Shovel Handbook En

7/28/2019 Shovel Handbook En

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ShovelOperatorsHandbo

ok

A

Guide

to

Safe

Operation

Shovel Operators Handbook

A Guide to Safe OperationL I C E N S I N G A G E N C Y

1st Edition November 2008


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Shvl Hanbk A Guide to SAfe oPeRAtioN


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Table of Contents

inrcn 5

Wha ths Hanbk s Ab 5

Why Ra ths Hanbk 5

Hw t us ths Hanbk 5

Hw Y Wll Larn 6Symbls 7

Par 1: Lcnc opra a Shvl 9

elgbly Crra 9

Larnng opra a Shvl 9


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Par 2: typs an Cmpnns Shvls 13

Wha s a Shvl? 13typs Shvls 14

Cmpnns Shvls 15

Shvl Cnrls 16

Bck Cnrls 17

Pals 18Par 3: Shvl Say 21

Larnng oprang an Hanlng Sklls 21

Wrk S Say 22

exrnal Vhcl Pr-pranal Chcks 23

inrnal Pr-pranal Chcks 34Sar-p an Sh-wn Prcrs 35

Sh-wn Prcr 38

Rlng 39


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Cnns

3

Shvl emrgncy Prcrs 40

Par 4: Shvl opran 40Plannng Wrk 45

fllng h Bck 46

fllng h Bck rm a Sckpl 47

t fll a Bck Whn dggng an Lang n Lvl Grn 48

transprng wh a fll Bck 49Lang a trck 50

Lvllng an Pshng oprans 51

travllng n Slpng Grn 52

Par 5: fng an Rmval Aachmns 55

frn Aachmns 55Rar Aachmns 58

Hw f, opra an Rmv Cmmn Aachmns 59


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Introduction

Wha ths Hanbk s Ab

ths hanbk s ab h sklls an knwlg rqr saly pra a shvl. th hanbk s ra shvl wh an mpy wgh xcng 7.5 nns.

Why Ra ths Hanbk

ths hanbk lls y ab sm h lgal rqrmns r shvl prars n dba, alng wh

mpran say nrman, backgrn maral, chncal nrman an crrn prcrs.

th knwlg s ha y ms pass g a shvl lcnc s bas n h maral n hshanbk. Y n nrsan h nrman n hs hanbk pass yr s.

Hw t us ths Hanbk

th tabl Cnns wll shw y whr n ach scn. A h n ach scn,hr s a scn call ts Yrsl Qsns hlp y chck y hav nrsmpran sss.


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Hw Y Wll Larn

Larnng pra a shvl s lk any hr cmplx ask. i y brak h ask n small, managabl pcs an n ry larn many hngs a nc, s mch asr. Y wll:

vlp h knwlg an sklls n pra rkls

b shwn hw rv an cnrl rkls saly

pracs an crrc yr rvng chnqs n an ncrasngly cmplx s cnns, s ha y ar capabl sccssllynrakng yr lcnc s.

th lngh ach sag larnng pns n h amn pracc y hav ha. B sr y ar cnn an cmpnbr mvng n h nx sag. Yr insrcr wll avs y whn y ar ray mv n.

Hw as an hw mch y larn wll pn n y. Y shl larn by:

rang hs hanbk carlly

ampng all h qsns an acvs n h hanbk

bsrvng h prans bng prrm by yr insrcr an n yr wrk s

askng qsns

pracsng h nw sklls ncl n hs hanbk

nrakng h assssmn asks n cmpln h ranng.

i hr s anyhng n hs hanbk y n nrsan r n agr wh, n b ara ask yr insrcr rasssanc.



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Symbls

Symbls s n h hanbk.Graphc symbls ar s g yr larnng an ny yps nrman. th manng ach symbl s as llws:

Caution Y ms llw nsrcns av amag prcs, a prcss rsrrnngs.

SafetyY ms llw say prcrs r war prcv clhng.

Test Yourself Questions Chck ha y hav nrs h nrman n hs scn byanswrng h qsns a h n ach scn.

inrcn

?


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Part 1: Licence to Operate a Shovel

elgbly Crra

th lgbly crra r a lcnc pra a shvl ar s blw.

Y may rv a shvl y:

areover20yearsofage

havepassedaneyetest

haveundertakenshoveloperatortraininguntilcompetencyisshownhavepassedapracticaltest

paytheagreedfees.

i y m hs crra, y wll b ss wh a Havy tracr an Mchancal eqpmnlcnc.

Larnng opra a Shvl

unl y g yr shvl lcnc, y may nly rv a shvl y ar nr h sprvsn

an insrcr wh hls a val lcnc r h yp vhcl y ar rvng.


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ts Yrsl Qsns

Q1 What age do you have to be to apply for your shovel licence?

Q2 What tests do you need to pass to obtain your shovel licence?


AQ1Youmustbeover20yearsofageAQ2Yes,aknowledgetestandapracticaltest

?


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Par 1: Lcnc opra a Shvl


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Part 2 : Types and Components of Shovels

Wha s a Shvl?

A shvl s als knwn as a rn-n lar, lar, a bck lar r smms a scp lar. i sa bck ha s n h n mvabl arms. i ls an s s l an mv maral. th shvl spar a racr. i s hr a prmann-mn vrsn r a rmvabl aachmn. th bck a h

n h arms can b rplac wh hr ls, sch as rks r lng palls r bal ls ha arspccally sgn hanl bals hay.

