LEVEL 1 Product Training

Safe Working Practice

TEREX CENTRE OF EXCELLENCE

TEREX Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
See Us At - www.terex.co.uk United Kingdom
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THIS IS NOT A CERTIFIED SAFETY TRAINING COURSE

THIS COURSE IS DESIGNED TO RAISE YOUR AWARENESS WHEN
WORKING WITH A TEREX EQUIPMENT LIMITED PRODUCT.

TEREX EQUIPMENT LIMITED STRONGLY ADVISE THAT REGIONAL HEALTH AND

SAFETY CERTIFICATION SHOULD BE GAINED THROUGH LOCAL GOVERNING AGENCIES.

ie. UNITED KINGDOM; CONSTRUCTION INDUSTRY TRAINING BOARD (C.I.T.B.)

CONSTRUCTION PLANT COMPETENCE SCHEME (C.P.C.S.)
 SAFE WORKING PRACTICE

Safety Working Practice

The machine should be properly operated and maintained to keep it in safe,

efficient operating condition. Be sure that all controls are free of mud, grease, or

other matter that might cause slips hazardous to the operator, service engineer, or

other personnel or equipment. Report all malfunctions to those responsible for

maintenance, and, do not operate the equipment until corrected. Normal service

or maintenance performed as required can prevent unexpected and unnecessary

downtime.

This training describes general safety precautions required for normal servicing and
operating conditions. It is not a guide however, for other than normal conditions or
situations, and therefore, service engineers and operators must be safety conscious
and alert to recognise potential servicing or operating safety hazards at all times, and
take, necessary precautions to assure safe servicing and operation of the machine.
SAFE WORKING PRACTICE

SAFETY IS UP TO YOU

YOU CAN PREVENT SERIOUS INJURY OR DEATH

GOOD SAFETY PRACTICE PROTECTS YOU AND OTHERS AROUND YOU

BE OBSERVANT - BE ALERT - BE AWARE

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General Safety Precautions

 Read the Operator’s Handbook and learn the
operating characteristics and limitations of the
truck.
 Study and fully understand all truck mounted
warning and information decals.
 Know the operating clearances of the vehicle.
 Know work area clearances of all side and overhead
obstructions such as wires, bridges, etc., for
operating safely.
 Be aware of operating hazards that weather
changes can create on the job.
 Never attempt to operate or work on a vehicle when
not feeling physically fit.
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• Safety Alert Symbol

The safety alert symbol is used to alert you to a potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.

• Hazard Classification
A multi-tier hazard classification system is used to communicate potential
personal injury hazards. The following signal words used with the safety alert
symbol indicate a specific level of severity of the potential hazard. Signal words
used without the safety alert symbol relate to property damage and protection
only. All are used as attention getting devices throughout this manual as well as
on deals and labels fixed to the machinery to assist in potential hazard
recognition and prevention.
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General Safety Precautions

 Know what safety equipment is required and use it. Such
equipment may be: Hard hat, safety footwear, safety
glasses, reflector type vests, respirators and ear plugs.
 Never wear loose clothing, rings, watches etc., that might
catch sharp edges, levers and controls as this could
cause serious injury.
Keep hands and controls free from water, grease and
mud to guarantee non-slip control.
 Handle fuels and lubricants carefully and clean up spills
to avoid fire and slipping hazards.
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General Safety Precautions

 Clean any mud, grease or oil from controls,
handrails, ladders and decks. Lash necessary tools
securely and remove all loose items before
operating the vehicle. Never rush. Walk, do not run.
 Keep the work area tidy. Tidiness is of decisive
importance for trouble free operation and service.
Oil or water on the floor or walk way can be
slippery and also dangerous in connection with
electrical equipment.
 Ensure that all flammable liquids are appropriately
stored and are in the correct containers.
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General Safety Precautions

 Be aware and alert to on-side warning devises
 Flashing Beacons
 Horns
 Alarms, eg Reverse Alarms
 Warning Lamps
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Preventing Fire Hazards

