DUMP TRUCK

DRIVERS TRAINING

Prepared By:
Dante B. Jardin
TESDA Trainer Assessor.
Dole OSH Practitioner in Mining
Accreditation No. 1030-10930-P-001
 OBJECTIVES
The outcome of this training is to provide
operators with the machine specific skills
and knowledge required to conduct safe and
efficient Dump Truck Operations.
 Driver Qualification
1. Not only be trained in the correct handling of
mobile plant, but also know the equipment and
understand the function of the various
components and controls
2. Must have a current drivers license from LTO
professional drivers license restriction 3.
3. Before operating a machine an operator has a
responsibility to have sound knowledge of the
rules and regulations of the work site
Training of Operators
1. Authorized site procedures

2. Safety practices and site standards

3. Operating conditions in all areas of the site, including
any special or hazardous conditions.
4. Basic information on the particular machine, its
components to be used including design features, centre
of gravity, capacity, stability and limitations
5. Location and functions of controls
6. Servicing, maintenance and reporting responsibilities
Responsibility
This training has been prepared in the interest of
safe operating practices for machine
drivers/operators, in accordance with the “Duty of
Care” principles of applicable OHS legislation.

It is the trainee’s responsibility to ask questions to

gain understanding of the concepts in this training.
Your aim is to drive/operate the machine in a safe
and responsible manner.
Duties of Employers

-The employer must provide you with

sufficient supervision, instruction,
information and training and personal
protective equipment (PPE) so that you can
perform your daily duties in a safe and
productive manner without being exposed to
hazards or harm.
Duties of Employee
- The employee must abide with all lawful
instructions and safe work procedures and take
reasonable care not to expose themselves or
others to hazards or harm and must ensure they
have received sufficient information, instructions
and training so as to perform their daily duties in a
safe and productive manner.
Operators Responsibilities
- Arrive for work in a fit for to work ready to
perform their duties in a safe manner
- To use, wear and maintain in good order the PPE
provided
- Perform daily equipment pre-start inspections to
ensure it is safe to operate
- Start and test the equipment in accordance with
safety requirements and manufacturers
recommendations
- Abide by all SOPs instructions received from
supervisors
- Operate/Drive the equipment in a safe
productive manner in accordance with site
procedures
Operators Responsibilities
- Comply with all Occupational Health &
Safety requirements for the site
- Report all accidents, incidents and near
misses to the Supervisor immediately to
minimize/eliminate the likelihood of a re-
occurrence of the Incidents.
- Report machine faults or site hazards
immediately to supervisor
- Clean and maintain the equipment to an
acceptable standard
 Environmental Issues
-Report all Environmental incidents including
spillage/leakage/release of hydrocarbons or other
substances which may endanger the environment.
-Where possible these incidents shall be
controlled, contained and cleaned up as soon as
practical.
-Any disposal of contaminants shall be done in
compliance with regulations and site specific
procedures.

-
 Hazard Identification

Most accidents involving mobile equipment are

due to faulty or improperly inspected machines, or
due to the operator not inspecting the work site
for possible hazards.
Stop and Think
Inspect the work area for possible hazards such
as:
· Open Service Drains
· Other Vehicles
· Pedestrians
· Open excavations
· Overhead Services (power, water, steam,
chemical, gas lines etc.)
· Underground services (water, gas, phone lines,
optical cables)
Stop and Think
Inspect the work area for possible hazards such
as:
· Buildings (structures, workshops, fuelling bays
etc)
· Uneven ground (potholes, slopes, cracks and
low windrows)
· Haul road widths, obstacles, wet, sticky or dusty
conditions
· Weather conditions (darkness, brightness, windy
etc)
· Blind Spots
· Restricted areas and exclusion zones
· Other operating equipment
· Lighting towers
Risk management
Machine operators should continually carry out a risk
assessment of the area in which they work and be
actively involved in reducing hazards in the workplace.
A number of considerations are as follows:
· Applying night or low visibility procedures
· Applying defect and incident recording or
reporting procedures
· Checking for services and other obstructions in
the operating area
· Checking for ground stability or cracks
· Maintain awareness of blind spots or
obstructions to vision
Risk management (Con’t)
· Maintaining communications with others who
are affected by the work
· Maintaining housekeeping standards
· Observing exclusion zone procedures
· Observing seating or seat belt requirements
during operations
· Observing warning and caution signs
· Observing overtaking or turning procedures
Personal Safety
Minimum PPE requirements, (please refer to your
site procedure and signage for your work area):

