Cat Electric Rope Shove 7495 7495 HF 495HR2HF2 Electric Rope Shovel Operators Manual - PDF DOWNLOAD

®

EM007181-10 (en-us)

August 2019

Operators Manual 7495, 7495 HF, 495HR2/HF2 Electric Rope Shovel

OM11089-EN

SAFETY.CAT.COM

EM007181

California Proposition 65 Warning This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Literature Information This manual should be read carefully before using this product for the first time and before performing maintenance. This manual should be stored in the product literature holder or in the product literature storage area. Immediately replace this manual if lost, damaged, or unreadable.

This manual may contain safety information, operation instructions, transportation information, lubrication information, and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your product. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your product, which are not included in this publication. Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.

Safety The safety section, if present, lists basic safety pre- cautions. In addition, this section identifies the text and locations of safety messages used on the product. Read and understand the basic precautions listed in the safety section before operating or per- forming lubrication, maintenance, and repair on this product.

Operation The operation section, if present, is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, controls, attachment controls, transportation, and towing information (if applicable). Photographs and illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the product. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the product and its capabilities.

Product Information The product information section, if present, may provide specification data, product intended use, product identification plate locations, and certification information.

EM007181

Maintenance The maintenance section, if present, is a guide to equipment care. Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. The Maintenance Interval Schedule lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the "When Required" service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance.

Use the Maintenance Interval Schedule as an index or "one safe source" for all maintenance procedures.

Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading.

Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty, or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.

Product Capacity Additional attachments or modifications may exceed product design capacity, which can adversely affect product performance characteristics, safety, reliability, and applicable certifications. Contact your dealer for further information.

EM007181

Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining LLC reserves all rights to this publication. Its content is protected by copyright laws.

No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar Global Mining LLC. Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors. © 2019 Caterpillar Global Mining LLC. LatchFree™ and HydraCrowd™ © Bucyrus International, Inc.

Table of Contents EM007181 Table of Contents

Table of Contents SECTION 1 - INTRODUCTION PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

SECTION 2 - SAFETY SECTION 3 - OVERVIEW SECTION 4 - OPERATOR’S STATION SECTION 5 - OPERATOR CONTROLS AND DISPLAYS SECTION 6 - PRE-START, START-UP & SHUTDOWN SECTION 7 - MACHINE OPERATION SECTION 8 - APPENDIX

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Table of Contents

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Revision History EM007181 Revision History

Revision History November, 2012

October, 2012 Added common safety features to Section 2. Updated Section 8 with additional CDA fault codes.

January, 2013 Updated description for the Emergency Stop Button.

Added notation to keep machinery house and cab doors closed.

July, 2013 Added avoid tight-lining information to Machine Operation section for Crowd and Propel Motion Control.

October, 2015 Added HydraCrowd Tie-Off Anchor (Option) to Safety section.

Document media number changed from BI006779 to EM007181.

Added Proposition 65 statement and Foreword to front of manual.

January, 2016 Removed Emergency Escape Chute (Option) from Safety section.

May, 2016 Updated Caterpillar Global Mining address in Section 1.

Added Figure 5-3, HOME Screen with Enhanced Motion Control Option to Section 5.

Added Machine Protections - Motion Limits to Section 7.

Added Machine Protections - Enhanced Motion Control (Option) to Section 7.

Added Home - Enhanced Motion Control (Option) to Section 8.

Added Enhanced Motion Control (Option) to Section 8.

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Removed CDA fault code messages from Appendix, Section 8.

Revision History EM007181

February, 2018 Added additional Safety Operating Precautions.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

August, 2019 Updates to cab graphics in Section 3.

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Introduction

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Introduction

1.1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2 Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.3 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.4 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.5 Precautions and Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.6 Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1-3 1-3 1-4 1-4 1-4 1-5

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1

Introduction

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Introduction About This Manual

EM007181 Introduction

1.1 About This Manual 1.1.1 Purpose

NOTES: •

•

This manual contains information for the Rope Crowd and HydraCrowd™ systems. While both machines operate the same, some functional differences exist. (For example, HydraCrowd™ machines do not have a crowd brake.) Where applicable, this manual provides both versions. Typically, the differences appear on the cab display.

This is not a maintenance manual. A separate, detailed maintenance manual for this machine has been supplied with the machine.

1.1.2 Organization •

• •

A main table of contents (TOC) is your guide to topics and subtopics. It is located at the front of the manual. Main topics are listed as numbered Sections, with subtopics listed beneath (and indented). Subtopics include the main topic's section number.

Additionally, each section contains its own TOC. In the electronic version, all TOC items are hyperlinked to their respective topics.

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This manual is designed to assist in the operation of your machine. Inside, you will find the following information: location and explanation of controls, instructions for machine operation, and certain maneuvering techniques.

Introduction About This Manual

EM007181

1.1.3 Terminology •

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

•

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.

On the cover and at the bottom of each page there is an alphanumeric code to identify the manual, formatted as follows:

XXnnnnnn-YY • •

XX represents the manual type. Below is a list of all manual types. nnnnnn represents the serial number for machine-specific manuals, or a generic manual number intended for several machines.

•

YY represents the language code. Below is a list of common language codes.

Code SM OM EM PM TM EM AM VM MM

Type Service Operation Electrical Parts book Troubleshooting Electrical training Addendum Vendor Miscellaneous

Code EN ES FR PT

Language English Spanish French Portuguese

So, for example, manual code EM141455-ES is an electrical manual written in Spanish for machine #141455.

1.1.4 Revisions This manual may be revised without notice. The most recent electronic version is available online.

1.1.5 Precautions and Disclaimers • •

•

Carefully study and follow all procedures in this manual. Safe operation of the machine minimizes production delays and costly damage to equipment.

Safety guidelines are intended to prevent accidents and are provided in the interest of all mine personnel. Overall safety depends on the use of good judgment and the alertness of the entire mining crew.

It is the owner/mine's responsibility to perform the necessary risk assessment to outline proper safety precautions. A minimum of unplanned machine downtime and more reliable machine operation should result when a systematic and thorough maintenance/service procedure is adhered to for this machine.

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Introduction About This Manual

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•

1.1.6 Contact For more information or factory service assistance, contact your regional service representative or: Caterpillar Global Mining LLC 1100 Milwaukee Ave. South Milwaukee, WI, USA 53172 Telephone (+1) 414.768.4000

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It is the policy of the manufacturer 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.

Introduction About This Manual

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Safety

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Safety

2.1 Safety Symbols And Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.2 Warning Signs And Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.3 Electrical Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.4 General Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.6 Operation Near Electrical Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.7 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.7.1 Fire Extinguisher Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.7.2 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.8 Common Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.8.1 Emergency Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Figure 2-1 Emergency Lighting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.8.2 Mine Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure 2-2 Mine Signal Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure 2-3 Mine Signal Horn Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.8.3 Dual Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Figure 2-4 Right Side Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 OM11089-EN

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Safety EM007181

2.8.4 Propel Warning Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Figure 2-5 Right Side Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.8.5 Propel Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

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Figure 2-6 Propel Back-up Horn Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.8.6 Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2.8.7 Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Figure 2-7 Camera Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.8.8 Boarding Stairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Figure 2-8 Right Side Boarding Stair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.8.9 Vertical Boarding Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 2.8.10 Man On Ground Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Figure 2-9 Left Side Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.8.11 Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 2.8.12 HydraCrowd Tie-Off Anchor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

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Safety Safety Symbols And Signal Words

Safety

2.1 Safety Symbols And Signal Words

Be certain that 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 service representative or the factory.

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

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.

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.

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.

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/her eyesight, hearing or reactions.

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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.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Safety Warning Signs And Decals

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Safety must always be paramount!

Consult your supervisor when safety is in doubt.

2.2 Warning Signs And Decals The warning signs and decals located throughout the machine convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.

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

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Safety Electrical Safety Precautions

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2.3 Electrical Safety Precautions

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.

HIGH VOLTAGE!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.

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 required.

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This manual provides information and data for the maintenance and/or operation of this machine. All electrical equipment must be serviced by qualified individuals who have been properly trained to work with high voltage systems and variable frequency AC drives. Failure to comply could result in personal injury or death.

Safety General Safety Precautions

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

2.4 General Safety 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.

•

Wear hearing protection when required.

•

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

•

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

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

•

Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off 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 is 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.

•

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

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Safety Operating Precautions

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2.5 Operating Precautions

NOTE:

The above recommendations are based upon U.S. Department of Labor, Mine Safety and Health Administration requirements, Title 30 CFR 62.0, which includes time weighted averages for exposure limits. At minimum, follow the requirements of your appropriate federal regulatory agency or your employer; whichever is most restrictive (most protects your hearing). Whenever in doubt about the noise level, wear approved hearing protection.

•

Keeping all doors closed helps to maintain pressurization. Keeping the cab door(s) closed significantly reduces noise levels and exposure to air borne contaminants to the operator.

•

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.

•

Always use proper communication methods (horn signals, radio, visual) to notify all personnel of your intentions before any equipment movement, and after equipment stop.

•

Do not move or operate the machine without first knowing the location and purpose of all personnel and 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 until personnel on the ground are at a safe working distance from the shovel in the event rocks or wear metal are discharged from the tracks due to operation.

•

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

•

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

•

Do not operate the machine on a slope greater than that specified in SLOPE LIMITATIONS later in this manual.

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Wear hearing protection. It is recommended that operators wear hearing protection (ear plugs or ear muffs) when they are exposed to noise levels of 90 dBa and above for any time duration.

Dual hearing protection (plugs and ear muffs) is recommended for any exposure to noise levels of 105 dBa and above, for any time duration. Exposure to noise levels of 115 dBa and above, at any time, requires dual hearing protection.

Safety Operation Near Electrical Power Lines

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

2.6 Operation Near Electrical Power Lines HIGH VOLTAGE! The following precautions shall be complied with whenever operating around or near electrical distribution and transmission lines. Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual we are considering the entire machine or its load, in any position, that can reach to within the minimum distance specified by local, state and federal regulations.

Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.

Before working in the vicinity of power lines, always take the following precautions: • • • • • • •

Always contact the owners of the power lines or the nearest electric utility before beginning work.

You and the electrical utility representative must jointly determine what specific precautions must be taken to ensure safety.

It is the responsibility of the user and the electric utility to see that necessary precautions are taken.

Consider all lines to be power lines and treat all power lines as energized even though it is known that the power is shut off and the line is visibly grounded.

Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.

Caution all ground personnel to stand clear of the machine at all times.

Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line.

The signal person must be in direct communication with the operator and the operator must pay close attention to the signals.

HIGH VOLTAGE!Death or injury could result should any part of the machine approach the minimum distance of an energized power line specified by local, state and federal regulations.

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Safety Fire Prevention

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2.7 Fire Prevention

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2.7.1 Fire Extinguisher Locations • • • • • • •

Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

DO NOT smoke while handling flammables or when near batteries.

Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.

Repair or replace loose or damaged lines, tubes and hoses as soon as possible.

Make certain all clamps, guards and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.

DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.

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Safety Fire Prevention •

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• • • •

EM007181

DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

Keep all structural frame compartments, walkways and work areas clean and free of lubricant residue.

NEVER weld, burn, or perform service on the machine alone.

If a motor or other component is running hot, shutdown the machine until it has cooled and the cause is determined and repaired.

2.7.2 Fire Extinguishers

Replace fire extinguisher immediately with fully charged extinguishers after ANY discharge is made from an extinguisher.

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Safety Common Safety Features

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2.8 Common Safety Features Most shovels can be equipped with the following safety features.

In case of a power failure, there are 13 emergency lights and 3 self-illuminating exit lights located throughout the machinery house and near walkways similar to the figure below.

Figure 2-1 Emergency Lighting Locations

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2.8.1 Emergency Lighting

Safety Common Safety Features

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2.8.2 Mine Signal

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A mine signal switch is located on either side of the machine at the back of the ballast box. A pull cord, which can be reached from the ground, activates an air horn located at the top of the lube room.

Figure 2-2 Mine Signal Switch

Figure 2-3 Mine Signal Horn Location 2 – 12 August 2019

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Safety Common Safety Features

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2.8.3 Dual Mirrors Dual convex mirrors are mounted outside right and left hand side of the operator’s cab. Mirrors can be mounted and adjusted for best operator’s viewing.

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Figure 2-4 Right Side Mirror

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Safety Common Safety Features

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2.8.4 Propel Warning Lights

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Propel warning lights will flash when the machine is in motion.The amber lights are usually mounted on both sides of the machine, outside of the electrical room.

Figure 2-5 Right Side Warning Light

2 – 14 August 2019

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2.8.5 Propel Back-up Alarm In addition to propel warning lights, machines can be equipped with a propel back-up warning alarm. The horn is usually mounted on the right side of the ballast box, bellow the deck extension.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 2-6 Propel Back-up Horn Location

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Safety Common Safety Features

EM007181

2.8.6 Emergency Stop Buttons

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

There are 5 Emergency Stop buttons on the Rope Crowd machines and 7 on HydraCrowd machines.

• • • • • • •

POEB1: Wall mounted behind the MCC facing inboard POEB2: On the front section of the MCC facing inboard POEB3: Operator's Console POEB4: LH front side of the Siemens Skid POEB5: RH side of the HydraCrowd Skid (not used on Rope Crowd machines) POEB6: LH side of the HydraCrowd Skid (not used on Rope Crowd machines) POEB7: Near Auxiliary Seat in the cab

Pressing any one of the Emergency Stop buttons will stop the machine under operational emergency conditions. Pushing this button will provide immediate electrical and mechanical braking simultaneously. Therefore, it should only be used if the operator intends the harshest braking of all motions. If the machine is in motion, power will remain on the motions in order to provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will power the DC bus to approximately zero voltage quickly after the time delay.

Pressing the emergency stop button when any drive is in motion may result in component damage.

2 – 16 August 2019

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2.8.7 Cameras There are 5 cameras located on the machinery house and boom. Video camera monitors are located in the operator’s cab above the front windshield.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 2-7 Camera Locations

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2.8.8 Boarding Stairs

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

A set of boarding stairs is attached to the machinery house platform - either on the left side of the machine, the right side or both. These stairs must be in their raised and latched position to enable the operator’s controls.

Figure 2-8 Right Side Boarding Stair

2.8.9 Vertical Boarding Ladder The vertical boarding ladder is one of the means for boarding the machine, located on the lefthand side of the machine, at the rear of the machinery house. When the ladder is not latched in place the operator's controls are deactivated.

2 – 18 August 2019

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2.8.10 Man On Ground Light A rotating light is used to indicate to other mine personnel in the pit that a person is on the ground in the vacinity of the shovel. This light is typically mounted to a handrail on the left side of the machine.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 2-9 Left Side Warning Light

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2.8.11 Cable Reel

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The optional cable reel assembly is mounted on the rear of the machine. It is a level winding wheel used to retrieve and pay out trail cable to keep the length of the cable as short as practical.

During normal operation of the machine a certain level of tension is maintained on the trail cable by a motor mounted on the cable reel. The motor drives the cable reel through a chain sprocket arrangement which powers the level wind mechanism through an intermediate right angle reducer.

