CAT Dragline 8750 Walking Dragline Operator’s & Maintenance Manual - PDF DOWNLOAD

BI010575 BI010575

BUCYRUS R

8750

WALKING DRAGLINE OPERATOR’S MANUAL

SN: 141428

10863

141428mc.cdr Pg. 1 2

Manual No.

Bucyrus International, Inc. 1100 Milwaukee Ave. • P.O.Box 500 • South Milwaukee, Wisconsin 53172-0500 USA

BI010575 BI010575

Bucyrus International, Inc. 8750 Walking Dragline

Manual No. 10863

March 2011

BI010575 BI010575 Inc. Bucyrus International, 8750 Walking Dragline

DANGER: THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER: DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY. The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

DANGER: DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

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Manual No. 10863

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8750 Walking Dragline Operator’s Manual Manual No. 10863 sn: 141428 Lot 36

Table of Contents INTRODUCTION ........................................................................................................................... 5 SAFETY .................................................................................................................................. 6 GENERAL SAFETY PRECAUTIONS ...................................................................................... 7 MAINTENANCE SAFETY PRECAUTIONS .............................................................................. 9 OPERATING SAFETY PRECAUTIONS ................................................................................ 11 FIRE PROTECTION SYSTEMS ................................................................................................. 12 MATERIAL STORAGE CABINETS .............................................................................................. 13 Hazardous Material Storage Cabinet Locations .......................................................................... 13

MACHINE OVERVIEW ................................................................................................................ 14 Nomenclature ............................................................................................................................. 14

BASE FRAME ....................................................................................................................... 15 Base Frame (Tub) ...................................................................................................................... 15

BASE BAY NUMBERING ....................................................................................................... 16 Base Bay Numbering ................................................................................................................. 16

SAFETY RAILS FOR BASE FRAME ACCESS ..................................................................... 17 Safety Rail ................................................................................................................................. 17

ROTATING GEAR AND RAILS .............................................................................................. 18 Rotating Gear and Rails (Section View) ...................................................................................... 18

ROLLER CIRCLE ................................................................................................................. 19 Roller Circle (Section Views) ...................................................................................................... 19

ROTATING FRAME BAY NUMBERING .................................................................................. 20 Rotating Frame Bay Numbering ................................................................................................. 20

MACHINERY HOUSE ............................................................................................................ 21 Machinery House ........................................................................................................................ 21

OPERATOR’S CAB .............................................................................................................. 22 Operator’s Cab ........................................................................................................................... 22

OPERATOR’S SEAT ............................................................................................................. 23 Operator’s Seat and Controls ..................................................................................................... 23

PROPEL MACHINERY .......................................................................................................... 24 Propel Machinery ........................................................................................................................ 24

HOIST AND DRAG MACHINERY .......................................................................................... 25 Hoist and Drag Machinery .......................................................................................................... 25

SWING MACHINERY ............................................................................................................. 26 FAIRLEAD ............................................................................................................................. 27 Fairlead Assembly ..................................................................................................................... 27

IMPORTANT NOTE This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.

© 2011 Bucyrus International, Inc. March 2011

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All Rights Reserved.

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Bucyrus International, Inc.

BI010575 8750 Walking Dragline

TRI-STRUCTURE ................................................................................................................. 28 Tri-Structure ...............................................................................................................................28

TRI-STRUCTURE SAFETY ROPES .................................................................................... 29 Tri-Structure Safety Ropes ......................................................................................................... 29

BOOM ASSEMBLY AND BOOM SUPPORT ......................................................................... 30 Boom Assembly and Boom Support .......................................................................................... 30

BOOM SUPPORT ROPES .................................................................................................. 31 Boom Support Ropes ................................................................................................................. 31

BOOM CLUSTER IDENTIFICATION ..................................................................................... 31 OPERATOR CAB AND ANTEROOM .......................................................................................... 32 Operator’s Cab and Anteroom .................................................................................................... 32

OPERATOR’S CAB - ANTEROOM ....................................................................................... 33 OPERATOR CONTROLS .......................................................................................................... 34 Operating Controls ..................................................................................................................... 34

PRIMARY CONTROLS ......................................................................................................... 35 Primary controllers ..................................................................................................................... 35

PLUGGING THE MOTION ............................................................................................... 37 OPERATOR'S SEAT ADJUSTMENTS ............................................................................ 38 SECONDARY CONTROLS .................................................................................................. 39 Top View .................................................................................................................................... 39

LEFT HAND CONSOLE CONTROLS ............................................................................ 40 Left Hand Console Controls ....................................................................................................... 40

RIGHT HAND CONSOLE CONTROLS .......................................................................... 42 Right Hand Console Controls ..................................................................................................... 42

WINDSHIELD WIPER ........................................................................................................... 45 Windshield Wiper Assembly Operator’s Cab .............................................................................. 45

CLOSED CIRCUIT VIDEO MONITOR .................................................................................. 46 OPERATOR’S DISPLAY ....................................................................................................... 46 Operator’s Display ...................................................................................................................... 46

DISPLAY AREA & INDICATORS ...................................................................................... 47 CAB DISPLAY SCREENS ............................................................................................... 48 Operator’s Cab Title Screen ....................................................................................................... 48 Operator’s Main Menu Screen ..................................................................................................... 49 Display Information Screen ........................................................................................................ 50 Alarm History ............................................................................................................................. 52 Rope calibrations and set points ................................................................................................ 53 Shoe position ............................................................................................................................. 54 Operating Hours ......................................................................................................................... 55 Tightline ..................................................................................................................................... 56 Boom Raise-Lower ..................................................................................................................... 57 Lube Setup ................................................................................................................................ 58 Lube Status ............................................................................................................................... 59 Encoder calibration .................................................................................................................... 60

HOIST/DRAG LIMIT CALIBRATION ....................................................................................... 61 HOIST LIMIT .................................................................................................................... 61 DRAG LIMIT ..................................................................................................................... 63 HOIST AND DRAG ENCODER CALIBRATION ............................................................... 64

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POWER CONTROL ROOM ....................................................................................................... 66 Power Control Room .................................................................................................................. 66

MACHINERY HOUSE REAR DOORS ........................................................................................ 67 Machinery House Rear Doors ..................................................................................................... 67

REAR DOOR OPERATION .................................................................................................. 68 Door Operating Sequence .......................................................................................................... 69

REAR DOOR CONTROL PANEL ......................................................................................... 70 Control Panel for the House Rear Doors ..................................................................................... 70

BOARDING STAIRS .................................................................................................................... 72 Right Side Boarding Stairs ......................................................................................................... 72

RUNNING THE MACHINE ........................................................................................................... 74 PRE-START INSPECTION ................................................................................................... 74 TYPICAL STARTUP ............................................................................................................... 75 PREPARING TO DIG ............................................................................................................ 80 TYPICAL DIGGING CYCLE ................................................................................................... 81 GROUND PREPARATION .................................................................................................... 82 CHANGING TO PROPEL MODE ................................................................................................ 83 PROPEL OPERATION .......................................................................................................... 84 Walking Phases ........................................................................................................................ 85

WALKING MACHINERY CONTROL ................................................................................ 86 AUTO PARK .............................................................................................................. 86 WALKING .............................................................................................................................. 87 Operator’s Seat and Controls ..................................................................................................... 88

TURNING THE MACHINE ...................................................................................................... 89 RETURNING TO DRAG (DIGGING) MODE ................................................................................ 90 NORMAL SHUTDOWN PROCEDURE ...................................................................................... 90 PARK AND SHUTDOWN PROCEDURE ................................................................................... 91 EMERGENCY SHUTDOWN PROCEDURE ........................................................................ 91 TIGHTLINE PARAMETERS ................................................................................................... 92 JOYSTICK CALIBRATION ..................................................................................................... 95 REMOTE ROPE REEVING .................................................................................................. 96 AIR SYSTEM ......................................................................................................................... 97 STANDBY GENERATOR ...................................................................................................... 98 MAIN HOUSE CRANE ........................................................................................................... 99 MAIN HOUSE CRANE BRIDGE LOCKDOWN ................................................................... 100 CRANE TRANSFER BEAM ................................................................................................ 101 TYPICAL MACHINE SPECIFICATIONS ............................................................................... 102 WORKING RANGES ..................................................................................................... 103

EMCP3 SERIES CONTROL PANEL .............................................................................. (INSERT) PNEUMATIC SUSPENSION OPERATING INSTRUCTIONS ......................................... (INSERT)

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8750 Walking Dragline Operator’s Manual

INTRODUCTION This manual is designed to assist the owner in the operation of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.

Safe operation of the machine minimizes production delays and costly damage to equipment.

Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon the use of good judgement and the alertness of the entire mining crew.

Throughout this manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied for this purpose.

Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance contact your regional service representative or: Bucyrus International, Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin, USA 53172-0500 Telephone (414)-768-4000 It is the policy of Bucyrus International, Inc. to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously. Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.

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SAFETY The safety alert symbols displayed here and throughout this manual, are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted in various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions.

If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION:

This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER:

This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER:

This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.

CAUTION:

STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/or damage to the front-end of the machine.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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GENERAL SAFETY PRECAUTIONS •

A scheduled maintenance program performed by qualified maintenance personnel is the best way to minimize machine downtime and maximize productivity of equipment.

•

Keep hands, feet, and clothing away from rotating parts.

•

Wear a hard hat, safety shoes and protective lenses at all times.

•

Replace any and all safety and warning placards if they are defaced or removed from the machine.

•

Think before you act. Carelessness is one luxury service personnel cannot afford.

•

Excessive or repeated skin contact with sealants or solvents may cause skin irritation.

In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.

•

Inspect safety catches (keepers) on all hoist hooks. Do not take a chance; the load could slip off the hook if they are not functioning properly.

•

If a heavy item begins to fall, let it fall, don’t try to catch it.

•

Keep your work area organized and clean. Wipe up oil or spills of any kind immediately.

Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.

•

Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.

•

Electrical cords and wet metal floors make a dangerous combination.

•

Regularly inspect for any loose bolts or locking devices and properly secure them.

•

Use extreme caution while working near any electrical lines or equipment whether it is high or low voltage. Never attempt electrical repairs unless you are qualified.

•

Check all sensors and limit switches for proper operation.

•

After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area.

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Mechanical Brakes are designed for use as static holding brakes only. Use them as a motion (dynamic) brake in emergency situations only.

•

Use proper interior and exterior lighting.

•

Install and maintain proper grounding and ground fault protection systems.

•

Perform functional tests of all safety circuits.

•

Electrical inspection and maintenance should only be performed by a qualified electrician.

•

National, state and site safety systems must be read in conjunction with this manual.

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MAINTENANCE SAFETY PRECAUTIONS •

Do not wear rings, wristwatches or loose fitting clothing when working on machinery.

They could get caught on moving parts causing serious injury.

•

Always wear a safety belt or harness when the danger of falling exists.

•

If a lifeline is used when working in confined spaces, always have a second person monitoring it.

•

Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.

•

Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate or isolate the entire system prior to performing maintenance.

•

Equipment should be parked on level ground at all times during machine servicing and periods of idleness.

•

Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, etc.) Always work within the limitations of the equipment being utilized.

•

Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.

•

Utilize guide lines or ropes to minimize the swing of heavy suspended components.

•

Have sufficient service personnel available when removing or installing large, heavy items to maintain control at all times.

•

Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load; they could fail.

•

When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

•

When using an oxygen/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.

•

Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable.

Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

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Extreme caution is required when using compressed air to dry parts. Use approved air blow guns; do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

•

Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

•

Protective eye goggles should be worn at all times when working on the air-conditioning system. Work on the air conditioning system only in a well ventilated area.

•

Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

•

Always wear approved rubber gloves and use insulated hooks or tongs when handling trail cable.

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OPERATING SAFETY PRECAUTIONS •

Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 85 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa

•

When in doubt about the noise level, wear approved hearing protection.

•

Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board or exit the machine.

•

Do not move or operate the machine without first knowing the location and purpose of all personnel, test or support equipment, on or near the machine.

•

Do not allow unauthorized personnel on board the machine while in operation.

•

Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.

•

A public address phone system located throughout the machine, including outside structures, broadcasts to internal and external speakers as well as providing phone to phone verbal communication.

•

Do not propel the machine until the travel route has been cleared of obstructions.

•

Prevent the trail cable from being dragged on the ground for long distances or at high speeds.

•

Limit the amount of cable being dragged by the machine. Pulling too much cable will damage both the cable and the machine.

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FIRE PROTECTION SYSTEMS 1.

The fire protection system shall incorporate fault annunciation, fault logging and include battery backup protection. The system design shall follow the principles outlined in Australian Standards AS1670, AS4214 and AS5062. A maintenance Switch (electrically disconnects the input - double pole and logically opens output logic) shall be installed at the Fire Panel.

2.

The Fire system supplier shall provide one set of preliminary service and maintenance manuals for the Dragline. Also see Dragline 42 Systems Operation Manual Rev 4_AS BUILT.pdf in the Vendor Manual.

3.

Fire extinguisher locations are as follows.

