6-C-RIIMPO301E - Conduct Hydraulic Excavator Operations - Learner Guide - V 1.1 02122019 PDF

RIIMPO301E Conduct Hydraulic Excavator Operations
Learner Name:
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Date Training Commenced:
This Book Contains:

Course Information.
Table of Contents
1.1 Introduction ............................................................................................................................... 4
1.1.1 What is an Excavator? ................................................................................................................................................. 4
1.1.1.1 Excavator Components ......................................................................................................................................... 4
1.2 Working Safely .......................................................................................................................... 5

1.2.1 Health & Safety Rules .................................................................................................................................................. 5
1.2.2 Operations Documentation ........................................................................................................................................... 5
1.2.3 How to Keep Everyone Safe ........................................................................................................................................ 6
Review Questions ................................................................................................................. Error! Bookmark not defined.
1.3 Work Instructions ..................................................................................................................... 6

1.3.1 Reading and Checking Your Work Instructions ............................................................................................................ 7
1.3.2 Work Method Statements ............................................................................................................................................. 7
1.3.3 Geological and Survey Data ......................................................................................................................................... 7
1.3.3.1 Geological Data ..................................................................................................................................................... 7
1.3.3.2 Survey Data ........................................................................................................................................................... 7
1.3.4 Site and Project Quality Requirements ......................................................................................................................... 8
1.3.4.1 Site Product Characteristics .................................................................................................................................. 8
1.3.5 Emergency Procedures ................................................................................................................................................ 8
1.3.5.1 Emergency Shutdown of Equipment ..................................................................................................................... 8
1.3.5.2 Evacuation ............................................................................................................................................................. 8
1.3.5.3 First Aid ................................................................................................................................................................. 8
1.3.5.4 Fire Fighting Equipment ........................................................................................................................................ 9
1.4 Inspect and Prepare the Work Area ......................................................................................... 9

1.4.1 Checking Level and Grade Requirements .................................................................................................................. 10
1.5 Hazard Identification & Control .............................................................................................. 10

1.5.1 Identify Hazards ......................................................................................................................................................... 10
1.5.2 Control Hazards ......................................................................................................................................................... 11
1.5.2.1 Personal Protective Equipment (PPE) ................................................................................................................. 12
1.5.2.2 Barricades and Signage ...................................................................................................................................... 12
1.5.3 Environmental Protection Requirements .................................................................................................................... 12
1.5.4 Take-5 Risk Assessments .......................................................................................................................................... 13
1.5.4.1 Completing a Take-5 Risk Assessment ............................................................................................................... 13
1.5.4.2 Filling in a Take-5 Form ....................................................................................................................................... 13

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2.1 Choose and Check Plant and Equipment.............................................................................. 14
2.1.1 Select and Fit Attachments......................................................................................................................................... 14
2.1.2 Conduct Routine Checks ............................................................................................................................................ 14
2.1.2.1 Pre-Start Checks ................................................................................................................................................. 15
2.1.2.2 Operational Checks ............................................................................................................................................. 16
2.1.3 Report all Faults ......................................................................................................................................................... 16
2.2 Position the Excavator ........................................................................................................... 16

2.2.1 Jump Turning ............................................................................................................................................................. 17
2.3 Operate the Excavator ............................................................................................................ 17

2.3.1 Assess Loads and Materials....................................................................................................................................... 18
2.3.2 General Excavator Operations ................................................................................................................................... 19
2.3.2.1 Safe Operating Speeds ....................................................................................................................................... 19
2.3.2.2 Safe Travel Speeds ............................................................................................................................................. 19
2.3.2.3 Bucket Loading and Discharge ............................................................................................................................ 19
2.3.2.4 Monitoring Systems and Alarms .......................................................................................................................... 20
2.3.2.5 Adjust Techniques to Meet Changing Conditions ................................................................................................ 21
2.3.3 Distribute Loads into Materials Handling Equipment .................................................................................................. 22
2.3.3.1 Loading Haul Vehicles ......................................................................................................................................... 22
2.3.4 Side Casting ............................................................................................................................................................... 22
2.3.4.1 Removing Overburden ........................................................................................................................................ 23
2.3.4.2 Extracting Materials ............................................................................................................................................. 23
2.3.5 Monitor and Check for Hazards .................................................................................................................................. 23
2.3.5.1 Reporting Hazards............................................................................................................................................... 24
2.3.6 Checking Completed Work ......................................................................................................................................... 25
3.1 Park and Shut Down the Excavator ....................................................................................... 25

3.1.1 Parking the Excavator ................................................................................................................................................ 25
3.1.2 Shutting Down the Excavator ..................................................................................................................................... 25
3.1.3 Post-Operational Checks............................................................................................................................................ 26
3.1.4 Reporting Faults ......................................................................................................................................................... 26
3.2 Carry out Maintenance Tasks ................................................................................................ 27

3.2.1 Vehicle Refuelling Procedures ................................................................................................................................... 27
3.2.2 Returning the Excavator to Service ............................................................................................................................ 28
3.2.2.1 Removing Locks and Tags .................................................................................................................................. 28
3.2.3 Processing Maintenance Records .............................................................................................................................. 28
3.3 Clean Up After Work ............................................................................................................... 29

3.4 Process Written Records ....................................................................................................... 29

Appendix A – Hydraulic Excavator Daily Inspection Checklist ................................................. 30
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1.1 Introduction
This course is based on the unit of competency RIIMPO301E Conduct Hydraulic Excavator Operations.
In this course you will learn how to use a hydraulic excavator including:
Planning your work.

Checking the equipment.
Using the excavator.
Maintenance and housekeeping.
1.1.1 What is an Excavator?

An excavator is a self-propelled vehicle (either crawler or wheeled) with an upper structure, which can rotate 360 degrees.
It can excavate, then swing and discharge materials.
1.1.1.1 Excavator Components

The following diagram and table outline the basic components of an excavator:
Component Description
Hydraulic Rams Control the boom/arms of the hydraulic excavator.
The ‘arm’ of the excavator may be used to excavate or control any other relevant attachment. The
Boom
boom is generally controlled through the use of hydraulic rams.
Cabin The position that the operator controls the excavator from.
The lower section of the excavator stays stationary while excavation work is being completed.
Chassis/Undercarriage
The upper section of the excavator is able to slew (rotate) independently from the undercarriage.
Attachments The tool used to perform excavation or other relevant tasks.

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1.2 Working Safely
You must follow all safety rules and instructions when performing any work. If you are not sure about what you should do,
ask your boss or supervisor. They will tell you what you need to do and how to do it in a safe way.
1.2.1 Health & Safety Rules

Every workplace has to follow laws and rules to keep everyone safe. There are 4 main types:
Acts These are laws that you have to follow.

