GENERAL OPERATING INSTRUm'IONS
How to operate a power excavator efficiently must be learned in much the same way as any skilled trade.. No one is a "born"operat.or. Regardless of previous experience, the new operator must use care to operate the machine safely so as not to endanger men or equipment.
At first glance the large number of levers and switches looks as though operating the machine might be complicated, but most of them control some aUXiliary function of the machine such as steering, etc., and are not used in the regular operating cycle • The two tall. levers and the two pedals in front of the operator are the principal. controls used in the regular operating cycle and their use will be described in detail further on in these instructions. The first thing the new operator must do is to familiarize himself with the purpose of each of these levers and operating switches.
When learning to operate the machine it is a good plan to study each separate function until fully familiar with the control of all the auxiliary functions of the machine such as propelling, steering, etc .• , then try out the main controls which are used in actual digging operations. The main functions can be tried separately until the operator becomes accustomed to the response of the machine to the controls.
When learning to handle the controls be sure there is plenty of clearance and no danger spots around the machine such as overhead wires, culverts, ditches or embankments.
A. INSPECT MACHINE BEFORE STARTING SHIFT
Before beginning to opel'ate the machine at the start of a shift, make a general inspection of the machine to make sure it is ready for operation:
1. Look under the cats and around the machinery to see if there is any evidence of lubricating oil leaks. Correct any major leaks and refill to required level. Make a note of minor leaks and correct at first opportunity possible.
2. Look over the electrical accessories to make sure all units are securely mounted and properly adjusted.
3. Lubricate all twice-a-shift (4 hour) and once-a.-shift (8 hour) points as covered in the lubrication section of this instruction book.
4. Consult the lubrication record for the machine and service all points which have gone the specified length of time since the last previous servicing.
5. Check operation of all hand levers and foot pedals to see that they work freely without binding, yet with n0 lost motion.
6. Check main line air pressure which must be at least 110 lb. sq. inch.
7• Engage the clutches to check operation of each motion.
B. POINTS TO WATCH DURING SHIFT
During the shift, watch fOr any signs of improper operation or adjustment. The following items are of particular importance:
1. Check generator, motors and gears for any unusual noise, loss of power or failure to respond.
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2. Check the clutches innnediately if they should start to slip excessively during normaJ. operation.
3. Watch the cables to see that they do not become crossed on the drums.
4. When propelling check the tracking of the drive tumblers on the cat links and, if necessary, readjust the belts to correct improper operat:Uon.
5. When auxiliary functions such as the steering clutches, etc." note any. tendency of the controls to "hang up" or jam which would indidate improper operation. Correct the adjustment at the earliest possible opportunity.
6. Watch the air gauge in the operator's cab and investigate innnediately should there be a sudden drop in air pressure.
C. CHECK MACHINE AT END OF SHIFT
At the end of the shift go over the machine again for evidence of excessive wear or damage which may have occurred during the shift.
1. Examine aJ.l cabJ.es carefully for broken strands or other evidence of wela.kness. Arrange to replace weakened cables before starting another shif"t.
2. Clean out carefully any grease or dirt which may have accumulated the machinery during the shift.
3. Clean out excessive mud or dirt in the cat belts. This is particularly important in freezing weather. Put planks, brush or dry material under cats before shutting down machine if it is likely to freeze.
4. If the machine is to be idle for several hours, move it away from a high bank where it might be damaged by a slide or faJ.ling rocks. Do not leave the machine in a low spot where there is any danger of flooding.
5. Let the dipper down to the ground, be sure aJ.l brakes are set and place all controls in neutral position.
6. Close the windows at the operator' s position and lock all cab doors.
STARTING INSTRUCTIONS
The motor generator set starting equipment usually furnished consists of an across-the-line oil circuit breaker. Special instaJ.lations may have push buttoh start and/or a double throw oil circuit breaker and an auto transformer.
Before initial starting of machine read. Section covering Care and Maintenance of Electrical Equipment and the electrical manufacturer I s bulletins incJ.uded in an,. other book for proper starting procedure of oil circuit breaker and maintenance of electrical equipment.
The direction of rotation of M.G. set should be checked on initial start and anytime thereafter when the cable has been removed from machine, or line trouble has been encountered. It is a good practice to number or letter the plugs and jacks to avoid difficulty.
The air compressor should be started as soon as possible so that sufficient pressure may be built up to operate brakes and clutches.
The emergency reset button should then be depressed, this supplies D.C. current I the operation of the brake and clutch magnet valves and the control field Of the rotating control Units. It will be necessary to have hoist blower motor operating and oil circuit breaker in before contactor will close.
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SHOVEL OPERATING INSTRUCTIONS
Snap, hoist, swing and crowd brake switches to off position. This energizes brake magnet valves and allows air to enter brake cylinder releasing brake.
A. SWINGING
Swinging machine to right or left is controlled by the two foot pedals located in the front center section of operator's cab.
1. To swing to the left - depress left pedal.
2. To swing to the right - depress right pedal.
The rate of swing can be controlled by varying the amount the pedal is depressed. To bring machine to a stop depress the opposite pedal. The braking effect can also be varied by the amount the pedal is depressed. This is called "plugging" and may be done as rapidly and as frequently as is required for safe operation.
The swing brake should not be used for stopping machine when in motion except in an emergency. The brake should only be used when machine is at rest.
B. HOISl'ING
The hoisting and lowering motion is controlled by the tall upright lever to the right of the operator.
1. Place the "Propel_Dig" switch in the Dig position. (This allows air to enter Hoist Clutch).
2. To hoist - push lever forward.
3. To lower - pull lever back.
The rate of hoisting and lowering can be controlled by varying the distance the lever is pushed forward or pulled back from the neutral position. To stop or change direction all that is required is to change direction of the lever or "plug" and bring dipper to a stop.
The hoist brake should not be used during operation of shovel except during an emergency, when machine is idle or to hold dipper in the air.
The horn is operated by a latch mounted on the hoist lever.
C. CROWD
Be sure that crowd clutch air pressure falls wi thin range on the instruction plate mowrted near crowd clutch air gauge.
The crowd motion is controlled by the tall upright lever to the left of operator.
1. To crowd out - push lever forward.
2. To retract or crowd in - pull lever back.
The rate of crowding and retracting can be controlled by varying the distance the lever is pushed forward or pulled back from the neutral position. To stop or change direction move lever in opposite direction or "plug".
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The crowd brake should not be used during operation of shovel except in an emergency or when the machine is idle.
D.DIPPER TRIP
The dipper trip is operated by a latch handle mounted on the crowd lever and controls a variable torque motor, driving suitable reduction gearing and associated rope drum, mounted as a unit on the right hand leg of the boom lower section.
1. Depress the latch handle to dump dipper.
2. The dipper door will latch when the dipper is lowered.
E. PROPELLING
The propelling motion is controlled by the hoist motion lever.
1. Snap hoist, swing and crowd motion brake switches to the on position.
2. Place "Propel-Dig" switch in propel position.
3. Place propel brake switch in off position.
4. (a) To move forward, with driving tumblers to the rear, pull hoist lever back.
(b) To move backward, push hoist lever forward. Motion can be stopped by plugging and returning controller to neutral.
F.
STEERING CONTROLL FROM OPERATOR'S POSITION (See Schematic Arrangement of Air Piping and General Arrangement of Steering Machinery Drawings.)
Full steering control from the operator's cab, and with the revolving frame in any position, is obtained by clutch-shifter cylinders mounted in the truck frame which are controlled by a valve lever at the operator's left.
Air under pressure, for operation of the clutch cylinders, is obtained from the compressor mounted on the left side of the revolving frame. Three concentric pipes, with a six way swivel connection at the upper end and carry the air through the center of rotation to the left-hand and right hand clutch-shifter cylinders and the digging-brake operating cylinder in the truck frame.