Shvls ar s r:

diggingoperations

levellingoperations

pushingoperations

loadandcarryoperations

handlingloadssimilartocrane

mountingotherequipmentandactingasatoolcarrier

preparingandlevellingstockstoragepads

towingloadsandotherequipmentsimilartoatractorgeneralcleanupofworkareas.


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typs Shvls

thr ar many maks an mls shvls. Y ms lca h prars manal r yr shvl an sy h prang ansay ars. Y wll n ha h psn an pran h cnrls vary cnsrably.

Br sarng r prang yr shvl:

lca an ny ach cnrl an amlars yrsl wh s ncn

chck h psn an pran park braks an mrgncy vcs

knw hw sp h ngn.

Sm shvls ar rack machns. th racks allw hm accss rghr wrkng aras ha wl amag yrs.

Largr shvls hav a srng ar knwn as arcla srng. thy sr rm a pv pn s bwn h rn an raraxls. ths allws h rn axl b sl an sppr mr wgh. th rvr can sr h la bck n a gh arch racha rck. thr s angr ppng vr, bcas h wgh s sh away rm h by h shvl.


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Cmpnns Shvls

Par 2: typs an Cmpnns Shvls


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Shvl Cnrls

thr ar a nmbr pals an lvrs pra. Vars cmbnans wll b s a h sam m, pnng n wha wrky wll b ng. Chck h prars manal r yr shvl r als psn an pran.

Typical controls

1. transmssn gar slcn lvr

2. frwar an rvrs sh lvr

3. Park brak swch

4. Say lck lvr

5. Bck cnrl lvr

6. L cnrl lvr wh ransmssn kck wn swch

7. Brak pals

8. Acclrar.

As wll as h cnrl lvrs an pals, shvls hav alarmsan gags hlp y chck h cnn h shvl.Alarms l y knw whn h shvl s n prang prprlyr whn hr s a angr.

Never continue to use a shovel when an alarm is sounding and never disconnect or tamperwith any warning system


7 8

3

1

2

5

6

4

5

6

4

1

3

7 8

2


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Bck Cnrls

th cnrls l h bck ar: 1. Ras 2. Hl 3. Lwr 4. fla

th cnrls p h bck ar: 1. Rll back, crw r l 2. Hl 3. tp r mp

Make sure you make the raised bucket safe by using chocks, blocks or safety barsbefore you inspect underneath it.


RAISE

LOWER

TILT

DUMP

1

1

2

2

3

3

4


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Pals

Right pedal srvc brak, nrmal brakng prans whnravllng.

Left pedal appls h brak an nralss hransmssn allw h ngn rvs b ncras, whchs s ncras h hyralcs sp.

Park Brake Operation

th park brak shl b abl hl h racr whn llyla h manacrrs maxmm prmssbl racr

wgh, nclng any ballas, qpmn an maral la.

Headlights, Turning Indicators and WindscreenWipers

Y wll n lk a h prars manal r yrshvl lca h swchs r prang h halghs,ncars an wnscrn wprs.

Whn y nrsan h ss a shvl, s pars an h alarms an cnrls, y ar ray prc h nx scn.



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ts Yrsl Qsns

Q1 Name four typical controls on a shovel.

Q2 Name five operations shovels are used for.

Q3 What should you do before inspecting underneath a bucket?

Q4 What are alarms on a shovel used for?

Q5 Large shovels have special steering that lets the driver steer a loaded bucket in atight arch to reach a truck. What is it called?


?

AQ1Transmissiongearselectionlever,Forwardandreverseshiftlever,Parkbrakeswitch,Safetylocklever,Bucketcontrollever,Liftcontrolleverwithtransmissionkickdownswitch,Brakepedals

AQ2Diggingoperations.Levellingoperations.Pushingoperations.Loadandcarryoperations.Handlingloadssimilartocrane.Mountingotherequipmentandactingasatoolcarrier.Preparingandlevellingstockstoragepads.

Towingloadsandotherequipmentsimilartoatractor.Generalcleanupofworkareas.AQ3Makesureyouhavemadetheraisedbucketsafebyusingchocks,blocksorsafetybarstosecureit.AQ4Toletyouknowwhentheshovelisnotoperatingproperlyorwhenthereisadanger.AQ5Itiscalledarticulatedsteering.


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Part 3: Shovel Safety

Larnng oprang an Hanlng Sklls

Yr insrcr wll mnsra a w rang rvng an hanlng sklls an hn g y praccacvs whn h wrk ara whls h sprvss rm whn h cabn. ths acvs wll ncl:

makingsurethattheworksiteissafe

locatingandunderstandingthevariouscontrolsandalarmswithinthecabin

startingtheshovel

movingforwardandreversingtheshoveldrivingaroundobstacles

loading,carryingandunloadingthebucket

unloadingintoadumptruck

spreadingaloadandlevellingoperations

stoppingandshuttingdowntheshovel.

Whl y ar pracsng, yr insrcr wll prv hlpl back.

Your safety and the safety of others depends upon your care andjudgement in the operation of the shovel.


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Wrk S Sayfllw all hs say rls, prcans an nsrcns whn prang r prrmng mannanc n h shvl.

d n pra h shvl y ar n lng wll, r y ar akng mcn whch wll mak y slpy, r y hav bnrnkng alchl.

