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Surface Mechanic
Contact:  Palmer.Melvin@dol.gov
1. Start-of-shift Activities
Attend Pre-shift Meeting
Discuss equipment down
Obtain copy of Down Sheet
Be sure the trainee gets the appropriate information at beginning of shift
Obtain assignments
Check trucks
Check dozers
Check shovels
Check graders
Check loaders
Teams of two, if possible
Enter Sub-topic
Self Assessment
2. Working on equipment in the pit and shop
Determine if downed equipment can be moved and move to another location, and coordinate maintenance work with pit boss
Maintaining safe work area Estimated time to repair equipment, ask about blasting times & locations
Have operators position equipment in a safe area to be worked on
Park equipment away from highwalls and spoil area
Refer to company policy
Park equipment out of traffic pattern
Refer to company policy
Have operators exit equipment (unless needed for testing)
Refer to company policy
Attach keys to tag out and place on steering controls
Refer to company policy
Examine immediate work area
Look for slip and fall hazards
Clean-up immediate work area of grease, oil mud, water, hydraulic fluid, anti-freeze, snow/ice/rain, rocks
Examine highwall/spoil
Check for loose material, major cracks, mud slides, movement, overhangs, slips, water running off highwall, weather conditions. If at all possible, do not work between highwall/spoil and equipment. If you must work in pit, keep equipment as far away from highwall spoil as possible
Determine if equipment is loaded/unloaded, especially trucks
Truck may have to be unloaded with a different piece of equipment
Barricade work area if necessary for traffic control or falling materials
3. Examine Work Areas
Establish communications
CB channels
Demonstrate use
Company FM radios
Demonstrate use
Examine Pit Areas
Examine haul road for congestion and traffic patterns (English/American)
Examine intersections
Mine
Public
Stop/yield right-of-way to public vehicle
Check for equipment
Check for pick-up trucks
Check for persons on the ground/in area
Observe condition of haul road
Check for debris (rocks), soft spots, & holes
Observe wet/dry and visibility conditions
Observe Berms
Report berm defects to supervisor
Maintain spacing
Keep safe distance between mobile equipment; use three second rule
Enter the pit
Examine ramp and look ahead for drop offs
Communicate with trucks or other equipment where you are going
Examine Shop Area
Examine Inside Shop
Use required PPE
Company policy; hard hats, steel toe shoes, safety glasses with side shields
Look for slip & fall hazards
Use oil dry to clean up all oil, grease, water, and hydraulic fluids
Remove other housekeeping hazards
Maintain supervisor policy. Trash, shop rags, flammable storage, pallets, used parts and materials
Look for trip & fall hazards
Air hoses, cables, tools, parts, cribbing and extraneous materials. Roll up all cables, cords, & hoses and pickup cribbing tools, and extraneous materials
Observe if clear access is provided to fire extinguishers and electrical boxes
If these areas are obstructed, you are to immediately provide clear access
Maintain clear access to first aid equipment and supplies
Keep eye wash station clean, keep supplies stocked
Maintain clear access to all exits
Maintain proper illumination
Check ventilation controls
Observe compressed gas tanks
All unguarded valves must be protected and secured
Examine Outside Shop
Keep area clean
Pick up cribbing, blocks, trash & used parts, use dumpster where provided
Secure compressed gas cylinders, use storage area provide, and observe the no smoking rule
All unguarded valves must be protected and secured
Observe metal rack for material storage and cleanliness
Be aware of sharp points
Adjust your work based on weather conditions to avoid slip and fall hazards
Be aware of snow accumulations on roof, rain/snow/ice, ground conditions (mud), & dust
Observe traffic and equipment in the area
Including vendors
Park service trucks in specified areas
North and East sides of building
Check Fuel Storage Area
Water inside containment area
Tank leaks & fire extinguishers
Two extinguishers required
4. Examine equipment for preventive maintenance
Obtain light
Examine Shovel
Conduct visual inspection
Ladders
Handrails
Bucket
Grease lines
Start at left side of shovel
Inspect pump room
check for bad hoses and leaks
Check mainframe for cracks
Inspect Engine for leaks, hoses, belts, and guarding
Cross top of machine
Inspect Fire suppression canisters
Inspect sheet metal for debris & build-up across top of machine
Inspect Air intake hoses for engine
Inspect Handrails