LOCATION Revolving Frame entry / exits

QUANTITY 4 x 4.5kg

TYPE ABE DCP

Machine House

6 x 4.5kg, 2 x 50kg

ABE (at exits) Mobile ABE DCP

PCR

2 x 5.0kg

CO2

HV Cabinets. (22kV)

2 x 5.0kg

CO2

HV Cabinets. (6.6kV)

2 x 5.0kg

CO2

Motor Control Centre Cabinets (Adjacent PCR)

2 x 5.0kg

CO2 within 2m -20m of the cabinets

Motor Control Centre LH

1 x 5.0kg

CO2

Motor Control Centre RH

1 x 5.0kg

CO2

Mezzanine Level (Air Compressor + Lighting Ballasts)

2 x 4.5kg 1 x 5.0kg

ABE CO2

Motor Control Centre Roof

2 x 5.0kg

CO2

Machine Roof

1 x 4.5kg

ABE

Operators Cabin

1 x 5kg, 1

CO2 1.8m x 1.8m, fire blanket

Anteroom

1 x 5.0kg

CO2

Lube Room

2 x 4.5kg, 1 x 9 litre

DCP, AFFF

Alternator Set

2 x 4.5kg

DCP

Rack Change out Compartment

1 x 4.5kg

DCP

LH Deck Extension (adj APT’s)

1 x 4.5kg

ABE

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MATERIAL STORAGE CABINETS Hazardous materials must be stored in approved cabinets. Please refer to local regulations for specific requirements.

A spill kit cart is has been provided. It is stored under the front-most, left hand swing platform.

Hazardous Material Storage Cabinet Locations

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MACHINE OVERVIEW The following diagram identifies major components of the Dragline. The following are the four major areas of this machine: Base Frame Rotating Frame External Structures Bucket and Boom

Nomenclature

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BASE FRAME The Base Frame (or Tub, as it is more commonly known) provides a stable platform on which rests the machinery house and external structures of this machine. In addition to its function as a platform, the Base Frame also provides the pivot point about which the entire dragline upper structures revolve.

Base Frame (Tub)

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BASE BAY NUMBERING Each bay in the base has an identifying number. This number is painted on the wall of each bay.

Numbers begin at position 001 at the center journal, and increase in a clockwise spiral manner to bay 252 on the outermost bay opposite the trail cable entrance.

Base Bay Numbering

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SAFETY RAILS FOR BASE FRAME ACCESS

Safety Rail

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ROTATING GEAR AND RAILS

Rotating Gear and Rails (Section View)

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ROLLER CIRCLE During rotation, the machinery house rides on 122 rollers arranged to evenly spread the load over the upper and lower rail segments.

Roller Circle (Section Views)

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ROTATING FRAME BAY NUMBERING Each bay in the rotating frame has an identifying number. This number is painted on the wall of each bay. Bay numbering generally increases from Bay 001 under the Lube Room to Bay 197 at the rear of the machine.

Rotating Frame Bay Numbering

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MACHINERY HOUSE The machinery house rotates using swing motor assemblies that engage a 360º circular segmented rack gear assembly mounted on the Tub. The machinery house contains the main powered elements of this machine: -

Hoist and Drag machinery, including eight separate motors, two gearcases, and one drum per machinery unit.

-

Swing machinery, including eight separate motor and gear packages.

-

Propel machinery, including two separate motors, two gearcases, and one walking assembly for each side.

Machinery House

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OPERATOR’S CAB

Operator’s Cab

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OPERATOR’S SEAT The operator’s seat is positioned at the front of the operator’s cab to provide the best location to view the machine’s work area. Two joystick assemblies are provided to control machine positioning functions.

CAT E

Operator’s Seat and Controls

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PROPEL MACHINERY The propel machinery consists of two motors, a gear package, a power transfer assembly, and a walking eccentric, arm and shoe. There is a similar setup on each side of the machine. To move, the walking dragline physically lifts the back of the base frame (tub) and machinery house off the ground, and drags the entire machine backwards.

Propel Machinery

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HOIST AND DRAG MACHINERY The Hoist and Drag machinery control the motion of the dragline’s bucket.

Hoist and Drag Machinery

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SWING MACHINERY Eight Swing Motor Assemblies are located within the machinery house. The primary components of these assemblies are a motor, brake assembly, gearcase, swing shaft, and a pinion gear which engages the segmented rack gear located on the top of the Base Frame (Tub) assembly.

Swing Machinery

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FAIRLEAD The Fairlead Assembly ensures the smooth operation of the drag ropes from the Bucket to the Drag Drum.

Fairlead Assembly

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TRI-STRUCTURE The Tri-Structure provides for accurate alignment and support of the Boom Assembly and ensures the smooth operation of the hoist ropes to the Hoist Drum.

Tri-Structure

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TRI-STRUCTURE SAFETY ROPES The purpose of the Auxiliary Safety Ropes is to temporarily support the front end equipment in the unlikely event that the top of the tri-structure should fail.

Tri-Structure Safety Ropes

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BOOM ASSEMBLY AND BOOM SUPPORT

Boom Assembly and Boom Support

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BOOM SUPPORT ROPES Boom support ropes stretch from the tri-structure to the boom point, holding the boom in proper alignment. Four spacers are used to maintain separation of the Boom Support Ropes.

Boom Support Ropes

BOOM CLUSTER IDENTIFICATION Each structural member on the boom can be identified by a boom cluster identification. Numbers are painted on the boom structure. Each identification contains a letter code and number. The letter codes are listed below. Numbers increase from the boom foot pivot (location 1) to the boom point (location 30).

CODE RT RB LT LB CT CB CRT CRB CLT CLB CM

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LOCATION RIGHT HAND TOP RIGHT HAND BOTTOM LEFT HAND TOP LEFT HAND BOTTOM CENTER TOP CENTER BOTTOM CENTER RIGHT HAND TOP CENTER RIGHT HAND BOTTOM CENTER LEFT HAND TOP CENTER LEFT HAND BOTTOM CENTER MIDDLE

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OPERATOR CAB AND ANTEROOM The Operator’s Cab and Anteroom extend from the right front corner of the rotating frame. This position provides the operator with an unobstructed view of the pit and spoil area, plus the boom point and bucket. The cab and anteroom area provides a controlled environment for the operator, crew, and electronic equipment.

Operator’s Cab and Anteroom

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OPERATOR’S CAB - ANTEROOM The cab contains the controls, switches, and indicators necessary for machine operation. These machine controls have been positioned in the cab to provide the operator with comfortable operation of the primary controls and easy access to all the secondary controls.

The operator’s cab has a phone system connected to receivers located at strategic points inside the machinery house and around the machine. This system provides easy communication between persons in the cab and elsewhere about the machine.

A combination heater-defroster/air conditioning unit is mounted on the cab roof. A duct within the ceiling provides the operator warmed or cooled air as set on A/C control. The control for this unit is on forward side of the operator’s cab rear wall.

The ceiling, walls and floor of both rooms are insulated. Adequate lighting is provided and the control switches are conveniently placed. The walls are made of 1-1/2 inch thick galvanized panels painted differing shades of white on the interior and exterior wall. The floor covering deadens sound and is easily maintained.

The front windshield is sloped out at top to reduce reflection, dirt adherence, and rain streaks. The safety-glass area extends from the cab floor to almost ceiling level for boom and ground visibility.

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OPERATOR CONTROLS DANGER:

DO NOT ATTEMPT TO OPERATE THIS MACHINE UNLESS YOU UNDERSTAND ALL THE MACHINE CONTROLS. NEVER LEAVE THE OPERATOR’S SEAT WITHOUT FIRST SETTING ALL MOTION BRAKES AND “DROPPING OUT” (DE-ENERGIZING) LINE EXCITATION BY PUSHING THE CONTROL STOP PUSHBUTTON.

The operating controls for this machine are grouped around or are part of the consoles on the operator’s seat in the cab. The machine startup controls are located inside the machinery house.

The operator’s seat has adjustments for operator comfort and control. Position it to the best location before taking over the controls. See the seat adjustment procedure following later in this section.

Operating Controls

The Display Screen is shown mounted to the right arm of the seat; it can be installed on the left arm as well.

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PRIMARY CONTROLS Primary controllers for machine operation are the manually-operated joysticks situated on each side of the operator’s seat and foot pedals on the floor in front of the operator. NONE OF THE MACHINE MOTION CONTROLS ARE OPERABLE UNTIL LINE EXCITATION HAS BEEN ACTIVATED AND ENGAGED as is indicated by the green light in the excitation start pushbutton on the Operator Console.

For emergency exits, there is a door located on the right side of the cab, just behind the operator’s seat. This door can be opened from either inside or outside the cab by pushing down on the handle.

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BI010575 8750 Walking Dragline

The LEFT JOYSTICK operates the drag or propel machinery, depending on the machine drive mode selected.

•

When in the DRAG mode: moving the left joystick forward from its neutral position will result in the drag ropes “paying out” off the drum and the bucket will move away from the machine.

•

Moving the left joystick rearward from its neutral position will cause the drag ropes to wind onto the drum and the bucket will “drag in” (move toward the machine).

•

The Hoist Tension pushbutton, on top of the left joystick, applies reduced hoisting power to the hoist drum (to remove hoist rope slack and to hold the rigging off the bucket while dragging).

•

When in the PROPEL mode: holding the left joystick in its FULL REARWARD position from its neutral position results in the shoes going through their walking step and propelling the machine in the direction away from the boom (front end).

•

Moving the left joystick forward from its neutral position when in propel is done ONLY to back up the shoes as needed to place them in their top dead center location after a step has been completed.

THE MACHINE WILL NOT PROPEL TOWARD THE BOOM. Refer to WALKING MECHANISM, in this section.

The RIGHT JOYSTICK operates the hoist machinery (fore and aft lever movement). The hoist control is activated during DRAG mode.

•

Moving the right joystick forward from its neutral position will result in the hoist ropes unwinding from the drum and the bucket will lower toward the ground.

•

Moving the right joystick rearward from its neutral position will cause the hoist ropes to wind onto the drum and the bucket will be raised toward the boom point.

•

The pushbutton on top of the joystick operates the air horns.

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The SWING PEDALS are located on the floor in front of the operator. They are used to control machine rotation. Pressing the RIGHT pedal rotates the machine to the right. Pressing the LEFT pedal rotates the machine to the left.

The hoist and drag drives are speed controlled. This means that the further the joystick is moved fore or aft from its neutral position, the faster the drive will go. Practically full torque (or line pull) is obtained with the slightest movement of the joystick from its neutral position. Lever movement should be only enough to obtain the desired speed. Never move either hoist or drag joystick too far and then back it off. Always use a smooth, steady lever movement. “Jockeying” the joystick is not required and only results in machinery overuse and motor overheating.

The swing drive is torque controlled. This means that the further the footpedal is depressed, the more torque the swing drive will develop, thus increasing the machine’s swing-acceleration rate.

Full swing speed is obtained at any position of the footpedal. THIS CONTROL SHOULD NOT BE “JOCKEYED” DURING OPERATION.

PLUGGING THE MOTION PLUGGING machinery motion is the use of motor torque, applied in the opposite direction of motor rotation, to slow or stop the motion. This process is recommended only on the swing motion on this machine. Plugging is accomplished when the operator engages the controller to swing the machine in the opposite direction of the current machine rotation. As the machine slows to a stop, the amount of plugging effort is gradually reduced to provide a smooth stop. Continued plugging effort will reverse the direction of the motion. Plugging rapidly dissipates the energy of heavy moving parts by regenerating into the power source. When the hoist or drag controllers are released with the machinery in motion, the motions automatically plug to slow the machinery. Only a small amount of plugging is required for the hoist and drag motions.

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BI010575 8750 Walking Dragline

OPERATOR'S SEAT ADJUSTMENTS

The operator cab seat has options including a pneumatic suspension, lumbar support, and a seat heater. For additional information about adjustments to the operator’s seat, see PNEUMATIC SUSPENSION OPERATING INSTRUCTIONS at the end of this section.

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SECONDARY CONTROLS The secondary controls are mounted on the consoles on each side of the operator, and include lights, switches, pushbuttons, and controller programs to support the primary controls. Also located here are components that signal the operator and announce faults in selected on-board systems.

A fault-warning buzzer and a signal bell notify the operator of potential machine problems. A public address phone system located throughout the machine, including outside structures, broadcasts to internal and external speakers as well as providing phone to phone verbal communication. Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.

Top View

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BI010575 8750 Walking Dragline

LEFT HAND CONSOLE CONTROLS

Left Hand Console Controls

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EARTH CONTINUITY LOCKOUT A 2-position, lockable, pushbutton used for Safety Lockout and Ground Test.

WINDSHIELD WIPER A 3-position switch to control the operator’s cab wiper and speed (Off, Low, High).

WINDSHIELD WASHER A pushbutton to operate the windshield washer pump.

ROPE LIMIT BYPASS A pushbutton used to back out of a final hoist, drag or tightline limit. A light will flash in a first stage limit and light steadily on a shutdown.

SHOE AUTOPARK A green illuminated pushbutton used to initiate the automatic parking function. When lit it indicates that the walking shoes are in their PARKED position. When flashing it indicates the shoe park is operating. See OPERATING WALKING MACHINERY in this section.

CABIN LIGHTS A 3-way dimmer switch used to control the interior cab lights.

TEMPERATURE A rheostat used to set the desired temperature for the operator’s cab heater or air conditioner unit (Cold to Hot).

COMFORT MODE HVAC A 3-position selector switch used to set the heating or cooling mode for the operator’s cab heater or air conditioner unit (Vent, Heat, Cool).

FAIRLEAD LIGHT SWITCH A 2-position ON-OFF switch.

BOARDING LIGHT SWITCH A 2-position ON-OFF switch.

HVAC FAN SPEED A 3-position selector switch used to set the fan speed for the operator’s cab heater or air conditioner unit (Off, Low, High).

ROPE CALIBRATION A keyed 2-position switch to run or set-up the rope calibration.

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BI010575 8750 Walking Dragline

RIGHT HAND CONSOLE CONTROLS

Right Hand Console Controls

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EMERGENCY STOP A red mushroom type pushbutton which sets ALL brakes and de-energizes ALL controllers on the machine when it is pressed.

