Only qualified heavy equipment operators shall be
permitted to operate heavy equipment. The qualification
shall show on the operator’s OF-346, Operator’s Identification
Card. Trainees shall operate heavy equipment
only under the immediate supervision of a skilled and
certified operator. For proper licensing, an employee
must be recommended for licensing by the employee’s
supervisor to a Certified Heavy Equipment License
Examiner.
Operation
Know the equipment, its capabilities, and its limitations.
Always operate the equipment properly for safety and
maximum efficiency.
Before operating an unfamiliar piece of equipment,
read the operator’s manual. Do not assume that one
piece of equipment will work exactly like a similar
piece of equipment. For example, a Case 680H and
a Cat 435 are both backhoes, but they are operated
differently. Always read the operator’s manual
provided by the manufacturer.
Before operation, appraise the job and decide how
the machine may best be used to accomplish the
work.
After the equipment has been started and all visual
warnings have been released, operate the equipment
under light loading. When normal temperatures are
reached and proper operation checks are completed
on all attached components, proceed with normal
operation.
Let the engine idle for 5 minutes before turning it off.
This permits it to cool down gradually, which is especially
important for turbocharged engines.
Select the proper gears to do the job and minimize
engine lugging. Avoid clashing gears when shifting.
When operating
over rough or rocky ground, use the lowest gear and idle the engine down.
Make proper blade adjustments before starting
operation and check the condition of the cutting
edges regularly.
Change the blade adjustments as necessary after
making an experimental pass or two on the material
you are working.
For the most efficient use of equipment, always
readjust the blade when the material changes.
Never operate equipment with your feet resting on
the brakes or clutch. (Place your feet on the pedals
only when necessary.)
Repair cracks or breaks immediately. Do not allow
them to deteriorate beyond repair.
To prevent equipment parked overnight and on weekends
from being pilfered, park in a nearby secured
area, or park out of sight of the public. Always protect
equipment from vandalism.
Safety Rules
When machinery or equipment, including that under
contract, is received, remodeled, or repaired, it shall
be inspected for safe operating condition by a qualified person before it is
turned over to the operator.
Do not operate defective or unsafe equipment. “Red
tag” it for repair.
Investigate and correct hazards before moving
machines into operating positions. Machines shall
be located and operated in areas where operators
will not be endangered by blasts, cave-ins, or other
hazards. Operators shall move machines into blasting
areas only after being instructed to do so by the
person in charge.
Stop all engines before refueling.
When the fuel tank is being filled, keep the funnel
or container in contact with the tank to avoid the
possibility that a spark of static electricity might ignite
the fuel.
When changing operators, the person in charge shall
discuss the plan of work, existing hazards, hand
signals, and other safety aspects of the job with the
new operator and crew.
When not in use, any machines with parts that raise
and lower, such as shovels, buckets, dozer blades,
and skid loaders, shall be left with those parts resting
on the ground.
Provide additional fire extinguishers for machines
that may cause fires, such as asphalt distributors.
Do not stand directly in front of, or in back of, a self-propelled
machine being started by another person.
Do not attempt to start a piece of equipment while
standing on the ground beside it.
Do not go under or into dangerous
places around equipment without notifying the operator and being
on the lookout for hazards.
Do not get on or off of moving equipment.
Operate only the equipment that you are qualified
and certified to operate.
Provide ample clearance for a person between any
solid material and the tail swing of a dragline, shovel,
or crane.
Use a sound-level meter to check all equipment
for excessive noise levels. If noise exceeds 85 decibels,
provide the operator with hearing protection, which
must be worn.
Keep cables in good repair and spooled properly.
All cable fittings shall be positioned properly and tightened.
Make
a thorough preventive maintenance
check at the beginning of each job.
Have a journey-level mechanic
inspect all equipment annually.
Suspend all crawler-tractor operations
during
storms and continue the suspension until good traction is ensured.