Examine Air compressor for oil leaks, guards, pressure gauge, pressure relief valve, and drain plugs
Open Cab door
Inspect Instrument panels for warning lights
Cross down to right side
Inspect Engine for leaks, hoses, belts, and guarding
Inspect pump room for bad hoses and leaks
Report problems for possible hold over
Common problems observed
Broken grease lines
Leaks
Hydraulic
Engine
Tooth tip missing
Guard missing on bucket
Damage to sheet metal
Damage to handrails
Maintain communications with equipment operator
For the 1800, inspect front-to-back instead of side-to-side
Examine Trucks
Ensure all trucks are in the ditch and operators exited cab before examination
All maintenance employees must be out of ditch by 15 minutes prior to start of shift
Inspect visually Left side of truck engine for the following
Inspect Intake Air Boots
Inspect the fan, alternator, AC belt and guards
Guards secured / Bolts intact
Inspect fuel filter and fuel lines for Leaks
Inspect steering hose
Inspect radiator hoses
Check clamps
Inspect Wheel for the following:
Inspect Seals
Oil in wheel, look for oil starting to pour, contact supervisor if conditions are found
Inspect Brake pad
Cracks in discs, wear
Check for missing or loose lug nuts and wedges
Check for spun (shiny metal)
Inspect Tire
Check for inflation/bulging
a low tire will bulge on the bottom
Check for Damage including the following:
Cuts
Sidewall Cuts
look for sidewall Cuts that bulge all the time and contact supervisor
Inspect Rim
cracks and bending
Inspect rings (bead & lock)
Inspect front trailing arm for cracks
Lock and tag out of service and notify supervisor immediately
Inspect tie rod ends
Show trainee a loose tie rod for reference
Inspect struts
Check for leaks in cylinders
Oil leaks indicates damage
Check for broken bearings
Examine steering cylinders
Check pins/bearings are in place
Check for oil leaks
Underneath - Middle of truck
Check drive shaft for U-joints, caps, & Damage
Examine truck body/frame & cracks
Notify supervisor immediately
Examine for hydraulic leaks
Look for hoses rubbing against each other or metal
Inspect transmission visually for leaks and loose bolts
Examine wish bone bearing
Look for bearing broken or bolts missing
Rear of Truck
Inspect struts for the following
Check for pins coming out
Lock and tag out of service; immediately contact supervisor
Check for bearings and oil leaks
Examine bed pins
Lock and tag out of service; immediately contact supervisor. Remember to check for crack on bed ears.
Check for broken lens/camera
Check visually for physical damage to back-up alarm
Check all lights
Go back to rear wheels
Inspect Tire for
Check for inflation/bulging
a low tire will bulge on the bottom
Check for Damage including the following:
Cuts
Sidewall Cuts
look for sidewall Cuts that bulge all the time and contact supervisor
Inspect Rim
cracks and bending
Inspect visually right side of truck engine for the following
Inspect Intake Air Boots
Inspect the fan, alternator
Inspect fuel filter and fuel lines for Leaks
Inspect steering hose
Inspect radiator hoses
Check clamps
Inspect Wheel for the following:
Inspect Seals
Oil in wheel, look for oil starting to pour, contact supervisor if conditions are found
Inspect Brake pad
Cracks in discs, wear
Check for missing or loose lug nuts and wedges
Check for spun (shiny metal)
Inspect Tire
Check for inflation/bulging
a low tire will bulge on the bottom
Check for Damage including the following:
Cuts
Sidewall Cuts
look for sidewall Cuts that bulge all the time and contact supervisor
Inspect Rim
cracks and bending
Inspect rings (bead & lock)
Inspect front trailing arm for cracks
Lock and tag out of service and notify supervisor immediately
Inspect tie rod ends
Show trainee a loose tie rod for reference
Inspect struts
Check for leaks in cylinders
Oil leaks indicates damage
Check for broken bearings
Examine steering cylinders
Check pins/bearings are in place
Check for oil leaks
Check hoist cylinder on both sides of truck
Front of Truck
Check grill for damage
Check handrails
Check steps and ladder
Check head lights in place
Check strobe lights in place
Check actuator on fire suppression system
Ensure red plunger is intact
Examine Dozers
Do not work on dozer if operator is in the cab - company policy
Ensure blade and ripper is on the ground
Check the push arm on the left side for cracks and ball wear
Check Tracks - left side
Check for broken/missing pads
Check bushings for wear
Check pins for stretch
Check for missing bolts
Check bottom roller bolts
Check front and rear idler bolts
Check final drives for heat
Check segment bolts
Check tilt cylinder pins (upper and lower)
Examine for missing or broken bearing
Check fire extinguisher