Regulations These explain what the law means.
Codes of Practice These are instructions on how to follow the law, based on industry standards.
Australian Standards These tell you what the minimum requirement is for a job, product or hazard.
Code of Practice - www.safeworksa.com.au

Work health and Safety Acts - https://www.legislation.sa.gov.au
Regulations www.safeworksa.com.au
Australian Standards - https://www.standards.org.au/
Some states use OHS laws, and other states use WHS laws. They both talk about the same thing, but use different words
or names for people. If you have any questions about safety rules you should talk to your boss or supervisor.
1.2.2 Operations Documentation

Before starting your work you need to make sure you have access to all operations documentation for the job. This will help
you to do your work in the safest way and make sure all work is compliant.
Operations documentation includes:
Operations Documentation Description

The information and safety requirements of the workplace environment (where you
Site Details
will be working).
Any hazards in the work area or related to the work. This could also include
Hazard Details
instructions on how to handle dangerous or hazardous materials.
Instructions of what the work is or what you will be doing. Also instructions on how to
Task Details
safely do the job.
Faulty Equipment Procedures Isolation procedures to follow or forms to fill out.
Site signage tells you what equipment you need to have, or areas that are not safe to
Signage
be in.
Instructions on what to do in emergency situations, for example if there is fire,
Emergency Procedures
accident or emergency where evacuation or first aid is needed.
Equipment and Work
Details of how to operate plant and equipment and the sequence of work to be done.
Instructions

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1.2.3 How to Keep Everyone Safe
WHS law says that all companies and workers need to keep themselves and other people safe while they work. This is
called a duty of care.
To keep yourself and other workers safe you need to:
Follow your instructions.

Follow all workplace rules.
Make sure all equipment is safe to use.
Carry out your work safely.
Report any problems.
If you think something is dangerous tell your boss or supervisor as soon as possible.
Your worksite will also have instructions for working

safely including:
Emergency procedures, including using fire fighting equipment, first aid and
evacuation.
Handling hazardous materials.
Safe work practices.
Personal protective clothing and equipment.
Safe use of tools and equipment.
1.3 Work Instructions

You need to be clear about what work you will be doing. Make sure you have
everything about the job written down before you start. This includes what you will be
doing, how you will be doing it and what equipment you will be using.
Make sure you have all of the details about where you will be working. For example:
The Site – Is there clear access for all equipment? Are there obstacles in the
way? What are the ground conditions like? Is the site ready for your work to
begin? Are there any ‘out of bounds’ areas you need to avoid?
The Weather – Is there wind, rain or other bad weather? Is it too dark?
Traffic – Are there people, vehicles or other equipment in the area that you
need to think about? Do you need to get them moved out of the area? Do you
need to set up barriers or signs?
Hazards – Are there dangerous materials to work around or think about? Will
you be working close to other people?
You also need to make sure you have all of the details about the kind of work you will
be doing:
The Task – What kind of material is being moved? How much is there to
move? How long do you have to complete the work? Where will the load be
discharged? Does it need a special type of bucket or attachment? Are there
grades and levels that need to be achieved?
Plant – What type of plant will be used? How big is it? How much room does it
need?
Attachments – What equipment will you need to shift the load safely? Is the
equipment available?
Communications – How are you going to communicate with other workers?
Procedures and Rules – Do you need any special permits or licences? Are
there site rules that affect the way you will do the work e.g. contamination
control requirements?

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1.3.1 Reading and Checking Your Work Instructions
All work needs to follow worksite, environment and company safety procedures.
Procedures help to make sure that all work is done in a safe way, without damaging
equipment or putting people in unsafe situations. They also help to make sure that work
is done in the correct order and doesn’t interrupt or get in the way of other work that is
happening on the site.
Your work instructions will tell you the safest way to do the job, and the equipment that
you will need to use. It is a good idea to check your work instructions with your boss or
supervisor to make sure you know exactly what you need to do.
If you don’t know where to get your instructions or you can’t understand them, you can
ask your boss or supervisor. They will tell you where to find your work instructions and
explain what they mean.
1.3.2 Work Method Statements

Many worksites require a work method statement before any work can start. A work method statement is a list of steps that
outlines how a job will be done. It also includes any hazards that occur at each step, and what you need to do about them.
These statements can also be known as Safe Work Method Statement (SWMS), Job Safety Analysis (JSA) or Safe
Operating Procedure (SOP).
1.3.3 Geological and Survey Data

Geological and survey data is used to guide you through a job. It tells you what the
area is like, what things you will need to think about and what work you need to
complete.
1.3.3.1 Geological Data

Geological data gives you information about:
Rock or material types and characteristics.
Wet and dry areas.
Water tables or other sources of water.
Broken ground, faults or joints.
Compaction levels.
All of this information will help you to decide on what equipment you need to use, where
and how you should travel with equipment and areas to avoid.
1.3.3.2 Survey Data

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Survey data covers information about job outcomes including:
Bench heights and widths.

Floor heights.
Floor, ramp and bench grades.
Underground working and voids.
Survey data can also be used to mark out:
Work circuits.
Pick up areas.
Dump areas.
Spill zones.
Routes or traffic ways.
1.3.4 Site and Project Quality Requirements

Every site will have quality assurance or quality management requirements that must be
met. These can range from standards of work through to the timeframes for tests to be
conducted.
Knowing in advance what requirements you need to meet will allow you to meet them
without a problem. Quality requirements support every aspect of the worksite.
1.3.4.1 Site Product Characteristics

Make sure you are familiar with the site product or materials before you start to
move them around. Have a look at the composition of the materials to see what kind
of equipment you will need to move them, and what techniques to use.
Some materials are more cohesive or sticky while others may be much less stable
to work with, or create hazards like dust, contamination or damage to equipment if
they are not handled just the right way.
1.3.5 Emergency Procedures

Emergency procedures will vary depending upon the worksite. These procedures could
include:
Emergency shutdown.
Evacuation.
First aid.
Fire fighting.
1.3.5.1 Emergency Shutdown of Equipment

If there is a fire, emergency or accident you might need to use the emergency stop on the equipment
you are using. This will turn the equipment off immediately. You can also use the emergency stop if the
equipment stops working properly or you lose control of the equipment.
1.3.5.2 Evacuation
Things to remember are:
1. Keep calm.
2. Move away from the danger to a designated evacuation point, sometimes called an
emergency assembly area.
3. Do not let other people into the area.
4. Call emergency services in accordance with workplace procedures and policies.
1.3.5.3 First Aid

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First Aid is the quick care given to an injured or ill person. Every site will have a First Aid Officer. If somebody needs first aid
you must tell your supervisor or First Aid Officer. Do not try to give first aid if you have not been trained.
1.3.5.4 Fire Fighting Equipment

Fire fighting equipment on site could be anything from small fire extinguishers through to
large water cannons. Different fire fighting equipment should be used for different types
of fire. Always check the equipment for information on what type of fire it can be used on.
Steps for using a fire extinguisher:
1.Evacuate the area.

2.Isolate the area.
3.Call emergency services or other designated on site procedure.
4.If it is safe to do so, use an extinguisher to attempt to control the fire using the
PASS system.
The PASS system:
Contact your site emergency management team as soon as possible and call the fire brigade on 000.
1.4 Inspect and Prepare the Work Area

Before you start any work you need to look around the site. The inspection and
preparation of the worksite includes:
Working out the path of movement for plant, vehicles and materials.
Identifying hazards, and taking suitable actions to deal with them.
Making sure all equipment, resources and workers are available for the task.
It is important to coordinate with other workers when you are inspecting and preparing the
site to make sure everyone knows what is going on, what you are planning to do and what
they need to do.
All workers on site must understand their own role and the roles of others before starting work.
It helps to make sure work is done safely and efficiently.
Workers you may need to coordinate with includes:
Other mobile plant operators.

Processing plant operators.
Maintenance workers.
Water truck/cart operators.
Service vehicle operators.
Crane and float operators.
Contractors.
Inspectors, both internal and external, including WHS, environmental and quality
assurance officers.
Supervisors.
Site visitors.

