Best practice guidelines for Mobile Plant

This Best Practice Guide being reviewed. is e The future of Best Practic Guides will be decided during 2015. Best practice guidelines for Mobile P...
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This Best Practice Guide being reviewed.

is

e The future of Best Practic Guides will be decided during 2015.

Best practice guidelines for

Mobile Plant

Vision,knowledge,performance

competenz.org.nz

He Mihi

Nga pakiaka ki te Rawhiti.

Roots to the East.

Nga pakiaka ki te Raki.

Roots to the North.

Nga pakiaka ki te Uru.

Roots to the West.

Nga pakiaka ki te Tonga.

Roots to the South.

Nau mai, Haere mai

We greet you and welcome you.

~ ki te Waonui o Tane

To the forest world of Tane.

Whaia te huarahi,

Pursue the path,

o te Aka Matua,

of the climbing vine,

i runga, I te poutama

on the stairway,

~ o te matauranga.

of learning.

Kia rongo ai koe

So that you will feel,

~ te mahana o te rangimarie.

the inner warmth of peace.

Ka kaha ai koe,

Then you will be able,

~ ki te tu whakaiti,

to stand humbler,

~

~ ki te tu whakahi.

Yet stand proud.

~ Kia Kaha, kia manawanui

Be strong, be steadfast.

Tena koutou katoa.

First edition December 2000 Revised edition January 2005 These Best Practice Guidelines are to be used as a guide to the operation of mobile plant. They do not supersede legislation in any jurisdiction or the recommendations of equipment manufacturers. FITEC believes that the information in the guideline is accurate and reliable; however, FITEC notes that conditions vary greatly from one geographical area to another; that a greater variety of equipment and techniques are currently in use; and other (or additional) measures may be appropriate in a given situation.

Other Best Practice Guidelines included in the series: •

Cable Logging



Chainsaw Use



Fire Fighting and Controlled Burnoffs



Ground-based Logging



Land Preparation



Loading



Maintenance inspections of Yarder Towers



Manual Log-making



Mechanised Harvesting and Processing



Personal Protective Equipment



Road and Landing Construction



Silvicultural Pruning



Transport



Tree Felling



Tree Planting



Working with Helicopters

© Copyright 2000, FITEC, New Zealand ISBN 0-9582261-1-3

Best Practice Guidelines for Mobile Plant

Contents Introduction Purpose of these guidelines How to use these guidelines Acknowledgements About Best Practice Training material

Mobile plant basics

1 1 1 2 2

3

Types of mobile plant Wheeled skidders Tracked skidders Excavator-based machines Mechanised Harvesters Forwarders Wheeled loaders Bell loaders All terrain vehicles (ATV) Power-operated work platforms

3 3 4 6 8 9 10 11 12 13

Safety requirements Rollover protection (ROPS) Operator protection on steep or unstable terrain (excavators) (COPS) Falling object protection (FOPS) Operator protection from objects entering the cab (OPS) Seat belts Night work High structures Brakes Other parts of machines Noise

13 13 14 14 14 15 15 15 15 15 15

Ergonomic issues Training and supervision Knowledge of hazards Health hazards Operational hazards Personal protective equipment (PPE)

15 16 16 16 18 23

Mobile plant procedures

24

Before using mobile plant

24

Wheeled skidders Before start-up Start up After starting the engine Before operating the machine Machine operation Shut down

24 24 25 25 25 26 26

Tracked skidders Before start-up Start up After starting the engine Before operating the machine Machine operation Shut down

26 26 27 27 28 28 28

Excavator-based machines Before start-up Start up After starting the engine Before operating the machine Machine operation Shut down

29 29 29 30 30 30 31

Mechanised harvesters Before start-up Start up After starting the engine Before operating the machine Machine operation Shut down

31 31 32 32 32 33 33

Forwarders Before start-up Start up After starting the engine Shut down

33 34 34 35 35

Wheeled loaders Before start-up Start up After starting the engine Shut down

35 35 36 36 37

Bell loaders Before start-up Start up After starting the engine Shut down

37 37 38 38 38

Power operated work platforms Before start-up Parking Start up Machine operation Shut down or stowing

39 39 39 39 39 40

Maintenance Pre-start and maintenance (everyday, or before each shift) Daily maintenance and checks (8hr) Periodic maintenance (e.g., 50hr) Storage, handling and filling procedures for fuels and oils

41 41 41 41 42

Glossary of terms

43

Index to unit standards

45

Introduction Purpose of these guidelines The Best Practice Guidelines for Mobile Plant have been designed by FITEC in conjunction with the forest industry to improve worker safety and performance. They combine industry training standards and best practice information to provide a valuable reference manual for operators of mobile plant. These guidelines focus on general mobile plant features and operating procedures. For a more detailed explanation of the use of mobile plant refer to separate Best Practice Guidelines for •

Road and landing construction



Land preparation



Tree felling



Ground-based logging



Loading.