 Clean all dirt, grease, oil and other contaminants
from the truck components to minimise fire
hazards. This will aid in the spotting of loose and
leaking hoses, fittings etc.
 Check condition of battery cables. Ensure
insulation around cable is in good condition.
 Check engine compartment for rubbish, oily rags or
other debris that could ignite and cause a fire.
 Do not allow oily, greasy rags to accumulate in the
operators cabin.
 Do not use diesel fuel or other flammable fluids for
cleaning purposes.
 Do not smoke or have an open flame when
checking fuel, lubricant or battery fluid.
 Do not smoke when re-fuelling the truck.
 Take care and stand down wind when adding fuel
or other flammable fluids. Avoid fluids being
splashed onto hot surfaces and clothing.
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Electrical Hazard Precautions

 Never smoke or allow open flames or

sparks near batteries.
 Leave battery box open when charging
batteries on the truck. This allows for
adequate ventilation of heat and explosive
gases.
 Always disconnect battery ground cable
first and reconnect last.
 Never check battery charge by placing
metal objects across battery posts.
 Never operate engine starter for more than
30 seconds. Allow 2 minutes between
cranking periods to allow starter to cool.
 Use jumper cables only as recommended.
Improper use can result in battery
explosion and catastrophic failure of truck
electrical circuits.
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Starting the Engine with Jumper Cables

WARNING
Hazardous hydrogen gas and sulphuric acid. Check for required voltage and
polarity connections to discharged batteries. Excessive booster voltage and/or
incorrect jumper cable connections, open flame, lighted cigar, or other
ignition source can cause battery explosion/fire. Keep all sources of ignition
away from batteries. Do not lean over batteries, and, wear eye protection at all
times to prevent personal injury.

Do not jump start a vehicle by using arc welding equipment.

Currents and voltages are dangerously high and cannot be sufficiently
reduced to make the method safe.
Note: Be sure machines are not touching each other. Use cables that are equal to cable size
on the machine. Booster battery should be the same specification as discharged battery.
If jumper cables are used to start an engine, be sure to follow this procedure:
Connect one end of a jumper cable, usually coloured red, to the discharged battery 'POSITIVE'
(+) post. Connect the other end of the same cable to the 'POSITIVE' (+) post on the booster or
charged battery.
Connect one end of the second cable, usually coloured black, to the 'NEGATIVE’ (-) post of the
booster battery. Connect the other end of the 'NEGATIVE' (-) cable to machine frame for
grounding so that if a spark occurs, it is away from battery fumes (explosive hydrogen).
Check for cause of failure on the dead battery.
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Ensure Work Area Is Properly Ventilated

If the engine has to be started and run

indoors, ensure area is properly ventilated to

remove dangerous gases.

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Mounting and Dismounting Truck

 Only use steps and hand holds provided to mount or
dismount the vehicle.
 Do not grasp steering wheel.
 Always face the access system and maintain at least
3 points of support to mount or dismount the vehicle.
 Always use care when mounting or dismounting the
vehicle with oil covered, frosted, or iced fenders,
decks, hand holds or steps.
 Never mount or dismount a moving vehicle. Never jump
off the vehicle. Never jump from vehicle to vehicle.

TA25 TA27 TA30 G7

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Mounting and Dismounting Truck

RIGID DUMP TRUCK

TA35 TA40 G7
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Mounting and Dismounting Truck

• Never jump from truck to truck.

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Safety When Servicing

 Service and maintenance work not carried out
correctly can be dangerous to yourself and others.
 Always attach a 'DO NOT OPERATE' or similar
warning sign to the ignition switch or a prominent
control before cleaning, lubricating or servicing the
vehicle. REMOVE KEY if necessary.
 Never allow anyone to work on the vehicle while it is
moving. Make sure there is no one on the vehicle
before working on it.
 Do not work under or near an unblocked or
unsupported body. Always use the body safety prop.
The body safety prop must only be used when the
body is empty.
 Do not work under or near any unblocked or
unsupported linkage, part or vehicle.
 Always install the steering lock bar before making
adjustments or servicing the vehicle with the engine
running.
 Block wheels from rotating when working in and
around and under the truck.
 Operators should always be aware of ground crew
before starting truck. SOUND HORN and WAIT
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Safety When Servicing – TA25 TA27 TA30 G7

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Safety When Servicing – TA35 TA40 G7

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Safety When Servicing – Rigid Dump Truck

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Safety When Servicing – Decals

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Safety When Servicing

 Tie long hair behind your head. Do not
wear any loose clothing or neck chain
when you are working near machine
tools or moving parts. If items were
caught, severe injury could result.