Guards and Safety
Devices
Guards shall be supplied with all gears, sprockets,
driver belt or chains, pulleys, drums, fans, or other hazardous moving
parts.
Guards
shall
not be removed or made ineffective, except while making repairs.
Power for machines shall be shut off until repairs are made and
guards are
replaced.
Operating platforms surfaced with nonskid material, footwalks,
ladders,
steps, handholds, guardrails, and toeboards necessary for
safe operation shall be
installed before a machine is operated.
Suitable protection
against falling objects,
swinging loads, and similar hazards shall be provided
for all operators.
Safety glass or a Lexan-type material shall be used
in
enclosed
cabs.
Signaling
A
competent flag person shall be posted at dangerous
or congested points, near crews, and near blind
areas.
Only one person shall give signals.
The correct use of hand signals shall be observed.
Ensure that signals and instructions are clearly
understood.
The flag person shall get as close to the operator as
safety permits so that the operator can clearly see
signal movements.
All signal motions shall be large enough to be understood
by the operator. Repeat signal motions frequently.
When a slow pull or easy move is wanted, the signal
motions shall be made at a slow tempo; signal motions
shall be faster for fast pulls or moves.
The following signals shall be observed when directing
drivers of vehicular or construction equipment,
except when standard industrial specialized signals
are agreed upon and understood in advance (Health
and Safety Code Handbook)
Come ahead: Wave your arm in front of your body,
from your waist to your arm’s length above your
head.
Reverse or back up: Move your arm in a full circle
in front of your body.
Turn: Move your arm on the side of your body from your
hip to your shoulder.
Slack up: Position one arm in front of you with
your hand moving up and down.
Raise: Raise one hand, palm up.
Lower:
Lower one hand, palm down.
Stop: Swing your arm back and forth (horizontally)
in front of your body at your waist.
Caution: Wave your arm in a half
circle over your head.
Transporting Equipment
Before moving heavy
machinery, check
the travel
route for hazards, such as overhead and side clearance, culverts
and bridges, and overhead lines.
Know the load weight, width, and height;
obtain all State and local permits; and comply with all requirements.
Never haul a piece of equipment on a
truck or trailer with a false bottom.
Block heavy equipment sidewise and
lengthwise
on truck beds. Bind the equipment securely to the truck or trailer bed, both
front and rear or on each side, with chain or cable, and tighten with load
binders. Chains used as a component of a tiedown assembly must conform
to the requirements
of the most recent
edition of the National Association of Chain Manufacturer’s welded and weldless
chain specification applicable to all types of chain and must match load requirements.
The load binders must be as strong or stronger than the tiedown assembly.
Angle or remove tractor blades or secure a special permit to comply with
State laws pertaining to the width of the load.
Do not leave loose tires,
planks,
or other material on moving equipment.
Crawler-Tractor Operation
Injuries
from crawler-tractor operation are usually serious, often fatal. Practice
defensive operation at
all times. This means:
Understand the equipment and its limitations. Accept
competent advice.
Always keep accident prevention in mind.
Avoid doubtful
or spectacular operations.
Allow apprentices to operate a crawler-tractor
only under the immediate supervision of a skilled operator.
Do not
operate a crawler-tractor
if any part of the control, hoist, or hydraulic system, including
the steering and brakes, is not in safe operating condition. Notify the
supervisor or
mechanic if a crawler-tractor
is unsafe.
Before starting the engine of a direct-drive crawler-tractor,
put the transmission in neutral, disengage
the master clutch, and keep the blade down. For a
power-shift transmission, place the transmission
gearshift lever in neutral and lock it by placing
the safety control in the on position.
Keep clear of a crawler-tractor that is moving. To
stop the operator, signal from a safe distance.
When stopped and the engine of a direct-drive
crawler-tractor is idling, put the transmission in
neutral and engage the master clutch so the tractor
cannot be jarred into gear. When motion is stopped
and the engine of a power-shift type crawler-tractor
is idling, apply the foot brake and lock in the safety
control lever.
