This module describes the basic job steps, potential hazards or accidents, and

recommended safe job procedures for front-end loader operation.

Front-end loaders are probably the most versatile machines utilized at surface metal and
nonmetal mines. The front-end loader can be used for many purposes, including: loading
haulers, pushing material, grading, hauling material, and working stockpiles or spoil areas.
Front-end loaders, typically with 14-16 cubic yard buckets, are sometimes used for stripping
overburden. The most common use at surface mines is for loading waste rock haulers and
ore haulers.

This module is designed primarily for use in the initial training of front-end loader operators.
The content deals with the loading of haulers or bins and hoppers, but can be applied to
other jobs performed by a loader. The material should be used by the trainer as a
supplement to practical knowledge and specific mine conditions.

Many surface metal and nonmetal miners are injured or kiled each year in loader
accidents. Loader accidents frequently occur when tramming an unloaded machine at high
speed. Accidents also result from collsions with other machines, a person getting caught
in pinch points, and spilage of material while tramming or loading. Numerous other
hazards exist, and loader operators must be aware at all times of hazards that can cause
injury.

Self-propelled machines that wil be used during a shift must be inspected by the machine
operator before operation. Particular attention should be given to the steering and braking
systems, in order to ensure proper working order. Headlights, horns, and backup alarm
systems must function properly at all times. Seat belts must be provided and worn.

The basic job steps included in this module are:

1. Conduct walk-around check of loader.

2. Mount loader and check cab.
3. Start loader and complete pre-shift examination.
4. Tram loader to work area.
5. Load bucket.
6. Tram to dump area.
7. Dump materiaL.
8. Tram back to loading area.
9. Refuel and park.
10. Perform repairs and maintenance.

The operator's manual provided with the machine, and the mine's operating procedures,
should also be used in training machine operators.

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The following safe job procedures wil help minimize incidents which may cause injuries and
adversely affect production:

Required and/or recommended personal protective equipment

Hard hat, safety shoes, safety glasses with side shields, gloves, clothing
appropriate for weather conditions, hearing protection where needed

SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB

BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS

1. Conduct walk- 1. A) Frostbite, 1. A) Dress to suit weather

around check hypothermia, conditions.
of loader. sunburn, heat
stroke, heat
cramps, heat
exhaustion.
B) Struck by B) Check to be sure loader bucket
moving loader is lowered to ground, and, if
or other parked on a grade, wheels are
machines. blocked and/or turned into a
bank. Be alert for nearby
machines.
C) Slips or trips, C) Conduct walk-around inspec-
struck by flying tion of loader. Avoid slick spots
objects such as and keep area free of slipping
dirt or splashed or tripping hazards. Be
fluids, caught in especially careful of ruts,
pinch points. uneven ground, and frozen
ground. Use suitable access if
necessary to mount and
dismount loader to check
engine or other area of
machine.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
1. (Continued) C) (Continued) Check:
1) Tires and wheels for lug nuts,
cracked rims, cuts, tire pressure.
2) Area around loader for people or
obstructions.
3) All bolts, guards, covers, and
mechanical components of
loader to make sure they are in
place.
4) Engine compartment for dirt,
debris, oily rags, tools. Grasp
engine covers firmly when
removing. Avoid over-reaching.
Get help if needed.
5) Fluid levels. Wear safety
glasses with side shields and
gloves. Remove tank caps or
covers carefully.
6) Hydraulic oil and coolant lines
and hoses for breaks, leaks,
rubbing lines or loose fittings,
especially in the pivot area.
7) Fire extinguisher (if on outside of
machine) to make sure it's in
place and fully charged.
8) Loader linkage for loose pins or
cracks in lift arms, bucket
attachment and bucket itself.
9) Ladders and steps for broken
rungs, loose bolts, breaks,
cracks, missing parts, or bent
and twisted steps.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
1. (Continued) D) Sludge deposits, D) If loader has air brakes, bleed
or ice, which the air lines to release any
might prevent condensation that might have
valve operation - accumulated, and trip the
tank rupture from pressure relief to be sure it's
excessive operable.
pressure.