Whn wrkng wh anhr rvr r wh a prsn n wrk s rac y, b sr ha all prsnnl nrsan all hansgnals ha ar b s.

Always llw all wrk s rls rla say.

B sr all gars an cvrs ar n hr prpr psn an hav hm rpar amag.

Av ls clhng an jwllry, an ls, lng har. thy can cach n cnrls r n mvng pars an cas srs njry rah.

d n war ly clhs, bcas hy ar lammabl. War a har ha, say glasss, say shs, mask r glvs whnprang r mananng h shvl. in sy r hazars aras y may n war a mask r hr brahng prcn.

Chck ha hr s n n nar h shvl br cmmncng prans.



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exrnal Vhcl Pr-pranal Chcks

Carry h llwng chcks br sarng h ngn a h bgnnng h ays wrk.falr carry hs chcks may la srs njry r amag.

Safety decals and shovelspecifications

Safety decals ar sgns ha ar s nca:

gnral say rls

pnally hazars sans

mma hazars whch cl casah r srs njry.

Chck ha y hav ra all say cals anspccan plas. Y wll n rr hs chck an pra qpmn.

Par 3: Shvl Say


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Specifications ar s nca lvls pran. fr xampl, a bl ha has bnghn byn rcmmn rq spccans can asly brak n s an can alscas angr h prar. tyr prssr spccans wll shw h maxmm prssr

r a yr.

Tyres and Wheels

tyrs ar vry xpnsv ms n shvl prans an ar n vrlk rng alychcks. tyr prssr shl b chck rglarly whl h yrs ar cl. Whn ang ar h yr, s a g say a san n s h whl. tyrs hav bn knwn ly h rm.

Chck ha yr prssrs ar whn spccans an qal prssr. Ajs as ncssary.Whn chckng h ar prssr war ll yrs, mak sr h valv s a h p hwhl.

Uneven tyre pressure will cause the load totransfer to the side with the lower pressure andmay cause an overturn.

Chck ha all whl ns ar gh ha hr s n lsnssan ghn rqr.

Vsally chck h yr cas r cs an ggs, sns, wrr mal mb n h rbbr. Rpr any amag yrsprvsr.



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Wheel Changing

dpnng n yr cmpany plcy, may b ncssary rmv an rplac a whl n

yr shvl.

ensr ha h shvl s n a sa psn r jackng. Br psnng h jack, chck hah shvl brakng sysms ar ngag.

Always blck h whls n h pps s h shvl.

Psn h jack n a bas pla an n a sa lng psn.

Lsn h whl ns br lng h shvl.

L h shvl s ha h whl s clar h grn.

Sppr h shvl n a sabl san r wn blcks prvn rm allng rm h jack.

Rmv h whl ns, hn h whl.

A shvl whl wh ballas wll wgh many klgrams. i may ak w ppl manally rmv h whl rh s a mchancal lng vc.

Rmvng h yr an b rm h rm s a spcals jb. thr ar svralyps rms n s n shvls. Y ms chck h prars manal ryr shvl r h rcmmn mh rmvng yrs rm rms r yrshvl.

Nwly yrs an bs wh a mnabl spl rm shl b nla n

a spcal say cag, bcas h rm can ly y ar n carl.

Rplac h whl sng h rvrs prcr.

tak car whn lwrng h shvl ha s n slp h jack. Whn hshvl s lly lwr, ghn h whl ns.

Par 3: Shvl Say


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Lubrication and Hydraulic Systems

Chck r laks an hav any laks rpar. Chck arn h ngn, all hyralc cylnrs an hss, nr h shvl ngn,

ransmssn an l clr. Ajs lvls manacrrs spccans, n. Chck h prars manal r yr shvlr als lbrcan ha s rqr br ach s.

Fuel System

fl lvls may b chck by l gag, p sck, sgh gag r mbl warnng vc.

Br rmvng h l cap, clan r an s rm arn h llr prvn cnamnan.

A l hrgh an accpabl l lr h rqr lvl. Rplac h llr cap whn nsh.

eqpmn shl b rll ar s cl h rmanng l an mnms h nak msr rm amsphr

vrngh.

Chck h brahr n h l ank. A blck brahr may cas a vacm n h l ank an rc r sp l lw. Clanh brahr a rglar nrvals.

Do not fuel the shovel near any fire or flame.



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Oil Levels - Engine Sump

ensr ha h shvl s n lvl grn an allw ngn cl.

Rmv h psck an wp clan wh a clh.

Rplac h psck lly n h hl.

Rmv h psck an chck h l lvl.

A l h crrc lvl n b nscn. Mak sr ha h l s h crrc yp.

Hydraulic Oil Level Reservoir

ol lvl may b chck by psck r sgh gag.

i chckng by psck, s h sam mh as chckng r ngn smp l lvls.

A l h crrc lvl n b nscn. Mak sr ha h l s h crrc yp.

Use a piece of cardboard or wood, rather than hands, and wear eye protection when searching forhydraulic leaks.

escapng hyralc l nr prssr can pnra skn. i l s njc n skn, ms b srgcally rmv whn aw hrs by a cr r gangrn may rsl.

Par 3: Shvl Say


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Engine Coolant Level

i h ngn has bn rnnng, rmv h raar cap wh can

av srs brns.