Cable reels are not designed to pull trail cable over the ground. Severe damage to the cable or the cable reel may result if this is attempted.

2 – 20 August 2019

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2.8.12 HydraCrowd Tie-Off Anchor (Option)

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2 – 21 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The safety tie-off anchor point provides an anchor point for personnel performing dipper back maintenance. The tie-off anchor is attached to the HydraCrowd pin in place of the existing retainer plate, and is available only on HydraCrowd shovels. The tie-off anchor may only be used by one person at a time. A second anchor may be added on the opposite side of the handle pin for use by a second person performing dipper back maintenance.

Safety Common Safety Features

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

EM007181

2 – 22 August 2019

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EM007181

Overview

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Overview

3.1 Boarding The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.1.1 Power Step – Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2 Operator Cab Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.2.1 Fire Extinguisher Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Figure 3-1 Cab Interior Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.2.2 Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.2.3 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.2.4 Cabinets & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.3 Exiting The Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

3

Overview

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

EM007181

3–2 August 2019

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Overview Boarding The Machine

EM007181 Overview

3.1 Boarding The Machine

Always notify the shovel operator before using the stairway controls.

• •

If a person aboard the machine wants to leave the parked machine, the boarding stairway is controlled by a handle operated valve, located on the exterior wall of the machinery house.

If a person on the ground wants to board the parked machine, a warning alarm for the operator can be activated by pulling one of the two mine signal switch cords hanging from the shovel at the rear.

After boarding the machine, raise the stairway to the stored position using the handle operated valve located on the machinery house wall.

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3–3 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Never attempt to board or leave a machine when it is operating. The swing, propel, and/or crowd functions can crush a person. Always wait until the machine is parked before attempting to board.

Overview Boarding The Machine

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

3.1.1 Power Step – Option The power step is another way to board the machine. Inspect that all pins and keepers are in place before using the power step. Use the lock/release foot lever to release the power step.

Always secure the safety chain or lever on the basket before boarding or dismounting the machine.

When raising the power step, engage the switch in the up position and hold until the unit is fully raised. To lower the power step, engage the switch in the down position and hold until the unit is fully extended to the ground.

3–4 August 2019

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Overview Operator Cab Interior

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3.2 Operator Cab Interior

There are three unique seats in the cab: Operator’s Seat — Auxiliary Seat — Swing Seat

3.2.1 Fire Extinguisher Location There are two fire extinguishers shown in the locations above. Both are wall mounted. One fire extinguisher is located inside the cab directly behind the auxiliary seat, the second is located just outside the rear door.

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3–5 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The operator's cab extends from the right front corner of the machine. The insulated cab provides a controlled environment for the operator, crew, and electronic equipment. A combination heater/ air conditioning unit is mounted on the roof of the cab and provides warmed or cooled air as set using the HVAC digital controller. Keeping all doors closed helps to maintain pressurization.

Keeping the cab door(s) closed significantly reduces noise levels and exposure to air borne contaminants to the operator. For more specific information regarding operator controls, refer to Section 4 ~ OPERATOR'S STATION later in the manual.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Overview Operator Cab Interior

EM007181

Figure 3-1 Cab Interior Amenities

3.2.2 Refrigerator Setting Temperature: The refrigerator is fitted with a manually operated thermostat. The control knob (located inside the refrigerator) is turned clockwise to reduce temperature and counter-clockwise to both increase temperature and activate the on-off switch at the end position. A certain spring resistance is recognized at the off position.

Maintenance: The refrigeration system has a closed cooling system and does not require any maintenance or refilling of refrigerant. Periodically clean the inside surfaces using lukewarm water and a mild detergent.

3–6 August 2019

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Overview Operator Cab Interior

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3.2.3 First Aid A first-aid kit is stored inside the top drawer above the refrigerator.

The fire suppression cabinet is located above the electrical equipment cabinet at the rear of the cab. Four personal storage lockers are located next to the cab’s right-side door.

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3–7 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

3.2.4 Cabinets & Storage

Overview Exiting The Cab

EM007181

3.3 Exiting The Cab

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

There are two doors in the cab. The rear door is best suited for emergency exit. There is a second door located on the right side of the cab, just behind the operator's station. This door opens onto the cab walkway and could also be used in an emergency.

3–8 August 2019

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Operator’s Station

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Operator’s Station

4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.1.1 Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Figure 4-1 Low Profile Fore and Aft Isolator Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.1.2 Adjustable Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Figure 4-2 Right Hand Grate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.1.3 Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.1.4 Armrest & Joystick Pod Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.1.5 Joystick Pod Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Figure 4-3 Standard Configuration – Button Locations . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.1.6 Operator Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.1.7 Display Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 4.1.8 Operator’s Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Figure 4-4 Operator’s Console Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.1.8.1 Emergency Stop Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.2 Window Shade Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.3 Wiper Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.4 Console Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.5 Flood Light Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.6 Heated Mirror Switch – Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.7 Front Ceiling Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.8 Back Ceiling Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-17 4-17 4-17 4-18 4-18 4-18 4-18 4-19

4–1 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

4

Operator’s Station EM007181

4.1.8.9 Man On Ground Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4.1.8.10 HVAC A/B Switch – Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4.1.8.11 HVAC Digital Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 4-5 HVAC Digital Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.1.8.11.1 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.11.2 Auto Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.11.3 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.11.4 Up & Down Arrows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.11.5 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.11.6 Air Circulation Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.11.7 Defog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8.11.8 Celsius / Fahrenheit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.9 Ground Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.10 Stereo AM/FM Receiver/CD Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.11 USB Stereo Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.12 Motorized Window Shades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.13 Task Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.14 Ethernet & USB Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.15 Telephone Handset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.16 Swing Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-20 4-20 4-20 4-20 4-20 4-21 4-21 4-21 4-22 4-23 4-23 4-24 4-25 4-26 4-27 4-29

Figure 4-6 Swing Seat in the Stored Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

4.1.17 Video Camera Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4–2 August 2019

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EM007181 Operator’s Station

4.1 General Information

Before operating the machine, the operator should read and carefully study the information and instructions outlined in this manual. The operator should become thoroughly familiar with the location and purpose of each component within the operator’s station.

The descriptions listed should familiarize the operator with each of the control’s location and functional use. The terms left, right, forward and reverse indicate directions with the operator seated in the cab and facing forward, and with the boom extending over the front of the crawlers.

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4–3 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The operator’s station consists of the operator’s seat, operator console, two display monitors (not shown). The operator console contains a bank of rocker switches, HVAC controller, radio/CD player, ground test switch and an Emergency Stop button.

Operator’s Station General Information

EM007181

4.1.1 Seat Adjustment

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The operator’s seat can be adjusted in a variety of ways.

For armrest’s refer to ARMREST ADJUSTMENTS, for pod’s refer to JOYSTICK POD ADJUSTMENT later in this manual.

To raise the seat assembly: Push in on the push/pull button at center of the seat.

To lower the seat assembly: Pull out on the push/pull button at center of seat.

4–4 August 2019

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To tilt the seat back: Pull up on the seat tilt lever located on left side of the seat (where the seat back meets the seat cushion).

To increase lumbar support:

To reduce lumbar support: Release air by opening the valve located on the bulb.

To adjust the back of the seat cushion height: Lift up on lever to release the back of the seat cushion. Adjust the seat up and down as needed, then release the lever to lock into position. The operator may need to shift their weight fore and aft to allow the lever to release from the locked position.

To adjust the front of the seat cushion height: Press down on lever to release the front of the seat cushion. Adjust up and down as needed, then release the lever to lock into position. The operator may need to shift their weight fore and aft to allow the lever to release from the locked position.

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4–5 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Pump the squeeze bulb several times. This will add air and increase support in the lumbar region of the seat back.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Operator’s Station General Information

EM007181

Figure 4-1 Low Profile Fore and Aft Isolator Assembly

The low profile fore and aft isolator assembly is designed to handle substantial loads without slack. The design is based on two long linear ball bearings. Each isolator dampens vibrations and shocks with a stroke of ±40 mm. Dampening characteristics are adjustable in six levels and can be locked out when isolation is not needed or wanted.

4–6 August 2019

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4.1.2 Adjustable Footrest The right hand grate acts as an adjustable footrest for the operator.

Figure 4-2 Right Hand Grate Assembly

4.1.3 Seat Belts The operator’s and auxiliary seat are both equipped with seat belts.

To fasten the lap belt: Insert the belt tongue into the buckle until you hear it snap and feel it latch.

Always keep the lap belt snug and low across the hips.

To unfasten the lap belt: Push the release button and remove the tongue from the buckle.

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4–7 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

To adjust the incline of the grate, push the latch mechanism forward with your foot to release.

The unit’s gas spring will push the grate upward. Adjust accordingly. Once the grate is in the desired position, take your foot off of the latch mechanism to reengage the latch.

Operator’s Station General Information

EM007181

4.1.4 Armrest & Joystick Pod Adjustments

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The armrests are attached to the seat assembly so they will stay properly adjusted when raising or lowering the seat itself. The armrests are easily adjusted in various directions for operator comfort.

Each armrest utilizes friction joints to allow side to side adjustment and armrest rotational adjustment. The friction joints do not lock the armrest in place, therefore no amount of tightening will lock these joints! Tighten the joint snuggly and test the amount of resistance to side movement with and without weight on the armrests. The armrest should adequately hold their position when the operator rests their arms and the added weight creates addition friction.

NOTE:

The armrests are designed to allow for movement in the friction joint if exposed to high forces. Simply re-orient armrests after movement occurs.

4–8 August 2019

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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4–9 August 2019

Operator’s Station General Information

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

EM007181

4 – 10 August 2019

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Joystick pods can be moved into the best position for the operator. Hold firmly and move in the direction desired to overcome the friction joint until it is located in the proper position.

NOTE:

Adjustment tools for the pod are located in the headrest.

This may take a little practice to begin with but will help to reduce fatigue and makes operation easier. It generally takes 3-4 shifts to feel comfortable operating with the pods pulled inward over your legs.

NOTE:

If the armrests seem to be short, the operator can adjust the tilt of the seat pan which will extend the armrest.

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4 – 11 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

To reduce fatigue and improve comfort while operating, bring the armrests and joystick pods in over your legs as shown below. This position allows operators to more easily view the crawlers.

Operator’s Station General Information

EM007181

4.1.5 Joystick Pod Buttons

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The left pod houses three unique buttons.

The yellow Auto Dig button can be accessed using the left thumb. When the joysticks are in the neutral position, this allows one-touch transfer from Propel to Dig. For more information, refer to PROPEL/DIG CYCLE later in this manual. The left pod is also fitted with a spare and a Truck Counter button which is located at the front edge of the pod. Pressing the button after each load captures tonnage and load information when the optional AccuLoad™ system is utilized.

Figure 4-3 Standard Configuration – Button Locations

The right pod houses three unique buttons.

The blue Auto Propel button can be accessed using the right thumb. When the joysticks are in the neutral position, this allows one-touch transfer from Dig to Propel. For more information, refer to PROPEL/DIG CYCLE later in this manual. The right pod is also fitted with a spare and an Alarm Silence button which is located at the front edge of the pod. This button silences the audible CDA (Cab Displayed Alarm).

4 – 12 August 2019

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4.1.6 Operator Displays Two touch screen displays are used in the operator’s station. The displays come with preinstalled software.

Adjust the brightness as needed.

There are two primary operator displays.

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4 – 13 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

If the green power indicator light is illuminated, the power is on. DO NOT shut off power to the operator displays. They should be left on at all times.

Operator’s Station General Information

EM007181

The standard default configuration is described below:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The left-hand unit displays STATUS screens that provide the operator with information on the status of the machine (air pressure, grade, lubrication, etc).

The right-hand unit displays CONTROL screens that allow the operator to control the machine (set or release brakes, turn the drive power on or off, etc).

The CONTROL screens are essential for machine operation; the STATUS screens are not. In the unlikely event that the right hand unit would fail, its CONTROL screen can be swapped to display on the left hand unit so production can continue. For more information, refer to DISPLAY INTERCHANGEABILITY later in this manual.

4 – 14 August 2019

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Operator’s Station General Information

EM007181

4.1.7 Display Interchangeability In the unlikely event that the right hand display would fail, its CONTROL screen can be swapped to temporarily display on the left hand unit so production can continue.

1.

2.

3.

4.

5.

On the Status screen, press the SETTINGS icon (graphic showing a wrench) which is located at the bottom of the screen.

Press the Operator Display icon (graphic showing a computer screen) which is located in the lower left side of the screen.

Under the heading “SWITCH DISPLAYS” select “Switch to Control Screen”.

A yellow screen will appear asking if you want to proceed. Press the green checkmark to proceed.

This completes the screen transfer process. Operation of the machine can resume.

Immediately notify the mine electrical maintenance that you have experienced an operator display failure.

NOTE:

This is a temporary fix. A new operator display should be installed as soon as possible.

The screens should then be returned to the standard configuration.

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4 – 15 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

To transfer screens follow the procedure outlined below:

Operator’s Station General Information

EM007181

4.1.8 Operator’s Console

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The operator’s console is located to the right of the operator’s seat.

Figure 4-4 Operator’s Console Layout

4 – 16 August 2019

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EM007181

4.1.8.1 Emergency Stop Button

Pressing the emergency stop button when any drive is in motion may result in component damage.

4.1.8.2 Window Shade Switches

There are three window shade switches used to raise and lower the left, right and front window shades. In the unlikely event that electrical control should fail, the shades can be manually raised and lowered by rotating the cassette by hand.

4.1.8.3 Wiper Switches

There are two switches used to operate the front windshield wiper. One switch controls the starting and stopping as well as the speed of the windshield wiper.

The second switch activates the washer fluid pump while pressed, pumping washer fluid onto the front glass as needed.

NOTE:

Pressing the washer fluid switch will also initiate the wiper motion and eliminates the need to press both switches.

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4 – 17 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The emergency stop pushbutton is used to stop the machine under operational emergency conditions. Pushing this button will provide immediate electrical and mechanical braking simultaneously. Therefore, this button should only be used if the operator intends the harshest braking of all motions. If the machine is in motion, power will remain on the motions in order to provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will power the DC bus to approximately zero voltage quickly after the time delay.

Operator’s Station General Information

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

4.1.8.4 Console Dimmer Switch

The console dimmer switch allows the operator to adjust the brightness of the console lights.

4.1.8.5 Flood Light Switches

Two on/off light switches are used to power two cab roof floodlights facing forward and one cab floodlight facing left.

4.1.8.6 Heated Mirror Switch – Option

This switch is used to activate the heating mechanism in operator’s cab outside mirrors.

4.1.8.7 Front Ceiling Light Switch

This switch controls the overhead light located in the front of the operator’s cab. This is a dimmable light controlled with the console and wall mounted light switch (dimmer).

4 – 18 August 2019

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Operator’s Station General Information

EM007181

4.1.8.8 Back Ceiling Light Switch

4.1.8.9 Man On Ground Light Switch

This switch turns the rotating light on and off. This light is typically mounted to a handrail on the left side of the machine. When this light is on, it indicates to other mine personnel in the pit that a person is on the ground in the vicinity of the shovel.

4.1.8.10 HVAC A/B Switch – Option

This two position switch allows the operator to switch between the primary or secondary HVAC units on the machine (only one unit can operate at a time).

