Leavitt Excavator Safety & Operation Training & Compliance PDF

EXCAVATOR SAFETY & OPERATION Training & Orientation for Heavy Equipment Operators "Everyone, and that includes you and me, is sometimes careless, complacent, overconfident and stubborn. At times each of us becomes distracted, inattentive, bored and fatigued. We occasionally take chances, we misinter...

EXCAVATOR SAFETY & OPERATION Training & Orientation for Heavy Equipment Operators "Everyone, and that includes you and me, is sometimes careless, complacent, overconfident and stubborn. At times each of us becomes distracted, inattentive, bored and fatigued. We occasionally take chances, we misinterpret and we misread. These are completely human characteristics."...I think we can at this stage of our evolution be reasonably confident in saying that people will continue to make mistakes and human error is here for the foreseeable future... The question is “ Did we learn from those mistakes” REGISTRATION Fill out the forms in the supplementary handout booklet. – – – – – Your full name Course Instructor Mervil Gudmundson Date 4 April 2024 Signature INTRODUCTION Instructor Students  Present position  Previous experiences  Previous near misses?  Family, hobbies, etc  Why are you here? WHY IS TRAINING IMPORTANT  Reduce risk to you and your co workers  Reduce Lost Time Injuries, cost of equipment.  GO HOME AT THE END OF THE DAY!!! OBJECTIVES At the end of the day you will be able to:  Conduct a complete walk around inspection  Conduct a complete site inspection  Achieve a min 80% grade on a written exam, and  Achieve a min 80% grade on a practical assessment. WHY TRAINING? First and Foremost  Operator training reduces the risk of injury.  Major cause of accidents is unsafe operation, and  An effective training program can reduce accidents by 25%. THEY DO TIP OVER But Who Really Tips Them Over WHY TRAINING? Secondly  Training can protect your company against product and property damage.  Employers have Millions in damage cost annually. COMPETENCY OF OPERATORS A person must not operate mobile equipment unless that person. Has received adequate instruction in the safe use of the equipment. Has demonstrated to a qualified supervisor or instructor competency in operating that equipment. COMPETENCY OF OPERATORS If operating equipment with air brakes, the operator must have an air brake endorsement or evidence of the completion of a air brake course recognized by the board. Is familiar with the operating instructions for the equipment. Has been authorized to operate the equipment. COMPETENCY OF OPERATORS Operator’s Responsibility The operator of mobile equipment must operate the equipment safely, maintain full control of the equipment, and comply with the laws governing the operation of the equipment. COMPETENCY OF OPERATORS Supervisor’s Responsibility A supervisor must not knowingly operate or permit a worker to operate mobile equipment which is, or could create, an undue hazard to the health and safety of any person, or is in violation of this Regulation. EXCAVATOR INCIDENT Incident #1 A 30,000 pound CAT excavator overturned at a construction site, and ended up near the railroad tracks. This area is extremely steep and is the site of new home construction. The operator had been removed from the excavator by construction workers. The operator was evaluated by paramedics and was not injured. EXCAVATOR INCIDENT Incident #2 An excavator operator was working alone to build the log foundation of a cabin. The excavator had no window glazing or guarding on the boom side and the front window was open. Logs were being lifted by cables attached to a hook on the excavator bucket. Ropes attached to each end of the log were run through the open front window where the operator could control them. When he leaned out the open boom side window to reposition a rope, he inadvertently moved the boom control lever. The boom dropped down, crushing his head between the lifting cylinder and the cab. Excavator Incident Incident #3 Company: ABC Excavating Fines Amount: $50,893 Date of penalty: 2011 Two of this firm's workers were in an unsafe excavation more than 1.2 m (4 ft.) deep. The firm failed to ensure that the sides of the excavation were sloped or shored as required before allowing the workers to enter it. Two excavators and a rock truck surrounded the excavation, increasing the risk of the sides collapsing. SECTION 1 FUNDAMENTALS At the end of this section you will be able to: – Define the characteristics of a professional Excavator operator – Explain the importance of the various warning plates and decals – Describe the various components and their function of an Excavator. EXCAVATOR FUNDAMENTALS Qualities of a Professional Operator – – – – Responsible & on-time Rested, alert and physically prepared Knowledgeable about company rules Wears personal protective clothes and equipment EXCAVATOR FUNDAMENTALS Qualities of a Professional Operator – – – – Uses safety equipment IE seatbelt Desire to learn Skilled and works to improve those skills, and Keeps machine under complete control EXCAVATOR FUNDAMENTALS Read and understand the manufacturer’s operator’s manual before using the machine if there is no manual with the machineGET ONE! If there is something in the manual that you do not understand, ask your supervisor to explain it to you. EXCAVATOR FUNDAMENTALS Signal words – Signal words are distinctive words which are used in manuals and decals on the machine at points where a hazardous situation could exist. – The purpose of these words is to make the operator and other personnel aware of the existence of a hazardous situation and the degree of hazard posed. – The degree of hazard is indicated as follows: WARNING PLATES & DECALS Danger Will result in injury or death Warning Can result in injury or death Caution May cause minor or moderate injury MOUNTING & DISMOUNTING EXCAVATORS Before entering equipment Ensure footwear is clear of dirt, oil and grease. Remove any mud, snow, ice, grease, or any other substance from equipment ladders. Steps and handrails should be secure. Avoid loose or torn clothing. 