Cat Electric Rope Shovel 182M-AC Mining Shovel Opertor'S Manual - PDF DOWNLOAD

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BUCYRUS

182M-AC MINING SMOVIL 0P,ERATr0R'S MANILJAIL SN: 141430 SN: 141431 Manual No.

10955

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

BI619854

Bucyrus International, Inc. 182M-AC Electric Mining Shovel

Manual No. 10955

Sept. 2010

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

DANGER: THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED

BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

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

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

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

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

Manual No. 10955

Sept. 2010

BI619854

Bucyrus International, Inc. 182M-AC Electric Mining Shovel

182M-AC Mining Shovel Operator’s Manual Manual No. 10955 sn: 141430 sn: 141431

Always refer to the safety information in this manual before starting any maintenance procedure on this machine.

Table of Contents GENERAL INFORMATION ............................................................................................................ 5 GENERAL SAFETY ....................................................................................................................... 6 SAFETY PRECAUTIONS .............................................................................................................. 7 FIRE PREVENTION .................................................................................................................... 10 MACHINE OVERVIEW ................................................................................................................ 11 TRUCK FRAME AND CRAWLERS ............................................................................................. 12 PROPEL MACHINERY ................................................................................................................ 13 CROWD MACHINERY ................................................................................................................ 14 MACHINERY HOUSE .................................................................................................................. 15 BOARDING STAIRS .................................................................................................................... 16 VERTICAL BOARDING LADDER ................................................................................................ 18 HOIST MACHINERY .................................................................................................................... 19 SWING MACHINERY .................................................................................................................. 20 FRONT END EQUIPMENT ......................................................................................................... 21 BOOM ......................................................................................................................................... 22 GANTRY ...................................................................................................................................... 23 BOOM SUPPORT ROPES ........................................................................................................ 24 DIPPER ASSEMBLY ................................................................................................................... 25 OPERATION NEAR ELECTRICAL LINES ............................................................................. 26 OPERATOR’S CAB .................................................................................................................... 27 Operator’s Cab ........................................................................................................................... 27

OPERATOR'S SEAT ............................................................................................................. 27 OPERATOR'S SEAT ADJUSTMENT .............................................................................. 28 OPERATING CONTROLS .......................................................................................................... 30 PRIMARY OPERATING CONTROLS ................................................................................... 30

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

© 2010 Sept. 2010

Bucyrus International, Inc. All Rights Reserved.

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CONTROLS ON THE LEFT CONSOLE ......................................................................... 31 LEFT JOYSTICK ....................................................................................................... 31 DIPPER TRIP ............................................................................................................ 31 SIGNAL HORN ........................................................................................................... 31 RADIO ....................................................................................................................... 31 HOIST BRAKE .......................................................................................................... 32 CROWD BRAKE ...................................................................................................... 32 SWING BRAKE ......................................................................................................... 32 PROPEL BRAKE ...................................................................................................... 32 Left Control Console .................................................................................................................. 32

CLIMATE CONTROL PANEL ..................................................................................... 32 WINDSHIELD WIPER SWITCH ................................................................................ 32 WINDSHIELD WASHER SWITCH ............................................................................ 32 CONTROLS ON THE RIGHT CONSOLE ....................................................................... 33 RIGHT JOYSTICK ..................................................................................................... 33 CONTROL STOP PUSHBUTTON ............................................................................ 34 CONTROL RESET PUSHBUTTON .......................................................................... 34 Right Control Console ................................................................................................................ 34

DIG/PROPEL TRANSFER SWITCH ............................................................................... 35 EMERGENCY STOP PUSHBUTTON ....................................................................... 35 MAIN POWER OFF PUSHBUTTON ......................................................................... 35 EARTH CONTINUITY LOCKOUT PUSHBUTTON .................................................... 36 TELEPHONE ............................................................................................................. 36 AUXILIARY CONTROLS ............................................................................................................. 37 REMOTE START CONSOLE ............................................................................................... 37 AIR PANEL ............................................................................................................................ 39 PRE-START CHECKS ................................................................................................................ 40 WALKAROUND GROUND LEVEL INSPECTION ................................................................. 40 ON-BOARD INSPECTION .................................................................................................... 41 MACHINE START-UP, OPERATION AND SHUTDOWN ............................................................. 42 START-UP ............................................................................................................................. 42 Start-Up Control Locations ......................................................................................................... 42

