Bulk Water Truck Operations - Guide

Bulk Water Truck
Operations
Resource Manual
Bulk Water Truck Operations
Table of Contents
1 Session Preliminaries.............................................................................................................7
1.1 Purpose of this Resource Manual...............................................................................................7
1.2 Safety Requirements....................................................................................................................7
1.3 Training Requirements...............................................................................................................7
1.4 Assessment Requirements...........................................................................................................7
1.5 Prerequisite..................................................................................................................................7
1.6 Getting Help.................................................................................................................................8
2 Introduction............................................................................................................................9
2.1 Scope.............................................................................................................................................9
2.2 Bulk Water Truck Variants and Functions..............................................................................9
2.3 Operating Authority..................................................................................................................13
3 Operate a Bulk Water Truck..............................................................................................15
3.1 Introduction...............................................................................................................................15
3.2 Identifying Safe Operating Practices.......................................................................................16
3.3 Identifying Personal Injury Hazards.......................................................................................17
3.4 Pre-Start Procedure..................................................................................................................18
3.4.1 Overview............................................................................................................................ 18
3.4.2 Driver Changeover............................................................................................................ 18
3.4.3 Operator’s Inspection Form............................................................................................... 19
3.4.4 Walk-Around Inspection..................................................................................................... 20
3.5 Start Up Procedure....................................................................................................................26
3.5.1 Final Pre-Start Checks....................................................................................................... 26
3.5.2 Start Up Process............................................................................................................... 26
3.5.3 Post Start Up and Moving Off Checks...............................................................................26
3.5.4 Continuing Checks............................................................................................................ 27
3.6 Emergency Procedures..............................................................................................................28
3.6.1 Under Inflated and Flat Tyres............................................................................................ 28
3.6.2 Tyre Failure....................................................................................................................... 28
3.6.3 Tyre Fires.......................................................................................................................... 29
3.6.3.1 Introduction................................................................................................................ 29
3.6.3.2 Suspect or Burning Tyres.......................................................................................... 29
3.6.4 Truck Fires......................................................................................................................... 30
3.6.5 Loss of Steering or Brakes................................................................................................ 31
3.6.6 Immobilised Water Truck................................................................................................... 31
Printed copy is UNCONTROLLED. The training web site has the latest version of this document
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3.6.7 Loss of Traction................................................................................................................. 31

3.6.7.1 Overview.................................................................................................................... 31
3.6.7.2 Rear Wheel Skid........................................................................................................ 32
3.6.7.3 Front Wheel Skid....................................................................................................... 32
3.6.7.4 All Wheel Skid........................................................................................................... 32
3.6.8 Breakdown on a Gradient.................................................................................................. 33
3.6.9 Water Truck Rollover......................................................................................................... 34
3.7 Driving the Water Truck..........................................................................................................35
3.7.1 Dash Indicators and Warnings...........................................................................................35
3.7.2 Visibility.............................................................................................................................. 35
3.7.3 Clearances........................................................................................................................ 35
3.7.4 Horn Signals...................................................................................................................... 36
3.7.5 Ramp Speed Limits........................................................................................................... 36
3.7.6 Trailing Distance................................................................................................................ 36
3.7.7 Turns................................................................................................................................. 36
3.7.8 Stopping and Parking........................................................................................................ 37
3.7.8.1 Parking...................................................................................................................... 37
3.7.8.2 Routine Stopping and Parking...................................................................................37
3.7.8.3 Stopping with the Secondary Brake System..............................................................37
3.7.8.4 Short Term Parking................................................................................................... 38
3.7.8.5 Long Term Parking.................................................................................................... 38
3.7.8.6 Fundamentally Stable Parking...................................................................................38
3.7.8.7 Emergency Braking................................................................................................... 39
3.7.9 Retarder Controls.............................................................................................................. 40
3.7.9.1 What is a Retarder?................................................................................................... 40
3.7.9.2 Retarder Operation.................................................................................................... 40
3.7.10 Hill Starts......................................................................................................................... 44
3.7.11 Uphill Driving................................................................................................................... 44
3.7.12 Reversing........................................................................................................................ 44
3.7.13 Wet Road Conditions....................................................................................................... 45
3.7.14 Fuel Consumption........................................................................................................... 45
3.7.15 Tyre Wear........................................................................................................................ 46
3.7.15.1 Speed...................................................................................................................... 46
3.7.15.2 Manoeuvring............................................................................................................ 46
3.7.16 Minimising Equipment Damage and Wear.......................................................................47
3.7.17 Spotting........................................................................................................................... 48
3.7.18 Maintenance Workshop Areas.........................................................................................49
3.7.18.1 Driving in and around Workshops............................................................................49
3.7.18.2 Spotting at the Workshops.......................................................................................49
3.7.19 Efficient Operations......................................................................................................... 49
4 Load, Haul and Distribute Water.......................................................................................51

4.1 Operating Rules for Watering..................................................................................................51
4.1.1 General Rules and Awareness..........................................................................................51
4.1.2 Overwatering..................................................................................................................... 53
4.1.3 Under Watering................................................................................................................. 54
4.2 Filling the Truck’s Water Tank...............................................................................................55
4.3 Watering Controls and Functions............................................................................................57
4.3.1 Controls in the Truck’s Cabin............................................................................................. 57
4.3.2 External Remote Controls.................................................................................................. 58
4.3.3 Using the Spray Bar........................................................................................................... 59
4.3.3.1 Overview.................................................................................................................... 59
4.3.3.2 Operating Procedure................................................................................................. 59
4.3.3.3 Spot / Patch Spraying................................................................................................ 61
4.3.4 Using the Water Cannon................................................................................................... 62
4.3.4.1 Operating the Water Cannon from the Truck’s Cabin................................................62
4.3.4.2 Operating the Water Cannon at Ground Level..........................................................63
4.3.5 Hose Operations................................................................................................................ 64
4.4 Watering Operations.................................................................................................................65
4.4.1 Overview............................................................................................................................ 65
4.4.2 Watering Haul Roads and Benches...................................................................................66
4.4.3 Watering Ramps................................................................................................................ 68
4.4.3.1 Ramp Slopes............................................................................................................. 68
4.4.3.2 Bottom of Ramps....................................................................................................... 69
4.4.4 Watering Pit Walls............................................................................................................. 69
4.4.5 Watering Stockpiles........................................................................................................... 69
4.4.6 Watering Faces................................................................................................................. 70
4.4.7 Watering Shovels, Excavators and Loader Work Areas....................................................71
4.4.8 Watering Dumps................................................................................................................ 71
4.4.9 Watering Access Roads.................................................................................................... 71
4.4.10 Servicing Drill Rigs.......................................................................................................... 72
4.4.11 Cleaning and Cooling Down Equipment..........................................................................73
4.4.12 Watering in Workshop and Service Areas.......................................................................73
4.4.13 Fire Fighting..................................................................................................................... 74
4.4.13.1 Introduction.............................................................................................................. 74
4.4.13.2 Standard Approach.................................................................................................. 74
4.4.13.3 Jet and Spray Functions..........................................................................................75
4.4.13.4 Monitoring Fires....................................................................................................... 75
4.4.13.5 Re-Ignition of Fires.................................................................................................. 76
4.4.13.6 Fire Fighting Support Role.......................................................................................76
5 Perform Post-Operational Procedures...............................................................................77

5.1 End of Shift.................................................................................................................................77
5.2 Maintenance...............................................................................................................................77
5.2.1 Preventative Maintenance................................................................................................. 77
5.2.2 Defect Reporting................................................................................................................ 78
5.2.3 Breakdowns....................................................................................................................... 79
5.2.4 Fluid Levels....................................................................................................................... 79

5.3 Refuelling....................................................................................................................................80
6 Activities................................................................................................................................81
6.1 Section 3 Operate Bulk Water Truck Activities.....................................................................81
Activity 1..................................................................................................................................... 81
Activity 2..................................................................................................................................... 81
Activity 3..................................................................................................................................... 81
Activity 4..................................................................................................................................... 82
Activity 5..................................................................................................................................... 82
Activity 6..................................................................................................................................... 82
Activity 7..................................................................................................................................... 83
Activity 8..................................................................................................................................... 83
Activity 9..................................................................................................................................... 83
6.2 Section 4 Load, Haul and Distribute Water Activities...........................................................84
Activity 1..................................................................................................................................... 84
Activity 2..................................................................................................................................... 84
Activity 3..................................................................................................................................... 85
Activity 4..................................................................................................................................... 85
Activity 5..................................................................................................................................... 85
Activity 6..................................................................................................................................... 86
Activity 7..................................................................................................................................... 86
6.3 Perform Post-Operational Procedures Activities...................................................................87
Activity 1..................................................................................................................................... 87
Activity 2..................................................................................................................................... 87
Activity 3..................................................................................................................................... 87
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Section 1 Session Preliminaries
1 Session Preliminaries
1.1 Purpose of this Resource Manual

The purpose of this Resource Manual is to provide detailed information and instructional
material for the subject matter of this training module. Where appropriate the content covers the
standards, procedures, safety and operational requirements for the workplace and tasks
described.
This Resource Manual is a key document in a suite of documents for the learning and
assessment requirements of this module.
1.2 Safety Requirements

If you demonstrate unsafe behaviour or perform a task without the necessary care or
confidence, the Trainer must direct you to cease work and terminate the training immediately.
1.3 Training Requirements

This Training module is conducted in accordance with the Training and Assessment Standard
and will be delivered in a variety of work situations and conditions appropriate to the role or task
to reinforce the required learning and repeated over a suitable time frame.
The Trainer will explain the training format, process and the progression to the assessment
requirements.
The content of this Resource Manual satisfies the training material requirements for this module.
Although you can keep this manual, the Activities at the end of each Section must be completed
and a copy of the Activities given to the Trainer.
1.4 Assessment Requirements

On completion of this training module an assessment will be conducted, which must be
successfully completed to attain an assessment of Competent for the material covered by this
module.
The assessment requirements are:
 A knowledge based test
 Practical demonstrations to establish a satisfactory understanding of the required
task/s and the associated safety requirements
 Workplace evidence completed by the Participant demonstrating competency in all the
required tasks
1.5 Prerequisite
Completing the training for the Generic Health, Safety and Environment Requirements and
being assessed as Competent, is a mandatory prerequisite for attending the training for this
module.
Information covered in the Generic Health, Safety and Environment Requirements Resource
Manual that is also applicable to water truck operations is not duplicated in this resource
manual. If necessary, review the HSE manual to assist you with the full understanding required
for water truck operations.
Section 1 Session Preliminaries
1.6 Getting Help

See your Line Manager or Supervisor to obtain further assistance with the subject matter in this
training module.
Section 2 Introduction
2 Introduction
2.1 Scope
This training module is aligned with the requirements of the unit of competency, RIIMPO206A
Conduct bulk water truck operations.
This Resource Manual discusses generic bulk water truck operations and is to be used in
conjunction with the relevant Original Equipment Manufacturer (OEM) manuals for the specific
bulk water truck models and types that you will be operating at your mine site.
The topics include planning and preparing for operations, operating the bulk water truck,
loading, watering and distributing water and carrying out post-operational procedures.
There is also relevant information covering the Health Safety and Environment (HSE) and
legislative requirements for the functions associated with operating a bulk water truck. This
safety information is extremely important and is discussed in detail with all related subject
matter, as required, throughout this manual.
2.2 Bulk Water Truck Variants and Functions