 Remove rings and other jewellery to

prevent electrical shorts and
entanglement in moving parts.

 Stay clear of rotating drives.

Entanglement in rotating driveline can
cause serious injury and death.
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Safety When Servicing

 Always relieve stored pressure before servicing any
pressurised system. Follow the procedures and safety
precautions detailed in the relevant Maintenance Manual
section.

 Be alert to high pressure fluid leaks. Stop Truck, Relieve

Stored Pressure and Fix Failure.

 When changing oil in the engine, transmission and

hydraulic systems, or removing hydraulic lines,
remember that the oil may be hot and can cause
burns to unprotected skin.

 When working on or around exhaust components,

remember that the components may be hot and can
cause burns to unprotected skin.
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Safety When Servicing – High Pressure Warning Decals

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Safety When Servicing

 Always allow tyres to cool prior to conducting any

maintenance.

 Always deflate tyres before attempting to remove any

embedded objects or removing the tyre and/or rim.
(Please refer to TEREX Level 1 Product Training – Tyre
Maintenance, for further details.)

 Ensure that correct tooling is being used. Ensure all

equipment being used is specified fit for purpose.
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Correct Slinging Method

 Correct
When slinging a component, always
have the lifting hooks - heel inboard

Incorrect 
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Safety When Operating

• Read the Operator’s Handbook and learn the

operating characteristics and limitations of the
truck.
• Study and fully understand all truck mounted
warning and information decals.
• Know the operating clearances of the vehicle.
• Know work area clearances of all side and overhead
obstructions such as wires, bridges, etc., for
operating safely.
• Be aware of operating hazards that weather
changes can create on the job.
• Never attempt to operate or work on a vehicle when
not feeling physically fit.
 SAFE WORKING PRACTICE

Pre-Operational Checks

• Before the engine is started ensure the machine is ready for operation.
• The machine should be in a level position to permit accurate checking of fluid
quantities in the engine and other components.
• Make sure parking brake is set and block wheels if necessary to prevent
accidental movement of the machine while checking component levels.
• Test all lights and horn for proper operation.
• Walk around the machine and carry out the Inspections and Component
Checks described in the drawing on the following pages.
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Safety When Operating

• Conduct all pre-operating checks as

detailed in the Operator Handbook
• Check that all personnel are clear from
the truck.
• Check under and around the truck for
service personnel and ground crew.
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Safety When Operating

• Check that there is no maintenance tags or

sheets inside the operators cab.

• Sound the horn as a final alert to all

ground crew prior to starting the engine.
• Do not sound horn and start the engine
immediately.

• Sound Horn

• Wait A Few Seconds

• Ensure That All Ground Crew Are Clear

• Start Engine
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Safety When Operating

• Check that all on-board safety devises

are operational prior to moving off.

• Ensure you have excellent visibility via

windows and mirrors prior to moving off.
Clean and adjust where necessary.

• Never attempt to move out of or into

areas that you consider restrictive. Ask
for help – use a guide or ‘Banksman.’
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Safety When Operating

Know Your Vehicles Limits

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Safety When Operating

Be Alert When Reversing - Observe Site Limitations

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Safety When Operating

Be Aware Of Other Site Vehicles

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Safety When Operating

Always Check Ground Conditions

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Safety When Operating

Observe Safe Working Payloads

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Safety When Operating

• Be prepared for sudden change in operating

conditions.
• Drive accordingly to the weather conditions.
• Know your stopping distance.
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Safety When Operating

Never Operate Vehicle When;

• Tired or When Not Feeling Physically Fit
• Under The Influence of Alcohol
• Check Medication Notes Prior to Operating