Mrn ngns s rcvry clng sysms. ths sysm has a smallxrnal cnanr r bl aach h raar vrlw b whchsrs clan. ths s rc rng pran xpansn.Sm h cnns h rcvry bl ar rawn back n hraar as h ngn cls ar sh-wn.

Oil Level - Transmission and Differential Case

transmssn an rnal cas l lvls ar bs chck whn h shvl s park an has cl wn.

th cass may hav a psck, sgh glass, lvl plg r llr plg rqrng rmval nca h l lvl.

A h crrc l hrgh h llr plg h rqr lvl.

Wp p any xcss l, l r hr lammabl ls. Rrn all l cnanrs hr prpr plac.


FULL

LOW

11


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Air Filters and Air Intake

Ar clanr sysms als n rglar mannanc. th ms cmmn sgn ha h ar

clanr sysm ns ann s ha h ncar wll chang clr r h gag wll shwn h r, r an alarm cl sn, pnng n h sysm. Chck r clggng h arclanr. Chck all bng, hss an clamps r scry an salng. Chck yr prar manalr h ar clanr warnng sysm n yr shvl. Sm ar clanr lmns can b clan anrs an sm wll n rplacng.

1. Raw ar nak ara

2. inak manl prssr sal

3. Ar clanr rsrcn ncar

4. Lw prssr (spr chargr) manl

5. Ar clanr

6. Clan ar b

7. Hmp hs clamps

8. Hmp hss

9. Sprchargr nak sal

10. trnkng sppr brack

11. Hgh prssr ar sal

12. Spr chargr

Par 3: Shvl Say

12

6

10

11

12

9

4

3

8

7

5

13

1 2

38

7

6

5

13

49

12

11

10


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Fan Belts

Y wll n chck h nsn h bl by prssng bwn h an an h alrnar pllys.

Electrical wiring

Chck r amag h lcrc wrng. us h prars manal r yr shvl lca h wrng lay r h shvl yar sng. Y shl chck r ray r brkn wrs, an ha lghs an hrn ar wrkng.


FAN PULLEYAPPROX. 75mm

(0.3in)

ALTERNATOR

PULLEY

CRANKSHAFT PULLEY


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Battery Condition

Chckng h bary rglarly s an mpran ask. Ms shvl sarng prblms ar h

rsl pr bary mannanc. Chck h bary r:Crrc lcrly lvl; lw lvl can cas h bary vr-ha an al prmarly; hghlvls can vrlw whn bng rcharg, casng crrsn.

tgh rmnals nsr a g cnncn rng sarng prans.

Ls rmnals can cas a spark, whch n rn can cas an xplsn.

Rs bl-p n h rmnals can cas charg lakag, h rmnals bcm crr anh ara arn h bary b amag. Clan by lshng wh war an hn ca h clanrmnals wh a cmmrcal an-crrsn pas r havy gras.

th bary s scrly rsran. Wrkng vr rgh grn may cas h bary jmp arn an b amag.

Mirrors, Handrails and Steps

Rmv any r rm h mrrrs, hanrals, an sps. Chck hanrals an sps r:

gras

l

m

any hr slppry sbsanc.

Ajs h s mrrr a psn whch gvsh bs vw rm h prars sa.

Clan h srac h mrrr. (i h mrrr glasss amag, rplac wh a nw par.)

Par 3: Shvl Say


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Operators Seat

Ajs h prars sa a psn whr s asy carry prans. Chck r war r amag

h sa bl an sa bl mnng qpmn.

Gauges

Chck ha h gags wrk prprly.

Levers

Chck ha h cnrl lvrs ar a h PARKiNG psn.



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Worksite Emergency Procedures

Y n knw emrgncy Say Prcrs r yr wrks.

Rmmbr ha y wll b abl al mr saly wh an mrgncy Youdo Not PANiC.

Wrks mrgncy prcrs shl nrm y h llwng:

h acn b akn n an mrgncy

wh rpr an whr

mrgncy phn nmbrs

psn mrgncy sp bns

r xngshrs

shwrs

brahng apparas

sa assmbly aras an mrgncy xs

manng hrns, srns, lghs an lags, han sgnals

warnng sgns

wha n h vn a r.

Par 3: Shvl Say


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inrnal Pr-pranal Chcks

Y wll n knw h llwng nrnal pr-pran chcks.

Correct Entry and Exit Procedure

Whn gng n r h shvl, always ac h shvl an manan hr-pn cnac (bh an n han, r bh hans an n ) wh h hanrals an sps nsr ha ysppr yrsl.

Never hold any control levers when getting on or off the shovel.

Always apply h say lck ( ) br lavng h prars sa. Whn sanngp rm h prars sa, always plac h say lck lvr h LoCK psn anparkng brak swch h oN psn scrly. i y accnally ch h ravl rswng lvr whn hy ar n lck, h shvl may snly mv an cas srsnjry r amag.

Whn lavng h shvl, lwr h wrk qpmn cmplly h grn, s hsay lck lvr h LoCK psn an h parkng brak swch h oN psn,

hn sp h ngn an s h ky lck all h qpmn. Always ak h kywh y.

It is very important to use the articulation lock when entering the chassis area between the wheels on anarticulated shovel.


FREE

LOCK


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An arclan lck s s r lckngh pv cnncn bwn h rnan rar rams an arcla vhcl

r prans sch as mannanc anransprng. th arclan lck has anmbr lckng psns. A rmvabllckng pn s sr nx h prarssa.