Bulk Water Trucks are typically a standard model truck of an appropriate size, capacity and
power with the capability of being modified to have a large water tank fitted. These trucks can
be modified haul trucks or a modified version of the larger road trucks, e.g. Mack and Kenworth.
Other modifications include water pumps, hoses, spray bar and water cannon, with additional
operator controls in the cabin. The controls and cabin layout in some of the trucks may vary to
accommodate the watering control functions.
All other features and instrumentation in the standard truck are generally unchanged.
The primary purpose of a bulk water truck is dust suppression, which is vital for safety and
environmental reasons. The watering function is not designed for nor can it achieve, dust
elimination.
The heavy payloads that can be carried by bulk water trucks make them an efficient means of
transporting and dispensing water for various purposes in short time frames.
All the water truck variants are capable of performing the full range of water use and supply
functions required by mining sites.
These include:
 Dust suppression on roads, pit walls, ramps, dumps, windrows, benches and park up
areas
 Dust suppression around Crusher and stockpile areas, e.g. gravel
 After blast dust suppression
 Fire fighting and preventing re-ignition of fires
 Cooling the tracks and rollers on equipment that have trammed over long distances
 Cleaning selected mine site infrastructure, i.e. Workshop apron areas
 Cleaning shovel, Loader and Excavator loading areas
 Replenishing drill water
 Assisting road crews and maintenance crews
 Assisting mobile plant
 Equipment wash downs
The following photographs are just some examples of the types of bulk water trucks that are
used on Leighton’s mine sites.
Caterpillar Bulk Water Truck
This water truck is a modified haul truck with a tank fitted.
Komatsu Bulk Water Truck
This water truck is a modified haul truck with a tank fitted.
Mack Bulk Water Truck
Kenworth Bulk Water Truck
Trailer Version of a Caterpillar Water Truck
Hitachi truck with a water tank mounted in the dump body
2.3 Operating Authority

To operate a bulk water truck under any circumstances you must:
 Have a current full drivers licence issued by the transport authority of an Australian
State or Territory
 Be at least 18 years of age
 Complete the relevant site induction/s
 Must be trained and deemed competent to operate by site training requirements
Generally, if you have committed a traffic offense resulting in the suspension or loss of your
State or Territory Driver’s Licence, you cannot operate a truck (or any other site vehicle) until
your Drivers Licence has been reinstated. However, under some circumstances and with
regards to your site’s policy, the Site Manager may grant permission to operate certain vehicles
under certain conditions during the period of your licence suspension. This is not automatic with
each case being considered individually.
If you are unsure about your authority to operate or what authorisation is required, seek advice
from your Supervisor.
Section 3 Operate a Bulk Water Truck
3 Operate a Bulk Water Truck

Important Note
Due to the various makes and models of bulk water trucks used across Leighton mining sites,
the following procedures for walk-around checks, start up and general truck operations are
generic. You must refer to your mine site’s procedures and the truck’s OEM documentation for
the specific truck that you will be operating for the full inspection and operational requirements.
3.1 Introduction
Operating a water truck is a skilled task that requires significant training and an on-going
discipline to manage and drive this highly specialised and unique vehicle.
While driving the vehicle, there are critical parameters for speed and braking that must be
strictly adhered to, with constant monitoring of systems and surrounds for alarms and
hazardous situations.
It is part of the Operator’s responsibility to help improve the general appearance, standard of
roadworthiness and operating efficiency of the truck. This is achieved by following the required
operating procedures.
These procedures are:
 Taking part in shift change-over procedures
 Conducting walk-around inspections and pre-start checks
 Reporting defects in or on the truck using approved defect-reporting forms or
procedures
 Operating the truck safely and productively
 Operating the truck with due care, so as not to reduce its service life or cause
unnecessary damage to it or to other machinery
 Parking the truck in secure locations or designated areas
 Observing shutdown procedures
 Ensuring the truck is available for use whenever it is required
 Ensuring that preventative maintenance is performed when scheduled
 Ensuring that high standards of housekeeping are maintained
 Keeping the truck clean
The truck must be operated with headlights on during truck operations to assist with mine site
safety. This is mandatory.
If you correctly perform all checks and drive within prescribed handling parameters, the
operation of the truck is always a safe task.
The Operator’s truck care responsibilities may vary depending on site regulations.
3.2 Identifying Safe Operating Practices

You must perform frequent pre-operational and operational checks and inspections on the water
truck. The purpose of these inspections is to discover and locate any adjustments that may be
required before operating the truck and to find any defects before they become significant
problems that may cause injury and equipment or environmental damage.
Ensure a high level of truck maintenance, safety and operating standards by:
 Carrying out quality walk-around inspections
 Performing the required pre-start checks at the beginning of each shift and before
starting the truck after a shutdown
 Only operate the controls while the engine is running as damage to some components
can occur and / or leave some functions in an unsafe setting causing unexpected
movement when systems are powered up
 Detailed and conscientious reporting of defects
 Ensuring all routine servicing and any other preventative functions are carried out as
scheduled
 Operating the water truck within its limits in a safe manner
 Ensure that the underground truck will not be damaged or made unsafe by any actions
that you may take
 Never drive an underground truck into an area that is suspected of being unsafe or
where vision is restricted
 Keeping the water truck clean
Warning : Do not operate the water truck if you believe it to be in an unsafe condition.
Report your concern and either get it cleared as safe to operate or report it for
repair.
Monitoring the truck’s operational status includes regularly checking:

 Temperature gauges
 Fluid level gauges
 All controls and switches
 Pressure gauges
 Alarms and indicator lights
 Steering
 Braking systems
 Hydraulic systems
Always include safety in your operating plan by:

 Monitoring personnel and equipment in the water truck operating area
 Constantly inspecting ground conditions around the truck, with particular attention to
windrows and edges
 Moving the truck by driving forwards wherever possible to avoid visual problems and
potential strain injuries to your neck and back
3.3 Identifying Personal Injury Hazards

Although you are operating the truck from inside a secure cabin, sitting on a suspended seat
with a seat belt, there are still occasions during normal operating conditions when you can
sustain an injury if you are not fully aware of some situations around you.
Back, neck and other limb injuries can occur by some operating conditions severely throwing
you around despite the wearing of a seat belt. Always remain aware of your operating
environment as Operators have sustained injuries while belted in the seat.
Potential injury situations include the following conditions.
Rough ground
When driving over rough ground slow down and ensure that you are correctly supported in the
seat to minimise the jolting and sideways motions that can cause injuries.
Load Movement
Load movement can change the handling of the truck and affect your stability in the seat. If you
unexpectedly have to make any quick recovery actions while driving or braking this can cause
injuries due to the tense nature of your body during the jolting and recovery movements.
3.4 Pre-Start Procedure
3.4.1 Overview
The primary reasons for a pre-start walk-around truck inspection are to identify any
maintenance concerns before they become serious problems and to identify any potential safety
issues before they become serious hazards.
A walk-around inspection must be performed:
 At the beginning of every shift
 Before operating any other truck during a shift
 After a hot seat changeover occurs
Perform a brief walk-around inspection whenever the opportunity arises, i.e. after refuelling.
Before starting the inspection, ensure that the:
 Truck is parked on stable, level ground in an appropriate place
 Park brake is on and the transmission is in neutral
3.4.2 Driver Changeover

The hot seat driver changeover procedures may vary according to site regulations and water
truck makes and models. Refer to your sites procedures for site and truck variations.
Observe the general safe procedures for a hot seat driver changeover by:
 Standing in a safe location and clearly visible to the end of shift driver
 Not approaching the truck until it has been parked and isolated
 Communicating with the out-going Operator regarding any concerns about the truck
and any site conditions as necessary
 Ensuring the out-going Operator is clear of the required area
3.4.3 Operator’s Inspection Form

The Operator’s pre-start safety inspection checks form must be completed during the
walk-around to record any faults or damage to the truck before commencement of your shift.
The information you record on this form can also protect you against being accountable for any
previous damage to the truck.
The following image is an example of the typical pre-start inspection forms used for
driver-operated vehicles at Leighton’s mine sites. The form used at your site may not be exactly
the same.
The forms typically have three fault categories for the repair actions required (see above form).
The following points specify your responsibilities as the Operator for each of these categories.
1. Do Not Operate – Report the fault to your Supervisor for repairs.
2. Authorisation Required – Report the fault to your Supervisor and obtain authority to
operate.
3. Corrective Action Required – Report the fault to your Supervisor and if the fault is not
corrected before the end of the shift, it must be recorded in the backlog defect list.
Note : All fire extinguishers on the truck must be operational with at least one of these
being a hand-held fire extinguisher readily available in the cabin before
operating the truck.
3.4.4 Walk-Around Inspection

Photos of a water truck based on the Caterpillar haul truck chassis are used as the water truck
examples in this section.
Truck Footprint
Warning : A walk-around inspection of the truck must be conducted outside the footprint
of the vehicle. However, it is acceptable to enter inside the footprint to place the
required Isolation after a Take 5 is conducted.
General Under and Around the Truck

As you walk around the truck check for:
 Leaks
 Hanging hoses or control cables
 Build-up of mud that could break away and cause injury
 Obvious damage
 Fuel tank for leaks and damage
 Transmission oil for correct level, if applicable
 Access steps and ladders for security and damage
 Fire extinguishers for correct pressure, security and damage
 Water pump hydraulic motor for secure mounting and oil leaks
 Auxiliary water outlet and valve and ensure the piping is secured
 Water cannon locks are securely fastened and there are no water leaks
 Water tank retainer bolts and springs are attached
 Level of water in the tank
 Isolation panel for security and damage, if applicable
General Safety Awareness

As you walk around the truck do not:
 Remove any caps or release any other fluid filling points as a sudden release of
pressure can be a serious hazard
 Touch any components that have the potential to be hot
Front
Check:
 Radiator for build-up of dirt or rubbish, leaks and damage
 Air intakes are clear of debris
 Working lights for cleanliness and damage
 Structure for cracks and damage
 Underneath for leaks and damage
 Engine bay inspection doors are secured
 Engine exhausts for cracks, security and damage
 Engine for leaks and damage
 Fluid levels are correct
 Windscreen and windows for cleanliness, cracks, damage
 Windscreen wiper blades for damage
 Windscreen washer reservoir is full
 Battery for leaks, security and damage
Left Side
Check:
 Tyres for correct inflation, cuts, damage to side walls or tread face, rocks trapped
between tyres and valve security
 Wheels for damage and security
 Front suspension strut for correct height, leaks and damage
 Underside for leaks and damage
 Left side rear vision mirror for cleanliness, security and damage
 Tank body for dints, cracks, leaks, weld cracks and general damage
 Turn indicator light for cleanliness and damage
Rear
Check:
 Tail, brake and hazard lights for cleanliness, security and damage
 Differential for oil leaks
 Rear suspension leaks and damage
 Spray bar and valve spray heads for correct gap settings, mountings, jammed debris,
damage and water or air leaks
 Grease lines and connections for leaks
 Rear sway bar and pins for grease and security
 Rock ejectors for security of pivot pin and damage, if applicable
 Tyres for rocks trapped between tyres
Right Side
Check:
 Tyres for correct inflation, cuts, damage to side walls or tread face, rocks trapped
between tyres
 Wheels for damage and security
 Right side rear vision mirror for cleanliness, security and damage
 Turn indicator light for cleanliness and damage
Cabin
Check:
 Doors for security, damage and correct operation
 For out of service, danger or information tags
 Spray bar controls are off
 Cabin seats and seat belts for cleanliness, security and damage
 Instruments and controls for cleanliness, damage and correct operation
3.5 Start Up Procedure
3.5.1 Final Pre-Start Checks

Prior to entering the truck to start your shift, ensure that any issues found during the pre-start
inspection are resolved and that the appropriate signatures have been obtained.
When you are cleared to enter the truck, check the immediate area to ensure that personnel
and equipment are clear of the truck.
After entering the cabin:

 Adjust the seat and mirrors
 Fasten the seatbelt
 Turn on the two-way radio and check that it is operating correctly
 Ensure the fire suppression system is active, if applicable
 Check that the doors and windows are secure
3.5.2 Start Up Process

Use the following sequence to start the water truck.
1. Use the key to turn on the ignition to power and check any automated systems that may
require it.
2. Check that all controls have the correct settings for start-up, e.g. hand brake and gears
3. Sound one horn blast to indicate an intention to start – wait five seconds to ensure all
personnel are clear.
4. Turn the ignition key to start and release once the engine has started.
5. Check for correct temperatures and pressures as they normalise after start-up.
3.5.3 Post Start Up and Moving Off Checks

Complete the following checks after the engine starts.
1. Keep engine at low idle until the engine operating temperatures and pressures indicate
normal.
2. Observe all other gauges, warning and service light panels for irregularities.
Gauges should register in the correct range and all warning and service indicators should
be off.
3. Cycle through the controls to ensure correct operation.
4. Ensure that the area is clear and sound the horn twice to indicate your intention to move
forward.
Sound the horn three times before reversing.
5. Select the appropriate gear for the intended moving off direction.
6. Press the accelerator pedal to start the water truck rolling.
7. Test the steering and brake controls for correct operation.
3.5.4 Continuing Checks

Throughout start-up and operation of the water truck you need to continue your checking and
safety vigilance by using all your senses to monitor the truck’s performance. This approach can
be summarised as follows.
Look: for unusual occurrences, e.g. oil or coolant leaks, obstructions, poor road
conditions, deterioration of components
Listen: for unusual noises, e.g. bearing failures, engine over-speed, warning alarms,
transmission and drive train failures
Smell: for burning and overheated oils, electrical equipment, engine or transmission
Feel: for unusual vibrations, from engine, transmission, drive train, bearings and
hydraulic controls
3.6 Emergency Procedures
3.6.1 Under Inflated and Flat Tyres

Under inflated tyres heat up very fast due to excessive flexing of the tyre walls, leading to the
possibility of tyre fires or blowouts.
The other, and perhaps most dangerous, situation is when a water truck is travelling loaded
while one of the rear tyres is flat. This means that the tyre next to the flat one is carrying the
weight of two tyres. Its walls bulge and rub against the flat tyre generating a lot of heat.
This situation creates extreme potential for a tyre fire. Anybody seeing a water truck with an
under inflated or flat rear tyre must immediately notify the truck Operator by radio.
The driver of the affected truck must park in a safe area, notify the Supervisor and follow their
instructions.
Warning : Never continue to drive on a flat or under inflated tyre and always advise your
Supervisor.
3.6.2 Tyre Failure

If a sudden tyre failure or blowout occurs, attempt to bring the water truck to a stop as quickly
and safely as possible by correctly using the trucks braking systems for this emergency.
Regardless of which tyre is affected, there are several factors that must be considered when
attempting to stop the truck.
These include:
 Road surface
 Weather conditions
 Travelling up or down inclines
 Loaded or empty
 Speed
 Other vehicles in the vicinity
After the water truck has been stopped:

 Reduce the engine to idle
 Place the transmission selector to park
 Apply the park brake
 Turn the ignition key off
 Notify your position and problem over the two-way radio
 Evacuate the area if a tyre is burning or displaying evidence of fire
When the water truck is parked after work, there can be a potential risk of fire or explosion from
an overheated tyre, wheel or brake component. If the tyres have a hot or burning smell or if
smoke is present, follow the site hot tyre procedure.
If you suspect that a tyre is overheated, do not bring the truck into the workshop. Park the truck
in a safe or designated area, well away from mine infrastructure and other equipment, and notify
your Supervisor.
Ensure that an exclusion zone of 500 metres is marked with barriers around the truck for a
period of 24 hours until the tyre has cooled down.
Warning : Do not attempt to extinguish the tyre if it is burning, as the risk of the tyre
exploding is extremely high.
3.6.3 Tyre Fires
3.6.3.1 Introduction
Tyre fires and explosions are a major hazard. A truck fire can also cause a tyre to explode.
When excess heat is developed in or applied to a tyre, a chemical reaction may occur within the
tyre’s material components and cause a build-up of flammable gases. If these internal gas
concentrations and temperatures exceed a critical level, the tyre explodes.
Heat in tyres can be caused by:
 Brake Problems – The over-use of braking system can cause over-heating in tyres
 Under-inflation – Insufficient air in the tyres or too much load on the tyre can cause
separation of the tread
 Flammable liquids on Tyres – Oil or fuel soaked tyres become fire hazards when
exposed to heat
3.6.3.2 Suspect or Burning Tyres

If the circumstances suggest there is a danger of a tyre fire or explosion:
 Move the truck to a remote area, as directed by the Supervisor, provided it can be
done without endangering the Operator or other personnel in the area
 Advise Mine Control where the truck has been parked
 If possible, drive the truck to the tyre fire area
 Park the truck
 Shutdown operation
 Do not attempt to use a hand-held extinguisher on a smouldering or burning tyre
 Exit the truck and move away keeping the vehicle between you and the burning tyre -
avoid passing in front of the suspect tyre when leaving the truck
For tyres that have not burnt or exploded, allow up to 24 hours (depending on the truck) for the
tyre to cool before approaching to inspect the truck.
If it is absolutely necessary to approach a truck with a suspect tyre, approach it from the front or
rear and use a large bulldozer blade as a shield in front.
If there is evidence of brake fire or smell of burning rubber, do not go near the truck.
Warning : Stay at least 500 metres from a truck with a burning or suspect tyre.
Tyre Explosion Danger Area
Warning : Never approach a burning tyre under any circumstances. The timing of a tyre
explosion is not predictable. Explosions can be immediate or occur anytime up
to 24 hours.
Burning tyres emit toxic fumes and are extremely difficult to extinguish. Dealing
with them is a job for the Fire Crew.
3.6.4 Truck Fires

If there is a fire on the water truck, use the following procedure to stop, apply fire-fighting
equipment, obtain help and ensure personal safety.
1. Bring the water truck operation to a stop as quickly as possible.
2. Turn the steering wheel to full lock towards a windrow or wall if possible.
3. Shut down the engine using emergency stop procedures for your truck – this stops the flow
of fuel, air and electrical energy helping to reduce the spread of the fire.
4. Apply the long term parking procedure.
5. Remove tamper tag / pin on the actuator and depress firmly to activate the on-board fire
suppression system – press button down hard.
6. Use the two-way radio to call, emergency, emergency, emergency and state your name,
location, nature of the emergency, assistance required and any injuries.
7. Leave the Operator cabin and dismount at the safest exit point.
8. ONLY use the hand-held fire extinguisher to help control the fire if it does not to place you
in any personal danger.
9. Once the extinguisher is discharged, move away from the water truck to a safe location.
3.6.5 Loss of Steering or Brakes

It is imperative that an Operator is competent in all aspects of water truck operations.
Operator’s experiencing malfunctions such as loss of steering or brakes must use the correct
procedures for the type of water truck being operated. It is imperative that the Operator acts as
quickly as possible to ensure the water truck can be brought to a complete stop to avoid
possible injury to personnel and damage to equipment.
Refer to the water truck’s OEM instructions for handling a loss of steering or brakes emergency.
3.6.6 Immobilised Water Truck

If the water truck is bogged or is unsafe to move due to a mechanical fault, immediately contact
your Supervisor. The Supervisor takes the appropriate actions to ensure that the water truck is
recovered in the correct and safe manner.
Warning : Do not attempt to recover an immobilised water truck on your own, as the risk
of serious injury or damage is high.
3.6.7 Loss of Traction
3.6.7.1 Overview
During wet weather (or where ramps have been over-watered), trucks can sometimes break
traction and begin to spin the rear wheels.
Skidding and sliding occur when the front or rear wheels lose traction with the ground. It occurs
more frequently in wet conditions, and is more likely to happen in conjunction with the following
bad driving practices:
 Swerving
 Excessive speed
 Rapid slowing
 Sudden and / or excessive braking
 Excessive acceleration
 Transmission change downs on wet roads
The three types of skidding are:

 Rear wheel skidding
 Front wheel skidding
 All wheel skidding
3.6.7.2 Rear Wheel Skid

This occurs when the rear of the truck tries to catch up with the front, which can result in the
truck turning completely around and facing the other direction.
To control rear wheel skidding:
1. Release foot off the accelerator
2. Simultaneously turn front wheels into the direction of the skid and reduce braking.
3. Take care not to over correct.
4. When the truck comes back into line, gently accelerate and steer in the required direction
3.6.7.3 Front Wheel Skid

This causes loss of steering by either excessive speed or excessive braking.
If caused by excessive speed:
1. Release foot off the accelerator
2. Apply appropriate braking system sufficiently to regain steering control
3. Steer into intended direction
If caused by excessive braking:

1. Remove foot from accelerator
2. Straighten front wheels
3. Momentarily remove foot from brake and allow the wheels to start turning again
4. Reapply the brakes with gradual pressure
3.6.7.4 All Wheel Skid

If the truck starts to slide sideways due to over-acceleration, road camber or rear wheel lock up:
1. Reduce acceleration
2. Steer in the direction of the slide
3. Stay close to the left hand windrow
If the truck starts to slide sideways while braking:

1. Release the brake
2. Steer into the direction of the slide
3. Gently accelerate making the rear wheels turn at the truck’s ground speed and increase
tyre to road friction giving more control
4. Brake again more gently
Note : Always report excessive loss of traction on any roads to the Supervisor.
3.6.8 Breakdown on a Gradient

The Operator must assess situation, perform a water truck risk assessment if necessary and
follow the breakdown procedure.
1. Turn wheels into windrow or high-wall.
2. Apply the long-term park-up procedures.
3. Operator informs Supervisor and all other road users of the breakdown situation.
4. Supervisor ensures adequate safety controls are in place for personnel and
equipment.
5. Operator uses the cabin two-way radio or a designated spotter to direct traffic flow
until bund building equipment is in place.
6. While construction of bund wall is taking place, all traffic flow on ramp is to cease.
7. Truck maybe positioned against high wall or bund if deemed safe by Supervisor to
ensure fundamental stability.
8. After the truck is secured, maintenance personnel gain permission from the
Supervisor to approach broken down truck.
9. Supervisor assesses the status of situation and acts accordingly.
Bund-wall Construction
There must be positive communication between all parties involved with the construction of the
bund-wall. The wall is constructed on the down side of broken down truck.
A spotter is used to oversee the material being pushed up to tyres of the truck.
The material must be pushed to the tyre from a 45° angle. When an adequate amount of
material has been placed in front / behind the truck it is then pushed up against the tyres from
directly in front / behind.
If an emergency ladder is fitted to the truck, it is only to be used for an emergency. If required,
release the ladder and dismount using 3-point contact.
3.6.9 Water Truck Rollover

When water trucks are operated correctly, the chances of a rollover are minimal. However, there
is no room for complacency because rollovers have and can occur with reduced awareness.
There are several conditions either, separately or in combination, that can cause rollovers.
These are:
 Flat tyres
 Rocks
 Rough ground
 Excessive speed
 Uneven load distribution
In the event of a rollover, follow the recommended precautions and procedures as much as
practicable in an attempt to prevent or minimise injury.
Brace firmly in the Operator’s seat with both feet firmly on the floor to minimise body movement
during the rollover. You should already be wearing your seat belt.
When the water truck has stopped moving, if there is no immediate danger, exit the cabin if you
can do it safely. If there is a possibility of the water truck moving again remain in the cabin until
assistance arrives.
Warning : Never attempt to jump clear while the truck is moving in a rollover situation.
At the earliest opportunity:

