Cat Dragline 8750 ELECTRIC WALKING DRAGLINE Operation & Maintenance Manual

BI616938

BUCYRUS R

8750

WALKING DRAGLINE OPERATOR’S MANUAL (UPDATED FEB. 2007)

SN: 141159 Manual No.

10348 Rev. 2

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

BI616938

Bucyrus International, Inc. 8750 Walking Dragline

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Bucyrus International, Inc. 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, AND/ OR WARD LEONARD LOOP DC 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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Bucyrus International, Inc. 8750 Walking Dragline

BI616938

Bucyrus International, Inc. 8750 Walking Dragline

8750 Walking Dragline Operator’s Manual Manual No. 10348 sn: 141159 Lot 30

Table of Contents INTRODUCTION ........................................................................................................................... 3 SAFETY .................................................................................................................................. 4 SAFETY PRECAUTIONS ........................................................................................................ 5 MACHINE OVERVIEW .................................................................................................................. 8 Nomenclature .............................................................................................................................. 8 Base Frame (Tub) ....................................................................................................................... 9 Rotating Gear and Rails (Section View) ...................................................................................... 10 Roller Circle (Section View) ........................................................................................................ 10 Deck Plan .................................................................................................................................. 11 Machinery House ........................................................................................................................ 12 Operator’s Cab and Anteroom .................................................................................................... 13 Operator’s Seat and Controls ..................................................................................................... 14 Propel Machinery ........................................................................................................................ 15 Hoist and Drag Machinery .......................................................................................................... 16 Swing Machinery ........................................................................................................................ 17 Fairlead Assembly ..................................................................................................................... 18 Tri-Structure ............................................................................................................................... 19 Safety, Ropes, Tri-Structure ....................................................................................................... 20

BOOM ................................................................................................................................... 21 Boom Assembly and Boom Support .......................................................................................... 21 Boom Support Ropes ................................................................................................................. 21

DRAGLINE BUCKET ............................................................................................................. 22 Bucket and Rigging Assembly ................................................................................................... 22

OPERATOR’S CAB AND ANTEROOM ....................................................................................... 23 Operator’s Cab - Anteroom ......................................................................................................... 23

OPERATOR’S CONTROLS ................................................................................................. 24 PRIMARY CONTROLLERS ........................................................................................................ 25 Operator’s Seat and Controls ..................................................................................................... 25

PLUGGING THE MOTION ..................................................................................................... 27 SECONDARY CONTROLS .................................................................................................. 28 Operator’s Controls .................................................................................................................... 28 Left-hand Operator’s Controls ..................................................................................................... 29 Right-hand Operator’s Controls ................................................................................................... 31

WINDSHIELD WIPER ........................................................................................................... 33 Windshield Wiper Assembly Operator’s Cab .............................................................................. 33

OPERATOR’S DISPLAY ............................................................................................................. 34 Operator’s Display ...................................................................................................................... 34

DISPLAY AREA & INDICATORS ...................................................................................... 35 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.

© 2007 Feb. 2007

Bucyrus International, Inc. All Rights Reserved.

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CAB DISPLAY SCREENS ..................................................................................................... 35 Operator’s Cab Title Screen ....................................................................................................... 35 Operator’s Main Menu Screen ..................................................................................................... 36 Display Information Screen ........................................................................................................ 36 Setup Screen ............................................................................................................................. 37 Active Alarms Screen ................................................................................................................ 37 Faults and Alarm History Screen ................................................................................................ 38 Alarm Help Screen ..................................................................................................................... 38 Propel Shoe Positions and Error Screen .................................................................................... 39 Hoist and Drag Limit Calibration Screen ..................................................................................... 39 Propel Shoe Encoder Calibration Screen ................................................................................... 40 Fault Counters and Operating Hours Screen .............................................................................. 40 Tightline Parameters and Operating Data Screen ....................................................................... 41 Operator’s Screen ...................................................................................................................... 41 Swing Position and Load Weigh Screen ..................................................................................... 42 Rope Reeving Screen ................................................................................................................. 42 Boom Raising and Lowering Screen ........................................................................................... 43 Lubrication Status Screen .......................................................................................................... 43 Automatic Lubrication Setup Screen .......................................................................................... 44 Propel Shoe Move Selection Screen .......................................................................................... 44

HOIST/DRAG LIMIT CALIBRATION ....................................................................................... 45 HOIST LIMIT .................................................................................................................... 46 DRAG LIMIT ..................................................................................................................... 47 OPERATOR CONTROLS IN THE MACHINERY HOUSE ........................................................... 48 Machinery House Operator Control Panel ................................................................................... 48

MACHINERY HOUSE REAR DOORS .................................................................................. 50 Machinery House Rear Doors ..................................................................................................... 50 Machinery House Rear Doors ..................................................................................................... 51

DOOR OPERATION ....................................................................................................... 52 DOOR OPERATING SEQUENCE .................................................................................. 53 Control Panel for the House Rear Doors ..................................................................................... 53

PRE-START INSPECTION ......................................................................................................... 55 TYPICAL START-UP ................................................................................................................... 56 TYPICAL DIGGING CYCLE ......................................................................................................... 58 Operator’s Controls .................................................................................................................... 58

GROUND PREPARATION .......................................................................................................... 60 WALKING/PROPEL OPERATION ............................................................................................... 61 WALKING MACHINERY ......................................................................................................... 61 WALKING MACHINERY CONTROL ...................................................................................... 62 WALKING .............................................................................................................................. 63 Operator’s Seat and Controls ..................................................................................................... 64

SHUTDOWN ............................................................................................................................... 66 PARTIAL SHUTDOWN .......................................................................................................... 66 COMPLETE SHUTDOWN .................................................................................................... 66 TYPICAL MACHINE SPECIFICATIONS ....................................................................................... 67 COMPONENT WEIGHTS ........................................................................................................... 68

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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. It provides the operator with the location and explanation of the controls, instructions for machine operation, and certain maneuvering techniques.

