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Toolbox Talk: Safe Loader Operation

Date: [DATE] Duration: [DURATION] minutes Presenter: [PRESENTER NAME] Location: [LOCATION]

Objective

The objective of this toolbox talk is to ensure all personnel understand the correct procedures for safely loading and unloading heavy machinery, particularly excavators, to prevent accidents and injuries. By the end of this talk, participants should be able to identify hazards associated with loading operations and implement appropriate control measures.

Introduction

Loading and unloading heavy machinery such as excavators presents significant risks. Incidents during these operations can lead to serious injuries, equipment damage, and project delays. It is crucial to follow established safety protocols and guidelines to mitigate these risks. This toolbox talk will cover key safety points, hazard identification, control measures, and safe work procedures to ensure everyone understands how to perform these tasks safely.

Presenter Note: Engage the audience by asking if anyone has personal experience related to the topic.

Key Points

Level Ground: Always load and unload machinery on level and hard ground [1], [2], [3]. This provides a stable base and reduces the risk of tipping.
Ramp Conditions: Keep ramps clean and free of debris. Remove mud, dirt, water, snow, ice, grease, and oil from the undercarriage and ramps to prevent skidding [1], [2], [3].
Speed Control: Set the engine speed to LOW and the travel speed select switch to LOW (1st) speed when loading or unloading [1], [2], [3]. This ensures better control of the machine.
Attachment Use: Never use the attachment for loading and unloading the machine [1], [2], [3]. Use only the travel levers when the machine is on ramps [1], [2], [3].
Balance: Maintain balance when driving over ramp joints and be aware of abrupt changes in the center of gravity [1], [2], [3]. Travel slowly to avoid losing control.

Hazard Identification

Tipping/Rollover: Machines can tip or roll over due to uneven surfaces or incorrect loading procedures. This can result in serious injuries or fatalities [4], [5], [6], [7].
Skidding: Mud, ice, or grease on ramps can cause the machine to skid, leading to loss of control and potential accidents [1], [2], [3].
Equipment Damage: Striking the trailer bed or ramp with the arm or bucket cylinder can cause damage to the equipment [8], [9], [10].

Presenter Note: Encourage participants to share any additional hazards they've encountered.

Control Measures

Elimination: Where possible, eliminate the need for loading/unloading on slopes by choosing a level location [1], [2], [3].
Engineering Controls: Use ramps, platforms, and embankments with sufficient width, length, slope, rigidity, and strength [1], [2], [3]. Ensure the angle of the ramp to the ground is 15 degrees or less [4], [5], [6], [7].
Administrative Controls: Develop and follow a detailed loading/unloading procedure. Ensure operators are trained and competent. Use a signal person to guide the operator [3].
Personal Protective Equipment (PPE): Wear appropriate PPE, including safety boots, gloves, and high-visibility clothing.

Safe Work Procedures

Inspect the Ramp: Before loading, inspect the ramp for any damage or debris. Ensure it is securely attached to the trailer [1], [2], [3].
Chock Trailer Tires: Chock the trailer tires to prevent the trailer from moving during loading/unloading [11], [8], [9], [10].
Set Speed and Travel Straight: Set the travel speed to LOW (1st) and ensure the machine is aligned with the ramp before ascending [1], [2], [3], [11], [8], [9], [10].
Maintain Balance: When driving over the loading ramp joint areas, maintain the balance point of the machine [1], [2], [3].
Secure the Machine: Once loaded, lower the work tool, chock the tracks, and install sufficient tie-downs at several locations [12].

Presenter Note: If possible, demonstrate the safe work procedure or use visual aids.

Personal Protective Equipment (PPE) Requirements

Safety Boots: Provide foot protection against slips, trips, and falls, as well as potential crushing injuries.
Gloves: Protect hands from cuts, abrasions, and vibrations during loading and securing the machine.
High-Visibility Clothing: Ensure the operator is visible to other workers and equipment operators in the area.

[Emphasize the importance of proper PPE use and maintenance]

Real-World Example or Case Study

[Provide a detailed description of a relevant real-world scenario or case study]

[Discuss what went wrong or right, and the lessons learned]

Presenter Note: Ask participants if they can relate this example to their own experiences.

Group Discussion

Discuss the following questions:

What are the most challenging aspects of loading/unloading machinery on our site?
How can we improve communication during loading/unloading operations?
What additional safety measures can we implement to prevent accidents?

Presenter Note: Encourage active participation and facilitate the discussion.

Emergency Procedures

Stop Immediately: If the machine starts to lose control or tip, stop the machine immediately.
Evacuate: If a rollover occurs, evacuate the machine and move to a safe location.
First Aid: Provide first aid to any injured personnel.
Report: Report the incident to the supervisor and safety department immediately.