Admission of air to the clutch shifter cylinders is controlled by a valve mounted on the wall to the operator's left in the operator's cab.
To turn to the left with driving tumblers to the rear, move the valve handle forward. This admits air pressure to the left-hand cylinder in the base and overcomes the spring to move the clutch to the locked position. It may be necessary to move the machinery slightly with the hoist controller in order to disengage the steering clutch. Moving the left-hand steering clutch to the locked position locks the left cat belt and when power is applied a sharp turn may be made.
Turn to the right are made by moving the handle to the rear, otherwise the sequence of operation is the same as for turns to the left.
In either case the clutch is returned to the engaged position by spring when air pressure is released from the system by moving valve lever to neutral or center position to exhaust air frQR lines. It may be necessary to move machinery slightly with the hoist controller in order to re-engage the clutdh.
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Since the steering clutches are jaw clutches, always stop the machine before shifting or in time the clutch jaws will become worn and round.
G. MANUAL Sl'EERING
To steer the machine manually it is necessary to have a ground man move the steering clutches as required.
1. With both clutches engaged and desiring to turn right the ground man moves the right clutch shifter lever to the outside. This disengages the clutch and allows the right hand cats to free wheel when power is applied as described under Propelling. The opposite applies in turning to the left using the left clutch shifter lever.
2. In order to use the locked steering it is necessary to move the steering clutch manually so that it engages with the locking jaws which are welded to the cat side frames. The clutch lever should be pinned to the clutch guard before starting to propel. To disengage the clutch it may be necessary to relieve the load on the jaws by momentarily reversing the controller. When steering the machine with. either clutch in the locked position, the ground man must be very careful so as not to allow the side frames to ride over or turn into a rock which IlIa\Y be projecting up from the floor of the quarry. To do so would place dangerous stresses in the links and side frames.
H. SHOVEL OPERATING HINTS
Actual digging operations with a shovel require combining the hoist, crowd and SWing motion into a fast, smooth operating cycle which cannot be described in any step by step procedure, as actual movement of the levers and pedals depends on actual digging conditions. There are many little operating tricks which will come from experience. Some of these are as follows:
1. Keep the shovel as near the face of the bank as safety will perm! t and always move up before it is necessary to "reach out" with the dipper to get material.
2. Spot trucks so that the swing is kept as short as possible.
3. Take a shallow cut in the bank so that the dipper will just be full when the top of cut is reached.
4. Crowd out only just enough to keep a uniform depth of the dipper in the bank.
5. Hoist the dipper only just high enough to provide clearance for the door when the dipper is tripped.
6. Don't continue hoisting if the dipper handle is fully extended against saddle block stop. Retract handle !:!: inches finish hoisting. Hoisting with dipper fully extended against stop places an extreme load on crowd cables and may result in the cables breaking.
7. Keep dipper teeth sharp.
8. Move up while waiting for trucks whenever possible.
9. Loosen material by cutting with open dipper while waiting.
To stop machine press "Emergency stop" button on control panel. This cuts off all D.C. current to brakes, rotating control units and clutch magnet valves. Thus all brakes are applied and controls made inoperative. Be sure to return controls to neutral.
To stop Motor-Generator Set depress button marked "MG stop" on control panel.
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DRAGLINE OPERATING INSTRUO'.rIONS
Snap hoist., swing and drag brake switches to off position. This energizes brake magnet .valves and allows air to enter brake cylinder releasing brake.
A. SWINGING
Swinging machine to right or left is controlled by the two foot pedals located in the front center section of operator r scab.
1. To swing to the left - depress left pedaJ..
2. To swing to the right - depress right pedaJ..
The rate of swing can be controlled by varying the amount the pedal is To bring machine to a stop depress the opposite pedal. The braking effect can aJ.so be varied by the amount the pedal is depressed. This is called "plugging" and may be done as rapidly and as frequently as is required for safe operation.
The swing brake should not be used for stopping machine when in motion except in an emergency. The brake should only be used when machine is at rest.
B. DRAG
The drag motion is controlled by the tall upright lever to the left of the operator.
1. Place the "Propel-Dig" switch in the Dig position. (This allows air to enter Drag Clutch).
2. To pay out - push lever forward.
3. To drag in - pull lever back.
Ele rate of dragging in and paying out can be controlled by varying the distance the lever is pushed forward or pUUed back from the neutraJ. position. To .stop or change directionaJ.l that is required is to change direction of the lever or "ptLug" and bring bucket to a stop.
The drag brake should not be used during operation of dragline except during an energency, when machine is idle or to hold bucket in the air.
The hoist motion is controlled by the tall upright lever to the right of operator.
1. To hoist - push lever forward.
2. To lower - pull lever back.
The rate of hoisting and lowering can be controlled by varying the distance the lever is pushed forward or pUUed back from the neutraJ. position. To stop or change direction move lever in opposite direction or "plug".
The hoist brake should not be used during operation of dragline except in an emergency or when machine is idle.
The horn is operated by a latch mounted on the hoist lever.
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D. PROPELLING
The propelling motion is controlled by the drag motion lever.
1. Snap hoist, swing and drag motion brake switches to the on position.
2. Place "Propel-Dig" switch in propel position.
3. Place propel brake switch in off position.
4. (a) To move forward, with driving tumblers to the rear, pull drag lever back.
(b) To move. backward, push drag lever forward. Motion can be stopped by plugging and returning controller to neutral.
E.
STEERING CONTROL FRCl4 OPERATOR'S POSITION (See Schematic Arrangement of Air Piping and General Arrangement of Steering Machinery Drawings.)
Full steering control from the operator's cab, and with the revolving frame in any position, is obtained by clutch-shifter cylinders mounted in the truck frame which are controlled by a valve lever at the operator's left.
Air under pressure, for operation of the clutch cylinders, is obtained from the compressor mounted on the left side of the revolVing frame. Three concentric pipes, with a three-way swivel connection at the lower end (See Drawing 288972) carry the air through the center of rotation to the left-hand and right-hand clutch-shifter cylinders and the digging-brake operating cylinder in the truck frame.
Admission of air to the clutch shifter cylinders is controlled by a valve mounted in the operator's cab.
To turn to the left with driving tumblers to the rear, move the valve handle forward. This admits air pressure to the left-hand cylinder in the base and overcomes the spring sUfficiently to move the clutch to the neutral or disengaged position. It may be necessary to move the machinery slightly with the drag controller in order to disengage the steering clutch. Moving the left-hand steering clutch to the neutral position allows the left cat belt to idle when power is applied and a turn may be made.
Turns to the right are made by moving the handle to the rear, otherwise the sequenc,e of operation is the same as for turns to the left.
In either case the clutch is returned to the engaged position by spring pressure ' when air pressure is released from the system by moving valve lever to neutral or center position to exhaust air from lines. It may be necessary to move the machinery slightly with the drag controller in order to re-engage the clutch.
Since the steering clutches are jaw clutches, always stop the machine before shifting or in time the clutch jaws will become worn and round.
F• MANUAL STEERING
To steer the machine manually it is necessary to have a ground man move the steering clutches as required.
1. With both clutches engaged and desiring to turn right the ground man moves
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the right clutch shifter lever to the outside. This disengages the clutch and aJ.lows the right hand cats to free wheel when power is applied as described under Propelling. The opPOsite applies in turning to the left using the left clutch shi:t'ter lever.