4.1.8.11 HVAC Digital Control Unit This digital controller is used to operate the heating and air conditioning operation within the cab.

Figure 4-5 HVAC Digital Control Unit

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4 – 19 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

This switch controls the overhead light located in the rear of the operator’s cab. This is a dimmable light controlled with the console and wall mounted light switch (dimmer).

Operator’s Station General Information

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

4.1.8.11.1 Heater

Press to activate the heating mode. In this mode the heaters will cycle on or off based on the thermostat set point. The fans will continue to run even if the heaters are cycled off.

4.1.8.11.2 Auto Climate Control

Press to activate automatic temperature control mode. Use UP and DOWN arrows to increase or decrease the desired temperature set point. In this mode the system will automatically go in to the heat mode or the cooling mode as required to maintain the desired set point.

4.1.8.11.3 Air Conditioner

Press to activate the cooling mode. In this mode the cooling circuit will cycle on or off based on the thermostat set point. The fans will continue to run even if cooling is not required.

4.1.8.11.4 Up & Down Arrows

Press the UP and DOWN arrows to increase or decrease desired temperature set point.

4.1.8.11.5 Power

Press once to provide power to the digital controller, press again to turn the power off.

4 – 20 August 2019

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Operator’s Station General Information

EM007181

4.1.8.11.6 Air Circulation Fan

4.1.8.11.7 Defog

In this mode, one bank of heaters as well as the cooling circuit will be energized to aid in clearing the cab glass of fog. The heaters will run regardless of the current thermostat set point, however the cooling circuit will cycle as normal using the current set point.

4.1.8.11.8 Celsius / Fahrenheit Setting

Press to switch between Fahrenheit and Celsius digital readout.

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4 – 21 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Press to activate air circulation fan. Use UP and DOWN arrows to increase or decrease the desired fan speed.

Operator’s Station General Information

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

4.1.9 Ground Test Switch

The Ground Test Switch is used to trip the breaker that supplies power to the machine. This is accomplished since pushing the Ground Test Switch opens up the pilot wire in the trail cable circuit.

This pushbutton should be used to shut down the machine only when removal of power to the machine is required or to test the pilot trip circuit.

The Ground Test Switch has a hasp on it so that the pilot circuit can be padlocked open.

4 – 22 August 2019

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Operator’s Station General Information

EM007181

4.1.10 Stereo AM/FM Receiver/CD Player The stereo unit is an AM/FM receiver that can also play MP3, WMA, WAV, and AAC files on compact disc. It has the capability to play digital files from the USB port as well. The unit is equipped with a 3-band Equalizer.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

For more detailed information, refer to the manufacturer’s instruction manual.

4.1.11 USB Stereo Port (Not Shown) This USB port can be used to play digital music files through the stereo receiver.

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4 – 23 August 2019

Operator’s Station General Information

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

4.1.12 Motorized Window Shades Motorized window shades are installed on the right, left and front windows of the cab. The shades travel along guide rods for smooth operation. Each shade is raised and lowered with its own rocker switch located on the operator’s console. In the unlikely event that electrical control should fail, the shades can be manually raised and lowered by rotating the cassette by hand.

There is no maintenance or lubrication required for the shades. However, upon initial set-up the upper and lower limits (where the shade stops when raising or lowering) can be adjusted. Each shade is adjusted individually. A small flat screwdriver and/or an allen wrench are required.

To adjust the limits: The upper limit is always the limit located closer to the window regardless of the motor side.

Motor mounted on the left side of the shade is standard.

NOTE:

One full revolution of the screw will move the shade approximately 0.25 inch (6.35 mm).

4 – 24 August 2019

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Operator’s Station General Information

EM007181

4.1.13 Task Lights There are two TouchLED Task Lights located in the operator’s cab. The flexible gooseneck allows for easy positioning. The lights have no mechanical switches.

The red nightlight function can be deactivated if it is not desired. This is achieved by one long touch (min. 3 seconds) to the center red LED. In this case, the center-red LED will remain in its stand-by mode, giving off a very subtle glow; just enough to allow one to locate the touch spot should it be necessary to turn on the light in the dark. Any change in operation mode is initiated by a brief quick flashing of the center red LED.

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4 – 25 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The center red LED performs the ON/OFF switching and serves as the nightlight function as well.

The nightlight function is activated automatically when it becomes dark. It will transform from its dim stand-by mode to a full on red light mode which is bright enough for reading in the dark. By quickly touching the center red LED you can switch ON/OFF the white LEDs. Nightlight function automatically deactivates during the day.

Operator’s Station General Information

EM007181

4.1.14 Ethernet & USB Ports

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Two port enclosures are located to the right of the operator’s seat. The Ethernet ports are used for service personnel to connect a laptop for troubleshooting or monitoring purposes. This allows access into the PLC, operator displays or maintenance station programs.

The USB ports are normally used by service personnel to connect a mouse or keyboard to monitor or program the operator displays.

4 – 26 August 2019

Electric Rope Shovel

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Operator’s Station General Information

EM007181

4.1.15 Telephone Handset

1.

2.

3.

4.

Lift the telephone handset from the cradle.

Depress and hold the handset pressbar.

Speak directly into the microphone to broadcast your announcement over the loudspeakers.

Release the handset pressbar, and if requested, wait for a response. The paged individual(s) responds by picking up a station handset.

NOTE:

Audio adjustments can be made by removing the cover of the remote amplifier located at the foot of the swing seat. Use a small standard screwdriver to adjust the receiver volume, sidetone and microphone gain.

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4 – 27 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

To make a page announcement:

Operator’s Station General Information

EM007181

Audio Adjustments: •

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

• •

Microphone Gain: adjusts the gain level from the microphone signal to the page or party lines.

Receiver Sidetone: adjusts the signal transmitted from the microphone to the receiver of a handset.

Receiver Volume: adjusts the gain level from a party line to the receiver.

4 – 28 August 2019

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Operator’s Station General Information

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4.1.16 Swing Seat A retractable swing seat is located directly behind the operator’s station.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 4-6 Swing Seat in the Stored Position

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4 – 29 August 2019

Operator’s Station General Information

EM007181

4.1.17 Video Camera Monitors

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Five video camera monitors are located above the front windshield.

In a standard configuration, the cameras are setup to monitor: • • • • •

Dipper Hoist Drum Left Side Facing Front Left Side Facing Rear Center Facing Rear*

The monitor settings should not require any adjustment. However, each unit can be adjusted accordingly.

Brightness Adjustment Press the Brightness button on the face of the monitor. Use the plus (+) or minus (-) buttons to select the desired brightness.

Contrast Adjustment Press the Contrast button on the face of the monitor. Use the plus (+) or minus (-) buttons to select the desired contrast. * To invert or “mirror” the image (reverse left and right) sent from the rear facing camera, the service menu of the appropriate monitor will need to be accessed.

4 – 30 August 2019

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Operator’s Station General Information

EM007181

To access or open the Service Menu:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Press the plus, minus and camera selection buttons at the same time.

• • •

With the “CAMERA SETTINGS” highlighted, press the Enter button.

Highlight the “MIRROR” option and toggle to ON (box checked).

Press the Enter button again to store the new setting.

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4 – 31 August 2019

Operator’s Station General Information

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

EM007181

4 – 32 August 2019

Electric Rope Shovel

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EM007181

Operator Controls and Displays

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Operator Controls and Displays

5.1 Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Figure 5-1 Standard Default Configuration Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2 Control Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3 Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Figure 5-2 HOME Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Figure 5-3 HOME Screen with Enhanced Motion Control Option . . . . . . . . . . . . . . . . 5-6 Figure 5-4 Primary Icons used to Navigate Status Screens . . . . . . . . . . . . . . . . . . . . 5-6

5.3.1 Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7 5-7 5-7 5-7

5.4 Permissives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.4.1 E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 1 Start Within 2 Minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.3 2 Starts Within 5 Minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.4 Drive Ready (No AFE Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.5 Drive Cabinet Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.6 Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.7 Auxiliary Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5-8 5-8 5-9 5-9 5-9 5-9 5-9

5–1 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

5

Operator Controls and Displays

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

EM007181

5.4.8 Incomplete Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.9 Joysticks Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.10 Joysticks In Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.11 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.12 Boarding Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.13 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–2 August 2019

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5-10 5-10 5-10 5-11 5-11 5-12

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Operator Controls and Displays Joysticks

Operator Controls and Displays

5.1 Joysticks The operator’s station contains two joystick controllers (Left and Right).

Figure 5-1 Standard Default Configuration Shown

For detailed information explaining hoist, swing, crowd and propel motion controls; refer to MACHINE OPERATION later in the manual.

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5–3 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

For detailed information about transferring from DIG to PROPEL mode; refer to either AUTO PROPEL - DIG CYCLE or MANUAL PROPEL - DIG CYCLE later in the manual.

Operator Controls and Displays Control Screens

EM007181

5.2 Control Screens

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Control screens allow the operator to control the machine (set or release brakes, turn the drive power on or off, etc) and are essential for machine operation.

In the screen above all the brakes are currently set. Note the “release” icons are grayed out. The machine is currently in the dig mode, control is in the stop position and the drive power is off. At the bottom of the screen the current configuration for the joystick and pod buttons is displayed.

5–4 August 2019

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Operator Controls and Displays Status Screens

EM007181

5.3 Status Screens

Figure 5-2 HOME Screen OM11089-EN

Electric Rope Shovel

5–5 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

As the name implies, status screens display the current status of the machines components (boarding ladders, air pressures, etc). Status screens also help the operator monitor current conditions and can display a record of past events (faults, alarm history, etc).

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Operator Controls and Displays Status Screens

EM007181

Figure 5-3 HOME Screen with Enhanced Motion Control Option

With proper authorization, the specific machine settings can be displayed and modified by qualified personnel. Not all screens are accessible by the machine operator.

Figure 5-4 Primary Icons used to Navigate Status Screens

5–6 August 2019

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Operator Controls and Displays Status Screens

EM007181

5.3.1 Home Selecting the HOME icon will allow the operator to display the current status of the machines handle lube, air pressure, boarding ladder position, intake fans, and other components. Access to Adaptive Control and Accuload Control falls under the HOME icon.

Selecting the MONITORING icon will allow the operator to view the component operating temperatures, current side to side incline, front to back incline, machine hours and fault counter.

The temperature monitoring feature is an option.

5.3.3 Alarms Selecting the ALARMS icon will allow access to the machines active alarms as well as the alarm history.

5.3.4 Settings Selecting the SETTINGS icon will allow the operator access to: • • • • • • • •

Setting Limits Rope Reeving & Pintle Tightening Joystick Calibration Lube Setup and Test Motivator (Option) Operator Display Setup Switch Displays Security

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5–7 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

5.3.2 Monitoring

Operator Controls and Displays Permissives

EM007181

5.4 Permissives

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Selecting PERMISSIVES displays the machines current readiness for startup.

5.4.1 E-Stop Green check mark indicates that none of the emergency stop buttons have been pressed.

5.4.2 1 Start Within 2 Minutes This contact detects whether the DC bus has been pre-charged within the past two minutes. The DC bus cannot be pre-charged more than once within the past two minutes. The green check mark indicates that the bus has not been pre-charged within the two minute timeframe.

5–8 August 2019

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Operator Controls and Displays Permissives

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5.4.3 2 Starts Within 5 Minutes

5.4.4 Drive Ready (No AFE Fault) There is no drive fault. The AFE drive is ready for startup.

5.4.5 Drive Cabinet Temperature The green check mark indicates that the drive cabinet temperature is within an acceptable range.

5.4.6 Phase Sequence AC phase sequence check. The red “X” mark indicates that the sequence is NOT proper.

5.4.7 Auxiliary Ground Fault Auxiliary ground fault check. The red “X” mark indicates that there is a ground fault.

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5–9 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

This contact detects whether the DC bus has been pre-charged twice within the past five minutes. The DC bus cannot be pre-charged more than twice within the past five minutes. The green check mark indicates that the bus has not been pre-charged twice within the five minute timeframe.

Operator Controls and Displays Permissives

EM007181

5.4.8 Incomplete Start-up Sequence

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The green check mark indicates that the sequence for start-up was complete.

5.4.9 Joysticks Calibrated The green check mark indicates that the joysticks are calibrated.

5.4.10 Joysticks In Neutral Checks if both joysticks are in the neutral position. The green check mark indicates that both joysticks are in neutral.

5 – 10 August 2019

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Operator Controls and Displays Permissives

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5.4.11 Brakes The red “X” marks indicate that the brakes have not been released.

Detects if any of the boarding ladders are down or in the process of being lowered. The green check mark indicates that all ladders are up.

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5 – 11 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

5.4.12 Boarding Ladder

Operator Controls and Displays Permissives

EM007181

5.4.13 Information

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Selecting the INFORMATION icon will display: • • • •

Machine Type & Serial Number PLC Filename Operator Station Filename WinCC Version Number

5 – 12 August 2019

Electric Rope Shovel

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EM007181

Pre-start, Start-up & Shutdown

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Pre-start, Start-up & Shutdown

6.1 Pre-start Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.2 Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Figure 6-1 Machine Start-up Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Figure 6-2 Machine Start-up Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3 Compressor Startup & Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.3.1 Normal Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6.3.2 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6.4 Normal Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-3 Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.5 Emergency Shut-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Figure 6-4 Emergency Stop Buttons Inside the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.6 Restarting After An Electrical Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

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6–1 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

6

Pre-start, Start-up & Shutdown

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

EM007181

6–2 August 2019

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Pre-start, Start-up & Shutdown Pre-start Inspections

EM007181 Pre-start, Start-up & Shutdown

6.1 Pre-start Inspections

Check the following areas daily during a general walk-around inspection: 1.

2.

3.

Check the areas under and around the crawlers for signs of oil leaks. If single droplets are noticed, leakage is minimal. Determine the point of leakage and make a note of it on the log sheet. If pooling of oil is noticed, determine the source and take corrective action immediately. Determine if loose hardware, a defective gasket, a combination of both, or a similar problem is responsible. Tighten hardware or replace defective gaskets.

Inspect the crawler belts for missing links or lock pins, excessive belt sag, cracked shoes or other deterioration. Check the oil level in the propel planetary gearcase. Add oil as required.

Check the swing rack and pinion guards for rocks, dirt and other debris that will interfere with the operation of the machine. Inspect the swing rack gear and rollers for the proper lubricant film.

HIGH VOLTAGE!THE MACHINE TRAIL CABLE CARRIES A LETHAL VOLTAGE. Handle the cable in an approved manner with appropriate hot gloves and insulated hooks or tongs.

4.

5.

6.

Visually inspect the trail cable for cuts, abrasions and other damage.

Visually inspect exterior of machinery house for damage or evidence of internal leakage.

Inspect the dipper trip mechanism, rope and associated hardware for damage, adjustment and wear.

7. Inspect the dipper door, hardware and bumpers (if equipped) for damage and excessive wear.

8. Inspect fulcrum attachment points, take up cylinders and spacers and dipper handle for damage, excessive wear and evidence of adequate lubrication.