Questions and Answers

[Encourage participants to ask questions]

[Provide answers to common questions related to the topic]

Q: What do I do if the ramp is too steep?

A: Do not use the ramp. Find a safer, more level location or a different ramp with a shallower angle.

Q: How often should I inspect the ramps?

A: Inspect the ramps before each use to ensure they are in good condition and properly secured.

Q: What type of tie-downs should I use?

A: Use tie-downs that are properly rated for the weight of the machine and in good condition [13], [14], [15], [16].

Summary

Always load and unload on level ground [1], [2], [3].
Keep ramps clean and in good condition [1], [2], [3].
Use low speed and travel straight on ramps [1], [2], [3], [11], [8], [9], [10].
Secure the machine properly after loading [12].

Action Items

Review the site-specific loading/unloading procedures.
Inspect all ramps and tie-downs before use.
Report any hazards or concerns to your supervisor.

Remember: Safety First! Always follow the correct procedures when loading and unloading machinery.

Report all hazards, near-misses, and incidents to your supervisor immediately.

Safety powered by SALUS

16 source record(s)

Sources used for this answer

[1] Kobelco SK135SR-7, SK140SRLC-7, SK140SRL-7 Operation Manual (Excavators)

Page 335

Open source document

Source excerpt

## WHENUSING PLATFORM OR EMBANKMENT - 1. Make the embankment wide enough to the machine width. The angle (A) of the platform or embankment to the ground should be 15 degrees or less. - 2. Check that the embankment is sufficiently sturdy to hold the machine weight. - 3. The surface of the platform or embankment must be level to that of the trailer bed. - 4. Park the trailer properly at the required position.  ## LOADING A MACHINE WITHOUTATTACHMENT/EQUIPMENT  ## DO NOT SWING Do not swing the machine during loading and unloading the machine. It may cause the machine to tip/roll over to the counterweight side. - · When loading a machine without an attachment/ equipment, adjust the travel direction so the counterweight comes to the top of the slope.  ［ 5

[2] CAT 335 Excavator Operation and Maintenance Manual

Page 276

Open source document

Source excerpt

Illustration 467  - 8. Chock the tracks and secure the machine with tiedowns. Make sure that you use the proper rated wire cable. - Use the front towing eyes on the lower frame, the rear towing eyes on the lower frame, and the rear towing eye that is on the upper frame. - Securely fasten all loose parts and all removed parts to the trailer or to the rail car. When the engine is stopped, the swing parking brake is automatically applied. The swing brake prevents the upper structure from rotating. ## NOTICE In freezing weather, protect the cooling system with antifreeze, to the lowest outside expected temperature on the travel route. Or, drain the cooling system completely. i07785977 ## Lifting and Tying Down the Machine SMCS Code: 7000; 7500  Improper lifting and tie-down techniques can allow the load to shift or fail resulting in personal injury or property damage. Use only properly rated cables and slings with lift and tie down points provided on the machine. Keep the deck of the transport vehicle clean and use anti-slip mats on steel decks. Follow the instructions in Operation and Maintenance Manual, 'Lifting and Tying Down the Machine' for the proper technique for securing the machine. Refer to Operation and Maintenance Manual, 'Specifications' for specific weight information.  Illustration 468 The lift and tie-down film is located near the base of the boom.

[3] CAT 374F Excavator Operation and Maintenance Manual

Page 228

Open source document

Source excerpt

- 4. Position the machine so that the machine can drive straight up the loading ramps. The final drives should be toward the rear of the machine. Do not operate the control levers while the machine is on the loading ramps. - 5. When you drive over the loading ramp joint areas, maintain the balance point of the machine. - 6. Lower the work tool to the bed or to the floor of the transport machine. - 7. To prevent rolling of the machine or sudden movement of the machine, perform the following items: - · Chock both tracks. - · Install sufficient tie-downs at several locations. - · Fasten wire cables. - 8. If equipped, remove door hooks, cab bumpers, and fuel tank step as necessary. Refer to local regulations.  Illustration 341 - (1) Cover - (2) Nuts - (3) Door Hook - (A) Inside - (B) Outside - a. Remove cover (1) and nuts (2) to remove door hook (3). Illustration 342  - b. Remove any bumpers on your cab. NOTICE Do not allow the chrome surface of the bucket cylinder rod to touch any part of the trailer. Damage to the rod can occur from impact with the trailer during transport. Note: Refer to Operation and Maintenance Manual, 'Specifications'. ## Shipping a Machine that is not Completely Assembled If the machine must be shipped when the boom, stick, or counterweight is not assembled on the machine, follow the instructions in Operation and Maintenance Manual, 'Operation'.