RESTARTING AFTER AN ELECTRICAL FAULT ................................................................... 44 OPERATION ......................................................................................................................... 45 STOPPING THE MACHINE ................................................................................................... 46 MACHINE SHUTDOWN ........................................................................................................ 46 GROUND PREPARATION .......................................................................................................... 47 MACHINERY MOTIONS ........................................................................................................ 48 HOIST MOTION ............................................................................................................... 48 CROWD MOTION ........................................................................................................... 49 PROPEL MOTION ........................................................................................................... 50 Propel - Straight Forward/Reverse .............................................................................................. 50

SWING MOTION ............................................................................................................. 51 PROPER SWING MOTION ............................................................................................. 52 STEERING ...................................................................................................................... 53 COUNTER-ROTATION TURNS ...................................................................................... 55

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POSITIONING THE MACHINE .................................................................................................... 56 BACK-UP METHOD .............................................................................................................. 56 DRIVE-BY METHOD ............................................................................................................. 57 START OF THE DIG CYCLE .......................................................................................... 58 Force the Dipper Lip into the Bank .............................................................................................58 Variations on Dipper Penetration ................................................................................................ 59 Dig with the Dipper Beneath the Boom Point .............................................................................. 60

ENGAGING THE BANK ................................................................................................... 60 COMPONENT WEIGHTS ........................................................................................................... 62 TYPICAL MACHINE SPECIFICATIONS ....................................................................................... 64

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182M-AC Mining Shovel Operator’s Manual

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

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

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

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

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

Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance contact your regional service representative or: Bucyrus International, Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin 53172-0500, USA Telephone (414)-768-4000 Fax: (414) 768-4210 It is the policy of Bucyrus International, Inc. to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously. Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.

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

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

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

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

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

CAUTION:

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

DANGER!

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

DANGER!

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

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

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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SAFETY PRECAUTIONS

General Precautions: • The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment.

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

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

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

• Think before you act. Carelessness is one luxury the service man cannot afford.

• Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.

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

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

• Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.

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

• Electrical cords and wet metal floors make a dangerous combination.

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

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

• Check limit switches for proper operation.

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

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

• Use proper interior and exterior lighting.

• Install and maintain proper grounding and ground fault protection systems.

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

• Use extreme caution when working around drilled holes.

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Maintenance Precautions: • Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.

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

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

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

• Never utilize the machine air or hydraulic systems for support when working on the machine.

Deactivate or isolate the entire system prior to performing maintenance.

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

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

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

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

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

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

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

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

• Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

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

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

• Protective eye goggles should be worn at all times when working on the air conditioning system.

Work on the air conditioning system only in a well ventilated area.

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

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

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Operating Precautions: • Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa • When in doubt about the noise level, wear approved hearing protection.

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

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

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

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

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

• 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.

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FIRE PREVENTION •

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. See Chapter 4 of this manual for the Scheduled Maintenance recommendations and the Daily Inspection procedure.

•

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.

•

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.

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MACHINE OVERVIEW This Mining Shovel is designed and constructed to provide efficient service under the most severe conditions. The machine is built to the highest possible standards and will provide trouble free operation if properly maintained. This section of the manual introduces the machine and its functional capabilities and limitations.

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TRUCK FRAME AND CRAWLERS

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PROPEL MACHINERY

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CROWD MACHINERY

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MACHINERY HOUSE The machinery house encloses the revolving frame, ballast box and deck extensions. It is constructed of self-supporting steel panels with built-in framing. Removable roof sections are provided over the swing machinery and to the side and rear of the Gantry. The house also provides mounting for the air ventilation and pressurization system. A separate electrical room is located over the ballast box. Platforms and stairs facilitate access to the sides and tops of the house for inspection and maintenance purposes. Boarding stairs and/or ladders permit easy access onto the machine.

