Face Shovel Operation And Safety Training

Objectives:
• Understand the role and applications of face shovels in mining and construction.
• Identify key components and their functions.
• Recognize the importance of safety in face shovel operations.
• Familiarize with relevant legislation and standards.
• Outline the course structure and assessment criteria.

Topics:
• Overview of face shovel equipment and uses.
• Main components: boom, stick, bucket, cab, undercarriage.
• Basic principles of hydraulic systems.
• Introduction to safety culture and legal requirements.
• Course outcomes and unit standard 116054 alignment.

Objectives:
• Interpret key health and safety legislation (MHSA, OHS Act).
• Understand employer and employee responsibilities.
• Identify environmental management requirements.
• Apply safety policies and procedures on site.
• Recognize the importance of safety representatives and committees.

Topics:
• MHSA and OHS Act provisions relevant to earthmoving.
• Duties of operators and supervisors.
• Environmental care: dust, spillage, noise control.
• Safety files, risk assessments, and toolbox talks.
• Incident reporting and investigation basics.

Objectives:
• Select and inspect appropriate PPE for face shovel operations.
• Apply correct PPE usage and maintenance.
• Identify site hazards and implement control measures.
• Understand emergency procedures and evacuation routes.
• Demonstrate proper housekeeping practices.

Topics:
• PPE types: hard hats, high-vis clothing, steel-toed boots, gloves, hearing protection.
• Inspection and care of PPE.
• Hazard identification: unstable ground, overhead power lines, other equipment.
• Emergency response: fire, first aid, spill containment.
• Housekeeping: maintaining clear access and egress.

Objectives:
• Conduct thorough pre-start inspections according to manufacturer guidelines.
• Identify and report defects or potential failures.
• Check fluid levels, filters, belts, and hoses.
• Verify safety devices and warning systems.
• Complete inspection documentation correctly.

Topics:
• Walk-around inspection procedure.
• Engine compartment checks: oil, coolant, fuel, hydraulic fluid.
• Undercarriage and track tension.
• Cab controls, gauges, and safety interlocks.
• Logbook entries and defect reporting.

Objectives:
• Identify all controls in the cab and their functions.
• Start and shut down the machine safely.
• Perform basic maneuvers: travel, steering, braking.
• Understand control patterns and adjustments.
• Demonstrate safe entry and exit from the cab.

Topics:
• Joysticks, pedals, switches, and display panels.
• Engine start-up procedure and warm-up.
• Travel controls: forward, reverse, turning.
• Braking systems and parking brake.
• Cab ergonomics and seat adjustment.

Objectives:
• Describe the hydraulic system components and operation.
• Explain bucket types and their applications.
• Perform basic bucket movements: crowd, hoist, dump.
• Understand hydraulic safety precautions.
• Identify common hydraulic issues and symptoms.

Topics:
• Hydraulic pumps, valves, cylinders, and filters.
• Bucket designs: general purpose, rock, heavy-duty.
• Crowd and hoist cylinder functions.
• Dump and retract operations.
• Hydraulic oil checks and contamination prevention.

Objectives:
• Apply correct digging techniques for different materials.
• Optimize bucket fill factor and cycle times.
• Manage material segregation and placement.
• Use face shovel for loading trucks and hoppers.
• Minimize spillage and maintain efficiency.

Topics:
• Digging angles and depth control.
• Material types: loose soil, hard rock, blasted rock.
• Bucket fill techniques: penetration, curl, lift.
• Swing and dump coordination.
• Load profiling for truck loading.

Objectives:
• Position the face shovel for efficient loading.
• Coordinate with haulage equipment using signals.
• Perform accurate dumping into trucks and hoppers.
• Understand load distribution and weight limits.
• Apply safe dumping practices to prevent overloading.

Topics:
• Spotting for truck loading.
• Communication with haul truck drivers.
• Dumping techniques: controlled release, even spread.
• Weight monitoring and payload indicators.
• Safety around dump points and tip areas.

Objectives:
• Assess slope stability and ground conditions.
• Operate safely on inclines and uneven surfaces.
• Use proper techniques to maintain stability.
• Recognize signs of ground failure.
• Apply grade control for bench preparation.

Topics:
• Slope angle limits and stability factors.
• Traveling uphill and downhill.
• Digging on slopes: benching and terracing.
• Ground bearing capacity and compaction.
• Level indicators and grade control systems.

Objectives:
• Understand face shovel applications in quarrying.
• Adapt techniques for high-wall and low-wall operations.
• Coordinate with drill and blast crews.
• Manage muck pile digging and cleanup.
• Apply stripping and extraction methods.

