies you if oversize rock is to be loaded in your truck. You have the
option of staying in the cabin or leaving.
If you elect to leave, ensure that you are well clear of the truck before loading commences.
Remain in clear view at all times.
The excavator Operator places fine material into the tray before loading the oversize material.
The load is placed so that the truck is stable when hauling the load.
The loading of oversized rocks is not practiced at all sites.
4.4.5 Positioning a Truck for Loading

When joining the queue, move slightly to the left to ensure rear view mirror vision of the truck in
front is maintained.
Do not move forward in the queue until the truck in front has stopped.
To start the loading process, park your truck facing the truck being loaded remaining at least
one truck length away and wait until the loaded truck leaves.
Proceed towards the rear of the loading unit so the truck is at a 45-degree angle when the
loading unit reaches its loading position.
The loading unit Operator indicates when ready to load your haul truck by placing its full bucket
in the air in the position where the loading unit Operator requires the haul truck tray to be
positioned. (Site-specific procedures may vary for this manoeuvre.)
Carefully reverse into the required position under the loading unit’s bucket.
Communicate with the loading unit Operator to determine the truck’s position along the pit face.
Warning : Always use your mirrors to ensure that the bucket is high enough to clear the
tray.
When your haul truck is correctly positioned under the bucket, the loading unit Operator sounds
one blast on the horn for you to stop the haul truck.
The loading unit Operator allows between one and two metres stopping distance, so there is no
need for a hard application of the service brakes.
When positioned under the loading unit, set the transmission in neutral, apply the park brake
and release the service brake to initiate the load indicator lights.
The loading unit indicates when the tray is full with one long blast of the loading unit’s horn.
This image below shows a truck that has travelled too far past the loading unit at 90 degrees.
This error increases cycle time and is not an effective way of backing.
4.4.6 Loading with Loading Units
4.4.6.1 Overview
A loading unit is not mobile when loading, making the positioning of the truck in relation to the
loading unit dipper arm important for efficient loading.
When the bucket is full, the loading unit Operator spots the truck so that loading commences as
the truck reverses into position.
Different techniques are required depending on the loading method used.
The loading methods are:
 On-Side Loading – This is the Operator cabin side of the truck, i.e. Left Side, also
known as the Near Side
 Off-Side Loading – Right side of the truck
 Single Sided Loading – This can be either side of the truck, but is typically the On-Side
 Double-Sided Loading – When trucks are loaded alternately using both sides of the
loading unit
4.4.6.2 Onside Loading

The loading unit loads the truck from the left side.
When reversing under the loading unit dipper on the onside, align the dipper trip-lever
counterweight or the white stripe painted on the dipper handle with the side of the body.
The truck Operator uses the onside mirror to reverse back under the loading unit. The onside
window may need to be opened slightly to hear the loading unit’s horn.
When the truck is correctly positioned the loading unit Operator loads the first bucket of
material.
4.4.6.3 Offside Loading

The loading unit loads the truck from the right side.
Follow the same procedure as for onside loading, being extra cautious during reversing and to
ensure the blind spots are clear.
Line-up the loading unit bucket teeth with the top of the side of the tray.
Reverse back so that the bucket disappears into the tray.
Keep watching through the offside mirror and listen for the horn blast from loading unit.
4.4.6.4 Single-Sided Loading

If there is a truck being loaded, park in a position no less than one truck length away from the
truck being loaded. After the loaded truck has departed, drive into a position approximately 1.5
truck lengths in front of the fixed loading position and reverse under loading unit.
The illustration below shows the truck movement during a single-sided loading operation. The
truck must approach the loading unit opposite to the loading unit’s direction of dig.
4.4.6.5 Double-Sided Loading

Double-sided loading is used whenever possible because it is considered the most productive
system of operation.
The loading unit is positioned with the tracks at 90° to the face and advanced directly into the
face as material is removed. This operation is particularly suited to high face heights and a large
number of trucks with little or no loading unit relocation over the shift.
With trucks positioned on each side of the loading unit, the loading unit can load with virtually no
interruption and not exceed 90° of swing for each truck. Clean-ups are done during the load
cycle with little or no disruption to loading unit and haul truck productivity.
Trucks are required to spot without the aid of the loading unit and are usually positioned below
the boom point swing path within 90° of loading unit swing.
Inefficiency can affect the high productivity normally achieved with this system if the haul trucks
spot either inside or outside of the boom point swing path. It is also important for the trucks to
spot parallel to the loading unit tracks. Poor load distribution and excess spillage can result from
trucks being incorrectly positioned.
Cycle times for the loading unit and truck are affected when repositioning is required. The
double-sided loading system is less productive with low face heights and insufficient trucks to
ensure continuous loading unit operation.
Low face heights mean that the loading unit must relocate more frequently. Reduced truck
numbers, with higher truck manoeuvring time required, results in waiting time for the loading
unit.
Warning : Remain inside the cab during loading, seated and with seat belt fastened.
4.4.6.6 Modified Drive-By Loading