MG SET STOP A red, flush-mounted pushbutton used to initiate MG SET shutdown.

HOIST BRAKE A red light that indicates when the HOIST brakes are set.

DRAG BRAKE A red light that indicates when the DRAG brakes are set.

PROPEL BRAKE A red light that indicates when the PROPEL brakes are set.

SWING BRAKE A red light that indicates when the SWING brakes are set.

DRAG MODE A red light that indicates the machine is in DRAG mode.

PROPEL MODE A yellow light that indicates the machine is in PROPEL mode.

HOIST BRAKE A switch which sets or releases the HOIST brakes (Set, Release).

EXCITATION STOP BUTTON A pushbutton that DE-ENERGIZES the hoist, drag and swing controllers and also the solenoid circuits.

EXCITATION START / FAULT RESET A green illuminated pushbutton that ENERGIZES the hoist, drag and swing controllers and also the solenoid circuits. It is also used to clear all faults after the problem had been solved.

SWING BRAKE A switch which sets or releases the SWING brakes (Set, Release).

DRAG/PROPEL TRANSFER SWITCH A 2-position switch to transfer between DRAG mode and PROPEL mode.

DRAG /PROPEL BRAKE SWITCH A switch which sets or releases the DRAG/PROPEL brakes (Set, Release).

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BI010575 8750 Walking Dragline

SEAT CONSOLE POSITION A selector switch used to adjust the left-to-right position of the operator’s seat (Left, Right).

12V POWER OUTLET Connection for 12v powered outlet.

PCR TEST POINTS Interface for testing.

NOTE: The motion brakes are HOLDING BRAKES ONLY and are not intended to retard or stop any drive motion EXCEPT in an emergency situation. See Plugging the Motion. Always bring any drive motion to a halt before applying these brakes.

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WINDSHIELD WIPER

Windshield Wiper Assembly Operator’s Cab

The cab’s front window assembly is equipped with an electric powered wiper to assist with visibility in inclement weather. Its control is on the console next to the operator.

The wiper control is located on the LEFT control console. The wiper motor and gear reducer mounts on the roof of the operator cab. Adjust the rod from the gear reducer to center the wiper blade on the window.

Maintain pressure of the wiper on the glass with the adjusting nut on the spring rod located at the top of the wiper arm on the outside of the window.

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BI010575 8750 Walking Dragline

CLOSED CIRCUIT VIDEO MONITOR The dragline is equipped with a closed circuit video monitoring system. Instructions for the closed circuit video monitor system can be found in section C527ML-EXT in the Vendor Manual.

OPERATOR’S DISPLAY The Operator’s Display is a CTR panel used to provide the operator with an interface to the machine and its functional areas. From this informational display the operator can make inputs that affect machine operation, monitor systems and make system adjustments. Through this display terminal the operator will receive pertinent fault data to identify potential problems and prevent machine damage.

Operator’s Display

The display panel is mounted on a tilt-swivel bracket on the side arm of the seat. Individual operators can position the screen in any desired position.

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DISPLAY AREA & INDICATORS The display area of the monitor screen is the large area in the center of the screen. This area is “touch sensitive.” All information will be displayed on this area in either a text format or in the form of visual icons. The buttons and icons that appear on the screen will respond to touching the screen in the appropriate area of the icon.

These icons and buttons will react by activating the screen, switch activation or display information relevant to the icon.

All the machine controls can be found on the Operator’s Display Panel touch sensitive screen or the left or right Control Consoles of the operator’s seat.

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BI010575 8750 Walking Dragline

CAB DISPLAY SCREENS The Title Screen display appears when the machine is initially started.

Operator’s Cab Title Screen

The information provided in the central area of the screen is machine specific and lists the machine serial number, the customer name and a listing of important documents and drawings associated with the machine.

The Operator’s Screen is the primary operational information tool to be visible to the machine operator during daily use of this machine. The controls available on this screen will provide the operator with the information needed to view “at a glance” the status of items required for digging and to make changes in control settings.

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Operator’s Main Menu Screen

The Main Menu screen will provide the operator with a choice of several buttons to select. Touching the screen in any of these button areas will cause the display to change to the requested option.

Many of these screens will be displayed in the following pages. Several screens have an INFO button which will provide more detailed information concerning the functionality of listed buttons and switches.

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BI010575 8750 Walking Dragline

Display Information Screen

The Main Menu Information screen provides information about the various display screen options available through the Main Menu screen.

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The Active Alarm screen will provide a list of all active alarms and faults that have been initiated on the machine.

Active Alarms

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The Alarm History screen displays all alarms, active and cleared.

Alarm History

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Rope calibrations and set points

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Shoe position

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Operating Hours

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BI010575 8750 Walking Dragline

Tightline

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Boom Raise-Lower

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Lube Setup

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Lube Status

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BI010575 8750 Walking Dragline

Encoder calibration

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HOIST/DRAG LIMIT CALIBRATION An encoder attached to the end of the hoist and drag drum shafts continually monitors the drum position during operation. As the bucket nears the preset limits, reference is gradually removed until the drum rotation is stopped. To prevent tight-lining or pulling the bucket into the boom, the sum of the hoist and drag ropes payed out is monitored. If this sum reaches a preset length, the hoist or drag functions will be slowed, then stopped.

The limits must be recalibrated after changing the ropes, or anytime maintenance is performed that alters the encoder versus drum rotation. Recalibration is required on the function, hoist or drag, being serviced.

There are two calibration points on each rope. The first is with 1.5 dead wraps on the drum. The second is with the ropes at 16,5 ft. (5 M) from either the point sheaves or the fairlead. Rope length is calculated from the calibration points, and the active rope length is used to determine limit status.

There are three limits at each end of travel. Slowdown limit is the first. When this point is passed, the reference is starting to be limited linearly toward the stop limit. Stop limit is the second. At this point the reference is reduced to zero. The last limit is the final limit. When this is reached, the brakes are set and the drive is turned off. The first two limits can be exited by reversing the joystick to the opposite direction. The final limit needs to be exited with the limit bypass switch.

Limits are set using the Hoist/Drag Limit Calibrate screen. A password is required to access this screen. On this screen, limits are defeated and maximum speed is reduced.

Rope installation should be done using the Rope Reeving Screen. A password is required to access this screen. On this screen, limits are defeated and maximum speed is reduced.

HOIST LIMIT Hoist Calibration new rope 1.

Select Rope Reeving Screen.

2.

Position the drum with minimum 1.5 dead wraps on drum.

3.

Set hoist and drag brakes, turn excitation off.

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4.

Select Hoist/Drag Limit Calibrate screen. Press and hold the “Hoist Encoder Calibrate 1” button for three seconds. A position accepted light should turn on.

5.

Tie a flag on the hoist rope 16.5 ft. (5 M) from the socket at the dump blocks. Use the Rope Reeving Screen to hoist the bucket until the flag touches the boom point sheave.

6.

Set hoist and drag brakes, turn excitation off.

7.

Select Hoist/Drag Limit Calibrate screen. Press and hold the “Hoist Encoder Calibrate 2” button for three seconds. A position accepted light should turn on. The active rope should show 16.5 ft. (5 M) and the total rope length will be visible.

All of the limits will be set. If changes to individual limits are desired, they can be manually entered.

The limit entries are checked for valid values before they are accepted.

Hoist Calibration shortened rope 1.

Set hoist and drag brakes, turn excitation off.

2.

Tie a flag on the hoist rope 16.5 ft. (5 M) from the socket at the dump blocks. Use the Rope Reeving Screen to hoist the bucket until the flag touches the boom point sheave.

3.

Set hoist and drag brakes, turn excitation off.

4.

Select Hoist/Drag Limit Calibrate screen. Press and hold the “Hoist Encoder Calibrate 2” button for three seconds. A position accepted light should turn on. The active rope should show 16.5 ft. (5 M) and the total rope length will be visible.

5.

All of the limits will be set. If changes to individual limits are desired they can be manually entered. The limit entries are checked for valid values before they are accepted.

After completing the above steps, the upper and lower limits are set and the machine can be returned to service. The limits should be checked for proper operation.

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DRAG LIMIT Drag Calibration new rope 1.

Select Rope Reeving Screen.

2.

Position the drum with minimum 1.5 dead wraps on drum.

3.

Set hoist and drag brakes, turn excitation off.

4.

Select Hoist/Drag Limit Calibrate screen. Press and hold the “Drag Encoder Calibrate 1” button for three seconds. A position accepted light should turn on.

5.

Tie a flag on the Drag rope 16.5 ft. (5 M) from the socket at the dump blocks. Use the Rope Reeving Screen to Drag the bucket until the flag touches the fairlead.

6.

Set hoist and drag brakes, turn excitation off.

7.

Select Hoist/Drag Limit Calibrate screen. Press and hold the “Drag Encoder Calibrate 2” button for three seconds. A position accepted light should turn on. The active rope should show 16.5 ft. (5 M) and the total rope length will be visible.

8.

All of the limits will be set. If changes to individual limits are desired they can be manually entered. The limit entries are checked for valid values before they are accepted.

Drag Calibration shortened rope 1.

Set hoist and drag brakes, turn excitation off.

2.

Tie a flag on the Drag rope 16.5 ft. (5 M) from the drag rope socket. Use the Rope Reeving Screen to drag in the bucket until the flag touches fairlead.

3.

Set hoist and drag brakes, turn excitation off.

4.

Select Hoist/Drag Limit Calibrate screen. Press and hold the “Drag Encoder Calibrate 2” button for three seconds. A position accepted light should turn on. The active rope should show 16.5 ft. (5 M), and the total rope length will be visible.

5.

All of the limits will be set. If changes to individual limits are desired, they can be manually entered. The limit entries are checked for valid values before they are accepted.

After completing the above steps, the drag in and payout limits are set, and the machine can be returned to service. The limits should be checked for proper operation.

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HOIST AND DRAG ENCODER CALIBRATION The hoist and drag limits are used to prevent the bucket rigging from contacting the dragline components.

Encoders on the Hoist and Drag Drums provide position and rotation information about the drums for calibration and operation of the limits. The hoist and drag encoders need to be calibrated prior to setting the limits. The encoders have 4096 counts per revolution. Encoders must count up in the lowering or payout direction.

•

The Hoist Limits provide a slowdown, stop and final limit prior to the Bucket Hoist Rope Sockets contacting the Boom Point Sheave.

•

The Lower Limits provide a slowdown, stop and final limit prior to the hoist rope coming off of the drum.

•

The Drag Limits provide a slowdown, stop and final limit prior to the Bucket Drag Rope Sockets contacting the Fairlead.

•

The Payout Limits provide a slowdown, stop and final limit prior to the drag rope coming off of the drum.

When limits are active, the drive reference ramps are made quicker.

Slowdown Limit starts the linear reduction of the drum speed reference toward the Stop Limit. At the Stop Limit, the speed reference is set to zero to electrically stop the motion. The reduction to speed reference is a clamp, thus, if the operator has reduced the speed command below the clamp there will be no further reduction in reference. The slow down and stop limits can be exited by moving the Hoist or Drag Joystick in the opposite direction. If the rope length reaches the Final Limit, the brakes are set and the drive is turned off.

The final limit can be exited from with the rope limit bypass mode. The rope limit bypass mode is entered by pressing and holding the bypass button in the cab. The rope bypass light will flash. The motion can be started by control start once the motion control on light is on and the bypass mode is latched. The rope bypass light will be on. The motion brakes can then be released and the motion moved out of the final limit. If the motion is moved in the wrong direction, the rope limit bypass mode will be exited and motion will shut down. Speed is limited to 15% in bypass mode. When the motion is outside the stop limit, then the bypass mode will be exited. Normal limit functions will be active.

Limits are set from the Hoist/Drag Limit Calibration screen, which is password protected.

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The encoder calibration needs to be enabled. Once encoder calibration is enabled, hoist and drag motions will be in a reduced reference (15% maximum speed) mode. The hoist encoder needs to be set to increase count in the lower direction. The drag encoder needs to be set to increase count in the payout direction. The motion travel limits will be disabled. Drive start and stop operation is standard.

The first calibration point relates to the Lower and Payout Limits that prevent the rope, on the Hoist and Drag Drums, from unwinding less than 1.5 dead wraps on the drum. The second calibration point relates to the hoist and drag limits. The calibration point is with the rope sockets at 16.5 ft.

(5M) from the Boom Point Sheave or the Fairlead. If the second calibration value is greater than the first calibration value, the encoder direction value is generated. The PLC calculates the rope length between the calibration points including the 16.5 ft. (5 M) offset. The limits are set to default values relative to the rope length. The total rope length is displayed on the Limit calibrate screen as well as the active rope length. The active rope length is the rope that is between the rope sockets and either the point sheave or fairlead. The active rope length will be 16.5 ft. (5 M) after calibration 2 is pressed. The individual limits can be altered using data entry on the Limit Calibrate Screen. All data entry values are checked for valid information.

The limits require calibration after changing or reattaching the ropes, or anytime maintenance is performed on the drums, which alter the encoders with respect to drum rotation. Calibration is required only on the system being serviced either hoist or drag. When a rope is shortened, only calibration 2 is required.

Displays of length are selectable between meters and feet.

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POWER CONTROL ROOM

Power Control Room

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MACHINERY HOUSE REAR DOORS The rear doors of the machinery house consist of a set of 3 doors on each half of the rear wall.

Each set of doors includes 1 top door, and an inboard and outboard door. The doors are opened and closed by hydraulic cylinders actuated by manual hydraulic valves, one for each door, located at the center of the rear machinery house wall. Refer to the following figure.

Either set of doors or both can be opened, however each set must be opened in sequence and closed in the opposite sequence.