 Shut down the engine
 Radio for assistance
 Shut down all electrical systems
Note : Always maintain a high standard of housekeeping in the cabin as serious injury
can occur from loose objects during a rollover.
3.7 Driving the Water Truck
3.7.1 Dash Indicators and Warnings

Operators need to be familiar with all the indicators on the dash as this allows you to take timely
corrective action for any problems while operating and to report all the information required by
maintenance crews for repair.
Always refer to the relevant OEM manual for your truck model and type, as the dash indicators
may be different.
3.7.2 Visibility
When driving the water truck remain totally aware of your surroundings and concentrate fully on
the safe operation of the truck.
Be constantly aware of the height of the water truck to avoid contact with overhead obstructions.
Remember to be constantly aware of the truck’s blind spots in your particular truck model and
type to help prevent accidents.
As with driving most vehicles, with a slight movement of your head and body, you can see
around the door pillars and rear view mirrors. However, there are areas that are always blind.
When driving, you have full visibility of the areas that become blind spots as the truck moves
forward. However, if you are not fully concentrating some areas can become blind spots without
you being aware if the area is clear or if the road condition immediately in front is safe.
The care and attention required will constantly test your driving skills and experience. You can
never afford to be over confident.
The need to be fully alert and safety conscious all the time cannot be overstated.
3.7.3 Clearances
It is the Operator’s responsibility to ensure the truck has sufficient clearance whenever it is in
operation.
Be aware of clearances when:
 Reversing
 Parking
 Turning – slow down and avoid making contact with bund walls / windrows
 Operating in tight areas around other equipment, overhead power lines, near cables,
lighting plants and park up areas
If in doubt when entering into an area for the first time, seek clarification and guidance from the
Supervisor.
In relation to visibility from vehicles, a blind spot is defined as a line of sight obscured by a
window column or other obstruction.
3.7.4 Horn Signals

Operators of mobile equipment in the mine operational areas use horn signals to indicate the
three main vehicle actions.
These are:
 1 blast indicates the equipment is about to start
 2 blasts indicate the equipment is going to move forward
 3 blasts indicate the equipment is going to reverse
3.7.5 Ramp Speed Limits

The traffic regulations reflect the safety requirements for water trucks at your mine site.
Speed limits vary according to location, conditions and each mine site. The typical speed limits
for water trucks are shown in the following table.
Speed Limit Maximum kph Location
16 At the crest of a ramp

20 – must use 2nd gear Travelling down a ramp loaded
40 Travelling down a ramp unloaded
3.7.6 Trailing Distance

The trailing distance for all water trucks behind other mobile equipment is no closer than 50m.
This procedure is particularly important when following a haul truck.
The reasons for this are:
 Material falling from haul truck tray
 Provides an increased reaction time if required for:
 Potential tyre explosion
 Loss of drive
3.7.7 Turns
Turns with the water truck are usually conducted at either low speed with a small turn radius or
at operational speed with a large turn radius as normally encountered on the haul road.
Always use indicators and allow enough time for other vehicles in the vicinity to stop or avoid
the indicated path of travel.
The rate or speed of entry into a turn together with the truck weight and the distribution of that
weight over the drive and steering axles determine how the water truck steers.
3.7.8 Stopping and Parking
3.7.8.1 Parking
Mine site rules for parking are:
 Parking is not permitted on a haul road
 Utility vehicles and other personnel transport vehicles must park at least 50 metres
away from heavy equipment
 Water trucks must be correctly parked for the truck model and type in designated park
up bays
 If parking on an incline, prevent uncontrolled movement by turning the front wheels
toward the embankment or windrow
 Chocks are to be used where a V drain is not present – Empty trucks only
3.7.8.2 Routine Stopping and Parking

When stopping and parking the water truck, perform the following procedures in sequence.
1. Use appropriate braking for the water truck model and type to stop in a safe or designated
area with sufficient clearance on each side.
2. Move the transmission selector to the Neutral position.
3. Applying the long term parking procedure for your truck.
4. Switch off all lights and electrical service.
5. Apply the engine shut off procedure for your truck.
6. Report any known defects.
3.7.8.3 Stopping with the Secondary Brake System

For trucks with this function
The secondary brake is used to provide emergency braking if the low air pressure alarm
sounds, the indicator illuminates and the service brakes are inoperative.
Depress the secondary brake pedal and hold it down until the water truck stops.
Note : After an emergency stop, do not operate the water truck until a complete check
has been made of the entire braking system and any necessary repairs have
been completed.
Emergency braking and parking is discussed under the heading, Driving the Water Truck later in
this manual.
3.7.8.4 Short Term Parking

When parking for a short term for any reason, your truck must be at least one truck length
behind, slightly to the left and stop in the line of vision of the rear view mirror on or offside of the
truck in front.
You must remain in the seat in the cabin with the park break / wheel brake lock applied.
Note : If you can see one of the mirrors of the truck in front then you can be seen.
3.7.8.5 Long Term Parking

Operator out of cab park brakes must be applied.
Trucks are to be parallel parked next to each other at the designated park up or as per site
procedures.
There must be at least a 3-metre space between parked trucks.
Many park-up areas have a V drain for the front wheels of the truck to provide extra security
against uncontrolled truck movement.
Many park-up areas allow for driving forward to park and driving forward to leave the area. This
is the preferred parking method where possible due to greater visibility when moving in and out
of the park up areas.
Do not reverse park when trucks are parked on your blind side.
3.7.8.6 Fundamentally Stable Parking

It is sometimes necessary to park a truck due to a fault with the truck or an emergency. In these
instances it may not be possible to apply the standard short or long term parking procedures.
However, it is necessary when parking the truck to ensure that it is always parked in a
fundamentally stable state. This is defined as a state in which the truck cannot roll in either
direction.
The test for fundamental stability is stopping the truck on flat level ground wherever possible
and applying all brakes with the engine still running. Place the truck in neutral and release all
brakes. If the vehicle is in a fundamentally stable state it will not roll when the brakes are
released.
After testing for stability, return the truck to a safe state by reapply all long term parking brakes.
Fundamental stability can be achieved by:
 The truck’s front or rear wheels being driven into a ditch
 The truck being parked at a designated park up
 Parking the truck against a windrow
 Using wheel chocks – this only applies when the truck is empty and the truck is parked
on level ground
Warning : Depending on the truck type and model, chocks may not hold a full truck or a
truck parked on an incline.
Under these circumstances the Operator must remain with the truck, in the cab,
until a stabilising windrow has been tipped in front of or behind the truck as
required and a test for fundamental stability has been successfully completed.
Except in an emergency or a breakdown, trucks should not be parked on inclines. In these

circumstances fundamental stability can sometimes be achieved by parking up against a
windrow or by having a suitable amount of material pushed up to hold the truck, i.e. a bund-wall.
When parking against windrows ease the truck tyre against a windrow and ensure the windrow
is substantial and free of tyre damaging material.
3.7.8.7 Emergency Braking

If an emergency situation occurs requiring the water truck to be stopped immediately, apply
whatever braking is deemed necessary to stop the truck safely to appropriately respond to the
emergency.
When the truck has come to a complete stop:
 Turn wheels left hand down into the windrow or high wall
 Apply the long-term parking procedures for your truck’s model and type
 Ensure truck is fundamentally stable
 Activate hazard lights
 Notify your position and emergency details using the two-way radio
3.7.9 Retarder Controls

For mechanical water trucks with a haul truck chassis only
3.7.9.1 What is a Retarder?

A Retarder is a complex braking mechanism use to slow the water truck in a controlled and
sustained manner using the truck’s brake system / power train to maintain engine speed at a
constant rpm to protect the engine from over-speeding.
3.7.9.2 Retarder Operation

Mechanical water trucks are equipped with manual and automatic retarder controls and power
shift transmissions.
3.7.9.2.1 Approaching a Downgrade

Before approaching a downgrade, especially with a loaded truck, select the transmission gear
range that limits the truck’s speed to a point where the retarder can be safely applied. This
prevents over-speeding of the power train and excessive use of the service brakes.
When selecting a gear range to descend a grade, remember that the retarder is most efficient
when the converter is in direct drive (lockup).
Select a gear range that allows the converter to go into direct drive before the retarder is
applied. This may not always possible, but it is the most efficient method of using the retarder.
When a grade is descended, select the appropriate gear range and move the retarder lever to
position that produces the most effective braking action. Hold the lever in the full on position
until the downhill speed of the truck has been reduced to a safe speed.
Note : The transmission can be up-shifted or downshifted with the retarder fully or
partially activated. However, when downshifting, the converter must not be in
direct drive (lockup).
3.7.9.2.2 Calculating the Gradient

To select the appropriate gear range, the downgrade percentage must be considered.
The following chart illustrates the grade percentages and the recommended gear changes.
Using an example from the chart, a truck approaching a 13-16% grade is in the first gear range
and the retarder is applied to achieve the most effective braking action. This allows you to
maintain control of the truck.
This chart is a guideline only. Variations in road construction, road conditions, traffic, weather
and other factors may make it necessary to select a different gear range than the chart
recommends.
The retarder may be applied in any range. However, the lower the range the greater the braking
affect. If a grade less than 13% is encountered, select the second gear range with the retarder
activated to achieve the most effective braking action and the service brakes used intermittently,
if necessary, to maintain control of the truck.
Warning : The retarder control lever is to be always in the off position whenever the truck
is operating on a level road, going up a grade, or is at a standstill with the
engine running.
3.7.9.2.3 Downgrade Retarding

Always keep the transmission in gear. Transmission controls prevent shifting from forward gear
to neutral or reverse at ground speeds greater than 5 km/h.
If you attempt to stay in a lower gear on a long downgrade by retarding you may be
unsuccessful because engine speed may reach the up-shift point. The resulting lower engine
speed reduces brake cooling oil flow and may cause brake overheating.
The transmission up-shift point is raised to a higher rpm than the normal shift point whenever
the service brake or retarder is applied.
Remember to closely monitor the retarder temperature and reduce road speed by shifting to the
next lower gear if the temperature rises above the normal operating range.
3.7.9.2.4 Automatic Retarder Control

The Automatic Retarder Control is activated by moving the control switch to the on position.
This allows the transmission to up-shift to the gear selected by the transmission selector lever.
The automatic retarder control governs the engine speed in the selected gear. When the engine
speed is between 1850 and 1950 rpm, the ARC applies the brakes, as necessary, to maintain
the engine speed.
The brakes are not to be applied when the engine speed is below 1800 rpm.
The Automatic Retarder Control can be overridden at any time by depressing the accelerator
pedal, applying the manual retarder lever or pressing on the service brake pedal.
Note : For correct operation of the Automatic Retarder Control, the switch remains on
during all normal operation. Select the correct gear for the grade, load and
ground condition.
3.7.9.2.5 Slowing
The correct procedure for slowing the water truck is by using the retarder and downshifting in
coordinated movements. The throttle must not generally be used while the retarder is engaged.
However, in attempting to control the water truck under slippery conditions (in case of a slide) it
is acceptable to use service brakes. Constant use of power against service brakes can result in
excessive brake wear.
The service brakes are capable of absorbing the large amounts of power required to slow the
water truck, but only for a very short period of time. This braking capacity is reserved for
emergency situations and usually results in a rapid temperature rise in the brake cooling
system.
Judgement of distance and speed and anticipation of what the truck does before an emergency
situation arises must be mastered quickly.
3.7.9.2.6 Transmission Selection

