MODULE NUMBER 2

OF
INSTRUCTION GUIDE NUMBER 43

ON-THE-JOB TRAINING MODULES

FOR
SURFACE METAL AND NONMETAL MINES

DOZER OPERATION

This module describes the basic job steps, potential hazards or accidents, and
recommended safe job proceures for dozer operation.

This material is designed primarily for use in the initial training of dozer operators at
surface metal and nonmetal mines. The content deals with general operation and clearing
and pushing, but this material can be applied to other jobs performed with a dozer. This
material should be used by trainers as a supplement to practical knowledge and specific
mine conditions.

Dozers are one of the strongest and heaviest pieces of equipment used at surface mines.
Dozers can be used effectively for clearing operations, pushing material, grading work,

compacting loose material, etc. The most common uses are for clearing and pushing

operations.
Accidents involving dozers often result in disabling injuries or fatalities, due to the massive
weight of the dozer. Crushing type injuries involving dozers most often result in fatalities.

Most of these occur when operators are run over by their own machine. Many other
hazards exist, requiring the dozer operator to remain alert at all times.

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 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 dozer.
2. Mount dozer and check cab.
3. Start dozer and complete pre-shift examination.

4. Tram dozer to work area.

5. Examine work area.

6.
7.
8.
9.

Clear materiaL.
Push materiaL.
Refuel and park.
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.

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 BASIC JOB

POTENTIAL
ACCIDENTS OR

STEPS

HAZRDS

1. Conduct
walk-around
check of
dozer.

RECOMMENDED SAFE JOB

PROCEDURES

1. A) Frostbite,

1.A) Dress to suit weather conditions.

hypothermia,

sunburn, heat
cramps, heat
exhaustion.
B) Check to be sure dozer blade is
lowered to ground. Be alert for

B) Struck by

moving dozer or

other
equipment.

nearby equipment.

C) Slips or trips.

C) Conduct walk-around inspection of

dozer. Avoid slick spots, and keep
area free of slipping or tripping
hazards. Use suitable access if
necessary to mount and dismount
dozer to check engine or other area of

Struck by flying
objects, such as
dirt or splashed

fluids. Caught
in pinch points.

machine.

SEQUENCE

JOB
STEPS

OF BASIC

1. (Continued)

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
During walk-around inspection, check:
1. Area around dozer for people or

1. C) (Continued)

obstructions.
2. All bolts, guards, covers, and
mechanical components of dozer
to make sure they are in place.
3. Engine compartment for dirt,
debris, oily rags, tools. Grasp
engine covers firmly when

removing. Avoid over-reaching.

Get help if needed.

4. Fluid levels. Wear safety

glasses with side shields and

gloves.
5. Hydraulic oil and coolant lines

and hoses for breaks, leaks,

rubbing lines or loose fittings,
6. Fire extinguisher (if on outside of

machine) to make sure it's in

place and fully charged,

holds, and
handrails for loose bolts, breaks,
cracks or missing parts.

7. Ladders, steps, hand

D) Report and, if possible, repair

any defects found. Do not use

D) Defects and
hazards not fixed.

equipment with uncorrected

safety defects.

2) Mount dozer

2. A) Slips and falls.

and check

Clothing

cab.

caught on

2. A) Wear snug fitting clothing. Keep

steps and boots free of mud, ice,
snow, grease, and oiL.

control levers
or other

projections.

SEQUENCE
OF BASIC JOB

POTENTIAL
ACCIDENTS OR

STEPS

HAZRDS

2. (Continued)

RECOMMENDED SAFE JOB

PROCEDURES

B) Use belt hooks, pockets, etc., to

B) Fallng from
machine.

carry materials up to cab. Keep

both hands free for climbing. Use

handholds and select firm footing.
Avoid haste and projections.

C) ROPS/FOPS

C) Check for any damage to

rollover/fallng object protective

failure in a

structure. Check fire extinguisher

(if located at cab).

rollover or

fallng object
accident.
Missing or

inoperative fire

extinguisher.

D) Remove or secure any loose

D) Struck by f1ying

objects.

objects in cab. Avoid projections.

Jammed
controls.
Projecting
control levers.
E) Inspect and clean windows and
mirrors. Adjust mirrors if

E) Accident

caused by poor

necessary.

visibility.

F) Be sure seat is properly adjusted.

F) Improper seat

adjustment may
not allow
maximum
brake pedal
pressure in an

emergency.
G) Thrown against
cab interior, or
thrown out of
the machine.

G) Make sure seat belts are provided

and in good condition. BUCKLE
UP!

SEQUENCE

JOB
STEPS

OF BASIC

2. (Continued)

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
H) Check all instruments and gauges
to be sure they are not stuck. Make
sure all controls are in neutral

H) Equipment

malfunction.

position, and parking brake is set.

3. Start dozer
and
complete
pre-shift
examination.

3. A) Hitting or

3. A) Check equipment for warning tags.

running over
persons or

Be sure blade is lowered to ground.