The parallel approach or modified drive-by loading system is the best alternative if the optimum
conditions of double-sided loading cannot be fulfilled.
Instead of working into the face, the loading unit traverses the face, removing material at less
than the maximum digging radius. The trucks are positioned parallel to the strike with the
outside track positioned outside the toe of the face.
The loading unit digs at a maximum of 45° to the left or right of the inside track, depending on
the direction of travel. The conditions required for modified drive-by operation are low face
heights with the loading unit moving along the strike as material is removed, completing these
moves in very small increments without affecting production.
Trucks are loaded from one side only and are usually spotted with the loading unit within 90° of
loading unit swing.
The main advantage of this system is high production with a relatively low number of trucks, as
time is saved during truck manoeuvring and by spotting with a full bucket. Interference to the
truck flow by the clean-up dozer is also reduced, as less clean-up is required because of the
number of loading unit movements.
A large percentage of spillage is cleaned up after the loading unit and trucks have passed.
The truck approach circuit for this system is opposite the direction of dig, reducing the
manoeuvring time required when positioning the truck. While one truck is loading, the following
truck parks one truck length from the unit being loaded.
When the loaded truck has departed, the following truck can move into position approximately
1.5 truck lengths from the loading unit and wait to be spotted by the dipper.
4.4.7 Loading with Front-End Loaders
4.4.7.1 Overview
The front-end loader stands out from the face to enable the haul truck to reverse into the correct
position without obstruction. The loader Operator indicates readiness to tip the load by raising
the bucket over the tip position.
Carefully reverse under the full bucket ensuring that the haul truck is square to and
approximately one metre from the front wheels of the front-end loader.
Stop as the loader tips the first bucket of material and remain in that position during loading.
Leave immediately when instructed to by the loader Operator.
Do not self-spot when loading from a front-end loader. The risk of collision is too high when
working on the same level.
4.4.7.2 Onside Loading

The loading unit loads on the left side of the truck.
Truck to reverse under bucket pivot point (dog bone) and square with tyres, the onside window
may need to be opened slightly to hear the loading unit’s horn. When being double side loaded
the truck always reverses under the loading unit on the onside (follow instructions from the
onside loading unit)
4.4.7.3 Offside Loading

The loading unit loads on the right of the truck.
The truck Operator uses the mirror on the offside to reverse back under the loading unit.
The truck Operator may be required to open the side window slightly in order to hear the loading
unit’s horn.
Great care and attention must be applied whenever reversing offside to a loading unit.
4.4.8 Loading with Excavators
4.4.8.1 Overview
Excavator Operators use top loading or bottom-loading techniques to load haul trucks,
depending on the digging configuration.
The reversing techniques used under the excavator are very different to those used under
loading units and loaders.
The most significant difference is that the Operator has to line up the excavator’s bucket in the
centre of the tray, usually without the assistance of bucket pins to guide alignment.
When the excavator is sitting up on a bench the onside of the truck can be lined up with the
outside of the excavator Operator’s cabin or the work light or horn just below the cabin.
Reverse back until the excavator’s horn sounds, stop prior to rear wheels climbing up the face
or running over rubble.
Occasionally, circumstances can prevent the excavator Operator presenting the bucket by the
standard methods. If this occurs, the excavator Operator gives verbal instructions over the two-
way radio. If you are unsure about anything ask the excavator Operator or your Supervisor.
Various procedures for excavator and truck interaction are illustrated in the following diagrams.
Loading Through the Rear
With this type of loading the Operator informs the driver to line up on the teeth or come in on the
teeth. This means reversing back on a 45° angle, lining up the onside of the truck tray with the
line of teeth on the bucket of the excavator.
Reversing to Cabin
Reversing to the Teeth
4.4.8.2 Top Loading

Top loading with an excavator is one of the most hazardous loading techniques and requires full
concentration by both the excavator Operator and the truck Operator.
Haul trucks are top loaded when the excavator and haul truck are on the same level. The top
loading technique is generally used when the cut is too deep to dig in one pass. Top loading
may also be used when the trucks are experiencing difficulty pulling out from the face or when
the material is unsuitable on which to drive the trucks.
Because of the increase in swing and lift time as compared to other methods, top loading is not
the preferred loading method and is only to be carried out when necessary.
The principal risk of this configuration is collision requiring extra care when reversing into
position. The excavator Operator indicates whether the loading is to be carried out using the 45°
or 90° method.
A berm (earth wall) is always present to indicate the correct spotting point. The loading zone is
to be kept clear of rocks and other material to prevent excessive tyre wear and provide a clear
path for the haul truck to move into position.
Whatever the loading configuration, be alert, concentrate on the job and look for potential
hazards.
4.4.8.3 Top loading at 45 Degrees