On a direct-drive crawler-tractor, gently engage the
master clutch, especially when going up a hill or
pulling out of a ditch. On a power-shift crawler-tractor,
select the proper gear and adjust the speed control
lever for additional power.
Always study the ground to be traveled and the job
to be done. If you cannot see the ground clearly from
the driver’s seat, dismount and examine it before proceeding, unless a spotter
is available for guidance. Avoid setups for upsets.
Always be especially careful
around overhanging rocks, on rock slides, and near dead trees.
Only a
trainee or mechanic engaged in actual repair is permitted to ride on the
seat with the
operator, and then only if the slope is less than 30 percent. Exceptions
may be made only during fire emergencies.
Handholds to assist the operator
when
mounting
and dismounting should be installed and maintained
as necessary.
A heavy mesh screen should be installed on the rear
of the cab protector between the operator and the
rear-mounted towing winch, to protect the operator’s back.
Know the location
of all persons nearby.
Use extreme caution while going over obstacles
when headed downhill. Be sure the slope is safe. Use caution when steering
downgrade
on steep slopes.
Observe the safe limits of crawler-tractor operation
on side slopes. Small narrow-gauge crawler-tractors are more dangerous than
wide-gauge
equipment.
Reduce speed before making any turn or applying the brakes.
When the speed of a crawler-tractor is doubled, the danger of overturning
is increased
four
times.
When on steep side slopes, take the following precautions:
Do not run over
obstacles with the upper track or
wheels.
Keep off solid rock faces.
Have the transmission in gear when the
crawler-tractor
is going down steep grades; use the blade
as a brake.
Usually, lock the uphill track and immediately turn the machine
if the crawler-tractor slides sideways.
Make turns so that the operator
is on the uphill side if possible.
Lower the dozer blade whenever
the operator
dismounts.
Do not get under an unblocked, raised blade for any
purpose.
When dozing downhill or over embankments, it is
best to doze several loads to the edge of the hill and
push the loads in one pass.
Hitching and Towing
Do not ride on the drawbar, dozer blade, frame, or
materials.
Use a bar or stick to steer the coupling bar into
drawbar jaws.
When the towing winch is in operation, keep hands
away from the cable and working parts.
Look behind before backing up to slack the chain
or cable. Do not take up slack in the chain or cable with
a jerk.
When towline is being hooked to the front pull
hook, rest the blade on the line on soft ground or on a
block or rock; then the worker can climb over the
blade to attach the line.
Hookers and other people directing or assisting
on the ground shall stand clear of all chains and lines
and shall stay away from the crawler-tractor
for at least the length of the towline.
When working near an electric powerline, the
length of the cable attached to the load shall be at least
10 feet shorter than the distance from the tractor to the
powerline so that the cable cannot strike the
line.
Operate the crawler-tractor so that it does
not nose up or tip when pulling a heavy load upgrade or slide
sideways when pulling around a sidehill.
In most cases, the crawler-tractor should
be stopped, taken out of gear, and the brake set before the load
is released.
After each work shift or after
each hard haul, the crawler-tractor operator and towline setter shall inspect
the equipment, including rope and eye splices
on the winch, choker eye splices, and ferrules.
Avoid sharp turns when
pulling draft equipment
such as carryalls or rippers. Do not “two-block” the sheaves.
Timber Operations
Crawler-tractors used in dangerous, timbered country or in places where
there is danger of falling objects, shall be equipped with protective
canopies and
an approved rollover protective structure (ROPS), including front (logging)
sweeps and side screens that will protect the operator.
Look for hazards,
such as
dangerous snags, green trees, and trees uprooted while piling brush.
Before operating alone, crawler-tractor operators shall be skilled in
pushing over
trees. Never run the crawler-tractor into a tree and try to knock
it over
by speed and
force. When felling trees, leverage can be increased by raising
the dozer blade as high up the tree trunk as possible. If the tree measures
more
than 14 inches
in diameter and is difficult to push over, it is best to make passes
on three sides of the tree, cutting the roots. If the tree is still difficult
to push
over, build a ramp on the side opposite the fall. This will give
the
crawler-tractor
added leverage. When the tree begins to fall, back away so that
the upturning roots will not damage the crawler-tractor.