Throughout this section, and the remainder of the 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 machine.

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 Telephone (414)-768-4000

53172-0500

It is Bucyrus International’s policy 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 on 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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SAFETY PRECAUTIONS

General Precautions: • The employment of qualified maintenance personnel, through a scheduled maintenance program, 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 the service man 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 of 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 be high or low voltage. Never attempt electrical repairs unless you are qualified.

• Check 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.

• Mechanical Brakes are designed for use as static holding brakes only. Use 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.

• Allow electrical inspection and maintenance to be performed only by a qualified electrician.

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Maintenance Precautions: • Do not wear rings, wrist watches 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.

• Always have a second person to monitor the lifeline when working in confined spaces.

• 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 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 suspended heavy 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 oxy/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.

• Use extreme caution when using compressed air to dry parts. Use approved air blowguns, 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.

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• 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 a trail cable.

Operating Precautions: • Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 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/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.

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

• Do not propel the machine on a slope greater than specified in the GROUND PREPARATION section of the Operators Manual for this machine.

• Do not leave the rotary gearbox suspended in the air when leaving the machine unattended.

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

Nomenclature

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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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Rotation of the machinery house occurs as the gear packages of the swing motor assemblies engage a 360º circular segmented rack gear assembly.

Rotating Gear and Rails (Section View)

During rotation, the machinery house rides on a package of 138 rollers arranged to evenly spread the load over the upper and lower rail segments.

Roller Circle (Section View)

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Deck Plan

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Within the machinery house are the main powered elements of this machine. This includes Hoist and Drag motors and drums, Swing machinery, consisting of six separate motors and gear packages, plus the Propel machinery including four separate motors plus gear and walking assemblies.

Machinery House

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The Operator’s Cab and Anteroom extend out from the front of the machinery house on the right hand side of the machine. The operators cab has glass on the front, left, and right hand sides allowing the operator to see the work area clearly and safely.

Operator’s Cab and Anteroom

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The Operator’s seat is positioned at the front of the operators cab providing the best location to view the work of the machine. Controls for the machine are located on the two armrests of the machine. Joystick assemblies are provided to control machine positioning functions.

Moving the RIGHT joystick forward and backward controls the height of the bucket (Hoist functions).

Moving the RIGHT joystick from side to side controls the rotation of the machine on the base frame.

Moving the LEFT joystick forward and backward controls the distance of the bucket from the front of the machine.

In addition, setting a selector switch also allows the LEFT joystick to control the propel motion of the machine. Pulling back on the LEFT joystick, with the selector switch set, initiates the propel or backwards motion of the machine, while pushing forward repositions the shoe for the next propel motion.

Operator’s Seat and Controls

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The propel machinery consists of four motors (two per arm), a gear package, a power transfer assembly, and the walking eccentric, arm and shoe. To move, the walking dragline physically lifts the back of the base frame (tub) off the ground, and drags the frame backwards.

Propel Machinery (Right Hand Shown, Left Opposite)

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The hoist and drag machinery control motion of the draglines bucket. The Hoist Ropes go up the Boom of the machine and are used to raise and lower the bucket. The Drag Ropes control the relative distance of the bucket from the front of the machine. Different combinations of tension control the relative distance, depth and height to which the bucket is positioned.

Hoist and Drag Machinery

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Six 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 assembly.

Swing Machinery

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

Fairlead Assembly

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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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The purpose of the Tri-Structures Safety Ropes is to provide a safety anchor for the back legs of the tri-structure.

Safety, Ropes, Tri-Structure

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BOOM

Boom Assembly and Boom Support

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

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DRAGLINE BUCKET

Bucket and Rigging Assembly

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OPERATOR’S 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 - 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. Ducts from it to the floor area surround the operator for comfort and visibility. The control for this unit is on forward side of the operator’s cab rear wall.

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The ceiling, walls and floor of both rooms are insulated. Adequate lighting is provided and the control switches are conveniently placed. The ceiling and walls are made of a stainless material and are easily cleaned. The floor covering deadens sound and is easily maintained.

CAUTION:

There is a drop from the cab floor to the walkway on the outside of the cab.

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.

OPERATOR’S CONTROLS The operating controls for this machine are all grouped around or are a part of the operator’s station in the cab. The machine start-up controls are located inside the machinery house.

The operator’s seat has adjustments for positioning it to the best location to suit individual operators.

The operator should always adjust the seat to suit before taking over the controls. See the adjustment procedure following later in this section.

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 EXCITATION STOP PUSHBUTTON.

The machine’s operating motions - HOIST, DRAG, PROPEL and SWING - are controlled by the operator using the 2 Joysticks positioned on the right and left armrests of the operator’s seat.

These are the primary controls. Moving any of these off their neutral position, when the drives are activated, will initiate motion.

The secondary controls are mounted in the console on each side of the operator. They are the necessary 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 systems on-board.

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PRIMARY CONTROLLERS The 2 primary controllers for machine operation are the manually-operated joysticks (masterswitches) situated on each side of the operator’s seat. 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 smaller 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.

Operator’s Seat and Controls

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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 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 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 rearward 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) as well as swing motion (left and right movement). The hoist control is activated during DRAG mode.

• Moving the right joystick forward from its neutral 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 is for the air horns.

The RIGHT JOYSTICK also controls machine rotation. Moving the lever to the RIGHT rotates the entire machine to the right. Moving the lever to the LEFT rotates the entire machine to the left.

When no pressure is applied to the controller, it automatically returns to the neutral position.

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. 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.

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The swing drive is torque controlled. This means that the further the controller is moved, 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 controller. 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 positions 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 returned to neutral 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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SECONDARY CONTROLS The secondary controls are located on the control panels beside the operator. They consist of the necessary lights, switches, and pushbuttons to support the primary controls. A fault warning buzzer, and a signal bell notify the operator of potential machine problems or to get his attention. The phone set for the operator is mounted on the OIT stand behind the operator.

Operator’s Controls

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Left-hand Operator’s Controls

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The following items are on the LEFT CONTROL PANEL 1.

EARTH CONTINUITY LOCKOUT - 2-position, lockable, pushbutton used for Ground Test / Lockout.

2.

WINDSHIELD WIPERS, FRONT - (On, Off) A 2-position selector switch for controlling the wiper assembly on the front cab window.

3.

SHOE PARK - (Set, Release) A green illuminated pushbutton used to initiate the automatic parking function. When lit it will indicate that the walking shoes are in their PARKED position, when flashing indicates that shoe park is operating. See OPERATING WALKING MECHANISM in this section.

4.

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

5.

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

6.

HVAC - (Vent, Heat, Cool, De-Mist) A 4-position selector switch used to set the heating / cooling mode for the operator’s cab heater / air conditioner unit.

7.

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

8.

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

The following items are located on the RIGHT CONTROL PANEL: 1.

EMERGENCY STOP - A red mushroom type pushbutton that will set ALL brakes and deenergize ALL controllers on the machine when pressed.

2.

MACHINE SHUTDOWN - A red flush-mounted pushbutton used to initiate machine shutdown.

3.

HOIST BRAKE - A green light that indicates when the HOIST brakes are released.

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Right-hand Operator’s Controls

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4.

DRAG BRAKE - A green light that indicates when the DRAG brakes are released.

5.

SWING BRAKE - A green light that indicates when the SWING brakes are released.

6.

PROPEL BRAKE - A green light that indicates when the PROPEL brakes are released.

7.

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

8.

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

9.

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

10.

HOIST BRAKE - (Set, Release) This switch sets or releases the HOIST brakes.

11.

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 has been solved.

12.

DRAG BRAKE - (Set, Release) This switch sets or releases the DRAG brakes.

13.

PROPEL TRANSFER - (Drag, Propel) A 2-position switch to transfer the machine between DRAG mode and PROPEL mode.

14.

SWING BRAKE - (Set, Release) This switch sets or releases the SWING brakes.

15.

AIR COMPRESSOR - (Off, On) A 2-position selector switch to turn the air compressor on or off.

16.

PROPEL BRAKE - (Set, Release) This switch sets or releases the PROPEL brakes.

17.

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

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 upper right hand corner on the inside of the window. 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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OPERATOR’S DISPLAY The Operator’s Display is a CTR panel used to provide the operator with an interface to the machine and it’s functional areas. From this informational display the operator can make inputs that effect 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 left side of the operator. 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 and right Control Consoles of the operator’s seat.

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 2 buttons available, if touched, will cause the display to refresh with the information of the desired screen.

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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.

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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Setup Screen

The Active Alarm screen will provide a list of all active alarms and faults that have been initiated on the machine. The Alarm History screen displays all alarms, active and cleared. A brief screen explanation can be found on the Alarm help screen.

Active Alarms Screen

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Faults and Alarm History Screen

Alarm Help Screen

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Propel Shoe Positions and Error Screen

Hoist and Drag Limit Calibration Screen

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Propel Shoe Encoder Calibration Screen

Fault Counters and Operating Hours Screen

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Tightline Parameters and Operating Data Screen

Operator’s Screen

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 make changes in control settings.

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Swing Position and Load Weigh Screen

Rope Reeving Screen

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Boom Raising and Lowering Screen

Lubrication Status Screen

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Automatic Lubrication Setup Screen

Propel Shoe Move Selection Screen

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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 in 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 which 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 10 meters from either the point sheaves or the fair lead. 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 master switch 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.

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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.

4.

Select Hoist/Drag Limit Calibrate screen. Press and hold Hoist calibrate 1 for three seconds.

A position accepted light should turn on.

5.

Tie a flag on the hoist rope 10 meters 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 Hoist calibrate 2 for three seconds.

A position accepted light should turn on. The active rope should show 10 meters 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 10 meters 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 Hoist calibrate 2 for three seconds.

A position accepted light should turn on. The active rope should show 10 meters 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 Drag calibrate 1 for three seconds.

A position accepted light should turn on.

5.

Tie a flag on the Drag rope 10 meters 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 Drag calibrate 2 for three seconds.

A position accepted light should turn on. The active rope should show 10 meters 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 10 meters 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 Drag calibrate 2 for three seconds.

A position accepted light should turn on. The active rope should show 10 meters 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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OPERATOR CONTROLS IN THE MACHINERY HOUSE

Machinery House Operator Control Panel

1.

INTAKE FAN 1 ON, green light; ON when intake fan 1 running.

2.

INTAKE FAN 1 START/STOP, spring return to center switch to START or STOP intake fan 1

3.

INTAKE FAN 2 ON, green light; ON when intake fan 2 running.

4.

INTAKE FAN 2 START/STOP, spring return to center switch to START or STOP intake fan 2

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5.

INTAKE FAN 3 ON, green light; ON when intake fan 3 running.

6.

INTAKE FAN 3 START/STOP, spring return to center switch to START or STOP intake fan 3

7.

INTAKE FAN 4 ON, green light; ON when intake fan 4 running.

8.

INTAKE FAN 4 START/STOP, spring return to center switch to START or STOP intake fan 4

9.

INTAKE FAN 5 ON, green light; ON when intake fan 5 running.

10.

INTAKE FAN 5 START/STOP, spring return to center switch to START or STOP intake fan 5

11.

LAMP TEST, will light all lamps to check for operation.

12.

SYSTEM RUN push button (black), is used to start the machine.

13.

NORMAL STOP push button (Red), shuts the machine down in a controlled manner; allows cooling fans to run for a time delay after machine shutdown.

14.

SYSTEM READY light (green), will be ON when there are no faults to prevent machine operation.

15.

FAULT RESET push button (black), used to reset faults if possible to allow system ready light to turn on.

16.

COOLING SYSTEM ON light (green), will be ON when the water cooling system for the drives is on.

17.

COOLING SYSTEM FAULT light (red), will be ON when the water cooling system has a fault.

18.

DC BUS PRECHARGE light (green), ON while the control system precharges the DC bus in each of the drive cabinets.

19.

PRECHARGE INCOMPLETE light (red), ON if the precharge does not complete in a specified time.

20.

DC BUS ON light (green), ON when all of the main transformers are on line and the control system is regulating the DC bus in each of the drive cabinets.

21.

DC BUS INCOMPLETE light (red), ON if any of the main transformers do not come online in a specified time.

22.

APT 1 Ph. Seq. OK light (green), ON when the phase rotation of APT 1 is correct; must be on for machine operation.

23.

APT 2 Ph. Seq. OK light (green). ON when the phase rotation of APT 2 is correct; must be on for machine operation.

24.

EMERGENCY STOP push button (red), that will set ALL brakes and de-energize ALL controllers when pressed.

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

Each set of doors includes 1 top door, and a left and right side 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 figure on the following page.

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 IN 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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Machinery House Rear Doors

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DOOR OPERATION (Refer to 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 door to be opened. The green indicator light should be lit.

3.

Open the top door using Valve #1 on the same side of the machine as the door to be opened.

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 on the same side of the machine as the door to be closed.

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 door to be closed. The green indicator light should go out.

6.

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

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DOOR OPERATING SEQUENCE

Control Panel for the House Rear Doors

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Items on the control panel: 1.

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

2.

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

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.

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

The following check lists 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 pieces stored in proper compartments or removed?

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

Is the proper lube supplied to all bearings and lube points?

Is all lube piping connected and filled?

Are all lube (grease) spills wiped up?

Is the machine thoroughly clean?

Tub ~ Check for the following items: • • • • • •

Cracks, broken welds; Deformed bottom plates; Bent or damaged bulkhead plates; Hook shoe(s) adjustment, with pin lock(s) in place; No obstructions in roller path or main rotating gear; 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 not parked on a crossover beam.

Front End ~ Check the following items: • • • • • •

Bucket - for wear, worn, broken or missing teeth, loose or missing pins, weld cracks; Boom - for cracks, bent pipes; The condition of the boom support ropes; The intermediate boom support ropes with correct tension; 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 check lists, notify maintenance at once so that correction can be made.

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TYPICAL START-UP 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 power on before proceeding with start-up. These are located primarily on the outside of the Power Control Room (PCR) and in the Operator’s Cab/Anteroom.

CAUTION:

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

2.

Go to the rear of the right side MCC for the start panel. Both APT1 and APT2 phase sequence lights must be on.

3.

Start air compressors at the left rear of machine.

4.

System ready light must be on. If off press FAULT RESET button once. If System ready light comes on continue, otherwise trouble shoot with HMI in cab or on motion control.

IMPORTANT NOTE: During each component start-up always be ready to immediately stop it if there are any unusual sounds, smells, or visual effects. Any time a problem arises, check the OIT display in the Operator’s cab for assistance.

5.

