Safe Work Instruction

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Patience Bertina Logan
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1 Safe Work Instruction Version 4 (11 March 2013) Status: Approved Site: Department: GOONYELLA RIVERSIDE Mobile Maintenance PPE Required Job Step Analysis reference Document Attached BMA Standard reference GRM SOP Safe Operation and Movement of Vehicles 010 GRM SOP Isolation & Tagging Additional Hazard Considerations Other Relevant Information RIISAM210A RFW Wheel Assembly (KM# ) Mandatory - Pre-start Actions Required permits Complete BMA Safe Conduct work area inspection BCC required to operate under RIISAM210A Personal Isolation Multi Lock Isolation Required permit number: Relevant OEM instructions & Specification available Required permit number: People, Equipment, Materials and Tools Required People Equipment Materials & Tools Qualified Vehicle Operator/Fitter Appropriate Jacks & Accessories Correct Tooling Stand Safety Warning Triangle Clean Equipment EXPECTED JOB DURATION: Hours: Shifts: READ THIS ENTIRE DOCUMENT BEFORE PROCEEDING -IF CONDITIONS OR ENVIRONMENT CHANGE, OR YOU ARE UNSURE ABOUT ANY ASPECTS OF THIS SWI STOP AND CONTACT YOUR SUPERVISOR Uncontrolled when printed Page 1 of 11

Light Vehicle 1. Preparation 1. Personnel must be competent under RIISAM210A RFW Wheel Assembly 2.

Engage transmission in park (automatic transmissions) 1st or reverse gears (manual transmissions) 4.

If using a non-locking jack (i.e. hydraulic) ensure jack and stand capability is adequate for the job 7. Ensure jack and/or stand are positioned on firm & adequate foundations 8.

2 Light Vehicle 1. Preparation 1. Personnel must be competent under RIISAM210A RFW Wheel Assembly 2. Select appropriate area for tyre change solid, level, safe area, away from other traffic park brake applied 3. Engage transmission in park (automatic transmissions) 1st or reverse gears (manual transmissions) 4. Remove keys from ignition & isolate vehicle as per 010 GRM SOP Isolation & Tagging 5. Place safety warning triangle at an appropriate distance from vehicle 6. If using a non-locking jack (i.e. hydraulic) ensure jack and stand capability is adequate for the job 7. Ensure jack and/or stand are positioned on firm & adequate foundations 8. Place wheel chocks at adjacent wheel (i.e. diagonally across from the wheel to be changed) 9. Inspect wheel assembly to be removed for any damage or unsafe condition before wheel removal. Warning Untrained operators Uneven ground Soft foundations Uncontrolled movement Energy sources Other traffic - collision Damaged wheels & hubs Crush/pinch potential Incorrect selection of jack & stand Uncontrolled when printed Page 2 of 11

2. Jacking Process 1. Place suitable jack under OEM approved jacking points a. Inspect jacks & stands b. Review OEM instructions/manual for correct placement of jacks & stand(s) c.

For pit type vehicles fitted with wheel nut retainers, use wheel brace on wheel nut to twist, this will break the teeth retaining the nut and removal of nut is possible. 5.

3 2. Jacking Process 1. Place suitable jack under OEM approved jacking points a. Inspect jacks & stands b. Review OEM instructions/manual for correct placement of jacks & stand(s) c. Correct posture & manual handling techniques d. Stay clear of vehicle (Screw Jack in Place) 2. Clean the studs of any dirt 3. Remove wheel nut indicators (if fitted) 4. For pit type vehicles fitted with wheel nut retainers, use wheel brace on wheel nut to twist, this will break the teeth retaining the nut and removal of nut is possible. 5. Slightly loosen (crack) the wheel nuts with appropriate wheel brace/ tooling Hazards Uneven load Incorrect jacking points Incorrect Jack & Stand (wrong SWL) Vehicle falling Poor ergonomics (Hydraulic Jack with Stand in Place) Uncontrolled when printed Page 3 of 11

3. Removal of Wheels 1. Jack vehicle up until bottom of wheel clears the ground 2. If using hydraulic or air type jack correct safety stand must be used 3.

