MODULE NUMBER 8

OF
INSTRUCTION GUIDE NUMBER 43

ON-THE-JOB TRAINING MODULES

FOR
SURFACE METAL AND NONMETAL MINES

POWER SHOVEL OPERATION

This module describes the basic job steps, potential hazards or accidents, and
recommended safe job procedures for power shovel operation.

Power shovels are used at surface metal and nonmetal mines for overburden removal and
for ore loading. Many different sizes of shovels may be used, depending on the type of
operation and application.

Accidents relating to shovel operation most often result from slips and falls, becoming
caught in or struck by moving mechanisms, and standing or walking near the machine
while it is in operation.

Slips and falls occur most often during maintenance,' repair, or cleanup, and when
mounting and dismounting the machine. Miners are most often struck by moving
mechanisms during greasing or oiling, or when performing maintenance or repair. Injuries
to persons standing or walking near the machine often occur when the person is in the
area and the shovel operator is unaware of their location.

The basic job steps included in this module are:

1. Conduct walk-around inspection of shovel and work area.

2. Mount and dismount.
3. Conduct on-board inspection.
4. Generaloperation.
5. Shutdown procedure.
6. Perform repairs and maintenance.

Several of these proce~ures apply to the oiler and ground man as well as the shovel
operator.

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:

Reguired and/or recommended personal protective eguipment:

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) Personal injury, 1. A) Visually inspect machine and
around unsafe equipment work location for defective
inspection of or work area. equipment and/or unsafe
shovel and conditions prior to operation.
work area. Report any unsafe conditions to
your supervisor and correct all
defects.
B) Electrocution. B) Visually inspect trailng cable for
cuts, abrasions, and other
damage (electric power
shovels). If inspection requires
handling the cable, power must
be off at switch house, or proper
protective equipment (insulated
hooks, tongs, ropes, or slings)
must be used.
C) Rock falL. Striking C) Inspect highwall, spoil and pit
personnel, or conditions in your work area.
damaging Know traffic patterns, and
machinery with communicate with fellow
shoveL. workers before operating
shoveL. Warning signs are
recommended to prohibit
unauthorized persons from
coming near the shoveL.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
1. (Continued) D) Fallng material, D) Inspect bucket dipper teeth and
improper adapters for tightness. Inspect
operation. latch bar for wear and proper
adjustment.
E) Slips and falls. E) Be especially careful of ruts,
uneven ground, and frozen
ground. Make sure all steps,
ladders, handrails, handholds,
and walkways are in good
condition and free from oil,
grease, mud, snow, and ice.
F) Machine damage, F) Check for oil leaks, gear wear,
rope failure. seized bearings, loose or
damaged crawlers or rollers,
NOTE: IG 43 Module 14, lubrication of gears and rollers~
contains detailed Check ropes and boom
procedures for structural strands (to the extent
inspecting wire rope and possible).
related items.

G) Splashed fluids, G) Check fluid levels. Wear safety

burns. glasses with side shields and
gloves. Remove tank caps or
covers carefully. It is important
to know if gear cases are hot or
cold.

2. Mounting and 2. A) Slips, falls, caught 2. A) Use caution when mounting or

dismounting. between shovel dismounting. Do not get on or
and other off until the operator is notified.
machine.
B) Struck by or B) Do not get on or off while the
thrown from shovel is in motion.
ladder.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
2. (Continued) C) Slips and falls. C) Use steps, ladders, handholds,
etc., provided for mounting and
make sure they are in good
condition. Keep both hands
free for climbing.
D) Rock fall, caught D) Never walk or stand between
between shovel the shovel and the bank,
and other highwall, spoil, or other nearby
machines. machines while mounting.
E) Clothing caught E) Wear snug fitting clothing and
on control levers keep boots, steps, ladders, etc.,
or other free from oil, grease, mud, etc.
projections, slips NOTE: Slip resistant flooring is
and falls. recommended in walkway
zones.
F) Ladder failure. F) Raise boarding ladder (if
provided) and be sure it is
secured.