Press SYSTEM RUN button. The water cooling system should start, the Cooling system On light will flash. When both of the cooling pumps are on and the PLC determines the cooling system is operational, The Cooling System On light will turn on steady. The cooling system radiator motors may also start . The Precharge sequence is started and the DC Bus Precharge light will flash (may take up to 30 seconds). When the DC’s reach a preset voltage the DC Bus Precharge light will be on steady. The drive power transformer contactors are told to close. When all three transformers are on line and the DC bus voltage is at rated value the DC Bus On light will turn on. All of the bleed fans and intake fans will start in sequence.

6.

The intake fans can be manually stopped and started from the start panel. The purpose of the fans is to supply cooling air to remove the heat generated by the machine. Additionally the air into the machine provides pressurization to help prevent ingress of dust when the access doors are all closed.

NOTE: If the sequence fails to complete at any point, the cause should be investigated and problems resolved. Do not attempt to precharge more than twice in a 20 minute period because damage may occur.

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7.

When the above systems have been started and are operating correctly, go to the Operators 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 115 PSI during machine operation.

8.

Sit into and adjust the operators seat.

9.

Check the Hoist, Swing, Drag, and Propel Brake selector switches. If they are not at their SET positions, put all of them there now.

10.

Check to be sure that the hoist, swing and drag controllers are in their NEUTRAL position.

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.

11.

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

12.

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

DANGER:

THE MACHINE IS NOW OPERATIONAL. DO NOT LEAVE THE OPERATOR’S SEAT UNLESS THE CONTROLLERS ARE DEENERGIZED AND THE BRAKES ARE SET.

The operator controls the machine.

PLEASE KEEP SAFE OPERATING PROCEDURES IN MIND AT ALL TIMES.

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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 controller in the opposite the direction of machine movement, to hold the machine steady.

Operator’s Controls

Begin dragging the bucket in by pulling back on the drag (left) controller. The more the controller is moved off 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 controller movement will increase the hoist speed (right controller back) and decrease the drag speed (left controller forward) to lift the bucket out of the pit. Keep just enough tension on the drag ropes to prevent the bucket from 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.

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As soon as the bucket clears the digging face, slowly move the swing lever 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 INSURE 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.

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 out some rope off the drum. This dumps the bucket. As the bucket dumps, move the right controller 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 combined effort 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 DRAGLINE.

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.

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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 two walking shoes area, moderate ground bearing pressure is obtained and the machine 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 shoes 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 rotating frame to stresses much greater than experienced while digging. For a new machine, ramping should be restricted to no greater than a 5% grade (See Note). Later, this can be increased up to a 10% grade maximum. It is possible to traverse (cross) a 5% grade with this machine; however, AVOID CROSSING ANY GRADE IF POSSIBLE. NOTE: When beginning to propel the machine, the transition from one grade to the next should gradual, no more than 2% over the length of the walking shoes (for this machine is approx. 70 feet). For example, starting from level ground, the machine should travel at least 3 shoe lengths before reaching a 5% grade.

The 8750 dragline 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 Bucyrus for consultation on this problem immediately.

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WALKING/PROPEL OPERATION WALKING MACHINERY Two separate but identical propel machinery assemblies are located at each side of the rotating frame. These assemblies operate independently but are tied together electrically by encoders and a monitoring system to synchronize them during the step.

Each propel assembly consists of a AC drive motor, 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 rotating frame, lift the rear of the tub during the step.

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

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 raises the shoes into their park position (top dead center). The shoe return mechanism on each shoe realigns it parallel to the rotating frame as it is raised.

WALKING MACHINERY CONTROL The Swing-Propel Switch, located in the swing-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” or PARK position.

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WALKING Some preparations are required before moving the dragline. Its travel path must be adequately prepared. See the previous sub-section 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 TYPICAL START-UP in this section for the procedure. Sound the signal horns to indicate the machine will propel.

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 or the propel 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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Move the left controller rearward and hold it there during the entire propel period. This controller is pushed forward from neutral while in PROPEL ONLY to realign the two shoes if they get out of sync or to position them at top dead center for parking. This is a warning at 10o error and the propel is shut down at 15o error.

Operator’s Seat and Controls

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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 reposition the bucket. This can be done without transferring to the DIG mode. Stop the walking shoes in their PARK position. Check that the CLEAR TO SWING indicator is lit and the propel brakes are set.

Press the EXCITATION ON pushbutton, then release the Hoist and/or Swing brakes. To continue propelling, set the hoist and swing brakes, 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.

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 PARK” in the second half of the last step. Keeping the master switch 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.

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SHUTDOWN PARTIAL SHUTDOWN A partial shutdown, for shift change or a lunch break, begins with a full machine rotation to reposition the roller circle and promote even wear.

Lower the bucket to the ground. Place both controllers in their NEUTRAL position. Place hoist, drag, propel, and swing brake selectors in the SET position (red indicator lights out). Deactivate the controller circuits by pushing the STOP button on Operator Console (green light in START button will go out).

COMPLETE SHUTDOWN A complete shutdown procedure starts with the steps listed under PARTIAL SHUTDOWN. Then the operator must go to the controls at the START panel located on the right MCC or by pressing NORMAL STOP on the console.

To completely shut down the machine perform the following to the controls on the START panel: •

Press the NORMAL STOP button.

•

Turn each air compressor selector to OFF ~ only if the machine is to be stopped for an extended period of a week or more.

The motor blowers, cooling pumps and radiators will run for up to 15 minutes.

The machine is now shut down and ready for inspection, maintenance, etc.