Sar-p an Sh-wn Prcrs

Y wll n chck h shvl oprars Manal r h crrc prcr r sarng p an sppng yrshvl.

Br sarng h ngn:

Walk arn yr shvl agan js br mnng an chck r ppl an bjcs ha mgh b n h way.

Knw whr ban warnng ags.

Nvr sar h ngn a warnng ag hasbn aach a cnrl lvr r any hr par h shvl.

Prr sarng h ngn, sn h hrn asan alr. Sar an pra h shvl nlywhl sa.

Par 3: Shvl Say

FREE

LOCK

1

DANGERDO NOT operate

When this plate is not being usedkeep it in the storage compartment.

1


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An additional worker should only ride in the shovel when sitting in the

passenger seat. Do not allow anyone to ride on the shovel body.

fllw hs sqnc prans sar h shvl:

Chck ha h park brak s s h ngag psn.

Chck ha h gar slcr s n nral.

Chck ha h rwar an rvrs lvr s n nral an lck ( ).

Chck ha h acclrar pal s psh ar ngh wn (pas h n r nrmal

psn) wrk n wh h brak, s ha a parkng m s ngag r h shvl whl na sanary psn.

Chck ha h l cnrl lvrs ar n h hl psn an h cnrl lck s acva ().

Br rnng h gnn ky, sn h hrn l hr prsnnl knw ha y arab sar h ngn.


ON

OFF

2

1

3

4

FREE

LOCK

1

23

4


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trn h ky h sar psn an hl r a maxmm 10 scns r nl h ngn sars.

Whn h ngn has sar, rrn h ky h oNpsn.

Chck h l an l prssr gags nsr ha hyar wrkng.

Warning:

i h l prssr gag s n cm p h rcmmn prang prssr, shh ngn wn mmaly an hav chck br rsarng.

i h ngn s n sar ar apprxmaly n scns,allw h sarr cl wn an ry agan. i sll wll nrn, rr h oprars Manal an lk nr hangvcs r h ngn (glw plgs).

onc h ngn has sar, l warm prangmprar br s p nr la.

i a rb chargr s , warm p h ngn a hal hra rvs pr mn (RPM) allw h l b sppl

h rb chargr barngs.

Par 3: Shvl Say

OFF

ON

START

OFF

ON

START

Sh l H b k


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Sh-wn Prcr

Sh-wn prcrs wll vary pnng pn spcc maks an mls shvl. Chck h oprars Manal r yr

shvl.

Y wll n llw hs sps sh wn h shvl:

Park n lvl grn an nsr ha h shvl s n bsrc any rac r accss pns prva prpry.

Lwr all grn ngagng mplmns.

Plac h ransmssn an h rwar-rvrs lvrs n nral (an p lcks n).

Plac bck cnrl lvrs n h nral psn.

Apply h park brak.

il wn h shvl r hr v mns, spcally r rb charg shvls. ths prcr allws h cmpnns rmanlbrca whl h rbn sha slws wn an allw hr cmpnns cl wn.

Br lavng h cab, sh wn h ngn, rmv h kys an rlv prssr n h hyralc lns by mvng h bckcnrl lvrs hrgh all psns.

Br lavng h shvl, walk arn an lk r any l laks r any amag ha may hav ccrr rng pran. Rprany laks.

i ncssary, plac a barrca arn h shvl mak sa.


P 3 Sh l S


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Rllng

Rllng a h n h ay wll hlp rc h amn cnnsan n h l

ank. Br rllng:

Sh wn h ngn.

Mak sr hr ar n nak lams n h ara rc h rsk r.

Rmv h ky, lck h cab an rn h slar swch ( ).

Br lavng h shvl, walk arn an lk r any l laks, r any amag ha may havccrr rng h ays acvs. Rpr any prblms.

Chck all l lvls s ha h shvl s ray r h nx ays acvs.

Par 3: Shvl Say

Sh l H b k A Guide to SAfe oPeRAtioN


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Shvl emrgncy Prcrs

th llwng s a srs pssbl mrgncy sans. th prcr ls s nly a g an may vary wh

ach nval san as vlps.

Shovel Begins to Side Slip on a Grade

immaly sps h la.

trn h shvl wnhll.

Plac h bck n h grn ac as a brak.

Shovel Catches On FireSp h shvl.

i pssbl ras h alarm sng h ra.

trn h shvl .

G pssbl.

us r xngshrs pssbl.

Shovel Contacts Live Power Lines

d n panc.Rman ns h cabn.

Warn all hr prsnnl kp clar rm h shvl an n ch any par h machn.

try na, an wh anyn apprachng h shvl, mv h shvl nl s clar h pwr lns.

i h shvl cann b mv, rman ns h cabn. i pssbl, hav smn nrm h pwr spply ahry an havh pwr scnnc. tak n acn nl has bn cnrm by h ahry ha cnns ar sa.


P 3 Sh l S


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i y ms lav h shvls cabn bcas r r hr rasns, ak h llwngacn:

Jmp clar as ar as pssbl rm h shvl.

d n a any m mak cnac wh h shvl an h grn a h sam m.

Whn mvng away rm h shvl, h prar shl shl r hp slwly away rm hshvl acrss h grn ara ha s nrgs wh lv pwr.

Av larg sps bcas n cl b n a hgh vlag ara an h hr n a lwvlag ara. unr sm crcmsancs, h rnc bwn h w cl b aal.