3 POINT MOUNT Getting on the machine Make sure the machine is off and all boom attachments are lowered. Face the excavator when climbing up and maintain 3 point contact. Don’t climb up with anything in your hand. Take your time entering the machine. Ensure that you have a solid grip on the handles before stepping up. Avoid contact with machine controls. 3 POINT DISMOUNT Exiting your machine Position the machine on even ground when possible. Make sure the machine is off and all boom attachments are lowered. Face the excavator when climbing down and maintain 3 point contact. Don’t climb down with anything in your hand. Take your time exiting the machine. Be aware of your surroundings. Watch for obstacles when dismounting such as rocks, or ice. Q. Statistically, the most dangerous activity is dismounting from the machine. True False Q. When dismounting and securing the machine, always: a) Shut off the engine. b) Lower the attachments completely to the ground. c) Maintain a 3 point contact and face the machine. d) All of the above EXCAVATOR FUNDAMENTALS WARNING: Do not operate this machine if you are under the influence of drugs or alcohol which may impair your alertness or coordination. An operator on prescription or over-the-counter drugs needs medical advice on whether or not he can safely operate machines. SECTION 2: PRE-OPERATIONAL INSPECTION PRE-OPERATIONAL INSPECTION At the end of this section you will be able to: Explain the importance of the pre-operational inspection performed at the beginning of each shift. Describe the procedures for completing both the visual and operational inspection. PRE-OPERATIONAL INSPECTION Walk Around Check Essential Before each shift Each new operator during a shift Same order each day Q. Do not crank the starter motor more than -------------- then allow to cool for 2 minutes: a) 5 seconds b) 20 seconds c) 45 seconds d) 1 minute Q. If after starting the engine, the engine oil pressure gauges reads zero. a) Increase throttle for 60 seconds. If no change in pressure, shut off engine. b) Operate the machine in low gear only, pressure will usually change. c) Shut off the engine immediately and investigate. d) Idle the engine for 5 minutes. If no change in pressure, shut off the engine. Q. Running the engine at high idle for cooling is NOT required on equipment with turbos. True---------- False--------- PRE-OPERATIONAL INSPECTION Walk Around Check Benefits Life of equipment, co-workers and YOURSELF. Helps mechanic Q. The “ service “ position includes removing the key. True------------- False-------------- PRE-OPERATIONAL INSPECTION Warning Diesel fuel and hydraulic fluid under pressure can penetrate the skin or damage eyes and cause serious injury, blindness or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use bare hands. The boom arm pins and bushings should show evidence of regular greasing Check for structural damage, cracks or welds on the boom and dipperstick Hydraulic cylinders should be smooth and blemish-free. Presence of oil indicates a scratched cylinder or the need for new packing inside the cylinder housing On the dipper and bucket pins and bushings look for signs of regular greasing Make sure the bucket is the right size and type for your intended application. Check for dents, damage, cracks or welds Inspect the overall condition of the cab. Note any broken or cracked glass, dented sheet metal or structural rust Open the service service access doors and inspect the engine Dip stick and sight gauges. Check the hydraulic pump hoses and valve bank for leaks Check the ring gear and turntable for deflection. Rotate the cab and boom arm to detect any hesitation or roughness The front idler should have some room left to extend forward on the track frame Check clearance between the bottom of the rollers and the top of the track pins Inspect roller frame for or welds Pins and bushings loosen up over time, causing the tracks to sag Inspect final drive and sprocket for wear or leaks HYDRAULIC SYSTEMS Hydraulic System Valves or Levers High Pressure Pump (Driven by EWP engine, moves oil under pressure) Low Pressure 4/4/2024 (control pressure rate of flow) Supplementary line flows back to reservoir. Reservoir Oil (supply of hydraulic oil) High Pressure Hydraulic Ram (hydraulic power is turned into mechanical power) High Pressure 36 PRE-OPERATIONAL INSPECTION Warning Wear a face shield or safety goggles for eye protection. If any fluid is injected into the skin, a doctor familiar with this type of injury must surgically remove it within a few hours. PRE-OPERATIONAL INSPECTION Q. Hydraulic accumulators require hydraulics to be relieved before removing hoses. True----------- False----------Q. It is the operators responsibility to always have a fire extinguisher and first aid kit available. True----------- False---------- SECTION #3 EXCAVATOR OPERATION 4/4/2024 39 EXCAVATOR OPERATION Excavators are used for digging , loading , clearing , spreading , leveling , and rough grading. In most cases we think of excavators as tracked machines. We often see them on rubber Example: ( municipal ditch clearing) Excavators have all the same functions as a backhoe. Backhoes can swing at 180 degrees , Excavators can swing 360 degrees which makes them more versatile. Excavators are mostly used for mass excavation, when the use of loaders and backhoes are impractical. 