9. Inspect boom bumper (if equipped) for security and damage.

10. Inspect the dipper teeth and tooth adapters for tightness and excessive wear.

11. Inspect padlocks for damage, wear and evidence of adequate lubrication.

12. Check both the running ropes and the boom structural strands for broken strands and loose sockets.

Check the following areas daily on board the machine: 1.

Visually inspect the swing, crowd (if equipped) and hoist gearcases for oil levels and leaks.

Repair or service as required.

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6–3 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Before starting, inspect the machine to ensure it is ready to be put into operation. Failure to make such a routine check could result in unnecessary downtime. For example: an undetected oil leak could result in a dry gearcase, eventually leading to excessive gear wear or destruction, seized bearings or other mechanical problems. Broken strands in the hoist ropes, crowd rope, retract rope or structural strands could, if undetected, result in serious injury or damage to the machine or haulage unit. A few minutes spent inspecting the machine often results in considerable savings in time and machine efficiency.

Pre-start, Start-up & Shutdown Pre-start Inspections 2.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

3.

EM007181

Visually inspect all machinery for loose bolts, nuts, clamps or unusual deterioration. Repair as required.

Visually inspect the open gears of the swing, crowd (if equipped) and hoist machinery for proper lubricant film and evidence of adequate lubrication from the automatic lubricant dispensing system.

Visually inspect hoist and crowd*ropes for wear, lubrication and evidence of birdcaging near the drum attachment beckets. Check that the ropes are properly seated in the drum grooves.

5. Check the oil level in the air compressor. Add oil if required.

6. Check lubricant supply level in the air system lubricator and lube system lubricators.

7. Inspect the automatic lubrication central pumping stations for any signs of malfunctioning.

Check the lubricant supply and refill tanks if required.

8. Visually inspect swing, crowd and hoist brake assemblies for damage, wear and evidence of an overheated condition.

9. Check the operator’s cab for cleanliness and visual condition of controls and location of special equipment that may be required by the mine site. Check all operating controls for freedom of movement. Controls should move freely without binding.

10. Clean windows of operator’s cab using the machine’s windshield wiper system. If the wiper blades need replacement, refer to the maintenance manual.

11. Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a safety hazard.

12. Ensure all external stairways and/or ladder(s) and optional power step are raised and properly stowed.

4.

*.Crowd ropes are not used with HydraCrowd machines 6–4 August 2019

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Pre-start, Start-up & Shutdown Start-up Procedure

EM007181

6.2 Start-up Procedure Whether starting the machine for the first time, or starting after the machine has been in service for some time, the procedures are essentially the same.

Perform all pre-start inspections. For a detailed list, refer to PRE-START INSPECTIONS earlier in the manual.

2.

Ensure the air compressor has been started and is running with adequate operating pressure.

Navigate to the “home” screen to verify the compressors operating pressure. If the air compressor (located in the left side of the machinery house) is not running, it will need to be manually started.

Refer to COMPRESSOR STARTUP & SHUTDOWN later in this section of the manual.

On the left-hand operator display, the Permissives screen will appear by default. Verify the items A through L below are ready for start-up.

3.

Figure 6-1 Machine Start-up Permissives

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Electric Rope Shovel

6–5 August 2019

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1.

Pre-start, Start-up & Shutdown Start-up Procedure a. b.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

c. d. e. f.

EM007181

Verify that the E-Stop icon indicates a green check mark. This means that no Power Off or Emergency Stop buttons have been detected as being pressed.

Verify that the”1 Start Within 2 Minutes” icon indicates a green check mark. This means that the DC bus has not been pre-charged within the past two minutes.

Verify that the”2 Starts Within 5 Minutes” icon indicates a green check mark. This means that the DC bus has not been pre-charged twice within the past five minutes.

Verify that the Drive Ready icon indicates a green check mark. This means that there is currently no drive fault and the AFE drive is ready for start-up.

Verify that the Drive Cabinet Temperature icon indicates a green check mark. This means that the drive cabinet temperature is within operating range.

Verify that the Phase Sequence icon indicates a green check mark. This means that the phase sequence is proper.

Figure 6-2 Machine Start-up Permissives

g. h.

i. j.

Verify that the Auxiliary Ground Fault icon indicates a green check mark. This means that there is no ground fault detected.

Verify that the Incomplete Start-up Sequence icon indicates a green check mark. This means that the start-up sequence is complete. If all start-up indicators are checked, the machine is ready to start.

Verify that the Joysticks Calibrated icon indicates a green check mark. This means joysticks are properly calibrated.

Verify that the Joysticks in Neutral icon indicates a green check mark. This means that both joysticks are in the default (neutral) position.

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Pre-start, Start-up & Shutdown Start-up Procedure

EM007181

k.

Verify that all brake icons indicate a red “X” mark. This means that the brakes are SET.

4.

5.

6.

7.

Verify that the Boarding Ladder icon indicates a green check mark. Ensure that all boarding stairs and/or ladders are in the raised and latched position. If all the control permissives are indicated with a green check mark, the machine is able to operate.

Press the Drive Power ON button.

If the button is not active (faded in appearance), press the Control RESET button (shown below), then press the Drive Power ON.

Monitor the air pressure using the appropriate status screen on the left-hand operator display.

Address any CDA Faults that arise after start-up.

Sound the signal horn and be sure all personnel are clear of the machine.

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6–7 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

l.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Pre-start, Start-up & Shutdown Start-up Procedure

EM007181

8.

Ensure the joysticks are in the neutral position. Select the DIG Mode.

When the process is complete, press the Control RESET to activate the controls.

9.

10.

11.

12.

RELEASE the brakes using the control screen.

Briefly actuate the swing, crowd and hoist controls to make sure each motion is operational.

Perform a pre-operational check of the propel motion before operating the propel.

Before operation, verify that hoist and crowd limits are set properly and operational.

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EM007181

Pre-start, Start-up & Shutdown Compressor Startup & Shutdown

6.3 Compressor Startup & Shutdown

A brief description of the compressor startup and shutdown process is included in order to guide the user through the processes. It is not intended to replace the manufacturer’s documentation. If you are not familiar with the proper and safe operation of the air compressor, read the manufacturer’s operator’s manual before proceeding.

To start the air compressor: 1.

2.

3.

Verify that the shut-off valves are fully open.

Verify that the main power is on.

Press the START button. The electronic controller may delay the starting process under certain conditions. Once the compressor begins startup, monitor the digital display until the set operating pressure is achieved.

4.

When the digital display reads STANDBY RUN ON, run the compressor through a number of load/unload cycles and check for consistent, smooth operation.

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6–9 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The air compressor is located along the left side wall of the machinery house.

Pre-start, Start-up & Shutdown Compressor Startup & Shutdown

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

6.3.1 Normal Shutdown

Never assume that the compressor has completely stopped, even if the compressor does not appear to be running. The compressor may have stopped in STANDBY mode and may restart at any time!

To shut down the air compressor: Press the STOP button on the digital display. The compressor will begin a delayed stop sequence STOP RUN ON along with the remaining time in seconds until compressor stop. The compressor will stop automatically after the delayed stop period.

NOTE:

If during the stop delay period the START button is pressed, the STOP RUN ON timer function will be cancelled and the compressor will run normally loaded/unloaded as necessary to maintain system pressure.

6.3.2 Emergency Shutdown

Press the EMERGENCY STOP button on the front of the compressor. DO NOT use the emergency stop button for normal shutdown!

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EM007181

Pre-start, Start-up & Shutdown Normal Shutdown Procedure

6.4 Normal Shutdown Procedure When shutting down the machine proceed as follows: 1.

Figure 6-3 Control Screen

3.

4.

5.

Make sure all brakes are SET. Press the Control Stop button.

Press the Drive Power Off button. This shuts down the drive.

NOTE:

The house and motor blowers will continue to operate to ensure the drive components have cooled down sufficiently. Once the drives are cool, the house blowers will shutdown automatically.

DO NOT use the Emergency Stop button for normal shutdown! The emergency stop pushbutton is used to remove power and stop the machine under emergency conditions.

Pushing this button will immediate set all brakes. Therefore, this button should only be used if the operator intends the harshest braking of all motions.

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Electric Rope Shovel

6 – 11 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

2.

Park the machine on firm ground in a position where it cannot be damaged by a slide, falling rocks or flooding, and where the next operator can safely conduct their pre-operational inspection. In cold climates, be sure the crawler belts will not freeze into the ground.

Place the dipper firmly on the ground.

Pre-start, Start-up & Shutdown Emergency Shut-down

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

6.5 Emergency Shut-down Pressing any one of the Emergency Stop buttons will stop the machine under operational emergency conditions. Pushing this button will provide immediate electrical and mechanical braking simultaneously. Therefore, it should only be used if the operator intends the harshest braking of all motions. If the machine is in motion, power will remain on the motions in order to provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will power the DC bus to approximately zero voltage quickly after the time delay.

Pressing the emergency stop button when any drive is in motion may result in component damage.

Figure 6-4 Emergency Stop Buttons Inside the Cab

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EM007181

Pre-start, Start-up & Shutdown Restarting After An Electrical Fault

6.6 Restarting After An Electrical Fault To restart the machine after the electrical control system has gone into a fault condition, proceed as follows: Before any or all motions can be reset, the following conditions must be met:

a.

1.

2.

3.

4.

For hoist/propel motion the hoist/propel transfer switch is in the position called for by the operator’s mode selector switch. b. The joystick for the motion being reset must be in the NEUTRAL position. c.

The motion mechanical brake selector button must be in the SET position.

For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the controls will remain active. Reversing the joystick will remove the fault and allow continued operation.

For a boom jacking fault, ALL motions will stop but the controls will remain active. Reversing the crowd joystick will remove the fault and allow continued operation. Gently retract the dipper handle until the boom is completely lowered. You can then resume normal operation.

If the boarding ladder and/or stairs are pulled down while the machine is in operation, an alarm message will be sent to the operator, and swing and propel motions will be shut down. The hoist and crowd motions will remain active. a. Once the ladder and/or stairs are back in position, the motions may be restarted by pressing the control reset pushbutton.

For most other faults, the machine will be shut down and brakes set. In these situations, the controls cannot be reset until the fault has been corrected by an electrician.

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6 – 13 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

NOTE:

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Pre-start, Start-up & Shutdown Restarting After An Electrical Fault

6 – 14 August 2019

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EM007181

Machine Operation

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Machine Operation

7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.1.1 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.2 Auto Propel - Dig Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.3 Manual Propel - Dig Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7.4 Hoist Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 7.5 Swing Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 7.6 Proper Swing Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 7.7 Crowd Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 7.8 Propel Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 7.8.1 Recommended Handle Position During Propel . . . . . . . . . . . . . . . . . . . . . . 7-15

7.9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 7.10 Counter-rotation Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

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7

Machine Operation EM007181

7.11 Positioning The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 7.11.1 Back-up Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 7.11.2 Drive-by Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.12 Machine Protections - Motion Limits . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 7.12.1 Hoist and Crowd Limit Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 7.12.1.1 Setting Limits In The Hoist & Crowd System . . . . . . . . . . . . . . . . . . 7-22 Figure 7-1 View A - Calibration Limits Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7.12.1.1.1 Crowd Slowdown/Stop Limits - Rope Crowd . . . . . . . . . . . . . . . 7-24 7.12.1.1.2 Retract Slowdown/Stop Limits - Rope Crowd . . . . . . . . . . . . . . 7-25 7.12.1.1.3 Crowd Slowdown/Stop Limits - HydraCrowd . . . . . . . . . . . . . . . 7-26 Figure 7-2 Crowd Slowdown/Stop Limits - HydraCrowd . . . . . . . . . . . . . . . . . . . . . 7-27

7.12.1.1.4 Retract Slowdown/Stop Limits - HydraCrowd . . . . . . . . . . . . . . 7-28 Figure 7-3 Retract Slowdown/Stop Limits - HydraCrowd. . . . . . . . . . . . . . . . . . . . . 7-29

7.12.1.1.5 Lower Slowdown/Stop Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30 7.12.1.1.6 Hoist Slowdown/Stop Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

7.13 Machine Protections - Enhanced Motion Control (Option) . . . . . . . 7-32 7.13.1 Anti-Swing in the Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.2 Hoist Stall Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.3 Rope Crowd Impact Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.4 Crowd Overspeed Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.5 Hoist Rope Slack Prevention/Boom Jack Minimization . . . . . . . . . . . . . .

7-32 7-35 7-39 7-40 7-41

7.14 Start Of The Dig Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Figure 7-4 Force the Dipper Lip into the Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Figure 7-5 Variations on Dipper Penetration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Figure 7-6 Dig with the Dipper Beneath the Boom Point . . . . . . . . . . . . . . . . . . . . . 7-45

7.15 Engaging The Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Figure 7-7 Engage the Bank Under the Boom Point. . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Figure 7-8 Hoist Force Opposes Crowd Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Figure 7-9 Make Effective Use of the Hoist Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47

7.16 Slope Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 7.17 Excavating Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 7.18 Operation Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 7.19 Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

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Machine Operation Introduction

EM007181 Machine Operation

7.1 Introduction

Due to the many varied mining conditions, situations may arise which are not directly discussed in detail in this manual. When such situations arise; past experience, availability of equipment, and common sense play a large part in what steps should be taken. General safe practices for working machines must be followed as well as safe operating practices. However, it is impossible to foresee all such conditions, and it must remain the responsibility of the mining company and the operator to anticipate and avoid any unsafe conditions not described in detail in this manual. Safety rules within individual mining companies vary. If a conflict exists, the rules of the company take precedence over the suggestions contained within this manual.

7.1.1 Operator Responsibilities • •

•

The operator must read and understand the operator's manual and be familiar with all instructions and signs on the machine.

The operator must see that the machine is in proper order before starting to work each shift. Refer to PRE-START INSPECTIONS for details. Check with mine maintenance and operations management to see that periodic maintenance and inspections have been performed and all necessary repairs made.

Refer to START-UP PROCEDURE for detailed instructions on starting the machine.

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7–3 August 2019

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The purpose of this section is to describe the operation of the individual motion controls and include some recommended operating procedures and practices that will aid the operator in the safe, smooth and efficient operation of the machine.

Machine Operation Auto Propel - Dig Cycle

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.2 Auto Propel - Dig Cycle It is strongly recommended that the manual transfer process be utilized whenever performing maintenance functions to avoid releasing brakes (which the auto transfer process will do).

Transferring from DIG to PROPEL mode and back again can be done using the control screen or the transfer process can be accomplished (often quicker) using the buttons located on the left and right joystick pod. When using this auto transfer method, it is important that both joysticks remain in the NEUTRAL position until the transfer is complete.

NOTE: • • • • •

In the short time the auto transfer is in process, the following occur automatically: The applicable brakes are set The Control is stopped The transfer occurs The Control is reset The applicable brakes are released

To transfer from PROPEL to DIG: •

Push the (yellow) Auto Dig button on the left-hand pod to initiate the process.

•

Control screen icons associated with the transfer will flash on and off during the transfer.

Once the transfer is complete the icons will go solid green.

To transfer from DIG to PROPEL: •

Push the (blue) Auto Propel button on the right-hand pod to initiate the process.