When using a
crawler-tractor
to clear land, lower the blade just far enough into the ground
to remove
the brush
and roots. Be alert for protruding trees and limbs when operating
in timber or when piling brush.
After the towlines are set, the setter
moves
to
a safe
place where the setter can see the operator, and vice versa,
at all times. Both shall watch for falling trees and limbs and warn each
other of dangers.
The towline setter stays at least 10 feet behind the
load.
The towing winch is adjusted only when the motor
is stopped. For adjustments requiring the motor to
be in operation, put the transmission in neutral and
engage the master clutch.
Before work is done on the towing winch, lower the
dozer blade to the ground.
Do not hoist the dozer blade repeatedly with one
corner caught under a stump or other heavy object.
This may result in blade damage. Use the center of
the blade rather than the corners for this type of
operation.
Sidehill Operations
A competent, well qualified, experienced person is
needed to supervise and direct sidehill tractor operation.
Such a person could be a construction
superintendent, crew leader, or an equipment operator
who knows tractor capabilities. This person has
the responsibility to ensure project safety, the proper
care of equipment, and to monitor production.
Select only fully qualified equipment operators,
experienced in firefighting, logging, or other tractor
sidehill operations.
Tractors must be in top mechanical condition.
Sidehill operations can be very difficult. During these
operations, it is particularly important for operators
to be vigilant about safety and use mature judgment.
Check equipment often enough to ensure that it is
completely safe. Unsafe units must be shut down
and repaired before continuing to work.
All machinery must
be equipped with ROPS, safety belts, and a rearview mirror positioned to
give the operator full view of rear attachments.
Check all
work areas for loose logs, rocks, stumps, bedrock outcroppings, and similar
hazards.
Identify and remove all hazards before work begins. The safe maximum slope
on which a crawler-tractor should be operated is 42 percent on firm ground.
To operate
on a maximum slope, the operator must control the machine, recognizing the
following conditions that
may upset tractor stability:
Speed of travel.
Roughness of terrain.
Attachments.
Characteristics
and nature of the ground (for example: track slippage caused by excessive
loads can cause the downhill track to dig in, increasing the possibility
that the crawler-tractor
will roll over).
When using a high-mounted drawbar, a crawler-tractor
is less stable than when a drawbar with a
standard or lower height is used.
Wide-track shoes tend to decrease digging
in,
making the crawler-tractor more stable.
Jerking the steering clutches
or brakes may make the crawler-tractor less stable.
Whenever slopes
steeper
than 45
percent must be worked, use the dozer blade to build a trail or roadway
wide enough to accommodate the crawler-tractor.
All rollovers or tipping
of crawler-tractors
onto their sides will be investigated and reported to the regional
forester. Operators in training will work only under the direct supervision
of
a qualified operator; they will not work on slopes steeper than 20
percent.
Fire Operations
When crawler-tractors are operated in front of a fire, build
a safety strip for retreat in case the fire makes a run. This is especially
necessary when
working along a ridgetop above fire in a canyon below.
Avoid
fast travel over rocky ground or through dense,
unburned brush or stands.
Generally, firefighters shall not try to outrun the head
of a fast-moving fire. Instead, they should first try to
get around to the flanks.
Terracing Operations
Trainee operators shall not be allowed to operate a
tractor on terracing work.
When more than one crawler-tractor is working on
a project, organize operations so that one crawler-tractor
is working directly below another.
Provide a safety scout where ground visibility is poor
because of dense brush or weeds.
Do not drag the dozer blade backward over rocks
and stones.
Limit heel trenching with the lower corner of the
dozer blade to slopes no steeper than 35 percent.