First gear (torque converter drive) is engaged when the transmission selector lever is moved
from neutral to first (or any desired higher speed) with the water truck stopped and the engine at
low idle.
As the engine is accelerated and ground speed increases, the transmission automatically
up-shifts. The lockup converter activates on each gear change.
Shifting is governed by ground speed. Therefore, moving the transmission selector lever to a
higher gear while in motion does not force an up-shift. When ground and engine speed are
reduced, by increased load or deceleration, the transmission automatically downshifts one gear
at a time to select the correct gear. A downshift inhibitor prevents forced downshifts.
Accidentally moving the transmission selector lever to a low gear while travelling, does not force
a sudden downshift.
Note : The water truck must be stopped and the engine at low idle before changing
direction. After moving the shift lever, do not accelerate until the transmission
clutches engage.
The water truck is equipped with a reverse transmission neutraliser that prevents reverse from
engaging with the hoist in the raised position. If the hoist lever is moved to the raised position
when the transmission is in reverse, the transmission returns to the Neutral position. If this
occurs:
 Depress the service brake
 Move the transmission selector lever to neutral
 Return the transmission selector lever to reverse
3.7.10 Hill Starts

Hill starts need to be performed using caution, as Operators must avoid rollback regardless of
the type of truck being driven.
The start process is:
 Apply the appropriate braking system for your truck’s model and type
 Release the park brake
 Engage forward or reverse
 Slowly release the brakes and increase the throttle (engine speed)
Note : Always refer to the OEM manual for your type and model of water truck for
specific operating instructions for these conditions.
3.7.11 Uphill Driving

The water truck is capable of developing high power, but that power is only useful if the drive
wheels do not lose traction or spin. Therefore, the useable power is limited to the traction effort
that can be developed depending on the water truck’s weight and the grade of the incline.
Some water truck models are equipped with a Traction Control System (TCS) that electronically
monitors and controls wheel slippage. The TCS prevents the wheel spin that can otherwise
occur if low gears and high rpm are used when driving uphill.
However, increased performance can be obtained when driving up an incline by selecting the
highest possible gear to maintain a ground speed that is suitable for the surface conditions.
3.7.12 Reversing
General Guidelines
Reversing is a necessary operation that can be dangerous due to restricted visibility and blind
spots. Mirrors and back-up alarms provide some level of protection and having a spotter
working with the driver also decreases the potential for backing accidents.
Sound the horn three times to indicate that the truck is about to reverse.
Extreme care must be exercised and it is the driver’s responsibility to ensure that the area they
intend to reverse into is clear.
Reversing without the aid of a spotter is only permitted in haul truck loading and tipping areas
and designated park ups.
Before attempting to reverse, check through left and right rear vision mirrors, if in any doubt
physically check that the area into which the truck is to be reversed is clear of personnel and
equipment.
If you are required to reverse into a confined area, maintain a minimum clearance on the onside
of the truck where there is greatest visibility. You can then be confident that there is sufficient
clearance on the offside of the truck. During the reversing operation, continually monitor the off
side mirror to ensure that no obstructions are present.
You must become proficient at judging distance and accurately positioning the water truck using
the rear-vision mirrors.
Note : When reversing outside normal operations a Spotter must be used.
Reversing Over a Distance

There may be occasions when the water truck is required to reverse for some distance into a
tight area negotiating bends and obstacles.
Maintain minimum clearance on the Operator’s side of the truck so that you can be confident
that there is sufficient clearance on the offside of the water truck.
Continually check the offside mirror when performing this manoeuvre to ensure that no
obstructions are present.
3.7.13 Wet Road Conditions

The following warning is for water trucks based on the mechanical haul truck chassis.
Warning : Applying the retarder on a slippery road can cause the wheels to lock up and
the transmission to down shift. This can cause serious damage to the power
train.
Gradually apply the retarder control lever on slippery roads to prevent the
wheels from locking and the transmission from down shifting.
3.7.14 Fuel Consumption

Some simple causes of high fuel consumption are:
 Driving faster than is necessary
 Heavy acceleration when starting off, particularly when loaded
 Incorrect use of the braking system
 Excessive revving
3.7.15 Tyre Wear
3.7.15.1 Speed
Excessive speed, particularly when loaded:
 Causes heat build-up in the tyres, leading to ply separation that contributes to a
reduction in the tyre’s serviceable life
 Increases the possibility of a tyre over-heating and catching fire
 Requires heavier braking leading to increased tyre wear, possible damage and a
reduced tyre life cycle
3.7.15.2 Manoeuvring
When travelling straight, a loaded water truck’s weight is distributed evenly over all wheels.
However, in a turn, weight is transferred to the outside steer tyre, e.g. When turning right, the
left steer wheel carries more weight.
The weight transfer to the truck’s tyres increases with tight turns and higher speeds. This
causes the tyres to distort, the outer walls to bulge and become more exposed to stones, which
can either cut or bruise the tyre walls causing internal fractures. A tyre with internal fractures
heats up quickly under load with a greater potential for failure.
If you identify a water truck with an underinflated tyre, you must immediately notify the water
truck Operator of the situation by radio. The water truck Operator must park the truck in a safe
area and advise the Supervisor that assistance is required with a tyre problem.
3.7.16 Minimising Equipment Damage and Wear

Steady and consistent driving maintains an acceptable level of operating safety, production
efficiency and care for the water truck.
To minimise undue wear and possible damage to the water truck, where possible, avoid the
following operating conditions.
Excessive speed
This causes:
 Increased fuel consumption
 Heavier braking
 Increased tyre wear
 Increased vibration and strain on the truck
Violent Manoeuvring
This causes increased:
 Tyre wear
 Strain on the steering and suspension components
Excessive acceleration from stationary

Especially when loaded this causes:
 Tremendous strains on the transmission and final drive components
Over Revving the Engine

This causes:
 Increased engine wear
Heavy Braking
This causes:
 Increases tyre wear
 Tremendous loads on suspension components
 A high risk of tyre damage, suspension and body damage, especially when driving
over dirty ground
Changing from Forward to Reverse while in Transit

Ensure the truck is completely stopped and the engine is at low idle before moving the
transmission lever between the forward and reverse directions.
After moving the shift lever, do not accelerate until after hearing or feeling the transmission
clutches engage.
For water trucks with a haul truck chassis – If the transmission is in forward gear and
reverse is selected, the truck remains in forward gear until 8 km/h is achieved when the
transmission selects neutral. When the road speed is below 3km/h, reverse is engaged.
3.7.17 Spotting
Refer to site procedures for specific spotting practices. The following information is typical, but
may vary across sites.
Day time from Ground

Spotting from ground is only to be carried out when absolutely necessary due to the danger of
falling rocks and tyre bursts or explosions.
The Spotter instructs the truck driver of his requirements either by radio or in person. The
Spotter must be in clear view of the truck driver at all times or the truck must stop immediately
vision is lost.
The Spotter must ensure adequate distance is kept from the truck to avoid injury from falling
rocks. The Spotter uses a hand stop signal to stop the truck.
Night
At Night the Spotter must be in a position to be seen clearly by the truck driver and must have
an operational torch and reflective clothing.
The Spotter indicates to the truck driver to keep reversing slowly by swinging the torch light
beam in a back and forth motion on the ground alongside his / her body.
The Spotter indicates to the truck driver to stop by changing the motion of the light beam
movement to back and forth across his / her body.
If for any reason the torch goes out, the driver must stop immediately.
The torch beam must not be shone into the truck mirror as a signal to stop.
Note : If you cannot see the Spotter, stop immediately until the Spotter is sighted.
3.7.18 Maintenance Workshop Areas
3.7.18.1 Driving in and around Workshops

When driving in and around workshops:
 Trucks must be at low idle (below 8kph) entering the truck shop at all times
 Always use horn signals around workshop areas
 Obey the speed signs and drive to conditions
 Do not enter or exit truck bays unless guided in and out by a Spotter
 Always use the appropriate braking methods (trucks with a haul truck chassis do not
use the retarder) when inside the truck shop
 Apply long-term parking, idle truck down and chock the wheels when in position
3.7.18.2 Spotting at the Workshops

A spotter is required to assist the water truck Operator when manoeuvring around and in and
out of the maintenance workshops due to visibility restrictions.
It is important when you are manoeuvring the water truck under the guidance of a spotter that
you only accept hand signals from one person.
Prior to any movement, you and the spotter must discuss the process that will be used and have
a full understanding of the task. A risk assessment can be completed if required.
Note : When guiding a water truck in and out of the workshop, the spotter has the
authority. If there is any confusion, you are to stop the operation immediately.
3.7.19 Efficient Operations

Efficient operations contribute to overall productivity while maintaining safety.
When operating the water truck:
 Show initiative – maintain safety standards while maximising productivity
 Be alert for hazards while operating the water truck
 Act promptly on instructions
 Monitor the truck operating system and react to hazards promptly
 Anticipate problems and act before problems occur
 Cooperate with personnel involved in your work program
 Be proactive – recommend and act on improvements to your work procedures
 Act professionally at all times
Section 4 Load, Haul and Distribute Water
4 Load, Haul and Distribute Water
4.1 Operating Rules for Watering
4.1.1 General Rules and Awareness

The general rules for operating the water truck and distributing water for the various mine site
requirements are:
 Always have the amber flashing light activated
 Always having the headlights on while operating to assist with pit safety
 Always remain alert to what is happening in the pit as watering methods may need to
be changed at short notice
 Always avoid holding up the flow of traffic while watering the haul roads
At the first opportunity turn off the haul road and allow the traffic to precede
 Always turn off the sprays when stationary
 Only using bore or other designated water sources, and not potable water, for filling
the water truck tank
 Maintain alertness for radio communications and modular systems for any required
changes in your work patterns
 Planning the watering route for operating efficiency and maximising water usage
 Notifying road users of freshly watered surfaces because a wet road surface can have
less traction
 Coordinating watering with road maintenance and haul truck Operators to ensure that
the water is being applied where and when needed
 Adapting to high wind conditions to ensure effective watering
 Not watering within 20 metres of a digging unit, except when working at a dig face
 Not watering within 10 metres of any crusher or hopper
 Avoiding spraying water on surveying equipment or laser levellers as this causes them
to become obscured and may cause damage
 Never driving a water truck into an area that is suspected of being unsafe or where
vision is restricted
Notify a Supervisor and have the area inspected or get assistance
 Never spraying water on or near personnel or into areas where personnel are working,
i.e. workshops, buildings, offices or where there are plant maintenance activities
 Never spraying water near other vehicles, e.g. spotter’s vehicles, light vehicles and
mobile plant
All sprays must be switched off before allowing anyone to overtake
 Never spraying water near cable plugs, cable mats, cable bridge poles, cable arches,
switch stations, de-watering trailers and lighting plants
 Avoiding spraying onto or into electrical installations, e.g. transformers
Spraying water over electrical equipment or accessories can create dangerous
situations and equipment failure
 Not spraying onto ore cars or bogie journals