7–4 August 2019

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Machine Operation Auto Propel - Dig Cycle

EM007181

Control screen icons associated with the transfer will flash on and off during the transfer.

Once the transfer is complete the icons will go solid green.

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Electric Rope Shovel

7–5 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

•

Machine Operation Manual Propel - Dig Cycle

EM007181

7.3 Manual Propel - Dig Cycle

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Transferring from DIG to PROPEL mode and back again can be done using the control screen.

This manual transfer is strongly recommended whenever performing maintenance functions to avoid releasing the brakes (which the auto transfer process will do).

To manually transfer from PROPEL to DIG using the control screen: 1.

Press to set the appropriate brakes; All Brakes or Propel.

2.

Press the Control Stop button.

3.

Press the DIG button. Allow time for the transfer to be completed.

4.

Press the Control Reset button. When the button is pressed, it turns to blue (as shown below). When this button is released, it turns back to black.

5.

Press to release the appropriate brakes; All Brakes or Hoist and Crowd.

To manually transfer from DIG to PROPEL using the control screen:

7–6 August 2019

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Machine Operation Manual Propel - Dig Cycle

EM007181

Press to set the appropriate brakes; All Brakes or Hoist and Crowd.

Press the Control Stop button.

3.

Press the PROPEL button. Allow time for the transfer to be completed.

4.

Press the Control Reset button. When the button is pressed, it turns to blue (as shown below). When this button is released, it turns back to black.

5.

Press to release the appropriate brakes; All Brakes or Propel.

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Electric Rope Shovel

7–7 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

1.

2.

Machine Operation Hoist Motion Control

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.4 Hoist Motion Control Hoist motion is controlled by the operator’s right joystick. To transfer to the DIG mode, refer to PROPEL-DIG CYCLE for more information. The crawlers should be positioned so that the digging is done over the front of the crawlers. Move the joystick between the hoist and lower until a “feel” is developed for the height, depth range and speed at which the dipper moves. Practice the hoist function until movement can be stopped smoothly.

NOTE:

The speed of the hoist movement is proportional to the distance the joystick is moved away from neutral. There are slowdown and stop limits at both ends of each stroke.

Stop movement by moving the joystick to the neutral (center) position. The joystick is spring loaded and will return to the neutral position when released.

The right joystick also controls the swing motion through left and right motions.

NOTE:

The standard (default) configuration is shown above. The hoist and lower directions can be inverted.

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Machine Operation Swing Motion Control

EM007181

7.5 Swing Motion Control

NOTE:

The joystick also controls the hoisting and lowering of the dipper through forward and backward motions.

Each motion - hoist or swing - is fully operational throughout the complete movement of the other motion.

NOTE:

When this joystick is used for propelling the right track of the machine, the hoist and swing motions are locked out.

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Electric Rope Shovel

7–9 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Swing motion is controlled by the operator’s right joystick. To swing in either direction, move the joystick lever in the direction of swing. Practice swinging in each direction until a “feel” is developed for start-up and stopping. The speed of the swing movement is proportional to the distance the joystick is moved away from neutral. Unlike other motion controls, swing movement does not stop when the joystick is returned to the neutral (center) position. The operator must counter swing to stop.

Machine Operation Proper Swing Motion

EM007181

7.6 Proper Swing Motion

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Proper swing motion means smooth control and an efficient swing cycle. The swing motion begins toward the haulage unit when the dipper is filled and is clear of the bank.

Extensive damage to the dipper handle and dipper can occur if the machine is swung before the dipper clears the bank.

The swing motion begins with acceleration to an optimum point at which the excavator is brought to a stop over the haulage unit. Maximum efficiency and minimum swing machinery wear are direct results of mastering the swing motion.

NOTE:

Improper swing motion results in erratic control, and an inefficient swing cycle.

The dipper should never be swung over personnel, trail cables, related electrical equipment or other equipment. When the dipper is loaded, accidental tripping of the dipper door could result in death or serious injury to personnel, and extensive damage to equipment. Empty dippers may contain small fragments of material that can be extremely dangerous when dropped from a considerable height. On long moves it’s best to have the door open on an empty dipper and the dipper lowered to a point that permits moving without striking the ground.

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Machine Operation Proper Swing Motion

EM007181

Haulage units should be positioned so their centerline is approximately under or not more than slightly outside the swing path of the boom point. This substantially reduces the amount of dipper maneuvering required of the operator when positioning the dipper for dumping. Positioning of the haulage unit inside or outside the boom point makes it necessary to retract or crowd the dipper handle and dipper, which breaks the operator’s natural rhythm.

A clean, level pit floor must be maintained. A good operator will always clean the floor before moving into the bank. A clean and level floor grade is a requisite to safe and stable machine operation, and reduces damage to crawler links and related components.

“Sweeping” should never be attempted with the machine. Sweeping consists of lowering the dipper to the ground and using the swing motion of the machine to move the dipper from side-to-side and “sweep” the pit floor. The dipper, dipper handle and boom structures can be damaged by this tactic. A bulldozer or loader should be used to help the machine operator maintain a clean pit floor in conjunction with the machine.

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7 – 11 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Time is required to accelerate any motion from zero to working speed, and also to decelerate from working speed back to zero. The time expended for accelerating and decelerating the swing represents the major part of the entire dig cycle. Therefore, the swing arcs must be kept to a minimum to obtain maximum operating efficiency. As an example: assuming that a 90° swing results in 100 percent of the maximum output, increasing the swing arc to 180° reduces output to 70 percent, while decreasing the swing arc to 45° increases the output to 126 percent. Therefore, a swing arc of 90° or less should usually be used.

Machine Operation Crowd Motion Control

EM007181

7.7 Crowd Motion Control

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Crowd motion is controlled by the operator’s left joystick. Transfer to the DIG mode, refer to PROPEL-DIG CYCLE for more information. Move the joystick forward to crowd and backward to retract the dipper handle until a “feel” is developed for the limits and speed of the motion.

NOTE:

The speed of the crowd movement is proportional to the distance the joystick is moved away from neutral. There are slowdown and stop limits at both ends of each stroke.

Stop movement by moving the joystick to the neutral (center) position. The joystick is spring loaded and will return to the neutral position when released.

Practice the crowd and retract functions until the movement can be stopped smoothly. Combine the crowd and hoist functions and practice until smooth coordinated motions and subsequent machine effectiveness is achieved.

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Machine Operation Crowd Motion Control

EM007181

NOTE:

On HydraCrowd machines, avoid “tight-lining”.

“Tight-lining” occurs when the dipper is pulled up close to the underside of the boom when the handle extension is less than 4.5 m (15 feet). Routinely placing the dipper in this position will adversely affect cylinder life and could lead to premature cylinder failure.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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7 – 13 August 2019

Machine Operation Propel Motion Control

EM007181

7.8 Propel Motion Control

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Prior to moving the machine, position the dipper in the recommended position. Avoid “tightlining”. See topic “Recommended Handle Position During Propel”.

To propel, transfer to the PROPEL mode. Refer to either AUTO PROPEL-DIG CYCLE or MANUAL PROPEL-DIG CYCLE for more information.

THE HOIST BRAKE MUST BE SET WHENEVER IN THE PROPEL MODE. To propel in a straight forward direction, move both joysticks forward slightly past neutral and pause until the slack in the crawler belts and drive tumblers is taken up and motion begins. This will reduce potential damage to the crawlers and tumblers. Then push the joysticks farther in the direction of travel for more speed. The speed is increased as the joysticks are displaced farther from neutral.

To propel straight in reverse, pull equally on both joysticks to the rear, just past neutral to eliminate the crawler belt / tumbler slack. Then pull both joysticks back farther for more propel speed.

When propel motion is complete, reverse the direction of the joysticks just past neutral to relieve any crawler belt / tumbler tension, then return the joysticks to neutral to stop.

NOTE:

The control stop pushbutton must be pressed before the propel transfer switch can be activated.

7 – 14 August 2019

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Machine Operation Propel Motion Control

EM007181

7.8.1 Recommended Handle Position During Propel During propel, the handle should be horizontal and the hoist ropes should be vertical. This will ensure the forces on the handle are minimal.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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7 – 15 August 2019

Machine Operation Steering

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.9 Steering

• •

To make a gradual forward right turn, move the LEFT joystick (crowd) forward and leave the right joystick (hoist) in neutral.

To make a gradual forward left turn, move the RIGHT joystick (hoist) forward and leave the left joystick (crowd) in neutral.

Whenever possible, gradual turns should be made in short increments of 15° to 20° maximum.

Propel straight for a short distance (usually 1/2 the length of the crawler belts) to clear the crawler belts of stone and other debris; then make another 15° to 20° turn. Continue until the turn is completed.

NOTE:

When steering in soft material such as sand, clay, etc., increments of less than 15° to 20° might be used to minimize material build up on the crawler belt roller path. A single sharp turn should be avoided to minimize material build up on the crawler belt roller path and subsequent high loading of crawler belt and associated propel components.

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Machine Operation Counter-rotation Turns

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7.10 Counter-rotation Turns

Move the LEFT joystick forward (just past neutral) and pull the RIGHT joystick to the rear (just past neutral) to take up the slack in the respective crawler belts and drive tumblers before moving the joysticks to full travel and faster propel speed.

To make a sharp left turn: Move the RIGHT joystick forward (just past neutral) and pull the LEFT joystick to the rear (just past neutral) to take up the slack in the respective crawler belts and drive tumblers before moving the joysticks to full travel and faster propel speed.

NOTE:

When the turn is completed, reverse the direction of the joysticks slightly past neutral to relieve any tension on the crawler belts and drive tumblers. Then return the joysticks to neutral to stop.

Although possible, a single sharp turn should be avoided to minimize material build up on the crawler belt roller path. This results in high loading of the crawler belt and increased stress on the propel components. Therefore, counter-rotation turns should be limited to 15° to 20° increments.

When using the counter-rotation method for turning, use a helper to ensure that the trail cable does not get fouled and/or torn from the machine.

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

To make a sharp right turn:

Machine Operation Counter-rotation Turns

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

NOTE:

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The ability of the machine to turn sharply is dependent on the surface on which the machine is setting. A soft surface will cause the crawlers to dig-in and machine to bog down.

When moving the machine in a straight line, always propel forward (in the direction of the take-up axle) to reduce strain and wear on the crawler belts and propel mechanism. This is especially important in long propels or in deadheading back to the beginning of a cut. When not possible to propel forward, and propelling to the rear is required, make sure the trail cable is clear of the machine and follow the signals given by the helper. For increased safety the machine’s upper works should be rotated in a position that allows the operator to face the direction of travel.

NOTE:

Turning when propelling to the rear requires that the joystick be positioned in a direction opposite the actual direction in which the turn takes place. The machine should be moved close to the bank in short and frequent moves to maintain digging efficiency.

Movement should occur between the loading of haul units.

7 – 18 August 2019

Electric Rope Shovel

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Machine Operation Positioning The Machine

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7.11 Positioning The Machine There are two basic methods for positioning an excavator at a bank working face. The first method is the “back-up method”. The second method is the “drive-by method”. Both methods are acceptable and effective when set up correctly.

7.11.1 Back-up Method When using the back-up method, the excavator is placed in the bank with the front of the machine turned directly toward the digging face. The haulage units are spotted on both sides of the machine. The bank is worked until a 180° semicircle has been excavated. When the point is reached where a 90° swing to either side is required to load haulage units, the excavator is moved to a new cut.

Work the machine from right to left along the bank. To move over, the operator should back up, turning the machine gradually until the crawlers are at a 45° angle to the original digging path.

Then, back the machine straight until the right crawler crosses the corner of the excavated semicircle.

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Ensure that personnel and auxiliary equipment are at a safe working distance prior to moving the shovel. Wear metal from track operation can break off and become a projectile. The compression of rocks under the weight of the machine can cause rock to become high speed/energy projectiles.

Machine Operation Positioning The Machine

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Then, propel forward, turning the crawlers gradually to the left. When the right crawler is aligned with the corner of the semicircle, move forward to the digging face and proceed to load the haulage units. The back-up method will minimize the swing arc and reduce moving time. Other advantages are less bank toe area clean up and simplified handling of the trail cable, cable towers and trail cable boat.

7.11.2 Drive-by Method NOTE:

If the machine and haulage units cannot be set up as described below, the drive-by method should be avoided.

Position the machine crawlers parallel to the bank with the inside edge of the outer set of crawler tracks directly in line with the bank toe. The trucks must approach the machine from the front making a turn away from the machine as the front wheel approaches the outside crawler. The truck should stop in a position to allow backing toward the point of the bank for loading. During the load cycle, the swing arc should not exceed 90°. The time between finishing one truck to the first digging cycle of the next should not exceed that of any cycle during a load.

7 – 20 August 2019

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Machine Operation Machine Protections - Motion Limits

7.12 Machine Protections - Motion Limits 7.12.1 Hoist and Crowd Limit Systems

Hoist/Crowd encoder calibration provides the limit system a reference point for tracking both the hoist and crowd positions. Performing the encoder calibration sets all the hoist and crowd limits to their previously set values in order that the actual limits do not require reset after initial commissioning.

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Electric Rope Shovel

7 – 21 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

All electric rope shovels incorporate a PLC-based limit position system that permits the setting of the Hoist/Lower and Crowd/Retract operational limits. Hoist and crowd encoders send digital signals to the PLC relative to the hoist crowd motor positions. The setup of the hoist and crowd limits is accomplished through the operator’s display terminal by following the instructions provided here in this manual along with those on the operator’s display. When encoder calibration and hoist/crowd positional limits have been properly set the system will prevent the dipper handle from hitting its end stops and will prevent the padlocks from being pulled into the boom point sheaves.

Machine Operation Machine Protections - Motion Limits

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.12.1.1 Setting Limits In The Hoist & Crowd System

The hoist and crowd limits may be changed as often as desired without encoder recalibration providing the ropes have not been replaced. The individual limits may be set in any order.

Suggested slowdown and stop points are shown as a guide only, and must be adjusted to suit local operation.

NOTES: •

•

Hoist and crowd limits should be set with care, as the limits will affect the digging range of the machine. After the motion limits have been set initially, it is necessary to calibrate the encoder if the ropes have been replaced, or if the encoder has been replaced. Performing the encoder calibration will reset the motion limits to their previous positions.

The slowdown limits reduce handle speed to 20% of maximum prior to reaching the stop limit. Because the drive requires a discrete distance to stop that is different at all positions, it is recommended that the slowdown limit be tried several times. Increase speeds from minimum to maximum to determine if sufficient distance is available in the limits as set to stop without impacting the mechanical stops.

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Machine Operation Machine Protections - Motion Limits

To calibrate the encoder: 1.

Go to the Limits screen on the operator display shown in Figure 7-1.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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Figure 7-1 View A - Calibration Limits Screen

2.

3.

Raise the dipper to the maximum point (just touching boom point sheaves).

Extend the handle to its crowd end stop.

4.

Press the CALIBRATE button on the operator display. This calibrates the rope lengths prior to setting limits. This is required only after changing the ropes, or if the encoder has been replaced.