3. Conduct on- 3. A) Equipment 3. A) Check operator's cab. Make

board movement and/or sure all controls are in the
inspection. failure, stuck or neutral position, brakes set, and
inoperative bucket lowered to the ground.
controls, poor Make sure cab is free from
visibility. debris, etc., and windows
clean.
B) Caught in, or B) Make sure all guards and safety
struck by, moving devices are in place and in
parts. good condition.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
3. (Continued) C) Slips, trips, falls, C) Check decks and house area
fire hazard. for uncovered openings,
slipping, or tripping hazards,
and accumulations of flammable
or combustible material or
liquids. Practice good
housekeeping.
D) Fire hazard. D) Know location and operation of
fire extinguishers, and make
sure they are fully charged and
operable. Don't smoke or use
open flame sources around
combustible or flammable
liquids or materials.
E) Fire and/or E) Keep all compressed gas
explosion hazard. cylinder tanks secured, and
keep covers in place. Keep all
compressed gas cylinders,
hoses, torches, and regulators
free of grease and oiL. Do not
store this equipment in the
same enclosed area where
flammable or combustible
liquids are stored.
F) Electrocution, F) Be sure all electrical equipment
burns, equipment (switches, breakers, controls,
failure. panels, guarding, etc.) is in
proper operating position and in
good condition. Never perform
any electrical work or enter any
energized electrical panels or
cabinets unless you are a
qualified electrician. Be sure to
lock out and tag the equipment
or circuit.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
3. (Continued) G) Boom or gantry G) Inspect boom, boom pockets,
failure, rope and gantry for cracks, breaks,
failure caused by structural damage, excessive
sheave failure, wear, missing parts, etc. Check
excessive rope point sheaves and saddle
wear. blocks for damage or excessive
wear.
H) Rope failure. H) Check both the running ropes
and the boom structural strands
for broken strands and loose
sockets. Periodic
nondestructive testing of
sockets is recommended.
I) Trips and falls. i) Check all steps, ladders,
handrails, platforms, and
walkways for cracks, corrosion,
damage, or any deterioration.
J) Potential hazards J) Report and, if possible, repair
that remain any defects or hazards found
uncorrected. during walk-around or on-board
inspections. Do not use
machine with safety defects. If
the shovel is unsafe and
removed from service, tag it to
prohibit further use until repairs
are completed.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS

4. General 4. A) Striking or 4. A) Sound an audible horn prior to

operation. catching other starting shovel in motion, after
personnel. repairs or after being idle.
B) Personal injury B) By visual observation or verbal
due to lack of communication, make certain
communication. machine crew (oiler/
groundman) and all other
persons and machines are clear
before starting. Be sure the
machine crew reports to you
throughout the shift, so that you
have a general idea of where
they are at all times.
C) Machine or control C) Make sure air pressure is at
malfunction. proper operating range. Check
out motions of machine and all
controls, limits, and warning
devices. Check all brake
systems. Stop machine if you
feel or see any unusual
response or hear any abnormal
sounds.
D) Personal injury, D) Clearly understand any work
inefficient assignment before starting.
operation. Make certain machine crew and
others know and understand all
signals.
E) Unsecured raised E) In the event of a power failure,
equipment, injury move all brake switches to set
from sudden position, place other controls in
machine the neutral position, and secure
movement when the machine's position until
power is restored, power is restored.
equipment
damage.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
4. (Continued) F) Personal injury, F) When operating and/or moving
machine damage. shovel, be alert for pit
elevations, highwall, spoil,
trenches, faults, clearances,
traffic, machine crew, other
workers, sump holes, and
trailing cables. Keep shovel on
good sound footing.
G) Injury or G) Never swing bucket over
equipment workers, vehicles, machines, or
damage from fall trailng cable. When loading
of materiaL. haulers, don't swing over cab.
Be sure of clearance over
hauler bed and position bucket
before tripping.
H) Equipment H) Never suddenly set brakes
damage, while swinging, except in an
overturning. emergency. Avoid jerking and
abrupt motions.
I) Fall of material I) Do not suspend a loaded or
and/or bucket. empty bucket in the air, with the
brakes set, for long time
periods. Lower to ground when
not in use.
J) Ground failure, J) Observe condition of highwall
rock fall. and spoil banks at all times.
When freezing, thawing, rain,
etc., have created a potential
highwall or spoil bank failure
condition, immediately notify
crew, others working in the
area, and your supervisor. Use
machine's audible alarm signal
to warn personnel of this
immediate danger if necessary.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
4. (Continued) K) Ground failure, K) Loose hazardous material must
rock falL. be stripped for a safe distance
(1 0 feet or more) from the top of
NOTE: IG 43, Module pit or quarry walls, and loose
15, contains more unconsolidated material must
information on ground be sloped to the angle of
controL. repose. Leave highwall as safe
as possible before moving up.
L) Cab struck by L) When dumping to a higher
rollng material, level, be alert for rocks or
machine damage. material rollng down the bank,
especially when cab is beside
the bank.