4/4/2024 40 OPERATION AND MAINTENANCE Being a good operator involves more than the ability to safely control the machine. Skilled operators never waste a move, and seldom move materials more than necessary. Excavator operators are often the guys that service the machine, or at least do the greasing. We need to understand that machine pre – operational checks are required. 4/4/2024 41 MACHINE ORIENTATION TURNTABLE AND CARRIER  The carrier or undercarriage is the stability base of the machine, and provides forward and reverse movement. The carrier consists of tracks or rubber tires.    The turntable is located between the undercarriage and the working components. Which allows 360 degree rotation. There are also excavators that are stationary, meaning no travel. 4/4/2024 43 CONTROL LEVERS Left Track Control – Allows for forward and reverse movement of the left track. Pedal positions are forward, neutral, and reverse, and can be operated with the right control or independently. Right Track Control – Allows for forward and reverse movement of the right track. Pedal positions are forward, neutral, and reverse, and can be operated with the left control or independently Note: Control foot pedals generally have lever extensions for hand control. 4/4/2024 44 Q. Track components include: a) Shoes, idler, grousers, and edges. b) Idler, shoes, sprocket, and rollers. c) Edges, grousers, and rollers. d) Grousers, edges, and sprocket. Q.. It is permissible to leave a machine running and unattended when within the work area. True------------- False------------- CONTROL LEVERS Swing Control – Allows for left, right and 360 rotation. Boom Control – Used to raise and lower the complete digging apparatus including the bucket. Arm Control – Allows for movement towards or away, in or out. It is sometimes referred to as the crowd or dipper stick. Bucket Control – Allows for rollback or curling the bucket. For filling or dumping. 4/4/2024 46 CONTROL LEVERS Auxiliary Control – Often located on the boom control lever as a rocker switch or button to operate various attachments or the bucket thumb. 4/4/2024 47 Simulator View of Actual Operation CONTROLS PATTERNS 4/4/2024 49 CONTROLS 4/4/2024 50 PILOT CONTROL SHUT-OFF When co-workers are present, lower the attachments and engage the pilot lock. Pull the pilot control shut-off lever before allowing anyone to approach the machine. 4/4/2024 51 STABILIZERS Rubber tire excavators may be equipped with stabilizers, (outriggers) used to enhance the footprint of the machine. It is good practice to use pads under the stabilizers foot. Beam Float Pad 4/4/2024 Foot 52 Q. On a rubber tire chassis, axle oscillation locks are used to: a) Carry the load b) Increase stability c) Eliminate suspension d) Provide suspension WORK MODES Today’s excavators are designed with work modes, often referred to as power modes that prioritize hydraulic circuits to tailor them to a specific task. These computerized controls give the operator preferences of how to best customize the operating characteristics of the machine. Work modes allow the computer to draw more or less horsepower from the engine by automatically adjusting the hydraulic pump. 4/4/2024 54 WORK MODE EXAMPLES Many excavators have work mode settings or dig levels. The following are some examples. Light Duty: Allowing 65 percent maximum hydraulic output at a given engine RPM, for precision or fine control application. Standard Duty: Allowing 85 to 90 percent of the maximum hydraulic output for normal operating conditions. Heavy Duty: Allowing 100 percent of maximum hydraulic output for heavy-duty ( breakout force ) fast –cycling or high production work. 4/4/2024 55 BUCKETS General Purpose & Heavy Duty Bucket are for digging in soft to moderate material where some abrasion is expected, and may have hard – surfacing on wearing surfaces. Heavy duty buckets are for digging in moderate to hard material and feature large ground engaging tools, thick cutting edges and thick bottom and side wear plates. 4/4/2024 56 TRENCHING BUCKET The trenching bucket is similar to the general purpose bucket design, but distinguished by its narrow width and deep design. It is used specifically for trenching. Bucket teeth are present for penetration of hard or compact material. 4/4/2024 DITCHING & CLEANUP BUCKET These are extra wide and less shallow in depth. Generally used for soft material. They are also used for skimming loose material from ditches leaving behind a smooth surface. 4/4/2024 58 Q. A ditching bucket differs from a general purpose bucket because it: a) Is narrow and deep. b) Is wide and shallow. c) Has teeth. d) There’s really no difference. Q. Roadside ditches always include surface, inslope, backslope, and ditchline. True---------- False---------- V – BOTTOM BUCKET The vee”d cutting edge is effective for penetrating frost or shale. The teeth are arranged to concentrate digging forces on the single tooth. As the cut depends, additional teeth penetrate the material in a ripping manner 4/4/2024 60 CRIBBING BUCKET Used for narrow trenching jobs and digging in tight quarters. This unit allows for the removal of minimal material. 