When moving downhill from one terrace to another,
lower the dozer blade and back the crawler-tractor
downhill.
If the slope is steeper than 65 percent, build a road
from one terrace to another.
Endloader and Scraper Operation
Endloaders
Only the operator and trainee ride on the seat of
the vehicle and then only when supervised by a competent
crew leader.
Be sure that the wheels or tracks are on firm ground.
Pick up loads under the center of their weight.
Start and stop machines slowly when raising
and lowering the bucket and when traveling.
Maintain and use the brakes
properly.
Avoid excessive slopes and speeds when traveling on roads.
Work only at right angles to the bank or fills.
Watch booms and buckets for clearance when working or moving.
Take
extreme care when working an endloader downhill.
Install and maintain
an automatic
backup alarm.
Scrapers
Block up the bowl to prevent it from
dropping when changing the cutting edges or working underneath the
scraper.
Place blocks
between the apron arms and scraper sides before the work
is performed under the apron.
Keep hands away from the cable, sheaves,
and linkage while
the unit
is operating.
Wear leather-faced gloves when handling
cable.
When traveling down a steep hill, be ready to drop the
cutting edge to the ground
to serve
as a brake if the scraper should start to jackknife
or get out
of control.
Replace
weak or frayed cables immediately.
Grader Operation
Be alert to the danger of fatigue caused by monotony on the job.
Supervisors shall only
allow
competent operators to operate a grader.
Trainees shall operate
a
grader only under the
immediate supervision of a qualified
operator.
The operator is the only
one allowed on a machine
when it is in motion, unless the operator is instructing
a trainee or a supervisor is directing the work.
Never back a machine until you are certain that there
are no hazards. Install and maintain an automatic
backup alarm.
Avoid clashing the gears and spinning the wheels.
Mount and dismount a grader only when it is stopped
and properly braked.
Post Crew and Equipment Working signs and flags
on the section of road being worked to warn and
protect forest users.
Plan blading so that a section can be completed each
day. If a windrow must be left overnight, warning
signs or lights shall be placed to warn motorists.
If it is impossible to park the grader well off the road,
post reflectors or flags to warn traffic.
Keep the cab ventilated to avoid the effects of exhaust
fumes. The exhaust tailpipe should be set at
an angle of 45 degrees to the rear and right or left
of the line of travel.
Adjust levers or controls directly. Never reach through
the steering wheel to adjust them.
Watch the road for hazards. Dismount and look things
over carefully if visibility is poor.
Pull—rather than push—logs and windfalls out of the road if they might slide
or roll onto the machine.
Grade slowly enough to prevent the machine or yourself
from being thrown out of control if you strike
roots, rocks, or stumps.
Only on rare occasions should the grader be
operated faster than 5 or 6 miles per hour.
Be sure the entire crew is in full view before starting,
and be sure they do not get too close to the moving
machine.
Shift into the lowest gear necessary to climb or
descend a grade.
Maintain control on hills by keeping the machine in
gear; never coast out of gear. Do not depend entirely
on the brakes to hold the grader while traveling,
working, or when parked.
Keep graders away from the edge of the road on fills.
When sloping a bank, watch above the cut for rocks,
logs, and trees that may roll when loosened by the
blade.
When turning a grader, point the front wheels toward
the fill shoulder.
When backing, remember that the brakes do not
hold as well in reverse as in forward gear.
Before refueling, doing maintenance work, or checking
the machine, stop the engine; set the brakes; and
lower the blade, scarifiers, or rippers to the ground
or onto a block.
When fueling a grader, make sure that the refueling
can or pump nozzle touches the fuel tank opening
to prevent static electricity from creating a spark.
On motor graders and all units with pneumatic tires,
be sure driving tires are matched for size and are
installed so they rotate in the proper direction.
Grader Transport
Observe State requirements for headlights, taillights,
and warning flashers.
Angle the moldboard enough so that both ends are
within the width limits of the tires.
Mount a Slow Moving Vehicle sign
on the rear
of all graders.