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1.4.1 Checking Level and Grade Requirements
You need to check the floor clean up procedures to make sure you are able to
achieve the specified levels and grades. These will be outlined in the project
details and your instructions.
This could also include other areas such as the pad, road, ramps, and bench
clean up procedures.
1.5 Hazard Identification & Control

Before you start work, you need to check for any hazards or dangers in the area.
If you find a hazard or danger you need to do something to control it. This will help
to make the workplace safer.
The best way to control hazards is to use a simple problem-solving approach:

1. Identify the problem. (What is the hazard?)
2. Identify the cause of the problem. (What is causing the hazard?)
3. Work out the different options that you have to solve the problem. (What can be
done to eliminate or minimise the hazard as much as possible?)
4. Choose the best option to solve the problem and apply it. (What is the best option
to eliminate or minimise the hazard?)
5. Check to see if the problem has been solved. (Has the hazard been eliminated or
reduced to a safe level?) If not, you will need to use additional, or better options for fixing the problem. (Controlling
the hazard.)
1.5.1 Identify Hazards

Part of your job is to look around to see if you can find any hazards before you start any work.
A hazard is a thing or situation that causes injury, harm or damage.
When you start checking for hazards, make sure you look everywhere. A good way to do this is to check:
Up high above your head.
All around you at eye level.
Down low on the ground (and also think about what is under the ground).
Some hazards you should check for in the work area:
Hazards Example
Weather Conditions Electrical storms, wind, heat, floods and fires.
Work Area and Ground Uneven or unsafe ground, excavations, holes and potholes, unstable faces, overhanging rocks,
Conditions sinkage areas, dust and noise.
People Site personnel or visitors.
Structural Hazards Adjoining pit walls or structures, ramps, cuttings, and embankments.
Chemical Hazards Fuel, chemicals, contaminants, gases or dusts.
Other vehicles, conveyors, fixed plant, abandoned or unattended equipment, ancillary
equipment, lifting equipment.
The times when the equipment is moving is the most hazardous.
Equipment or Machinery As an operator, you need to be very aware of your surroundings when moving the
vehicle, but you should also keep an eye on other vehicles moving around you.
Follow vehicle movement or traffic plans and your worksite procedures for equipment
movements.

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1.5.2 Control Hazards
After you have found hazards or dangers you need to work out how bad they are:
1. What is the chance that the hazard will hurt someone or cause damage?
2. If it does happen, how bad will the injury or damage be?
Thinking about these things will help you to choose how to control the hazards.
Hazards controls need to follow:
Legislation (laws).
Australian Standards.
Codes of Practice.
Manufacturers’ specifications.
Industry standards.
The best way to control hazards is to use the Hierarchy of Hazard Control. The hierarchy of hazard control is a range of
options that can eliminate, or reduce the risk of hazards.
You start at the top of the list and see if you can take away (eliminate) the
hazard or danger.
If you can’t take it away you move down the list to see if you can swap it for
something safer (substitution). Keep working through the list until you find
something that controls that hazard or danger.
This table shows you the 6 different types of controls in order from best to
worst:
Hierarchy Level Action
1. Elimination Completely remove the hazard. This is the best kind of hazard control.
2. Substitution Swap a dangerous work method or situation for one that is less dangerous.
3. Isolation Isolate or restrict access to the hazard.
4. Engineering Controls Use equipment to lower the risk level.
5. Administrative Controls Site rules and policies attempt to control a hazard.
6. Personal Protective Equipment The least effective control. Use PPE while you carry out your work.
It is important to think about all of the options available when deciding on the
best hazard controls. You may need to use more than one control measure to
bring the risk level down to an acceptable level.
Check the situation after you have applied a control measure to see if more
controls, or different controls are needed to make the job safe. If more controls
are needed, make sure they are applied before you start or continue the work.
Talk to your supervisor or safety officer if you are not sure if it is safe enough to
carry out your work. If you think the hazard is still too dangerous you should not
try to do the work.

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1.5.2.1 Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) is clothing and equipment designed to lower the chance of you being hurt on the job.
It is required to enter most work sites.
It includes:
Head protection – hard hats and helmets.
Foot protection – non-slip work boots.
Hand protection – gloves.
Eye protection – goggles, visors or glasses.
Ear protection – plugs or muffs.
Breathing protection – masks or respirators.
Hi-visibility clothing – clothing that makes you stand out and lets other
people know where you are.
Weather protection – clothing that protects you from the sun or from the
cold.
Make sure any PPE you are wearing is in good condition, fits well and is right for
the job.
If you find any PPE that is not in good condition, tag it and remove it from
service. Tell your supervisor about the problem and they will organise to repair or
replace the PPE.
1.5.2.2 Barricades and Signage

In some cases you may need to isolate the work area. Set up barricades and
signage to warn others that you are working in the area and that it is dangerous for them to come too close.
Check vehicle routes to make sure you are not blocking off roads or pathways for other vehicles.
1.5.3 Environmental Protection Requirements

Environmental protection requirements are part of every worksite. Make sure you check with your supervisor about what
environmental issues need to be managed during your work.
All environmental details should be listed in an ‘Environmental Management Plan’ for the
site. It can include details for:
Waste management.
Water quality protection.
Noise control.
Vibration control.
Dust management.
The plan will outline the steps and processes needed to prevent or minimise damage to
the environment through the use of machinery and equipment.

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1.5.4 Take-5 Risk Assessments
A ‘Take-5’ is a quick and simple tool for use in the field to conduct a ‘HAZOB’
(Hazard Observation).
It can be used to identify hazards and assess the risks associated with activities
where documentation or a procedure already exists or when conditions (such as
weather) change.
Once identified, the hazard is controlled, where possible, and recorded in

accordance with site procedures.
Sites generally have a Take-5 book, checklist or process that is used as standard
procedure in line with documentation and processes such as
SWMS/JSA/JHA/JSEA and other safety procedures.
1.5.4.1 Completing a Take-5 Risk Assessment

The Take-5 system uses 5 simple steps to identify and deal with any hazards, on the spot. The steps are:
Different sites may have specific procedures or books for recording the details of the Take-5 process. It is important that
you always record and report the details of any hazard in line with site policies and procedures.
1.5.4.2 Filling in a Take-5 Form

A Take-5 form should be used to record the details of the hazard where the hazard cannot be recorded as per standard
procedures. This will generally include listing:
Date.
Time.
Your name.
Location of the hazard.
Details of the hazard (what is the hazard?).
Action taken.
Details of any further action that is required.
Details of recommendations for controls or treatments.
Details of the risk level.
It is the responsibility of the person who has identified a hazard during a Take-5 risk
assessment to record and report the hazard in accordance with site procedures in a timely
fashion.