Depending on the bench height, 45° loading may be safe and productive.
With this technique, the excavator is able to swing through the rear of the truck body. To load
the truck, wait until the excavator has spotted the bucket and then line up the side rail of the
truck with the bucket teeth to put the truck into position.
Reverse in until you hear the excavator horn or a telemetry signal.
4.4.8.4 Top loading at 90 Degrees

If the haul truck is to be loaded at 90°, line up the truck with the teeth on the bucket.
At night, use the lower left side cabin light as a guide. Reverse in until you hear the excavator
horn or a telemetry signal.
4.4.8.5 Bottom Loading

Bottom loading of the haul truck is carried out when the excavator is operating from the top of
the bench and the haul truck is positioned on the floor beneath.
The excavator Operator may position the truck at 45° or 90° for loading. The floor is cleaned as
the bench is dug to prevent trucks from reversing over rocks or material spillage while accessing
the loading point.
The bottom loading technique requires you to reverse up to the face. Reverse until you feel the
berm against the rear wheels and hear the excavator horn to stop.
Alternatively, reverse against the berm and stop on the telemetry signal.
Ensure that you do not run the rear wheels or tray up the digging face or have the rear wheels
sitting up on rocks or the toe of the face.
Note : Apply the park brake while the truck is being loaded, not the retarder.
Often a newly developed bottom loading excavation is not wide for a truck to turn. Under these
circumstances it is necessary to turn the truck outside of the loading area and reverse down to
the excavator.
When working in narrow cuts it is often necessary to turn close to the cut edge. Under these
circumstances keep a special lookout for loose stones that can damage tyres and be mindful of
the clearance required by the stairwell (if fitted).
Note : Trucks must not try to turn on an angle under the bucket when in a drop cut.
Trucks must reverse straight down following the sidewall until the correct floor level has been
achieved and the truck can leave the loading unit safely.
Maintain correct speed and control of truck using retarder / dynamics.
Lock the transmission in first gear (mechanical drive) when leaving the loading unit until the
truck is clear of the ramp.
Warning : Do not try to turn a loaded truck on the ramp due to the risk of truck rollover
and spillage.
Avoid self-spotting during bottom loading as this practice in very unsafe and can lead to
expensive truck damage.
4.4.8.6 Bottom Loading 45 Degrees

Reverse the haul truck into position at 45° from the excavator. The back-in position is
determined by the excavator Operator.
4.4.8.7 Bottom Loading 90 Degrees

Reverse the haul truck into position at 90° from the excavator. The approach may be from the
left or right of the excavator.
Loading and Waiting Positions
4.4.8.8 Drive-By Loading

Drive by bottom loading is only used when the loading zone is in a tight spot and the bench
width is narrow.
This method is generally avoided because of the exposure of the truck tyre walls to the safety
berm / rill as the vehicle is being moved into position.
To position the haul truck for drive-by loading, spot the truck so that your left shoulder aligns
with the counterweight on the loading unit and drive into position.
The excavator indicates the loading position by sounding the horn or a telemetry signal
indicating that the correct position has been reached.
4.5 Hauling
All the hauling functions of operating loaded and empty trucks has been discussed earlier in this
training module under several headings covering normal and emergency driving requirements
and conditions.
The following is an essential summary of normal operating requirements for haul trucks that are
always present and applicable between the loading and tipping functions.
During the hauling phase ensure that efficiency and safety are maintained at all times by:
 Using the established departure tracks out of the pit area
 Being aware of other traffic on the haul road, i.e. faster light vehicles
 Constantly using mirrors and maintaining observation in all directions
 Selecting the highest possible gear for maximum efficiency for the grade and surface
 Increasing the distance between trucks during wet and slippery conditions
When using the haul road:

 Travel on the left side away from the centre and avoid dropping the tyres off the main
formation
 Observe all speed and advisory signs
 Maintain a watch for haul road maintenance equipment, e.g. graders and water carts
 Remember graders on haul roads always have right of way
4.6 Tipping Techniques
4.6.1 Overview
Emptying a loaded tray is probably the most dangerous function of operating a haul truck. A
truck with a raised loaded tray could become unstable if the safety and operating procedures for
tipping are not strictly followed.
Warning : The truck must be level before unloading. If the truck is not parked on relatively
horizontal ground, the sudden change of weight and balance due to lifting of
the full tray can cause the truck to slide or in extreme circumstances, to turn
over.
There are various methods and situations under which you are required to tip a load. They all
have specific procedural variations to ensure the safety of personnel and to prevent damage to
equipment.
It may be necessary to refer to the OEM manuals for your truck model and type any specific
precautions or restrictions that may apply to the tipping process.
4.6.2 General Tipping Guidelines

The following are some general tipping situations and required precautions that can apply
across a variety of tipping locations.
Tipping During Daylight Hours