CAUTION:

DO NOT ATTEMPT TO OPERATE THE REAR DOORS UNTIL THE GREEN LIGHT IS ILLUMINATED, INDICATING THE DOOR LATCHES HAVE BEEN RELEASED.

CAUTION:

DO NOT OPEN OR CLOSE THE REAR DOORS OUT OF THE SEQUENCE SHOWN. FAILURE TO FOLLOW THE SEQUENCE WILL RESULT IN DAMAGE TO THE DOORS.

CAUTION:

DO NOT OPERATE THE MACHINE (DIG OR PROPEL) WITH THE REAR DOORS OPEN.

CAUTION:

DO NOT LEAVE THE REAR DOORS OPEN DURING INCLEMENT WEATHER. FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN DAMAGE TO THE DOORS OR TO THE EQUIPMENT INSIDE THE MACHINE.

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REAR DOOR OPERATION (The door operating sequence is also located on the nameplate located near the control panel on the rear wall.)

To OPEN one of the doors: 1.

Press the START button on the control panel to activate the hydraulic system.

2.

Press the UNLOCK button for the particular side to be unlocked. The green indicator light should be lit.

3.

Open the top door using Valve #1.

4.

Open the inboard side door using Valve #2.

5.

Open the outboard side door using Valve #3.

6.

Press the STOP button on the control panel to deactivate the hydraulic system.

To CLOSE one of the doors: 1.

Press the START button on the control panel to activate the hydraulic system.

2.

Close the outboard side door using Valve #3.

3.

Close the inboard side door using Valve #2.

4.

Close the top door using Valve #1.

5.

Press the LOCK button for the particular side to be locked. The green indicator light should NOT be lit.

6.

Press the STOP button on the control panel to deactivate the hydraulic system.

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Door Operating Sequence

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REAR DOOR CONTROL PANEL

Control Panel for the House Rear Doors

ITEMS ON THE CONTROL PANEL 1.

START - A green pushbutton which starts the rear door hydraulic system.

2.

E/STOP - A red mushroom head pushbutton which stops the rear door hydraulic system.

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3.

LEFT SIDE UNLOCK - A black pushbutton which releases the upper and lower door latches.

4.

LEFT SIDE UNLOCK - A green light which, when lit, indicates that the door latches are released.

5.

LEFT SIDE LOCK - A black pushbutton which sets the upper and lower door latches.

6.

RIGHT SIDE UNLOCK - A black pushbutton which releases the upper and lower door latches.

7.

RIGHT SIDE UNLOCK - A green light which, when lit, indicates that the door latches are released.

8.

RIGHT SIDE LOCK - A black pushbutton which sets the upper and lower door latches.

9.

RIGHT DOOR MANUAL OVERRIDE - A black button which allows manual door movement if the lock system fails.

10.

RIGHT DOOR MANUAL OVERRIDE - A red light that indicates manual override condition.

11.

LEFT DOOR MANUAL OVERRIDE - A black button which allows manual door movement if the lock system fails.

12.

LEFT DOOR MANUAL OVERRIDE - A red light that indicates manual override condition.

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BOARDING STAIRS Access to the main frame and machinery house can be attained by using the boarding stairs located on the right and left sides of the machine. When lowered, the stairs allow boarding from ground level. These stairs must be in their raised and latched position to enable the operator’s controls.

Right Side Boarding Stairs

When lowered, the stairs allow entrance to the base frame and machinery house from ground level. To lower the stairs, press and hold the DOWN pushbutton on the control panel. The stairway will return to ground. To raise the stairs, press and hold the UP pushbutton. Release the button to stop motion.

NOTE: The stairs must be in the RAISED position to enable the operator’s controls.

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Use the Emergency Stop pushbutton to stop stair motion in an emergency situation. When pushed, the power to the hoist is shut off and the button locks automatically. Turn the button to the right to release the lock.

A proximity switch and target magnet are located on the inside of the stair walkway. Adjust the proximity switch to actuate in the up position.

NOTE: The maximum air gap allowed between the proximity switch and the target is 0.35 inches (8.9 mm).

Generally, very little maintenance is required for the stairs. However, ensure that the two flanged bearings on the pivot shaft are lubricated and also that the proximity and target switches are in good working order.

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RUNNING THE MACHINE

PRE-START INSPECTION Visual inspection of the machine should be performed by the operator at the beginning of each shift. A potential problem may be prevented if discovered early.

The following checklists can be used to help with the inspection.

General (all areas of the machine): •

Are guards, cover plates, and safety devices secured in place?

•

Are all loose parts stored in proper compartments or removed?

•

Check all hardware for missing bolts, nuts, pins, etc.

•

Are all lube (grease) spills wiped up?

•

Is the machine thoroughly clean?

Tub ~ Check for the following items: •

Cracks, broken welds on exterior;

•

Hook shoe adjustment and condition;

•

No obstructions in roller path;

•

Trail cable in correct position.

Machinery House ~ Check the following items: •

Automatic lube system with adequate lube supply;

•

All gearcases have proper oil level and all filters installed;

•

Air compressor crankcase oil level and drive belts’ tension;

•

Main house crane hoist is parked and pinned correctly and in a safe manner.

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Front End ~ Check the following items: •

Bucket - for wear, worn, broken or missing teeth, loose or missing pins, weld cracks;

•

Boom & Tri-Structure - for cracks, bent pipes;

•

The condition of the boom support ropes;

•

The condition of the hoist and drag ropes;

•

The condition of the fairlead components.

NOTE: If any problems are found after going through the above checklists, notify maintenance at once so that corrections can be made.

TYPICAL STARTUP To start up the machine from a complete shutdown, use the following procedure. DO NOT start this machine unless you are completely familiar with the various controls. Perform the Pre-Start Inspection given on the previous page.

1.

All the circuit breakers for the applicable controls and equipment must be closed and the power on before proceeding with startup. These are located primarily on the outside of the Power Control Room (PCR) and in the Operator's Cab/Anteroom.

CAUTION:

2.

DO NOT use circuit breakers as ON/OFF switches. Make sure that all the circuit breakers are ON before starting the machine.

Go to the rear of the PCR and to the Starting and Metering Cabinet. Observe the various meters and the startup controls and that the PHASE CHECK light is on.

IMPORTANT NOTE: During each component start up, always be ready to immediately stop it if there are any unusual sounds, smells, or visual effects. Always let the system being started come up to its normal operating speed before starting the next system. Any time a problem arises, check the OIT display in the Operators Cab for assistance.

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3.

Press the "MG Set Start" pushbutton to automatically start the MG Sets in sequence. Be sure that both green indicators are lit and that all meters are stabilized for all four MG Sets.

The individual buttons can be used to start each MG Set individually.

4.

The motor blowers start automatically when the MG Sets are on. These blowers are used in cooling the DC motors. Check that the green indicator is lit and for the sound of the blowers.

IMPORTANT NOTE: If the vacuum breaker for the synchronous motor on the MG set does not stay closed when the start button is released, repeated attempts to start the set should not be made. On a motor of this type, only attempt two successive starts if the motor is at ambient temperature. More that two attempts to start without success can damage the motor windings. Before attempting another start, the vacuum breaker starting circuitry or mechanism should be inspected by qualified personnel and its proper operation verified.

5.

The Machinery House Intake Filter Fan units will start automatically once the MG Sets are on.

These fans introduce clean air into the machinery house to cool the dragline operating equipment. They also maintain a positive pressure within the house to prevent dust entry if all the access doors are kept closed.

To start each fan unit individually, fully press and release the pushbutton for each unit. This will start the bleed duct fans. In approximately 5 seconds the main fans will automatically start and then the light will come on.

6.

When the above systems have been started and are operating correctly, go to the operator’s cab and observe the air pressure indicator in the OIT. This indicator provides a visual reference for the air system pressure and should indicate from 95 to 155 PSI (650 to 1070 kPa) during machine operation.

7.

Sit into and adjust the operator's seat.

8.

Check the Hoist, Swing and Drag and Propel Brake selector switches. If they are not at their SET positions, put all of them there now, even if the red light in the switch is on.

9.

Check to be sure that the hoist and drag controllers are in their NEUTRAL position and that there is no pressure applied to the swing pedals.

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IMPORTANT NOTE: This machine is equipped with an electronic rope limit control system.

This system is designed to aid the operation in avoiding serious mechanical damage to the machine due to hoist or drag bucket overtravel or bucket tight-lining. However, the system is not a substitute for careful operating procedures. The rope limit control system should be verified for proper operation on a daily basis. It is EXTREMELY important that the system be recalibrated after any rope or bucket rigging changes have been made. Refer to the Electrical Service Manual for this machine for proper procedures.

10.

Press the EXCITATION START pushbutton on the operator's console.

11.

Turn the Hoist, Drag and Swing drag break selector switches to the RELEASE position.

DANGER:

THE MACHINE IS NOW OPERATIONAL. DO NOT LEAVE THE OPERATORS SEAT UNLESS THE CONTROLLERS ARE DEENERGIZED AND THE BREAKS ARE SET.

THE OPERATOR CONTROLS THE MACHINE. PLEASE KEEP SAFE OPERATING PROCEDURES IN MIND AT ALL TIMES.

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PREPARING TO DIG Before preparing to dig, contact support equipment and personnel to ensure that they are prepared for digging operations and are clear of the machine.

Perform the following operations to start the machine and prepare to dig. Confirm your operations on the SCADA screen.

1.

Check the SCADA screen to ensure that the air pressure is in the working range between 655 kPa (59 PSI) and 793 kPa (115 PSI).

2.

Check that the swing pedals are in the neutral position.

3.

Ensure that the hoist, swing, drag, and propel brakes have been set (SCADA screen).

4.

Check that the hoist and drag joysticks are in the neutral position.

5.

Transfer to drag mode on the right console.

6.

Sound the horn twice to indicate movement.

7.

To start excitation, press the Excitation Start button on the right console.

8.

Release the hoist, swing, and drag brakes on the right console.

9.

When the area is clear, check the boom protection by lifting the bucket to ensure the boom limits are operating.

10.

The machine is now ready to dig.

NOTE: Transfer to propel on the right console if you are intending to propel the machine immediately.

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TYPICAL DIGGING CYCLE Start a digging cycle with the bucket on the ground, in the pit, and under the boom point. If the machine tends to rotate freely, apply just enough swing effort with the RIGHT pedal in the opposite direction of machine movement, to hold the machine steady.

Begin dragging the bucket in by pulling back on the drag (left) joystick. The more the joystick is moved from its neutral position, the faster the bucket will be pulled toward the machine. As the bucket is dragged in, take care to remove any slack from the hoist rigging. Do not allow the spreader bar to rest on the bucket. Additional hoist pull can be applied to reduce the cutting depth and wear on the bucket heel. Do not drag the bucket any further than necessary to fill it. Dragging a full bucket wastes time and energy.

With the bucket full, a correct combination of hoist and drag joystick movement will increase the hoist speed (right joystick back) and decrease the drag speed (left joystick forward) to lift the bucket out of the pit. Keep just enough tension on the drag ropes to prevent the bucket dumping.

Too much rope tension tightens the “line of bucket carry” and positions the bucket close to the boom. This adds strain to the boom and slows down the hoist speed.

As soon as the bucket clears the digging face, slowly press the swing pedal in the desired direction of machine rotation. A correct combination of hoist and drag effort with swing motion added avoids any excessive bucket and rope swing. Swing the machine and lift the bucket at the same time so that the bucket reaches the dump height and spoil location at the same time.

CAUTION:

USE EXTREME CARE WHEN SWINGING TO ENSURE THE BUCKET CLEARS ALL OBSTRUCTIONS AND THAT CLEARANCE EXISTS AROUND THE MACHINE.

Upon approaching the dump point, reverse the swing motion to bring the machine to a smooth and accurate stop. Coordinate the hoist and pay-out so that the bucket dumps as the machine stops swinging, and the bucket is empty as it starts back to the pit.

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All the drives are “plugged” while digging to bring each motion to a stop and control the bucket as desired. There are no “operating” brakes on this machine. All the brakes on the drives are “parking” brakes only.

Release the drag rope tension by paying some rope out from the drum. This dumps the bucket. As the bucket dumps, move the left joystick just slightly forward of its neutral position. Be cautious - do not allow an excessive amount of drag rope to pay out.

Never hold the load any longer than necessary to complete the dumping cycle. Once the material clears the bucket, slowly swing the machine back over the work area and lower the bucket into the pit, using a combination of the hoist and drag motions to place the bucket at its new dig site.

CAUTION:

NEVER LOWER A FULL BUCKET OVER AN EXTENDED DISTANCE. DOING SO COULD CAUSE SEVERE DAMAGE TO THE ELECTRIC DRIVE COMPONENTS ON THIS MACHINE.

While operating the machine, observe its components for problems. Look for loose bucket pins, broken or frayed strands on the boom support, hoist, drag, and dump ropes, and bucket and rigging damage or wear. Keep an eye on the boom and the boom point. Report any maintenance requirements promptly to the appropriate personnel for attention so that unnecessary downtime can be minimized.

GROUND PREPARATION Ground preparation is very important. The walking dragline requires a properly prepared ground base for operation. The tub and walking shoes must have full contact with the ground when the machine is digging or propelling. With the machine weight distributed over the entire tub bottom, or the partial tub bottom and the area of the two walking shoes, the components are less stressed.

The ground supporting a walking dragline must be as near level as possible, firm, and dry. Sand, clay, and topsoil can be leveled easily with a dozer or grader. Sharp rocks and boulders cause point loading, which will damage the tub and shoe structures and should be removed if possible. Where this is impractical, cover the working area with fill dirt to a sufficient depth that will eliminate the effects of the rocks.