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2.1 Choose and Check Plant and Equipment
Once you have confirmed your job requirements you need to choose the right
equipment and attachments to get the job done.
When choosing equipment and attachments you
need to think about:
The task requirements, specifications and
goals.
The appropriateness of the equipment for
the completion of the task.
The characteristics, correct use, operating
capacity and limitations of each item.
The potential risks to yourself and others in
the intended use of the equipment.
Information about technical capabilities and limits can be found in the operator manuals for
each item.
It is not safe to operate plant, equipment or attachments beyond the manufacturer’s
specifications. This may cause the machinery to break and could also cause an accident.
2.1.1 Select and Fit Attachments

There are a range of attachments and equipment that can be fitted to an excavator including:
Buckets.
Ripper tynes.
Rock breakers or hammers.
Grapples.
Compactors.
Magnets.
Augers.
When selecting an attachment you have to work out if it is suitable for the tasks you need to
complete by confirming:
What the attachment is designed for.
If it is an approved attachment that can be used with the excavator you are operating.
The manufacturer’s requirements for the attachment.
That you know how to use the attachment properly.
You will find this information in the operator’s manual for the excavator and the operator’s manual
for the attachment. Otherwise you may need to check the workplace equipment procedures for
your site.
Once you have decided that the attachment is right, you need to attach it securely using approved
attachment points and methods.
Again, the operator’s manual for the specific excavator you are operating will have exact
instructions on the connection process which must be followed at all times.
Once the attachment is fitted to the excavator you need to inspect the coupling points and any
auxiliary hydraulic hoses to make sure they are secure. Auxiliary hydraulic lines need to be
properly connected for some buckets and attachments to work properly.
2.1.2 Conduct Routine Checks

Before you use any piece of plant or equipment, you need to conduct routine checks to
make sure it is safe to use. Check the machine logbook before you start your inspection to
see if there are any faults that still need to be fixed before you can use the excavator.
Also make sure you are wearing the correct PPE before you start checking the machine.
Routine checks are made up of:
Generally, routine checks are performed at the start of each day or shift. You can use an inspection checklist to keep a
record of the checks you have made.

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2.1.2.1 Pre-Start Checks
Pre-start checks are done before the engine is started. Walk around the excavator and look for anything that is out of the
ordinary.
Part or Component What to Check

Structure Check the general condition of the excavator and the ROPS (Roll Over Protective Structure)
and FOPS (Falling Object Protective Structure) are fitted.
Check for oil or other fluid leaks.
Check for any signs of visual weaknesses, damage, stressed welds or paint separation.
Tyres Check for mud, which may be thrown from the tyres and cause damage.
Check the condition and air pressure of the tyres to make sure they are within the
manufacturer’s specifications.
Tracks Make sure the track pin is centred over the track roller, and that track sag is within acceptable
limits. The track tension should be adjusted if it is too loose.
To check the tension of tracks place a straight edge on the track from the roller to the drive
wheel/cog and measure the distance from the edge down to the track.
As a general rule, the allowable track sag is 2.5-3.8cm but you need to check the
manufacturer’s specifications for the excavator you are operating to be sure.
Safety Pins Check that the safety pins are in place where needed. Tighten any loose bolts. Make sure the
keeper plates and pins are in place.
Bucket Check the capacity of the bucket to avoid overloading and look for worn or broken teeth.
Inspect the hydraulics and connections for wear and tear. Check the condition of the pivot
pins.
Boom Arm Make sure you check the arm for damage or defects, but be careful not to put yourself in a
position where you could be crushed if there is a malfunction.
If you find excessive wear in the power arms and connections that make the excavator
dangerous to operate you need to inform your supervisor or an authorised person. Then
isolate the excavator and don’t use it until it is repaired.
Fluids & Lubrication Check that the oils (engine, transmission) are at the right levels, and that there are correct
amount of diesel fuel and hydraulic fluids.
Check that the water or other approved coolant is at approved levels.
Transmission fluid needs to be checked in accordance with the manufacturer’s specifications.
Check that appropriate parts are lubricated to ensure the smooth operation of all parts.
Hydraulic Rams & Hydraulic rams and pressure hoses are checked for splits, leaks, fractures, bulges and bent
Hoses piston rods.
A hydraulic leak in the quick hitch line causes a reduction in the pressure of the hydraulic
line, which can in turn cause the quick hitch to release the bucket attachment, particularly
when the engine is stopped.
Ladders, Walkways & Check that there is safe access up to the cabin and other platforms on the excavator.
Guardrails
Decals & Signage Check that all decals and signage are present on the machine. This includes the load chart,
which must be clearly readable for the excavator to be used.
Windows Check that the windows are clean and you have good visibility from the operator’s chair.
Cabin Check that the seat and safety belt are in good condition. Check that the cabin is clean and
that there are no objects on the floor that could get in the way of the controls or trip you over.
Service History & Check the machine hour meter, manufacturer’s recommendation and logbook to find out if
Logbook the excavator needs to be serviced.
For exact details on the components for the machine you are operating, check the operator’s manual as different brands
may have different requirements.

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2.1.2.2 Operational Checks
Operational checks are made once the engine is started.
Climb up to the excavator cabin using 3 points of contact at all times (2 hands and 1 foot
or 2 feet and 1 hand). This is the safest way to climb in and out of the excavator. Never
jump from the excavator.
Adjust the seat until comfortable and make sure you have maximum visibility.
Start up the excavator following the manufacturer’s instructions. If the excavator will not
start after being refuelled there may be air that needs bleeding from the fuel system.
You will need to let the engine idle for the required amount of time. Depending upon the
individual machine this idle time could range from 3 to 10 minutes.
Always make sure your seat/safety belt is on and attachments are raised before moving
off.
Controls and functions that need to be checked on the excavator:
Part or Function What to Check

All Controls Test all boom and bucket movements. Check that the excavator can properly
turn and slew (cabin and platform rotate).
Gauges and Instruments Check that all instruments are displaying properly and are not signaling any
alarms or warnings.
Attachments Check that the attachment is secured and connected to the excavator
properly. Check the condition of the attachment. Check that it works properly.
Travel, Turning and Brakes Test the accelerator and brakes, including the emergency stopping device.
Ancillary Equipment Test out all communications devices and any other systems or functions
fitted.
Once you have finished your operational checks it is a good idea to check for external signs of oil or fluid leaks. It is
common for the start-up process to cause a leak through hoses breaking. Look for signs of leaks.
2.1.3 Report all Faults

Once all routine checks are finished, you will need to report any problems, faults, defects
and damage that you found during the inspection so that they can be repaired and the
machine and equipment are safe for you or the next operator to use.
Make sure the excavator is tagged out (isolated from use) until the repairs have been
made.
Record the details of the problem in a fault report or the excavator logbook.
2.2 Position the Excavator

‘Walking an excavator’ is driving it slowly into position so you can start work.
Excavators are extremely heavy so movement is slow. If you are walking the
excavator up an incline make sure you travel in a straight line directly up the hill and
do not turn while on the slope – the excavator could lose stability and slip.
Make sure all workers are away from the area or out of the danger zone before you
start to move off.
Keep clear of any obstacles and try not to run over anything. If necessary use a
spotter to assist with the move but make sure they are kept in sight and clear
communication is maintained with the person.
Once you have moved the excavator to the location you need to be working in you will need to position it for use.

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2.2.1 Jump Turning
Jump turning is a method used to reposition the excavator. It is a useful way to make sharp turns and avoid cutting up the
ground by using just the tracks to move.
To perform a jump turn:
1. Turn the bucket in and lower it straight down with the heel
resting on the ground. This will help to support the weight of
the excavator.
2. Use your right hand to push the bucket into the ground lifting
the excavator up slightly.
3. Use your left hand to rotate the cabin at the same time as
turning the undercarriage with the foot controls.
2.3 Operate the Excavator

During excavator operations you will need to:
Assess the materials you are working with.
Use the equipment safely within the technical specifications and limits.
Use the equipment for tasks that it is specifically designed for.
Continuously monitor and check for hazards.
Respond to emergency and unsafe situations.