Check controls to be sure they are

objects in area.

in neutral. Sound horn before

starting or moving. Check backup
alarm after start-up.

Striking inside
of cab if dozer

moves
suddenly.
B) Let engine run at low idle until it
reaches normal operating

B) Engine or

auxiliary

equipment

temperature. Check gauges and

malfunction.

warning lights again for normal

readings.

C) Check engine for smooth idle, and

C) Engine or

decelerator

unusual smoke or noise. Check

malfunction.

decelerator operation.

D) Poor visibility.
Poor operation.

D) Check wipers and lights. Check

hydraulic controls.

E) Loss of control.

E) Check brakes and steering after

moving a short distance. Brakes
may also be checked against
partial engine power before
moving, according to company

policy. Check transmission

operation.

SEQUENCE
OF

JOB
STEPS

BASIC

4. Tram dozer

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
4. A) Personal injury.

4. A) Do not allow anyone to ride outside

to work area.

the cab for any reason. No one

shall ride with the operator unless
safe seating facilities are provided.

B) Sound horn before starting to tram.

B) Running over

someone.
C) Poor visibility,
poor stability,

C) Observe travel area. Adjust speed

for conditions. Tram with blade low
(15 to 20 inches off the ground).

overturning
dozer, striking

other
equipment or

people.

D) Keep doors latched securely.

D) Caught in

pinch points.
E) Travel at acceptable speeds for
conditions. Avoid loose material,
slick spots, and weak areas.
Observe road hazards, and travel
in stable areas.

E) Overturning

dozer.

F) Loss of steer-

F) Monitor gauges/indicators. Follow

ing and/or

traffic rules.

brakes.
Collsions.

5. Examine

work area.

5. A) Stop dozer a safe distance away

5. A) Fallng material

from highwall

from highwall or fresh excavations

or fill. Loose
ground.

where loose material could be a

hazard.
B) Observe area for other equipment.
If leaving dozer, lower blade, set
brakes, and shut-off the engine.

B) Struck by

moving

equipment.

SEQUENCE

JOB
STEPS

OF BASIC

5. (Continued)

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
C) Select firm footing, avoid slick
spots. Be aware and cautious of

C) Slipping/
tripping

mud, snow, ice, loose material and

hazards.

steep inclines.

D) Inspect working areas for:

1. Overhanging material,
2. Loose rock,

D) Struck by
fallng materiaL.

3. Vertical and horizontal cracks,

4. Boulders, trees, or other material
which might fall or roll,
5. Jagged sections of highwall,
6. Undercuts,

7. Sliding or fallng material,

8. Miscellaneous debris,
9. Compliance with standard
procedures for degree of slope,

benching, etc.

E) Be aware of weather changes

which affect ground conditions

E) Slips and falls.

Hypothermia.

including rain, snow, freezing, and

thawing. Dress for weather

conditions.

6. Clear

materiaL.

6. A) Loss of brakes,

6. A) Avoid overheating brakes.

equipment
damage, dozer

Maintain dozer stability. Avoid

turning sideways. Frequently
check gauges to be sure fluid pressures are adequate, preventing
engine shutdown and transmission

overturning,
steep slopes,
operator error.

shifting. Be sure you know location

and use of appropriate controls.

SEQUENCE
OF

JOB
STEPS

BASIC

6. (Continued)

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
B) Dozer over-

B) Keep blade down and avoid

turning,

running on downed material, such

as felled trees. Operate in gear
consistent with the area and
material being cleared. Keep doors
closed and securely latched.

ineffcient
operation,
equipment
damage, flying

brush, caught
in pinch points.

C) Frequently check location of any

C) Ground

personnel

ground personnel to ensure they

are not in path of dozer or in an
area where they could be struck by
flying brush, fallng trees, etc.

struck by

dozer, tree,
cable, etc.
D) Skidding or

D) Use extra caution if clearing in rain,

snow, ice or other conditions that

sliding, steep
slopes, striking

could reduce traction. Be aware of

ground personnel, unstable

limited sight distance in fog, rain,

dust, or snow; operate at lower
speeds to allow quicker stops, etc.

ground, poor
visibility.

E) Rocks, loose material, heavy

E) Skidding or

sliding.

vegetation, etc., will reduce traction

and cause sliding/ skidding when

braking. Operate in gear consistent

with material, reduce load that is
being pushed and operate in
direction that will provide most
traction and best braking surface.

SEQUENCE
OF

JOB
STEPS

BASIC

7. Push

materiaL.

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
7. A) Sliding

7. A) Be alert for ground conditions

which may cause accidents; loose
material, large rocks and ice can
result in sliding equipment. Steep
slopes, cut out areas, and freezethaw cycles can result in weak
areas that cannot support the
weight of a dozer, causing the

equipment.
Ground failure
under weight of
dozer.

ground to break under the dozer.