When tipping on the tip head during the day, start tipping from the lighting plant end or right
hand side as viewed approaching the tip head.
Continue to tip in the same area until a load appears on the windrow - then move along tip
head.
Tipping During Hours of Darkness

When working on a tip head during hours of darkness tipping is only to be done in the area
illuminated by a lighting plant. Always tip in the illuminated area.
Paddock Tipping
If trucks are required to paddock tip, (top tip) Operators need to ensure that the loads are butted
up close together and tightly packed. Avoid reversing up the tail of the previous load. If material
is rocky axle box and / or tyre damage can occur.
Running Out a Load

This practice places large amounts of stress on the truck and lift rams and is not recommended.
If it needs to be done a risk assessment may be required before tipping. Consult your
Supervisor if required.
Tipping Oversized or Rocky Material

If instructed to discontinue tipping at a tipping location due to oversize or rocky material and the
tray is already being raised ask your Supervisor for direction.
4.6.3 Operating the Tray
4.6.3.1 Tray Hoist Control

There are four tray hoist control positions.
These are:
 Lower
 Float
 Hold
 Raise
Lower – Fully Forward

Move the tip control lever to the lower position to lower the tray from a fully raised position.
When the tray starts to lower, release the lever. This reverts the system to the Float function
and allows the tray to slowly lower and settle on to the truck frame.
Float – Second Position

The Float position relieves hydraulic pressure in the hoist cylinders.
The lever is released from the Lower position during the lowering procedure to allow the tray to
settle on to the truck frame.
The tip control lever remains in this position when the truck is being driven.
Hold – Third Position

When the tip control lever is in the Hold position, all flow to and from the hoist cylinders is
blocked. Move the tip control lever to Hold, to stop and hold the tray at any position while it is
being raised or lowered.
Releasing the tip control lever at any time during hoisting automatically engages the Hold
function and the lever moves to the Hold position.
Raise – Fourth Position

Move the tip control lever to the Raise position to raise the tray. When you release the lever it
automatically returns to the Hold position.
4.6.3.2 Tipping a Load

With the truck in neutral and the park brake applied, move the control lever to the Raise position
and accelerate the engine to approximately 1500 rpm to raise the body.
Warning : When a loaded tray is being raised, a shift in the centre of gravity assists the
body to rise once it has gone past centre.
Do not release the lever from the raise position or the tray may self-raise and
cause voiding of the hoist cylinders. With no oil flow into the cylinders, the tray
may free-fall when the load has emptied, causing hoist cylinder and hydraulic
system damage.
At the last stage of hoisting, reduce engine speed to prevent the hoist cylinders from bottoming
out against the end of the cylinder shafts as this can damage the hoist mechanism.
Release the lever driving the final stage of hoisting. The lever moves to the Hold position and
the body remains raised.
Release the brakes and drive the truck forward slightly to clear the remaining material from the
body.
Warning : Never jump tip. This technique is dangerous and causes severe frame and body
damage. Using berms to stop the truck or applying the brakes in conjunction
with raising the body can cause body trunnion failure.
The tray comes down as you move the truck forward.

If the tray does not come down, you must contact your Supervisor.
Warning : When operating the truck the lever is to be in the Float position. Operating in
other positions cause hydraulic system damage.
4.6.3.3 Tipping Safety Procedures

The tip area is to be kept as level as possible in all directions to provide a stable tipping
platform.
Tip sites with an uneven ground surface can produce instability and rollover risks when a full
load is being hoisted into a tipping position.
The shift in the haul truck's centre of gravity, brought about when the wheelbase is inclined from
the horizontal, may be enough to upset the balance of the haul truck.
The safe operation of a haul truck while tipping includes:
 Not hoisting the body to the tip position whilst the wheels are positioned on uneven
ground
 Not tipping on wet or soft areas
 Remaining alert for signs of soft spots on the tip site that may collapse under the
wheels of a tipping truck and subsequently generate a body tilt problem
 Avoided tipping uphill as greater energy is required to lift the load and high loads are
imposed on the body trunnions and truck frame
 All traffic following the established circuit
 Only tipping in places indicated by the dozer Operator
 Not entering tips that are closed or blocked off unless specifically directed to do so by
the Supervisor
 Cycling clockwise when preparing to tip and cycling no closer than 10 metres from the
windrow at the tip head
Warning : Remember to stay focused on the complete tipping process because material
hang-ups combined with haul truck lean can caused haul truck rollovers.
Other safety precautions for raising a tray include:

 Checking that all personnel are clear of the truck and that there is adequate clearance
from other equipment and obstructions
 Not raising the body under overhead cables
 Not standing behind the body as it is being raised or after it’s raised because there
could be material hang-ups remaining in the tray that can dislodge causing serious or
fatal injuries
 Avoiding operating the truck with the body in the raised position - if the truck must be
moved with the body raised, it is to be on level ground with no overhead obstructions
and in first gear only
Warning : Never place yourself under a raised tray without first installing the body safety
cable.
Report the tray operation to maintenance if:

 It bumps when fully up
 The kick-out is not working
 The hoist pump emits a screaming noise
4.6.4 Tipping at Tip Heads
4.6.4.1 Tipping under Normal Conditions

Tipping can be a hazardous operation. It is important to know and follow the correct procedures
when approaching the edge of the tip head and when at the tip edge.
The procedures for operating a haul truck at the tip head and tip edge are described below.
1. Approach the tip in a clockwise direction. This puts the tip edge on the same side as the
Operator’s cabin (onside).
2. Drive parallel to the tip edge maintaining a 10-metre distance from the windrow. This
provides you with good visibility of the edge and you can examine the surface for potential
hazards, obstructions and overall stability of the tip edge.
3. Look for:
 Cracks
 Slumping
 Correct windrow height is half the tyre height of the largest haul truck using that
tip head
 Wet material
 General condition of the tip slope
 Any other potential problems
Always report defects to dozer Operator or Supervisor
4. Drive around the tip head to the furthermost tipping point available. This prevents tip head
congestion. Also note where other equipment is operating.
The tipping area on a tip head is indicated by markers, such as tyres or lighting plant.
Always tip between these markers.
5. Commence the tipping sequence from right to left when facing the tip edge.
6. Check the area chosen to reverse back into, ensuring there is no equipment operating or
going to operate in that area.
7. Tip in the same spot as the other trucks have been tipping, until there is one full load on the
top, this ensures the tip head remains straight when pushed.
8. Keep a minimum distance of ten metres from any other truck that is tipping.
9. Approach the tip edge from an angle instead of straight on and reverse in a manner that
allows the driver’s side rear wheels and the tip edge to be kept in view at all times.
10. While reversing, all other trucks must be on the open side and in clear line of vision at all
times. Occasionally a spotter must be used to guide you into position.
11. Reverse slowly to the windrow until the rear wheels evenly and gently touch the windrow.
Note : Never use the tip head windrows to stop the truck. They are there to indicate
the limit of the tip head only.
12. When the truck is in a safe position and stationary, place the transmission in neutral and
apply the park brake.
13. If the windrow is not standard, the load is to be tipped at least one truck length from the
edge. After the load is tipped, drive forward approximately ten metres then lower the hoist.
Ensure the tray is fully lowered before driving off.
14. Report to the dozer Operator when the tip head is half-full to allow time for the dozer to
arrive and push the tip.
4.6.4.2 Soft Tipping

When reversing in wet or soft conditions while loaded, the front wheels may not provide the
desired turning force and cause the haul truck to slew from its intended course.
Soft tipping procedures are to:
 Enter the tip area in a clockwise direction
 Inspect the tip edge for a minimum of 15 metres
 Locate the tip site
 Make a right turn to locate the haul truck at a 90° angle to the tip edge
 Stop and reverse straight back to the tip edge
 Stop at the windrow
 Make the tip
 Move out squarely from the tip edge
4.6.5 Special Tipping Requirements
4.6.5.1 Tipping in Crushers

When approaching the crusher location keep to the mandatory vehicle separation of at least 50
metres.
Always stay alert for potential hazards in the crusher area.
These can include:
 Low windrows
 Other equipment operating
 Spillage
 Poor lighting
All potential hazards must be reported to your Shift Supervisor immediately.

Advise the crusher Operators by two-way radio of your arrival and wait for acknowledgment and
approval before proceeding to the tipping position.
The Truck’s Approach to the Crusher
When given clearance and the green light is visible, reverse back to the hopper and tip the load.
Do not tip when the light is red.
Raise the body to ¾’s of its travel and wait for all material to discharge before lowering the tray.
¾ Tipping into the Crusher
The ¾-raised position is used for tipping in to hoppers to prevent overfilling and spillage of the
hopper.
Wait until the tray is fully lowered before moving off to prevent spillage and damage to hoist
rams.
4.6.5.2 Back Filling Pits Containing Water