· Hard Hat
· Hi Vis Clothing
· Safety Glasses (dark or clear)
· Steel cap safety Boots
· Ear Plugs (Where applicable)
· Gloves (Where applicable)
· Dust mask (Where applicable)
Injury Prevention
You have a responsibility under law to protect
yourself and others from injury.

• Personal Protective Equipment (PPE) must be

worn in the workplace, as directed by Signage or
site procedures
• Always check the machine LOTO prior to
boarding the machine
• Maintain three points of contact and face the
machine when boarding or dismounting
• Always use appropriate horn signals when ever
starting or repositioning a machine
Injury Prevention
(Con’t)
• Never allow unauthorized personnel to operate
the equipment
• Whenever personnel are on the ground or in
the vicinity of the Equipment you are
operating, YOU MUST EXERCISE EXTREME
CAUTION and maintain clearances from them
• Manoeuvrings a machine into confined areas
such as workshop service bays, tire bays or fuel
bays may require the assistance of a spotter.
• Ensure a spotter is familiar with
communication signals.
Fatigue (As Discussed)
If you are finding it hard to concentrate or keep
your eyes open or if you start to make mistakes
that you would not normally make, then you need
to contact your supervisor immediately and
arrange alternate duties
Emergency Situations
Emergency will differ from site to site and you will be
trained in the site specific requirements during an
induction. In most cases the process is as follows:

Call emergency, emergency, emergency

· State name, location, nature of the emergency,
assistance required
· Amount of injured people
· Assist anyone who is injured to the level of your
expertise and training
· Do not put yourself in danger
· Assist with reporting and incident / accident
investigation
Communication Systems
There is a wide range of communication systems used
on sites between all personnel. These may include:
· Radio
· Hand signals
· Verbal communications (Pre-Shift
Information PSI or toolbox Meeting)
· Procedures and Job Hazard Analysis
(JHA/JSA/JSEA)
· Signage's and notice Bulletin boards
Information that may be gathered can
include:
· The location of the machine
· Any hazards that have developed
· Type of machine required and requested
· Loading and Unloading areas
· Locations, maps
· Any changes to road rules or LTO rules
· Proper reporting of machine defects
Machine Safety
Caution, Warning and Danger Labels
In various locations around the machine,
there are caution, warning and danger
labels. These are there to prevent
serious accidents or fatalities so take
notice of them.
Accessing Mobile Equipment
When accessing mobile plant/equipment it is
important that you maintain 3 points of
contact facing the machine at all times. If
personnel wish to approach the machine,
ensure good clear communications are
maintained.
· The machine must come to a complete
stop, if applicable have all Ground
Engaging Tools (GET) lowered
· Relevant brakes system applied.
Operator must position themselves
out of cab
When a person approaches mobile
plant/equipment the following rules should
apply:

· Ensure the machine is safe to walk-around and

that all other personnel including other
operators are clear of the machine
· Check the machine for tags
· Check the machine above prior to walking under
the machine
Passengers
It is not permissible to carry any passengers unless there is
a manufacturer’s seat and seat belt provided and you have
authorization from your Supervisor.
Battery
Touching both negative and positive points of the battery
at the same time with anything that is conductive, will
give you an electric shock.
Hearing Protection
In addition to site PPE, hearing protection must be worn
whenever signs or procedures indicate this. If you have to
shout to be heard around machinery, you should be using
hearing protection.
Cooling System
The cooling system of a machine can be extremely hot and therefore
under no circumstances, is the radiator cap to be removed by any
person other than maintenance personnel who are trained in doing
this task.