2. In order to use the locked steering it is necessary to move the steering clutch manu.aJ.ly so that it engages with the locking jaws which are welded to the cat side frames. The clutch lever should be pinned to the clutch guard before starting to propel. 'ro disengage the clutch it may be necessary to relieve the on the jaws by momentarily reversing the controller. 'When steering the machine with either clutch in the locked position, the ground man must be very careful so as not to allow the side frames to over or turn into a rock which may be projecting up from the of quarry. 'ro do so would place dangerous stresses in the links and side frames.
DRAGUNE OPERA'l'ING HIN'rS
Actual digging operations with the dragline require coordination between the hoist and drag motions which may be a little difficult to attain. Attention to the ' following suggestions and a little practice will soon give the operator the of filling the dragline bucket smoothly and quickly and permit accurate
1. Keep the boom angle as high as conditions will permit so as to provide .-,x1mum stability. Do not exceed figures given in the machine specificatipns.
2. Regulate the depth of cut by taking in orp8\Y'ing out hoist line.
3. Hoist the bucket out of the pit as soon as it is full and before dirt pushed up against the machine.
4. start and stop the swing motion slowly so as not to place wmecessary strain on the boom.
5• 'When dropping back into the pit be careful to check the hoist and drag drums with the controllers so that the cables do not run off the drams.!
'ro stop machine press "Emergency Stop" button on control panel. This cuts off Ul D.C. current to brakes, rotating control units and clutch magnet valves. 'J!hua all brakes are applied and controls made inoperative. Be sure to return controls to neutral.
'ro stop Motor-Generator Set depress button marked 1'MJ Stopll on control panel.
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CONTROL OF BRAKE AND CLUTCHES - SHOVEL
I. Control of Brakes
All brakes are controlled by means of switches located in the cab panel in the operator's cab.
Flipping the switch to the "off" position energizes the magnet valve which in turn allows air to enter the brake cylinder and thus releasing the brake. If the magnet valve is de-energized by power failure, by opening the brake switch, or if a broken air line caused loss or pressure, the brake shoes are set by spring pressure.
The hoist brake, as are all others, is separately controlled by the snap switch marked "Hoist Brake" in the panel at the operator's right. If the loaded dipper is held extended or the hoist line is otherwise under load when shifting from hoist to propel, it is a good plan to set the brake by means of the IlHoist Brake" snap switch before snapping the "Dig-Propel switch to the propel position. The swing and crowd brake are controlled by the switches marked "Swing Brake" and "Crowd
II. Control of Clutches
The hoist and propel clutches are primarily used as a coupling only and are used as slipping clutches only when the load becomes excessive.
The hoist and propel clutches are operated by the switch marked "Dig-Propel". To admit air to the hoist clutch the switch is snapped to the dig position. This de-energizes the hoist clutch magnet valve and admits air to the clutch and couples the hoist machinery to the hoist motor. At the same time the propel clutch magnet valve is energized thus shutting off the supply of air to the propel clutch and disengaging it.
To engage the propel clutch flip the hoist brake to "onll position and the "DigPropel" switch to the Propel position. This de-energizes the propel magnet valve and admits air to the propel clutch, thus coupling the hoist motor to the propel machinery. At the same time the hoist clutch magnet valve is energized shutting off the supply of air to the hoist clutch and disengaging it. By moving the propel brake switch to the "off position, the machine is ready to move.
The crowd clutch is engaged it all times as long as sufficient air pressure is available. The crowd air gauge should be checked daily to see that proper pressure is being obtained. Adjust pressure at regulator in crowd line in accordance with instructions shown on the instruction plate mounted near the gauge. The crowd clutch differs from the hoist and propel clutch in that a certain amount of slippage is permitted under heavy loads thus protecting the machinery from shocks encountered in hard digging.
The Airflex clutches require very little maintenance other than a daily visual inspection to insure proper working order. Air lines should be checked for leaks, clutch lining inspected for wear, clutch tubes for cracks or weak spots. Lubricant should not be allowed to get on clutch lining as it will cause wear and slipping. Page 1
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