2. Mount loader 2. A) Slips and falls, 2. A) Wear snug fitting clothing. Keep
and check clothing caught ladders and boots free of mud,
cab. on control levers ice, snow, grease, and oiL.
or other projec-
tions.
B) Fallng from B) Use belt hooks, pockets, etc., to
ladder. carry materials up ladders, and
keep both hands free for
climbing. Ropes can be used to
hoist bulkier items. Face ladder
and use three points of contact
when climbing (two hands and
one foot, or two feet and one
hand, in contact with ladder at
all times). Use hand holds and
select firm footing. Avoid haste
and projections.
C) Sudden machine C) Do not use steering wheel as a
movement on grab point.
some loaders
(even with
engine off,
fallng from
loader.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
2. (Continued) D) ROPS failure in a D) Check for any damage to
rollover, canopy rollover protective structure or
failure in a fallng fallng object protective
object accident. structure. Check fire
Missing or extinguisher.
inoperative fire
extinguisher.
E) Struck by flying E) Remove or secure any loose
objects, jammed objects in cab. Avoid projec-
controls, tions.
projecting control
levers.
F) Accident caused F) Inspect and clean windows and
by poor visibility. mirrors. Adjust mirrors if
necessary.
G) Thrown against G) Make sure seat belts are
cab interior, or provided, and are in good
thrown out of the condition. Seat belts must be
machine. worn by the operator.
H) Machine H) Check all instruments and
malfunction. gauges before start-up to be
sure they aren't stuck. Make
sure all controls are in neutral
position, and parking brake is
set.

3. Start loader 3. A) Hitting or running 3. A) Check machine for warning tags.

and complete over persons or Be sure bucket is lowered to
pre-shift objects in area. ground. Check controls to be
examination. Striking steering sure they are in neutral. Sound
wheel or other horn before starting or moving.
parts of cab if Check backup alarm after start-
loader moves up.
suddenly.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRbs
3. (Continued) B) Engine or B) Let engine run until it reaches
auxiliary normal operating temperature.
equipment Check all gauges, indicators,
malfunction. and warning lights again for
normal readings.
C) Engine C) Check engine for smooth idle
malfunction. and unusual smoke or noise.
D) Poor visibility. D) Check wipers and lights. Check
Poor operation. hydraulic controls.
E) Emergency E) Check emergency steering, if
steering failure. equipped and if recommended
by manufacturer.
F) Loss of control. F) Check brakes and steering after
moving a short distance. Brakes
may also be checked against
partial engine power before
moving, according to company
policy or manufacturets
recommendations. Check
transmission operation.
G) Potential hazards G) Report and, if possible, repair
not corrected. any defects found. Do not use
machine with uncorrected safety
defects. If the loader is unsafe
and removed from service, tag it
to prohibit further use until
repairs are completed.
H) Hearing loss. H) Use ear protection when
necessary.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
4. Tram loader to 4. A) Personal injury. 4. A) Do not allow anyone to ride
work area. outside the cab for any reason.
No one shall ride with the
operator unless safe seating
facilties are provided.
B) Running over B) Sound horn before starting to
someone. tram.
C) Poor visibility, C) Observe travel area. Adjust
poor stability, speed for conditions. Tram with
overturning bucket low (15 to 20 inches off
loader, striking the ground) to increase stability.
other machines
or people.
D) Caught in pinch D) Keep doors latched securely.
points.
E) Overturning E) Travel in proper gear at
loader. acceptable speeds for condi-
tions. Avoid loose material, slick
spots, and weak areas. Observe
road hazards, and travel in
stable areas.
F) Loss of control, F) When carrying a loaded bucket
overturning down a steep grade, travel in
loader. reverse.
G) Loss of control, G) Control speed and slow down
overturning carefully if loader starts "road-
loader. walking."
H) Loss of steering H) Monitor gauges/indicators.
and/or brakes - Follow traffic rules.
collsions.
i) Struck by fallng i) Stay out from under swing of
ore or rock. dragline.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
JOB
BASIC ACCIDENTS OR PROCEDURES
STEPS HAZRDS
5. Load bucket. 5. A) Obstructed work 5. A) Clean loose material from
area. loading area.