Overhead Cables and Power lines

Safety procedures MUST be observed at all times, as follows:
· When travelling underneath power lines, follow the site
specific requirements at all times.
· “Any activities carried out near overhead power lines, must
ensure that a power line corridor of 8 meters for high voltage
and 6 meter for low voltage is maintained under and each side
of those overhead power lines”.
If Power Contact Occurs
· Stay calm, don’t panic, contact supervisor
· Remain in the cab of machine and refrain from touching metal parts
· Don’t move the machine until advised by supervisor
· Do not leave the machine until it is safe to do so or directed by supervisor·
As a last resort and if power can’t be switched off and contact with
power lines can’t be broken away, then jump well clear so as not to
touch machine and the ground at the same time. Shuffle away maintaining
contact with the ground with both feet to a safe distance

The supervisor will determine the course of action to take in the event of an electrical
storm approaching the work area.
Blasting Practices
Blast practices may affect your work area in the following ways:
· Introducing exclusion zones
· Safe working distances from the affected area
· Miss-fires
· Hazardous fumes
· Fly-rock
· Time of blasts and radio silence
Fire Extinguisher and Suppression system

Dry Chemical Powder fire extinguishers or Foam Suppression units will

be located on all machines.

Tire Blow-out
A tire blow out would generally be caused through a combination of
wear, rock damage and excessive pressure due to over-inflation or over
loading etc.

Tire Explosion
A tire explosion would usually occur after a tire has ignited. Machine
contact with electrical cables, lightning or welding on a wheel rim must
also be treated as a possible source of a tire explosion.
HAUL TRUCK
Pre-Start Inspection
Always ensure the dump truck is parked in a safe condition and location prior to
pre-inspection and ensure the previous operator is clear of the dump truck
before you begin the pre-inspection. Ensure the haul truck is positively isolated
prior to commencing the pre-start inspection.

When performing a Pre-Start Inspection on the dump truck, start at the front of
the unit working your way around and finish back where you started.

Items to look for will include;

· Main Isolation Switch
· Tags
· Front and rear tires for cuts and visible pressure
· Step ladder condition, grab handles, hand rails lights & indicators
· Engine oil, coolant, power steering oil levels
· Fuel, oil, and coolant leaks
· Fan belts for condition security and tension
· Oil, coolant, and air hose for leaks, damage and security
·
Complete Pre-Start Inspection Book

The operator must complete the pre-start inspection book at the

commencement of each shift. Any faults found during this
inspection must be recorded even if they have been recorded
previously; they need to be recorded until they have been
repaired.

Most pre-inspections have a fault category system in place, this

allows you to determine the severity of the fault and take the
necessary appropriate action.
Horn Signals

The following audible signals shall be given

by dump truck operators:

· ONE blast before starting the engine

· TWO blasts before moving forward
· THREE blasts before reversing
Starting the Dump Truck
Once all checks are documented and provided the haul truck is safe to
operate, it can be started. Starting the Dump Truck requires you to:
• Ensure your seatbelt is fastened
• It’s a safety requirement that all windows and doors are keep
shut when operating equipment
• Check the immediate area for personnel and other vehicles
• Make sure the Dump truck is in neutral and the park brake is
applied
• Sound the horn once and wait 5 seconds
• Start the engine

Electronic Management Systems

The Electronic Management Systems (EMS) are designed to monitor the
critical components of the haul truck engine, transmission and differentials
and alert the operator if there is problem area developing.
Depending of the type of dump truck you are operating, faults are
categorized into levels.
Check Pressures and Gauges

With the engine running at idle, check the appropriate gauges for the model
of machine. You will be instructed in which gauges to view in the machine
specific module. Allow the engine to run for 2 to 3 minutes to warm up and
pressures to build up to operating range.