Avoid these areas, or repair and
compact prior to beginning work.
Wear seat belts at all times.

B) Be aware of other equipment

B) Striking other

operating in the area. Frequently

check the location of other
equipment. Keep lights and backup horns in operating condition.

equipment or

persons.

C) Use extra caution if operating in

rain, snow, ice or other conditions

C) Skidding or

sliding, steep
slopes, striking
ground personnel, unstable

that could reduce traction. Be

ground, poor

aware of limited sight distance in

fog, rain, dust, or snow; operate at
lower speeds to allow quicker

visibility.

stops, etc. Keep in mind that

adverse weather can cause ground

conditions to change rapidly, check
for these changes and adjust
operation accordingly and report

them to your supervisor.

D) Frequently check highwalls and

D) Falling or
sliding
material,

storage piles. Keep blade low, and

operate in gear needed for the

ineffcient
operation.

material being worked.

10

SEQUENCE

JOB
STEPS

OF BASIC

7. (Continued)

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
E) Loss of braking
and/or
steering,
equipment
damage,
ineffcient
operation.

E) While working, monitor gauges and

performance for proper pressures,

temperatures, and possible
equipment damage. Report
damaged/faulty equipment to your

supervisor and have repairs made

before continuing. Operate the
dozer for maximum performance at
all times.

F) Leave berms along edges of

F) Overturning

dozer, or going
over the edge.
Operator error.

slopes. Concentrate on work at all

times. Do not over estimate your

ability or the capabilities of the

dozer. DO NOT take chances. Be
sure you know location and func-

tion of controls.

8. Refuel and

park.

8. A) Struck by

8. A) Park at refueling station, place

equipment, fuel
spilage, fire

controls in neutral, set brakes,

lower blade until firmly seated, and
shut off engine. No smoking at or
near the refueling station.

hazard.
B) Slips and falls.

B) Dismount dozer (see 2. A-B). DO

NOT JUMP. Check surrounding

Clothing
caught on

area for loose material and slick

control levers

spots.

or other

projections.

C) Fuel on skin

C) Take fuel hose from storage rack,

remove tank cap slowly and pump

and in eyes.

fuel into tank.

11

SEQUENCE

JOB
STEPS

OF BASIC

8. (Continued)

RECOMMENDED SAFE JOB

POTENTIAL
ACCIDENTS OR

PROCEDURES

HAZRDS
D) Avoid fuel spilage and keep area
free of extraneous materials. If
necessary to climb on dozer to
refuel, use steps, available rails or

D) Trips, slips,
and falls, fire

hazard.

hand

holds. Keep walking or

standing areas free from slipping

and/or stumbling hazards. Avoid

fuel spilage onto hot engine parts.

E) Fire hazard,

E) Shut off fuel, remove nozzle hose,

fuel spilage or

and replace fuel cap. Return hose

discharge.

to rack.

F) Park only at designated parking

F) Collsion,

runaway
equipment,
traffc
obstruction.

areas and always set brakes.

Avoid parking on inclines or
haulroads. If parking on a haulroad
is required, pick the safest place.

G) Lower blade to ground. Place

controls in neutral position.
Engage parking brake.

G) Unsecured

raised equipment, runaway

equipment.

H) Keep yourself and other personnel

out of pinch points while dozer is
operable.

H) Caught
between parts
of dozer.
i) Engine

i) Idle engine for a short period of

damage.

time and then shut it off.

J) Observe parking area for other

moving equipment before leaving
dozer. Make other operators aware
of your presence.

J) Struck by other

equipment.

K) Dismount dozer (see 2. A-B). DO

K) Slips and falls,

NOT JUMP. Check surrounding

clothing caught
on control

area for loose material and slick

spots.

levers or other
projections.

12

SEQUENCE
OF BASIC JOB

POTENTIAL
ACCIDENTS OR

STEPS

HAZRDS

8. (Continued)

RECOMMENDED SAFE JOB

PROCEDURES

L) Hazards due to

L) Always inform appropriate

lack of
communication.

9. Performing

9. A) Personal injury

repairs and

from improper

maintenance

procedure.

personnel of any abnormal

conditions, defects, changes made
in equipment and/or job procedure
or condition.

9. A) Do not attempt repairs or

maintenance you do not
understand and are not trained to

do.

(if

applicable).

B) Caught by or

B) Do not attempt any repairs or

struck by

fallng parts, or

maintenance until the power is off

and the machinery is blocked
against motion and all raised

moving

equipment lowered. If necessary to

machine.

perform work on a raised piece of

equipment, securely block in place.
Remove ignition key to prevent
dozer from being started while work
is performed.

moving or

C) Struck by

C) Do not attempt repairs or

maintenance until any material
frozen to frame, blade, etc., has

material fallng

from machine.

been removed.

13

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," Junej
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 of the 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 diffcult. A complete series of
job steps could be presented through the use of slides developed at the mining operation.
14