 Never attempt a U-turn on a haul road or a ramp
 Always start the watering cycle on flat roads and in dump areas to lighten the load
before descending ramps.
This is important for added personnal safety and extended truck serviceability.
 Never commence watering:
 Over the crest of a ramp
 Halfway round a corner
 Halfway down a ramp
 Being aware of loaders side casting or loading when working around the crusher
areas.
 Using caution when working in the vicinity of waiting haul trucks and active dumps to
prevent the potential for a collision
 Using caution around loading units (e.g. shoves, excavators and loaders) and avoiding
driving directly behind them or within their working radius without notification
 Avoiding overwatering
This is expanded in the next topic.
 Never spraying water onto Burning Pyritic Shale
Warning : Pyritic Black Shale gives off Sulphuric fumes (SO2) when exposed to air and / or water
and is hazardous to your health.
Water also aggravates existing shale fires and may also initiate additional fires.
4.1.2 Overwatering
General Guidelines
You must take care not to over water the haul roads, ramps and benches as this severely
erodes and damages the road surfaces creating hazards that include:
 Potholes
 Rutting
 Slippery conditions
 Washing away of road contours and edges
 Environmental damage
 Prematurely degrades road surfaces by softening and run off
 Ruining many hours of road maintenance with more being required
 Causing significant amounts of mud to be transported to sealed road surfaces
 Loss of traction and steering control
 Increasing the risk of skidding
 Greater braking distances
 Increasing risk of accidents
 Reducing tyre life due to increased wear and cutting
 Increasing the need for vehicle maintenance
 Increasing the driving stress on vehicle Operators
Night Watering
During nightshift watering, the water does not evaporate as quickly as it does during day
watering, reducing the volume of water required to complete the dust suppression task. The
water on the roads is also more difficult to see increasing the risk of double watering.
Caution must be taken during night watering to avoid overwatering.
Cool Conditions
Overwatering of the road during cool and overcast conditions can cause water to pool on the
road increasing the chance of road damage by vehicles using the road.
Floats
If you know that a large heavy load is to be repositioned within the pit by the float, be aware not
to over water the route that the float will be utilising. Always listen to the two-way radio and
remain alert for a change in pit tasks and conditions.
Spray Usage
You need to be familiar with each spray location and its spread capacity.
Utilising too many sprays in the wrong areas and at the wrong speed increases the possibility of
overwatering.
Determine what is required to control dust, allowing for the different geological materials utilised
in the construction of the roads, the road surface conditions, weather conditions and equipment
utilisation in the area.
Intersections and Crests of Ramps

Watering through areas such as at stop signs, give way signs, intersections and the crest of
ramps or any area that vehicles may be required to slow down or stop, must be avoided.
Turn the sprays off at least a truck length before these areas. The vehicle tyres of the road
traffic should spread enough water over these areas to avoid dust.
Ensure that road users in these areas are informed of the watering for safety reasons.
Refer to site procedures for special watering requirements in these areas when under extreme
conditions, e.g. very high temperatures.
Note : Never leave the sprays activated when stopping at intersections as this causes spot
flooding and erosion.
4.1.3 Under Watering

When watering, it is crucial to apply the correct amount of water to control the dust. Under
watering issues include:
 Increased dust emissions
 Decreased road stability
 Causing blowouts in the road surface
 Causing unsafe road conditions
4.2 Filling the Truck’s Water Tank

Use the following procedure for the water tank filling process.
1. Slowly approach the tank filling point.
The area will often be wet and muddy. Take care not to slip when walking around and drive
slowly to avoid digging up the ground with the truck’s tyres and to minimise further spillage.
2. Position the water truck’s tank filling chute accurately under the standpipe to avoid water
spillage during the filling process.
The water truck tank is filled through a hatch on top of the tank.
This example of a truck’s tank filling chute is on the tank of a modified haul truck.
3. When in position, apply the truck’s park up procedures.

Turn off the headlights if filling on nightshift.
4. Check the water level on the gauge in the operator cabin.
The water tanks on the trucks have capacities up to of 70,000 litres. Estimate the amount
of water required to fill the tank by checking the level gauge.
5. Turn on the water storage tank pump to fill the water tank.
Fill the tank to at least 30% to ensure that air is purged from the suction line.
Different filling points take different amounts of time to fill the tank. Monitor the amount of
water being pumped to the tank to prevent an overflow.
Allowing the tank to overfill creates slippery and unsafe areas on both the truck and the
ground area.
6. When dismounting the truck and operating the valve, watch your footing and beware of
slippery areas, puddles and mud.
7. Sound the horn twice to indicate leaving the filling bay and re-enter the roadway carefully.
8. Go slowly around bends and corners with a full tank to avoid water spillage from the filling
chute.
4.3 Watering Controls and Functions

Most bulk water trucks of any type have all or most or an equivalent function to those described
in the following table.
4.3.1 Controls in the Truck’s Cabin

The following photo shows some of the typical water spraying controls in the truck’s cabin.
Item Function and Operation
Batter Spray Toggle Switch Activates the Batter spray on the side of the truck, if fitted
Dribble Bar Button Activates water from the Dribble bar
Allows water to dribble out of the spray heads
Fog Button Activates the water cannon Fog spray function
Jet Button Activates the water cannon Jet spray function
Monitor OFF / Monitor ON Turns off the water cannon spray jet or overrides the water
Override Toggle Switch cannon activation function
The override maintains an open value for continuous water
flow through the cannon
Monitor On Button Activates the water cannon spray jet
Pulse Continuous Button Causes the water pump to operate intermittently
For use during uphill and downhill Watering operations to help
prevent overwatering
Pump Speed Dial Controls the water pressure to the outlets
Spray Pump Speed Control Sets the speed of the vehicle’s spray pump
Engine speed affects the pump speed
Spray Valve Buttons Activates the various spray heads for the water pattern
required
The number and positions of the spray valves on the bar is
identical to the layout of the spray controls on the panel
Tank Lights Typically located on both sides, rear and on top of the water
tank to assist with night operations, e.g. spraying and filling
the tank
Water and Detergent Sprays Activates the vehicle’s rear mounted left, right and centre
spray functions and arms the vehicle’s front mounted fire
hose reel with detergent, if fitted
Water Cannon Has an instinctive joystick control for directing the spray
Water Level Display Indicates the current water level in the tank – instrument types
vary
Water Pump Button Activate the water pump to obtain water pressure for the
spray bar, water cannon and auxiliary connections, e.g. hoses
Do not exceed the recommended engine revs for driving
the pump and do not allow the water pump to operate
without water
To avoid pressure build up ensure at least one spray
valve or the water cannon valve is open before activating
the water pump
Water Pump Override Button When the water tank level drops to a pre-set level the Water
Pump also stops
This function overrides the pre-set level and enables the
remaining water to be pumped out – this function is used for
maintenance purposes only
4.3.2 External Remote Controls
Remote (external) water Control the pump pressure at ground level

pump throttle lever The truck must be park with the brakes applied before the
throttle is activated
Water Hose Outlet Valve Controls water flow to the fire hose/s
Lever
4.3.3 Using the Spray Bar
4.3.3.1 Overview
Dust is minimised on roads and work areas by spraying water or a water based dust
suppressant through the nozzles on the spray bar mounted on the rear of the truck. The
spraying controls are typically located in a module on or near the console in the cabin.
Each spray nozzle is fully adjustable to suit spray direction and water volume. An adjustable
collar around the spray nozzle can be loosened and turned to a number (e.g. 4mm gap) position
for winter conditions (less water) or a number (e.g. 6mm gap) for summer conditions (more
water).
The spray nozzles are electronically controlled from the Operator’s position and air pressure is
used to activate the valves.
The Water Pump supplies high water pressure to the spray nozzles and is driven by the Water
truck’s hydraulic oil pump. The hydraulic oil is directed through the water tank to assist in
cooling.
4.3.3.2 Operating Procedure

Use the following procedures to operate the spray system.
1. Ensure that there are no vehicles or personnel behind the truck before activating the spray
system.
2. Open a spray valve to avoid a build-up of pressure in the system.
3. Activate the main water pump.
4. User the spray system controls to configure the spray pattern required.
All spray valves are activated individually or collectively to suit requirements by pressing
the corresponding button/s on the spray control panel. Each button lights up when the
corresponding spray nozzle is activated.
5. Monitor the water tank level.
6. When the spraying operation has been completed, turn off the pump and refill the tank as
necessary.
The following photo and diagram illustrates a full spray pattern from the rear spray bar.
Spray Pattern
4.3.3.3 Spot / Patch Spraying

This is the preferred method of spraying haul roads and is achieved by placing the sprays on
pulse or by manually turning the sprays on and off.
The patch affect is achieved by spraying in 20 to 50-metre lengths.
The advantages of spot / patch spraying are:
1. Haul truck Operators can maintain control throughout their production cycles
2. Less time needed for road maintenance and repair
3. Smoother travel for all pit users
4. Less time spent refilling under the water stands for water truck Operators
Follow up return spraying is completed in reverse to help ensure consistency.

The following photo shows and example of spot or patch spraying.
4.3.4 Using the Water Cannon
4.3.4.1 Operating the Water Cannon from the Truck’s Cabin

The water cannon is used to direct water jets or sprays for fire fighting, hosing down pit walls
and other auxiliary functions. The water cannon can be operated from the Operator’s cabin or
by using ground level controls.
Example of an In-Cabin Control Panel
The following procedure is used to start and control water cannon operations from the Operator
cabin.
1. Position the truck correctly for the watering function required.
If watering a pit wall, the truck is mobile during the watering.
If using the water cannon for a fire or cleaning, park the truck in an appropriate position,
place the transmission in neutral and set the park brake.
If washing down plant and equipment, do not spray directly onto windows, electrical
equipment and engines.
2. The water cannon is typically held in position by two locking devices – horizontal and
vertical. A third lever halfway down the standpipe turns on the water. All the locks must be
released before use.
3. Ensure the sprays are turned off.
4. Open the water cannon valve to avoid a build-up of pressure in the system.
5. Start the main water pump, checking that the pump is armed.
6. Start the water cannon pump to activate the water cannon.
7. Adjust the pump speed dial on the spray control panel
If the pump speed dial is set to maximum, the water cannon operates at about 80%
capacity with the engine idling.
8. Select the nozzle pattern required, i.e. jet or fog.
9. Use the joystick to aim the cannon.
10. Control the pump pressure by pressing the accelerator pedal.
11. When the operation has finished, check the tank level and replenish as necessary.
4.3.4.2 Operating the Water Cannon at Ground Level

Example of the Ground Level Remote Throttle
The following procedure is used to start water cannon operations and use the remote throttle at
ground level to control the flow.
2. The water cannon is typically held in position by two locking devices – horizontal and
vertical. A third lever halfway down the standpipe turns on the water. All the locks must be
released before use.
3. Ensure the sprays are turned off.
4. Open the water cannon valve to avoid a build-up of pressure in the system.
6. Start the water cannon pump to activate the water cannon.
7. Adjust the pump speed dial on the spray control panel
If the pump speed dial is set on the maximum, the water cannon operates at about 80%
capacity with the engine idling.
8. Select the nozzle pattern required, i.e. jet or fog.
9. Use the joystick to aim the cannon.
10. Arm the remote throttle using the remote throttle lever in the cabin.
The remote throttle will only work if the park brake is engaged.
11. Open the remote throttle control box to access the throttle.
12. Control the water pressure by moving the hand throttle lever.
13. When the operation has finished, return the remote throttle lever to the neutral position.
14. Disarm the remote throttle.
15. Check the tank level and replenish as necessary.
4.3.5 Hose Operations

The hose reel/s can be used to control and extinguish fires and wash equipment and
installations.
Example of the Hose Fittings mounted on Water Trucks
The following procedure is used to operate the reels and hoses.