These guidelines should be read in conjunction with the: •

Approved Code of Practice Safety and Health in Forest Operations. In particular, these guidelines provide direct support for Part 3 - Section 4 (Mobile Plant and Machinery) of the code.



Approved Code of Practice for Operator Protective Structures on Self-propelled Mobile Mechanical Plant.

They are a valuable reference document for the following Unit Standards registered on the NZQA framework:

Unit 6928 - Operate a Bell machine in a forestry situation Unit 6929 - Operate a knuckle boom loader in a forestry situation Unit 6930 - Operate a forked loader in a forestry situation Unit 6934 - Operate a skidder in a forestry situation Unit 6935 - Operate an excavator type tracked machine in a forestry situation Unit 6936 - Operate a tracked machine in a forestry situation Unit 6937 - Extract logs to a landing Unit 6938 - Operate an extraction machine in a forestry production situation Unit 6942 - Operate a forestry mechanised harvesting machine Unit 6946 - Extract tree lengths using a forwarder

How to use these guidelines These guidelines have been arranged in two main sections: •

Mobile Plant Basics - provides information on the types and features of mobile plant.



Mobile Plant Procedures - describes specific operations commonly performed by machine operators. These are presented in sub-sections specific to the machine type.

The Glossary of Terms gives the meaning of terms used throughout these guidelines. The Index to Unit Standards allows the reader to locate information specific to each of the Unit Standards listed above.

Introduction

1

Acknowledgements FITEC acknowledges the assistance of the Occupational Safety and Health and Service, Liro Forestry Solutions, and numerous forest industry trainers, forestry contractors, and forest company staff in the development of these Best Practice Guidelines.

About best practice training material FITEC has developed the material in this publication. It has been reviewed by representatives of the forest industry. At the time of publication, FITEC considers the practices and approaches in this publication to exceed accepted industry standards with regard to production and business management. In addition, the practices recommended in the publication exceed all the New Zealand regulatory standards, in particular those related to health and safety, environmental management, and human resources / employment. This material is reviewed and reprinted regularly by FITEC.

2

Introduction

Mobile plant basics Types of mobile plant The main types of mobile plant used in the forest industry are: •

Wheeled skidders



Tracked skidders



Excavator-based machines



Mechanised harvesters



Forwarders



Wheeled loaders



Bell loaders



All terrain vehicles



Power-operated work platforms

The following sections describe the features of each of these.

Wheeled skidders Description •

Wheeled skidders are articulated four-wheel drive machines. Their main use is for wood extraction, from the felling site to the landing. They are used widely in production thinning (tree size 0.2 to 0.5 tonnes) and clearfell (tree size 1.2 to 2.5 tonnes) operations. In clearfell operations, load sizes can average 5 to 7 tonnes.



Wheeled skidders may be fitted with wider types of dual rear wheels to reduce ground pressure and increase stability.

A wheeled skidder with 109 cm tyres for operation on wet sites



The Approved Code of Practice for Safety and Health in Forest Operations states that as a guide, wheeled skidders should not operate on slopes exceeding 18° (30%) unless otherwise specified by the manufacturer. Where weather or ground conditions affect machine stability, the maximum operating slope will be actually less than this.



Skidders are classed as either cable or grapple machines.



Cable skidders employ a winch, wire rope (generally 25 to 30 m long), and strops to attach and move felled trees. Safety cab

Exhaust Air cleaner

Fairlead

Motor

Winch

Blade

Butt pan

Pivot Components of a cable wheeled skidder

Mobile plant basics

3



Grapple skidders use a large hanging grapple (conventional or swing-boom) to grab the felled trees.

Hydraulic cylinder

Rotator

Grapple

Components of a grapple wheeled skidder



There is a range of wheeled skidder sizes. They are classified by the output of the engine. Skidder size

Engine power output (kW)

Examples

Optimum load size (tonnes, level terrain)

Small

76-105

John Deere 540G Ranger F65 Timberjack 360

3-5

Medium

106-135

Caterpillar 525C Timberjack 460 Ranger H67 John Deere 640G

5-7

Large

136+

Caterpillar 545 John Deere 748G Timberjack 560

7-8

Safety features •

Wheeled skidders shall have a certified Falling Object Protection Structure (FOPS), an Operator Protection Structure (OPS), and a Roll Over Protection Structure (ROPS).



