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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 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 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 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 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 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 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 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 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 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 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 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 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