Construction Vehicle and Plant Servicing Procedure

Below are some guidelines to establish set of rules for safely carrying out general construction vehicle and plant service works.

Project manager and plant and machinery incharge are responsible for the implementation of this standard procedure.

Before start of the servicing work:

Ensure that all maintenance and servicing activity is done only in designated area.

Make sure that all environmental precautions have been implemented.

Check that all fire protection precautions are implemented in the servicing area.

Guidelines for construction plant and vehicles servicing:

a) Clean or wash the vehicle or plant unit before doing any servicing activity.

b) While bringing the unit into the workshop, make sure there is a person to guide the driver. Pay attention to the guides’ commands to avoid accidents.

c) Place the chocks, minimum 2 pieces under 2 wheels.

d) Activate parking brake. Turn off the engine and remove the keys.

e) Enforce Lock-out Tag Out procedure as applicable.

f) Turn off the battery isolator switch.

g) If dump Body is raised up, ensure that the lock pin is installed (e.g. on the 777D) and make sure the dump body lock arm is installed. Barricade the work area and general purpose area (e.g. on the D400E). Also refer to Truck Body Isolation procedure.

h) When servicing a dozer, ensure to put a board or plate under the Ripper & Blade so that they do not damage the floor/pavement.

i) After shut down release any remaining hydraulic pressure by shaking the implement levers.

j) Make sure that the bucket for waste oil has sufficient capacity to receive the oil that will be placed into it.

k) When changing filters for oil and diesel, make sure there is an oil bucket ready to capture any spills so that they do not spill onto the floor.

l) Always use safety gloves and rags to avoid heat burns while changing the filters.

m) Open up the hydraulic & transmission tank caps, before changing the filters to release pressure build up and avoid oil spraying out.

n) Be careful while opening the final drive plug, as there will be air pressure inside. Release slowly.

o) While leveling the final drive plug, make sure that the machine operator is able to see the command from down below.Construction Vehicle and Plant Servicing Procedure

p) While re-filling oils always make sure that they are correct type as per the machine operation and maintenance manual. Ask the supervisor if you are unsure.

q) When re-tightening the Filter or Drain plugs after filling always make sure it is done in accordance with manufacturer’s service manual. Use correct method (Open Hand)

r) Use correct tools for the required job/activity.

s) While checking the battery, wear safety gloves, glasses and mask.

t) Clean up the workplace and dispose any waste oil and rags properly as per applicable housekeeping procedure and in designated areas.

u) Before starting the engine, recheck to make sure the Plug and Filter are tight.

v) Remove your Lock-out facility.

w) Before taking the unit out of Workshop, make sure the wheel chocks have been removed and pay attention to the guide’s commands.

x) Park the unit in the appropriate area for it.

y) Report to the field supervisor that vehicle unit is ready to use.

Truck Body Isolation Procedure

For detailed descriptions of securing the dump trays in the raised position refer to the Manufacturers Handbooks.

Following these procedures ensures that the dump tray cannot lower due to hydraulic system failure or accidental activation of the dump tray raise/lower control.

After securing the dump tray the isolation procedures Lock-out Tag Out must be followed.

CAT 777D and CAT 773D

The dump tray should be raised to full height. The safety retaining pins located at the rear of the dump truck should then be inserted to secure the bottom of the dump tray to the truck chassis.

CAT D400E – Standard Procedure

Raise the dump tray approximately 1.5 meters. There is a red coloured safety stay bar on the right hand side of the D400E on the chassis beneath the dump tray. Raise this by hand to the fully up position. Lower the dump tray slowly onto this bar. Check that the end of the bar fits into the locating well on the dump tray.

Fully raised Dump Tray Procedure

This procedure is to be followed only if it is essential for the dump tray to be fully raised for maintenance purposes. Before doing maintenance with the dump tray in the fully raised position authorization must be made by the Senior Shift Supervisor and this procedure then followed.

Held In the stores, there are two hydraulic ram clamps for the lift cylinders of the D400E. These should be issued from stores and one placed either side of the D400E. The dump tray should then be raised to full height. Isolation procedures must then be immediately put in place.

Lift the red coloured safety stay in the fully upright position. The ram clamps are then clamped around the spears of the extended lift cylinders. Personnel undertaking this must not place themselves under the dump tray but do so by standing on the ground next to the truck or if necessary on a stable platform. In addition install Props as a secondary measure under dump tray.

HINO Nissan and Isuzu 18 Ton Trucks

Note: These trucks do not come fitted with a safety stay however a stay has been provided by the owners.

Raise the dump tray approximately 3 meters. There is a red coloured safety stay bar in the workshop. Place this stay by hand under the front of the tray.

Lower the dump tray slowly onto this bar. Check that the end of the bar fits into the locating well on the dump tray.

Important: The above procedures must be undertaken if trucks are being washed with the body raised.

All truck drivers; workshop and associated personnel must be trained in the use of this Instruction.


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