A seat belt shall be fitted and worn when the machine is being operated.

Tracked skidders Description •

There are two types of tracked skidder: Conventional tracked skidders (earthmoving or modified bulldozers) that have a rigid track frame. Flexible track skidders with suspension to allow the track to conform to the shape of the ground. These are specialist machines, designed to operate on wet and/or weak soils.



Conventional tracked skidders are used widely in production thinning and clearfell operations. In clearfell operations, load sizes can average 6 to 9 tonnes.



They can have a lengthened track frame or wider tracks to reduce ground pressure and increase stability.

4

Mobile plant basics

Safety cab Exhaust Air cleaner Drive sprocket Motor Fairlead roller Blade Winch Track rollers

Track frame

Front idler

Components of a cable tracked skidder

Hydraulic cylinders

Rotator

Grapple

Components of a grapple tracked skidder

Safety cab Fairlead

Motor

Exhaust

Blade

Choker arch

Drive sprocket Track

Rear idler Road wheel Components of a flexible tracked skidder Mobile plant basics

5

Tracked skidders cont... •

The Approved Code of Practice for Safety and Health in Forest Operations states that tracked skidders should not operate on slopes that exceed 22° (40%) unless otherwise specified by the manufacturer. Where weather or ground conditions adversely affect machine stability, the maximum slope will be actually less than this.



Tracked skidders are equipped with winches, ropes and strops, or a grapple (similar to wheeled skidders).



Tracked skidders manoeuvre by altering the speed or direction of the two tracks. This allows them to turn within their own length.



A conventional tractor may tow a two-wheeled arch to provide lift for the front of the load and reduce load friction. This enables larger loads to be carried.



Tracked skidders can be classified into four classes according to engine power output. Tractor size

Engine power output (kW)

Examples

Estimates of optimum load size (tonnes, level terrain, no arch)

Small

50-74

John Deere 450G Komatsu D37E-5 Caterpillar D3C

3-4

Small-medium

75-100

Caterpillar D5M Komatsu D53A-7

4-6

Medium

101-130

John Deere 750C Caterpillar D6M Caterpillar 527

6-8

Large

131+

Caterpillar D7R Komatsu D65EX-12 Komatsu D85E-21 KMC 2400 CA

7-9

Safety features •

Tracked skidders shall have a certified FOPS, OPS, ROPS.



A seat belt shall be fitted and worn when the machine is being operated.

Excavator-based machines Description •

An excavator comprises a tracked undercarriage and a continuous rotating upper body with a hydraulically operated boom.



Excavators can be fitted with a range of boom attachments according to the activity being undertaken.

Activity

6

Attachment

Earthworks

Bucket, ripping tine

Land preparation

Rake, bucket, ripper-mounder, mulcher, cultivator, winch set

Mechanical felling

Felling/processing head

Bunching or extraction

Grapple

Processing

Grapple, felling/processing head

Sorting, fleeting, and loading

Grapple

Mobile plant basics

Outer boom (stick)

Outer boom cylinder

Rotator Main boom (dipper arm) Protected cab

Counterweight

Main boom cylinder

Grapple

Turntable Track

Excavator components



Two boom configurations are available. On the conventional boom, the stick is operated by a hydraulic ram fixed to the top side of the dipper arm. This configuration is designed for pulling a bucket (or similar) towards the excavator during digging. The logging boom is designed for lifting heavy weights. The hydraulic ram operating the stick is fixed to the bottom side of the dipper arm.



Excavators may have a lengthened track frame or wider tracks to reduce ground pressure and increase stability.



The Approved Code of Practice for Safety and Health in Forest Operations states that as a guide, excavators should not operate on slopes that exceed 22° (40%) unless otherwise specified by the manufacturer. Where weather or ground conditions adversely affect machine stability, the maximum slope will be actually less than this.

Conventional boom



Logger boom

Excavator-based machines can be divided into four classes (often the base weight of the machine will be increased considerably with the addition of guarding, strengthening, and an attachment such as a harvesting head): See table.

Mobile plant basics

7

Excavator size

Gross weight (tonnes)

Examples

Small

30

Caterpillar 330 Komatsu PC400 Hyundai 290 Kato HD1880

Safety features •

Excavators used in forestry operations shall be fitted with FOPS and OPS.



If operating on terrain where stability cannot be assured, the excavator shall be fitted with a certified Cabin Operator Protection Structure (COPS) to a minimum of Grade 3.



A seat belt shall be fitted and worn when the machine is being operated.



Disabling levers or switches (to be used when leaving the cab).

Mechanised harvesters Description •

Mechanised harvesters are either excavators, or custom-built (usually tracked) machines fitted with a harvester head.