4/4/2024 61 ATTACHMENTS The thumb attachment resembles a thumb on a human hand. It is hinged off the top part of the bucket. ( grapple ) it is used to hold bulky type material in place. Or pry loose heavy material. It can also be used to soft drop large rock. 4/4/2024 62 POWER CLAM This unit allows for grip , pull, turn and curl. It is suited to easily handle offcenter objects such as stumps, rock, and loose debris. 4/4/2024 63 GRADING & BACKFILL BLADES These are used for leveling and sloping. Lack of tilt can limit blade effectiveness. 4/4/2024 64 HYDRAULIC HAMMERS Hammers may have multiple tools, which can quickly be changed from one to another. 4/4/2024 65 COMPACTION DEVICES These devises are used to provide adequate compaction of excavated areas to specific engineered tests. They can be vibrators or wheels that roll the area. 4/4/2024 66 GRAPPLE The grapple facilitates grabbing of objects or material. This may be used in industries such as demo , disposal , construction, and logging. Note: This example is free hanging 4/4/2024 67 TEETH &SHANKS Buckets have 2 types of cutting edges Teeth and Smooth cutting. Q. A worn shank indicates proper timing for tooth replacement. True--------- False---------4/4/2024 68 QUICK COUPLERS Machines have become more flexible with the use of quick coupler attachment systems. These allow ease of use and a quick change to adapt if conditions change. 4/4/2024 69 TRACK ADJUSTMENT After prolonged use or aggressive turns, track tension will loosen. If proper track tension is not maintained, unnecessary wear will result, and the track will run off the drive sprocket. Tracks that are to tight will reduce the life of the components, especially bushings and drive sprockets. Generally putting grease in the proper fittings will keep the tracks at the right tension. Note: Operators need to understand this process as part of an effective PM program 4/4/2024 70 GENERAL STEPS FOR CHECKING TRACK SAG: 1. Swing upper structure 90 degrees and lower the bucket to raise track off the ground. 2. Keep boom and arm angle between 90-110 degrees and position the bucket’s face on the ground. 3. Place blocks under the machine frame for support. ( safety ) 4. Rotate the track both forward and reverse two full rotations. 5. Measure distance at the middle track roller from bottom of the track frame to top surface of the track shoe. 4/4/2024 71 Note: If the operator is unsure of this procedure call a mechanic. HYDRAULIC SYSTEM The leading cause of hydraulic system failure is dirt or debris in the system. The second cause of system failure is too little oil in the reservoir. The result is pump failure or system contamination. Overfilling the reservoir can also cause problems. Fortunately, hydraulic systems often hint that problems may be happening. Warning signs will include leaks, oil stains, kinked hoses, jerky operation, discolored oil. Be aware of noises, smell of burnt oil, hot pumps and hoses. 4/4/2024 73 DIESEL FUEL Consult the operators manual, fuel distributor. For information for safe use and handling of Diesel Fuel. 4/4/2024 74 START-UP & SHUTDOWN PROCEDURES The operator might be responsible for maintenance so doing an effective PRE-OP Is a big part of any PM program. Perform the daily lubrication as per the operators manual. Check for leaks in the hydraulic, fuel, and oil systems. Check for damaged hoses, loose, worn, broken parts. Check oil levels in the crankcase, power steering, brakes. Check hydraulic and transmission reservoirs. Check cooling system level ( do not open the cap when engine is hot) Check the radiator for dirt and debris that will reduce airflow. 4/4/2024 75 CON’T Check all the drive belts for wear and adjustment Check the air cleaner ( primary and secondary). Check mirrors, horn, wipers, lighting. Check fuel level and keep tanks full over night to reduce condensation. Check tires for low air / cuts / gouges / loose wheel nuts. When a trained operator performs the daily check properly, it will cut down on costly repair do to main component failure. And also help reduce costly downtime to a minimum. 4/4/2024 76 DOCUMENTATION OF THE RESULTS 4/4/2024 77 STARTING THE ENGINE Before starting the engine, always sit in the seat and apply the park brake or lock. Make sure the area is clear. Turn on the master disconnect switch if equipped. Adjust the mirrors, seat, and fasten the seatbelt. Start the engine and check all the gauges. To avoid carbon build-up Allow engine to idle at about 650/700 RPM. Operate under light load for first 5 minutes. 4/4/2024 78 COLD WEATHER WARM-UP Hydraulic functions move very slowly when cold. It is important the operator cycles functions slowly. Major damage can happen if operated cold. Run engine ½ speed for at least 5 minutes. Move track propel and swing functions slowly, short distances. If tracks are frozen raise the machine to free the tracks. Operate all cylinders increasing as they warm up to full stroke. Swing the upper structure. 4/4/2024 79 Shut-Down & Service Procedure 1. 2. 3. 4. 5. 6. 7. 8. Turbocharger may be damaged if engine is not properly shut down. Park machine on a level surface. During freezing weather, clean mud from the track rollers and frame. Lower all attachments to the ground. Turn auto-idle switch OFF. Idle engine at 1/3 speed for 5 minutes. Move engine speed control lever to SLOW IDLE. Stop engine by turning key switch to off. 4/4/2024 80 SHUT-DOWN & SERVICE PROCEDURE 8. Release hydraulic pressure by moving control levers until equipment does not move. 9. Close windows, roof vent, and cab door. 10. Lock all access doors and compartments. 