The tip is inspected by the Geo-Technical Engineer detailing any required remedial work before
using the tip and while it is being used.
Supervisors and dozer Operators inspect the tip area before tipping commences and the
Supervisor continues inspections on a regular basis while the tip is being worked.
While tipping at water-filled pits is being undertaken a tip diary is maintained detailing the
findings of all tip inspections, any required remedial work and when this work was completed.
This is recorded in the Supervisors hand over sheet.
The safe operation of a haul truck under these conditions includes:
 Tipping is only to take place if there is an operating track dozer present on the tip
platform
 Ensuring sufficient light exists so as both the tipping platform and the tip face is
adequately illuminated
 Ensuring two marker tyres are present to indicate the 15m minimum tipping distance
and the location for the material to be tipped
 Ensuring clear visibility exists before entering the tipping area
 Checking for light vehicles and other machinery / equipment operating on the tip
platform
 All tipping of waste material is to be tipped short and at least 15m from the open face
of the tip head
 Ensuring a minimum of 15m is maintained between the tip head and the back of the
truck before tipping
 Not reversing the truck past the 15m marker tyres
 Following all and any tipping directions as required by the dozer Operator and / or
Supervisor
 All tipping operations at water-filled pits cease during heavy or extended periods of
rainfall
 Ensuring that water does not pool on the tip platform
After rain the tip is only re-opened after a full inspection is carried out by the Shift Supervisor
and the Geo-Technical Engineer.
4.6.5.3 Free (Block) Tipping

When you are required to carry out free tipping in rehabilitation areas or for roadwork the
following procedures must be followed.
These are:
 Observing the tipping site to ensure it is level, clear of obstruction and able to support
the weight of the loaded haul truck
 Planning the approach and exit from the tip-site
 Not driving on unmarked areas
 Liaising with the dozer or grader Operator to determine the location for tipping the load
 Tipping the material in a manner that allows access by the equipment required to
spread or move the material
 Removing or reporting contaminants as required by site procedures
4.6.5.4 Tipping in Corners

If you are required to tip in tight corners, take care to back to the exact tipping position.
If manoeuvring is a problem use a spotter. The higher an open corner, the more unstable it is
and the more prone to slumping.
Perform a risk assessment if you are unsure that the tipping operation will be safe.
When tipping in tight corners:
 Check that the safety berm is at least half way up the rear truck tyres
 Ensure that the tip head is safe for tipping
 Locate the tip position
 Turn to between 45° and 90° to the tip head berm
 Slowly reverse the truck into the corner, touching the left and right safety berms with
the back tyres
 Back into position carefully avoiding excessive contact with the safety berm
 Tip short if the position is too tight - the dozer will clean and reshape the corner
 Set the park brake and tip the load
Warning : Do not attempt to back into an open corner by backing against the safety berm.
The ground adjacent to the face is relatively uncompacted and may slump.
4.6.5.5 Tipping for Dozers to Build a Tip Head

Working Dozers have right of way on tip heads.
When working with a track dozer building up a tip head or reforming windrows, the dozer
Operator may require a load tipped near the dozer. This is indicated by the blade being raised
or by radio communication.
Back up parallel to the track dozer, which is positioned at 90° to the tip face on the truck’s
onside, by reversing parallel to the blade keeping clear of the corner tip at all times. Keep the
truck at a minimum distance of 3 metres from the dozer at all times.
When the truck is in the required position the dozer Operator signals to stop reversing by:
 A hand signal
 Radio communication, or
 Reversing back
Stop the truck and tip the load when dozer is clear.
If there is any doubt about the dozer Operator’s requirements, request clarification via the two-
way radio.
4.6.6 Managing an Overloaded Haul Truck

An overloaded truck may not perform as expected. Serious injuries to co-workers and / or
equipment damage can result if the correct procedures are not followed.
4.6.6.1 Special Tipping Area

If overloading does occur:
 Communicate with Supervisor and conduct a risk assessment before commencing
task
 Adviser the loading unit Operator that your truck is overloaded and request a tipping
location in pit area– this area must be no steeper than 3% gradient
4.6.6.2 Return to Loading Unit

If it is not possible to perform the above procedure, the truck can travel back to a loading unit for
load repositioning by using the following procedure, which is to:
 Communicate with Supervisor and conduct a risk assessment before commencing the
task
 Communicate intention to travel back to loading unit to all pit users
 Do not travel down a gradient steeper than 1:10 on return to loading unit for
repositioning of load
 Crest at 16kph maximum
 Travel down ramp at a maximum of 16kph
Loads are not to be bumped off due to the risk of damage to the truck and injuries to personnel.
4.6.6.3 Partially raised Tray

If the tray is loaded and partially raised, but can raise no further, lower the tray, contact the
Supervisor and follow site requirements.
Never travel with the tray loaded and partially raised.
Guidelines are:
 Conduct a haul truck risk assessment if required
 Gradient to be constructed clear of production cycle
 Tip area gradient must not be steeper than 3%
 Gradient no longer than half truck length
 One and a half truck widths wide -minimum
 10 metres clear of any tip head edge
 Adequate demarcation
 Travel to area indicated by Supervisor to tip load
 Truck does not travel to the tip location with the tray partially raised
Section 5 Perform Post-Operational Procedures
5 Perform Post-Operational Procedures
5.1 End of Shift

The end of shift haul truck checks and tasks include:
 Cleaning the cabin
 Removing any rubbish from the cabin
 Cleaning glass and mirrors
 Complete a final walk-around checking for:
 Damage
 Leaks
 Items requiring cleaning, e.g. lights, tapes, beepers, radiators and coolers
The Operator is responsible for haul truck housekeeping.
5.2 Maintenance
5.2.1 Preventative Maintenance