This walking dragline can be propelled up or down a grade or ramp. Ramping the machine (moving it from one level to another) requires exercising great care because this situation subjects the tub and revolving frame to stresses much greater than experienced while digging. For a new machine, ramping should be restricted to a maximum 5% grade; later after the machine has propelled approximately 250 to 500 steps this can be increased to a 10% grade maximum. It is possible to traverse (cross) a 5% grade with this machine; however, AVOID CROSSING ANY GRADE IF POSSIBLE.

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When beginning to propel the machine, the transition from one grade to the next should be gradual, no more than 2% over the length of the walking shoes. For example, starting from level ground, the machine should travel a minimum of three shoe lengths before reaching a 5% grade.

This machine design incorporates a calculated balance between boom length, boom angle, allowable bucket load, machine weight, and ballast used. During normal digging cycles, the center of gravity shifts from the front to the rear within a specific area called the “kern”. The machine maintains stability and relatively even ground bearing pressure over the entire tub area. If, for any reason, the digging radius or load increases to cause the center of gravity to extend out of the kern to the tub perimeter, an undesirable rocking motion will occur due to the cone shape that will develop in the ground under the tub. This results in an unstable machine and concentrated ground bearing pressure at the center of the tub. This condition is very detrimental to the machine and must be eliminated.

Contact the Bucyrus International, Inc. Service Department for consultation on this problem immediately.

CHANGING TO PROPEL MODE Perform the following procedure if you need to move the machine during digging operations. Confirm your operations on the SCADA screen.

1.

Set the hoist, drag and swing brakes.

2.

Stop excitation by pressing the Excitation Stop button on the right console.

3.

Transfer to propel mode using the Propel button on the right console.

4.

Sound the horn three times to indicate your intention to move (walk).

5.

Start excitation by pressing the Excitation Start button on the right console.

6.

Release the propel brakes.

7.

Pull the left joystick backward to propel the machine backwards. The joysticks must be pulled back during the entire propel operation.

NOTE: The machine can only walk backwards - not forward toward the boom direction.

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PROPEL OPERATION Two separate but identical propel machinery assemblies are located at each side of the revolving frame. The operations of the two assemblies are tied together electrically by encoders and a monitoring system to synchronize them during the step.

Each propel assembly consists of DC drive motors, shafts and gearing, an eccentric, a walking arm with a stabilizing arm, and a walking shoe. The walking arm connects to the shoe through a ball joint that allows the shoe to swivel in all directions. It also permits limited lateral movement. Consequently, each shoe can adapt to ground contour within its design range.

A walking step is created when the eccentric rotates. During a walking step, the top of each eccentric turns toward the rear of the machine (away from the boom). The eccentric turns the walking arm in a path restricted by its stabilizer arm that generates the walking step through the shoes. Hook shoes, attached to the underside of the revolving frame, lift the rear of the tub during the step.

The walking process can be separated into 4 distinct phases: •

During the first quarter turn of the eccentric, the walking shoe moves from its “top dead center” or parked position toward the rear of the machine and down until it contacts the ground. Refer to PHASE 1 on the previous page. Just before the eccentric turns into the second quarter of its rotation, the rear of the machine and the rear edge of the tub raise and move slightly forward.

This movement raises the tub out of any depression formed while digging and breaks any suction between the tub and the ground.

•

During the second quarter turn of the eccentric, (PHASE 2) the shoes cause the machine to move rearward, dragging the front edge of the tub along the ground.

•

The third quarter turn of the eccentric (PHASE 3) completes the propel movement of the machine. Near the end of this quarter turn, the machine is slowly lowered and the tub settles down onto the ground again.

•

The fourth and final quarter turn of the eccentric (PHASE 4) raises the shoes into their park position (top dead center). The shoe return mechanism on each shoe realigns it parallel to the revolving frame as it is raised.

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Walking Phases

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WALKING MACHINERY CONTROL The Drag-Propel Switch, located in the drag-propel cabinet, connects the drag motors or the propel motors, depending on what machine control mode the operator selects. In the DIG mode, the drag (left) controller in the cab controls the drag motors for digging. In the PROPEL mode, this same lever controls the propel motors for walking.

The walking shoes at each side of the machine are not mechanically connected. The position of the two shoes is electrically monitored to keep them in time/synchronized. This timing system detects when one shoe gets ahead of the other and generates an error signal to slow down the leading shoe. This timing system functions to align the shoes through the complete step. This provides a smooth, shock-free propel movement. The propel portion of the step will be completed.

The encoders in this timing system are also used to detect when the shoes are at their “top dead center” (TDC) or PARK position.

AUTO PARK Auto park is the method of bringing both shoes to top dead center (TDC) and setting the brakes.

The operator can initiate auto park any time. The operator must pull the joystick back in the propel direction. When either shoe reaches 340 degrees, the shoe synchronization is turned off; reference is clamped to 15%. When each shoe reaches 350 degrees their references are linearly reduced to about 2%. When each shoe reaches 359 degrees, their brakes are told to set. When both brakes are set, the propel motion is turned off.

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WALKING Some preparations are required before moving the dragline. Its travel path must be adequately prepared. See the previous subsection GROUND PREPARATION. The bucket must be positioned to suit the ground conditions. The machine must be rotated so its rear faces the desired direction of travel. Provision must be made for safely and correctly handling the trail cable during the move.

DO NOT USE A WALKING SHOE TO PULL OR MOVE THE TRAIL CABLE to avoid damaging the trail cable.

The position at which the bucket is carried when the machine is propelled contributes considerably to the walking operation and is dependent upon the condition of the ground. When traversing firm, level surfaces, the bucket should be suspended from the boom point approximately 1/3 the dump radius of the machine. The same position is used when propelling up a ramp. When propelling down a ramp, carry the bucket below the boom point. In all cases, the bucket should be high enough so that it will not touch the ground during a walking step.

“Heeling” the bucket while walking is done by letting the rear of the bucket contact the ground during the step and slide along when the tub slides rearward in the direction of travel. As the tub is lowered to the ground, the bucket is picked up as the boom point raises. THE BUCKET SHOULD NOT BE JERKED OFF THE GROUND. Heeling is useful while traversing dry, sandy, or powdery soil conditions to reduce the ground pressure under the sliding area of the tub and stop soil build up behind the tub’s front edge or to avoid shoe slippage on the ground.

Each operator will learn through experience where to carry the bucket while propelling to suit the ground conditions encountered. The above are general guidelines for any operator to follow initially for positioning the bucket for walking.

When all is ready for the machine to be moved, transfer the machine control from DIG to PROPEL mode. Refer to CHANGING TO PROPEL MODE in this section for the procedure. Sound the signal horns to indicate the machine will propel.

Move the left controller rearward and hold it there during the entire propel period.

IMPORTANT NOTE: The operator should check that the drag machinery is inoperative and that the transfer to PROPEL is complete. This is done by moving the left controller (drag) slightly forward off neutral and then back to neutral to see if the drag machinery moves. This check can avoid inadvertent damage to the boom or front end in case the drag motion is still activated when the controller is moved full forward to take a step.

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Operator’s Seat and Controls

As the first walking step commences and the shoes move off their PARK position, the swing and hoist brakes will automatically set if they had not already been set manually. During extended travel over long distances, it sometimes becomes necessary to alter the direction of travel or position the bucket. This can be done without transferring to the DIG mode. Stop the walking shoes in the PARK position. Check that the SWING CONTROL indicator is lit and the propel brakes are set. Press the EXCITATION ON pushbutton, and then release the Swing brakes. Reposition the dragline to the desired direction of travel. To continue propelling, press the EXCITATION ON pushbutton and release the propel brakes.

During walking, if a ground roll develops at the front edge of the tub, “heel” the bucket for a couple of steps. If the tub roll persists, swing the machine 30º - 40º to one side and propel one or two steps. This will spread the roll over the ground. Then return to the line of travel desired.

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When the machine is walking, both shoes should contact the ground at the same time. If one of the shoes sets down on a high spot, or does not contact the ground, or steps into a soft ground area that will not support it, then the machine will rotate in relation to the tub if the walking step is completed. If this occurs and the operator can, he should stop the step before the machine is lifted and reverse the shoes up to top dead center position. He can then change machine travel direction with the swing motion and walk around the problem ground area.

When the number of steps taken is completed and return to digging is required, the operator can press “SHOE AUTO PARK” in the second half of the last step. Keeping the joystick rearward, the machine will complete the step and slow the shoes as they approach their park position. The propel brakes will set when each shoe has reached its park position.

TURNING THE MACHINE Conduct the following operation to turn the dragline.

1.

Press the Auto Park button to the left of the left joystick controller, while continuing to hold the Propel Joystick back in the walking travel direction to bring both shoes up into an auto park position.

2.

Move the drag/propel joystick to the neutral position.

3.

Set the propel brakes.

4.

Sound the horn twice to indicate movement.

5.

Release the swing brake.

6.

Swing the boom to the correct position and return the swing controllers to neutral.

7.

Set the swing brakes.

8.

Sound the horn three times to indicate propel movement.

9.

Release the propel brakes.

10.

Pull back on the joystick to lower the shoes for walking the dragline.

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RETURNING TO DRAG (DIGGING) MODE The machine will need to be returned to drag mode to begin digging after the machine has been repositioned.

1.

With the shoes parked, move the propel controller to neutral.

2.

Set the propel brakes.

3.

Press the Excitation Stop button on the right console to stop excitation.

4.

Transfer from propel to drag mode by pressing the Propel button on the right console.

5.

Sound the horn twice to indicate movement.

6.

To start excitation, press the Excitation Start button on the right console.

7.

Release the hoist, drag, and swing brakes.

8.

The machine is ready to start digging.

NORMAL SHUTDOWN PROCEDURE To shutdown the machine: 1.

Place the bucket on the ground.

2.

Set all brakes.

3.

Press the Excitation Stop pushbutton.

This process first slows the Drag/Propel motor speed, then sets the mechanical brakes and turns off the generator/motor field drive.

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PARK AND SHUTDOWN PROCEDURE Park the machine in a safe position, away from the low wall edge, on firm level ground. If the machine is currently in propel mode, transfer to drag mode. The machine must be in drag mode to shut the machine down properly and set the bucket on the ground.

The shutdown procedure first involves shutting down the functions in the operator cab, then the power in the machinery house.

Operator Cab Shutdown Sequence 1.

Set the bucket on the ground in a safe location with all of the controllers in neutral.

2.

Set the hoist, drag, and swing brakes.

3.

Press the Excitation Stop button on the right console to stop excitation.

4.

Shut down the MG set on the right console.

5.

Move to the house power control center control panel.

Machinery House Shutdown Sequence 1.

Shut down the blowers.

2.

Shut down the fans.

3.

Shut down the oil and cooling pumps.

4.

Call for an electrician to shut down the power sources.

EMERGENCY SHUTDOWN PROCEDURE 1.

Press the E-Stop pushbutton on the right console. This will cause an immediate shutdown of the entire machine. All drive motions will stop, all mechanical brakes will set and the generator/ motor field drives will turn off.

2.

Follow standard mine procedures and/or notify mine personnel as to the reason the machine was shut down.

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TIGHTLINE PARAMETERS

The Bucyrus Tightline Control System reduces motion reference values whenever hoist and drag operation occurs within a preset envelope. All of the control algorithms are done in the PLC and all setup parameters are entered using the operator’s interface terminal. The system uses hoist and drag rope lengths and velocities obtained from encoders coupled to the drums. The encoder calibration, motion slowdown, and stop limit logic is independent of the tightline control. One encoder per motion is used to provide the position information for both tightline and limits.

The PLC continuously calculates the hoist and drag rope lengths and velocities from the drum encoder signals. The hoist and drag chain/hardware lengths are summed with the calculated rope lengths to determine the operating envelope. The rope velocities are positive for the hoist and drag directions. These are summed algebraically to give a net rope velocity. If this velocity is positive, it is multiplied by the rope velocity factor to form a dynamic compensation length. This is then added to the dynamic tightline length parameter. Whenever the operating envelope is less than the dynamic tightline length with velocity compensation, the motion reference or references causing the tightline condition will be reduced. If the operating envelope continues to decrease, the references will be reduced to zero when the static tightline length is reached.

The tightline protection must operate rapidly to stop the motion. The system changes the reference ramps to allow faster motion response. If the bucket enters the static tightline envelope by a small amount, the brakes will be set and the motions turned off. To exit the tightline condition, the appropriate motion must be moved away from the Boom. The Tightline Final Limit must be exited with the Limit Bypass Mode. When the machine is in a hoist or drag limit, the tightline operation is suspended for the motion in limit.

The final limit can be exited from within the rope limit bypass mode.

The rope limit bypass mode is entered by pressing and holding the bypass button in the cab. The rope bypass light will flash. The motion can be started by control start, once the motion control-on light is lit and the bypass mode is latched. The rope bypass light will be on. The motion brakes can then be released and the motion moved out of the final limit. If the motion is moved in the wrong direction, rope limit bypass mode will be exited and the motion will shut down. Speed is limited to 15% in bypass mode. When the motion is outside the static tightline envelope, rope limit bypass mode will be exited. Normal tightline limit functions will be active.

Dynamic tightline velocity compensation provides anticipation at higher operating speeds by increasing the dynamic tightline length and thereby reducing motion reference earlier than at lower operating speeds.

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The theoretical tightline length is the straight-line distance between the drag rope exit point at the fairlead sheaves to the hoist rope exit point at the boom point sheaves. This length is somewhat smaller than the dragline boom length. The following are conservative values for static and dynamic tightline lengths: •

Static tightline length = 1.10 x theoretical tightline length

•

Dynamic tightline length = 1.16 x theoretical tightline length

Refer to the machine settings for actual values.