11. Perform post walk around inspection. 12. Fill with clean fuel. 13. Turn the battery isolation switch to the OFF position. 14. Attach a DO NOT OPERATE tag on the steering wheel if service is required. 15. Note: The machine is now ready for service when needed. 4/4/2024 81 MACHINE OPERATION Operators are expected to have enough knowledge and ABILITY to safety and effectively operate the machine, and must be capable of recognizing mechanical defects to avoid the many abuses of a careless or untrained operator. The operator should make a habit of practicing preventive maintenance, including making minor adjustments. Keeping a machine clean is also the operators responsibility. Note: Operators need to be aware of bystanders, & co-workers. 4/4/2024 82 PILOT CONTROL SHUT-OFF The pilot control shut-off lever prohibits all hydraulic control functions. found on the left side of the operator station, between the seat and door. It is located in this manner to purposely make it difficult to exit the machine before locking. Always lock the pilot control when controls are not in use. 4/4/2024 83 TRAVEL PEDALS & LEVERS 1. 2. 3. 4. 5. 6. Forward Travel: Push front of pedals ( or push both levers away ) Reverse Travel: Push rear of pedals ( or pull both back ) Neutral Position: Propel brakes will stop and hold the machine. Right Turn: Push front of left pedal (or push left lever away ) Left Turn: Push front of right pedal (or push right lever back ) Short Turn: (counter – rotate ) push one pedal more than the other ( or push pull on lever more than the other) 4/4/2024 84 EXCAVATOR CONTROL LEVERS 1. 2. 3. 4. 5. 6. 7. 8. Dipperstick Raise ( left control ) Dipperstick Lower ( left control ) Boom swing Left ( left control ) Boom swing Right ( left control ) Boom Lower (right control ) Boom Raise ( right control ) Bucket Load ( right control ) Bucket Dump ( right control ) Backhoe Type controls are similar refer to the operator manual. 4/4/2024 85 AVOID MACHINE TIP OVER Seat belt use is mandatory Do not jump if machine tips. Load and unload trucks carefully. Take care on slopes. Take care with heavy loads. Ensure solid footing 4/4/2024 86 AVOID WORK SITE HAZARDS Avoid contact with gas lines, buried cables and water lines. Avoid structures or objects that may collapse. Avoid boom, arm or bucket contact with power lines ( 3m/10ft ) Min safe approach distance in Alberta is 7m/23ft. Or site specific. Keep pedestrians clear. When working close to an excavation, position the propel motors away from the excavation or trench. 4/4/2024 87 DRIVING THE MACHINE Select a route that is flat as possible without obstructions. While driving, carry the boom and attachment low for better visibility, machine stability. Visibility may also improve when rotating upper structure slightly. Always select the correct engine speed and work mode for the task at hand. Refer to the operators manual for proper work modes. 4/4/2024 88 DRIVING DOWN A SLOPE Begin by positioning the boom and arm at 90 – degrees. Lower the bucket near the ground and then swing the boom to the downhill side of the machine to drive. If the machine begins to slide, lower the bucket to the ground to slow and or stop the machine. 4/4/2024 89 DRIVING UP A SLOPE When driving up a slope, position the undercarriage so the drive motors will be on the uphill side. ( so the unit is pulled ) Extend the arm to the uphill side. Position the bucket ( cutting edge) 12” (30 cm ) above the surface. If the machine becomes unstable use the bucket to maintain control. 4/4/2024 90 FORWARD ON A STEEP OR SLIPPERY SLOPES a) b) c) d) e) f) 4/4/2024 Position the boom up hill. Open the bucket and push it into the ground for gripping. Drive up the slope using the bucket to pull while driving. Make sure the bucket keeps in contract with the ground to help prevent rollback. Do not reposition the bucket on this maneuver. Do not swing the superstructure. 91 REVERSE ON A STEEP OR SLIPPERY SLOPE a) b) c) d) e) f) 4/4/2024 Position boom and the bucket downhill Fully open the bucket and push into the ground. Back up the hill pushing with the bucket as you drive. Make sure the bucket keeps in contract with the ground to help prevent rollback. Do not reposition the bucket on this maneuver. Do not swing the superstructure. 92 WHEN TRAVELLING ALWAYS MAKE SURE YOU HAVE A CLEAR SIGHTLINE Q. Drive down steep slopes with the bucket placed on the uphill side. True----------- False---------------4/4/2024 93 MOVING OFF AN EMBANKMENT # 1 a) Position the bucket on the lower level. b) Place the bucket arm at 90* c) Slightly raise the boom arm d) Drive forward to the lower level until the tracks reach the lower level. 4/4/2024 94 MOVING OFF AN EMBANKMENT # 2 a) b) c) d) e) Raise the bucket and rotate 180* Position the bucket arm at 90* Push down with the bucket slightly. Drive off the embankment as the boom arm pushes. Once clear raise the bucket arm to lower the machine. TO MOVE THE MACHINE ONTO AN EMBANKMENT REVERSE THIS PROCEDURE 4/4/2024 95 SWING & ROTATION There are two distinct types of excavators, Left hand swing and right hand swing. Swing design is based on location of the boom in relation to the cab. a) b) Left hand machines swing right empty, When loaded swing left Right hand machines swing left empty, When loaded swing right. WHEN IN THE SWING MODE ALWAYS BE AWEAR OF COUNTERWEIGHT CLEARANCE 4/4/2024 96 BE CLEAR ON ROTATION FILLING THE BUCKET Steps to filling the bucket. 