The danger when dismounting is that you may make contact with the live truck and the

earth at the same time, causing the power to earth through you resulting in death or injury.

Hav h shvl chck by a cmpn prsn r amag prr rhr s.

Shovel Ruptures a Gas Line

Sp h shvl.

trn h machn.

Lav h shvl.

Ny h apprpra ahrs.

Kp h ara clar any prsnnl.

Par 3: Shvl Say



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Shovel Stalls on Steep Ramp or Road

Say ns h cabn.

Apply brak r mrgncy brak.Brng shvl a sp.

Lwr all qpmn.

Amp r-sar h ngn.

Chck h whls.

Rpr h prblm an plac an srvc ag n h shvl, rqr.

Shovel Has a Steering Failure

Say ns h cabn.Apply h brak r mrgncy brak.

Brng h shvl a sp.

Lwr all qpmn.

Chck h whls.

Plac an srvc ag n h shvl.

Rpr h prblm.

Shovel Has Brake Failure on Steep Ramp or Road

drp h bck an s as a brak, ncssary.

Brng h shvl a sp.

Say ns h cabn.

Apply h mrgncy brak.

Chck h whls.


Par 3: Shvl Say


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Plac an srvc ag n h shvl.

Rpr h prblm.

Shovel Becomes Hung-up On Edge of StockpileSay ns h cabn.

Apply h park brak r mrgncy brak.

Call r asssanc.

Shovel Rolls Over or Partially Rolls on a Slope

Say ns h cabn nl h shvl sps.

Call r asssanc.

Shovel Slips into a Cone or Hole When Pushing Up a Stockpile

Say ns h cabn.

Swch h mr.

Call r asssanc.

Gv yr xac lcan whn callng r asssanc.

Shovel Rolls Over the Edge of a Stockpile

Say ns h cabn nl h shvl sps.

Wa r asssanc.

Par 3: Shvl Say



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Part 4: Shovel Operation

Plannng Wrk

i s mpran hav a g knwlg h wrk s br cmmncng prans.

th yp wrk an maral b hanl wll n b cnsr whn prparng h shvl rwrk. Par yr plannng prans wll ncl carryng any sa prang prcrs rqra h s.

thnk ab h llwng pns:

Whereisthematerialtobemovedto?

Isittobemovedonlywiththeshovel?

Willitbeloadedontoahaultruck?

Isittobestockpiled?

Areyoudiggingitdirectfromthefaceorfromastockpile?

Say cnsrans shl ncl:

observationsofsitespeedlimits

safeworkingaroundoverheadpowercablesundergroundpower,water,gas,telephonelines

overheadconveyorsandequipment

workingsafelyaroundothershovelsandpeople

sitetrafficrules,forexample.loadedvehicles,watertrucks,etc.



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nrgrn srvcs sch as pwr, lphn, gas, war, swr, ranag, br-pc cabl lns

vrha angrs sch as pwr an lphn lns r hr bsrcns

vrrnng angrs sch as slpng grn, hn hls an rp-s.

fllng h Bck

Y wll n knw h llwng mpran acs:

Smh shvl prans, rahr han jrky mvmns, nabls mr cn an spy s h shvl. ths rsls nlss war an ar n h shvl an lss prar ag.

th sgn h cnrl valvs n h shvl prm h prar cmbn ncns an cnrl sp, ha s ras an

crw h bck a h sam m.th prar can ahr h cnrls r slw, asy mvmn, hs avng rrac, jrky mvmns whch can cassbsanal war n h shvl.

Ms shvls ar sgn s ha mr han n mvmn can b achv wh h s n han, whl h hr han ss r h srag h shvl.

t ll h bck capacy a vry amp rqrs pracc an g han y crnan.

A nw prar may n svral amps lly la h bck; wh pracc h skll wll b masr.

d n b mpan! tak yr m! G h cab h rs w ms an lk a h bck psn, y ar havngcly.


Par 4: Shvl opran


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fllng h Bck rm a Sckpl

Y wll n knw hw ll h bck sng h llwng prcss:

S h shvl acng rcly h rn whn carryng ggng r scpng prans, nvr carry hsprans wh h shvl arcla.

drv h shvl rwar an lwr h bck ab 30cm rmh grn, hn lwr slwly h grn. Sh wn h rqr gar, prss h acclrar pal an hrs hbck n h la.

A h sam m as hrsng h bck n h maral, rash l arm prvn h bck rm gng n ar an ncras h pnrang rc.

Chck ha hr s ngh maral la n h bck, an

hn pra h bck cnrl lvr l h bck an la lly.

i hr s mch maral la n h bck, mp anl h bck qckly rmv h xra la. ths prvnsspllag h la rng halng an assss n kpng hwrk ara lr clan.

Par 4: Shvl opran

Come in level

30 cm

(12in)



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t fll a Bck Whn dggng an Lang n Lvl Grn

ths pran shl b carr n 1s gar.

S h g h bck acng slghly wn.

drv h shvl rwar an pra h l arm cnrl lvr rwar c a hn layr hsrac ach m whn xcavang h sl.

opra h l arm cnrl lvr slghly p an wn rc h rssanc whn rvng hshvl rwar. Whn ggng wh h bck, av mpsng h ggng rc n nly ns h bck.