The Approved Code of Practice for Safety and Health in Forest Operations states that as a guide, mechanised harvesters should not operate on slopes that exceed 22° (40%) unless otherwise specified by the manufacturer. Where weather or ground conditions adversely affect machine stability, the maximum slope will be actually less than this.

Main boom Outer boom

Accumulator arms

Safety cab

Motor

Boom cylinders

Turntable

Cutting unit

Track frame Components of a mechanised harvester

8

Mobile plant basics



The body of the harvester may be non-levelling (similar to an excavator) or levelling up to 27° forward and 20° sideways. The levelling body allows the cab and boom to be horizontal when operating on a slope.



The non-levelling body is capable of continuous rotation. The levelling body is generally restricted to 540° of rotation.



The harvester head may be able to perform a range of tasks. These include: Fell

Delimb

Process stems into logs

Bunch or shovel stems or logs



The head is a hydraulically powered attachment which may be equipped with drive rollers, delimbing grapple-type knives, and integral chainsaw, rotary saw or shears. There may be provision for a computerised measuring and log cutting (bucking) system.



Harvester heads come in different sizes: from thinning heads (mounted on 20 to 25 tonne base machines) to 4 tonne clearfell heads (mounted on 30 to 40 tonne base machines). Head size

Fell diameter/delimb diameter limits (cm)

Examples

Likely application

Small

55/41 60/45

Waratah HTH 20 Lako 60

Production thinning

Medium

64/14-46 69/3-50

Waratah HTH 22 Super Logmax GM650

Production thinning/ Small clearfell

Large

76/20-66 75/10-75

Waratah HTH26 AFM Magnum

Clearfell

Safety features •

All mechanised harvesters shall be equipped with certified FOPS, COPS and OPS.



A seat belt shall be fitted and worn when the machine is being operated.



Immobilising levers and switches will be fitted and used to avoid accidental start-up of the machine during maintenance or repair.

Forwarders Description •

Forwarders are articulated four, six or eight wheel drive machines with a knuckle-boom crane designed primarily for the transport or extraction of logs 3 to 6 m in length.



They range from the more basic converted skidder designs to sophisticated purpose-built machines.



Forwarders can be fitted with wider tyres or band tracks to reduce ground pressures and increase stability.



The Approved Code of Practice for Safety and Health in Forest Operations states that as a guide forwarders should not operate on slopes that exceed 18° (30%) unless otherwise specified by the manufacturer. Where weather or ground conditions adversely affect machine stability, the maximum slope will be actually less than this.



Forwarder load size typically ranges from 14 to 18 tonnes.

Mobile plant basics

A forwarder with band tracks fitted to the rear bogies

9

Outer boom Main boom Rotator

Grapple

Protected cab Exhaust

Gate

Pedestal

Slew mechanism

Staunchions

Motor

Rear Bogie

Pivot Steering cylinder

Walking beam

Forwarder components

Forwarder size

Optimum load size (tonnes)

Examples

Medium

14

Timberjack 1410 Valmet 860

Large

18

Timberjack 1710 Valmet 890

Safety features •

Forwarders shall have a certified FOPS, OPS, and ROPS.



A seat belt shall be fitted and worn when the machine is being operated.

Wheeled loaders Description •

Wheeled loaders used in forestry are articulated four-wheel drive machines fitted with loading forks (or a bucket for earthworks).



They are designed to handle stems and logs during sorting, fleeting, loading and unloading operations.



Wheeled loaders are designed to operate on formed roads, landings, log yards and wharves. In these situations, operating slopes are minimal.



Wheeled loaders are classified according to engine power output. Loader size

Gross engine power output (kW)

Examples

Application

Light

66-100

Cat 914, Volvo L70 Cat 928, Komatsu WA180

Thinning and small clearfell operations

Medium

101-120

Cat 938, Komatsu WA320 Volvo L90

Small to medium clearfell operations

Heavy

121-200

Cat 950, Volvo L120 Komatsu WA380

Larger clearfell , some log yard use

10

Mobile plant basics

Clamp arm

Fork cylinder Loading fork

Safety operators cab Exhaust Lifting arm

Motor

Pivot Wheeled loader components

Safety features •

Wheeled loaders normally operate on level ground. Although legally exempt, forest owner policy may require a certified ROPS be fitted. A seatbelt shall be fitted and worn while the machine is operated.



Wheeled loaders shall be equipped with a certified FOPS and OPS.



Notwithstanding the legal requirement for a seat belt with ROPS, it is best practice to ensure that a seat belt is fitted and worn.

Bell loaders Description •

Bell loaders are small (