3. Turn on the fire reel valves.
4. Arm the remote throttle.
5. Unwind the hose and apply the water flow.
6. Control the water pressure using the remote throttle.
7. When the operation has finished, return the remote throttle lever to the neutral position.
8. Disarm the remote throttle.
9. Check the tank level and replenish as necessary.
4.4 Watering Operations
4.4.1 Overview
All personnel on site have a responsibility to monitor dust conditions.
If dust suppression is required, personnel must notify their Supervisor where and when dust
suppression is needed. The Supervisor is then responsible for directing the water truck Operator
to the required area to apply the water.
The following photos show a typical example of watering a haul road.
Water truck Operator’s must ensure that water is not wasted. Specific care is to be taken during
filling of the water tank to ensure minimal spillage.
The Supervisor can authorise unused roads to be watered thoroughly.
When watering a new run into the pit area, the Operator starts watering on a flat area first to
make everybody aware that there is a watering operation in the area.
Never begin watering at the top of a ramp or on corners.
Ramps and corners must be spot watered. A minimum of one truck length must be maintained
between spotting of water to provide Operators with a dry zone to apply the brakes firmly
without losing traction.
On the next run into the pit, water the sections that were not watered in the last run. This
suppresses the dust sufficiently without causing the ramp to be slippery.
Operators may also be required to assist in emergency situations. In this instance follow the
directions of your Supervisor or the Emergency Response Coordinator.
4.4.2 Watering Haul Roads and Benches

Ideally, the haul road has a damp under surface with minimal evidence of water on the surface.
The road should be damp enough so that just a light puff of dust comes off the tyres of a truck.
This can be difficult to achieve, especially at night.
There are four main areas of control for which the Operator must ensure that the correct amount
of water is being applied.
These are:
 Spray selection
 Pump speed control
 Pulse or continuous function
 Ground speed
Correct manipulation of these four elements can maintain an acceptable level of water
application.
Select the spray heads required and the appropriate ground speed to achieve the desired
watering affect.
The following illustration shows some of the possible spray patterns for laying down the correct
volume of water for the road conditions.
Various Water Spray Patterns
Monitor the condition of the road in front of the Water truck and if it is still damp or no dust is
coming off the tyres of other vehicles, stop watering. This practice also saves the water for
where it is really needed and reduces the filling frequency.
When dealing with dry haul roads, make two passes using a lighter spray rather than one heavy
application. This will allow the water to absorb into the road.
Remember to avoid excessive watering as this creates a muddy surface, which when dry,
breaks up faster adding to the dust problem.
Do not apply water to current road works or operating Graders unless specifically instructed.
4.4.3 Watering Ramps
4.4.3.1 Ramp Slopes

Take extra care to avoid spraying excess water on ramps and inclines. In general, less water
should be used on ramps than on haul roads.
Too much water results in loss of traction for haul trucks and other vehicles climbing the ramp
and reduced braking capabilities as they travel down the ramp.
Start watering ramps before the crest to indicate to equipment Operators that the ramp has
been watered.
The down ramp side must be intermittently sprayed at a ratio of 1 to 2, i.e. 1 wet and 2 dry. This
means that if you spray for 10 metres, leave the next 20 metres dry by turning the sprays off
and on as the truck travels down the ramp. This results in dry and wet sections so that haul
truck Operators are provided with a surface for braking and if necessary for having more control
over skids and slides.
Water ramps travelling downhill wherever possible at normal travel speed to avoid water run-off.
If it is necessary to water uphill use fine sprays only.
On ramps that are known to be slippery, use an intermittent spray pattern making sure you
leave adequate dry areas between spray patterns to reduce the risk of slippage. Use the pulse
function or manually control the application of the water by turning the pump on and off.
The following photograph illustrates the spray patterns for the up and down directions on a
ramp.
On slippery ramps, where possible, keep the outside edges dry.

The centre of the road tends to stay wet longer due to overlapping sprays – adjust spray
controls to keep water off these areas.
Reduce the volume of water being applied when the truck slows down on ramps.
4.4.3.2 Bottom of Ramps

The bottom of a ramp where it turns a corner is the most likely section for an accident to occur if
excess water has been applied to the road.
At ramp corners adjust the water spread so that only half of the roadway is sprayed, e.g. half of
the left hand road surface where the units drive when going down ramp.
Spraying half of the road allows following vehicles to drive with one set of wheels on dry surface
and the other on a wet surface.
The approaches to any corner are to be watered to indicate that the corner area has been
watered. Take extra care not to overwatering fantails and corners.
4.4.4 Watering Pit Walls

Loose rocks on pit walls and at the crest of digging faces often remain after the digging unit has
finished digging. This material must be dislodged because it is a major hazard.
Use the cannon jet to dislodge the loose material on a high wall, stockpile or pit walls.
Use the following procedures for watering a pit wall.
1. Position the water truck at a safe distance from the wall, out of the range of falling rocks or
slumps.
2. Start at the top of the wall and work down, dislodging the loose material.
3. Blast the face at maximum pressure from the cannon.
4. Notify the OCE or Shift Supervisor to inspect when the job has been completed to ensure
that the wall is clear of loose debris.
4.4.5 Watering Stockpiles

Traffic building up and moving continually over stockpiles, causes stockpiles to eventually
become dusty.
To help suppress dust from stockpiles (e.g. coal dust) the water truck sprays the stockpile at
regular intervals to ensure that working conditions are more comfortable for the grader / dozer
Operators.
When the loader and trucks are hauling from the Run of Mine (ROM) stockpiles the hauling
circuit is to be kept lightly watered.
The Run of Mine refers to the ore stockpiles on or near the crusher pad. This material is used to
feed the crusher during downtimes caused by, e.g. inclement weather and digger breakdowns.
4.4.6 Watering Faces

Water trucks are sometimes used to water down digging faces where excessive dust is being
produced during excavation.
Use the following procedures for watering a face.
1. Position the water truck at a safe distance away from falling debris and the digging unit,
following the instructions of the digging unit Operator.
2. Stand off from the toe of the wall and to one side.
Do not water down the face from directly in front.
3. Aim the water cannon where directed by the digging unit Operator.
Warning : Remain constantly alert for falling debris and the location of the digging unit bucket
when wetting down dig faces.
4.4.7 Watering Shovels, Excavators and Loader Work Areas

When the grader Operator requires water, always communicate with the grader Operator and
gain a clear understanding of what is required before you begin watering.
If there is more than one water truck being utilised around the pit, be aware of overwatering and
ensure communication remains open.
Look for the approach and line-up routes that the haul trucks are using and water along these
routes. If you are not sure ask if the benches need water in particular areas.
You must observe the demarcations (e.g. 35-metre radius exclusion zone) and get positive
clearance to approach from the Operator of the equipment.
Make all communications clear and use call signs / equipment Id to avoid confusion.
Watch for haul trucks pulling out and do not drive too close or directly behind the loading unit,
unless given permission from the Operator.
4.4.8 Watering Dumps

Water along the windrow contour of the available dump area, which is usually the route the
trucks will take to the spotter.
Spray some water over the windrow, if required.
Put extra water around the area where the trucks are tipping.
4.4.9 Watering Access Roads

Water access roads and park-up areas only as needed or when instructed.
An escort is required when watering these areas.
4.4.10 Servicing Drill Rigs

Use the following general guidelines for servicing drill rigs and refer to your site’s procedures for
specific requirements.
Servicing drill rigs involves filling the drill rig’s water tank with a hose connected to the auxiliary
water outlet on the water truck.
Filling the drill rig’s water tank is a two-man operation because it involves hose transportation
and connection, spotting of the water truck if it needs to reverse and road blocks if the drill rig
has to be filled from an active haul road.
Use the following procedure to fill the drill rigs water tank.
1. Obtain permission from the drill rig Operator before entering the drill work area.
2. Approach the drill rig from the cabin side, if possible, and follow the signals of the drill rig
Operator to position the water truck.
The water truck Operator must remain in the cabin at all times when on the pattern so that
full control of the water truck is maintained.
3. The drill rig Operator must remain in clear vision of the water truck Operator until the park
brake is applied.
4. The drill rig and water truck Operator’s attach their restricted operations tag to the
equipment.
5. The drill rig Operator places two wheel chocks at the front wheels of the water truck.
6. The drill rig Operator attaches the hose from the drill rig to the water truck and opens the
valves.
7. The drill rig Operator stands clear and in vision of the water truck Operator signalling that it
is safe to start filling.
8. The water truck Operator starts filling the drill rig.
9. When the tank is full, the drill rig Operator signals the water truck Operator to stop the flow.
10. The drill rig Operator:
 Turn off the valves
 Disconnects the hose
 Removes the wheel chocks and place them back into to their appropriate location
 Removes the restricted operations tags
 Signals to the water truck Operator that all is clear to leave the area.
Personnel that left the area during the filling operation contact the drill rig Operator for
permission to re-enter the drill pad.
Note : Do not reverse into position without using a spotter.
4.4.11 Cleaning and Cooling Down Equipment

Water trucks are also used to:
 Wash down equipment that has been bogged or has a large build-up of material
 Wash down various types of plant and equipment in preparation for maintenance
 Wash information and safety signs that have become obscured by dust
 Cool down the tracks and rollers of large plant items that have trammed over long
distances, e.g. excavators
Remain in constant contact with excavator and other plant operators when cooling
down track rollers.
DO NOT spray directly onto windows, electrical equipment, engines, air-intakes or any other
aspect of the equipment that is fragile, should not be wet or cannot take high-pressure spray.
Check with the equipment Operator or maintenance personnel if you are not sure.
Warning : Check that all personnel are clear before spraying equipment.
4.4.12 Watering in Workshop and Service Areas

Service bays, workshops and other industrial buildings are busy areas. Keep the truck speed to
a maximum of 10kph and a lookout for personnel and other vehicles operating in the vicinity.
Do not spray concrete pads. Avoid spraying personnel and stationary machines in workshop
and service areas.
4.4.13 Fire Fighting
4.4.13.1 Introduction
Water trucks have important fire fighting roles at mine sites.
The water cannon is equipped with both jet and fog spray modes for directional use and low
energy fire suppression. The trucks hose lines can also be used for fire fighting.
The objective of applying water is to cool down flammable materials and smother the fire.
Warning : Do not use water on electrical equipment unless you are authorised and are sure that the
electrical power running into the fire area has been isolated.
4.4.13.2 Standard Approach

Use the following procedure if you are instructed to operate a water truck to fight a fire.
1. Your initial directions are given by the Shift Supervisor and then the Emergency Services
personnel when they arrive at the scene, if their attendance is required.
2. Position the truck upwind of the fire and with some protection for the cabin, if possible and
park at least 60 metres from the fire.
If a building is on fire, position the water truck at the corner of the building so that you can
see two sides of the building.
If the building is at least 80 metres high, the truck needs to be placed 80 metres or more
from the side.
3. Operate the spray bar / water cannon onto the fire area as directed by supervision /
emergency services.
4. Do not use a direct jet. This has the potential to spread the fire.
5. Provide water service as requested by Emergency Services personnel / Supervisor.
6. Provide extra water to fire tender, if required.
7. After fire is extinguished, provide cooling water to prevent re-ignition. Spray bar / water
cannon nozzle/s to be pointed upwards to put a spray over the affected area / building /
equipment.
4.4.13.3 Jet and Spray Functions

A jet is an unbroken high-pressure water stream. It has several advantages over fogs or sprays
for controlling and extinguishing fires.
These are:
 Greater reach than spraying or fogging
 Greater penetration power
 Less likely to disturb normal thermal layering of heat and gases
Direct the jet at the base of the fire. Sweep the cannon from side to side to contain the spread
and smother the fire. Do not concentrate on one spot as this can displace material and spread
the fire, especially if a jet is used.
A jet stream may also be useful for combating spontaneous fires in mined coal by cooling the
source of heat and depriving the combustion zone of oxygen.
Jet streams should never be used on flammable liquids, powdered materials or dust, because
these materials are easily spread and water has little or no effective on these fuels, especially
petroleum based liquids.
A fog pattern will absorb much more heat than the same volume in a jet stream and because of
its reduced direct water impact, it is ideal for combating flammable suspended material, e.g.
coal dust.
Fogs are also useful for slowing the spread of fires by removing heat from the outer margins of
the fire.
Warning : Fog will turn to steam very quickly over a fire, and will cause respiratory problems or
death if superheated steam is inhaled. Avoid applying a fog upwind of a fire.
4.4.13.4 Monitoring Fires