1. Lower the boom to the ground with desired bucket angle of attack. 2. Move arm ( dipper stick) inward while adjusting the bucket angle and boom height (pressure) 3. Curl the bucket and raise the boom. Excavators and backhoes are designed to pull material toward the machine do not allow bystanders in the bite 4/4/2024 98 DIGGING AND BUCKET ANGLE As the bucket is moved towards the machine, the leading edge of the bucket must follow the desired grade. Maintaining specific grade can be challenging due to the pivoting motion of the arm or crowd. The illustration shows a 30* change In arm (dipperstick) position (1-3) Compared to vertical (2). 4/4/2024 99 AUTO SET CONTROL FOR DEPTH Q. Which of the following is a true statement? a) Diesel fuel is not flammable b) Seat belts are not required to be worn in cabs equipped with a roll - over protection system. c) Bucket elevation changes with arm pivot. d) Crowd digging primarily uses the boom. CROWD (ARM) DIGGING Crowd utilizes the crowd cylinder (A) for the majority of movement. 1. Position arm in vertical position then move away from the machine approximately 2ft (.6m). 2. Retract arm and curl bucket together to make first cut 4ft (1.2m) and 3-4inches (75-100mm) deep. 3. Repeat 1 and 2 for remaining cuts at 4-6 inches (100-150mm) deep 4/4/2024 102 BUCKET DIGGING This is used for power digging and for working in confined areas. For digging deeper the boom forces the bucket cutting edge into the material. If it stalls !! slightly lift the boom to relieve some force. 1. Lower extended bucket to digging area and lower boom to force bucket into ground. 2. While retracting the arm (dipperstick) curl bucket cylinder (B) until full. 4/4/2024 103 Q. Crowd digging is typically used during trenching operations. True------------- False------------- CONTROLLING MATERIAL A well trained operator will know at least 4 moves ahead of time. The objective is to move it once. a) Load it onto a truck b) Put it on the spoil pile. It is very important that an operator learn proportional control of hydraulics. Jerky control is unsafe and productivity ( cycle time) will be compromised. 4/4/2024 105 LEVELING THE MACHINE Uneven ground can cause a machine to rock back and forth making control difficult. Counter rotating is an easy way to level the machine 1. Move the tracks back and forth in opposite directions until the machine settles level. 2. If counter rotating does not do the job ( hard material) you may have to grade with the bucket. 4/4/2024 106 CUTTING & FILLING Using the bucket to add or remove material can also help level the worksite. 1. Drive over new material to compact and level. 2. Be sure to add enough material to compensate for compaction. Q. Counter-rotating can be used to level the machine. True -----False --------4/4/2024 107 DOUBLE COUNTER-ROTATION Steps for Double Counter-Rotation. 1. 2. 3. 4. 5. 6. Position boom parallel to track direction. Lower bucket to ground, set arm at 90*. Lower boom to slightly lift tracks from ground. Counter-rotate tracks with foot pedals for undercarriage turn. Rotate superstructure in opposite direction. Reposition tracks to one quarter turn (3) 4/4/2024 108 CARRYING A LOAD At times the operator may have to carry or travel with loads. a) b) c) d) Keep the bucket and load as low as possible given the terrain. Crowd as tight to the machine as possible. Carry the load in the direction of travel. Use extra caution when carrying heavy or bulky material. Ie ( stumps / rocks ) 4/4/2024 109 LOADING TRUCKS Make sure the loading area is level and dressed. This will help maximize machine stability, increase productivity, and decrease operator fatigue. 1. Trucks should be loaded from the back or side. 2. Never swing the bucket over the cab. 3. Know where the truck driver is at all times. DO NOT LOAD UNTIL HIS LOCATION IS DETERMINED. Note: always know who is in the bite. 4/4/2024 110 LOADING FROM ELEVATED POSITION Position the machine so that the digging and dumping areas are of equal distance from the machine. This reduces the need for repositioning of digging components after each digging or dumping sequence. Done properly the operator can quickly transfer between digging and dumping. Resulting in smooth productive cycle. 4/4/2024 111 STEPS FOR LOADING TRUCKS 1. 2. 3. 4. 5. 6. 7. 4/4/2024 Fill and curl bucket Raise boom towards maximum height. Move arm outward to raise bucket while rotating towards the truck. Slow rotation speed prior to reaching target. Pour material in center of truck, load center-front to center back. Keep bucket open and arm extended until sideboard is clear, rotate back to dig. Look to dig area making adjustments during return. 112 Q. When loading trucks, the most important thing is to: a) Utilize the most productive maneuvers during the loading process. b) Control material. c) Load material from center front to center back. d) Ensure the safety of the truck driver and ground personal. Q. A digging cycle is composed of four segments; load bucket, swing loaded, dump bucket, swing empty. True-------------- False-------------- TRENCHING & EXCAVATION 1. Begin by walking the site looking for hazards and to plan the job. 2. Check for buried utilities like vaults, power lines, pipelines. 3. Activate the call before you dig system at least 48 hours in advance. 