On narrow roads, stop to let oncoming traffic pass.
Always travel at a safe speed based on road and weather conditions.
Point
the end
of the blade that is on the traffic side to the rear and away
from the direction of travel.
Shovel and Crane Operation
A shovel or crane
shall
be operated
only by a qualified operator or a trainee under the direction
of
a qualified operator.
Wear close-fitting clothing, such as coveralls
and nonskid
shoes.
Give a signal and wait until everyone is clear
before hoisting materials.
Only hoist loads that are well within the rated
crane capacity. When lifting heavy loads, a two-, three-, or four-part
line shall
be used to keep
within
the rated capacity of the hoisting cable. A data
sheet showing operating ranges and capacity ratings with the boom at various
angles should be
posted in the
cab.
Do not overload booms and cables.
The
distance
between
operations and live high-tension lines shall be the length
of the
boom plus the
length of the material being carried. This does not
apply when the power has
been cut off.
If the boom should contact overhead
wires carrying electricity, the operator shall:
Stay on the machine until the boom is cleared or
the power is shut off.
Keep personnel on the ground away from the
machine.
Jump off if the operator must leave the machine. The operator must
not step off.
Keep hands clear of moving cables and other moving parts.
Place all slings, ties, and hooks safely and securely before material
is hoisted.
Keep away from a dipper, boom, or load being operated or moved. Use
handlines for guiding long
materials.
Do not go under an idle dipper or boom—it may drop if the brakes are damp
or cold.
Keep away from the tail swing.
Load trucks only when they are
safely placed and
the driver is out of the truck’s cab and in the clear.
Swing loads over the
rear of a truck—not over the
cab—when possible.
Mount the machine only when it is not moving.
Clear
all personnel before a machine is backed up or moved.
Disengage the
master clutch before leaving the
grader’s cab temporarily.
Shut off the power, lock controls, and secure movable
parts before leaving the grader’s cab for the day.
The dipper or other
load shall rest on the ground before the operator leaves the cab. Never
leave a
dipper suspended.
Equip all crane booms with snubbers.
Placement
When a machine is placed near an excavation, keep
shoring and bracing back from the edge for a distance
at least equal to the depth of excavation.
Place the machine on ground that is as level as
possible. If cribbing or shims are used to level a
machine, be sure they are sturdy and will not overturn
or shift. The machine shall be well blocked to
prevent it from rolling or sinking after being placed
in position.
Stabilize a pneumatic-tired, self-propelled machine
with outriggers when necessary.
Transporting
Lower the boom so that its tip is no higher than the
cab, if feasible. If the machine is provided with a
cradle or rack to support the boom, use it.
Use a flagperson when there are hazards to the
operator or other persons.
Watch for overhead obstructions, such as underpasses,
low-hanging limbs, and wires.
Do not permit free rolling or coasting with the machine’s
traveling gear disengaged.
Crusher and Compressor Operation
Crushers
Permit
crusher operation only under
the supervision of a qualified employee whose only duty
is plant supervision.
Make, post, and maintain a safety operating plan
at the crusher.
Provide a safety switch (kill switch)
or remote control for the switch to stop the motor in an emergency. If possible,
place the switch near the chute
to the crusher jaw.
Construct all walkways, ladders, and guards of sound
materials, and complete them before the plant is
operated.
Level and surface the crusher’s feed platform with nonskid material, such
as rough lumber.
Inspect all construction annually for evidence of possible
structural failure.
When a crusher is operated from a platform above it,
install guards around the crusher opening that will prevent workers from
falling into
the opening.
Use a rock hook to feed, turn, or remove rocks from the crusher.
When belts are removed or replaced, shut off the power.
Stop all machinery
before it is cleaned, serviced, or
repaired.
In portable crusher operations:
Stop the power before removing obstructions.
Do
not stand on or close to the flexible power drive mechanism.
Compressors
Check the water and oil levels in the engine and compressor before starting.