4 3. Removal of Wheels 1. Jack vehicle up until bottom of wheel clears the ground 2. If using hydraulic or air type jack correct safety stand must be used 3. At no time shall the person place their body under the raised vehicle whilst the wheel is removed 4. Remove wheel nuts and place in clean area and discard old wheel nut retainers appropriately 5. Remove wheel from hub 6. All wheel studs are to be inspected for damage 7. Check hub for damage or accumulated dirt. If dirty, use a brush or similar to clean all surfaces paying particular attention to the mounting surface Hazards Manual handling tasks Unstable jack and/or stand Incorrect tooling 4. Fitment of Wheels 1. Select appropriate wheel to be fitted, ensuring the tyre size and tread pattern is the same type as currently fitted on same axle 2. Ensure the wheel studs are clean, undamaged and mounting area of both wheel and hub are free of dirt and contamination. 3. Lift the wheel (consider correct manual handling technique) and align wheel studs, and push wheel into position so that the back of the rim touches the hub 4. Replace wheel nuts onto studs (ensure free of dirt) and finger-tighten 5. Tighten the wheel nuts (approx half tension) ensuring tapered nuts travel into taper in wheel evenly 6. Lower the vehicle to the ground in reverse order of raising 7. Once the vehicle is resting on ground, wheel nuts should be tightened in a criss-cross fashion as shown in fig X in line with OEM specifications 8. Replace wheel nut indicators ( if applicable) 9. Remove wheel chocks 10. Place information tag on removed wheel and place it in designated storage area to be fixed/ replaced. Information on tag shall also contain vehicle registration and kilometre reading Caution Manual handling tasks Unstable jack and/or stand Uncontrolled when printed Page 4 of 11

Incorrect tooling Finger pinch/crush potential Incorrect fitment of wheels Unstable wheel alignment Burs & sharp material Crush potential (Information Tag) Note Correct ergonomics and manual handling

5 Incorrect tooling Finger pinch/crush potential Incorrect fitment of wheels Unstable wheel alignment Burs & sharp material Crush potential (Information Tag) Note Correct ergonomics and manual handling techniques Preparation & placement of equipment (wheels, nuts etc) Ensure appropriate tooling in line with OEM Clean all parts Stay clear of vehicle drop zone Appropriate housekeeping, lubrication & cleaning Tighten wheel nuts to OEM specs in line with Figure1 Figure 1 - Wheel Nut Tightening Sequence Uncontrolled when printed Page 5 of 11

5. Prepare for Use of Lifting Apparatus 1. A re-torque/information tag shall be attached to the key of the vehicle 2.

After re-torque fit wheel nut retainer if applicable 5.

Tag Re-torque) When new wheel rims are fitted to a vehicle they need to be re-torqued a number of times to allow the wheel nut to "settle". 6.

6 5. Prepare for Use of Lifting Apparatus 1. A re-torque/information tag shall be attached to the key of the vehicle 2. Make note in the next Light Vehicle daily inspection. 3. All wheels shall have nuts checked for tightness after kilometres use. 4. After re-torque fit wheel nut retainer if applicable 5. Wheels fully tightened in accordance with sequence noted in Section 4 Hazards Wheel becoming loose Loose control of vehicle Note (Information Tag Re-torque) When new wheel rims are fitted to a vehicle they need to be re-torqued a number of times to allow the wheel nut to "settle". 6. Additional Comments 6. Personnel required to change wheels on light vehicles must be Black Coal competent under MNC G1031C Remove, Fit & Adjust Wheel Assemblies 7. Refer to OEM Service Manual for Correct Torque Specs Uncontrolled when printed Page 6 of 11