[4] CAT 330 Excavator Operation and Maintenance Manual

Page 244

Open source document

Source excerpt

Illustration 429  - 8. Chock the tracks and secure the machine with tiedowns. Make sure that you use the proper rated wire cable. - Use the front towing eyes on the lower frame, the rear towing eyes on the lower frame, and the rear towing eye that is on the upper frame. Securely fasten all loose parts and all removed parts to the trailer or to the rail car. When the engine is stopped, the swing parking brake is automatically applied. The swing brake prevents the upper structure from rotating. ## NOTICE In freezing weather, protect the cooling system with antifreeze, to the lowest outside expected temperature on the travel route. Or, drain the cooling system completely. i07785977 ## Lifting and Tying Down the Machine SMCS Code: 7000; 7500  Improper lifting and tie-down techniques can allow the load to shift or fail resulting in personal injury or property damage. Use only properly rated cables and slings with lift and tie down points provided on the machine. Keep the deck of the transport vehicle clean and use anti-slip mats on steel decks. Follow the instructions in Operation and Maintenance Manual, 'Lifting and Tying Down the Machine' for the proper technique for securing the machine. Refer to Operation and Maintenance Manual, 'Specifications' for specific weight information. Illustration 430  The lift and tie-down film is located near the base of the boom.

[5] Kobelco SK330-10, SK250LC-10 Operation Manual

Page 288

Open source document

Source excerpt

［ ## 5.2.1 LOADING Use the following procedure. ## WHENUSING A RAMP - 1. Chock the trailer tires to prevent the trailer from moving. - 2. Use a ramp with sufficient length, width, strength and gradient. Install the ramp so its angle (A) to the ground is 15 degrees or less. - 3. Start the engine, and move down the control lock lever to the "UNLOCKED" position. - 4. On the switch panel on the gauge cluster, press the travel speed select switch to set it to the LOW (1st) speed. - 5. Make sure the machine position is aligned to the ramp before going up on the ramp, raise the dozer (if installed), and travel slowly.      When this machine is traveling up or down the ramp, fold the arm and attachment and raise the boom to avoid interference with the ramp or trailer bed, as shown in the figure. When the clearance between the ramp or the trailer bed is insufficient, the machine may abruptly lean to one side when it goes over the ramp top, and strike its arm or bucket cylinder against the trailer bed, ramp, or ground, resulting in damage to the cylinder. - 6. When the machine comes to the required position, slowly swing the upper structure 180 degrees. - 7. Lower the attachment/equipment slowly. - 8. Move the control lock lever to the "LOCKED" position. - 9. Perform cool-down operation with the engine in the low idle position, and then stop the engine and remove the starter key.

[6] Kobelco SK500XSLC-10, SK520XDLC-10 Operation Manual

Page 293

Open source document

Source excerpt

## 5.2.1 LOADING Use the following procedure. ## WHENUSING A RAMP - 1. Chock the trailer tires to prevent the trailer from moving. - 2. Use a ramp with sufficient length, width, strength and gradient. Install the ramp so its angle (A) to the ground is 15 degrees or less. - 3. Start the engine, and move down the control lock lever to the "UNLOCKED" position. - 4. On the switch panel on the gauge cluster, press the travel speed select switch to set it to the LOW (1st) speed. - 5. Make sure the machine position is aligned to the ramp before going up on the ramp, raise the dozer (if installed), and travel slowly.  ［     When this machine is traveling up or down the ramp, fold the arm and attachment and raise the boom to avoid interference with the ramp or trailer bed, as shown in the figure. When the clearance between the ramp or the trailer bed is insufficient, the machine may abruptly lean to one side when it goes over the ramp top, and strike its arm or bucket cylinder against the trailer bed, ramp, or ground, resulting in damage to the cylinder. - 6. When the machine comes to the required position, slowly swing the upper structure 180 degrees. - 7. Lower the attachment/equipment slowly. - 8. Move the control lock lever to the "LOCKED" position. - 9. Perform cool-down operation with the engine in the low idle position, and then stop the engine and remove the starter key.  5