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7 – 23 August 2019

Machine Operation Machine Protections - Motion Limits

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7.12.1.1.1 Crowd Slowdown/Stop Limits - Rope Crowd To set the crowd slowdown and stop limits:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

1.

2.

With the handle horizontal, position the handle approximately one foot from the rear end of the saddle block.

Press the CROWD STOP LIMIT button on the operator display.

3.

4.

Retract the handle until the crowd stops are approximately 2 feet from the saddle block.

Press the CROWD SLOWDOWN LIMIT button on the operator display.

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Machine Operation Machine Protections - Motion Limits

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7.12.1.1.2 Retract Slowdown/Stop Limits - Rope Crowd To set the retract slowdown and stop limits: 1.

3.

Position the handle with the retract stops approximately 6 inches from the saddle block and press the RETRACT STOP LIMIT button on the operator display.

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7 – 25 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

2.

Position the handle horizontally. Retract the handle until the retract stops are approximately 18 inches from the front end of the saddle block.

Press the RETRACT SLOWDOWN LIMIT button on the operator display.

Machine Operation Machine Protections - Motion Limits

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.12.1.1.3 Crowd Slowdown/Stop Limits - HydraCrowd

Before setting limits, ensure that the encoder is properly calibrated. Refer to the instructions “To calibrate the encoder” - SETTING LIMITS IN THE HOIST & CROWD SYSTEM. To set the crowd slowdown and stop limits: 1.

With the handle horizontal, extend the handle to 18.00 feet of Handle Extension (1.00 foot from the end of the saddle block). Refer to the Crowd Slowdown/Stop Screen graphic on the following page. Once the value appears in the “Handle Extension” field of the operator display screen, visually verify that the handle is in the correct position.

2.

3.

Press the CROWD STOP LIMIT button on the operator display.

Retract the handle at least 1.00 feet from the crowd stop limit (the value should appear as 16.50 feet on the “Handle Extension” field).

Press the CROWD SLOWDOWN LIMIT button on the operator display.

4.

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Machine Operation Machine Protections - Motion Limits

NOTE:

The limit values in this procedure are specified for maximum recommended handle extension. The crowd stop limit can always be set to a value LESS than 18.00 feet if desired. In doing so, this slightly reduces the extent of handle travel. Adjust the slowdown limit accordingly (1.00 feet from the stop limit). The crowd slowdown limit can always be set to a value LESS than 16.50 feet if desired.

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Electric Rope Shovel

7 – 27 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 7-2 Crowd Slowdown/Stop Limits - HydraCrowd

Machine Operation Machine Protections - Motion Limits

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.12.1.1.4 Retract Slowdown/Stop Limits - HydraCrowd

Before setting limits, ensure that the encoder is properly calibrated. Refer to the instructions “To calibrate the encoder” - SETTING LIMITS IN THE HOIST & CROWD SYSTEM. To set the retract slowdown and stop limits: 1.

Position the handle horizontally - as close to 90° as possible.

2.

Retract the handle to 1.50 feet of Handle Extension. Refer to the Retract Slowdown/Stop Limits graphic above. Once the value appears in the “Handle Extension” field of the operator display screen, visually verify that the handle is in the correct position.

Press the RETRACT STOP LIMIT button on the operator display.

3.

4.

Extend the handle at least 1.50 feet away from the retract stop limit (the value should appear as 3.00 feet on the “Handle Extension” field). Press the RETRACT SLOWDOWN LIMIT button on the operator display.

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Machine Operation Machine Protections - Motion Limits

NOTE:

The limit values in this procedure are specified for maximum recommended stroke (travel) of the cylinder rod. The retract stop limit can always be set to a value GREATER than 1.50 feet if desired. In doing so, this slightly reduces the extent of the stroke.

Adjust the slowdown limit accordingly (1.50 feet from stop limit). The retract slowdown limit can always be set to a value GREATER than 3.00 feet if desired.

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7 – 29 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 7-3 Retract Slowdown/Stop Limits - HydraCrowd

Machine Operation Machine Protections - Motion Limits

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7.12.1.1.5 Lower Slowdown/Stop Limits

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

To set the lower slowdown and stop limits: 1.

Position the handle vertically with the dipper teeth just touching pit floor and the hoist ropes tight. Press the LOWER SLOWDOWN LIMIT button on the operator display.

2.

Keeping the handle vertical, let the padlocks fall forward until the padlocks contact the dipper.

Press the LOWER STOP LIMIT button on the operator display. The lower stop limit helps prevent rope from spooling off the hoist drum.

3.

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Machine Operation Machine Protections - Motion Limits

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7.12.1.1.6 Hoist Slowdown/Stop Limits To set the hoist slowdown and stop limits: With the handle at full crowd extension, hoist the dipper so the padlocks are approximately one foot from the boom point sheaves.

2.

3.

Press the HOIST STOP LIMIT button on the operator display.

Lower dipper until the padlocks are three feet from the boom point sheaves. Press the HOIST SLOWDOWN LIMIT button on the operator display.

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7 – 31 August 2019

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1.

Machine Operation Machine Protections - Enhanced Motion Control (Option)

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.13 Machine Protections - Enhanced Motion Control (Option) The goal of Enhanced Motion Control is to improve shovel performance by intelligently controlling how motions are allowed to operate under certain conditions. This will help the machine control for operators, allowing them to dig productively and effectively without inadvertently causing damage to machine components.

The components of Enhanced Motion Control are as follows: • • • • •

Anti-Swing in Bank- Monitor crowd force to determine when the dipper is in the bank and limit swing reference from operator.

Hoist Stall Prevention - Monitor hoist speed and acceleration and adjust crowd reference to maintain a minimum hoist speed.

Rope Crowd Impact Prevention - Limit the maximum speed the crowd can operate at when rope forces are high, which will reduce the severity of the impact.

Crowd Overspeed Prevention - Reduce the crowd over speed occurrences.

Hoist Rope Slack Prevention / Boom Jack Minimization - Minimize the occurrences of boom jacking by limiting slack in the hoist ropes.

7.13.1 Anti-Swing in the Bank •

Current situation / Why This Change is Needed?

A swing in bank occurs during a digging cycle. In this event, the dipper is engaged in the bank and the operator tries to swing the machine. This is not desired by good operating practices. This results from swing torque acting against the dipper and further produces significant damaging stresses on the saddle block, boom, swing gears, dipper and dipper handle.

The objective of this feature is to restrict undesirable swing motion during the digging operation only when the dipper is engaged in the bank and allowing full swing *reference during any other operation. By preventing the operator from swinging while digging we can increase machine reliability and life by reducing stress on the front end.

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Machine Operation Machine Protections - Enhanced Motion Control (Op-

* Reference: A reference is a joystick command from the operator. In Hoist, Crowd and Propel it is a speed command proportional to the joystick throw. In Swing, it is a proportional torque command.

•

How it Works / What You Notice as an Operator:

Operators who attempt to engage the swing while the dipper is still in the bank cannot do so.

Operators will notice that the swing control will not engage until the dipper is retracted enough to clear the bank.

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7 – 33 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Indicator on Status Screen, Swing Rack turns blue.

Machine Operation Machine Protections - Enhanced Motion Control (Option)

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

There is also an Anti-Swing in the Bank Counter (located on the Machine Hours/Fault Counters screen) that tracks the number of times the software adjusted the swing reference.

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Machine Operation Machine Protections - Enhanced Motion Control (Op-

7.13.2 Hoist Stall Prevention •

Current situation / Why This Change is Needed?

NOTE:

The Hoist Stall Prevention is an enhancement to the current Adaptive Control feature.

What is Hoist Stall Prevention?

The hoist stall prevention will go into slight retract if necessary, if the hoist starts to stall. It is designed to keep the hoist moving through the bank at optimum speed. Even if full hoist and crowd reference are given when the bank is engaged, the software will automatically adjust crowd reference to keep the hoist moving through the bank.

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7 – 35 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Excessive stalling causes strain on the hoist system. A Dipper Stall occurs when the dipper enters the bank, and it experiences enormous resistance that prevents it from cutting through the bank. This occurs when there is either too much material in the Dipper (big rock) that is beyond the machines capacity to handle or the operator is not coordinating the Hoist and Crowd operation as desired by good operating practices.

Machine Operation Machine Protections - Enhanced Motion Control (Option)

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

•

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How It Works / What Will You Notice When Operating:

To resolve this dipper stall condition, the machine will control the amount of crowd to maintain the optimum hoist speed. The dipper stalling directly affects dig cycle time and hence decreases shovel productivity. An operator may notice the machine taking over when they are crowding, the machine may stop the crowding, allow less crowding, or even retract slightly to prevent an over crowd situation. The operator may have to move the shovel closer to the bank in order to be able to dig more effectively.

There is an override button on the operator's display to disable this feature for 2 minutes at a time. This allows operators to bypass hoist stall prevention in extreme situations (such as working with frost caps or boulders).

When the override button is pushed it will turn blue to indicate that the override is engaged. The override will automatically turn off after 2 minutes and shows a countdown in seconds on the button until it disengages.

There is also a Help screen available by pressing the “?” button.

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Machine Operation Machine Protections - Enhanced Motion Control (Op-

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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Machine Operation Machine Protections - Enhanced Motion Control (Option)

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

A Hoist Stall Prevention Override Counter is found on the Machine Hours/Fault Counters screen. It logs the number of times that the operator overrides the system.

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Machine Operation Machine Protections - Enhanced Motion Control (Op-

7.13.3 Rope Crowd Impact Prevention •

Current situation / Why This Change is Needed?

What is Impact Prevention?

Impact prevention calculates the amount of force being applied to the crowd ropes. If this force gets too high, the drive will limit the maximum speed the crowd can run at, which reduce the severity of the impact. Basically, if the crowd is already pushing on something at full force, there is no reason to continue crowding.

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7 – 39 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

A Rope Crowd Impact occurs with the operator crowds the dipper at a significant speed and contacts the digging bank with a force that is higher than desired by good operating practices.

This results in a significant crowd rope force. Crowd impact loading can be the result of hoisting a dipper through the bank, crowding into the bank or a combination of the two. It can be exacerbated by contacting material, such as a rock formation or ice shelf, which is immobile.

Computer simulations and field testing have shown crowd impact deceleration rates more than 2 times higher than designed.

Machine Operation Machine Protections - Enhanced Motion Control (Option) •

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How it Works / What will You Notice as an Operator?

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

It is always on and the operator WILL NOT see an indicator.

When digging a hard toe the crowd may seem weak when first contacting the toe. "This can be overcome by more gently engaging the toe and then applying more crowd reference. With impact prevention full crowd force is still available. However, trying to ram into the toe by winding up the crowd will be less effective. The purpose of this circuit is to prevent high stresses that occur from running the crowd at full speed into a solid object.

7.13.4 Crowd Overspeed Prevention •

Current situation / Why This Change is Needed?

A crowd overspeed occurs with the crowd motor exceeds 2250 RPM. The machine then faults and the mechanical brakes are immediately set. This can result from actions such as doubledipping, material carry back, and excessive vertical speed in the tuck position. The overspeed event results in significant damage to the mechanical brake as well as reduced machine production.

The current system reduces crowd speed when the handle is near vertical.

What is Crowd Overspeed Prevention?

This change will reduce crowd overspeed occurrences, which will increase crowd brake life, and improve machine availability.

There will be increased crowd speed with a vertical handle.

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How it Works / What will You Notice as an Operator?

• • • •

Operator will see no indications on the screen.

Operator will notice more crowd speed capability with a near vertical handle and improved control.

Operator confidence that they won't get a crowd overspeed.

Fewer delays and improved productivity.

7.13.5 Hoist Rope Slack Prevention/Boom Jack Minimization •

Current situation / Why This Change is Needed?

A boom jack occurs when the operator crowds the dipper too far out in any given position, which is not desired by good operating practices. The result is that instead of the dipper "handing" from the boom, it actually lifts, or jacks up the boom. The boom suspension strands go slack, and if good care is not taken by the operator, the boom will abruptly come back down, shock-loading the suspension strands and applying great pressures on the A-Frame. Over time, this could lead to premature failure of the suspension strands.

A boom jack is not a recommended practice and can be a sign of an inexperienced operator. It can also be from cutting into a hard toe or skipping along a solid layer of rock at the toe of the face.

What is Hoist Rope Slack Prevention?

This limits the maximum joystick command for hoisting and lowering, whenever no load is detected on the hoist ropes, indicating the hoist ropes are getting slack.

What is Boom Jack Minimization?

This limits the crowd joystick command when there is slack in the hoist ropes and significant force on the crowd.

•

How it Works / What will You Notice as an Operator?

•

NOTE:

The Boom turns blue when the boom jack minimization is actively regulating (trying to minimize the boom jack).

Boom will still turn red if a boom jack occurs.

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7 – 41 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

•

Machine Operation Machine Protections - Enhanced Motion Control (Op-

Machine Operation Machine Protections - Enhanced Motion Control (Option) Better hoist control during vertical handle conditions.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

•

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Electric Rope Shovel

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Machine Operation Start Of The Dig Cycle

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7.14 Start Of The Dig Cycle The crowd motion forces the dipper lip into the bank at the start of the digging cycle. It is the crowd thrust which enables the dipper lip and front opening to get into a column of material of sufficient cross section to fill the dipper rapidly.

There is a direct relationship between crowd depth of bank penetration and the distance the dipper must rise in the bank to fill the dipper. The deeper the “bite” the quicker the dipper will be filled, providing the hoist force is sufficient to cut the column of material. Do not attempt to lift the entire bank with each pass. As soon as the dipper is full, retract it from the bank and swing the machine to fill the truck.

Crowd penetration should be rapid just at the arc of entry and rise as the dipper enters the bank.

This will permit as much digging as possible near the base of the bank. This is of particular advantage when digging loose or blasted material. The greater the hoist force and crowd thrust, the faster the dipper filling time of the dig cycle. The crowd thrust should be maintained to hold the dipper in the bank while it is being hoisted. An added benefit of proper crowd thrust and hoist force is that the opposing vertical resistance of the bank material tends to have a “ramming” effect in the dipper front opening, minimizing voids and producing larger dipper loads.

It is important that the full cutting surface of the dipper contact the bank on each pass. A full face cut combined with deep bank penetration will result in a full dipper for the least amount of hoist. A partial cut, even with deep bank penetration, requires a greater rise, and tends to leave voids in the dipper. This could necessitate additional passes to fill the haulage unit.

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7 – 43 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 7-4 Force the Dipper Lip into the Bank

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Machine Operation Start Of The Dig Cycle

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Shallow bank penetration of the arc of entry and rise is ineffective and inefficient. A shaving cut dribbles material into the dipper resulting in voids and making additional passes necessary while accelerating dipper lip wear.

NOTE:

A deeper bite = quicker fill times

Figure 7-5 Variations on Dipper Penetration

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Machine Operation Start Of The Dig Cycle

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Digging should take place under the boom point for maximum machine effectiveness. If necessary, the machine should be moved closer to the bank face, rather than extending the dipper handle. Reaching for material results in a partially filled dipper and excessive crowd and retract time. Use caution not to damage the boom point sheaves when operating close to the high wall.