7 Uncontrolled when printed Page 7 of 11

8 JOB STEP ANALYSIS FOR TASK OR PROCESS DESCRIPTION OF TASK/PROCESS/SYSTEM: WHAT CHANGE/ACTION IS BEING PROPOSED? RISK ASSESSMENT SCOPE: ASSESSMENT CONDUCTED BY: ASSESSMENT REVIEWED BY: DATE: DATE: ITEM N o 1 JOB STEP OR ACTIVITY POTENTIAL HAZARDS OR ENERGIES EXISTING/CURRENT CONTROLS CONSEQUENCE INHERENT RISK RISK ANALYSIS LIKELIHOOD RISK RATING ADDITIONAL/NEW RECOMMENDED CONTROLS CONSEQUENCE RESIDUAL RISK RISK REVIEW LIKELIHOOD RISK RATING Uncontrolled when printed Page 8 of 11

9 ITEM N o JOB STEP OR ACTIVITY POTENTIAL HAZARDS OR ENERGIES EXISTING/CURRENT CONTROLS CONSEQUENCE INHERENT RISK RISK ANALYSIS LIKELIHOOD RISK RATING ADDITIONAL/NEW RECOMMENDED CONTROLS CONSEQUENCE RESIDUAL RISK RISK REVIEW LIKELIHOOD RISK RATING OVERALL RESIDUAL RISK RATING FOR TASK IF RISK RATING IS EXTREME OR HIGH - INFORM SAFETY ADVISOR IMMEDIATELY A CRITICAL ACTIVITY WORK INSTRUCTION SHALL BE REQUIRED Uncontrolled when printed Page 9 of 11

10 RISK ASSESSMENT TOOLS Uncontrolled when printed Page 10 of 11

11 THIS WORK INSTRUCTION FLOWCHART MINE MAINTENANCE SAFE WORK INSTRUCTION (LIGHT VEHICLES WHEEL CHANGES) GOONYELLA RIVERSIDE WHEEL NEEDS CHANGING PERSON IS QUALIFIED TO BCC (MNC G1031C) BMA SAFE SELECT SAFE, LEVEL, SOLID GROUND APPLY PARK BRAKE ERECT WARNING TRIANGLE AUTOMATIC TRANSMISSION ENGAGE TRANSMISSION IN PARK YES VEHICLE HAS AUTOMATIC TRANSMISSION? NO MANUAL TRANSMISSION ENGAGE TRANSMISSION IN 1 st OR REVERSE GEAR CHOCK WHEELS ON ADJACENT SIDE ISOLATE VEHICLE SELECT & INSPECT APPROPRIATE JACK & STAND WITH CORRECT SWL YES NON-LOCKING JACK? (HYDRAULIC ETC) NO SELECT & INSPECT APPROPRIATE LOCKING TYPE JACK PLACE JACK UNDER OEM JACKING POINTS USING APPROPRIATE TOOL, CRACK NUTS AND REMOVE RETAINERS. PLACE INFORMATION TAG NOTING VEH REGISTRATION, KM READING & COMMENTS ON WHEEL NO FURTHER ACTION REQUIRED RAISE VEHICLE PLACE STAND IF REQUIRED REMOVE WHEEL NUTS CAREFULLY REMOVE WHEEL FROM HUB CHECK FOR DAMAGE SELECT REPLACEMENT WHEEL (CORRECT SIZE, TREAD ETC) AND CAREFULLY LIFT TO HUB REPLACE WHEEL NUTS TO HUB & FINGER TIGHTEN TIGHTEN WHEEL NUTS TO APPROX HALF TENSION & LOWER VEHICLE TO GROUND When new wheel rims are fitted to a vehicle, they need to be re-torqued a number of times to allow the wheel nut to settle TIGHTEN WHEEL NUTS FULLY IN LINE WITH OEM (CRISS-CROSS) [SEE FIG 1 SWI] RE-TORQUE TAG NOTIFY AND CHECK AT KM, MAKE NOTE IN NEXT LIGHT VEHICLE INSPECTION AND REPLACE RETAINERS REPLACE WHEEL NUT INDICATORS (IF APPLICABLE) REMOVE WHEEL CHOCKS & ISOLATIONS Uncontrolled when printed Page 11 of 11

Electric motor testing

Electric motor testing MOTOR (MODELS EJ4-4001 AND EJ8-4001A) 23 GENERAL INFORMATION The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed