1. General Hazards and Controls
General Hazard/Risk
A1. User entanglement with trailer.
• Accidental entanglement.
• Entanglement of user effects (clothing, hair, ear phones etc.)
Control
A1. Incase of accidental entanglement, the following Personal Protective Equipment (PPE) is required:
• Protective eye-wear.
• Safety boots.
• Gloves.
• High visibility clothing.
• Other PPE as required by worksite.
To avoid entanglement when operating the trailer; loose hair, clothing, and personal effects should be tied-up or removed as practicable.
A2. Unintended trailer movement caused by user error.
• Incorrect operation of controls.
• Errors in judgment.
A2. To avoid user error, do not operate the trailer when:
• Fatigued.
• Unwell.
• Under the influence of drugs or alcohol, including medication. (If operating the trailer whilst on medication, a medical certificate declaring fitness to work is required).
• Unfamiliar with ESS trailer controls.
• Unfamiliar with ESS trailer operating/ risk assessment manuals.
• The familiarisation checklist has not been completed.
Only operate the trailer after you have:
• Read this document thoroughly.
• Familiarised yourself with all controls.
• Followed all instruction and warning notices (this document and the trailer plates/decals).
If an instruction or warning is unclear, seek help and explanation from someone with greater training and experience.
If the operating manual is lost, or becomes illegible (in part or whole), replace immediately.
If a plate/decal is removed or becomes illegible (in part or whole), replace immediately.
General Hazard/Risk
A3. Unintended movement of trailer caused by trailer malfunction.
• Counterbalance valve breakage.
• Hose failure on suspension circuit to the hydraulic cylinders.
Control
A3.
• Always lock suspension valves before going underneath the trailer.
• Ensure the valving is not compromised. Damaged valves need to be replaced as they can cause the hydraulic cylinders to move unexpectedly.
• Regularly inspect the trailer for hose chafing (pinch/crush) damage.
Note: Servicing should be conducted by qualified service technicians only.
A4. Fire caused by fuel or chemical ignition.
• Open flames.
• Refuling.
A4. Do not smoke or have open flames near:
• Fuel - do not refuel hot power pack engine.
• Oil.
• Batteries.
• Any other ignitable source.
Prior to refueling (and handling other flammable materials):
• Check worksite for potential sources of ignition.
• Extinguish and/or isolate all potential ignition sources as practicable.
• Refuel in a well-ventilated area.
• After refueling securely fasten all caps and clean any spillage.
Caution: Hot parts can ignite diesel. Take care to avoid spills when re-fueling the power pack.
General Hazard/Risk
A5. Fire and emergency response
Control
A5.
• Carry a fire extinguisher and first aid kit in the truck or trailer at all times.
• Familiarise yourself with the fire extinguisher instructions before trailer operation.
• Be aware of the worksite assembly points in case of unmaintainable fire.
2. General Hazards/Risk Working Procedures
B1. Unfamiliarity with site conditions or scope of work
B1. Start planning for the ESS trailer operation as early as possible. Planning should involve:
• Inspection of the site.
• Consultation with all persons involved in the work including:
• Principal contractor.
• Electricity entity.
• Employer.
• Local authorities if required.
• National authorities if required.
• Site foreman.
B2. Before starting work check the work area for the presence of:
• Pedestrian and vehicle traffic.
• Overhead power lines.
• Nearby structures.
• Aerial hazards.
• Other obstructions.
• Sub surface integrity.
Isolate the work area and prohibit vehicles/people entering by:
• Using safety cones/barriers.
• Temporary barriers.
• Fencing.
Prepare a safety plan of the surrounding hazards by consulting:
• Principle contractors.
• Supervisors.
• Other operators.
• Site tradesmen.
General Hazard/Risk
B3. Collisions resulting from:
• Turning or reversing.
• Inadequate visibility resulting from, but not limited to:
1. Dirty windows and mirrors.
2. Poor lighting.
3. Poor weather.
B4. Collisions when:
• Operating on public roads.
• Pedestrians or workers in the work area.
• Machinery or equipment in the work area.
Control
B3. When positioning the ESS trailer consider potential hazards including:
• Structures nearby.
• Obstructions from overhead.
• Other equipment.
• All traffic in the area.
Use a guide and signaling person when reversing in low-visibility conditions.
1. Keep all windows, mirrors, lights and gauge-glassware clean. (Replace if cracked/damaged).
2. If weather conditions significantly reduce visibility, cease operation until visibility improves.
3. In low-light environments, additional lighting may be required to improve visibility.
Note: Use ‘spotter(s)’’ when maneuvering the trailer in areas where a collision may occur.
B4.
When working on public roads ensure:
1. Traffic guidelines/laws are followed.
2. The work area is cordoned off using cones/barriers etc.
3. Traffic and signal personnel are used.
• Work using universal signals familiar to all parties.
• Identify communication channels prior to work starting.
• Where practicable, remove excess equipment and personnel from the work area.
General Hazard/Risk
B5. Electrocution & Electromagnetic Radiation.
• Electrocution from contact with power lines.
• Electrocution from lightning.
• Electromagnetic radiation.
Control
B5. When working near power lines electrocution can occur without contact, take the following precautions when loading/unloading:
1. Consult the local controlling electricity authority/power company to arrange a localised power cut. Alternatively move to a safe working position with relevant signing (prior to work start).
2. Consult the local controlling electricity authority/power company to gain the relevant information on safe working distances (prior to work start).
3. Ground the ESS trailer as instructed by the power authority.
Thunderstorms present a risk of lightning strike. During such conditions ensure the ESS trailer is positioned safely, take shelter until the storm passes.
• Before operating the ESS trailer near high-power electromagnetic wave emitters (such as cell phone towers, radio, television, radar etc.) consult relevant authorities to identify the safety requirements and precautions to be observed.
General Hazard/Risk
B6. Not observing instructions on warning plates could cause operation beyond limitation of plant.
Control
B6. Observe all instructions on the:
• Warning plates*
• Decals*
*Clean warning plates/decals regularly.
*Replace damaged or illegible warning plates/decals immediately.
B7. Unintentional movement from:
1. Poor signaler.
2. Poor housekeeping.
3. ESS trailer operated by more than one operator.
B7. Always work according to universal signals. Prior to work starting the following entities should be familiar and/or briefed on common signals as required:
1. Controller.
2. Signaler.
3. Other participating parties.
Note: Keep the work area around the ESS trailer clear of idle equipment as practicable.
General Hazard/Risk
B8. The ESS trailer could tip over due to:
1. Poor ground conditions such as drains.
2. Rapid lateral movement.
3. Overloading.
B9. Falls
Control
B8.
1. Avoid drains/water tables etc.
2. Avoid jerky/sudden movements while driving at high speed.
3. Always operate within the ESS trailer limitations.
B9. The ESS trailer goose-neck at the power pack is 2.6m high. This presents a fall risk. Care needs to be taken when servicing and refueling the power pack. Height safety and fall prevention equipment may be required.
B10. Spare Wheels
B10. Take care when removing the spare wheel(s). Ensure no personnel are at risk of being crushed should a wheel come loose suddenly. Use a fork-hoist or tether as required.
B11. Oils and compressed air.
B11. Always use adequate PPE when handling hydraulic oils and compressed air (gloves, eye-wear, overalls etc.):
• Compressed air can penetrate into the blood stream.
• Hydraulic oil can penetrate body parts (especially when pressurised).
B12. Environmental conditions (including wildlife).
Hazard - Pre Operation
C1. Inspections.
C2. Poor Housekeeping.
C3. ESS trailer operator’s vision obstructed.
C4. Failure of controls and/or parts of ESS trailer.
B12. Be aware of the potential for dehydration, heatstroke, and sunburn when working in direct sunlight. Be aware of the potential for hypothermia when operating in cold conditions. Inspect work area for wildlife prior to operation, especially spiders, snakes, toads etc.
Control
C1. When under or around the suspension or steering axles, lock the suspension, and ensure the power pack is disabled via the E-stop. If the power pack power source is enabled the steering will operate which may result in crush or death to any personnel in or around the trailer.
C2. Maintain a clean and tidy workspace around the ESS trailer controls.
C3. Do not attempt any steering/height adjustments if unable to clearly view work area. In such cases make use of signaling personnel.
C4. Before operating the ESS trailer:
• Conduct all pre-operational procedures and checks (includes checking the control levers).
• Ensure all tyre pressures are at the recommended pressure.
• Ensure the ESS trailer is serviced to manufacturers’ guidelines.
3. Operational Hazards & Controls
Hazard - Starting the power pack
A1. Ensure no personnel are under or near the steering axles.
Control
A1. Starting of the power pack will cause axles to steer relative to the skid plate angle. Keep personnel clear of trailer at start up. Failure to do so may result in crushing injuries (or death).
A2. Poisoning from exhaust fumes when operating indoors.
A3. Fire from spills.
A2. When operating indoors, ensure adequate ventilation with doors windows etc. Run pipe from exhaust to outside if necessary.
A3. Immediately clean up any spillage. Keep the engine compartment away from potential ignition sources.
1. After inspection and maintenance, wipe off any spilled oil or fuel.
2. Check that flammable material is not discarded/left near the engine.
A4. Operating the ESS trailer power pack when being serviced or repaired.
A4. Always turn-off the power pack for servicing and/or repairs.
A5. Collisions - people and objects.
A5. Ensure the ESS trailer is isolated from people and objects prior to operation.
A6. Crushing when opening/closing power pack main engine cover.
A6. When lifting or lowering the cover (heavy), ensure all people, fingers/limbs, and tools are clear of the pinch points.
Hazard - ESS Trailer Operation
B1. Tip over during operation from:
1. Structural failure - overloading.
2. Unstable load.
3. Side slope of ground.
4. Unsuitable ground.
B3. Loss of load from:
1. Overloading.
2. Unstable load.
3. Unsecured chains or lashings.
Control
B1.
1. Do not exceed the capacity of the ESS trailer - if unsure refer to the loading capacity specifications supplied by manufacturer.
2. Check that the load is correctly secured.
3. Ensure the ESS trailer and load do not travel beyond the center of gravity on a side slope.
4. Ensure the trailer path and unload area(s) are capable of supporting the laden trailer.
B3.
1. Ensure the load is within manufacturer specification and legal limits.
2. Check the load is correctly positioned and adequately secured (in accordance with manufacturer and legal guidelines).*
3. Note:
• Only use lashings rated for the load (or greater loads).
• Lashings should be in good working order (not fraying or split).*
• Always arrange lashings to avoid entanglement.
B4. Collision - personnel near the ESS trailer when:
• Raising/lowering the trailer.
• Lengthening/shortening the trailer.
B4.
• Ensure no personnel are underneath the ESS trailer prior to raising/ lowering.
• Keep all personnel clear of the ESS trailer when lengthening/shortening. Failure to comply may result in crush injuries or death.
B5. Steering
B6. Steering failure in travel mode.
• Accumulator Emergency Steer (AES) redundancy system
B5. Stay clear of the wheels at all times when the power pack is starting-up or running.
*Refer to local/national regulations.
B6. The ESS house trailer is equipped with an accumulator emergency steer (AES) system. This becomes active when the power pack fails/stops in travel mode.
• If a major issue is detected; an alarm is activated and the main hydraulic lines are pressurised for approx. 6 seconds, during this time the driver must pull over.
• Test the AES system every 6 months to ensure functionality (refer operators manual section on the AES system.
B7. Instability during an earthquake. B7. If an earthquake occurs during operation, stop work immediately and do the following:
• Move a safe distance from the trailer and load.
• Using the remote, lower the load to a suitable location.
• Shut down the trailer.
• Brace yourself until the earthquake stops.
Work should not resume until a full site, load and ESS trailer inspection has been conducted.
5. Inspection - Maintenance Hazards & Control
Hazard - Special Operations
A1. Failure of controls or components.
Control
A1. Never operate a damaged ESS trailer. Should an ESS trailer control or component fail, cease work immediately and have it repaired or replaced.
A2. Equipment malfunctions from incorrect adjustment/calibration.
A2 Always keep the ESS trailer well serviced, use recommended service agents to ensure the ESS trailer is operating correctly. Consult the manufacture if operational issues are relevant.
A3. Collision from a run-away ESS trailer.
A4. Unintentional operation of the ESS trailer during inspection/maintenance.
A3. When inspecting and maintaining the ESS trailer, ensure the ESS trailer is parked safely (use wheel chocks if required).
A4. Always disable the ESS trailer and lock all hydraulic suspension valves also drain the AES accumulator.
A5. Mechanical failure of the ESS trailer after repair.
A5. Use only authorised service agents to repair the ESS trailer.
A6. Hydraulic component repairs.
A6. Only qualified hydraulic technicians should be used to undertake ESS trailer hydraulic repairs.
A7. Burns from radiator and/or coolant.
A8. Mechanical failure due to:
• Contamination.
• Incorrect oils, grease, and/or filters.
A7. Take care when removing the radiator cap as pressurised coolant will spray out. If possible, wait until radiator has cooled to ambient temperature before removing cap.
A8.
• Take care to avoid contamination when topping-up/replacing; fuel, oil, or grease.
• Oils should be changed by authorised service agents using approved parts and lubricants.
A9. Environmental hazards from lubricants or fuel.
A9. Never allow oils or other contaminants to enter storm water systems, streams, rivers or wetlands.
A10. Accumulator discharge.
A10. Always drain the AES accumulator when coupling and uncoupling clip-ons Drain the AES accumulator when working on ANY hydraulic system in this trailer Isolate the Goose neck accumulator if working on ANY goose neck Hydraulics.
A11. Washing the ESS trailer.
A11. When washing the ESS trailer take the following precautions:
• Wear suitable PPE (eye wear, gloves, slip-resistant boots etc.) when using high-pressure steam/water.
• Avoid electrical equipment and brake valves when water pressure cleaning! Warning: wet electronics are prone to failure and may cause electrical shocks
A12. Falls.
A13. Inspection/maintenance with the engine running.
A12. When working at heights the following precautions should be taken:
• Walk carefully, do not run.
• Keep the work area free of trip hazards (tools, lashings, lubricant spills etc.).
• Use additional safety devices (ropes, harnesses etc.) as required.
A13. If possible, always shut the engine down when conducting inspections/ maintenance. If the engine is on, secure loose items while inspecting to avoid entanglement with moving parts.
A14. Explosion of battery, or acid burns from battery fluid.
A15. Burns from engine.
A16. Fire/explosion from exposure to naked flame.
A14. When welding or servicing the electrical system, disconnect the batteries. If welding near the battery, remove it from the trailer. Isolate the controllers by turning off the 24v isolator and keep the earth as close to the weld area as possible.
A15. Where practicable, wait for hot parts (engine/hydraulic components) to cool down before commencing maintenance.
A16. Do not use a lighter or other naked flames near flammable materials.
A17. Fire from the hydraulics.
A18. Hydraulic oil pressure.
A17. Do not apply heat (via welders etc.) to hydraulic equipment. This may lead to rupture.
A18. The oil pressure in lines can penetrate skin - extreme care should be taken. Only trained technicians are authorised to repair/service the hydraulic system.
