DOZER OPERATORS

TRAINING

ISO 14001:2015
CERTIFIED
Certificate No.: PH16/1421
•The aim of the program is to provide trainees with the
basic skills and knowledge required to operate a machine.

• assist the trainee in passing the certificate of competency

as an operator in accordance with the industry national
standards.
Training of Operators

1. Authorized site procedures

2. Safety practices and site standards
3. Operating conditions in all areas of the site, including any
special or hazardous conditions.
4. Basic information on the particular machine, its components to be
used including design features, centre of gravity, capacity, stability
and limitations.
5. Location and functions of controls
6. Servicing, maintenance and reporting responsibilities
 Responsibility

This training has been prepared in the interest of safe operating practices
for machine operators, in accordance with the “Duty of Care” principles of
applicable OHS legislation.

It is the trainee’s responsibility to ask questions to gain understanding of

the concepts in this manual. Your aim is to operate the machine in a safe
and responsible manner.

It is the trainer’s responsibility to clarify these concepts and provide the

links to site standards and operating procedures. At no stage should risk be
compromised during the training program.
 Legislation
- For a detailed explanation of the “Duty of Care” provisions applicable to both
employees and employers, operators should consult the OHS legislation applicable to
the state or territory in which they are operating.

Duties of Employers
- The employer must provide you with sufficient supervision, instruction, information
and training and personal protective equipment (PPE) so that you can perform your
daily duties in a safe and productive manner without being exposed to hazards or harm.

Duties of Employee
- The employee must abide with all lawful instructions and safe work procedures and
take reasonable care not to expose themselves or others to hazards or harm and must
ensure they have received sufficient information, instructions and training so as to
perform their daily duties in a safe and productive manner.
Operators Responsibilities

- Arrive for work in a fit state ready to perform their duties in a safe manner
- To use, wear and maintain in good order the PPE provided
- Perform daily equipment inspections to ensure it is safe to operate
- Start and test the plant/equipment in accordance with safety requirements
and manufacturers recommendations
- Abide by all lawful instructions received from supervisors
- Operate the plant/equipment in a safe productive manner in accordance
with site procedures
- Comply with all Occupational Health & Safety requirements for the site
- Report all accidents, incidents and near misses to the Supervisor as soon as
practicable so as to minimize the likelihood of a re-occurrence
- Check for and report machine faults or site hazards immediately to
supervisor
- Clean and maintain the plant/equipment to an acceptable standard
 Environmental Issue
Report all Environmental incidents including spillage/leakage/release
of hydrocarbons or other substances which may endanger the
environment. Where possible these incidents shall be controlled,
contained and cleaned up as soon as practical. Any disposal of
contaminants shall be done in compliance with regulations and site
specific procedures.

Machine Hazards & Risk

Hazard Identification
Most accidents involving mobile equipment are due to faulty or
improperly inspected machines, or due to the operator not inspecting
the work site for possible hazards.
Inspect the work area for possible
hazards such as:
• Open Service Drains
• Other Vehicles
• Pedestrians
• Open excavations
• Overhead Services (power, water, steam, chemical, gas lines etc)
• Underground services (water, gas, phone lines, optical cables)
• Buildings (structures, workshops, fuelling bays etc)
• Uneven ground (potholes, slopes, cracks and low windrows)
• Haul road widths, obstacles, wet, sticky or dusty conditions
• Weather conditions (darkness, brightness, windy etc)
• Blind Spots
• Restricted areas and exclusion zones
• Other operating equipment
• Laser set up / TBM
• Lighting towers
Risk management
Machine operators should continually carry out a risk assessment of the area in
which they work and be actively involved in reducing hazards in the workplace.

A number of considerations are as follows:

· Applying night or low visibility procedures
· Applying defect and incident recording or reporting procedures
· Checking for services and other obstructions in the operating area
· Checking for ground stability or cracks
· Maintain awareness of blind spots or obstructions to vision
· Maintaining awareness of other personnel, vehicles and equipment
· Maintaining communications with others who are affected by the work
· Maintaining housekeeping standards
· Observing exclusion zone procedures
· Observing seating or seat belt requirements during operations
· Observing warning and caution signs
· Observing overtaking or turning procedures
:
Personal Safety

Minimum PPE requirements, (please refer to your site procedure and

signage for your work area):

· Hard Hat
· Hi Vis Clothing
· Safety Glasses
· Steel cap safety Boots
· Ear Plugs (Where applicable)
· Gloves (Where applicable)
· P2 Dust mask (Where applicable)
· Personal Danger Tag and Lock
You have a responsibility under law to protect yourself
and others from injury.
 - Personal Protective Equipment (PPE) must be worn in the workplace, as directed
by Signage or site procedures
 - Always check the machine for tags prior to boarding the machine
 - Maintain three points of contact and face the machine when boarding or
dismounting
 - Always use appropriate horn signals when ever starting or repositioning a
machine
 - Never allow unauthorized personnel to operate the equipment
 - Whenever personnel are on the ground or in the vicinity of the Equipment you
are operating, YOU MUST EXERCISE EXTREME CAUTION and maintain
clearances from them
 - Manoeuvring a machine into confined areas such as workshop service bays, tire
bays or fuel bays may require the assistance of a spotter. Ensure a spotter is
familiar with communication signals.  
Lifting Techniques
Manual handling injuries can be caused by;
· Overexertion
· Repetitive actions
· Poor housekeeping
· Incorrect lifting techniques

Fatigue
If you are finding it hard to concentrate or keep your eyes open or if you start to make
mistakes that you would not normally make, then you need to contact your supervisor
immediately and arrange alternate duties.
Things to look out for:
· Yawning
· Moodiness
· Rubbing of eyes
· Loss of concentration
· Restlessness
· Lack of attention
· Becoming intolerant

.
Emergency Situations
Emergency will differ from site to site and you will be trained in the site specific requirements
during an induction.

In most cases the process is as follows:

· Call emergency, emergency, emergency
· State name, location, nature of the emergency, assistance required
· Amount of injured people
· Assist anyone who is injured to the level of your expertise and training
· Do not put yourself in danger
· Assist with reporting and incident / accident investigation

Communication Systems
There is a wide range of communication systems used on sites between all personnel on site. These
may include:
· Radio
· Hand signals
· Verbal communications (Pre-Shift Information – PSI, toolbox)
· Procedures and Job Hazard Analysis
· Signs and notice boards

.
Information that may be gathered can include:
· The location of the machine
· Any hazards that have developed
· Type of machine required and requested
· Loading area
· Tipping locations, maps
· Geological and technical data (location of underground workings, slips,
etc)
· Any changes to road rules
· Reported defects

Caution, Warning and Danger Labels

In various locations around the machine, there are caution, warning and danger
labels. These are there to prevent serious accidents or fatalities so take notice of
them.

.
Passengers
It is not permissible to carry any passengers unless there is a manufacturer’s seat and seat belt
provided and you have authorization from your Supervisor.

Battery
Touching both negative and positive points of the battery at the same time with anything that
is conductive, will give you an electric shock.

Hearing Protection
In addition to site PPE, hearing protection must be worn whenever signs or procedures indicate this.

Pressure Systems
All hydraulic and fuel systems on a machine should be treated as active and pressurized at all times.

Cooling System
The cooling system of a machine can be extremely hot and therefore under no circumstances, is the
radiator cap to be removed by any person other than maintenance personnel who are trained in
doing this task.

.
Exhaust System
Always take extreme care when working in confined spaces; ensure that the work area is well
ventilated. Remember that Carbon Monoxide produced from the exhaust system is color
less and odor less, and can render you unconscious rapidly.

Overhead Cables and Power lines

Safety procedures MUST be observed at all times, as follows:

· When travelling underneath power lines, follow the site specific requirements at
all times.
· “Any activities carried out near overhead power lines, must ensure that a power line
corridor of ten (10) meters is maintained under and each side of those overhead power
lines.”

.
If Power Contact Occurs
· Stay calm, don’t panic, contact supervisor
· Remain in the cab of machine and refrain from touching metal parts
· Don’t move the machine until advised by supervision
· Do not leave the machine until it is safe to do so or directed by supervision
· As a last resort and if power can’t be switched off and contact with power lines can’t be broken
away, then jump well clear so as not to touch machine and the ground at the same time. Shuffle
away maintaining contact with the ground with both feet to a safe distance.
Lightning
The supervisor will determine the course of action to take in the event of an electrical storm
approaching the work area.