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2.3.1 Assess Loads and Materials
You will need to assess the materials you are working with to figure out the best way to handle it. For example, clay is more
cohesive and harder to excavate than topsoil.
The following table describes some of the common materials that are dealt with on a worksite:
Material Description
Gravel Rock fragments or pebble-sized rocks.
Ore Material from which minerals or metals can be extracted.
Overburden The layers of soil or other materials that covers the materials being mined.
Materials that have been exposed to oxygen causing a chemical process called oxidisation.
Oxidised Waste
These materials will need to be removed from the area.
Rejects Materials that are generated during the extraction and processes used in the mining industry.
Road Base Materials used to create roads, which can also be used to build roadways within the mines.
Includes materials that are unusable and unprocessable or could refer to general rubbish on site.
Rubbish If you as an excavator driver are required to load general rubbish onto a haul vehicle, ensure it is
evenly distributed and covered (if necessary).
Can move around as the haul unit moves. This can make moving sand with haul vehicles
Sand
problematic if it isn’t loaded in accordance with site procedures and processes.
This rock has an acid content that will become acid sulphate when it comes into contact with the
Sulphide Rock Fill
air. This can lead to damage to the haul vehicle, the excavator or you, the operator.
Waste materials that cannot be used any further in operations. Distinguished from other site
Tailings
materials by the process of extraction.
The top 5 to 20cm of soil that has the highest concentration of organic matter. It can be difficult
Topsoil
to manage once removed from the ground because of the organic material.
You will also need to assess the weight of the materials you are working with.
Common Material Weights

Bronze 8.5t per cubic metre Lead 11.4t per cubic metre
Clay 1.9t per cubic metre Lime – stone 2.6t per cubic metre
Coal 864kg per cubic metre Sand – beach, dry 2.0t per cubic metre
Concrete 2.4t per cubic metre Sand – beach, wet 2.3t per cubic metre
Earth 1.9t per cubic metre Sand – river, wet 1.5t per cubic metre
Granite 2.6t per cubic metre Shale 2.6t per cubic metre
Gypsum 2.3t per cubic metre Terracotta 1.8t per cubic metre
Iron Ore 5.4t per cubic metre Zinc 7.0t per cubic metre
Think about the size of the bucket you are using and work out the weight of the load.
To work out the volume that the bucket can hold multiply the height (H), width (W), and length (L) and divide it by 2:
Check the weight of the materials against the load chart to make sure you will not overload the excavator.

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2.3.2 General Excavator Operations
Keep in constant communication with other personnel throughout your excavator operations. Continuously monitor and
check for hazards, and warn other workers if there is danger.
Report your progress on a regular basis to your supervisor and modify your work
to meet any new project or quality requirements, or changing conditions.
The operator’s manual and load chart will outline the limitations of the excavator
you are using this will include information about:
Safe operating speeds and techniques.
Safe travel speeds.
Bucket loading and discharge.
Monitoring systems and alarms.
2.3.2.1 Safe Operating Speeds

While operating the excavator make sure movements are smooth, not jerky, and
that you operate the excavator (move the boom) at a safe speed.
Operating the excavator too fast can cause instability.
Maintaining safe operating speeds that reflect the conditions is essential for the
smooth and safe operation of the excavator.
2.3.2.2 Safe Travel Speeds

Going too fast will increase the likelihood of loss of control of the excavator, as well as endangering the driver and others on
the worksite.
Your speed may be affected by a range of factors including:
The age of the machine.

The work environment.
Ground conditions.
Attachments fitted.
Visibility.
Site rules, policies and procedures.
The amount of traffic, other vehicles or obstructions in the area.
2.3.2.3 Bucket Loading and Discharge

It is important not to overload the bucket. Keep materials as stable as possible with smooth movements and try to keep the
materials from spreading out too much.
When discharging materials it is important to be on a level surface to avoid rollover.
Make sure you have applied the correct brakes to stop movement if
applicable.
Raise the bucket to the correct height for discharge before starting to roll
bucket. Then roll the bucket to ensure clean discharge of materials.

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2.3.2.4 Monitoring Systems and Alarms
Each machine has its own set of alarms, monitoring systems and gauges to help you safely and efficiently operate it, and
warn you if something is wrong. Each make and model of the same type of machine can be different so it is important that
you are familiar with all of the systems for the equipment you are using. Check the operator’s manual for a full list of
devices, alarms and warnings.
Here are some examples of the gauges and warning systems that may be found on an excavator:
System Type Specifics

Air pressure.
Brake oil temperature.
Brake Monitors
Parking alarms.
Retarder.
Oil.
Temperature Gauges
Water.
Pressure Gauges Engine oil.
Fuel.
Filters Steering.
Transmission.
Fuel.
Engine Gauges
Engine oil pressure.
Tachometer.
Torque converter.
Voltmeter.
Gauges and Meters
Speedometer.
Odometer.
Service meter.
GPS.
Computerised Indicators
Laser levels.
Generally alarms and warnings fit into 3 categories:
Warning
Category Examples What You Should do
Type
These types of warnings let you know Low fuel. Keep operating as long as it is
Category 1 that the machine needs some Low system voltage. safe to, and report the problem
attention, but it is still safe to operate. once you stop work.
These warnings indicate that there is a Equipment is Change the way you are
problem caused by the way you are overheating. operating and if the problem is
Category 2 operating that may lead to problems not fixed, stop operating and
Equipment is
with the equipment. overloaded. report the issue.
This is the most serious warning level. The park brake is on. Stop operating and shut down
Continuing to operate while this Low engine oil pressure. the equipment immediately.
Category 3
warning is sounding will cause damage Report the problem straight
to the machine. away.

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2.3.2.5 Adjust Techniques to Meet Changing Conditions
While you are working and moving materials, the site will change. These changes will be in the environment and the ground
conditions.
Lighting Changes – While working underground, you may not be greatly

affected by changes between night and day, but when working on the surface
you could be. Twilight is the time when your eyes might become more tired and
difficult to focus. It could be more difficult to see the terrain and to judge
distances. Set up temporary lighting where possible and go slowly.
Weather Conditions – Rain, sleet, snow, wind and humidity can all affect both
your excavator and the materials you are working with. Additional moisture from
any source will change the composition of the materials, possibly making them
heavier and slippery. This means you will not be able to lift or haul as much and
you will need to adjust the quantities you are dealing with in each load. You
should notify your supervisor or another appropriate person that schedules and
completion times may not be met.
Ground Conditions – When working an area the ground will change, either
through a breakdown or an increase in the degree of compaction. This means
you may need to be more aware of slips and problems with gaining traction on
the ground. A broken surface can lead to instability of the ground or an increase
in the likelihood of sinking or bogging. Operating on soft or uneven ground will
reduce the load capacity of an excavator. You may also need to clean out the
undercarriage of the excavator as the work goes on so you can properly move
and reposition the equipment.
During your operations with the excavator, the work conditions will change. It is important to be prepared for these changes
as they occur so that you are not caught off guard or find yourself in a dangerous
situation.
These changes could include:
Gradient Changes – When hauling out or excavating, the grade or slope of the
ground will become steeper or deeper. Either condition leaves you with a much
steeper slope than when you started. This steeper slope leaves you with a
greater risk of rollover. Always travel straight up and down an incline (not
across) and select an appropriate gear and speed while travelling.
Height of Face Changes – As you excavate a face it will change dimensions,