The hoist and drag encoders need to be calibrated prior to tightline set up. This is a separate procedure.

The tightline protection requires information to be entered on the operator display to set the tightline limits. This is a password protected screen.

•

Static tightline length = Hoist and drag envelope for zero reference.

•

Dynamic tightline length = Hoist and drag envelope where reference reduction starts.

•

Hoist chain/hardware length = Chain and hardware lengths from the hoist rope socket to the bucket hoist trunnion.

•

Drag chain/hardware length = Chain, hardware, and bucket lengths from the drag rope socket to the bucket hoist trunnion.

•

Rope velocity factor = Dynamic tightline length velocity compensation.

The data entry can be selected in meters or feet. The PLC calculates in meters. The Chain Hardware lengths are shown in the attached figure.

The hoist chain/hardware length and Drag chain hardware length should be physically measured prior to the operation of the dragline and should be measured on site; these measurements should be recorded for later use. These measurements will be required to be input into the tightline parameter screen in the operator’s cab OIT.

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The tightline protection can be turned off with the rope limit bypass pushbutton. This will enunciate a visual tightline protection off fault. The time that tightline protection is turned off will be recorded by the PLC.

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JOYSTICK CALIBRATION The Hall Effect type Joystick is designed for use on mining equipment with the output voltage for the x and y axis between +/- 10 volts dc and zero volts in the neutral (center) position. The Joystick will have spring return in both the x axis and y axis with a full throw handle travel of 30 degrees off neutral for each axis. The Joystick will include a “type GK2” pushbutton incorporated in the handle with a change over contact.

Each Joystick provides an analog signal to the PLC for each axis of motion and is interpreted as the operator’s control request for each respective motion. There are also discrete signals that are used in conjunction with the analog signal to determine the operator’s request.

The Joystick calibration takes the raw data input and creates a scaled value in the PLC equal to +/ - 10 volts. This can compensate for drift in the input signals.

There are conditions that are checked for in the software including Joystick neutral readings and power supply checks. If an out-of-tolerance condition is detected, a fault is posted on the Operator Display.

NOTE: The Joysticks are the same for all the motions (dual axis). Therefore, in the Drag Joystick, the Y-axis is not used and labeled as a spare.

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REMOTE ROPE REEVING Rope Reeving (Drum Inching Control) is used by maintenance in the installation or removal of the hoist or drag wire ropes, and for drum maintenance. Rope Reeving is controlled by the Pony Drive System.

The Pony Drive system is comprised of one (1) electric motor directly coupled to a hydraulic pump.

The pump flow is controlled by two (2) proportional directional control valves. Each valve is used to control a separate hydraulic motor, one for hoist and one for drag. The system is designed to “ramp in or ramp out” providing a controlled speed change. It is a single speed bi-directional system.

The MC-1000 Radio Control Pendant will have the following controls: Function Buttons: F0: Brake Release F1: Brake Set F2: Forward F3: Reverse F4: Pump Start F5: System Enable F6: Pump Stop The DC Drives, MG Sets and bleed fans must be off when Reeving mode is selected.

CAUTION:

ROPE AND TIGHTLINE LIMITS ARE TURNED OFF WHILE IN REEVING MODE, OTHER NORMAL PROTECTIONS ARE STILL ACTIVE. WHEN ALL REQUIREMENTS ARE MET THE PLC WILL SEND A SIGNAL THAT ALLOWS THE PONY DRIVE SYSTEM TO BE TURNED ON.

The pony drive system is activated by pressing the hydraulic motor start button located on the pendant.

The hydraulic motor for hoist or drag is manually engaged by sliding the unit into the hoist or drag drum input shaft. Each hydraulic motor is mounted on a sliding frame adjacent to the Hoist and Drag drums. While sliding the hydraulic motor in place, the operator can use the controls to jog the hydraulic motor to line up with the drum for engagement. A proximity sensor will sense when the hydraulic motor of the pony drive is fully engaged in the drum. The PLC will then enable the brake release pushbutton.

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Rope Reeving is conducted from the machinery house with the MC-1000 Radio Control Pendant.

A pushbutton is pressed to cause CW or CCW motion; the selected motion will continue as long as the pushbutton is pressed, releasing the pushbutton will cause the drive to stop. Only one pushbutton will respond if more than one is pressed, the first button pressed will have priority.

The Pony Drive system has two faults that will shut it down and set brakes, neither of these will be enunciated to the PLC. Low oil level is triggered if the oil level in the hydraulic power pack falls below a preset level. High oil temperature is triggered when the oil temperature in the hydraulic power pack reaches a preset temperature.

If a communication fault occurs between the local control panel and the pendant, the pony drive will stop and the brakes will set. Once communication has been reestablished, it will be necessary to restart the pony drive system.

The PLC will set the brakes when the hydraulic motor is stopped or the proximity switch indicates that the pony drive hydraulic motor is not fully engaged. Anytime the head is neither fully engaged nor fully disengaged, the brakes will be set. A proximity switch will sense when the head is fully disengaged indicating to the PLC that normal machine operation will be allowed to commence. All applicable starting procedures will be followed.

If either of the hydraulic motors moves from fully disengaged while the MG sets are running, a fault will be initiated and hoist or drag will be immediately shutdown.

DANGER:

THE NATURE OF THIS PROCEDURE ALLOWS PERSONNEL TO BE IN CLOSE PROXIMITY TO THE ROPES AND DRUMS WHILE THEY ARE IN MOTION. ALL RELEVANT SAFETY PROCEDURES MUST BE FOLLOWED.

AIR SYSTEM The machine requires a compressed air system to provide for the release of the motion brakes and the lubrication system.

There are two air compressors on board the machine. These are standalone units with their own protective and operational controls.

The machine PLC monitors the on/off status and health of each compressor.

Additionally there is a pressure transducer in the air system that monitors the air pressure. This sensor is 0 to 200 PSI (0 to 1380 kPa) with an output to the PLC of 1 to 5 volt. This is scaled in the PLC to Pressure in PSI and is displayed on the operator screen.

The air compressor system status will generate faults. Air pressure below 85 PSI (590 kPa) will generate a warning. Air pressure below 80 PSI (550 kPa) will shut the machine down.

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STANDBY GENERATOR The standby generation system is self-contained, requiring minimum outside support for its operation. It does require a signal to initiate starting and stopping when in the ”AUTOMATIC” mode of operation and can be started and stopped “MANUALLY” at the EMCP3.2 control panel The standby power generation system includes one diesel generator set, installed inside an acoustic enclosure with a noise level tested at 80 dBA @ 1 meter (39.4 inches).

The diesel generator set is a 6 cylinder in-line configuration 4 stroke diesel turbocharged engine, close coupled to a single bearing, 4-pole alternator.

Its electrical output is 500kVA (400kW at 0.8 Power Factor) at 415V 50HZ 1500rpm Prime Power Duty.

The control systems are so arranged that they may be started and stopped either “AUTOMATICALLY” or “MANUALLY” by the set mounted “EMP3.2 model control panel.

Please see section titled EMCP3 SERIES CONTROL PANEL at the end of this section for EMCP3.2 quick reference information.

Please see the Electric Service manual for standby generator operation data.

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MAIN HOUSE CRANE The main house crane consists of two 37.5 ton crane bridges with traversing motors and two 18.75 ton hoists with traversing motors. Each hoist can be maneuvered onto either crane bridge using two transfer beams.

The crane is controlled by two radio control pendants. Each crane bridge has its own pendant.

When plugged into the same crane bridge, both hoists can be controlled from the same controller, either independently, or slaved together.

The main house crane must be locked down before the dragline propel and swing functions are enabled.

To unlock the Main House Crane 1.

Switch the main crane power on.

2.

Press and hold the Unlock button. The green light will go out. The locking pins will retract, and the red light will illuminate. At this point, the crane is in the unlocked position, and ready for long travel.

To lock the Main House Crane 1.

Slowly traverse the main house crane to a lockdown position. When the crane is in position, the yellow light will illuminate.

2.

Press the Lockdown button until the green “locked” light illuminates. The crane will power down.

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MAIN HOUSE CRANE BRIDGE LOCKDOWN The main house crane bridges can only be locked down at either of the two transfer beam positions on the runway beam.

NOTE:

The lockdown function is disabled unless the crane bridge is in a lockdown position.

There are three indicator lights on the crane. The green light indicates the crane is in position and locked. The yellow light indicates the crane is in position for lockdown, but is NOT locked down.

The red light indicates the crane is unlocked.

To lock down the crane bridge 1.

Traverse the crane bridge near the lockdown position. Use the slow speed when approaching the position.

2.

When the crane is in close proximity, the yellow light will illuminate. The Lockdown button is now operational.

3.

Press and hold the Lockdown button on the radio control pendant. When the red light goes out, long travel is disabled. The locking pins will engage, and the green light will illuminate. At this point, the crane bridge is locked down, and the main crane power is switched off.

NOTE:

The dragline will not propel or swing while the crane bridge is unlocked.

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CRANE TRANSFER BEAM Either main crane hoist can be located on either of the crane bridges, or on either of the transfer beams.

NOTE:

For both hoists to be operated from the same radio controller, both hoists must be plugged into the control cables from the same crane bridge.

A main crane hoist may be transferred from one crane bridge to the other using either of the two transfer beams. One transfer beam is located above the hoist drum, and the second is located above the drag drum.

1.

With the crane unlocked, and with the red light on, bring the crane near the lockdown position using slow speed. When the yellow light illuminates, the crane bridge is in position.

2.

Press and hold the Lock button. The crane bridge long travel is disabled, and the red light turns off. The crane bridge brakes will set, the locking pin will engage, the crane bridge hoist end stops will disengage, and the green light will be illuminated.

3.

Transfer the hoist from the crane bridge onto the transfer beam. Only slow speed will be available.

NOTE:

4.

To transfer a hoist from one crane bridge to the other, both bridges must be locked down on the same transfer beam.

Turn both cranes off.

The following steps only apply if a hoist has been transferred from one crane bridge to the other.

1.

Access the hoist that has been transferred. Disconnect the cable plug leading to the previous crane bridge from the transferred hoist. Using a rope, slowly allow the cable to retract into the cable reel on the previous crane bridge.

2.

Extend control cable from the current crane bridge cable reel, and connect it to the transferred hoist.

NOTE:

Each crane bridge contains two cable reels, labeled A and B. Ensure the cables are connected to the proper hoist. Failure to do so may result in operation of the wrong hoist.

3.

Turn on power for the main crane. Test that the hoist controls are operational from the radio controller for that crane bridge.

4.

Unlock the crane bridge from the lockdown position. Refer to “MAIN HOUSE CRANE UNLOCK” in this section.

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TYPICAL MACHINE SPECIFICATIONS This specification describes the principal mechanical features of a standard Bucyrus International, Inc. 8750 Walking Dragline.

NOTE: These are typical machine specifications.

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WORKING RANGES BOOM Boom Length Boom Point Sheave, Pitch Diameter A Boom Angle, Approx.

B Operating Radius C Dumping Height D Depth Maximum Allowable Load Hoist Drum, Pitch Diameter Hoist Ropes, Twin, Single Hitch, Diameter Drag Drum, Pitch Diameter Drag Ropes, Twin, Single Hitch, Diameter BASE E Outside Diameter, Nominal Bearing Area, Effective Bearing Pressure Rail Circle, Mean Diameter Circle Rollers, Mean Diameter Total Number of Rollers Main Swing Gear, Pitch Diameter, Approx.

WALKING TRACTION F Width of Shoe G Length of Shoe H Width over Both Shoes Bearing Area of Both Shoes Bearing Pressure @ 80% of Working Weight Length of Step, Approx.

Walking Speed REVOLVING FRAME J Width @ Rear End K Length L Clearance Radius, Rear End M Clearance Under Frame N Center Rotation to Boom Foot P Ground to Boom Foot WEIGHTS Domestic Shipping Weight (Inc. Bucket) Working Weight.

Ballast (Furnished by Customer)

360 feet-0 inch @ 39° 150.33 inch 39° 310 feet 175 feet-0 inch 213 feet-0 inch 715,000 pounds 125 inches 5.0 inches 125 inches 5.0 inches

109.7 M 3.818 mm 39° 94.5 M 53.3 M 65.0 M 324,322 kg 317.5 cm 127.0 mm 317.5 cm 127.0 mm

80 feet-0 inches 5,027 ft² 21.8 PSI 55 feet-0 inches 16 inches 546 inches

24.4 M 467 m2 150.3 kPa 16.8 M 406 mm 122 13.87 M

16 feet 80 feet-0 inches 117 feet-0 inches 2,560 ft² 34.2 PSI 100 inches 0.14 mph

4.87 M 24.4 M 35.7 M 182.1 M2 235.8 kPa 2540 mm 0.23 km/h

109.9 feet 125.3 feet 92.5 feet 15.9 feet 24 feet-0 inches 22 feet-0 inches

33.5 M 38.2 M 28.2 M 4.8 M 7.3 M 6.7 M

15,145,000 pounds 15,745,000 pounds 600,000 pounds

6,869,656 kg 7,141,812 kg 272,156 kg

Shipping Weight Subject to 5% Variation.

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EMCP3 SERIES CONTROL PANEL FRONT VIEW, DISPLAY SCREEN AND NAVIGATION KEYS QUICK REFERENCE GUIDE

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Navigation Keys AC OVERVIEW The AC Overview Key (2) will navigate the display the first screen of AC information. The AC Overview Key information contains various AC parameters that summarize the electrical operation of the generator set.