Do not leave a fire zone until you are sure that the fire is out, you are replaced or emergency
services personnel arrive to continue fighting the fire.
When monitoring the effectiveness of the fire-fighting operation:
 Ensure your personal safety by retreating to a safe distance from the fire, while
maintaining a good vantage point
 Remain aware of the potential for sudden fire escalation or an explosion
 Avoid inhaling smoke or fumes from the fire as these can be lethal
 Remain in constant communication with Emergency Services personnel (if in
attendance) and site Supervisors giving fire updates, as requested
 Ensure injured personnel are safe and stabilised
Administer first aid if you are qualified
 Evacuate the area if the fire escalates or the hazard potential increases, e.g. if a
vehicle tyre catches on fire
 If the fire has been extinguished, monitor the fire zone to prevent re-ignition
4.4.13.5 Re-Ignition of Fires

A fire is not extinguished until all materials in the area are cooled well below their flashpoint
temperature and ignition sources are removed.
Ensure that flare-ups due to re-ignition of flammable materials do not cause the fire to re-start.
Re-ignition of flammable materials at a fire may occur for several reasons.
These are:
 Ignition sources such as electrical arcs or open flames have not been removed
 The fire zone is still hot enough to ignite flammable gases and vapours
 Flammable fuel with a low flashpoint or ignition temperature is still available.
Prevention of re-ignition is generally performed by:

 Cooling down the fire zone and fuel sources with water spray or fog
 Smothering the fire with non-flammable material, e.g. powder, water or chemical agent
 Powder, water or chemical retardant
4.4.13.6 Fire Fighting Support Role

The fire hoses are only attached and used by a trained fire-fighting crewmember under the
direction of a crew captain.
If you are required to support a ground-based fire fighting crewmember, one of the functions
that you need to understand are the hand signals that are used when verbal communication is
not possible.
Fire Crew Hand Signals

Water on One arm raised straight over head
Raise pressure One arm straight out from the side of the body moving in an upward arc
Lower pressure One arm straight out in front of the body moving in a downward direction
Water off One arm coming from chest height straight out from the body
Section 5 Perform Post-Operational Procedures
5 Perform Post-Operational Procedures
5.1 End of Shift

The end of shift water truck checks and tasks include:
 Cleaning the cabin
 Removing any rubbish from the cabin
 Cleaning glass and mirrors
 Complete a final walk-around checking for:
 Damage
 Leaks
 Items requiring cleaning, e.g. lights, tapes, beepers, radiators and coolers
The Operator is responsible for water truck housekeeping.
5.2 Maintenance
5.2.1 Preventative Maintenance

A strict definition of preventative maintenance is, maintenance tasks conducted at regular
scheduled intervals based on average statistical and anticipated lifetime to avoid failure.
In simple terms preventative maintenance is any action taken to prolong the life of equipment
and avoid unnecessary down time.
Typically, preventative maintenance includes:
 Equipment inspections
 Lubrication
 Adjustments
 Cleaning
 Non-destructive testing
 Statistical recording
 Fault reporting
 Minor replacements
Effective preventative maintenance programs are the result of a well-organised and carefully
executed effort among operational and maintenance personnel.
All preventative maintenance activities are to be conducted according to the site’s safety
guidelines and the equipment’s prescribed maintenance schedules.
Regular walk-around inspections are an important part of the site preventative maintenance
program.
The benefits of a comprehensive walk-around inspection include:
 Fewer equipment failures and emergency breakdowns
 More planned work completed
 Reduced labour costs and better labour utilisation
 Extended equipment life
 Improved equipment operation
 Less downtime and maximised production output
 Generally reduced maintenance costs
 Increased operational safety
 Decrease in unexpected breakdowns
This diagram illustrates the benefits of a proactive approach to maintenance by reacting

immediately to small problems before they become major repair issues.
5.2.2 Defect Reporting

Defects or faults are occasionally identified during walk-around checks or other inspection
activities. If a defect results in the equipment assessed as unsafe to operate, you must attach
an Out of Service tag to the appropriate location on the equipment to ensure that it is not
operated.
Note : Do not attach a Personal Danger Tag to equipment requiring maintenance.
Ensure that the defect / fault is either repaired or reported by filling out a defect report and then
forwarding it to the designated maintenance area.
Section 6 Activities
5.2.3 Breakdowns
You are responsible for immediately reporting any faults or breakdowns of the water truck to
your pit control, Supervisor or appropriate maintenance personnel. Do not leave it to the next
person or until it causes an accident or further damage.
If you must leave a broken-down truck unattended, ensure that it does not cause a hazard.
Place lights or cones as necessary and leave the hazard lights on. Even if you think the problem
is obvious, leave an Out of Service tag attached to the main isolation control to make sure any
person checking the vehicle is made aware of the problem.
If the truck is likely to cause a hazard where it has broken down, you can attach an Out of
Service tag to the main isolation control without isolating the truck so the hazard lights can be
left on.
5.2.4 Fluid Levels

Fluid measuring methods include:
 Sight-glasses
 Dipsticks
 Level plugs
 Instrumentation and other devices that signal low levels via audible and / or visual
warnings
It is essential that you accurately determine the fluid levels during your walk-around inspection
and constantly monitor them via cabin instrumentation. Remember the dangers of removing the
caps for system that operate under pressure.
The characteristics of the particular fluid containers concerned determine the consequences of
fluid level problems.
The general affects of incorrect fluid levels are summarised in the following table.
Low fluid levels lower than the recommended Fluid levels higher than the recommended
minimum maximum
Component seizure Aeration and overheating

Seal damage Fluid oxidation
Reduction in heat dissipating capability Lubrication problems
Concentration of contaminant Seal damage
5.3 Refuelling
Important site safety procedures apply to the refuelling of water trucks. Always exercise caution
during the whole process.
Warning : Smoking is prohibited during refuelling operations.
Entering the Fuelling Facility

When entering and parking at the refuelling facility:
 Only enter the fuelling point when safe to do so
 Approach with caution, in first gear and at low speed
 When in the correct position, put the transmission in neutral and set the park brake
 Isolate the truck
 Complete the Test and Try step procedure to ensure there are no remaining potential
sources of energy by attempt to move the steering wheel from side to side and
activating the starter to ensure it does not work
 Apply wheel chocks (if necessary)
 Move away from the truck and remain outside the footprint until the service crew have
completed the refuelling and any other required maintenance
 Remove earth strap and wind up cable, if applicable
 De-isolate truck and enter fuel quantity into dispatch – follow site procedures
After Refuelling
Perform a walk-around inspection before starting and moving the water truck.
Check for out of service, danger tags and refuelling in progress signs.
Use the relevant horn signals for starting the truck and leaving the fuel facility.
6 Activities
6.1 Section 3 Operate Bulk Water Truck Activities
Activity 1
Complete a Take 5 assessment for placing the appropriate isolation on a water truck so as to
allow a walk-around inspection inside the vehicle’s footprint.
Attach a copy of the completed Take 5 assessment to a copy of this Activities page.
Activity 2
Complete a start of shift Operator / Equipment Pre-Start Safety Inspection on a water truck at
your mine site.
Explain what you are checking and why to the Assessor as you go.
Attach a copy of the completed form to a copy of this Activities page.
Activity 3
Several less than ideal operating conditions can occur when it is necessary to change your
driving approach to maintain a safe operation of the truck. Describe what you would do and
change regarding the operation of the truck in substantial wet conditions.
Activity 4
You receive a two-way radio call from a vehicle travelling behind you. Your water truck has a full
water tank and you are advised that an inside rear tyre is almost flat and showing signs of
smoke from rubbing against the outside tyre. What procedures must you follow to manage this
situation as safely as the problem allows?
Activity 5
A. What actions must you take, or try to take if conditions permit, if your truck breaks down on
an incline?
B. Provided it is safe for you to remain in the truck, what must occur before you can leave the
truck?
Activity 6
What is the procedure for a water truck to overtake a moving haul truck?
Activity 7
It is critical when parking a water truck for it to be fundamentally stable, especially when the
water tank is full.
A. What is fundamental stability?
B. How do you achieve it?
C. How do you test it?
Activity 8
Why is it considered to be potentially dangerous to reverse a water truck and what is the single
most important thing that you can do to make it safe?
Activity 9
What are the driving and parking conditions for operating a water truck around workshops?
6.2 Section 4 Load, Haul and Distribute Water Activities
Activity 1
List three (3) things that you must ALWAYS do when operating a bulk water truck and three (3)
things that you must NEVER do when operating a bulk water truck.
Activity 2
There are many reasons why you must be careful not to overwater the mine site roads. List six
(6) potential changes to the condition of haul road surfaces if the roads are overwatered.
Activity 3
What is the technique for spraying ramps and why is this technique necessary?
Activity 4
What are the rules for watering crests and corners and why is this approach important?
Activity 5
What type of watering is used on high walls and pit walls and what is the reason for using this
type of watering?
Activity 6
What must be your first action, as a water truck operator, if you are called to assist with putting
out a fire that is suspected of being started by an electrical fault?
Activity 7
When watering mine site roads, what are the functions that you must always ensure are right for
the correct amount of water to be applied for the current road surface conditions?
6.3 Perform Post-Operational Procedures Activities
Activity 1
What is the main reason for applying good preventative maintenance practices to operating a
water truck?
Activity 2
If you identify a defect in an item of equipment that makes it unsafe to operate, what are the two
things that you must do and why?
Activity 3
What are the rules for operating a water truck in the fuel farm?

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Bulk Water Truck

3.6.7 Loss of Traction................................................................................................................. 31

4 Load, Haul and Distribute Water.......................................................................................51

5 Perform Post-Operational Procedures...............................................................................77

5.2.4 Fluid Levels....................................................................................................................... 79

1.1 Purpose of this Resource Manual

1.2 Safety Requirements

1.3 Training Requirements

1.4 Assessment Requirements

1.6 Getting Help

2.2 Bulk Water Truck Variants and Functions

Caterpillar Bulk Water Truck

This water truck is a modified haul truck with a tank fitted.

Komatsu Bulk Water Truck

This water truck is a modified haul truck with a tank fitted.

Mack Bulk Water Truck

Kenworth Bulk Water Truck

Trailer Version of a Caterpillar Water Truck

Hitachi truck with a water tank mounted in the dump body

2.3 Operating Authority

3 Operate a Bulk Water Truck

3.2 Identifying Safe Operating Practices

Monitoring the truck’s operational status includes regularly checking:

Always include safety in your operating plan by:

3.3 Identifying Personal Injury Hazards

3.4 Pre-Start Procedure

3.4.2 Driver Changeover

3.4.3 Operator’s Inspection Form

3.4.4 Walk-Around Inspection

General Under and Around the Truck

General Safety Awareness

3.5 Start Up Procedure

3.5.1 Final Pre-Start Checks

After entering the cabin:

3.5.2 Start Up Process

3.5.3 Post Start Up and Moving Off Checks

3.5.4 Continuing Checks

3.6 Emergency Procedures

3.6.1 Under Inflated and Flat Tyres

3.6.2 Tyre Failure

After the water truck has been stopped:

3.6.3 Tyre Fires

3.6.3.2 Suspect or Burning Tyres

Tyre Explosion Danger Area

3.6.4 Truck Fires

3.6.5 Loss of Steering or Brakes

3.6.6 Immobilised Water Truck

3.6.7 Loss of Traction

The three types of skidding are:

3.6.7.2 Rear Wheel Skid

3.6.7.3 Front Wheel Skid

If caused by excessive braking:

3.6.7.4 All Wheel Skid

If the truck starts to slide sideways while braking:

3.6.8 Breakdown on a Gradient

3.6.9 Water Truck Rollover

At the earliest opportunity:

3.7 Driving the Water Truck

3.7.1 Dash Indicators and Warnings