including its height. This can make the face dangerous or more prone to
collapse. Keep an eye on the materials and the face and check for any loss of
stability throughout operations.
Material Grade Changes – Changes to the grades can occur when moving
materials. This could include changing from acceptable grade materials to spoil
materials, or changing from a loose grade (such as sand) to a denser grade
(such as rock). Modifying what you are doing to meet these changing material
grades is essential.
Haulage Units – These units could include any machine or item of equipment
that is used to haul materials away. As one haulage unit leaves the location,
another will generally arrive. This means the place where you are discharging
could constantly be changing slightly.
It is often slight changes in location or arrangements that cause the largest

problems for excavator operators. Be very aware of the positioning and the
changeover of haulage units when unloading materials.
Distance From Services – If you are working materials up onto a fill area you
need to monitor the location of overhead power lines, services and structures.
They will be coming closer with each load, increasing the risk of electrical line
contact or ‘arcing’ of electricity from the lines to the excavator.
As you get closer to overhead services use a spotter or have the power turned
off to avoid an incident.
Voids – Being aware of the location of underground voids or previous workings

allows you to calculate how close you are to them. If you are working near
underground workings or voids it is essential you do not move materials away,
making the area unstable or causing a collapse or sinkage.

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2.3.3 Distribute Loads into Materials Handling Equipment
Materials handling equipment could range from feed hoppers, barges, feeders and crushers through to haul trucks or
conveyors. These trucks could be off-highway or on-highway (registered) vehicles.
Be careful not to overload the materials handling equipment.
Your instructions and worksite procedures will outline:
The rate you can discharge materials into handling equipment.

The materials allowed to be discharged into handling equipment.
Which handling equipment you should be loading.
2.3.3.1 Loading Haul Vehicles

The table below lists the basic requirements for the safe and effective loading of a haul vehicle:
Basic Requirements for Loading a Haul Vehicle

Check in with the driver of the haul truck using communication equipment (e.g. two-way
radio) to make sure that it is correctly positioned and that you know where the driver is.
Make sure the loaded bucket is within the capacity of the machine.
Place a layer of soil in the vehicle to take the impact of large rocks.
Never pass or slew a load over the cabin of the truck as the bucket could hit the cabin or
load could drop onto the cabin.
Be careful of large boulders tipping out of the bucket onto the truck.
Make sure anyone in the area is at a safe distance from loading operations and that they
remain within your view.
Do not overload the haul vehicle.
Distribute the load evenly across the tray of the vehicle.
Don’t just dump the materials, unload carefully.
Place the heaviest loads over the axles.
Follow worksite requirements.
2.3.4 Side Casting

Side cast mining is also known as strip mining. During this process the overburden is removed and placed near the mine
area to get access to materials for extraction.
Once the coal or other materials have been extracted the overburden is replaced. Side casting occurs in open-pit (or open-
cut) mines.
Excavators are vital to the smooth operation of open-pit mines. The types of
excavators used during side cast mining could range from dragline excavators
through to tracked or wheeled excavators.
Regardless of the type of excavator being used the basic principles of working with
the bulk materials are the same. You need to either remove the overburden or
extract the minerals.

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2.3.4.1 Removing Overburden
If you are removing overburden you will need to place the overburden in the appropriate location and consider the
environmental requirements such as the size of the stockpiles.
Check your site procedures or work instructions for details of where the
overburden needs to be placed and how.
It is particularly important to keep the size small enough to allow seed germination
but still large enough to be efficient. This is important because the overburden will
be returned once extractive activities have been completed.
When removing overburden make sure you create your benches to the correct
specifications or surveyed marks. If you are not sure of the required benches,
speak with your supervisor.
2.3.4.2 Extracting Materials

Once the overburden is out of the way the materials will need to be extracted.
Normally this is done with large excavators such as bucket-wheel or dragline
excavators. These machines are designed to move large amounts of materials in a
short period of time.
2.3.5 Monitor and Check for Hazards

While you work it is important to always be on the lookout for new hazards, and to check that hazard controls are still in
place and working effectively. This will help to ensure the safety of yourself, other personnel, plant and equipment.
Check the following things while you work:
Overhead Power Lines or Structures – Know how far you are from overhead
power lines at all times. Use a spotter to guide you if visibility is reduced. Be
aware that the distance to the overhead services may be reduced as fill goes up.
Other Machines – At all times you need to know when other machines are
working near the excavator. Know and stick to your agreed travel paths or roads.
Good communication between operators is essential to avoid incidents such as
collisions.
Live Stockpiles – Movement of materials in a live stockpile is likely. There is

always the potential for the walls of a stockpile to collapse if it is incorrectly
excavated.
You may experience problems when loading out from a stockpile that may be in
use (e.g. being loaded from a different side). This problem can be solved with
good communication between plant operators and supervisors.
Personnel – Good communication is the

key to working with other workers. Be
aware of people in work area. Make sure they are not in danger and are a safe
distance from the excavator.
If you are authorised, tell them to leave if they shouldn’t be there, or call on someone
who is authorised.
Make sure you are aware of the correct worksite procedures for working near or
around other people in the area.

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Operator Fatigue – Fatigue is one of the leading causes of accidents for operators of all types of vehicles and equipment.
Fatigue can be caused by:
Warning signs that you are suffering fatigue include:
Slow reaction time.

Tiredness, yawning or sore eyes.
Physical
Headaches, stomach or other problems.
Micro sleeps (nodding off for a short period of time).
Trouble concentrating and thinking clearly.
Mental Shorter than normal attention span.
Boredom, irritability or lack of motivation.
Poor or careless performance.
Work Overlooking minor but potentially important details.
Lower levels of communication and cooperation with others.
It is very important that fatigue is managed properly. Here are some ways you can
manage fatigue:
Get enough sleep.

Drink plenty of water.
Take regular breaks.
Keep a healthy diet.
Keep a reasonable level of fitness.
Talk to your boss or supervisor about breaking up boring or monotonous tasks or

rotating the work you are doing with other workers if possible.
2.3.5.1 Reporting Hazards

Any hazard or environmental issue that you
identify during your work will need to be reported. If you have taken any action you will
also need to report those details. This could include written or verbal reports.
Your worksite may have standard paperwork that needs to be filled out, for example:
Hazard report forms.

Take-5 forms.
Work method statements.
Other reports or documents.