All mobile equipment must have a fire extinguisher - company policy
Check blade yoke and pins for missing bushings/pins and wear
Check grab rail
Walk to front of dozer
Check for missing bolts in cutting edge
Check skin on blade
Walk to right side
Check Tracks - right side
Check for broken/missing pads
Check bushings for wear
Check pins for stretch
Check for missing bolts
Check bottom roller bolts
Check front and rear idler bolts
Check final drives for heat
Check segment bolts
Walk to rear of dozer
Check ripper pins, bushings, cylinder leaks, and missing ripper tooth/teeth
Ensure fire suppression canisters are intact
Craw underneath dozer
Check for major oil leaks
Immediately shut down, lock & tag out and report it to supervisor
Check belly pans bolts are in place
Check seals on pivot shaft
Check roller and idler bolts (left and right)
Check equalizer bar (E-Bar), center pin, left & right outer pin
Check for tightness
Craw out the front of the dozer
Check stabilizer arm
Mechanic Truck
Conduct pre-shift
Check seat belt
Refer to company policy
Check back up alarm while in cab
Must be audible - company policy
Check cab for extraneous materials
Check parking brake
Check forward horn while in cab
Check radio/communication
Check all lights
Check glass for cleanliness and damage
Check fire extinguisher
Check bay doors
Chock tires
Chock tires before crawling under truck. Chock tires when if parked on incline, refer to company policy
Check tires
Tap with hammer
Look underneath
Check oil leaks
Check drive shafts
Ensure acetylene and oxygen tanks are secured and stored upright
Check gauges and gauge guards
Ensure hoses are rolled up
Ensure crane is cradled and electrical wires are connected
Check bumper for loose materials
Refer to company policy
Remove extraneous materials from bed of truck
Remove chocks and store in truck
Complete and turn in inspection sheet
Put on seat belt
Company policy
Sound horn before moving
Company policy
Drive defensively
5. Replacing Shovel Crowd or Level Cylinder
Place shovel in a safe and level location
Use manlift or bucket truck
Refer to company policy on manlift use
Secure cylinder by chaining to bottom of boom
Use a minimum 3/8" chain and 1 1/2 ton come-along.
Remove stick end pin using a pry bar and sledge hammer
Check with lead man
Retract and secure cylinder rod completely with chains
Lock controls
Shut machine down
Bleed Hydraulic System using valve and auto shut down switch
Beware of hot hydraulic oil wear PPE - gloves& glasses. Leave key on for shut down switch to work
Remove hydraulic hoses
Refer to procedures
Cap hoses
Position forklift under cylinder
Use specific forks and cradle. Check for clearance and balance
Secure cylinder to forklift with rated come- alongs
Remove second pin
Check with lead man
Lower cylinder slowly ad beware of surroundings
Remove old cylinder with mechanic crane truck
Replace cylinder
Reverse procedure for installing new cylinder
Close bleed off valve
Charge the system (start shovel)
Warranty requires this
Bleed air from cylinder at bleeder ports
6. Equipment Cribbing
Ensure stable foundation for cribbing and jacking
Weather conditions
Determine method of lifting equipment prior to cribbing
Hydraulic equipment and/or jack used for lifting only - cannot be used as cribbing
Using hydraulic Jack
Know jack and hose rating and check gauge
Using machine hydraulics
Check machine hoses. Test machine drift from hydraulics leaking off prior to cribbing
Determine cribbing needed for the equipment being worked on
Spacing, weight, type of repair to be performed
Obtain cribbing materials
Improper lifting and handling causes several injuries. Get additional help if needed
Use solid cribbing such as straight-grained hardwood
Check condition of cribbing material and discard damaged or defective material
Use rated or approved metal jack stands on solid surfaces
Use only proper pins (not bolts)
Use rated or approved stands
Know the capacity of the stand
Lower machine weight onto cribbing
Recheck the stability of cribbing
Lower and lock all machine components to the ground
7. Using Cutting Torch (from service truck at equipment)
Use required PPE
Face Shield, gloves, leather welding vest, safety glasses, footwear, secure pant legs
Remove all personal combustible items
Matches & lighters. Check clothing for combustibles
Inspect (visual) equipment and area
Accumulation of flammable/combustible materials
Wash down or wet area
Identify and inform personnel exposed to work-site
Barricade areas affected if necessary
Maintain proper ventilation
Use confined space guidelines
Examine work area for hazards near cutting site
Refer to Examine Work Areas. Fuel Tanks, hydraulic tanks, hoses, electrical wires.