Brake Test

A series of brake tests must be performed prior to operating a dump truck.

Brake testing is used to check brake holding capability and condition, through
a particular component, at its maximum threshold.

Moving the dump truck to Work

With all systems checked, all documentation completed, it is now time to

move the dump truck to work. If the area is clear of personnel, use the
correct horn signal, apply correct brake, release the park brake, select the
appropriate gear, and release the brake.
Dump Truck Operation

Operating the dump truck correctly requires a good understanding

of the dump truck together with the right attitude and operating
technique.

Site Speed Limits

Speed limits on site will be in alignment with various rules and

regulations for the site you work on.
Haul Road Conditions

The nature and condition of the ground surfaces over and through which
the machine must be operated must be continuously assessed by the
machine operator as part of their tasks. Failure to continuously assess the
conditions of the ground can result in loss of control of the machine or
damage to the machine components. Always remain vigilant to:

Dust generation – Water carts for haul road watering

Large rocks/spillages/poor road surface conditions – contact Pit
Supervisor
Supervisor will issue hazard warning via two-way radio to all
operators in area
Wet slippery conditions – obey all directives given during shift
briefing and throughout shift
Missing/poorly constructed windrows along road edges – contact
Pit Supervisor
Supervisor to arrange remedial work – issue hazard warning via
two-way radio to all operators in area
Loose, gravely surfaces
Oil or other hydrocarbon spills
Travelling on Haul Roads

When travelling along haul roads, it is important to drive to conditions at

all times. This will include when there is excessive water due to rain or
over watering from the water cart. Each dump truck type will have a
exhaust system that will be used to slow down the haul truck when
required.

A minimum distance of 50 meters must be maintained behind all vehicles

that are travelling on haul roads.

Blind spot area behind the haul truck

All Vehicles Are At No Times Allowed To Over Take On Haul Roads

Travelling Uphill

When uphill hauling, the speeds travelled at are relatively slow. Always
drive up a ramp by selecting the gear at which the truck will climb the
ramp.

Note: Always climb a ramp in the correct gear when fully loaded.

This will stop:

· Gear changing on the ramp which is hard on the drive train
· Rock spillage from rough gear change
· Eliminate gear hunting

Downhill
When travelling downhill, you must travel at a safe speed that
ensures the dump truck does not accelerate too fast. Depending on
what type of dump truck you are operating, will determine how you apply
the braking system and gear selection when travelling downhill.
Emergency Stopping on Grades

If engine has to be shut down (Emergency Situation) the following is to

apply:
· Turn wheels towards high wall or windrow.
· Apply the correct brake as per the model of dump truck
· Select Neutral and shut the engine down using the appropriate
switch
· Turn on hazard lights
· Inform Supervisor of situation and make general call to all road
users
· Assess the situation and only leave the cab if you are in further
danger i.e. fire
Cornering
Correct cornering is an important factor in reducing the wear and tear of the machinery.
When approaching a corner, ensure you slow down, gently going into the corner and slowly
accelerate as you power out of the corner

Intersections
All dump truck operators must ensure it is safe to proceed prior to entering any intersection.
Most intersections will be controlled by signage with either STOP or GIVE-WAY signs. Normal road
rules will apply in each situation.

Driving at Night
The distance that you can see ahead and to the side is severely reduced after dark. This means
that it will take you longer to respond to hazards after dark. You must use extra caution to allow
for the reduced visibility after dark.