Topics:
• Quarry layout: benches, ramps, and haul roads.
• High-wall safety: scaling, bunding, barriers.
• Loading blasted rock: digging patterns.
• Selective mining and blending.
• Cleanup operations: floor maintenance.

Objectives:
• Optimize digging cycles for maximum productivity.
• Apply advanced techniques for tough materials.
• Use machine features like auto-lube and power modes.
• Monitor and improve fuel efficiency.
• Analyze cycle times and identify bottlenecks.

Topics:
• Penetration techniques for hard ground.
• Using boom float and crowd assist.
• Power mode selection: economy vs. performance.
• Fuel-saving practices: idle reduction, efficient loading.
• Cycle time analysis: dig, swing, dump, return.

Objectives:
• Perform routine maintenance tasks according to schedule.
• Grease pivot points and lubricate components.
• Replace filters and fluids safely.
• Identify wear items and replacement intervals.
• Maintain maintenance records and logs.

Topics:
• Daily and weekly maintenance checklists.
• Grease points: pins, bushings, bearings.
• Engine oil and filter change procedures.
• Hydraulic and transmission fluid checks.
• Undercarriage maintenance: track adjustment, sprockets.

Objectives:
• Diagnose common engine and hydraulic problems.
• Interpret warning lights and fault codes.
• Perform basic troubleshooting steps.
• Decide when to call for specialist assistance.
• Document fault findings and actions taken.

Topics:
• Engine issues: overheating, low power, excessive smoke.
• Hydraulic problems: slow operation, leaks, noise.
• Electrical faults: battery, alternator, sensors.
• Undercarriage wear patterns and alignment.
• Fault code retrieval and interpretation.

Objectives:
• Identify potential emergency scenarios.
• Execute emergency shutdown and evacuation.
• Apply firefighting techniques for equipment fires.
• Administer basic first aid.
• Conduct risk assessments for non-routine tasks.

Topics:
• Emergency stop procedures.
• Fire types and extinguisher use.
• First aid for common injuries: cuts, fractures, burns.
• Risk assessment methodology: JSA, HIRA.
• Emergency drills and simulation.

Objectives:
• Use standard hand signals and radio communication.
• Coordinate with other equipment operators.
• Understand roles of spotter and signalman.
• Practice clear and concise communication.
• Resolve conflicts and promote teamwork.

Topics:
• Hand signals for face shovel operations.
• Two-way radio etiquette and channel discipline.
• Working with dozers, graders, and trucks.
• Role of spotter in tight areas.
• Team safety briefings and debriefings.

Objectives:
• Implement environmental controls during operations.
• Minimize dust, noise, and vibration.
• Manage spillages and waste disposal.
• Understand rehabilitation requirements.
• Comply with environmental management plan (EMP).

Topics:
• Dust suppression techniques: water sprays, covers.
• Noise reduction: mufflers, enclosures, scheduling.
• Spill response: containment and cleanup.
• Waste segregation: oil, filters, scrap metal.
• Rehabilitation: topsoil management, recontouring.

Objectives:
• Practice face shovel operations in a simulated environment.
• Refine digging and loading techniques.
• Respond to simulated emergencies.
• Receive feedback on performance.
• Identify areas for improvement.

Topics:
• Simulator introduction and controls.
• Basic digging and loading exercises.
• Advanced scenarios: slope work, tight spaces.
• Emergency scenarios: fire, hydraulic failure.
• Performance review and debrief.

Objectives:
• Consolidate all skills learned.
• Practice pre-operational checks thoroughly.
• Demonstrate safe operating procedures.
• Perform loading and dumping tasks accurately.
• Prepare for final practical assessment.

Topics:
• Full machine inspection.
• Start-up and shutdown procedures.
• Digging and loading cycles.
• Communication with team.
• Mock assessment with feedback.

Objectives:
• Complete pre-operational checks independently.
• Demonstrate safe and efficient operation.
• Perform digging, loading, and dumping tasks.
• Respond to assessor questions.
• Achieve competency in all assessment criteria.

Topics:
• Assessor observation of pre-start checks.
• Operating skills: travel, digging, loading.
• Safety compliance: PPE, procedures, communication.
• Knowledge assessment: oral or written questions.
• Feedback and results.

Objectives:
• Review key learning outcomes.
• Discuss challenges and solutions.
• Complete course evaluation.
• Receive certificate of competence.
• Understand post-training responsibilities.

Topics:
• Summary of course content.
• Q&A session.
• Evaluation forms and feedback.
• Certificate issuance.
• Continued professional development and refresher training.