Blasting Practices
Blast practices may affect your work area in the following ways:
· Introducing exclusion zones
· Safe working distances from the affected area
· Miss-fires
· Hazardous fumes
· Fly-rock
· Time of blasts and radio silence

 
Fire Extinguisher and Suppression system
Dry Chemical Powder fire extinguishers or Foam Suppression units will be located on all machines.
They should be accessible and in good working condition, e.g. charged to the right pressure.

Tire Blow-out
A tire blow out would generally be caused through a combination of wear, rock damage and
excessive pressure due to over-inflation or over loading etc.

Tire Explosion
A tire explosion would usually occur after a tire has ignited. Machine contact with electrical cables,
lightning or welding on a wheel rim must also be treated as a possible source of a tire explosion.

When a tire burns, the excessive heat forms volatile gasses inside, which eventually ignite causing
the tire to explode with considerable force. The effect of a tire explosion can be quite catastrophic,
especially from the side, due to the wheel components being forcibly scattered over a very large
area.

.
Tire Fire
In the event of a tire fire, immediate corrective action must be taken for the safety of the
operator and to minimize the damage to the machine.
• Raise the alarm via emergency radio procedure and then isolate the
batteries if possible
• If possible allow access for emergency response vehicles to the effected
wheel
• When alighting from the vehicle, options include
• Step down using the front ladder, on the direct opposite side of the fire
• If not able to alight using the steps, await rescue
•  Walk directly away from the truck, in the opposite direction to the fire
• The machine must then be isolated for a period of not less than twenty four (24)
hours with an isolation radius of at least 300 meters and guards placed to prevent
access. If necessary evacuate buildings within the vicinity
• Do not try to fight the fire with a hand held fire extinguisher. A fire extinguisher
will have little or no effect and the risk of explosion is imminent
Track Dozer
What are some of the tasks the dozer performs?

· Road construction
· Creating construction pads
· Dump maintenance
· Ripping
· Rehabbing
· Equipment recovery
· Pit maintenance
General View of the Dozer
If directions are indicated in this section, they refer to the directions shown by the arrows
in the diagram below.
Pre-Start Inspection
Always ensure the dozer is parked in a safe condition and location prior to pre-inspection
and ensure the previous operator is clear of the dozer before you begin the pre-
inspection.

Complete Pre-Start Inspection Book

The operator must complete the pre-start inspection book at the commencement of each
shift.

Horn Signals
The following audible signals shall be given by dozer operators:
· ONE blast before starting the engine
· TWO blasts before moving forward
· THREE blasts before reversing

 
Starting Engine
The start-up procedure is as follows;

· Turn on battery isolation key

· Ensure all personnel are clear of the dozer
· Adjust mirror, to allow good vision of the rear of the machine
· Clean windows to ensure good vision
· Adjust seat belt to fit firmly
· It’s a safety requirement that all windows and doors are keep shut when operating
equipment
· Adjust the throttle control
· Turn the engine key to start

 
 Electronic Management Systems
The Electronic Management Systems are designed to monitor the critical components of the
dozer engine, transmission and differentials and alert the operator if there a problem
developing.

Check Pressures and Gauges

With the engine running at idle, check the appropriate gauges for the model of machine. You
will be instructed in which gauges to view in the machine specific module. Allow the engine to
run for 2 to 3 minutes to warm up and pressures to build up to operating range.

 
 Pre-Start Inspection
Always ensure the dozer is parked in a safe condition and location prior to pre-inspection
and ensure the previous operator is clear of the dozer before you begin the pre-inspection.

Complete Pre-Start Inspection Book

The operator must complete the pre-start inspection book at the commencement of each
shift.

Horn Signals
The following audible signals shall be given by dozer operators:
· ONE blast before starting the engine
· TWO blasts before moving forward
· THREE blasts before reversing

 
 EMS Panel

Decelerator Pedal
This pedal is used for reducing the engine speed. When switching between forward
and reverse, or when stopping the machine, use this pedal to reduce speed.