Par 4: Shvl opran


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transprng wh a fll Bck

th llwng chnq s r ravllng wh a la bck.

Carry h la bck as lw as pssbl, a all ms, rbs vsbly an sably.

only ras h bck js prr scharg h la.ths wll kp h lars cnr gravy lw an hlp av nsably makng a sn sp.

i s mpran av sn sars, sps r changsn rcn. opra h shvl cnrls as smhly aspssbl.

Y n ak car whn lng an ransprng las, sch as larg blrs, as hs cl p hbck as s ras an cas njry r amag.

Par 4: Shvl opran

40 - 50 cm

(16 - 20 in)

INCORRECT



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Lang a trck

th crrc prcss r lang a rck s as llws:

Always apprach h sckpl an h rck a a 90 gr angl.

Algn h bck wh h cnr ln h rck, ras h bck clar h rck byan cmmnc mpng h maral. i ncssary, shak h bck slg any sckmaral.

Spra h maral as y g nsa js mpng n p. Wrk rm h cabn halga. By mpng hrgh h pl y can spra an mp a h sam m. t hs, lwr h bck n a way ha nsrs ha as s mp, smhs h prvsla (back blas ), hrby sprang h la wars h shvl.


Par 4: Shvl opran


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Lvllng an Pshng oprans

th crrc prcr r lvllng shl always b n wh h shvl n rvrs. (i s

ncssary ravl rwar whn carryng lvllng, h bck mpng angl shl nb s mr han 20 grs rm lvl.)

Scp sl n h bck. Mv h shvl backwar whl sprang sl rm h bck llby ll.

G vr h spra sl wh h bck h chng h grn an lvl h grn by backraggng.

Scp sm mrsl n h bck,p h l arm nla, lvl h bcka grn lvl ansmh h grnby mvng backwar.

Whn carryng pshng prans,s h bm h bck paralll h grn srac.

Nvr s h bck h duMP psn whn carryng pshngprans.

p

12

3



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travllng n Slpng Grn

Y wll n b vry carl whn ravllng n slpng grn. Y shl:

Wrk rm a lvl srac whrvr pssbl. i n pssbl, hn mak sr y hav a la arar sa rnng, lang an nlang.

Always hav a la bck phll h machn whn ravllng p r wn nclns.

Whn ravllng mpy n an ncln, always hav h rar n h machn pn phll.Always BACKuP an dRiVe doWN nclns.

Slc a lw gar whn ravllng wn nclns maxms ngn brakng an mnms h nr brak pran. NeVeR cas r rwhl wn gra n nral.

Av makng any rns r ravllng acrss nclns. i navabl, mak sr h cnr

gravy h machn s as lw as pssbl an ak car n mak any sn changs nsp r rcn.

Chck sl cnns whn wrkng n banks - sls an cavng ar a ral hazar. Shr anbrac as rqr.

Wach r ls maral whl wrkng n nclns, as h machn may sl an b plac n aangrs psn.

Whn wrkng nar chs r rnchs n slps, xra car ms b akn av h wgh h qpmn casng a sl r cavng.

Y wll nw hav an nrsanng h crrc way n whch pra a shvl.

CORRECT

INCORRECT

Par 4: Shvl opran


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ts Yrsl Qsns

Q1 Why is it important that the front tyres are of equal pressure on yourshovel?

Q2 Name 3 faults to look for in the hydraulic system.

Q3 What gear should you use when travelling on a sloping surface?

AQ1Uneventyrepressurewillcausetheloadtotransfertothesidewiththelowerpressureandmaycausetheshoveltotipover.AQ2Leaksformseals.Splitorbrokenhoses.Bentordamagedrams.AQ3Thelowestpossiblegear.

p

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Part 5: Fitting and Removal of Attachments

frn Aachmns

frn aachmns ar sally by hr pns. tw hs pns rm h hng bwn h lar armsan h aachmn an h hr s cnnc h

hyralc l cylnr/s r l mchansm an s cnrl h aachmns angl r plan.

Sm lars hav a qck hch mchansm

whch maks changng aachmns a smpl anspy n prsn pran, b bcas srngh, hs ar sally lm mrasz shvls an wll n b cvr n hscrs.

thr ar hr man yps bcks s nh cnsrcn nsry.

HINGE PIN BUSH BOSSES

CROWD CYLINDER BUSH BOSSES



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General purpose excavating buckets

Gnral prps xcavang bcks ar s r nvrsal xcavang,lang, backllng an lvllng. ths bcks can b s n js abany san.

th bck has a sragh bas g, rn crnrs an sragh s bars,all whch ar nrmally wl h bck assmbly.

thr s gnrally a spll pla r rck gar h p h shll.

General purpose penetration bucket

Gnral prps pnran bcks ar s r xcavan wrk n maral ha rqrs mra brak an mpacrcs.

Gnral prps pnran bcks hav lsh-mn h an crvs bars mprv h pnran, an a sragh bas g mprv hwrk srac.

thy gnrally hav a rnrc bck shll an a ll wh back rag g.th bcks hav wl n aaprs an lng ps.

SPILLPLATE

SHELL

BASE EDGECORNER

Par 5: fng an Rmval Aachmns


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Multipurpose bucket

th mlprps bck s a cmbnanbck ha has r psns; ach hspsns can b slc rm h prarssa.

th r psns ar knwn as:

Bucket: us as a nrmal bck hanlmaral.