4. Dig the trench ONCE !! Make it clean enough so you don’t have to go back. 5. Do not straddle an open trench ( cave-in from machine weight ) 6. Make the trench uniform in shape. 7. Understand regulations in your area that pertain to excavation. 114 POSITIONING SPOILS Spoil is material that has been removed from a trench or excavation. 1. There are stringent regulations that apply to excavation and trenching. ( the operator needs to understand them). 2. Place at least 3 ft (1m) away from the edge. 3. Keep in mind “deeper excavation” requires more storage. Don’t get caught scratching your head. 4. Make sure to place spoil in a location for ease of truck loading or backfill placement. 4/4/2024 115 SPOILS ON SLOPES Spoil piles should be placed up hill for improved stability during operation and ease of backfilling. EXCEPTION: When workers are in the trench the risk of material sloughing back is to great. Each job must be evaluated for safety and efficiency 4/4/2024 116 TRENCHING ON A SLOPE When trenching across a slope it is critical to level the machine so the bottom of the trench can be dug level. a. Fill the downhill side of the slope. b. Or cut into the uphill side of the slope. c. Severe slopes may require both methods to level the machine 4/4/2024 117 TRENCHING A STRAIGHT LINE For straight line trenching, drive 2 stakes in the ground at the beginning of the trench. The following is helpful during long trenching operations. 1. Place the first stake near the starting point 2. Place the second 30ft (9m) behind the first. 3. Use the stakes as a guide while repositioning. Note: Most long trenches are surveyed beforehand. 4/4/2024 118 CAVE-IN PREVENTION Work perpendicular to a trench or excavation with the propulsion motors to the rear. When positioned correctly you will maintain the ability to escape. 1. Never dig under the machine 2. Do not drive near the edge. 3. Do not make rapid rearward moves excessive pressure may cause the face or wall of the excavation to collapse. 4. As you cut deeper the greater the chance of collapse. 4/4/2024 119 BACKFILLING Excavations typically require backfilling. 1. 2. 3. 4. 5. 6. Backfill material should be non-clay Nothing larger than 3 inches. No frozen clumps No wood or foreign material. Bring in suitable material. Make sure of compaction. 4/4/2024 120 WORKING ON STEEP TERRAIN Before working steep terrain, consider these factors: 1. 2. 3. 4. 5. 6. 7. 8. 4/4/2024 Is the machine mounted on tracks or rubber. Is it the right machine for the job. Determine what type of terrain it is Are there obstacles or irregularities. What type of soil. What if the machine breaks down ( rescue plan ) Is there snow, mud, or vegetation that could limit traction. How has the machine previously performed on slopes. 121 WORKING ON STEEP TERRAIN 2 9. 10. 4/4/2024 What are the capabilities of the machine. Is the operator confident and well trained. 122 LAYING PIPE While excavating a trench to a predetermined width, depth and grade. You will need to put down some bedding material ie: sand crushed rock, drain rock. Bed material will most likely need compaction ( engineered ). This compacted material will protect the pipe from damage. The operator needs to be aware of some factors when laying pipe in the trench: 1. Length of the pipe 2. Weight of the pipe ( thin wall versus heavy wall ) 3. How to rig the pipe for lifting 4. Are there co-workers in the area. 123 LAYING PIPE It is important to understand that pipe laying needs extra focus. 1.You will most likely have fitters in the trench. 2.Know that as you move out with weight an imbalance can take place. 3.Rigging needs to meet criteria. 4/4/2024 124 ROADSIDE DITCHES Water is the greatest natural destructive element that affects roadways. Ditches need to be maintained to protect roadways as well as abutting property from damage. A typical ditch contains four elements: 1. Surface 2. Inslope or foreslope 3. Backslope 4. Ditchline 4/4/2024 125 LIFTING OBJECTS Prior to lifting with the machine, check the capacities specifications in the operators manual. Always use smooth proportional hydraulics to avoid shock loading. DO NOT USE BUCKET TEETH FOR LIFTING !! 4/4/2024 126 STEPS FOR SAFE LIFTING 1. 2. 3. 4. 5. 6. 7. Understand “Basic Rigging” Inspect rigging hardware before and after use. Position the machine close to the load. ( short stick lifting ) Secure appropriate sling or chain to a designated attachment point. Coordinate hand signals with signal person before lifting. Attach a tagline to the load to control spin. Clear area of by-standers. 4/4/2024 127 STEPS FOR SAFE LIFTING 1. Test load prior to lift. If the load is unstable lower to the ground and reset the rigging. 2. Lift the straight up and only as high as necessary. 3. Move load smoothly and slowly to designated location. 4. Lower and stabilize load by blocking if necessary. 5. Never lift or swing loads over people. 6. Never lift or carry people with the machine 4/4/2024 128 DEMOLITION Always use extreme caution when performing demolition operations as many hazards exist. a. b. c. d. e. f. g. 4/4/2024 Unstable structures The potential for personal injury to coworkers / bystanders. Maintain as safe distance when reaching with the boom. Avoid using the backside of the bucket. Position tracks in a manner that allows an “Escape Route”. Post a watch person to control the scene. Use barricades. 