B) Fallng or sliding B) Work material from toe, or in a

materiaL. manner which eliminates
hazardous rollng or sliding of
materiaL. Shake off excess
material before tramming out of
loading area. If working next to
a highwall, visually check it on a
regular basis for changing
and/or hazardous conditions.
C) Buried at toe of C) When loading from stockpile, do
stockpile by not allow hazardous overhangs
fallng or sliding or excessive slope angle to
materiaL. Failure develop. Work material from top
of ground under if necessary to maintain
machine weight stockpile stability.
at top of
stockpile.
D) Fallng or sliding D) Avoid digging into loose rock or
of loose, uncon- tailngs banks which are higher
solidated than bucket reach.
materiaL.
E) Overturning E) Watch for "soft spots,"
loader. particularly on tailings pond
reclamation work.

F) Rapid tire wear, F) Avoid spinning the wheels,

slashes and especially in wet conditions. If
gashes in tire loader is equipped with a
side walls. variable torque converter, adjust
to a lower setting.

6. Tram to dump 6. A) All hazards in 6. A) All procedures in Step 4 apply.

area. Step 4 apply.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
6. (Continued) B) Running over B) Check before backing, and keep
stationary backup alarm working.
objects, other
personnel, and
vehicles.
C) Reduced stability C) Tram at speed consistent with
and visibility. load and area conditions. Keep
bucket low off ground for
maximum stability and visibility.
D) Loss of control - D) Travel in reverse only when
overturning carrying a loaded bucket down a
loader. steep grade.

7. Dump 7. A) Spilage. 7. A) Position haulers perpendicular

materiaL. to, and backed into, material so
that spilage stays close to pile.
B) Overturning B) Load and dump on the level or
loader. uphil for greater stability. Avoid
having dumping point downhil
from loading point.
C) Fallng material, C) Raise bucket while positioning
equipment loader, and tilt bucket forward to
damage, excess avoid spilage. Raise bucket
spilage. only to height necessary for
clearance. Avoid striking hauler
or hopper with bucket or loader.
D) Excess spilage, D) Position loader to avoid spilage
overturning, on the off side. Make motions
knocking hauler smooth. Tilt bucket slowly to
operator against reduce shock of sudden drop of
something. material, and flying materiaL. DO
NOT swing loads over operating
compartments of other
equipment.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
JOB
BASIC ACCIDENTS OR PROCEDURES
STEPS HAZRDS
7. (Continued) E) Running over E) Be sure that other workers are
persons, fallng clear before positioning or
materiaL. dumping. Have hauler operators
stay in cabs or clear of dump
area.
F) Poor handling of F) Distribute load evenly in haulers.
hauler because
of unbalanced
load.
G) Ineffcient G) Signal hauler operator when
operation. hauler is loaded.
H) Caught in H) If a hang up occurs while
material flow, dumping material into a bin or
suffocation. hopper, do not attempt to free
the material yourself unless you
are experienced in this type of
work. If the bin or hopper must
be entered, the equipment must
be locked out, and a safety belt
and line must be used. The
lifeline must be tended by a
second person, with minimum
slack maintained.

8. Tram back to 8. A) Same as 8. A) Same as Steps 4 and 6

loading area. Steps 4 and 6.

9. Refuel and 9. A) Struck by 9. A) Park at refueling station, place

park. machinery, fuel controls in neutral and set
spilage, fire brakes. No smoking at or near
hazard. the refueling station.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
9. (Continued) B) Slips and falls. B) Dismount loader (see Job
Clothing caught Procedures 2.A-C).
on control levers
or other
projections.
C) Fuel on skin and C) Wear safety glasses. Take fuel
in eyes. hose from storage rack, remove
tank cap slowly, and pump fuel
into tank.