Use your high beam for better visibility; however, as high beam lights may dazzle oncoming
drivers, you are required to dip your headlights:
· As soon as an approaching vehicle’s lights are dipped
· When you are within 200 meters of an approaching vehicle; or
· When you are driving less than 200 meters behind another vehicle
Precautions for driving at night
· Keep your windscreen and headlights clean
· Do not wear tinted glasses, except under the advice of an eye specialist
· Notify your supervisor if you are feeling fatigued

Overtaking
Overtaking of vehicles will be as per site requirements. All Vehicles no overtaking on haul
roads

Losing Traction
If the dump truck you’re operating starts to lose traction on approach to or while
climbing the ramp, the following will apply:
· Stop the dump truck and do not attempt to move the dump truck under its
own power
· Apply the correct brake as per the model of dump truck and turn the dump
truck hazard lights on
· Use the two-way radio to inform all other dump truck operators and site
personnel of the current situation
· Contact the supervisor on the two-way radio and inform him/her or the
situation
· Keep the dump truck engine running and unless otherwise informed stay in
the cabin
Skidding
A skid or slide occurs due to loss of traction or when one or more wheels slide instead
of having a rolling action. Causes can be one or more of the following:
· Excessive speed
· Swerving
· Sudden, quick movements of the steering wheel
· Sudden excessive acceleration or deceleration
· Sudden or excessive braking
· Wet roads
Whopper Stoppers
Because of the location of some haul mine roads, it is necessary to haul downhill. In
this case, if it is an excessive gradient, and it is possible to do so, there may be run-off
ramps to the side or short windrows constructed in the middle of the haul road to
stop run-away trucks. These are called Whopper Stoppers.
General Operation

Dump Truck Loading with an Excavator

Under normal circumstances dump trucks shall approach the excavator in a
clockwise direction. Before moving into the loading area the operator shall check
for spillage and rocks falling down the bench face or from the bucket to assist
with tire damage prevention.

When dump trucks are approaching an excavator, they shall keep outside of the
excavators reach. Move forward to position the dump truck at approximately 45
degrees to the bench to shorten the reversing distance (no more than 2 truck
lengths) and to gain a sweeping view in the mirror of the ground to be reversed
over.

Prior to stopping, it is important to rotate the front wheels into the opposite
direction so when reversing occurs, the correct direction is maintained. Figure A
shows the truck nearing the end of the forward movement and figure B shows
how the truck should finish prior to engaging reverse.
Dump Trucks Queuing for Loading Operation

When more than one dump truck is waiting at a loading machine the
following is required;
• The first haul truck shall wait facing the loading machine and
maintain a distance of at least 20 meters
• The following dump truck shall inform the first dump truck via the
two-way radio that they are approaching from behind to park
and receive a positive response. The dump truck shall park no
closer than 10 meters behind the first dump truck
• Ensure that you can see the driver’s side mirror of the haul truck
in front
In “On the Teeth”
In this case the dump truck will be reversed at right angles to the stick and boom of the
excavator. Line up with the onside of the tray with the tips of the bucket teeth.

Offside Loading
Line the offside of the dump truck with the back of the bucket to maintain square
position up the incline.
Onside Loading
Onside loading is the most preferred and common form of loading a truck with an
excavator at mine site. Stop close to the Excavator upper car body at a 45° angle to
working face on the ON SIDE of the Excavator when the bucket is actively working the
face.
Top Loading
Top loading involves both excavator and truck working on the same level.
Some examples are:
· When finishing the remains of a bench
· Digging a sump
· Picking up batter trimmings
· Starting a drop cut

Note : Be aware that you are able to reverse into the excavator body as
they are on the same level as your tray, so be prepared to stop promptly.

Drop Cuts
The excavator will initially be on the same floor level as you are driving
on. Position the haul truck to reverse under the bucket, i.e. square on to
the bucket. Always complete turns on flat ground and not in the drop cut.
Digging alongside a Pit wall (Batter)

When digging alongside a pit wall where a cut-back is being conducted, the excavator
operator is to position the dump truck no closer than eight (8) to ten (10) meters
from the wall, this minimizes the potential for damage to machinery and operator
should the pit wall collapse.

The excavator operator is also to ensure that an adequate windrow is constructed on

the pit edge of the digging area to stop dump trucks from driving over the open face.