Overcrowding with the dipper lowered can result in lifting the boom. This jacking action can result in damaged components. Overcrowding the dipper in the bank slows up the dipper loading process, thereby reducing machine efficiency.

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7 – 45 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 7-6 Dig with the Dipper Beneath the Boom Point

Machine Operation Engaging The Bank

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

7.15 Engaging The Bank To make maximum use of the hoist rope pull, the dipper rise should be as close to vertical as possible. The dipper should enter the bank approximately under and behind the boom point. The actual cut should start a few degrees behind an imaginary vertical line from the front of the boom point sheaves. Proper bank engagement results in maximum hoisting force in line with the cut.

When the dipper is too far forward, bank penetration will be minimal, and the hoist and crowd forces will oppose each other rather than working together.

Figure 7-7 Engage the Bank Under the Boom Point

An excavator dipper capacity rating is the struck measure cubic yard capacity. When digging, a load greater or less than the rated capacity may be obtained, depending on the type of material.

An efficient operation can be measured by the number of dipper loads required to load a haulage unit. When the dipper capacity is efficiently sized to the truck capacity, not less than three or more than five dippers full should be required to load a unit. Other factors such as improper sizing of haulage units to dipper, improper material fragmentation, etc. also must be considered.

In all types of digging the skilled operator must carefully control the desired depth of cut, and control the hoist power requirements. Often, digging situations are encountered which require hoist and crowd motions to maneuver around oversize or lodged obstructions in the bank, rather than attempting to lift the entire bank.

Figure 7-8 Hoist Force Opposes Crowd Force

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Machine Operation Engaging The Bank

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Maintain a digging face which avoids any major slides which could cause an accident.

Examine the digging face for large boulders, large rocks, or frozen material which could slide and cause an accident. Avoid overhanging material.

Figure 7-9 Make Effective Use of the Hoist Effort

Do not suspend a loaded or empty dipper in the air with the brakes set for long time periods. Lower the dipper to the ground if the machine is to be idle or unattended for any length of time. Failure to comply can result in personal injury or death of anyone beneath the dipper.

For most efficient production, the dipper should be loaded from the most remote point while waiting for a truck. When the truck is positioned, excavating should begin close to the haulage unit, progressively working away from the unit. This technique saves time by allowing smooth, short dig cycles, and eliminates excessive swing, crowd and retract motions.

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7 – 47 August 2019

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The experienced operator does not repeatedly stall the dipper in the bank, nor maintain a stall condition. The life expectancy of the hoist machinery and hoist ropes is directly related to the operator’s skill in avoiding stalling. Whenever stall conditions are encountered, back off on the hoist motion, retract the dipper, or do both. Avoid stall conditions at all times.

Machine Operation Slope Limitations

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7.16 Slope Limitations

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

It is important to remember the difference between slope percent and degrees!

It is strongly recommended that the machine dig and propel on level ground for the greatest possible productivity and the longest component life.

DO NOT operate the machine on a slope greater than specified below: Limit the machines propel operation to a maximum of 13 degrees (23%) slope.

Limit the machines digging operation to a maximum of 4.5 degrees (8%) slope.

DO NOT EXCEED THE SLOPE LIMITATIONS SPECIFIED FOR THIS MACHINE. Failure to operate the machine within the specified limits could result in serious bodily injury or death.

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Machine Operation Excavating Material

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7.17 Excavating Material

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

It is important that the operator not only know the controls, but also recognize other aspects of the mining operation. Chief among these is the type of material to be excavated. It plays a great part in the overall efficiency of the machine.

Materials can be roughly divided into four categories: 1.

2.

3.

4.

Easy digging. This category includes all loose, free-flowing materials, such as sand and gravel deposits, stock pile materials such as finely crushed stone, ore fines, coal fines and any other similar materials. The dipper will usually obtain a heaped load.

Medium digging. This category includes only materials which can be excavated from their natural beds without blasting, and which break up in bulk with some voids. Such material includes clay, dry earth, clay-gravel mixtures, gravel with some boulders, certain types of ores, and coal. The dipper will usually obtain a full load, with filling augmented by the material’s natural tendency to break apart when it encounters the dipper lip and teeth.

Hard digging. Included in this category are materials that require blasting, resulting in good fragmentation, but leaving large chunks which develop voids. Limestone, gypsum shale, cemented gravel, wet earth, clay and certain types of ore and overburden all fall within this category. The dipper will average less than a full load because of the resistance of the material against flow and voids due to blocky material.

Very hard digging. This category includes all materials that require heavy blasting and give irregular fragmentation. Taconite, granite, laminar shale, certain types of limestone, and conglomerate overburden fall into this category. The dipper will average considerably less than a full load, because of the large chunks and interlocking action of the material which block fill.

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7.18 Operation Checks During machine operation there are several things to consider relative to safe, efficient machine operation.

3.

4.

5.

6.

Check the motors for unusual noise, loss of power or failure to respond to controls.

Check hoist, crowd, swing and propel machinery for unusual sounds and overheating of bearings.

Avoid slack hoist ropes which could allow the ropes to become crossed on the drum, or skip a groove.

Frequently check the air pressure readout on the “home” screen (shown below). Investigate immediately if there is a drop in air pressure. Correct all air leaks.

When propelling, check the engagement of the drive tumblers on the crawler belt links and adjust the belts to correct any improper alignment.

When operating auxiliary functions, such as steering, note any tendency of the controls to jam or hang up. Check and correct any problems at the earliest opportunity.

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2.

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7.19 Operating Tips

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The following tips are reminders of the do’s and don’ts related to excavator operation: • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Engage the bank properly.

Load with the successive pass technique.

Maintain a clean pit floor.

Use proper hoist control.

Make effective use of the hoist pull.

Use proper crowd control.

Force the dipper lip into the bank at the arc of entry.

Crowd the dipper into the bank for deep penetration.

Make full face cuts for faster loading cycles.

Dig under the boom point.

Make smooth, safe swing cycles.

Keep swing arcs within 90°.

“Spot” the haulage units properly.

Keep the working faces free of projections.

Propel forward whenever possible rather than backward.

Move up to the bank frequently.

Dig over the take-up axle end of the crawlers whenever possible.

Make gradual turns when propelling.

Do not suspend a loaded dipper for an extended time or set the hoist brake on a suspended load (except in an emergency situation).

Do not operate too close to material.

Do not operate with missing dipper teeth.

Do not stall hoist or crowd motions.

Do not reach for material.

Do not reach for haulage units.

Do not overcrowd and jack the boom or machine.

Do not make partial face cuts.

Do not make shallow bank penetration.

Do not make erratic swings.

Do not swing until dipper is clear of the bank.

Do not swing loaded or unloaded dippers over personnel or equipment.

Do not “sweep” the pit floor with the dipper.

Do not make sharp turns when propelling. Maximum turn is 15° to 20° at a time.

Do not make long inefficient moves.

Do not exceed swing arc of 90°.

Do not spot haulage units inside or outside the boom point swing arc.

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• • •

Maintain adequate clearance between digging face and point sheaves.

Do not allow the dipper to contact the crawler belts.

On HydraCrowd machines, avoid “tight-lining”. “Tight-lining” occurs when the dipper is pulled up close to the underside of the boom with the handle extension less than 4.5 m (15 feet).

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Appendix

Always refer to the safety section of this manual before starting any maintenance procedure on this machine.

Appendix

8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.2 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.2.1 Touch Screen and Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.2 File Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.3 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.4 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.5 Display Configuration and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.6 Opening the Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6 8-7 8-7 8-7 8-7 8-7

8.3 Software Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 8.3.1 Bootup (Power Up). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 8.3.2 Navigation, Program Control and Data Entry. . . . . . . . . . . . . . . . . . . . . . . . . 8-8 8.3.3 Icon Help Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 8.3.4 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Figure 8-1 Security Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Figure 8-2 Password Entry Pop Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.3.5 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.5.1 Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.5.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.5.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.5.4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Appendix EM007181

8.3.6 Permissives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 8.3.6.1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 8.3.6.2 Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 8-3 Home Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

8.3.6.3 Home - Enhanced Motion Control (Option) . . . . . . . . . . . . . . . . . . . . 8-16 8.3.7 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 8.3.7.1 Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Figure 8-4 Temperature Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8.3.7.2 Enhanced Motion Control (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8.4 HydraCrowd Warm-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 8.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1.1 Stage 1A: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1.2 Stage 1B: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1.3 Stage 1C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1.4 Stage 2A: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1.5 Stage 2B: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1.6 Stage 2C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1.7 Stage 3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.2 Alarms & Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-21 8-22 8-23 8-24 8-25 8-26 8-27 8-28 8-28

Figure 8-5 Active Alarms Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 Figure 8-6 Alarm History Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

8.5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 Figure 8-7 Settings Main Screen (Password Protected) . . . . . . . . . . . . . . . . . . . . . . 8-32

8.5.1 Setting Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.2 Rope Reeving & Pintle Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.3 Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.4 Lube Setup & Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.5 Motivator (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.6 Hydracrowd Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-33 8-34 8-35 8-36 8-37 8-38

Figure 8-8 Hydracrowd Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

8.5.7 HydraCrowd Hose Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39 Figure 8-9 HydraCrowd Hose Flushing Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

8.5.8 HydraCrowd Pump Trending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40 Figure 8-10 HydraCrowd Pump Trending Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

8.5.9 Operator Display (HMI) Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41 8.5.10 Security Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

8.6 Permissives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 8.6.1 E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 8.6.2 1 Start within 2 Minutes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 8.6.3 2 Starts within 5 Minutes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44 8–2 August 2019

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8-44 8-44 8-44 8-44 8-44 8-44 8-44 8-45 8-45

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8.6.4 Drive Ready (No AFE Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.5 Drive Cabinet Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.6 Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.7 Auxiliary Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.8 Incomplete Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.9 Joysticks Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.10 Joysticks in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.11 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.12 Boarding Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix

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Appendix Overview

EM007181 Appendix

8.1 Overview

All servicing of this display system is to be done only by qualified service personnel.

This manual is written to help the user understand the workings of the display information system as it pertains to the operation of the machine and troubleshooting the control system. Some objects referred to as “options” in this manual are only enabled where that particular feature has been purchased. On other systems those options will either be non-functioning “grayed out” screen objects or inaccessible.

NOTE:

The graphics and descriptions in this manual are for reference only. Actual screens may differ depending upon software version and purchased options. Actual screen colors may be different due to differences in printing and display technologies. The values shown are examples and may not exactly match those on your display.

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The operator displays are designed to assist the operator in efficient operation. It gives the user machine data, indicators, and alarms. Machine setup parameters and user options are entered through the display.

Appendix Hardware

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8.2 Hardware

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The operator display terminal consists of an industrial hardened computer running a proprietary operating system. The color touch screen was specifically chosen to provide optimum viewing in bright sunlight.

8.2.1 Touch Screen and Keyboard This display has a touch screen. This means that for normal operation it is designed to be used exclusively by simply choosing objects on the screen and touching them with your finger. DO NOT use anything other than your finger for selecting screen objects. Items such as pens, pencils, screwdrivers, etc. will damage screen and should never be used.

Certain functions for troubleshooting the display or for initial setup may require the use of a keyboard (supplied by manufacturer). Any standard USB keyboard from a desktop computer may be used. The USB ports are located near the operator’s seat. It is mounted below the display stand on the back of the left console. There are two ports here for a mouse and a keyboard.

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8.2.2 File Storage

To remove the hard drive, first remove power from the display. This is done by turning off the appropriate circuit breaker. Then press the small button located immediately left of the drive to eject it. Put the new drive in, making sure it faces the same way that the old drive did. Make sure the drive is pushed all the way in, but do not force it.

8.2.3 Ethernet Communication Communication is established to the PLC through Ethernet. An Ethernet port exists on the side of the operator display. This can also be used for programming the unit.

8.2.4 Power Power is supplied to a three-pin connector on the side of the display. Only 24VDC is allowed, regardless of the configuration of the machine.

8.2.5 Display Configuration and Setup All configuration and setup functions are done through software. Please refer to the Software section of this manual for a summary of these features.

8.2.6 Opening the Display The internal components of the operator display are not user-serviceable. It is not recommended that the user open the display for any reason, unless directed to by the manufacturer. If problems are serious enough to open the unit, it should be replaced or repaired by trained personnel.

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The complete operating system and application files are stored on a solid state hard drive mounted in an adapter, accessible on the side of the unit. If required, program updates may be delivered by exchanging the old hard drive for a new one. If this is done, please remember to return the old hard drive to the manufacturer as soon as possible.

Appendix Software Overview

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.3 Software Overview The application software for the operator display was created using a proprietary development tool, supplied by the manufacturer of the display. Most screens have been custom designed for the machine. However, certain features such as the alarm screens and the display configuration utilities are “pre-made” screens which are standard for the hardware being used.

Some of the screens have security attached to them, meaning that only personnel who enter the proper password may access that screen. These passwords are defined in the Setup Screen.

NOTE:

The Administrator has access to all screens. User1 has access to all screens except the Setup screen.

8.3.1 Bootup (Power Up) The operator display will automatically boot (power up) whenever power is applied to the unit.

The entire bootup process, from power-on until the unit is ready for use usually takes approximately five minutes. DO NOT TOUCH THE TOUCH SCREEN DURING THIS TIME. Once the boot process is finished, communication between the display and the PLC is established and the Status Screen appears. The display is now ready for use. If a yellow banner appears at the top of the display stating “PLC COMMUNICATION LOST,” this is an indication that communication with the PLC has failed. Refer to the Troubleshooting section of this manual for help.

Once the display is powered up, DO NOT shut off the power. The displays should be left on at all times.

8.3.2 Navigation, Program Control and Data Entry For normal operation, the operator display is controlled exclusively with the touch screen. To change screens or choose an object, simply touch it with your finger. Do not use anything other than your finger for selecting screen objects. Items such as pens, pencils, screwdrivers, etc. will damage the screen and should never be used.

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Appendix Software Overview

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Screens are changed by touching the on-screen button associated with the desired screen. Most screens or sections can be accessed from the Main Menu. Almost all screens have direct access to the Status Screen, and the Main Menu is located at the bottom of almost every screen.

8.3.3 Icon Help Screen Many of the screens have a “HELP!” button in the upper right corner which is indicated with a “?.”

Pressing this key will bring up a separate screen that displays and describes all the different icons that may be encountered throughout the program. When finished, press a button from the Main Menu at the bottom of the screen that corresponds to the desired function.

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When it is necessary to enter a number, a pop-up keypad will appear on the screen. Simply touch the keys on the keypad as you would with an actual keypad. Press <ENTER> when finished or <X> to abort the entry. With the keypad, errors are corrected with the delete key <del>.

Appendix Software Overview

EM007181

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.3.4 Security

Figure 8-1 Security Settings Screen

Since some of the screens contain setup parameters that may impact performance of the machine, it is not always desirable for all users to access all screens. Therefore, the parameter screens that are not required for day to day operation are protected by a three to five digit security code. The Administrator password has access to all screens. User 1 has access to all screens except the Setup screen. When a user attempts to access a secure screen, the Password Entry window will pop up.