Transmission
Most dozers have a power shift transmission system; this provides fast and easy gear
selection. Changing gears can be made while the dozer is in motion, but it is
recommended that a shift to a lower gear be accompanied by reduction of speed rpm
and ground speed.

Braking System on a Dozer

Service Brake Pedal – The service brake pedal is used to slow or stop the machine.
Park Brake – Park brake is always used when disembarking the machine.
Always bring the dozer to a complete stop and select neutral before applying the park
brake.
 
 Brake Test
After the pre-start inspection, a brake test is required. You will be instructed in how your model
of dozers braking system must be checked in the machine specific manual.

Moving the Dozer to Work

With all systems checked, all documentation completed, it is now time to move the dozer to
work. If the area is clear of personnel, use the correct horn signal, apply correct brake, release
the park brake, select the appropriate gear, and release the brake.

Geological and Technical data

Information or data a dozer operator may require access to;
· Mine planning information
· Survey information
· Environmental information
· Geological information
· Hand over information from previous operator
 
 
If unsure of your working area STOP and ask your supervisor to clarify work orders.
 Dozer Operation
The trainer will demonstrate the correct use for each of the controls and the correct operating
procedures. Remote trainees will need to consult the Manufacturer’s Operator Manual and be given a
demonstration of correct operating procedures by a competent person.

Operation Precaution
·As a dozer operator, you will also be required to coordinate movement with other machines and
equipment. Always use clear and good communication when confirming work orders

·Always obey all site instruction and safety procedures for health, safety, prevent damage to property,
protect the environment, meet legal requirement
·50/20 Rule –Within 50metre radius of a working machine you must notify the machine operator.

 
 ·
All clean up machines, where possible, shall work at right angles and no less than
45 degree angle to the working face. Where practical avoid working parallel to the face
· Always use two-way communication when entering or exiting the work area
· If any personnel are to approach the dozer, stop immediately, select neutral,

Capabilities and Limitations that affect your operations

limitation and capabilities of the dozer;
· Production rate required / production targets
· The size of the machine and type of material
· Safety requirements
· The amount of traffic on the roads
· Weather condition
· Night time or low visibility
· Change of priorities
· Work area condition
· Ground condition
 
Straight Dozing

Where possible, start the work on level starting point. Be sure you are carefully
conversant with the type of machine you are going to operate.

Full Blade of Material

When levelling or spreading material, it is much easier to level using a full blade of
material. The extra weight in the material allows the dozer to push and carry the material
spreading evenly.

 
 
Important point to remember:

· In the early stages of your training, try to start pushing on level ground
· To fill the blade on soft or ripped ground, lower the blade on top of the
material. Only apply a small amount of down pressure on the blade as it will tend
to dig into the soft material very easily.
· Try and maintain a level cut for the best performance. Fill the blade then ease
off any down pressure and carry the load to dump point.
· Avoid spinning the tracks as this can increase their wear rate. Reduce the load
being pushed if the tracks start spinning by slightly spinning the blade.
· Pushing a load downhill is much more effective than pushing a load uphill. If
possible, plan your work so that you are pushing downhill.
Rolling Vs Sliding:

Rolling
The dozer blade is designed to roll the material being pushed forward, whenever operating in
the digging stage of a cycle, and to discharge any excess material to the sides of the blade.
Continually digging, or cutting, as the dozer moves forward will produce this rolling action,
but will also result in:

· More material spillage off the blade

· Increased fuel consumption
· Lower efficiency or productivity
Sliding
As opposed to rolling, sliding is much more effective methos of pushing material. Using the
sliding method involves raising the blade once it is full of material to avoid cutting new
material, and sliding the load to the dumping area. The following improvements will result
from using this method:

· Faster cycles
· Reduced fuel consumption
· Decreased blade wear
· More efficient use of power
· Improved productivity:
How to Stop Making Waves

One of the more difficult techniques to master when you are first learning how to operate the dozer
is pushing without creating waves.

A wave is usually formed when either of the conditions below are combined with the
operator not operating the blade correctly to counteract their effect.