129 DEMOLITION 4/4/2024 130 OPERATING IN WATER & MUD Water and mud can do a lot of damage to an excavator if the upper surface of the undercarriage is submerged. It will mean costly repair and significant downtime. Ways to prevent becoming stuck or submerged: 1. Avoid or drive around questionable areas. 2. Use available resources to create a foundation for the machine. 3. Develop drainage, and than return in future. 4. Schedule work for drier days. 5. Consider alternative machinery 4/4/2024 131 BAD DECISION 4/4/2024 132 GETTING UNSTUCK As operators gain experience they develop creative ways to get unstuck. But they will all involve some kind of boom lift and rotation. 1. Counter-rotate the tracks double counter-rotate left to right toward undisturbed ground in an effort to gain travel. 2. Grab an outcropping or solid ground with the cutting edge of the bucket and pull while traveling. 3. Drop the backside of the bucket to solid ground and lift the machine while counter-rotating. 4. There are many more ways but in general they will include some form of the above. 4/4/2024 133 COLD WEATHER OPERATION Cold weather can cause many problems, during these severe conditions special MTC and operating instructions are required. 1. Batteries and electrical systems 2. Cooling systems. 3. Fuel system and supply 4. Lubrication 5. Hydraulic Systems 6. Track MTC especially when frozen. Refer to the operators manual for severe weather conditions. All machines have some difference 4/4/2024 134 PARKING THE MACHINE 1. 2. 3. 4. 5. 6. 7. 8. Park on solid level ground. Lower equipment to the ground. Turn auto-idle/ auto-acceleration switch to OFF. Run the engine at lower RPM without load for at least 2 minutes to cool the turbocharger. Position to slow idle. Turn off the key Pull pilot control shutoff lever to locked position. Close and lock the cab 4/4/2024 135 LOADING MACHINE ON TRAILER 1. 2. 3. 4. 5. 6. 7. 8. Park trailer on a level surface. Place wheel chocks against trailer tires. Keep the trailer deck clean Use the appropriate trailer that will allows loading at low angles. Turn auto idle switch off. Use reduced throttle speed Drive machine slowly. Centerline of machine should centerline the trailer. Place the bucket back on the deck with arm at 90* to lesson tipping affect. 4/4/2024 136 GOOD IDEA TO LOAD THEM RIGHT 4/4/2024 137 LOADING MACHINE ON TRAILER 9. Tuck the arm under to rest on the deck. 10. Synch the machine to the trailer using recommended procedure. 4/4/2024 138 UNLOADING MACHINE 1. 2. 3. 4. 5. Park trailer on a level surface. Place wheel chocks against trailer tires. Turn auto idle switch off. Use reduced throttle speed Raise the bucket to clear and rotate 180* Place bucket on the ground with arm at 90* DO NOT UNLOAD OFF THE DECK WITH THE BUCKET ARM TUCKED IN. 6. As the machine comes off the deck maintain force on the ground with the bucket. 4/4/2024 139 UNLOADING MACHINE 7. Controlled decent is the key to smooth transition of the machine. 4/4/2024 140 TRANSPORTING HEAVY EQUIPMENT Definitions You Should Know: Gross vehicle Weight: (GVW) – Weight of the single vehicle and load. Gross Combination Weight (GCW) – Weight of the powered unit, trailer, and the load Gross Vehicle Weight Rating: (GVWR) - Maximum GVW specified by the manufacture for single vehicle plus its load. 4/4/2024 141 TRANSPORTING HEAVY EQUIPMENT Gross Combination Weight Rating: (GCWR) – Maximum GCW specified by the manufacture for specific combination of vehicles plus its load. Axel Weight: - Weight to the ground by one axel or set of axels. Tire load: - Maximum safe weight a tire can carry at a specific pressure.This rating is stated on the sidewall. 4/4/2024 142 HEAVY HAULAGE POINTERS Legal Weight Limits: It is the drivers responsibility to know the axel and gross weight allowed for the jurisdiction traveled. Overloading any single axel is dangerous. Height and Width Limitations: Most jurisdictions have laws in place to cover legal Height/width. If over these restrictions in most cases permits are allowed for designated hours of travel. Balance the Weight: Drivers need to understand load balance is critical side to side or from front to back. Correct weight distribution on drive 4/4/2024 143 axels and steering axel is critical to control. HEAVY HAULAGE POINTERS Avoid Being Top – Heavy: Always keep load as low as possible, any vehicle that has high center of gravity is in danger of tipping on turns. Debris Removal: Keep the deck clear of debris, it may bounce off and take out a windshield or hurt an innocent bystander. 4/4/2024 144 PROCEDURES FOR LOADING / UNLOADING 1. 2. 3. 4. 5. 6. Park on a level surface. Use wheel chocks Keep trailer connected Authorized personnel only. Secure any Articulation Points ie loaders Make sure all attachments clear when loading or unloading. Q. Chain used for transporting heavy equipment requires a rating of at least G80. 4/4/2024 True------------- False------------145 TRAILER TYPES Below is a Dovetail or Beavertail loading ramps off the back which reduces the angle of load. 4/4/2024 146 TRAILER TYPES Below is a tilt deck these are ideal because there is no severe tipping action as the machine comes over center. Simply drive up the ramp the trailer deck will start to move to level.in most cases these trailers are meant for smaller equipment. 4/4/2024 147 TRAILER TYPES Below is a Lowboy / Low bed These are the heavy duty transport trailers they come in many different configurations today. And haul tremendous amounts of weight. Their axel configuration is dependent on the machine being hauled. 4/4/2024 148