Figure 8-2 Password Entry Pop Up

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Appendix Software Overview

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In order for the secure screen to open up, a specific code must be entered using this keypad. The user enters the password with the pop-up keypad. If the code is correct, the desired screen will appear. If the code is not correct, the Password Entry window will remain with a message indicating an invalid password. If the user decides not to enter the correct password, he can return to the previous screen by pressing the “X” button in the upper right corner.

8.3.5 Main Menu The Main Menu is the primary area from which the other screens are selected. The Main Menu is located across the bottom of many screens. Simply press the icon button at the bottom of the screen that you wish to call.

8.3.5.1 Home Selecting the HOME icon will allow the operator to display the current status of the machines handle lube, air pressure, boarding ladder position, intake fans, and other components. Access to Adaptive Control and AccuLoad Control falls under the HOME icon.

8.3.5.2 Monitoring Selecting the MONITORING icon will allow the operator to view the component operating temperatures, current side to side incline, front to back incline, machine hours and fault counter.

The temperature monitoring feature is an option.

8.3.5.3 Alarms Selecting the ALARMS icon will allow access to the machines active alarms as well as the alarm history. For more detailed information, refer to ALARMS & FAULTS later in this section of the manual.

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Since all machines are shipped with the same set of default passwords, mine supervision should change these passwords as soon as possible to prevent unauthorized screen accesses or updates.

Appendix Software Overview

EM007181

8.3.5.4 Settings Selecting the SETTINGS icon will allow the operator access to:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Setting Limits • • • • • • •

Rope Reeving & Pintle Tightening Joystick Calibration Lube Setup and Test Motivator (Option) Operator Display Setup Switch Displays Security

8.3.6 Permissives Selecting PERMISSIVES displays the machines current readiness for startup.

8.3.6.1 Information Selecting the INFORMATION icon will display: • • • •

Machine Type & S/N PLC Filename Operator Station Filename WinCC Version Number

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8.3.6.2 Home Selecting the HOME icon will allow the operator to display the current status of the machines handle lube, air pressure, boarding ladder position, intake fans, and other components. Access to Adaptive Control and AccuLoad Control falls under the HOME icon.

Figure 8-3 Home Screen

A — Dipper Handle Manual Lube Button: Pressing button initiates manual lubrication of the dipper handle.

B — Air Compressor Operating Pressure: Displays the current operating pressure of the air compressor.

C — Boarding Ladder Status: If the ladder symbol is in the UP position (as shown) all ladders are in the raised position. If the ladder symbol is solid red and appears below the machinery house, one or more ladders have been lowered or have not yet been fully raised.

D — Intake Fan Status: If the fan symbol appears gray (as shown) the fans are ON. The fan symbol appears solid red when one or more of the intake fans are OFF. E — Boom Status: If the boom symbol is solid red, this indicates a boom jack fault.

F — AccuLoad: Displays the current load per truck and is reset to zero when the NEW TRUCK button is pressed.

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

At startup, once the DC bus has been activated the HOME screen (shown below) automatically appears. If the PLC determines that a warm-up period is required prior to startup, the appropriate screen will appear prior to the HOME screen.

Appendix Software Overview

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G — Dipper Load: Displays the current weight of the material loaded in the dipper.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

H — Adaptive Control: Activates adaptive control feature when pressing the ON button. If the PLC accepts the command the button will turn blue.

J — AccuLoad: The operator presses the NEW TRUCK button to tell the AccuLoad system that a truck has left. The current truck load is added to the Shift Total then reset to zero. The PAUSE button temporarily disables the AccuLoad counter without clearing them. This is useful when using the shovel to perform cleanup tasks and not actively loading trucks.

K — Inclination Status: Displays the current incline in degrees or a percentage value. If the slope limits have been exceeded*, the background behind the value will flash yellow and gray. * In DIG mode, any value >4.5° (8%). In PROPEL mode, any value >13° (23%).

L — Crowd/Retract Limit Indicator: The dipper handle will turn solid yellow when a Slow Limit has been entered on either end. The dipper handle will turn solid red when a Stop Limit has been reached at either end.

M — Truck Count: Displays the running total of loaded trucks during the current shift.

N — Hoist/Lower Limit Indicator: The hoist rope will turn solid yellow when a Slow Limit has been entered on either end. The hoist rope will turn solid red when a Stop Limit has been reached at either end.

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.3.6.3 Home - Enhanced Motion Control (Option)

These optional screens are available with Enhanced Motion Control. The Home screen on the left will show a blue boom and blue swing rack to indicate that either the Hoist Rope Slack Prevention/Boom Jack Minimization or the Anti-Swing in Bank are engaged to protect the machine.

•

•

O - Hoist Rope Slack Prevention / Boom Jack Minimization: This limits the maximum joystick command for hoisting and lowering, whenever no load is detected on the hoist ropes, indicating the hoist ropes are getting slack. It also limits the crowd joystick command when there is slack in the hoist ropes and significant force on the crowd.

P - Anti-Swing in the Bank: This monitors crowd force to determine when the dipper is in the bank and limits swing reference from the operator.

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Appendix Software Overview

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8.3.7 Monitoring Selecting the MONITORING icon will allow the operator to view the machine hours / fault counter, current side to side / front to back inclination, and optional temperature monitoring. A warm-up sequence icon will appear on HydraCrowd machines.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.3.7.1 Inclination

NOTE:

When acceptable slope limits are exceeded, tilted background of screen will flash between yellow and gray.

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 8-4 Temperature Monitoring OM11089-EN

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.3.7.2 Enhanced Motion Control (Option)

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Appendix HydraCrowd Warm-up Sequence

8.4 HydraCrowd Warm-up Sequence

During the warm-up sequence the operator needs to be present to monitor the progress throughout the entire procedure. The PLC will prompt the operator at various stages to turn the crowd control ON and OFF. The PLC displays the estimated time remaining to complete the warm-up sequence.

8.4.1 Overview The warm-up sequence typically begins at machine start-up. After all the permissives are met and the Drive Power is turned ON, the PLC will determine if the hydraulic oil is up to operating temperature. If not, the warm-up sequence will appear and the process will begin. As a rule, components highlighted in red are in the warm-up process. Components in gray have not yet begun warm-up.

Individual components highlighted in green have reached operating temperature. When all components are green the entire operating system is up to operating temperature and the warm-up sequence is complete. The “home” screen will then appear.

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The HydraCrowd Warm-up Sequence will come up anytime the PLC senses that the hydraulic fluid has fallen below operating temperature. This typically happens at machine startup, but can also occur when the machine is running but has sat idle for a period of time. Temperature sensors are located in the upper hydraulic tank, lower hydraulic tank (power module) and the cylinder control manifold. Hydraulic oil temperature throughout the system must be at least 95110° F (35-44° C).

Appendix HydraCrowd Warm-up Sequence

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8.4.1.1 Stage 1A:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The hydraulic oil in the upper tank begins warm-up. The crowd control should be OFF.

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Appendix HydraCrowd Warm-up Sequence

8.4.1.2 Stage 1B: The hydraulic oil in the upper tank has reached operating temperature. The circulation pump begins operating at half speed as the lower tank begins warm-up.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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8.4.1.3 Stage 1C:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The circulation pump begins operating at full speed as the lower tank continues to warm-up.

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Appendix HydraCrowd Warm-up Sequence

8.4.1.4 Stage 2A: The main pump heating is ready to start. The operator will be prompted to energize the crowd motor by pressing the Crowd Control ON button. Ensure the ON button appears solid green. The hydraulic oil in the lower tank (power module) begins warm-up.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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8.4.1.5 Stage 2B:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The four main pumps are operating and oil is circulating through the system with the exception of the crowd cylinder manifold and the crowd cylinder. When 2B is complete, the operator will be prompted to turn the crowd control OFF.

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Appendix HydraCrowd Warm-up Sequence

8.4.1.6 Stage 2C: At this point, heating of the cylinder manifold will begin. The operator will be prompted to turn the crowd control back ON. During this process, dipper handle motion may occur.

Once Stage 2C is complete, the option to perform hose flushing and pump trending operations becomes available. Those options are accessed through the HydraCrowd Maintenance screen. When 2C is complete, the operator will be prompted to turn the crowd control OFF.

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NOTE:

Appendix HydraCrowd Warm-up Sequence

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8.4.1.7 Stage 3:

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

The operator will be prompted to turn the crowd control back ON. The operator will also be prompted to extend and retract the dipper handle two full cycles to complete the process.

When all components are green the entire operating system is up to operating temperature and the warm-up sequence is complete. The “home” screen will then appear.

8.4.2 Alarms & Faults The operator display serves as a means of informing its users when various alarm or fault conditions occur on the machine. It also records these conditions in a short-term history so the user can see problems that may have occurred during the current operating session.

When a new alarm occurs, an alarm window pops up with an acknowledge button and an audible alarm sounds. A yellow message banner will also appear at the top of the screen that displays the alarm number and description of the most recent alarm. Other screens allow the user to see all currently active alarms/faults, as well as the short-term history.

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Appendix HydraCrowd Warm-up Sequence

Alarms, faults, and messages are always referred to by their CDA (Cab Displayed Alarm) number. If you are contacting the manufacturer about a specific message, make sure that you know its exact CDA number.

The Active Alarm Screen lists all of the alarms and faults that are currently in the active state and have not been cleared or reset.

The Alarm History Screen lists all of the alarms, faults, and messages currently recorded since the display was powered up. By default, the most recent event is shown on top.

The first two columns list the time and date that the event occurred. The third column lists the alarm number (CDA). This is the primary key to identifying the message. The fourth column lists a brief description of the alarm. If the number of events is large enough, the Page Up and Page Down buttons to the left of the list can be used to scroll through the list. This is a rolling history so the oldest entries will be deleted when the limits are reached.

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Figure 8-5 Active Alarms Screen

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Appendix HydraCrowd Warm-up Sequence

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Figure 8-6 Alarm History Screen

Alarms shown in red text are active.

Alarms shown in green text have been cleared.

The list of faults can be sorted in two ways: a. b.

Type in the three digit code in the CDA FAULT FILTER. Type in the desired time range in the DATE/TIME FILTER.

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Appendix HydraCrowd Warm-up Sequence

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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8.5 Settings The Settings Screens are password protected.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Selecting the SETTINGS icon will allow the authorized personnel access to: • • • • • • • •

Setting Limits Rope Reeving & Pintle Tightening Joystick Calibration Lube Setup and Test Motivator (Option) Hydraulic Crowd Maintenance (HydraCrowd Only) Operator Display Setup Security Settings

Figure 8-7 Settings Main Screen (Password Protected)

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8.5.1 Setting Limits This screen is used to set the slowdown and stop limits for:

Crowd and Retract Hoist and Lower

For detailed information on Setting Limits, refer to Section 4 of the maintenance manual.

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• •

Appendix Settings

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.5.2 Rope Reeving & Pintle Tightening

This screen allows authorized personnel to enter the hoist and crowd reeving modes or the center pintle tightening mode. The meter along with the numeric display show the number of degrees since one of the reeving modes was entered.

NOTE:

The remote hoist and crowd reeving modes are optional. The crowd reeving modes are not applicable for HydraCrowd machines. When remote reeving options are not selected the icons are invisible. When the machine has HydraCrowd, the crowd reeving icons are invisible.

For detailed information on Rope Reeving & Pintle Tightening, refer to Section 4 of the maintenance manual.

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8.5.3 Joystick Calibration

For detailed information on Joystick Calibration, refer to Section 4 of the maintenance manual.

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This screen allows authorized personnel to calibrate the joysticks.

Appendix Settings

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.5.4 Lube Setup & Test

The Lube Setup Screen allows authorized personnel to set the lube intervals for various components. The Lube Test Screen permits authorized personnel to initiate lube system tests (allow injection operation, inspection and adjustment).

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8.5.5 Motivator (Option)

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The Motivator Screen permits use of an off-board portable generator to propel the machine instead of using trail cable power. It reconfigures some drive system software parameters for this to happen properly.

Appendix Settings

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.5.6 Hydracrowd Maintenance

The HydraCrowd Maintenance Screen allows authorized personnel access to Pump Trending and Hose Flushing operations. The latest Trending Data can be viewed by pressing the DATA button. Warnings can be reset in this screen as well.

Figure 8-8 Hydracrowd Maintenance Screen

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8.5.7 HydraCrowd Hose Flushing Pressing the FLUSHING button allows access to hose flushing operation. The estimated time remaining to complete the hose flushing operation is displayed in minutes for convenience.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Figure 8-9 HydraCrowd Hose Flushing Screen

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8.5.8 HydraCrowd Pump Trending

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

Pressing the TREND button allows access to manual or automatic pump trending operations.

After an automatic pump trending operation, the trend data will be displayed and stored for future reference.

Figure 8-10 HydraCrowd Pump Trending Screen

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8.5.9 Operator Display (HMI) Setup

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The HMI setup screen allows authorized personnel to set the format of the current time/date Units of measure can be set individually or reset to exclusively metric or imperial units. The “Switch To Control” button can be used to swap the CONTROL and the STATUS screens. For a step-by-step procedure, refer to DISPLAY INTERCHANGEABILITY in Section 4 of this manual.

Appendix Settings

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.5.10 Security Settings

The Security Settings Screen allows the Administrator to change passwords.

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8.6 Permissives Selecting PERMISSIVES displays the machines current readiness for startup.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.6.1 E-Stop Green check mark indicates that none of the emergency stop buttons have been pressed.

8.6.2 1 Start within 2 Minutes This contact detects whether the DC bus has been pre-charged within the past two minutes. The DC bus cannot be pre-charged more than once within the past two minutes. The green check mark indicates that the bus has not been pre-charged within the two minute timeframe.

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

8.6.3 2 Starts within 5 Minutes This contact detects whether the DC bus has been pre-charged twice within the past five minutes. The DC bus cannot be pre-charged more than twice within the past five minutes. The green check mark indicates that the bus has not been pre-charged twice within the five minute timeframe.

8.6.4 Drive Ready (No AFE Fault) There is no drive fault. The AFE drive is ready for startup.

8.6.5 Drive Cabinet Temperature The green check mark indicates that the drive cabinet temperature is within range for startup.

8.6.6 Phase Sequence AC phase sequence check. The red “X” mark indicates that the sequence is NOT proper.

8.6.7 Auxiliary Ground Fault Auxiliary ground fault check. The red “X” mark indicates that there is a ground fault.

8.6.8 Incomplete Start-up Sequence The green check mark indicates that the sequence for start-up was complete.

8.6.9 Joysticks Calibrated The green check mark indicates that the joysticks are calibrated.

8.6.10 Joysticks in Neutral Checks if both joysticks are in the neutral position. The green check mark indicates that both joysticks are in neutral.

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8.6.11 Brakes The red “X” marks indicate that the brakes have not been released.

Detects if any of the boarding ladders are down or in the process of being lowered. The green check mark indicates that all ladders are up.

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8.6.12 Boarding Ladder

Appendix Permissives

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY August 29,

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®

Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining LLC reserves all rights to this publication. Its content is protected by copyright laws.

No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar Global Mining LLC. Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors. © 2019 Caterpillar Global Mining LLC. LatchFree™ and HydraCrowd™ © Bucyrus International, Inc.