D) Trips, slips, and D) Avoid fuel spilage, and keep

falls. Fire area free of extraneous
hazard. materials. If necessary to climb
on loader to refuel, use access
ladder, steps, available rails or
hand holds. Keep all walking or
standing areas free from slipping
and/or stumbling hazards. Avoid
fuel spilage onto hot engine
parts.
E) Fire hazard, fuel E) Shut off fuel, remove nozzle
spilage or hose, and replace fuel cap.
discharge. Return hose to rack.
F) Collsion, F) Park only at designated parking
runaway areas, and always set brakes.
machine, traffic Avoid parking on inclines or haul
obstruction. roads. If necessary to park on
an incline, turn wheels into bank
and/or block securely. If parking
on a haul road is required, pick
the safest place.

G) Unsecured G) Lower bucket to ground. Place

raised equip- controls in neutral position.
ment, runaway Engage parking brake.
machine.
H) Engine damage. H) Idle engine for a short period of
time and then shut it off.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
9. (Continued) i) Slips and falls, I) Dismount loader (see Job
clothing caught Procedures 2.A-C).
on control levers
or projections.
J) Hazards due to J) Always inform appropriate
lack of com- personnel of any abnormal
munication. conditions, defects, changes
made in machine and/or job
procedure or condition.

10. Perform 10. A) Personal injury 10. A) Do not attempt repairs or

repairs and from improper maintenance you do not
maintenance procedure: understand and are not trained
(if applic- to do.
able).

B) Caught by or B) Do not attempt any repairs or

struck by maintenance until the power is
moving or fallng off, the machinery is blocked
parts, or moving against motion, and all raised
machine. equipment lowered. If
necessary to perform work
above, under, or around a
raised piece of equipment,
block or mechanically secure
the equipment to prevent
accidental rollng, fallng, or
lowering. Remove ignition key
to prevent loader from being
started while work is performed.
Tag out machine.
C) Struck by C) Do not attempt repairs or
material fallng maintenance until any frozen
from machine. material under machine frame,
bucket, etc., has been removed.

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GENERAL INFORMATION

This module is part of an Instruction Guide that was developed to assist the surface metal and
nonmetal mining industry in conducting effective on-the-job training (OJT) of new employees,
or employees reassigned to different jobs. The use of training materials, such as this module,
is an important part of an effective, systematic, OJT program.

This Instruction Guide uses a generic Job Safety Analysis (JSA) of jobs common to the
industry. The JSA format facilitates uniform basic training in safe job procedures, while
requiring only a minimum of time and effort on the part of the trainer. This material is generic
to the industry; therefore, each company using this guide wil need to tailor the material
somewhat to fit their particular requirements. In some cases, the material must be general in
nature, and wil not include specific details of procedures or equipment that must be taught
by the trainer.

Recommendations for an overall OJT program are contained in the Mine Safety and Health
Administration (MSHA) guide: "Structuring Effective On-The-Job Training Programs," June,
1983.

TRAINING RECOMMENDATIONS

On-the-job training is usually best done by the employee's immediate supervisor. If the
supervisor relies on another employee to do certain parts ofthe training, the supervisor should
be present to monitor the training. OJT is conducted at the actual job site where the work wil
be done.

The supervisor/trainer should use the training materials (this module, or other materials) while
the training is being done, to help ensure that all job steps are covered, and that no important
safety precautions are omitted. Effective OJT should begin with an explanation (lecture and/or
discussion) of the safe job procedure. The explanation should be followed by a hands-on
demonstration of the proper job procedure. A good demonstration is, perhaps, the most
important part of OJT. The demonstration is followed by supervised practice, during which
the supervisor/trainer coaches (corrects and encourages) the employee, and evaluates when
the employee is ready to do the job without direct supervision.

The first step - explaining the job to the employee - can be done in different ways. The
supervisor/trainer and the employee can sit down and go through the training materials
together. It may be advantageous to provide the employee with a copy of the training modules
that are applicable to his/her job. The fact that most of the training is conducted at the job site
does not preclude the use of a classroom or a quiet offce for the first part of the training. Any
general theory or knowledge training, as well as the initial explanation of the job procedure,
may be best done in an offce/classroom setting; especially when noise levels, or other
conditions at the job site, make communication difficult. A complete series of job steps could
be presented through the use of slides developed at the mining operation.

14