[7] Kobelco SK200-10, SK210LC-10 Operation Manual

Page 320

Open source document

Source excerpt

## 5.2 LOADING/UNLOADING THE MACHINE   Loading/unloading the machine - · Load/unload the machine on a level and hard ground. - · Use ramps, platforms, and embankment with sufficient width, length, slope, rigidity, and strength. - · Remove mud and dirt of the undercarriage to prevent the machine from skidding on the ramp. In addition, remove any deposit on the ramp including water, snow, ice, grease, and oil. - · When loading or unloading the machine, set engine speed to LOW and travel speed select switch to LOW (1st) speed. - · Do not use the attachment for loading and unloading the machine to avoid danger. - · Use only the travel levers when the machine is on ramps. - · When going over the ramp top to/from a trailer, the machine may lose balance due to an abrupt change in the center of gravity. Be sure to travel slowly. - · Be sure to turn the auto acceleration switch to the "OFF" position. When the machine is operated with the auto acceleration turned to the "ON" position, the engine speed may change abruptly. - · Do not make a turn on the ramp to avoid tipping. Make a turn after returning to the ground or the trailer bed. - · When the machine is going down a slope or being loaded on or unloaded from the trailer, set the LOW (1st)/ HIGH (2nd) travel speed select switch to LOW. - Since the LOW (1st)/HIGH (2nd) automatic travel speed select switching system automatically changes the traveling speed, it may adversely affect machine control when the machine is going down a slope or being loaded on or unloaded from the trailer. This abrupt change of machine control may cause severe accidents.

[8] Kobelco SK135SR-7, SK140SRLC-7, SK140SRL-7 Operation Manual (Excavators)

Page 333

Open source document

Source excerpt

[9] Kobelco SK200-10, SK210LC-10 Operation Manual

Page 321

Open source document

Source excerpt

## 5.2.1 LOADING Use the following procedure. ## WHENUSING A RAMP - 1. Chock the trailer tires to prevent the trailer from moving. - 2. Use a ramp with sufficient length, width, strength and gradient. Install the ramp so its angle (A) to the ground is 15 degrees or less. - 3. Start the engine, and move down the control lock lever to the "UNLOCKED" position. - 4. On the switch panel on the gauge cluster, press the travel speed select switch to set it to the LOW (1st) speed. - 5. Make sure the machine position is aligned to the ramp before going up on the ramp, raise the dozer (if installed), and travel slowly. ［     When this machine is traveling up or down the ramp, fold the arm and attachment and raise the boom to avoid interference with the ramp or trailer bed, as shown in the figure. When the clearance between the ramp or the trailer bed is insufficient, the machine may abruptly lean to one side when it goes over the ramp top, and strike its arm or bucket cylinder against the trailer bed, ramp, or ground, resulting in damage to the cylinder. - 6. When the machine comes to the required position, slowly swing the upper structure 180 degrees. - 7. Lower the attachment/equipment slowly. - 8. Move the control lock lever to the "LOCKED" position. - 9. Perform cool-down operation with the engine in the low idle position, and then stop the engine and remove the starter key.   5

[10] CAT 325 Excavator Operation and Maintenance Manual

Page 268

Open source document

Source excerpt

Illustration 438  - 8. Chock the tracks and secure the machine with tiedowns. Make sure that you use the proper rated wire cable. - Use the front towing eyes on the lower frame, the rear towing eyes on the lower frame, and the rear towing eye that is on the upper frame. Securely fasten all loose parts and all removed parts to the trailer or to the rail car. When the engine is stopped, the swing parking brake is automatically applied. The swing brake prevents the upper structure from rotating. ## NOTICE In freezing weather, protect the cooling system with antifreeze, to the lowest outside expected temperature on the travel route. Or, drain the cooling system completely. i07956081 ## Lifting and Tying Down the Machine SMCS Code: 7000; 7500  Improper lifting and tie-down techniques can allow the load to shift or fail resulting in personal injury or property damage. Use only properly rated cables and slings with lift and tie down points provided on the machine. Keep the deck of the transport vehicle clean and use anti-slip mats on steel decks. Follow the instructions in Operation and Maintenance Manual, 'Lifting and Tying Down the Machine' for the proper technique for securing the machine. Refer to Operation and Maintenance Manual, 'Specifications' for specific weight information. Illustration 439  The lift and tie-down film is located near the base of the boom.