Check
other applicable items at proper intervals
based on the manufacturer’s recommendations. Mechanical shop inspections
should be made at the
same intervals prescribed for other heavy equipment.
Allow the engine
and compressor to warm up to operating temperature before closing
the drain valve.
Check the safety valve by operating it manually.
Check all gauges for proper operating pressures.
Clean and service the compressor air cleaner daily,
or more often in extremely dusty conditions.
Check the compressor daily for air leaks.
Bleed the tank and leave the valve open when
shutting down the compressor.
Leave the clutch between the engine and compressor
disengaged when the engine is shut down.
Brush-Chipper Operation
The operator is responsible for safe operation of the
chipper. All workers on the chipper crew shall obey
the operator’s instructions regarding safety.
Wear long-sleeved
shirts and gloves that protect the wrist and hands at all times when
feeding the
machine.
When conditions warrant, wear dust masks. Wear hearing protection
when sound levels exceed 85 decibels.
Stop the driver motor before making
any adjustments
or repairs to the chipper.
Do not allow anyone to stand directly
in front of the exhaust chute while the cutterhead is in motion.
No more
than two persons
may feed the chipper. If they must stand closer than 6 feet
from the hopper, only one person feeds it, working from the side. Never reach
into the throat
of an operating chipper.
Only limbs between 2 and 6 feet long
should be chipped. Dry and excessively crooked pieces should not be chipped.
Use a long limb to feed short pieces
into the chipper.
The diameter of limbs to be chipped is governed by
the size of
the chipper being used. Do not overload it.
Throw material butt-end first
into the hopper.
Use a pusher stick or another limb to clear the hopper.
When adjusting blades, cover the cutting edge of the blades below the
one being
adjusted with a section of split hose. Gloves cannot be used safely in such
a tight space.
Thoroughly clean pitch and sawdust accumulations from
the seating
surfaces of the cutter head and wedge blocks when blades are being changed.
Tighten wedge bolts and adjusting bolts according
to the manufacturer’s specifications. Recheck all bolts before the machine
is started in the morning and at noon.
After the blades are changed and
adjusted,
rotate the cutter knife once by hand to make sure that all blades clear
the bed knife.
After a blade change, stand well back from the machine
while
the operator
brings the cutter head to operating speed slowly by engaging and disengaging
the clutch. Run the machine at operating speed for a few minutes and
then stop. Recheck
the blade wedge bolts for proper tightness.
Preventive Maintenance
Operator Responsibility
Operators shall maintain equipment
to comply at all
times with the items listed on form FS 7100-9a, Operator’s Safety and Preventive
Maintenance Inspection
(Crawler-Tractors and Loaders), and form FS 7100-9b,
Operator’s Safety and Preventive Maintenance Inspection (Motor Graders, Wheel
Tractors, and Loaders). Any questions about lubricants, lubrication requirements,
or service adjustments should be referred directly to the immediate supervisor.
Lubrication is an essential part of preventive maintenance and, to a great
extent, controls the useful life of the machine.
The operator is the most important
person
in the preventive maintenance program. The operator is the first one to notice
that a machine is not functioning properly and should visually check the engine
temperature, oil pressure, fuel pressure, ammeter, and so forth, while operating
the machine. The operator should inform the supervisor or the mechanic of adjustments,
repairs, and loose parts that need to be tightened. Inspection adjustments
and minor repairs can be made while the machine is being lubricated.
To perform
preventive
maintenance checks correctly, the operator must know the machine thoroughly.
The
manufacturer’s instruction manual was prepared so the operator would have the
information needed for satisfactory performance. It should be reviewed regularly.
Lubrication Guide
Different makes and models of equipment require different
kinds of lubrication at different points and intervals. Consult the lubrication
guide
for instructions on each make and model. Always keep lubrication equipment
clean and in good operating condition. Replace worn or
broken fittings.