A strict definition of preventative maintenance is, maintenance tasks conducted at regular
scheduled intervals based on average statistical and anticipated lifetime to avoid failure.
In simple terms preventative maintenance is any action taken to prolong the life of equipment
and avoid unnecessary down time.
Typically, preventative maintenance includes:
 Equipment inspections
 Lubrication
 Adjustments
 Cleaning
 Non-destructive testing
 Statistical recording
 Fault reporting
 Minor replacements
Effective preventative maintenance programs are the result of a well-organised and carefully
executed effort among operational and maintenance personnel.
All preventative maintenance activities are to be conducted according to the site’s safety
guidelines and the equipment’s prescribed maintenance schedules.
Regular walk-around inspections are an important part of the site preventative maintenance
program.
The benefits of a comprehensive walk-around inspection include:
 Fewer equipment failures and emergency breakdowns
 More planned work completed
 Reduced labour costs and better labour utilisation
 Extended equipment life
 Improved equipment operation
 Less downtime and maximised production output
 Generally reduced maintenance costs
 Increased operational safety
 Decrease in unexpected breakdowns
This diagram illustrates the benefits of a proactive approach to maintenance by reacting

immediately to small problems before they become major repair issues.
5.2.2 Defect Reporting

Defects or faults are occasionally identified during walk-around checks or other inspection
activities. If a defect results in the equipment assessed as unsafe to operate, you must attach
an Out of Service tag to the appropriate location on the equipment to ensure that it is not
operated.
Note : Do not attach a Personal Danger Tag to equipment requiring maintenance.
Ensure that the defect / fault is either repaired or reported by filling out a defect report and then
forwarding it to the designated maintenance area.
Section 6 Activities
5.2.3 Breakdowns
You are responsible for immediately reporting any faults or breakdowns of the haul truck to your
pit control, Supervisor or appropriate maintenance personnel. Do not leave it to the next person
or until it causes an accident or further damage.
If you must leave a broken-down truck unattended, ensure that it does not cause a hazard,
place lights or cones as necessary and leave the hazard lights on. Even if you think the problem
is obvious, leave an Out of Service tag attached to the main isolation control to make sure any
person checking the vehicle is made aware of the problem.
5.2.4 Fluid Levels

Fluid measuring methods include:
 Sight-glasses
 Dipsticks
 Level plugs
 Instrumentation and other devices that signal low levels via audible and / or visual
warnings
It is essential that you accurately determine the fluid levels during your walk-around inspection
and constantly monitor them via cabin instrumentation.
The characteristics of the particular fluid containers concerned determine the consequences of
fluid level problems.
The general affects of incorrect fluid levels are summarised in the following table.
Low fluid levels lower than the recommended Fluid levels higher than the recommended
minimum maximum
Component seizure Aeration and overheating

Seal damage Fluid oxidation
Reduction in heat dissipating capability Lubrication problems
Concentration of contaminant Seal damage
5.3 Refuelling
Important site safety procedures apply to the refuelling of haul trucks. Always exercise caution
during the whole process.
Warning : Smoking is prohibited during refuelling operations.
Entering the Fuelling Facility

When entering and parking at the refuelling facility:
 Only enter the fuelling point when safe to do so
 Approach with caution, in first gear and at low speed
Note : Do not use dynamic braking in a fuel farm — service brakes only to be used
below 10kph for a mechanical truck and 5kph for an electric truck.
 When in the correct position, put the transmission in neutral and set the park brake
Note : Do not use the service or other brakes for parking the truck.
 Isolate the truck