· The dozer travels over a bump in the ground

· The dozer blade hits a soft spot on the ground of the operator drops the
blade down too low and creates a hollow

Slot Dozing

The slot dozing technique allows for larger loads to be carried in front of the blade.
It is often used on stockpiling and for production work. Slot dozing is much easier
for pushing material straight ahead. Using the ‘rills’ made by the first cut helps to
hold the material on the next and following passes in front of the blade.
CAUTION - Do not make deep slots above the dozer blade; otherwise the vertical face may
fall onto the machine.
Criss Cross Slot Dozing

Caterpillar recommends the criss cross method of removing berms remaining after slot
dozing. Starting at the back of the cut, angle the tractor to load the blade as it removes a berm
and then straighten the tractor to use a slot during the push to the front of the cut.
Side by Side Dozing

Side by side dozing is normally used when moving large quantities of loose
material. Two dozers working side by side will push more material than two dozers
working separately.

The dozer blades must work closely together and must be parallel. The operators
must maintain good communication and have a thorough understanding of the
process of side by side dozing. This includes the following;

· Working at the same speed

· Pushing with the blades at the same depth
· Maintaining the same distance between the dozers
 

 
 

 
Tilt Dozing

Tilt dozing is used in a variety of applications:

· Ditching
· Gouging out rocks
· Trimming batters
· Working on uneven slopes
· Benching

 
Hill Side Cuts
There is a number of operating and safety points to be considered when pushing a road across
a slope. These are outlined below.

· It is generally easiest to start pushing a road with the dozer in a level attitude. The
easiest way to do this is to start by pushing downhill. This creates a pile of dirt on which
the outside track of the doer can ride
· Tilt the inner edge of the blade down so that it is lower than the outer edge. This will
keep the road sloping slightly inwards.

 
• Start pushing the road. Depending on the looseness of the material being pushed, you may
have to keep reversing back to take another cut, to ensure that the dozer is always operating
on the complete track.

• Keep a windrow of dirt piled on the corner edge of the cut. This can be used to help finish
and level
the cut, or it can be left as a safety guide to the road’s limits.

 
 Descending Steep Slopes
If, during the course of your operations, you are required to descend a steep lope, there are a
number of precautions to take to increase the safety of the descent. The easiest way to reduce
the risk factor is to reduce the grade that the dozer must travel down.

· Start by pushing material from position 1 over the edge of the slope
· Move back to position 2 (if necessary) and continue cutting the ground away and
pushing it over the edge until a safe grade is obtained
· When the grade is sufficiently reduced, the dozer can descend in safety

 
 Stockpiling

Stockpile work can be dangerous. Have a good understanding of how to work on and around a
stockpile. When pushing material up into the stockpile, avoid pushing up too steep a face; the
dozer may labor and overheat causing unnecessary wear and tear.

Dozing Roads Down the Open Cut

Start well back from the face using cut and fill down the side of the face. Make sure the incline
is not too steep, so the machine can reverse up. Try to keep the blade full of material. Keep
plenty of material in front of you, so the roadway is at least half as wide again as the dozer.

 
 Dozing Over High Walls

Inspect the edge of the high wall before starting operations. Push the material at right angles
at all times, push along a high wall.

 Don’t try to push a blade full directly over the edge. Place a pile at the edge and push that with
another loaded blade.
 
Leave a windrow of approximately half the wheel height of a dump truck along the edge of the
wall top, so that the trucks tipping their load can back up and rest the rear wheels against the
windrow before tipping.

 
 

 
Ripping

Ripping can be a major requirement to break and move large amounts of overburden. Therefore, the following procedures
apply to using the ripping attachments on track type dozers and address:
· Gear selection
· Position of the ripper at the start of the pass
· Position of the ripper during the pass
· Ripping depth
· Use of the decelerator
· Pass spacing
· Ripping direction
· Cross ripping
· Removal of ripped material

Gear Selection
First gear is used most for ripping operations because 2-3kph generally gives the most economical
production. Undercarriage and tip wear increases rapidly with only a small increase in speed, so monitor your
speed carefully.

 
Positioning the Ripper at the Start of the Pass

Being able to achieve initial penetration is critical and may be the determining factor for
whether a material can be ripped.

. Look or faults, weak spots or fractures in the surface that may aid initial penetration, and
then try different shank angles until the best angle for penetration is found.