CAUTION:

INCOMING ELECTRICAL POWER EXISTS TO THE TRANSFORMERS, CABINETS, COLLECTOR RINGS, ETC. SO OBSERVE CORRECT CAUTIONS AND WARNINGS, AS INDICATED THROUGHOUT THE MACHINE AND SPECIFIC EQUIPMENT MAINTENANCE MANUALS. SAFETY FIRST IS BEST.

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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.

WORKING RANGES Boom Length ····································································································· 360'-0" @ 34° ················· 109.7 M Boom Point Sheave, Pitch Diameter ················································································· 135" ·················· 343 cm A Boom Angle, Approx. ································································································· 34° ························· 34o B Operating Radius ································································································· 328'-0" ····················· 100 M C Dumping Height ···································································································· 148'-0" ···················· 45.1 M D Depth ···················································································································· 233'-0" ···················· 71.0 M Maximum Allowable Load ·············································································· 590,000 lb. ··········· 267,600 kg.

Hoist Drum, Pitch Diameter ······················································································· 128" ·················· 325 cm Hoist Ropes, Twin, Single Hitch, Diameter ······························································· 4.5" ·················· 11.4 cm Drag Drum, Pitch Diameter ······················································································· 128" ·················· 325 cm Drag Ropes, Twin, Single Hitch, Diameter ································································ 4.5" ·················· 11.4 cm BASE E Outside Diameter, Nominal ····················································································· 70’-0" ···················· 21.3 M Bearing Area, Effective ····················································································· 3,849 ft² ················ 357.6 m2 Bearing Pressure ······························································································· 21.1 PSI ·············· 145.5 kPa Rail Circle, Mean Diameter ····················································································· 55'-0" ···················· 16.8 M Circle Rollers, Mean Diameter ···················································································· 14" ················· 35.6 cm Total Number of Rollers ······························································································································ 138 Main Swing Gear, Pitch Diameter, Approx. ···························································· 45'-6" ···················· 13.9 M WALKING TRACTION F Width of Shoe ········································································································ 14'-0" ························· 4.3 G Length of Shoe ······································································································ 70'-0" ······················· 21.3 H Width over Both Shoes ························································································ 101'-0" ······················· 30.8 Bearing Area of Both Shoes ············································································· 1,960 ft² ················ 182.1 M2 Bearing Pressure @ 80% of Working Weight ··················································· 33.2 PSI ·············· 228.9 kPa Length of Step, Approx. ··························································································· 7'-6" ······················ 2.3 M Walking Speed ··································································································· 0.13 mph ················ 0.21km/h REVOLVING FRAME J Width @ Rear End ································································································· 95'-1" ···················· 29.0 M K Length ·················································································································· 126'-0" ···················· 38.4 M L Clearance Radius, Rear End ··············································································· 96'-10" ···················· 29.5 M M Clearance Under Frame ··························································································· 9'-1" ······················ 2.8 M N Center Rotation to Boom Foot ················································································ 24'-0" ······················ 7.3 M P Ground to Boom Foot ··························································································· 16'-10" ······················ 5.1 M WEIGHTS Domestic Shipping Weight (Inc. Bucket) ··························································· 10,807,000 lb. ········· 4,902,327 kg Working Weight. ································································································ 11,702,400 lb. ········· 5,308,209 kg Ballast (Furnished by Customer) ··········································································· 485,000 lb. ············ 219,992 kg Shipping Weight Subject to 5% Variation.

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COMPONENT WEIGHTS Qty.

Weight Ea. (Lbs.)

BASE FRAME ASSEMBLY (Tub) ........................................................ 1,200,000 Base Section, Inner Ring ................................................... 2 ..................... 90,000 Cover, Inner Section .......................................................... 4 ............................ 80 Base Section, Center ........................................................ 1 ................... 120,000 Base Section, Inner Ring Pinion ........................................ 1 ..................... 90,500 Base Section, Inner Ring ................................................... 3 ..................... 90,000 Base Section, Ctr Intmd Outer .......................................... 2 ..................... 30,000 Base Section, Ctr Intmd..................................................... 2 ..................... 53,000 Base Section, Outer Ring Cable ....................................... 1 ..................... 45,000 Base Section, Outer Ring .................................................. 7 ..................... 45,000 Center Journal Pin ............................................................. 1 ..................... 13,100 Roller Circle Assembly ...................................................... 1 ..................... 76,100 Roller ............................................................................... 138 ........................ 500 Rail Segment (typ.) ........................................................... 24 ...................... 2,600 Gear Segment (typ.) ......................................................... 24 ...................... 5,600 Thrust Rail Segment (typ.) ................................................ 24 ......................... 210 ROTATING FRAME ASSEMBLY ......................................................... 3,045,000 Hook Shoe ......................................................................... 2 ..................... 13,700 Main Collector Rings .......................................................... 1 ....................... 3,400 House Rear Door Assembly .............................................. 1 ..................... 12,000 Air Cleaner, Dynavane Filter .............................................. 5 .......................... 300 Air Compressor ................................................................. 2 ....................... 1,200 Deck Winch ....................................................................... 2 ....................... 2,620 Transformer, Auxiliary ........................................................ 2 ..................... 12,700 Transformer, Main .............................................................. 3 ..................... 42,800 Transformer, Con, Voltage ................................................. 1 ....................... 1,500 Transformer, Lighting ......................................................... 1 ....................... 1,100 Switch Panel Board, Main .................................................. 2 ....................... 2,500 Air Conditioner / Heater (Cab) ............................................ 1 .......................... 900 Reactor ............................................................................. 24 ...................... 3,400 Pump #1, Water Cooling System ...................................... 1 ....................... 4,500 Switchgear, 25KV High Voltage .......................................... 1 ..................... 39,000 PLC Station, LH / RH ......................................................... 2 .......................... 500 Resistor, Neutral Grounding ............................................... 1 ............................ 80 Resistor, Overvoltage ........................................................ 8 .......................... 150 Invertor Control Hoist/Drag #1 ........................................... 1 ..................... 16,500 Invertor Control Hoist/Drag #2 ........................................... 2 ..................... 16,500 Invertor Control Hoist/Drag #3 ........................................... 1 ..................... 16,500 Invertor Control Swing/Walk ............................................... 1 ..................... 16,500 Ballast ................................................................................ 1 ................... 485,000