M) Striking other M) After being notified, allow

machines/ suffcient time for vehicles or
vehicles with machines to pass by shovel
fallng material or before resuming normal
machine. operations.
N) Fall of materiaL. N) Do not work between machines
and the highwall or spoil bank
where your escape from falls or
slides may be hindered.
0) Electrocution, 0) Protect trailing cable from
burns, cable damage. Never carry or move
damage, strains cable with bucket unless slings
and overexertion. are used. If energized cable
must be moved manually, use
proper protective equipment
(insulated hooks, tongs, ropes,
or slings). Keep kinks, twists,
and short bends out of trailing
cable. Don't pull long lengths at
one time. Take several loops to
minimize strain on cable. Don't
run over power cables.

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 SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
4. (Continued) P) Electrocution, P) Never work or swing boom
burns, machine within a minimum distance of 10
damage. feet from any energized
overhead power line.

S. Shutdown S. A) Personal injury, S. A) Park shovel on firm ground in a

procedure. equipment position where it does not
damage. create a traffc hazard and is not
subject to damage by slides or
falling materiaL.
B) Fall of equipment, B) Place bucket on ground firmly
machine damage. and release cable tension.
C) Injury or C) Place all controls in proper
equipment position. Make sure all brake
damage if controls are in the set position.
machine moves
when energized.
D) Personal injury. D) Do not permit anyone to get on
or off the shovel while it is in
motion unless equipped to do
so safely.
E) Slips, trips, falls, E) Dismount shovel (see Job Step
caught between No.2).
ladder and other
machine or
obstruction.
F) Hazards due to F) Communicate with fellow
lack of employees and supervisor at
communication. end of shift. Notify of any
hazardous conditions, machine
malfunctions, etc.

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SEQUENCE OF POTENTIAL RECOMMENDED SAFE JOB
BASIC JOB ACCIDENTS OR PROCEDURES
STEPS HAZRDS
6. Performing 6. A) Personal injury 6. A) Do not attempt repairs or
repairs and from improper maintenance you do not
maintenance procedure. understand and have not been
(if applicable). trained to do.

B) Caught by, or B) Do not lubricate any moving

struck by, moving part unless guarding, and
or fallng parts, or extended fittings, prevent
moving machine. access to hazardous moving
parts. Do not attempt any
repairs or maintenance until the
power is off, the machinery is
locked out and tagged and
blocked against motion, and all
raised equipment lowered. If
necessary to perform work on
top of, under, around, or from a
raised piece of equipment, block
or mechanically secure the
equipment to prevent accidental
rollng, fallng, or lowering.

C) Fall of person. C) Don't climb boom or gantry

while shovel is in motion. Use
safety belts with lanyards in
elevated positions outside work
platform, or where there is a
danger of fallng.
D) Fall of hoisted D) Do not overload hoisting or
loads or lifting device. On hoisted
equipment. materials that require steadying
and guidance, use taglines.
E) Personal injury. E) Plan any work to be done and
maintain good communications.
Know and observe safe work
practices. Inspect tools and
maintain in good condition.

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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 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 ofthe 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.

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