 
 
After you have completed the ripping pass, raise the ripper to the carry position before trying to turn the
dozer. Turning the dozer with the ripper still in the ground will cause severe twisting stress on the ripper
frame, shank and tips.

Ripping Depth

Sometimes it is practical to rip as deep as possible. However, where considerable stratification is

encountered, this may not be true.
Using the Decelerator to Control Track Slippage

Too much power while ripping can result in excessive track spin; reducing
undercarriage and ripper tip life. A constant steady pull when ripping maximizes
production and minimizes wear and tear on the machine.

Pass Spacing
Pass spacing helps determine the production rate, indicating the time required to cover
the area. Maximum spacing helps hold down the costs, however, the material’s end-use
and method of removal must be considered. The closer the spacing, the smaller the
ripped chunks will be.

Ripping Direction
Generally, ripping direction is dictated by the job layout. There are, however, certain
conditions under which ripping direction will greatly affect production and results.
Cross Spacing

Cross ripping should be used only when unidirectional ripping will not adequately loosen the
formation. This is because it makes the pit rougher and is more severe on the machines.

Removing Ripped Material

Never doze or scrape all of the ripped material before ripping deeper. Always keep at least
150mm of ripped material above the un ripped formation to cushion the dozer and provide
traction.

Park Up and Shut Down

Parking on Go-Line

When parking in the go line all machines shall head for the furthermost parking area and
starting from the left hand side of the line first.
Parking on Grades

When the dozers are parked on grades the following applies:

· The dozer shall have the blade turned into the windrow/high wall and the park brake applied and
all GET lower to the ground
· Where there is a danger of the dozer rolling away, the Shift Supervisor will direct the tracks to be
chocked or a windrow established
· Use hazard lights when it is necessary to highlight the position of the dozer

Shutdown

Ensure machine is parked in a safe location, in neutral, lower all the GET and that the park brake has been
applied.

Cabin Maintenance

Use the available shutdown time to clean the dozer cabin

· Make sure you remove all rubbish from the dozer
· Clean all windows, mirrors and cabin handrails
· Clean steering center console area
· Sweep the floor and remove all dirt from the cabin
 
 

 
Equipment Housekeeping

All equipment and related attachments shall be maintained in a clean and tidy condition with
adequate location/storage.

Documentation

It is important that all documentation be completed accurately and in line with site
requirements at completion.

· Pre-start sheets for maintenance records

· Time sheet for pay-role records
· START – risk assessment of task to be carried out
· Training documentation for training records

 
 

 
End of Shift Inspections
Perform an end of shift inspection of the dozer, start at the front of the dozer and working around and finish back to where
you started. Main items to look for include:

· Track conditions
· Oil Leaks
· Fuel leaks
· Wear and tear
· Damage to machine
· Cabin housekeeping

Breakdown Procedure / Operation

If the dozer you are operating breaks down then the following rule shall apply:
·Attempt to park the dozer in a safe area or passing bay or as close to the left hand side of the road as possible
·If the area is wet or if ground conditions are soft, do not park the dozer off the road or on uneven ground
·Contact the supervisor/workshop and let them know that a problem exists with the dozer
·Make sure that the hazard and the revolving lights are operating if equipped

 
 

 
Trouble Shooting

The four steps in the process of trouble shooting equipment faults on your dozer are:

· Stop
· Identify or investigate
· Rectify if in scope
· Notify supervisor

Most Common Faults

There are a lot of different things that can cause faults throughout the dozer some of the most common faults are;

Engine faults Faulty lights

Oil leaks Low fluid levels
Loss of power Transmission
Seat / seatbelt fault Hydraulic problem
Steering faults Two-way faults
Structural damage Blown fuse Vibration / Smell / Noise
Broken windrow GET wear Air conditioner Blown hoses
 

 
 

 
Towing Requirements

When using the dozer to tow, make sure it has the necessary capacity to do the job and a
certified wire sling/rope or snatch strap (meant for that purpose) must be used between the
tow vehicle and the vehicle requiring towing.

Always do a written risk assessment with the group conducting the towing operation.
Ensure that the Towing
Heavy Equipment procedure is reviewed prior to the task being conducted.

 
 
 Thank you