Safe driving instructions for pure electric wide-body mining dump trucks

Core Principles: Safety First, Prevention First. Familiarize yourself with the vehicle’s characteristics and strictly adhere to regulations.

Part I: Pre-Departure Inspection and Preparation

A comprehensive pre-departure inspection is the first line of defense for driving safety. This inspection should be carried out step by step, starting with the driver, the vehicle’s exterior and chassis, the cab interior, and finally system self-checks. Special attention should be paid to the high-voltage safety and electronic control system inspections unique to pure electric vehicles.

1.Driver Preparation

Certification Requirements: Must undergo professional training for pure electric wide-body mining dump trucks and obtain the corresponding operator qualification certificate. In-depth familiarity with the vehicle’s core characteristics and operating procedures, including the high-voltage system, electric braking principles, and energy recovery.

Physical and Mental Health: Ensure adequate sleep daily (recommended: at least 8 hours). Driving while fatigued (driving for more than 4 hours continuously), under the influence of alcohol, or after taking sedatives, hypnotic drugs, or other medications that affect mental state is strictly prohibited. Before driving, maintain mental focus and avoid emotional fluctuations that may affect operator judgment.

Standard attire: Wear work clothes that comply with mining safety standards at all times, a hard hat (the straps must be securely fastened), anti-smash and anti-puncture shoes, and a high-visibility reflective vest (ensure there are no damage or stains, and the reflective strips are clearly visible).

2.Vehicle Exterior and Chassis Inspection

High-voltage Safety (Key Points): First, confirm that the vehicle’s main power switch is “OFF” and the high-voltage service switch (if equipped) is not plugged in. Walk around the vehicle and inspect the high-voltage wiring harness for damage or loose connections. Ensure there are no residual high-voltage insulation fault alarms on the instrument panel (power off).

Vehicle Structure: Focus on inspecting key areas such as the frame welds, vehicle side panels and floor, lift bracket connection points, and hinge pins. Verify there are no cracks, deformation, loose bolts, or severe wear (wear must be within the manufacturer’s specified range).

Tires: Use a tire pressure gauge to check the tire pressure of each tire to ensure it meets the vehicle’s load requirements (tires with an empty or fully loaded tire have different pressures; refer to the manual). Inspect the tire tread for cuts, cracks, bulges, and abnormal wear (tread depth should be at least 3mm). Check the wheel hub bolts for tightness in diagonal order to prevent loosening.

Braking System:

• Visually inspect the brake lines (air and hydraulic hoses) for signs of aging, damage, or leaks (no sound of air leaking from air hoses, no oil stains from hydraulic hoses).
• Remove the brake inspection port cover and inspect the brake pads/shoes for wear (remaining thickness should be at least the manufacturer’s specified minimum), oil stains, or unusual noises.
• Start the vehicle in place (without high pressure). Test that the parking brake (handbrake) does not slide when the vehicle is engaged, and that the service brake (footbrake) pedal has normal travel and firm feedback, with no deadening or binding.
• Steering System: Inspect the steering rod, ball joint, and hydraulic cylinder for looseness, deformation, or signs of oil leakage. Turn the steering wheel to test steering force and ensure that the steering is light and smooth when unladen, and that the steering returns to center properly.
• Lighting and Signaling: Turn on the vehicle’s low-voltage power supply and check that the headlights (low and high beam), lowlights, turn signals (left and right), brake lights, and reverse lights are illuminated normally and bright enough. Test the reverse alarm for clarity and no noise. Check that the reflective markings (front, back, left, and right) are not damaged or faded, and that the dome light (safety warning light) is flashing normally.
• Cooling System: Open the coolant filler ports for the drive motor and electronic control system and check that the fluid level is between the “MIN-MAX” scale. Inspect the coolant lines and connections for leaks (no traces of coolant). Check that the cooling fan is visually intact and that the protective cover is secure.

3.Cabin Interior Inspection Before Powering On

Fire Safety: Verify that the pressure gauge on the built-in fire extinguisher (dry powder or water-based, suitable for electrical fires) is in the green, normal range and within its expiration date. The driver should physically handle the extinguisher once to ensure familiarity with the opening method and spray direction.

Operating Mechanism: Turn the steering wheel to check for normal free travel. Shift the gear lever (forward, reverse, neutral) to ensure clear and smooth shifting, without any sticking or shifting. Test the lift switch, wipers, horn, and other control switches to ensure smooth operation and accurate return.

Instrumentation and Monitoring: Wipe the interior and exterior mirrors and the cameras around the vehicle (especially the backup camera) with a clean cloth to ensure an unobstructed view and a clear image. Check the instrument panel for damage and that all indicators (power, fault, brake, etc.) are not abnormally illuminated.

Seatbelts: Stretch the seatbelts to check for damage or deterioration. The buckle should lock properly when inserted and retract smoothly when released, without any binding or looseness.

4.System Self-Test After Power-On

Turn the key to “ON” (or press the power button) and wait for the vehicle to complete the automatic test of the high-voltage system, electronic control system, and braking system (usually takes 30-60 seconds). Do not operate any controls during this time.

Pay close attention to key information on the instrument panel:

• State of Charge (SOC): Confirm that the battery level is at least 80% (if a long operation is required) to meet the route and load requirements and avoid power outages.
• High-Voltage Insulation Status: The “High-Voltage Insulation” indicator on the instrument panel is normal (green or off), with no red fault alarms.
• System Ready Indicator: The “READY” light is on (usually green), indicating that the vehicle is ready to drive.
• Air Pressure Gauge: For air brake models, confirm that the air pressure gauge reading reaches the operating pressure (usually at least 0.6 MPa) before starting. Before starting, honk the horn once or twice (each honk lasting 1-2 seconds) to warn people around the vehicle to stay clear.

Part II: Driving Safety Procedures

While driving, strictly control speed and maintain a safe distance. Take full advantage of the electric braking advantages of pure electric vehicles and avoid blind spot risks. Exercise extra caution on curves, downhill slopes, and in unusual weather conditions.

1.Starting

Before starting, reconfirm that the cabin is fully lowered and the lift mechanism is locked (the “Lift” indicator on the instrument panel is off).

Use the rearview mirror, camera, and exit the vehicle (if necessary) to ensure there are no obstacles, people, or other equipment in front, behind, or on both sides of the vehicle. Pay particular attention to areas under the wheels and in blind spots.

Slowly apply the accelerator pedal for a smooth start. Avoid sudden acceleration (keep the accelerator pedal open no more than 30%) to prevent wheel slip (especially on slippery roads) and spillage of materials inside the cabin.

2.While Driving

Speed Control: Strictly adhere to the mining area’s speed limit (generally no more than 30 km/h on main roads and 15 km/h in work areas). On downhill slopes, curves, intersections, and roads with poor visibility (such as fog and tunnels), reduce speed 50-100 meters in advance to below 10 km/h. Exceeding the speed limit is strictly prohibited.

Maintaining Clearance: Maintain a safe distance of at least three vehicle lengths from the vehicle ahead (e.g., a 10-meter vehicle length requires a minimum of 30 meters). In rainy, foggy, or icy conditions, increase the distance to at least five times. Tailgating the vehicle ahead is strictly prohibited.

Right of Way and Warnings: Obey mining area traffic regulations and give priority to emergency vehicles (such as ambulances and fire trucks). When crossing intersections, adhere to the “slow down, look, then pass” principle. Honk your horn twice in advance and confirm that there are no oncoming vehicles before crossing.

Curves and Downhills (Core Differences and Advantages):

• Utilize Electric Braking (Energy Regeneration): One of the core advantages of pure electric vehicles, activate the electric braking function in advance when going downhill (select the appropriate braking level based on the slope, such as a high level for long, steep slopes). This generates braking force by driving the motor in reverse. This effectively reduces wear and thermal decay on traditional mechanical brakes (preventing brake failure) while also recovering energy back into the battery pack, extending battery life.
• Predictive Driving: Observe the slope, length, and road conditions of the downhill slope in advance, select the appropriate gear (low) and electric braking level, and avoid sudden, slamming on the mechanical brakes mid-way through a long downhill slope.
• Coasting in neutral is strictly prohibited: Coasting in neutral cuts off the power to the electric braking system, causing the vehicle to lose its ability to slow down and lose energy recovery. This is an extremely dangerous operation!
• Merging and Overtaking: When merging, slow down to below 10 km/h, keep to the right side of the road, and maintain a safe distance of at least 2 meters from oncoming vehicles. Overtaking should be done on wide, flat, straight roads with good visibility. Honk the horn (three times in a row) and flash your headlights beforehand to signal. Only accelerate to overtake after confirming that the vehicle ahead is not slowing down or turning, and that there are no oncoming vehicles behind. After overtaking, maintain a distance of at least 50 meters from the vehicle being overtaken before returning to your original lane. Overtaking on slopes, curves, intersections, or roads with obstructed visibility is strictly prohibited.
• Blind Spots: Always be aware of your vehicle’s significant blind spots (1.5 meters in front, 3 meters behind, and 2 meters to the left and right). Check your rearview mirrors and cameras every 30 seconds while driving. Stop and check at intersections, crowded areas, or when unsure of the situation ahead. Ensure safety before proceeding.
• Rainy, foggy, and nighttime: In rainy conditions, use the windshield wipers (speed adjusted according to the amount of rain), low beam, and position lights. In foggy conditions, use the fog lights, low beam, and hazard warning flashers. Stop and wait when visibility is less than 50 meters. At night, use low beams (do not use high beams to shine directly at oncoming vehicles). Pay attention to reflective road signs, reduce speed to 60% of the daytime speed, and increase the following distance.

Part III: Safety Regulations for Loading and Unloading Areas

Loading and unloading areas are densely populated with equipment and a high flow of personnel. Strictly adhere to parking, loading, and unloading procedures to prevent risks such as slope collapse, uneven loading, and lifting accidents.

1.Approaching a Loading/Unloading Point

Slow down to below 5 km/h 50 meters in advance. Observe the hand signals of the on-site supervisor (if present). Avoid excavators, loaders, and other loading and unloading equipment. Do not drive within the operating radius of these equipment.

When approaching a slope, maintain a safe distance of at least 3 meters from the edge (adjusted based on slope height and soil stability) to prevent the slope from collapsing and causing the vehicle to roll over.

2.Parking

Following the supervisor’s instructions or designated signs, park the vehicle securely on a firm, flat surface. Apply the parking brake (maximum travel), and shift the gear to neutral (N).

Even when stopping briefly (e.g., waiting to load materials), always set the lift switch to “Park” or “Lock” to prevent the vehicle from accidentally lifting the lift button.

3.Loading

Before loading, the driver must wait in the cab or in a safe area designated by the operator (away from the operating radius of the loading and unloading equipment). Wandering around the vehicle (especially under or to the sides) is strictly prohibited to prevent materials from falling or colliding with equipment.

Observe the loader loading process and remind the operator to load evenly and avoid uneven loading (no more than 5% left to right and no more than 10% front to back) to prevent the vehicle from tipping over during operation. The loading volume must not exceed the vehicle’s rated load capacity, and overloading is strictly prohibited (overloading can increase braking distance, damage tires, and deform the frame).

4.Unloading

Verify the site: Before driving onto the unloading platform, check that the platform’s surface is firm and flat (no sinkholes or cracks) and that the platform’s load-bearing capacity meets the vehicle’s total weight (vehicle weight + load). Maintain a safe distance of 1-1.5 meters between the rear of the vehicle and the retaining wall (or the edge of the unloading area) to prevent over-reversing and causing a fall.

Ensure safety: Use the rearview mirror, rearview camera, and exit the vehicle (if necessary) to ensure there are no people or other equipment around the vehicle (especially behind it), and no personnel are located below the unloading area.

Lifting Operation:

• After re-confirming that the vehicle is stationary and the parking brake is engaged, turn the lift switch to “Lift.”
• Gently press the accelerator pedal (pedal opening no more than 20%) to control the lift compartment to lift smoothly. Ensure the “Lift” indicator on the instrument panel is operating normally and that there are no abnormal alarms.
• Lifting the vehicle compartment while in motion (lifting and moving) is strictly prohibited. Adjusting the vehicle’s position (forward, reverse, or steering) while the compartment is lifted is strictly prohibited to prevent the vehicle from becoming unbalanced and rolling over.

Lowering the Carriage:

• After unloading, check that there is no residual material adhering to the carriage (if any, clean it manually or by shaking). Then, turn the lift switch to the “lower” position and control the carriage to lower smoothly.
• Make sure the carriage is fully lowered (the “lift” indicator on the instrument panel is off and there is no “unlocked” alarm). Manually shake the carriage to confirm that it is not loose before releasing the parking brake and engaging a gear.

Part IV: Vehicle Collection and Charging Safety

After collecting the vehicle, proper parking and maintenance handover must be carried out. Charging, as a unique operation for pure electric vehicles, requires strict adherence to the principles of dedicated personnel and standardized operation to prevent the risk of high-voltage electric shock and fire.

1.Parking

Drive the vehicle to a designated parking area within the mining area. Choose a flat, firm surface free of water and flammable materials (away from sources of fire and high-voltage lines).

Engage the parking brake, shift the gear to neutral (N) or park (P), turn off all electrical devices (lights, air conditioning, fans, etc.), turn the key to “OFF” (or press the power off button), and disconnect the vehicle’s main power switch.

2.Daily Maintenance and Handover

Perform a basic cleaning of the vehicle, wiping the cab window and camera lens, and clearing any remaining material from the cabin.

Walk around the vehicle to inspect for new damage (such as scratches or dents), tire damage, and pipe leaks, focusing on any abnormalities in the high-voltage system connections.

Complete the “Vehicle Operation Record Sheet,” detailing the daily mileage, operating hours, power consumption, and any vehicle anomalies (such as alarms or unusual operating noises). Hand over the vehicle in person to the next shift driver or maintenance personnel to ensure timely feedback.

3.Charging Safety (Top Priority)

Dedicated Personnel: Charging operations must be performed by professionals trained in high-voltage safety. Unauthorized personnel are strictly prohibited from touching the charging equipment or the vehicle’s high-voltage connector.

Charging Equipment Inspection: Before charging, check that the charging station display is functioning normally and has no fault codes. Inspect the charging plug for damage, deformation, or burn marks, and the cable for aging or cracking. Verify that the charging station’s emergency stop button is functioning properly (it cuts off power when pressed).

Standard Operation:

• After the vehicle is parked and the main power is turned off, open the vehicle’s charging port cover, clean the charging port (clean it of dust and water stains), and gently insert the charging gun into the port until it clicks into place.
• Operate the charging station, select the appropriate charging mode (e.g., slow charge or fast charge, depending on the battery condition), start the charging process, and observe that the charging station displays “Charging” and the vehicle’s instrument panel displays normal charging current and voltage.
• During charging, it is strictly forbidden to start the vehicle, operate high-voltage equipment, or perform any maintenance work. Charging personnel must be on duty (focus on observation for the first 30 minutes, and patrol every hour thereafter) and must not leave the vehicle.
• After charging is complete (the charging station displays “Charging Completed” and the vehicle’s SOC reaches the target value), first click “End Charging” on the charging station, wait for the charging gun to unlock, then slowly remove the charging gun and turn off the vehicle’s charging port cover and the charging station power.
• Environmental requirements: The charging area must be well ventilated (ventilation holes must not be blocked), fireworks are strictly prohibited (“No Smoking” and “No Open Flames” signs should be posted in the area), and sufficient dry powder fire extinguishers (no less than 2 per 50 square meters) and fire sand (no less than 1000 square meters) should be provided.

Part V: Emergency Response

In an emergency, remain calm, prioritize personal safety, and follow established procedures to minimize losses.

1.Vehicle Loss of Control

Maintain a steady steering wheel and avoid sudden turns. Slowly release the accelerator pedal while simultaneously applying the electric brake (high level) and mechanical brakes to gradually decelerate.

Continuously sound the horn to alert surrounding personnel and equipment. If the vehicle remains uncontrollable, seek safe areas within the mine, such as designated escape lanes, hillsides, or gentle slopes. Use friction to reduce speed and avoid rushing into crowded areas or equipment.

2.Brake Failure

Immediately activate the hazard lights and horn, keep a firm grip on the steering wheel, and keep the vehicle moving straight.

Gradually downshift (if available), while simultaneously engaging the highest level of electric braking. Intermittently apply the parking brake (apply no more than 3 seconds each time to prevent the parking brake from overheating and failing), gradually reducing speed.

If there is an open area ahead, slowly drive toward a roadside obstacle (such as a sandbag or mound) and use the obstacle to slow down and stop, avoiding direct impact with rigid objects.

3.High-voltage system failure/alarm

Immediately drive the vehicle to a safe, open area (away from personnel and equipment), turn off the main power, and apply the parking brake.

Set up warning signs (such as warning triangles or cordons) within 50 meters of the vehicle and evacuate all personnel to a safe distance (at least 10 meters).

Immediately call the mine dispatch and maintenance hotlines to report the failure (such as alarm code and symptoms). Do not disassemble or attempt to repair high-voltage components yourself (high-voltage system voltages can reach hundreds of volts, which can easily cause electric shock).

4.Fire

Stop the vehicle immediately, turn off the main power, apply the parking brake, and quickly evacuate the cab and away from the vehicle.

If the fire is small (e.g., a fire in the cab or wiring), use the vehicle’s onboard dry powder fire extinguisher to spray directly at the source of the fire.

If the fire is inside the battery pack (which spreads quickly and generates high temperatures), the primary priority is personal safety. Immediately evacuate to a safe area 100 meters away, call the fire department, notify them of a “pure electric mining vehicle lithium battery fire,” and assist firefighters in preparing to extinguish the fire (provide a diagram of the vehicle’s battery location).

5.Traffic Accidents

Stop the vehicle immediately, turn off the main power, apply the parking brake, activate the hazard lights, and place a warning sign 50 meters from the oncoming direction.

Check for injuries. If any, call emergency services immediately, prioritizing those with serious injuries (avoid moving those with neck or spinal injuries). Secure the accident scene.

Immediately report the accident to the mine dispatch and security departments, stating the time, location, casualties, and vehicle damage. Wait for the arrival of relevant personnel and do not leave the scene without permission.

Summary

As efficient and environmentally friendly mining transportation equipment, pure electric wide-body dump trucks offer operational advantages with their high-voltage systems and electric brakes, but also impose higher safety requirements. Drivers must prioritize safety.