[11] Kobelco SK135SR-7, SK140SRLC-7, SK140SRL-7 Operation Manual (Excavators)

Page 334

Open source document

Source excerpt

［ ## 5.2.1 LOADING Use the following procedure. ## WHENUSING A RAMP - 1. Chock the trailer tires to prevent the trailer from moving. - 2. Use a ramp with sufficient length, width, strength and gradient. Install the ramp so its angle (A) to the ground is 15 degrees or less. - 3. Start the engine, and move down the control lock lever to the "UNLOCKED" position. - 4. On the switch box, press the travel speed select switch to set it to the LOW (1st) speed. - 5. Make sure the machine position is aligned to the ramp before going up on the ramp, raise the dozer (if installed), and travel slowly.      When this machine is traveling up or down the ramp, fold the arm and attachment and raise the boom to avoid interference with the ramp or trailer bed, as shown in the figure. When the clearance between the ramp or the trailer bed is insufficient, the machine may abruptly lean to one side when it goes over the ramp top, and strike its arm or bucket cylinder against the trailer bed, ramp, or ground, resulting in damage to the cylinder. - 6. When the machine comes to the required position, slowly swing the upper structure 180 degrees. - 7. Lower the attachment/equipment slowly. - 8. Move the control lock lever to the "LOCKED" position. - 9. Stop the engine and remove the starter key. - 10. Lock the lock devices such as guards and doors.

[12] Kobelco SK330-10, SK250LC-10 Operation Manual

Page 289

Open source document

Source excerpt

- 10. Lock the lock devices such as guards and doors. ## WHENUSING PLATFORM OR EMBANKMENT - 1. Make the embankment wide enough to the machine width. The angle (A) of the platform or embankment to the ground should be 15 degrees or less. - 2. Check that the embankment is sufficiently sturdy to hold the machine weight. - 3. The surface of the platform or embankment must be level to that of the trailer bed. - 4. Park the trailer properly at the required position.  ## LOADING A MACHINE WITHOUTATTACHMENT/EQUIPMENT  ## DO NOT SWING Do not swing the machine during loading and unloading the machine. It may cause the machine to tip/roll over to the counterweight side. - · When loading a machine without an attachment/ equipment, adjust the travel direction so the counterweight comes to the top of the slope.  ［ 5

[13] Kobelco SK200-10, SK210LC-10 Operation Manual

Page 322

Open source document

Source excerpt

［ - 10. Lock the lock devices such as guards and doors. ## WHENUSING PLATFORM OR EMBANKMENT - 1. Make the embankment wide enough to the machine width. The angle (A) of the platform or embankment to the ground should be 15 degrees or less. - 2. Check that the embankment is sufficiently sturdy to hold the machine weight. - 3. The surface of the platform or embankment must be level to that of the trailer bed. - 4. Park the trailer properly at the required position.  ## LOADING A MACHINE WITHOUTATTACHMENT/EQUIPMENT  ## DO NOT SWING Do not swing the machine during loading and unloading the machine. It may cause the machine to tip/roll over to the counterweight side. - · When loading a machine without an attachment/ equipment, adjust the travel direction so the counterweight comes to the top of the slope.  ［

[14] CAT 330 GC Excavator Operation and Maintenance Manual

Page 230

Open source document

Source excerpt

Illustration 431  - 8. Chock the tracks and secure the machine with tiedowns. Make sure that you use the proper rated wire cable. - Use the front towing eyes on the lower frame, the rear towing eyes on the lower frame, and the rear towing eye that is on the upper frame. - Securely fasten all loose parts and all removed parts to the trailer or to the rail car. When the engine is stopped, the swing parking brake is automatically applied. The swing brake prevents the upper structure from rotating. ## NOTICE In freezing weather, protect the cooling system with antifreeze, to the lowest outside expected temperature on the travel route. Or, drain the cooling system completely. i07785977 ## Lifting and Tying Down the Machine SMCS Code: 7000; 7500  Improper lifting and tie-down techniques can allow the load to shift or fail resulting in personal injury or property damage. Use only properly rated cables and slings with lift and tie down points provided on the machine. Keep the deck of the transport vehicle clean and use anti-slip mats on steel decks. Follow the instructions in Operation and Maintenance Manual, 'Lifting and Tying Down the Machine' for the proper technique for securing the machine. Refer to Operation and Maintenance Manual, 'Specifications' for specific weight information. Illustration 432  The lift and tie-down film is located near the base of the boom.

[15] Kobelco SK500XSLC-10, SK520XDLC-10 Operation Manual

Page 292

Open source document

Source excerpt

[16] Kobelco SK500XSLC-10, SK520XDLC-10 Operation Manual

Page 294

Open source document

Source excerpt

Publication receipt

Publisher: SALUS
Final reviewer: Francis Langlois
Original answer: May 13, 2025

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Topics

Emergency response Equipment safety Hazard assessment Incident management Personal protective equipment Safety training

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Rosie's answer

Toolbox Talk: Safe Loader Operation

Objective

Introduction

Key Points

Hazard Identification

Control Measures

Safe Work Procedures

Personal Protective Equipment (PPE) Requirements

Real-World Example or Case Study

Group Discussion

Emergency Procedures

Questions and Answers

Summary

Action Items

Sources used for this answer

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