Blade: us r gnral pshng, sprang an grang.

Scraper: us r scrapng acns sch as sprang s marals an/rnsh lvllng an rmvng hn layrs maral whn s prprly; vrycv whn mvng rwar.

Clam shell: th clam pran h bck s s allw h prar pck pbjcs r grab an hl.

BLADE

BUCKET



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Rar Aachmns

thr ar vars yps rar aachmns ha can b s:

Augers

Agrs ar gnrally s rng nc cnsrcn r whn snkng prs rng slabcnsrcn.

GrabsGrabs ar mchancal hans s pck p an plac bjcs whr rqr. Grabs varyn pnng pnng n h jb. Marals may ncl rms, pps vars sz,mbr lgs an larg bjcs cra.

Rippers

Rpprs ar s n har grn prpar r rmval.

ths vary n sz an nmbr pnng n h sz h shvl. Gnrally rpprscm n n, w an hr yp arrangmns.

Y wll n chck h shvl r aachmn spplr hanbk bcas ngarrangmns wll vary.

HYDRAULIC MOTOR



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Hw f, opra an Rmv Cmmn Aachmns

th pran all aachmns, whhr rn r rar, shl always b accrng h

rlvan manacrrs spccans an say nrman.

Front Attachments

Aachmns s n a shvl all cnnc h samplac n h shvl. ths s a ypcal aachmn ancnncn:

Bcks an aachmns ar sally h bmsng pv pns ha naly n grasabl bshbsss, as shwn n h llwng agram.

th pns ar gnrally hl n plac wh crclps (snappns) r ar lck by lckng bls an sl lckng ns prvn h aachmn pns rm allng .

in ms cass washrs wll b s n h pns ak p any xcss claranc bwn h aachmn an hbm arms an/r crw cylnr. i s ncssary ha hs pars ar manan n g cnn an rplacr rpar amag r wrn. i s prrabl hav a s washrs r ach aachmn as hs nabls hcrrc spacng ach aachmn. N ha h washrs shl always b plac n hr rgnal psns rc war an bnng h aachmns.

Y shl always bsrv h llwng whn changng aachmns:

Sp h shvl n a rm, la srac an mak sa.Whn prrmng wrk n h jns an lnkags wh smn ls, svally mpran ha:- all sgnals ar ma clarly ach hr; an- bh h prars ar lly awar h prcr ha wll b s cmpl h changvr.

HINGE PIN BUSH BOSSES

CROWD CYLINDER BUSH BOSSES



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Fitting an Attachment

ths s h prcr mn a bck r aachmn:

Plac h aachmn r bck n h nrmal mnng psn.1.Clan all pns an bshs hrghly.2.

Apply gras all pv pns accrng h manacrrs spccans.3.

Sar shvl an l p h aachmn.4.

Algn h bm wh hr rspcv bsss n h aachmn.5.

insr h bm pns. Mak sr h washrs ar n plac. ths prcr n ns h hlp a small pry bar r g pn6. algn h bm an bss.

G h crw cylnr s bss. ths pran s mch smplr wh w ppl.7.

insr h crw cylnr pn. Mak sr h shms ar n plac.8.Sh wn h shvl.9.

f h snap rng, crclp r bl ach h pns.10.

Apply gras ach pn h manacrrs spccans.11.

i h aachmn has hyralc cnncns, hs shl nw b cnnc. Sr h bngs an caps r lar s.12.

Sar h shvl.13.

opra h aachmn, chckng r any bnng r n mvmn.14.

Chck r hyralc laks as apprpra.15.



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Removing an Attachment

ths s h prcr rmv h shvl bck r aachmn:

Rear Attachments and Connections

As h ng arrangmns r rar aachmns vary wly, y wll n cnsl h shvl r aachmn prarsmanal r h crrc prcr r h shvl an rar aachmn.

Slc a la srac an sabls h bck r aachmn n h grn.1.Sp h ngn.2.

i h aachmn has hyralc cnncns, hs shl b scnnc. f bngs an caps3. all hyralc lns.

Rmv h snap rngs, crclps r lck bls r ach pn.4.

Rmv h crwng cylnr pn. Wach r mvmn h crwng cylnr as h pn s5.rmv. ths can cas a crsh njry.

Rmv h bm pns rm h bck. Wach r mvmn h bck as h pns ar rmv.6.ths can cas a crsh njry.

Sar h shvl, rvrs away rm h bck slwly an l h bm as h shvl s rvrs.7.

Ar rmvng h pns, mak sr ha hy n bcm cnamna wh san r gr. Plac plgs8.r clan rag n h bsh bsss h aachmn r bck sp h ngrss san r gr n hbshs.



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ts Yrsl Qsns

Q1 What would you look for on the attachment pins to make sure they do not fall out?

Q2 During the routine check, you may find excessive wear in the power arms and connectionsthat will make the loader dangerous to operate?

Q3 What faults would you look for when doing the external check on the bucket of a front-end loader?

AQ1Makesurethatthesafetypinsandkeepersareinplace.AQ2Tagtheequipment.Tellthesupervisor.Donotusetheequipmentuntilrepairshavebeencarriedout.AQ3Lookforwornormissingteeth.Lookforaworncuttingedgeandotherdamagetothebucket.Checkbucketpivotpinsandkeeperplates.

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Copyright Roads and Transport Authority (RTA) 2008

Documents

Shovel Handbook En