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Qty. ROTATING MACHINERY Rotating Gearcase Assembly ............................................

Main Rotating Shaft ............................................................

Pinion, Main Rotating .........................................................

Coupling, Swing .................................................................

Rotating Motor....................................................................

Motor Brake, Swing ............................................................

Weight Ea. (Lbs.)

6 ..................... 22,000 6 ..................... 10,300 6 ....................... 2,600 6 .......................... 410 6 ..................... 15,000 6 ....................... 1,500

HOIST/DRAG MACHINERY ................................................................. 1,050,000 Machine Assembly, Hoist/Drag .......................................... 2 ................... 430,000 Drum End, Motor ............................................................ 2 ..................... 45,000 Shaft, End Cap ............................................................ 2 ....................... 6,000 Spider, Motor ................................................................ 2 ..................... 39,300 Retainer, Spider Shaft .................................................. 2 .......................... 350 Rotor, Barrel.................................................................... 2 ..................... 95,000 Rotor Cone ..................................................................... 2 ..................... 54,000 Drum, LH Grooves .......................................................... 2 ..................... 69,000 Drum, RH Grooves ......................................................... 2 ..................... 69,000 Rotor Half, Brake ............................................................ 4 ....................... 9,000 Drum End, Pedestal ....................................................... 2 ..................... 19,600 Shaft, End Cap ............................................................ 2 ....................... 4,500 Spider, Drum ................................................................ 2 ..................... 15,000 Retainer, Spider Shaft .................................................. 2 .......................... 350 Pedestal, Hoist Motor ...................................................... 1 ..................... 27,000 Pedestal, Drag Motor ...................................................... 1 ..................... 27,000 Pedestal, Hoist Drum ..................................................... 1 ..................... 31,000 Pedestal, Drag Drum ...................................................... 1 ..................... 31,000 Bearing Top Cap .......................................................... 4 ....................... 4,200 Spacer, Outer - Bearing ............................................... 2 .......................... 720 Retainer, Inner - Bearing .............................................. 2 .......................... 500 Cover, Drum Bearing ................................................... 2 .......................... 500 Bearing, Roller, Drum .................................................. 4 ....................... 2,400 Brake Assembly ............................................................. 20 ...................... 1,565 Guard, Brake ................................................................... 8 .......................... 350 Motor Stator Service Assembly ....................................... 1 ..................... 15,400 Bracket, Motor Stator Service ............................................ 2 ....................... 4,700 Roller Assembly, Service ................................................... 4 .......................... 220 Beam, Stator Lifting ........................................................... 2 ....................... 1,800

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Qty.

Weight Ea. (Lbs.)

PROPEL MACHINERY Walking Shoe .....................................................................

Walking Arm .......................................................................

Stabilizer Link .....................................................................

Pin, Arm to Stabilizer ..........................................................

Pin, Stabilizer to Frame .....................................................

Shaft, Walking Shoe ..........................................................

Main Propel Shaft ...............................................................

Main Propel Gear ...............................................................

Gear Hub ...........................................................................

Cam, Eccentric, Walking ...................................................

Main Propel Pinion Shaft Assembly ...................................

Main Propel Pinion Shaft ....................................................

Propel Gearcase ................................................................

Gearcase Structure ...........................................................

Gearcase Cover ................................................................

1st Intermediate Gear ........................................................

1st Intermediate Shaft ........................................................

2nd Intermediate Gear .......................................................

2nd Intermediate Shaft .......................................................

Motor Extension Shaft ........................................................

Propel Motor ......................................................................

Motor Brake, Propel ...........................................................

2 ................... 226,500 2 ..................... 78,000 2 ....................... 9,000 2 ....................... 6,000 2 ....................... 8,400 2 ....................... 8,100 2 ..................... 38,500 2 ..................... 35,000 2 ..................... 14,700 2 ..................... 48,000 4 ....................... 9,400 4 ....................... 5,900 4 ..................... 42,200 4 ..................... 21,300 4 ..................... 6,4000 4 ....................... 3,150 4 ....................... 1,200 4 ....................... 7,000 4 ....................... 4,600 4 .......................... 330 4 ..................... 15,000 4 ....................... 1,300

FAIRLEAD ASSEMBLY.....................................................