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2.3.6 Checking Completed Work
The key to completing tasks efficiently is good time management and knowing how to
use your equipment properly.
Once you have completed your work you will need to check it against:
Your work instructions or work plan.
Site quality requirements and timelines.
Product quality requirements.
Project details and information.
Speak to your supervisor when the work is completed to see if there are any other
tasks that need to be done to complete the job.
3.1 Park and Shut Down the Excavator

Every piece of machinery has slightly different park and shutdown procedures. For the exact procedure for the machine you
are operating, check the operator’s manual.
3.1.1 Parking the Excavator

The excavator needs to be parked in a safe way that will allow easy access to the vehicle.
Safe parking practices include:
Stop the excavator on a flat level surface in the designated area and
keep the access points clear.
Park the excavator away from overhangs, excavations, access ways and
tidal or flood areas.
Keep the excavator away from refuelling sites and areas when parking or
you can block the rest of the machines on the site from accessing fuel.
Apply all locks and brakes.
Move all attachments into the shutdown position and release any
pressure from the lines.
3.1.2 Shutting Down the Excavator

Shutdown procedures include:
Cooling of the engine before shutting it
down. This depends on the excavator
but is usually the same amount of time as the engine warm up time.
Monitoring the controlled lowering of temperatures and pressures.
Walking around the machine looking for any signs of damage or faults that may
have occurred during the task.
Securing the excavator using any applicable lock out or isolation devices and
removing the keys. This will prevent any unauthorised movement of the
excavator.
Ensuring equipment is correctly stowed in accordance with site and
manufacturer’s requirements.
Any problems found during the shutdown procedures need to be documented in the way
required by the worksite.

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3.1.3 Post-Operational Checks
Post-operational checks need to be done to make sure the excavator is ready for the next
operator.
General maintenance activities are done to keep all plant and equipment working safely
for longer.
As part of your job as an excavator operator, you need to inspect your machine to find
and report any faults or damage that may have occurred during your work activities.
Your inspection should include:
Post-operational checks should include all of the things you look for when conducting pre-start checks. For example:
Fluid levels.
Condition of tracks or tyres.
Visibility (windows and mirrors).
Hydraulics (rams, hoses and connections).
Structure and attachments for damage or wear.
3.1.4 Reporting Faults

Once a fault has been found, it needs to be reported and fixed.
Most sites have a fault report form that you will need to fill out with the details. The form
will generally need the machinery or equipment make and model numbers, the site
identification numbers, the type of fault and the person reporting the fault.
You also need to make sure the excavator is tagged out (isolated from use) until the
repairs have been made. This will stop anybody from using it before it has been repaired.
Some sites will have a verbal system of reporting where you speak with a supervisor who then documents the fault, while
others may require the operator to organise repairs of the fault directly.

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3.2 Carry out Maintenance Tasks
Before carrying out any maintenance on the excavator you may need to clean it. This
will need to be done in a designated area to avoid any negative impact on the
environment or contamination of the site.
Clean windows, mirrors and lights regularly. Clean hand holds and grip points to
make them safe. Clean the grill and check oils and coolants in the radiator.
Maintenance activities could include:
Air filters – should be checked daily in dusty conditions. Clean or replace them
as necessary.
Greasing or lubricating attachments.
Checking bucket teeth and replacing them as needed.
Tracks – Check track tension (not too loose or too tight). The exact range of
acceptable motion or movement for the tracks will be detailed in the operator’s
manual. The tracks and drive cogs are commonly known as the walking gear.
Make sure that all aspects of the walking gear are working in accordance with
the manufacturer’s specifications.
Battery checks – clean the battery, check electrolyte levels.
Fuel and other fluids – check and maintain levels.
Refuelling.
Recording and reporting of faults through workplace procedures.
When conducting maintenance activities it is important to keep people in the area safe
by using barricades or fences if necessary and locking out machines.
Tasks should be completed within designated

areas and others should be informed of what you
are doing.
You should conduct servicing, maintenance and housekeeping tasks to ensure the
excavator stays at its operating capacity for as long possible.
You will also need to coordinate with mechanics, maintenance supervisors or other
site workers to ensure the vehicle is serviced at regular programmed intervals.
3.2.1 Vehicle Refuelling Procedures

All refuelling of equipment needs to be done in line with safety procedures and workplace instructions.
Some sites may have refuelling areas for plant and machinery set up to make sure any
spills or incidents can be contained without causing damage to the environment. Spill
response procedures need to be clear and spill kits available to manage any incident.
Other sites use a service truck or fuel tanker that travels to each machine to refuel. On
these sites it is very important that all procedures are followed to avoid any incidents
(such as fires in a coal mine environment) or damage to the environment. For example,
there may be site rules against refuelling plant and equipment near a waterway or
sensitive area.
Refuelling can be a dangerous activity, so it is important that you know and understand the correct procedures and
techniques. If you are not sure what to do, speak with your supervisor.
These are some general guidelines for refuelling plant and equipment. Always check the procedure
for your work site before any refuelling is done.
Park the machine in an appropriate location or within a bunded area. This contains any
environmentally sensitive fluids or spills from entering and causing damage to the
environment.
Shut down the machine and apply all brakes and isolations.
Leave the cabin, or if company procedures do not allow this make sure you do not restart
the machine until you have permission from the refuelling operator.
If you are responsible for refuelling the machine make sure you have the right PPE on
before you start. This may include safety glasses, face shields, gloves or other approved
gear.
Activate the fuel pump correctly and make sure all safety procedures are followed.
Shut down the fuel pump once the machine has been refuelled.
Roll up or safely tidy all fuel lines or hoses.

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3.2.2 Returning the Excavator to Service
Before your excavator is returned to service you need to confirm that all maintenance activities and repairs have been
completed.
Each site will have different processes for checking that the designated work has
been correctly completed. Procedures could include:
Third party checks – often done by a non-involved team member.

Supervisor checks.
Checklists or worksheets.
Procedural documentation, e.g. maintenance contract.
Other site-specific processes.
Once the maintenance work has been completed and checked, any locks and tags
on the equipment will need to be removed.
3.2.2.1 Removing Locks and Tags

There are two primary people who are authorised to remove a lock or tag:
1. The person who applied it.
2. The designated repairer.
Locks and tags may have been applied to the excavator as a whole or to isolation devices
attached to the machine. Double-check each possible location for locks and tags. Never
assume that removing one lock from an isolation device will remove all locks or tags.
Before any tags or locks are removed, the excavator or equipment should have been checked
to ensure all repairs and maintenance have been completed.
Once tags and locks have been removed, follow record keeping requirements to log the
removal on the job card or other relevant documents.
3.2.3 Processing Maintenance Records

Most sites have workplace forms, logbooks or checklists for writing down details
of all machine maintenance work.
They are used to record the history of the machinery and equipment so that all
operations and any problems can be monitored.
They are also a way of making sure that all repairs and maintenance are done
correctly and on time.
Written maintenance records for your

excavator may include:
Inspection checklists.
Fault reports.
Fuel, oil, hydraulic and other fluid usage.
Computer readings of various equipment functions.
Diary entries.
Service manuals or logbooks.
Repair request forms.
Part requisition forms.
You will usually need to include details like the excavator
make and model number, site identification numbers, the
type of maintenance carried out, the repairs or
replacements that were done and the person who did the
work.
Follow your site record keeping and reporting procedures. If in doubt about completing and
processing written maintenance records, talk to your supervisor or an experienced worker.