Establish fire watch
Use fire blanket when needed
To protect electrical harnesses cylinder rods, glass, hoses
Hook up torch
Stand to side while pressurizing the gauges
Observe gauges for operating pressures
Acetylene pressure should not exceed 15 PSI
Oxygen - 40 lbs
Check tip condition
Check for installation of flash back arrestor
Mandatory- company policy
Check hoses for damage
Burn spots, cuts, holes, kinks
Locate and position fire equipment
Fire Extinguisher and Fire Suppression Cart
Disable automatic mode of fire suppression system
Refer to disarming procedures. Make sure you rearm the system after work is completed
Light torch
See JTA for welding and burning
8. Dropping the Belly Pan
Obtain sheet steel for field installations
Company policy
Determine a level, dry, and remote location to perform work
Place pan cradle on jack
Position jack and metal for field work
Position dozer over jack and metal
Lower all implements
Lock out and tag equipment
Company policy
Center jack under pan to be removed
Weight of pan on jack
Wear kneepads
Ensure that all pan bolts are in place
Accidents have occurred
Pull hinge pins on pan
Loosen until one full nut thread remains on all four bolts
Lower jack to check to ensure pan is free - resting on nuts, jack, and cradle
Raise jack back up to take weight of pan
Remove all four nuts
Stand clear
Lower Jack
Reinstalling Belly Pan
Reverse Procedure
Pan may not align with bolts. In this case, manual alignment maybe necessary.
Try to get one bolt down through the pan; install nut with all the thread you can get.
Finish aligning pan
Pull bolts through pan
Install nuts and tighten
Store Jack
Clean work area
9. Replacing a hydraulic hose
Make sure all implements are at rest
Shut machine down
Block against motion
Relieve tank pressure
Be aware of hot hydraulic fluid, wear PPE (glasses, gloves, full face shield)
Hold Vacuum on tank when needed
If in question ask experienced help because this does not apply to all applications
Clean work area and hose connections
Cover hose end with shielding material
Wrap in rags, ect.
Wiggle hose until fluid flows
Remove the hose
Install new hose
Use that meets manufactures specifications
Refer to parts manual or ask
Ensure new hose is clean
Clean ends and inside to prevent contamination
Reinstall all factory clamps
Prevents premature failure due to rubbing, pinching, and kinking
Leave area of repair
Restart machine
Check hydraulic fluids level and bleed system if necessary
Check for leaks
Clean up work area
10. Hinging Belly Pan
Determine a level, dry, and remote location to perform work
Get your service truck
Dig out roller frame
Run crane cable between roller frames and track
Center cable under pan
Secure cable to track pad on opposite side
Tighten tension on crane cable
Make sure all hinge pins and brackets are in place
Make sure all four bolts are in place
Loosen all nuts until one full nut thread remains on each bolt
Release cable tension slowly until pan is free
Tighten tension on crane cable so nuts can be removed
Remove nuts opposite the hinge first
Remove hinge side bolts last
Remove yourself from area
Release cable tension slowly until pan is resting on block
Make repairs
Tighten crane cable
Start raising pan in position
Install hinge side nuts first
Install opposite side nuts last
Tighten all nuts
Unhook crane cable
Retract crane cable
Clean area
11. Changing Dozer Rollers
Place machine on clean, level spot
Clean off the top of the roller frame
Chain major bogey to the side frame while machine is sitting on ground
Visually inspect chain
Relieve track tension
Raise the machine using the blade and/or riper
Test hydraulics for drift
Insert beam or spacing tool between rollers on minor bogey and track
Refer to diagram, use the right tooling
Lower dozer back down
Obtain and use proper lifting device
Use saddle beam or fork truck
Use saddle beam or fork truck. Caution hotness of roller. Refer to mfg's manual
Ensure two inside bolts are in place
Remove the outside two bolts first
Must be removed before installing tooling
Install lifting device
Go under tractor to loosen two inside bolts
Make sure roller stays against frame
Remove inside two bolts
Lower from under machine
Reverse procedure to install new roller
12. Working from Elevated Areas
Determine if you need to steam/clean area
Inspect and put on your fall protection equipment
Demonstrate the right way to put on fall protection. Discuss lanyard length
Use Fall Protection
Company policy
Determine if you need a man lift, ladder, or additional help
Communicate with co-worker
Operating the man lift
Ensure handrails/guardrails are in place and in good condition on the man lift
Use Fall protection (required)
Follow company policy on operating man lift
Using ladders
Use the right ladder for the job
Never climb on top step, secure ladder if needed. Refer to ladder safety sheet
13. Mounting & Dismounting Equipment
Ensure equipment is blocked/chocked from unplanned movement
Company policy
Visually examine ladders, steps, and handholds
Oil,grease, mud, make sure steps/ladders are in good shape. Clean if needed
Use the three points of contact
Use ropes to raise up supplies if necessary, do not hurry climbing ladder, use all steps in sequence, do not jump,face machine.
Check and clean the bottom of shoes
Wear proper footwear. Consider the surface you are going to be working on. Company policy.
Follow company policy
About
Title
Surface Mechanic
Subject
-
Company
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Author
debbie combs
Version
122
Comments
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