ENGINE OVERVIEW The Engine Overview Key (3) will navigate the display to the first screen of engine information. The Engine Overview information contains various engine parameters that summarize the operation of the generator set.

ALARM ACKNOWLEDGE / SILENCE Pressing the Alarm Acknowledge/Silence Key (6) for 2 seconds will cause the horn relay output to turn off and silence the horn. This will change the alarm condition from “present” to “active”.

Pressing the key will also cause any yellow or red flashing lights to turn off or to become solid depending on the active status of the alarms.

The Alarm Acknowledge/Silence Key may also be configured to send out a global alarm silence on the J1939 Data Link which will silence alarm horns on remote Alarm Annunciators.

The alarm or fault event must be rectified and cleared before resetting the system.

The system must be in the STOP mode and all alarms must be “active” to allow alarm and fault reset functions.

There are three ways to reset events, and details relating to alarm reset start on page 6 of this Quick Reference Guide. The most commonly used procedure is detailed on Page 8 of this Quick Reference Guide.

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LAMP TEST Pressing and holding the Lamp Test Key (7) will cause all of the LED’s and the display screen pixels to turn on solid until the Key is released.

RUN Pressing the RUN Key (8) will cause the engine to enter the RUN mode (Manual Mode of Operation).

AUTO Pressing the AUTO Key (9) will cause the engine to enter the AUTO mode (for Remote Start / Stop Operation).

SCROLL UP The Scroll Up Key (11) is used to navigate up through the various menus or monitoring screens. The Scroll Up Key is also used during set point entry.

During numeric data entry the Scroll Up Key is used in order to increment the digits (0-9). If the set point requires selection from a list, the Scroll Up Key is used to navigate through the list.

ESCAPE The Escape Key (12) is used during menu navigation in order to navigate up through the menu/sub-menu structure. Each key press causes the user to move backwards/upwards through the navigation menus. The Escape Key is also used to cancel out of data entry screens during set point programming. If the Escape Key is pressed during set point programming, none of the changes made on screen will be saved to memory.

SCROLL RIGHT The Scroll Right Key (13) is used during set point adjustment. During numeric data entry, the Scroll Right Key is used to choose which digit is being edited. The Scroll Right Key is also used during certain set point adjustments to select or deselect a check box. If a box has a check mark inside the box, pressing the Scroll Right Key will cause the check mark to disappear, disabling the function. If the box does not have a check mark inside the box, pressing the Scroll Right Key will cause a check mark to appear, enabling the function.

ENTER The Enter Key (14) is used during menu navigation to select menu items in order to navigate forward/downward in the menu/sub-menu structure. The Enter Key is also used during set point programming in order to save set points changes. Pressing the Enter Key during set point programming causes set point changes to be saved to memory.

DOWN The Down Key (15) is used to navigate down through the various menus or monitoring screens. The Down Key is also used during set point entry.

During numeric data entry the Down Key is used in order to decrement the digits (0-9). If the set point requires selection from a list, the Down Key is used to navigate down through the list.

SCROLL LEFT The Scroll Left Key (16) is used during set point adjustment. During numeric data entry, the Scroll Left Key is used to choose which digit is being edited.

The Scroll Left Key is also used during certain set point adjustments to select or deselect a check box. If a box has a check mark inside the box, pressing the Scroll Left Key will cause the check mark to disappear, disabling the function. If the box does not have a check mark inside the box, pressing the Scroll Left Key will cause a check mark to appear, enabling the function.

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STARTING AND STOPPING THE GENERATOR SET STARTING THE ENGINE Once the control is configured correctly, the control panel is powered up, and the generator set is ready to be operated, the generator set can be started.

There are several ways the generator set can be started from the control panel.

1. To START the engine for MANUAL OPERATION: Press the RUN KEY, to operate the system in Manual Mode.

2. Place the control in AUTO mode, for automatic start / stop function.

Then the engine can be started THREE DIFFERENT WAYS (via interface with a remote start initiation contact). a: Activate DIGITAL INPUT #2, which is the REMOTE INITIATE INPUT. b: Activate a REMOTE INITIATE over the MODBUS data link (register number 1055). c: Configure a PROGRAMMABLE CYCLE TIMER. When the control panel initiates a start command on a diesel engine, the control checks to make sure there are no SHUTDOWN EVENTS present (labeled PRESENT) or that there are no latched SHUTDOWN EVENTS (labeled ACTIVE).

If there are no shutdown events that are active or present, and after any pre-crank or start-aid activities have completed, the starter motor and fuel control will be activated.

The engine will continue to run whenever there is a remote start initiated and the Auto mode key has been pressed.

STOPPING THE ENGINE Once the engine is started, the engine can be stopped by pressing the STOP KEY on the control panel.

If the control is in AUTO, the engine can also be stopped by DEACTIVATING all of the remote initiate commands.

There are three possible sources for this command: 1. The remote initiate input (digital input #2) which is the REMOTE INITIATE INPUT. 2. The remote initial command over the MODBUS Data link (register number 1055).

3. The Programmable Cycle Timer Once the STOP command is issued, the control will go into COOLDOWN MODE. Cooldown mode will run for the duration of time that it is programmed in the COOLDOWN DURATION set-point (Normally set for 3 - 5 minutes). If the cooldown time is set for zero minutes, the engine will stop immediately.

The cooldown timer can be overridden by pressing and holding the STOP KEY for 5 seconds. The display will show a splash screen that will ask if you want to BYPASS COOLDOWN? or continue with the cooldown cycle.

If the ENTER KEY

is pressed from the splash screen, the cooldown timer will be bypassed.

is pressed from the splash screen, the cooldown cycle will continue until the programmed If the ESCAPE KEY cooldown time has elapsed.

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ALARM INDICATORS YELLOW WARNING LIGHT A flashing yellow light indicates that there are unacknowledged active warnings. A solid yellow light indicates that there are acknowledged warnings active. If there are any active warnings, the yellow light will change from flashing yellow to solid yellow after the Alarm Acknowledge/Silence Key (6) is pressed. If there are no longer any active warnings, the yellow light will turn off after the Alarm Acknowledge/Silence Key (6) is pressed.

RED SHUTDOWN LIGHT A flashing red light indicates that there are unacknowledged active shutdown events. A solid red light indicates that there are acknowledged shutdown events active. If there are any active shutdown events the red light will change from flashing red to solid red after the Alarm Acknowledge/Silence Key (6) is pressed. Any condition that has caused a shutdown event must be manually reset. If there are no longer any active shutdown events, the red light will turn off.

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RESETTING EVENTS ALARM ACKNOWLEDGMENT. To acknowledge any alarm or fault/shutdown event, press the “BELL” symbol pushbutton on the EMCP3 Display Panel for 2 seconds. This will change the condition from “present” to “active”.

The alarm or fault event must be rectified and cleared before resetting the system.

The system must be in the STOP mode and all alarms must be “active” to allow alarm and fault reset functions.

There are three ways to reset events. The most commonly used is detailed on Page 8 of this Quick Reference Guide.

1. RESETTING INDIVIDUAL EVENTS FOR THE EMCP 3 GSC. This applies to the EMCP 3 GSC only. The basic process is to reset individual events by navigating to the desired event in the event log.

To reset individual events on the EMCP 3 GSC, start by navigating to the event log: From the top of the Main Menu, enter Event Logs by pressing the Enter key.

FROM: MAIN MENU

Select EVENT LOGS

by pressing the ENTER KEY

Next, select the log that contains the event that needs to be RESET.

Scroll up or down to select the desired log and Press ENTER KEY In this example image, there are only two PRESENT or ACTIVE events, and they are both in the GENSET CONTROL log.

Scroll up or down through the list of events and find the ACTIVE event that requires resetting.

Events are ordered by the status of the event; PRESENT events are listed first, followed by ACTIVE

events, and finally the INACTIVE events.

Press ENTER KEY to view the event details.

Pressing the ENTER KEY will RESET the event.

If the control is in STOP mode, RESET will be shown and highlighted.

NOTE: If the event status is present, the RESET text will not be visible and the event cannot be reset until the condition that caused the event has been addressed.

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2. RESETTING ALL EVENTS FOR A SINGLE MODULE The second way, which applies to all modules other than the EMCP 3 GSC, is to reset all events in that modules event log by navigating to one of the active events in the event log.

With any method, you must be in STOP mode. A key difference between the EMCP 3 GSC and all other modules is that the other modules don’t display a PRESENT status for events.

Events are shown as ACTIVE if they are currently affecting the system, or as INACTIVE if they are not.

To reset all of a modules events on any individual module except the EMCP 3 GSC (listed as GENSET CONTROL in the event log), start by navigating to the event log.

FROM: MAIN MENU

Select EVENT LOGS

by pressing the ENTER KEY

Next, select the log which contains the event that needs to be reset. In this example image, there is only one ACTIVE event, and it is in the ENGINE CONTROL log.

Scroll up or down to select the desired log and Press ENTER KEY Events are ordered by the status of the event; ACTIVE events are listed first, followed by the INACTIVE events. Scroll up or down through the list of events and find the ACTIVE event that requires resetting.

Press ENTER KEY to view the event details.

If the control is in STOP mode, and engine speed is zero, RESET ALL will be shown and highlighted.

Pressing the ENTER KEY

will RESET all events.

Pressing the enter key will reset all of the ACTIVE events in that module’s event log that can be reset.

NOTE: Modules other than the EMCP 3 GSC cannot display events as PRESENT. So if pressing ENTER KEY at RESET ALL doesn’t reset all of the events, the condition causing the event being viewed may still be present.

For example, if the engine shut down on high coolant temperature, then the events will not reset until the coolant temperature drops below the shutdown threshold.

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3. RESETTING ALL EVENTS FOR ALL MODULES The third way to reset events is a shortcut to reset all events for all modules.

With any method, you must be in STOP mode.

Once all of the events have been viewed and the condition(s) that are causing the events have been corrected, all active events (those for which the condition is not present) on all modules can be reset using the RESET ALL EVENTS feature.

In order to do this, the control must be in STOP mode and engine speed should be zero.

FROM ANY SCREEN: Press the and hold the ACKNOWLEDGE

for approximately 5 seconds.

Pressing the

A confirmation prompt will appear. will continue and RESET all events on all modules.

ENTER KEY

Pressing the

will CANCEL the reset operation.

ESCAPE KEY

NOTE: Reset All Events will not reset Present events!

For example, if the E-Stop switch is pressed and an EMERGENCY STOP SWITCH ACTIVATED SHUTDOWN is present, it cannot be reset until the E-Stop is pulled out and the event status changes from PRESENT to ACTIVE.

TROUBLESHOOTING RESETTING EVENTS There are common reasons for the EMCP 3 GSC not allowing events to be reset.

First of all, in order to reset any event, the EMCP 3 GSC must be in STOP mode. In order to reset engine ECM events, the engine speed must also be zero.

One common confusion about events is the SERVICE MAINTENANCE INTERVAL WARNING. This event is explained below.

If a SERVICE MAINTENANCE INTERVAL WARNING is PRESENT, it cannot be reset. The warning is PRESENT because the countdown timer has reached zero. To clear the warning, the timer must be reset, rather than the event. When the timer is reset, it returns to the programmed interval (factory default is 180 calendar days or 500 engine hours). This timer must be reset from the display; it cannot be reset by using the Service Tool alone.

NOT IN AUTO is another event that can cause confusion is NOT IN AUTO. This event is Present whenever the control is in either RUN or STOP. As a result, it can not be reset in STOP (as the event is present).

It will be Active when the control is in Auto and Present when the control is in STOP. The event will reset when the control is returned to AUTO

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Grammer Actimo XXL Pneumatic Suspension Operating Instructions !

IMPORTANT: Read and understand this Grammer seat instruction manual before operating • For control system adjustments see enclosed instructions • Adjust the suspension to accommodate your weight before operating • If equipped with seat restraint, insure it is fastened before operating • Adjust the seat and seat system to your personal comfort preference before operating • Do not adjust seat or seat system while operating this equipment • Immediately report any malfunction or concern about the seat /seat system to your supervisor • Under no conditions should you operate equipment that is in disrepair or malfunctioning

!

IMPORTANT! Seating and Seat System Disclaimer can be found on our website at: www.jrmerritt.com/seatdisclaimer

Stratford, CT z www.jrmerritt.com 203-381-0100 z Fax: 203-381-0400

Distributors for Grammer, Inc.

Rev. 9/15/10

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9 7

10

6

11

4 5 3

18

1+2

13 12

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OperatingBI010575 Instructions Contents General instructions .................................................................................... 20 Safety instructions....................................................................................... 20 Connecting data.......................................................................................... 22 Guarantee and liability ................................................................................ 22 Seat functions and operation ...................................................................... 23 ù

Weight adjustment .............................................................................. 23

ú

Height adjustment ............................................................................... 23 û

Seat pan angle adjustment ................................................................. 23

ü

Seat depth adjustment ........................................................................ 24 ý

Absorber.............................................................................................. 24 þ

Armrest adjustment * .......................................................................... 24 ÿ

Armrests * ** ...................................................................................... 25 Headrest * ** ...................................................................................... 25

Seat heater * ** ................................................................................... 25 ù ù ù ù ú ù û

Lumbar support................................................................................... 26 Backrest adjustment ........................................................................... 26 Fore/aft isolator ................................................................................... 26 Fore/aft adjustment ............................................................................. 27

Maintenance ............................................................................................... 28

* if fitted

GB

** optional extra 19

General instructions

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The operating instructions must be read in full before use.

The operating instructions must be kept in the vehicle and always be at hand.