Fairlead Structure ..............................................................

Pin, Fairlead Foot ...........................................................

Backleg, Fairlead ...............................................................

Pin, Backleg, Upper .......................................................

Pin, Backleg, Lower .......................................................

Swivel Sheave Assembly, Lower .......................................

Swivel Frame Assembly, Lower .........................................

Swivel Frame .................................................................

Shaft, Lower Swivel .......................................................

Pin, Swivel Frame ..........................................................

Swivel Sheave Assembly, Upper .......................................

Sheave, Fairlead Upper/Lower ......................................

Shaft, Upper Sheave Assembly .....................................

Snubber, Lower Fairlead ....................................................

Snubber Collar Plate, Fairlead ...........................................

1 ................... 400,000 1 ................... 165,000 2 ........................ 1000 2 ..................... 12,400 2 ....................... 1,010 2 .......................... 460 2 ..................... 72,600 2 ..................... 48,300 2 ..................... 48,700 2 ....................... 1,700 2 ....................... 1,030 2 ..................... 24,200 4 ..................... 15,300 2 ....................... 5,900 2 .......................... 300 2 .......................... 300

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Qty.

Weight Ea. (Lbs.)

TRI-STRUCTURE ASSEMBLY .............................................................. 676,000 Structure Assembly ............................................................ 1 ................... 413,000 Backleg .............................................................................. 2 ..................... 87,400 Hoist Deflecting Sheave Assembly .................................... 2 ..................... 24,000 Backleg Safety Rope ......................................................... 2 ....................... 1,000 Boom Raising Sheave Assembly ...................................... 4 ....................... 6,200 Pendant, Backleg Safety .................................................... 2 ....................... 9,050 BOOM ASSEMBLY (Less Walkways) Boom Structure ..................................................................

Boom Structure, Point .......................................................

Boom Structure, Center .....................................................

Boom Structure, Foot-Left/Right ........................................

Boom Point Sheave Assembly ..........................................

Boom Point Shaft ...........................................................

Boom Point Sheave .......................................................

Trunnion, Boom Point Sheave ...........................................

Bearing Block, Trunnion - Rear ......................................

Bearing Block, Trunnion - Front .....................................

Boom Support Rope Assembly .........................................

Boom Support Rope Pendant ............................................

Intermediate Suspension Pendant .....................................

Intermediate Suspension Adjuster .....................................

Hoist Rope .........................................................................

Guard, Hoist Rope, Boom point .........................................

Drag Rope .........................................................................

Rope, Boom Raising .........................................................

1 ................... 638,300 1 ..................... 68,600 1 ................... 416,500 2 ..................... 42,500 1 ..................... 62,100 1 ....................... 8,010 2 ..................... 15,300 1 ..................... 13,200 1 ....................... 4,300 1 ....................... 1,700 2 ..................... 35,700 4 ....................... 9,020 2 ....................... 1,000 2 ....................... 2,400 2 ..................... 35,800 1 ....................... 1,400 2 ..................... 21,200 2 ..................... 26,400

BUCKET ASSEMBLY Bucket, Body .....................................................................

Pin, Trunnion ......................................................................

Link, Drag Chain ................................................................

Chain, Drag .......................................................................

Pin, Drag Chain ..............................................................

Pin, Drag Link .................................................................

Link, Dump Block ............................................................

Sock, Drag Rope ............................................................

Link, Drag Socket ...........................................................

1 ................... 140,000 2 .......................... 270 2 ....................... 2,500 2 ....................... 8,200 4 .......................... 550 2 .......................... 700 2 .......................... 550 2 ....................... 3,200 2 .......................... 400

Feb. 2007

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Manual No. 10348 - Rev. 2

BI616938

Bucyrus International, Inc. 8750 Walking Dragline

Qty. BUCKET ASSEMBLY (Cont.)

Spreader ............................................................................

Hoist Chain .....................................................................

Link, Hoist Chain .............................................................

Clevis, Hoist Rope ..........................................................

Link, Pickup, Hoist Rope .................................................

Link, Equalizer, Hoist Rope .............................................

Equalizer, Hoist Rope .....................................................

Socket, Hoist Rope .........................................................

Socket, Dump Rope ..........................................................

Dump Rope ....................................................................

Dump Block Assembly....................................................

Link, Dump Block ............................................................

Link, Dump Block ............................................................

Equalizer, Dump Block ...................................................

Link, Hoist Rope Equalizer ..............................................

Shroud, Corner ..................................................................

Cap, Tooth Base ................................................................

Shroud, Center ..................................................................

Adapter, Tooth ....................................................................

Tooth ..................................................................................

Manual No. 10348 - Rev. 2

72

Weight Ea. (Lbs.)

1 ....................... 7,200 4 ....................... 2,500 2 ....................... 1,050 1 ....................... 3,000 1 ....................... 3,700 1 ....................... 2,150 1 ....................... 1,900 2 ....................... 2,000 4 .......................... 700 2 ....................... 1,450 2 ....................... 2,900 2 .......................... 510 2 ....................... 1,000 1 ....................... 2,500 1 ....................... 2,400 2 ....................... 1,250 4 .......................... 250 5 .......................... 850 6 .......................... 600 6 .......................... 160

Feb. 2007