Adjustments by the Operator
Operator’s manuals should be consulted for adjustment procedures. If adjustments
do not correct a situation, the operator should notify the immediate supervisor
so a mechanic can be dispatched. Forms FS 7100-9a and FS 7100-9b list items that
the operator must maintain in a satisfactory condition. They also are used to
report
repair or maintenance services needed. The operator
is responsible for:
Adjusting and maintaining hoist and power control units,
foot and handbrakes, steering and master clutches, fan and generator belts,
and tracks.
Changing oil and fuel filters.
Draining water from sediment bulbs,
fuel tanks, and
fuel filters.
Installing new cables.
Keeping parts tightened on the unit.
Operational Checks
Before-Operation Checks. The importance of proper
startup and shutdown of construction equipment cannot be overemphasized.
Following
the recommendations in this guide and performing scheduled maintenance
procedures will increase equipment life.
Although an operator lubricates
and services
a
machine daily, there is always a chance that something might happen during
overnight and weekend shutdowns. A slow leak may deflate a tire on the
motor grader; an
oil or fuel leak might create a fire hazard or leave a machine without
fuel or lubricant; or someone might tamper with the machine during the night.
Before
operating your equipment, open the valve under the fuel tank and drain
at
least a pint to run
off any water that might have collected. Then
check for:
Tampering or damage.
Leaks.
Adequate fuel, oil, hydraulic
system, and water
levels.
Glass and rearview mirror—clean.
Rim and flange nuts—tight.
Tires—adequate
inflation.
Fan belt—adequate tension.
Battery—tight, clean, and water up
to required
level.
Gauges—operating properly.
Lights—operating properly.
Steering linkage—operating
properly.
Nuts and bolts—tight.
Missing tools.
Correct track adjustment.
Enough
antifreeze for freezing weather.
Operation Checks. Many defects can be detected only while the machine is
actually being operated. Prevent serious damage to a machine, as well as
lost time due to breakdowns, by keeping alert for signs of defects. Items
to be
checked include:
Steering brakes
Footbrakes and emergency brakes
Clutch
Transmission
Transfer
case
Engine
Instruments
Hydraulic control system
Blade and power
controls
Storage
To protect equipment during storage, follow the procedures
listed below.
NOTE: Catch and dispose of fluids in accordance with local regulations.
Thoroughly wash the complete unit, including the engine. Lubricate
thoroughly.
Drain the engine and refill with new oil.
If the
cooling system contains
antifreeze, check for
the lowest expected temperature and add additional antifreeze
if needed. Use the manufacturer’s recommended coolant or its
equivalent. Check all cooling system hoses and hose connections. If the cooling
system is
to be drained, be sure that the radiator engine block, water pump, and heater
are drained completely. Tie a warning tag marked Cooling
System Drained to
the steering wheel or levers.
Drain the fuel filter element housing and install
new filter elements.
Drain any accumulated dirt and water in the fuel
tanks; replace the drainplug and completely fill all tanks.
Clean the
sediment bulb
to remove water.
Cover the magnetos with waterproof material.
Store
the unit under cover, or cover it with canvas, giving preference to automobiles.
Release the power control unit’s brakes by tying the handles in the released position.
Cover the exhaust and intake pipes.
Rest moldboards, end
loader buckets, and scraper bowls on blocks or planks.
Coat moldboards
and end
loader buckets with heavy oil or grease.
Remove batteries, charge
them, and store them on a wooden base in a dry, frostproof place.
Clean the
cable terminals and battery carrier with soda solution and rinse
them with clean water.
Block up axles to take the weight off pneumatic tires. Run
track-type machines onto planks or poles to keep them from freezing to
the ground if they are to
be stored in the open or on a dirt floor.
Cover exposed pistons,
cylinders, rams, gears,
shafts, and all running parts with heavy grease or
oil. Do not grease tracks.
Coat all exposed steering ball joints on drive axles
with heavy grease or oil.
Remove exposed seats or backrests and store them
under cover.
Open the drainplug or draincock and bleed the air
receiver tanks on the air compressors.
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