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3.3 Clean Up After Work
Once all your excavator tasks are finished, you will need to clean up the site. It is your responsibility to clean up after your
work activities and not leave it to someone else to do.
In clearing your work area you will be carrying out housekeeping activities.
Housekeeping procedures on your site may include:
Eliminating or controlling any potential hazards. Your duty of care means you
shouldn’t leave a possible source of danger or accident for others. This will help
you to make sure the working environment is safe.
Removing any hazard controls that are no longer needed such as barricades
and signage.
Materials such as clays, mud, topsoil, overburden, organic materials, stones,

rocks and gravel may need to be cleared to avoid contamination, or reclaimed
once the work is completed.
Maintaining and storing plant, equipment and tools.
3.4 Process Written Records

Site record keeping procedures keep the site running smoothly. Part of your role will include completing and processing
records for your excavator and the tasks that you have completed.
As well as the maintenance records you have filled in, some other records, reports and paperwork that may be needed
include:
Computer readings – from process monitoring, test results, activity reports,

and materials readings.
Logs – supply logs, work activity logs, training logs, stockpile logs, usage or
driver logs.
Shift documents – end of shift, end of process, quality information.
Fault reports.
Hazard reports – including Take-5 forms.
Incident reports – accident forms, incident reports or environmental incident

reports.
It is important that you keep detailed records of all your activities, especially any problems you had during your shift. You
may need to explain what you saw, or what you did at a later time.
Make sure you keep notes about what happened and what you did to fix it. This includes faulty or broken equipment,
operational issues (mistakes or not following procedures correctly for some reason) and any other unusual things.

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Appendix A – Hydraulic Excavator Daily Inspection
Checklist
Hydraulic Excavator Daily Inspection Checklist
Company Name: Date:
Operator Name: Site:
Machine Number:
Check Type (please circle): Pre-Start Post-Operational
Component What to Check for ✓ Comments

Pre-Start Checks
External Check
Inflation, pressure, tension,
Tyres or tracks.
damage, covers.
Wear, damage, cracks,
Bucket. __________________________________________
leaks.
Excessive wear, damage,
Bucket linkage and cylinder. __________________________________________
cracks, leaks.
Damage, wear, cracks,
Stick, cylinders. __________________________________________
grease, loose parts.
Underneath machine. Leaks, loose parts, damage.
__________________________________________
Condition, damage,
Frame, steps, handholds.
cleanliness.
__________________________________________
Hydraulic cylinders, tubes,
Damage and leaks.
hoses, fittings.
__________________________________________
Covers and guards. Damage, wear, secured.
Windows, wipers and Cleanliness, damage, fluid __________________________________________
mirrors. levels.
Decals and signage. Readability, wear. __________________________________________
Load capacity plate. Damage, wear, visible.
__________________________________________
Loose or missing parts,
Overall machine. damage, wear, missing
Out of Service Tag Attached? Yes / No
guards and safety devices.
Engine Check
Engine oil, hydraulic oil,
transmission oil, coolant,
Fluids.
engine pre-cleaner, brake
fluid. __________________________________________
Cleanliness, loose nuts and
Batteries.
bolts. __________________________________________
Damage, dirt build up,
Air filter.
indicators. __________________________________________
Damage, leaks, dirt build
Radiator.
up, blockages. __________________________________________
Hoses. Leaks, wear, damage.
Belts. Tightness, wear or cracks. __________________________________________
Damage, dirt build up,
Overall engine. Out of Service Tag Attached? Yes / No
leaks.

Learner Guide
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V 1.1 02122019
Component What to Check for ✓ Comments
Internal/Cabin Check
Damage, cleanliness, labels,
Levers, controls, gauges.
working. __________________________________________
ROPS. Damage, cracks, wear.
__________________________________________
Floor plates. Clear and free of oil/grease.
Seat and seat belts. Adjustment, damage, wear. __________________________________________
Fire extinguisher. Damage and charge.
Logbook, running/ service __________________________________________
Present and correct
sheets, vehicle history.
Mirrors. Adjusted, clean, visible. __________________________________________
Cleanliness, damage,
Overall cabin interior. Out of Service Tag Attached? Yes / No
missing parts.
Operational Checks
Master and isolation Present, functioning,
switches, start switch/key. damage.
Joy sticks or levers. Functioning, damage, wear. __________________________________________
Accelerator and brakes, Working, damage, wear, dirt
emergency stopping device. build up on pedals. __________________________________________
Movements, smooth or
Bucket.
jerky. __________________________________________
Air-conditioning, radio, two-
Functioning, damage, wear.
way radios, lights, horn. __________________________________________
Windscreen wipers and
Wear, damage, functioning. __________________________________________
washers.
Oil pressure, fuel level,
Gauges. engine temperature, __________________________________________
hydraulics, speedometer.
Gear change buttons and or __________________________________________
Damage, wear, functioning.
quick shift arrangements.
Start-up alarms. Functioning and visible. __________________________________________
Working, visible, accurate,
GPS, auto levelling controls. Out of Service Tag Attached? Yes / No
damage, wear.
Action Taken to Repair Hydraulic Excavator:
Name: Date of
Repair:
Return to Service Authority by Supervisor
Comments:
Supervisor Name: Signature: Date:

Learner Guide
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V 1.1 02122019

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RIIMPO301E Conduct Hydraulic Excavator Operations

Learner Contact Number:

Date Training Commenced:

This Book Contains:

1.2 Working Safely .......................................................................................................................... 5

1.3 Work Instructions ..................................................................................................................... 6

1.4 Inspect and Prepare the Work Area ......................................................................................... 9

1.5 Hazard Identification & Control .............................................................................................. 10

RIIMPO301E Conduct Hydraulic Excavator Operations

2.2 Position the Excavator ........................................................................................................... 16

2.3 Operate the Excavator ............................................................................................................ 17

3.1 Park and Shut Down the Excavator ....................................................................................... 25

3.2 Carry out Maintenance Tasks ................................................................................................ 27

3.3 Clean Up After Work ............................................................................................................... 29

3.4 Process Written Records ....................................................................................................... 29

Appendix A – Hydraulic Excavator Daily Inspection Checklist ................................................. 30

© Safe Work Resources / StaySafe Training

RIIMPO301E Conduct Hydraulic Excavator Operations

Planning your work.

1.1.1 What is an Excavator?

1.1.1.1 Excavator Components

RIIMPO301E Conduct Hydraulic Excavator Operations

1.2.1 Health & Safety Rules

Acts These are laws that you have to follow.

Code of Practice - www.safeworksa.com.au

1.2.2 Operations Documentation

Operations documentation includes:

Operations Documentation Description

RIIMPO301E Conduct Hydraulic Excavator Operations

To keep yourself and other workers safe you need to:

Follow your instructions.

Your worksite will also have instructions for working

Handling hazardous materials.

Safe work practices.

Personal protective clothing and equipment.

Safe use of tools and equipment.

1.3 Work Instructions

Communications – How are you going to communicate with other workers?

RIIMPO301E Conduct Hydraulic Excavator Operations

1.3.2 Work Method Statements

1.3.3 Geological and Survey Data

1.3.3.1 Geological Data

Rock or material types and characteristics.

Wet and dry areas.

Water tables or other sources of water.

Broken ground, faults or joints.

1.3.3.2 Survey Data

RIIMPO301E Conduct Hydraulic Excavator Operations

Bench heights and widths.

Survey data can also be used to mark out:

1.3.4 Site and Project Quality Requirements

1.3.4.1 Site Product Characteristics

1.3.5 Emergency Procedures

1.3.5.1 Emergency Shutdown of Equipment

1.3.5.3 First Aid

1.3.5.4 Fire Fighting Equipment

Steps for using a fire extinguisher:

1.Evacuate the area.

1.4 Inspect and Prepare the Work Area

Workers you may need to coordinate with includes:

Other mobile plant operators.

RIIMPO301E Conduct Hydraulic Excavator Operations

1.5 Hazard Identification & Control