Windrows are to be no less than half the height of the largest dump truck wheels
using the area and a minimum thickness at the base of two thirds the height (if the
windrow is 3m high, the base is to be 2m wide)

Loaded by a Front End Loader

The loader will be on the same floor level as you are driving on. You will drive past
the loader and park so the loader is on your onside and you are approx 45deg to the
lifted bucket.
Trucks At Dump
Dump Operations on a Tip head
Care must be taken at all times when travelling over dump floors to
avoid any unnecessary damage to you, passengers, tires, and
suspension or chassis system.

Dump truck operators shall always approach the safety windrow in

a direction that allows for the visual inspection of the tip area
which is on your onside. When approaching the dump area, use
wide turning circles to avoid tire damage.

When approaching the tip head, you must ensure safety windrows
are of adequate height. Depending on the dump truck you operate,
the general rule is:
The windrow should be at least half the wheel height or
axle height of the largest dump truck in the area.
Park Up and Shut Down

Parking on Go-Line
When parking in the go line all machines shall head for the furthermost
parking area and starting from the left hand side of the line first.

A spacing of no less than 3 meters shall be kept between each machine when
parked. The front wheels of the machine shall be positioned in the “V”
provided with the park brake applied and the gear shift control in neutral.
• Ensure the front wheels are centralized in the bottom of the “V”
• Strict speed limits apply to ’go’ lines and workshop areas
• Under no circumstances should you attempt to reverse while on a
‘go’ line
Cabin Maintenance
Use the available shutdown time to clean the haul truck cabin.
· Make sure you remove all rubbish from the haul truck
· Clean all windows, mirrors and cabin handrails
· Clean the dash, top and centre console area
· Sweep the floor and remove all dirt from the cabin

Equipment Housekeeping
All equipment and related attachments shall be maintained in a clean
and tidy condition with adequate location/storage
End of Shift Inspections

Perform an end of shift inspection start at the front of the haul truck and
working around and finish back to where you started. Main items to look
for include:
· Tire conditions
· Oil Leaks
· Fuel leaks
· Wear and tear
· Damage to machine
· Cabin housekeeping
Breakdown Procedure / Operation
If the haul truck you are operating breaks down then the following rule
shall apply:
• Attempt to park the haul truck in a safe area or passing bay or
as close to the left hand side of the road as possible.
• If the area is wet or if ground conditions are soft, do not park
the haul truck off the road or on uneven ground.
• Turn wheels into high wall or windrow
Place haul truck into neutral
• Apply the appropriate brake
• Shut down engine
• Hazard lights on
• Notify supervisor / other personnel
• Remain in cab until instructed further
Basic Open Pit Terminology
ROM
‘Raw Ore Material’ Stockpile – Stockpile area for ore coming from the
pit ready for reclaim by crusher
Fingers
Small stockpile of a particular grade/type of ore usually found on a
ROM
Bench
The platform in which a loading unit takes its material from
TBM
Temporary Bench Mark – Distinguished by marker pegs and flagged
off
RL
Reduced Level - Term used by surveyors to measure the working level
in a pit
Tip head
Working area where material is dumped over an edge (waste dump,
ROM stockpile or fingers)
Rill Material
Material dumped over a tip edge with natural fall
Batter Slope
The sections of rock mass between catch berm within pit walls – usually
excavated to a specific inclination/angle from the horizontal
Catch Berm
The width of lateral ground (bench) separating successive batter slopes.
The purpose of the catch berm is to both reduce the overall angle of the
pit walls, and to catch
any loose material or local scale rock mass failures, thus reducing the risk
of injury at the base of the pit
Windrow
A continuous mound of loose material, of appropriate height, placed at
the toe or crest of a slope as a barricade to falling objects or to prevent
personnel/mine equipment from falling inadvertently down pit walls (can
also be referred to as a BUND)
Any Questions??