 Complete the Test and Try step procedure to ensure there are no remaining potential
sources of energy by attempt to move the steering wheel from side to side and
activating the starter to ensure it does not work
 Apply wheel chocks (if necessary)
 Move away from the truck and remain outside the footprint until the service crew have
completed the refuelling and any other required maintenance
 Remove earth strap and wind up cable, if applicable
 De-isolate truck and enter fuel quantity into dispatch – follow site procedures
After Refuelling
Perform a walk-around inspection before starting and moving the haul truck.
Check for out of service, danger tags and refuelling in progress signs.
Use the relevant horn signals for starting the truck and leaving the fuel facility.
6 Activities
6.1 Section 3 Operate Haul Truck Activities
Activity 1
Complete a Take 5 assessment for placing the appropriate isolation on a Haul truck so as to
allow a walk-around inspection inside the vehicle’s footprint.
Attach a copy of the completed Take 5 assessment to a copy of this Activities page.
Activity 2
Complete a start of shift Operator / Equipment Pre-Start Safety Inspection on a Haul truck at
your mine site.
Explain what you are checking and why to the Assessor as you go.
Attach a copy of the completed form to a copy of this Activities page.
Activity 3
Several less than ideal operating conditions can occur when it is necessary to change your
driving approach to maintain a safe operation of the truck. Describe what you would do and
change regarding the operation of the truck in substantial wet conditions.
Activity 3
You receive a two-way radio call from a vehicle travelling behind you. Your haul truck is loaded
and you are advised that an inside rear tyre is almost flat and showing signs of smoke from
rubbing against the outside tyre. What procedures must you follow to manage this situation as
safely as the problem allows?
Activity 4
A. What actions must you take, or try to take if conditions permit, if your truck breaks down on
an incline?
B. Provided it is safe for you to remain in the truck, what must occur before you can leave the
truck?
Activity 5
What is the procedure for a haul truck to overtake a moving water truck?
Activity 6
It is critical when parking a haul truck for it to be fundamentally stable.
A. What is fundamental stability?
B. How do you achieve it?
C. How do you test it?
Activity 7
What is the primary purpose of the “Retarder” function in a haul truck?
Activity 8
Why is it considered to be potentially dangerous to reverse a haul truck and what is the single
most important thing that you can do to make it safe?
Activity 9
What are the driving and parking conditions for operating a haul truck around workshops?
6.2 Section 4 Load, Haul and Tip Materials Activities
Activity 1
What are the rules for queuing haul trucks and why are they important?
Activity 2
What types of communication are used at the loading area and when are they used?
Activity 3
When the truck is in the correct position for loading, what else must you do to prepare the truck
for loading (i.e. the truck’s settings) and what must you do during the loading process?
Activity 4
If the windrow at the tip head is not up to standard and / or too low for reversing the truck up to,
what are the two things that you must do?
Activity 5
A. In what direction do you drive around a tip head and what are the reasons for travelling in
this direction.
B. What is the distance you must be from the windrow when driving around a tip head?
Activity 6
What are four things that you DO NOT do if your haul truck is overloaded?
6.3 Section 5 Perform Post-Operational Procedures Activities
Activity 1
What is the main reason for applying good preventative maintenance practices to operating a
haul truck?
Activity 2
If you identify a defect in an item of equipment that makes it unsafe to operate, what are the two
things that you must do and why?
Activity 3
What are the rules for operating a haul truck in the fuel farm?

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Haul Truck Operations - Guide

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3.5.5 Continuing Checks............................................................................................................ 36

3.8.9.2 Retarder Operation in a Mechanical Drive Haul Truck..............................................66

4 Load, Haul and Tip Materials............................................................................................79

4.4.6.3 Offside Loading......................................................................................................... 90

5 Perform Post-Operational Procedures.............................................................................121

5.2.4 Fluid Levels..................................................................................................................... 123

1.1 Purpose of this Resource Manual

1.2 Safety Requirements

1.3 Training Requirements

1.4 Assessment Requirements

1.6 Getting Help

2.2 Haul Truck Types and Specifications

2.2.2 Body Type

An Example of a Haul Truck with the Body Type used by Leighton

2.2.3 Drive Type

A Typical Mechanical-Drive Haul Truck Power Train

A Typical Electric-Drive Haul Truck Power Train

An Example of Haul Truck Dimensions using a Caterpillar 789C

Weights and Volumes

2.3 Identifying the Truck’s Main Components and Functions

2.3.1 Front View

2.3.2 Right Side View

2.3.3 Left Side View

Body Hoist System

2.3.4 Rear View

2.3.5 Operator Cabin Instruments and Controls

Key features include:

Vehicle Management Systems

2.4 Operating Authority

3 Operate Haul Truck

3.2 Identifying Safe Operating Practices

Monitoring the truck’s operational status includes regularly checking:

Always include safety in your operating plan by:

3.3 Identifying Personal Injury Hazards

Loading Oversized Material

Lowering the Tray

3.4 Pre-Start Procedure

3.4.2 Driver Changeover

The incoming Operator is now ready to start the walk-around procedures.

3.4.3 Operator’s Inspection Form

The forms typically have three fault categories.

3.4.4 Walk-Around Inspection

Warning : A walk-around inspection of an empty truck must be conducted outside the

Walk-Around Direction and Inspection Start

1. Front and isolation point 2. Left side 3. Rear

Under the Truck – All Around

Missing Wheel Nuts

3.5 Start Up Procedure

3.5.1 Final Pre-Start Checks

After entering the cabin:

3.5.2 Start Up Process

3.5.3 Post Start Up Checks

2. Allow the engine to warm up at low idle for five minutes.

3.5.4 Braking Systems Tests

Park Brake Test

Service Brake Test

Secondary Brake Test

Retarder Control Test

3.5.5 Continuing Checks

3.6 Moving Off Procedure

3.7 Emergency Procedures

3.7.1 Under Inflated and Flat Tyres

3.7.2 Tyre Failure