The driver’s seat may only be fitted, serviced and repaired by specialist personnel.

The respective national regulations and the vehicle manufacturer’s fitting instructions must be observed.

The national fitting regulations can be obtained from GRAMMER AG or from agencies of the company, or from the vehicle manufacturer.

A correctly functioning and individually adjusted driver's seat is essential to your health.

Take adequate care of your seat and have it serviced regularly to ensure that it functions correctly.

The functional checks are to be carried out at least as regularly as vehicle services (see maintenance plan for vehicle).

These operating instructions should always be kept with the driver's seat. If the seat is passed on to a third party, it must be accompanied by the relevant operating instructions.

Subject to modifications serving engineering progress and deviations compared to the standard type seat arising therefrom.

Safety instructions

Driver's seats that have been adjusted incorrectly have a smaller moving area.

In order to prevent any personal injury, the seat must be adjusted for the driver's weight

and .

! #" $ % %& ' (%& *) $ % $ *+ %

To prevent injury, of the driver's seat.

-,

.+!+/ % % of the driver’s seat, possible ( 0# /+* $ & has to be removed from the seat cushion and the backrest upholstery.

To eliminate any risk of accident, the settings must be checked to ensure they are

$ % & *

. correctly engaged

$ ) % & %

Adjustments must be made . $ %(% & $

21 $ 3 + & %$ 0 3 , the backrest frame must be supported, for example held in place, before the backrest adjuster is operated. If you fail to do so, there #"4 %

. is a danger that the backrest frame may jerk forward and

20

GB

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SafetyBI010575 instructions 2687 9 : ; < 7 = > ? @ A*@ ; > ? > B C > ? ? @ < 7 D < B D!A E%@ ; > ? > < @ (for example fitting parts which are not original FHG 68I I J G AG parts) may impair the safety standard to which it has been tested.

K%L 7 : @ C A 7 ? M*< 9 N > C M/O < C B > D , threatening your ? < E > @ 9 . For this reason, < 7 9 : ; < 7 = > C 7 D > ?%C = 7*A E%@ ; > ? > < @ must be approved by FHG 68I I J G AG. 5

During the removal and installation of the driver’s seat, the corresponding instructions by the specific vehicle manufacturer must be strictly observed!

5

Do not hold onto the covers for lifting the driver's seats. If you do so anyway, there is an C 7 : B > < ? > D'B C ?%PHA E3C 7#Q L B 9 D L > @ A'R A%A ? > 7%C 7 =!A B3N%B > < P C 7 =!: A S > B ? .

5

Before you remove the driver’s seat, disconnect all plug-in connections between the seat and the vehicle supply network. When you replace the plug-in connectors, make sure they are tight (dust, water).

5

Seatbelts are fitted or can be retrofitted to the driver’s seat. Seatbelts M*< 9 A 7%R 9 N > E C @ @ > D A 7 @ ; > < O%O%B A S < R A E%@ ; > S > ;%C : R >*M*< 7 L E < : @ L B > B , as they increase the load in the seat mounting area.

Seatbelts must be fitted in accordance with specific national regulations and guidelines, and must be approved by FHG 68I I J G AG. 5

Seatbelts must be fastened N > E A B > D B C S%C 7 = .

T ; > ? > < @ N > R @ ? M L ? @3N > B > O%R < : > D after an accident.

L Where seatbelts are fitted to the driver's seat, the ? > < @ and ? > < @UM A 7 @ C 7 = must be

< % D

D C @ C

A

7

< R R 9 checked by specialist personnel after an accident has occurred.

5

L Fasteners must be : ; > : P#> D'B > = R < B R 9VE A B%@ C = ; @%? > < @ . If the seat wobbles, there may be loose bolts or other faults.

5

If you notice that the seat does not function correctly (for example a defective suspension of the driver's seat; improper curvature of the lumbar support or damaged bellows), : A 7 @ < : @.< ?%O > : C < R C ? @%W A B PX?%; A O C M!M*> D C < @ > R 9 to arrange for repairs to be carried out.

If you fail to do so, your health may be affected and the B C ?%PHA E.< : : C D > 7 @3C 7 : B > < ? > D .

5

Before the vehicle is used, switches that might be in the seat (for shutting down mechanical equipment when the driver leaves his/her seat) must be checked for O%B A O > B E L 7 : @ C A 7 .

If malfunctions are detected, the vehicle must not be driven.

K 6 T [_[]Y `_J Z – – Y Z\[]G J%6\^_J3` G_Y ^_acb

5

-d A < D ? M L ? @37 A @3N > O%R < : > D!A 7 ? > < @ ? (e.g. with a built-in switch) except for the driver’s 5

weight during normal use, as the vehicle may otherwise start to move by itself.

K 6 T [_[]Y `_J Z – – Y Z\[]G J%6\^_J3` G_Y ^_acb If you take off the weight from the seat while driving, this will cause the vehicle to stop.

Do not indent the bellows while there is load on the driver’s seat.

K []G_e ^_f Y Z\F – – G_Y ^_acb 5

5

Make sure that the C 7 @ > B C A B A E%@ ; > D B C S > B g ? ? > < @ remains free of E A B > C = 7!O < B @ C : R > ? or R C h L C D ? .

GB

21

BI010575

Safety instructions

BI010575

The driver’s seat is k l%mHn l o p l q r s l and must be protected against splashes of water! i

j

Any conversion or refitting work on a HuUv8w w x3u AG driver’s seat must be performed z o {*m k p |X}%s k ~ } by l p n q o { or }%y%q l n % y n q q o {'~ o p } k % o and in exclusively in n y l s k p q adherence with the applicable operating, maintenance and installation instructions and in compliance with all relevant national regulations. i

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- ~%p k ~ o p3q } l n n l q k n { n } } o % bear the risk of k%{ q q # 4y%p or ~%p k ~ o p l { n n r o i

j

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and the proper function of the driver’s seat or mounted parts can no longer be guaranteed.

The driver’s seat is p o o k n q l o n o . Worn parts such as rollers, shock absorbers and the fixation must be checked from time to time. i

j

j

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- o k p o { p q %q r. you must check if all seat settings selected guarantee a } n o k ~ o p n l q k i

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of the vehicle.

Connecting data If you need to connect cables to the vehicle supply network, strictly observe the following instructions: i

o k p o k y* k % o l an o o l p q n k }%y o p fitted in the driver’s seat (e. g. the seat heater or the seat ventilation), you must obtain the relevant electrical data for the respective vehicle with reference to voltage, protection and the kind of connections from the manufacturer, from HuUv8w w x3u AG or the company’s agencies.

For safety reasons, the installation and connection to the vehicle supply network must be carried out by authorized specialist personnel only.

The seat connections must be protected independently of other vehicle components. j

j

j

t

\ 12V 24V

k ~%p o } } k p

3o n l3s o n l o p% k ~%p o } } k p

10A 7,5A

20A 10A

For building an electric connection, select an electric circuit by means of which the electric consumers of the driver’s seat are separated from the live network when l s o q r %q l q k !q } } m q l s o {!k . j

j

Guarantee and liability GRAMMER AG does not disclaim any guarantee or liability for damage resulting from incorrect assembly, use or repair of the seats. i

i

Further details on the guarantee granted by GRAMMER AG are stated in your contractual documents (see invoice or delivery note). Guarantee claims against HuUv8w w x3u AG beyond the guarantee obligations described there are excluded. t

22

GB

BI010575

Seat functions and operation BI010575 Weight adjustment The seat must be adjusted for the driver’s weight by briefly pulling the actuator lever of the automatic weight and height adjuster (arrow) with the vehicle at a standstill and the driver sitting on the seat.

The driver must sit absolutely still during adjustment.

Before adjusting the weight, adjust shock absorbers to the position “soft”.

F To prevent damage to the health, the setting for the driver’s weight must be checked and adjusted individually before the vehicle is driven.

Height adjustment The seat height can be set pneumatically and is continuously adjustable.

The seat height can be altered by pulling or pushing the adjustment lever fully up or down (arrow). If the adjustment reaches the top or bottom endstop, the height is adjusted automatically in order to guarantee a minimum spring travel.

Before adjusting the height, adjust shock absorbers to the position “soft”.

F In order to avoid damage, do not operate compressor for more than 1 minute Seat pan angle adjustment The angle of the seat pan can be individually adjusted.

To adjust the angle of the seat pan, pull the left handle upwards. By exerting pressure on or off the front or rear part of the seat pan it can be moved to the desired position.

* if fitted

GB

** optional extra 23

BI010575

Seat functions and operation

BI010575

Seat depth adjustment The depth of the seat pan can be individually adjusted.

To adjust the depth of the seat cushion, pull the right handle upwards. By moving the seat cushion backwards or forwards the desired seating position can be reached.

Absorber The absorber setting of the seat can be varied to suit the on and off-road driving conditions.

The cushioning effect can be individually adjusted for this purpose.

Turn the lever to the desired position and release

hard medium soft

Armrest adjustment * The inclination of the armrests can be modified by turning the adjustment knob.

When turning the knob to the outside the front part of the armrest will be lifted, when turning the knob to inside it will be lowered.

* if fitted 24

** optional extra

GB

BI010575

Seat functions and operation BI010575 Armrests * ** The armrests can be folded up if required and the height individually adjusted.

To adjust the armrests for height, separate the round cap (see arrow) from the cover, loosen the hexagon nut (size 13 mm) behind it and adjust the armrests to the desired position (5-steps) and tighten the nut again ( ). Replace the cap onto the nut.

Headrest * ** The headrest can be individually adjusted for height by pulling it upward over the various increments up the end stop.

By pushing foreward or rearward the angle of the headrest can be adjusted individually.

To remove the headrest, pull it over the end stop.

Seat heater * ** The seat heater can be turned on/off by pressing the switch.

0 = seat heater OFF 1 = seat heater ON

* if fitted

GB

** optional extra 25

BI010575

Seat functions and operation

BI010575

Lumbar support With the upper and lower switch the curvature in the upper and lower area of the backrest upholstery can be individually adjusted.

This increases both the seating comfort and the performance of the driver.

The lumbar support curvature can be increased pressing "+" or reduced by pressing "–" on the relevant switch.

When the backrest upholstery does no longer react to pressing "+", the maximum curvature has been reached and the switch should be released.

Backrest adjustment Pull up the locking lever to release the backrest catch. When releasing the backrest catch, do not apply load to the backrest by pressing against it.

By exerting pressure on or off the front or rear part of the seat pan it can be moved to the desired position. Release the locking lever to lock the backrest.

F

It should not be possible to move the backrest into another position after it has been locked.

Fore/aft isolator Under certain driving conditions (for example with a trailer attached), it is useful to activate the fore/aft isolator. This means that shock impacts in the driving direction can be better absorbed by the driver seat.

Position Position

= fore/aft isolator off = fore/aft isolator on

F After the adjustment of position , the locking lever must latch into the desired position.

For that, the seat must be pressed backwards until it latches with an audible click.

F

It should not be possible to move the fore/aft isolator into another position when it is locked. * if fitted 26

** optional extra

GB

BI010575

Seat functions and operation BI010575 Fore/aft adjustment The fore/aft adjustment is released by lifting the locking lever.

c 8 _ _ \ H _ % ¡ ¢H£ ¤.¥ ¦ ¦ § ¨ © ª¬« ­\£'© £ ª £ ® ¨ ¯ ¥ ª ¨ ª ° ¨ ± £%¦ ¢ © ²'± ¨ ³ ¨ ¯ § ¯ ³% © ² ´ °% ± ¨

F After the adjustment, the locking lever must latch into the desired position with an audible click. It should not be possible to move the driver’s seat into another position when it is locked.

F Do not lift the locking lever with your leg or calf.

* if fitted

GB

** optional extra 27

BI010575

Maintenance

BI010575

Dirt can impair the function of the seat, So make sure you keep your seat clean.

Upholstery does not need to be removed from the seat frame for cleaning.

¶ · ¸ ¹ º » ¼ ¸ ¶ ½#¾ ¿ ¶ À ¾ Á ¹ ¸  ¸  ¾ à ¶ ¿ ½ À ¾ Ä ¸ Å ¹ ¸UÆ*¶ Ç]È ¾ À ½ÊÉ º À ÁH¶ À Ë ¶ » Ë ¿ ¶ · Ä ¾ ¹ »#È4·%À Ç Ì Í Â ¾ »*¿ Î ¾ ¶ »%¹ » Ï*¸  ¾ à ¶ ¿ ½ À ¾ Ä ¸ ¿ · Ä%Â%¹ º » Ð ¸  ¾ à ¶ ¿ ½ À ¾ Ä ¸UÆ/· Ä ¸ à ¾  ¾ Î Ë'¹ »!Ñ%Î ¶ ¿ ¾ Á  ¾ »*º Ñ ¾ À ¶ ¸ ¹ » Ï*¸  ¾ à ¶ ¿ ½ À ¾ Ä ¸3Î ¾ Ò ¾ À Ó µ

Ô\Õ Õ Ö3×3Õ Ø ÙH×

: Do not clean the seat with a pressure washer!

When cleaning the upholstery, make sure the upholstery is not soaked.

Use standard commercially available ·%Ñ%Â º Î Ä ¸ ¾ À Ç º À3Ñ%Î ¶ Ä ¸ ¹ ¿ Ä*¿ Î ¾ ¶ »%¹ » Ï ¶ Ï ¾ » ¸ Ó Õ ¾ Ä ¸

É ¹ À Ä ¸%É º À ¿ º.Æ/Ñ ¶ ¸ ¹ Ã ¹ Î ¹ ¸ Ç

on a small, concealed

area.

28

GB

BI010575 BI010575

29