Safety Features Required in Tippers & Trucks in Mines – DGMS Guidelines + 25 MCQs

🧾 DETAILED NOTES

1️⃣ Introduction

Tippers, dumpers, and trucks are extensively used in opencast mines for haulage of coal, overburden, and minerals. These machines are involved in the highest number of fatal accidents due to blind spots, brake failures, and reversing accidents. DGMS mandates several critical safety features to ensure safe operation.

2️⃣ Mandatory Safety Features for Tippers/Trucks

Braking & Steering: Dual-line service brakes, Parking brakes with fail-safe capacity, Emergency braking system, Power steering with backup.
Visibility & Blind Spot Elimination: Rear-view camera with in-cab monitor, Proximity warning system (PWS), Rear-view and Blind spot mirrors, High-mounted LED tail lamps.
Audio-Visual Safety: Reverse alarm (audible), Flashing beacon light, Turn indicators & hazard lights, Two-stage horn.
Structural Safety: ROPS / FOPS cabin structure, Ladder with handrail, Non-skid steps, Safe cabin access.
Fire Safety: Engine compartment fire suppression system, 2× DCP extinguishers, Exhaust pipe heat guard, Fire-proof wiring.
Tyre & Wheel Safety: Tyre pressure monitoring system (TPMS), Safety circlips, Proper wheel chock system.
Dump Body Safety: Body raised indicator, Tailgate locking mechanism, Hydraulic hose burst protection, Overload warning system.
Speed & Stability: Speed governor (DGMS standard), Gradient control, Exhaust brake, Retarder system.

3️⃣ Preventive Maintenance Requirements

Daily pre-start checklist.
Periodic brake testing.
Steering inspection.
Tyre inspection for cuts & bulges.
Regular servicing and record maintenance as per DGMS norms.
Competent fitter certification.

4️⃣ Operator Safety Requirements

Training in simulator/VR, Annual refresher training, Strict wearing of seat belt, No mobile phone usage, Pre-operational inspection, Use of designated haul roads only.

5️⃣ Haul Road Safety (Indirect Requirements)

Proper gradient (≤ 1 in 16), Berm height ≥ ½ wheel diameter, Water sprinkling to control dust, Separate road for light vehicles, Proper signage & speed limits.

⚙️ QUICK ONE-LINERS (Revision Points)

Rear-view camera mandatory for reversing safety.
DGMS requires PWS for heavy mining trucks.
Speed governor essential for haul road safety.
DCP extinguishers must be provided in cabin.
Cabin must be ROPS/FOPS certified.
Tyre examination is crucial for preventing blowouts.
Reverse siren mandatory for night operations.
Body-up indicator prevents tipper running with raised body.
Fire suppression system required for engine compartment.
Seatbelts are compulsory for all operators.

🧠 DESCRIPTIVE Q&A

Q. Describe the safety features required to be incorporated in tippers and trucks operating in mines as per DGMS guidelines.

Answer:
Tippers and trucks must include critical safety features to avoid haulage accidents. DGMS mandates dual braking systems, power steering, reverse alarms, rear-view cameras, and proximity warning systems for improved visibility. ROPS/FOPS certified cabins, fire suppression systems, body-up indicators, and overload protection ensure mechanical and structural safety. Additional features such as speed governors, non-skid steps, hazard lights, and reflective tapes minimize risks. Regular maintenance and trained operators further ensure safe operation in mining environments.

🧮 25 MCQs (Dynamic Answers — 5 Options Each)

Q1. Rear-view camera is used to reduce:

Solution: A rear-view camera provides visibility directly behind the vehicle, an area that is otherwise a significant blind spot for operators of large trucks.

Q2. Mandatory cabin protection:

Solution: ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) are critical safety standards for cabins to protect the operator.

Q3. Reverse alarm is part of:

Solution: The reverse alarm provides an audible warning to personnel near the vehicle, complementing visual warnings.

Q4. PWS stands for:

Solution: Proximity Warning Systems use sensors (like radar or RFID) to detect nearby objects or people and alert the operator.

Q5. Body-up indicator warns:

Solution: This indicator prevents the truck from being driven with the dump body in the raised position, which can cause instability or collision with overhead structures.

Q6. Fire suppression system installed in:

Solution: The engine compartment is the primary source of fire risk due to heat and fuel, making it the critical location for suppression systems.

Q7. Speed governor ensures:

Solution: Speed governors physically limit the vehicle's top speed to ensure it stays within safe operating limits.

Q8. DCP extinguisher used for:

Solution: Dry Chemical Powder (DCP) is effective against fuel and oil fires (Class B) commonly found in engine compartments.

Q9. Non-skid steps provided for:

Solution: To prevent slips and falls while operators are climbing into or out of the high cabin, non-skid surfaces are mandatory.

Q10. ROPS protects against:

Solution: ROPS (Roll-Over Protective Structure) ensures the cabin maintains its shape and protects the operator if the vehicle overturns.

Q11. Tail lamp must be:

Solution: LED tail lamps are standard for their brightness, durability, and low power consumption, enhancing visibility.

Q12. Hydraulic hose burst protection is for:

Solution: If a hydraulic hose fails, check valves or burst protection sleeves prevent the dump body from dropping suddenly.

Q13. Wheel chocks used to:

Solution: Wheel chocks are physical wedges placed against tires to ensure a parked vehicle does not roll away, especially on slopes.

Q14. Hazard lights used in:

Solution: Hazard lights indicate that the vehicle is stationary in a potentially hazardous location or situation.

Q15. Tyre failures mainly due to:

Solution: Overloading puts excessive stress and heat on tires, leading to blowouts and failures.

Q16. Seat belts protect during:

Solution: Seat belts restrain the operator, preventing injury from impact or ejection during collisions or sudden stops.

Q17. Reflective tapes improve:

Solution: Reflective tapes make the vehicle's outline visible to others in low-light conditions.

Q18. Overload warning system prevents:

Solution: By alerting operators to excessive weight, these systems prevent structural damage and instability.

Q19. Steering backup required for:

Solution: Backup (emergency) steering allows control if the main engine or hydraulic pump fails.

Q20. Exhaust brake helps during:

Solution: Exhaust brakes provide retardation power, helping control speed on downhill grades without overheating service brakes.

Q21. Dump body lock prevents:

Solution: A locking mechanism ensures the dump body stays secured in the down position during travel.

Q22. Camera system works with:

Solution: The camera feeds video to a monitor inside the cabin for the operator to see.

Q23. Fire extinguisher required:

Solution: DGMS guidelines typically specify carrying two Dry Chemical Powder (DCP) extinguishers for redundancy.

Q24. Reverse siren must activate when:

Solution: The siren is linked to the reverse gear to automatically warn people whenever the vehicle backs up.

Q25. Proximity detection helps:

Solution: Proximity systems alert the operator to nearby objects or people, directly helping to avoid collisions.

🔗 INTERNAL LINKS

Related Topic	Read More On...
HEMM Safety	Accidents Due to Dumpers and Tippers
Brake Failure	Brake & Steering Failure Accidents
Haul Roads	Haul Road Design & Safety Standards
Simulator Training	HEMM Operator Simulator Training

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