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BOARDING STAIRS The boarding stairs are located on the left side of the machine at the rear of the walkway. The stairs are counter weighted to remain in the up position when the machine is in operation or down when boarding the machine. When the stairs are pulled down 3 to 4 inches a limit switch will trip and drop out line Excitation (LE) which will stop the machine. Refer to the figure on the following page.

To board when the machine is in operation: 1.

Pull one of the two signal chords at the rear of the ballast bar and wait for the operator to bring the machine to a halt.

2.

Lower the stairway.

WARNING:

3.

DO NOT ATTEMPT TO LOWER THE STAIRS WITHOUT SIGNALING THE OPERATOR FIRST. When the ladder is pulled down 3 to 4 inches, all brakes will set on the machine. FAILURE TO HEED THIS WARNING COULD RESULT IN DAMAGE TO THE MACHINE AND/OR RESULT IN PERSONAL INJURY.

After boarding the machine, raise the stairs to their full UP position. The machine will not be operable until the stairs are completely in the UP position.

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VERTICAL BOARDING LADDER The vertical boarding ladder is another means for boarding the machine, located on the right hand side of the machine, at the rear of the machinery house. Use the pull chord from ground level to lower the ladder. When the boarding ladder is not latched in place, the operator's controls are deactivated.

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HOIST MACHINERY The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist drum.

A spring-set, air-released disc brake is mounted to the motor. A hoist rotary encoder limits hoist travel. The hoist motor is connected to the motor pinion shaft by a multiple coupling shaft assembly.

The first reduction gear set is mounted in an oil lubricated, totally enclosed gearcase. The second reduction gears are drip lubricated with open gear lubricant from the automatic lubrication system.

All shafts run on anti-friction bearings. The hoist bull gear is bolted to a spider on the left hand side of the drum.

The hoist drum is manufactured with machined, flame hardened rope grooves. Drum spider stub shafts turn on an anti-friction bearings supported by side frames which are bolted to the rotating deck.

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SWING MACHINERY

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FRONT END EQUIPMENT

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BOOM The boom is a welded steel structure consisting of twin box girders integrally connected at the boom point and in the lower section between the shipper shaft and boom feet. Impact resistant steel is utilized, coupled with 100% penetration and UT quality welds on all main splice joints.

Design optimization has resulted in heavier outside skin plates, minimizing the need for internal diaphragms. This reduction in weld related stress concentrations further enhances structural life.

Open manholes have been incorporated in the boom as a standard feature permitting periodic structural inspection. Integral “ladders” within the upper boom sections permit internal access without lowering the boom.

The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer links on the Gantry. These inherent long life structural strands carry the working loads of the front end equipment. A boom limit switch with soft setdown prevents boom jacking shock loads.

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GANTRY

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BOOM SUPPORT ROPES

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DIPPER ASSEMBLY

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OPERATION NEAR ELECTRICAL LINES DANGER!

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 insure 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.

DANGER!

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

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OPERATOR’S CAB

Operator’s Cab

OPERATOR'S SEAT The operator's seat has adjustments for positioning it in the best location to suit individual operators.

It swivels into and out of operating position to provide easier entry/exit for the operator. Lift the spring loaded T-handle lock beside the seat pivot to swing it into and out of operating position. To raise or lower the seat, turn the hand wheel under it, clockwise (CW) to raise and counterclockwise (CCW) to lower. An adjustable foot rest is provided for operator comfort. Refer to the following page for more information on seat adjustment.

The operator should always adjust the seat to suit before taking over the controls.

DANGER!

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Do not attempt to operate this machine unless you understand all the machine controls. Never leave the operator's seat without first setting all motion brakes and de-energizing line excitation (LE) by pushing the EXCITATION STOP pushbutton.

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OPERATOR'S SEAT ADJUSTMENT The operator’s seat has been selected to provide a maximum of operator comfort along with easy control access for increased productivity. The seat has numerous adjustments allowing it to be tailored to meet the individual needs of each operator.

Weight Adjustment The seat should be adjusted for the operator’s weight by pulling the actuator lever of the automatic weight and height adjuster while the operator is sitting in the seat and the machine is stationary.

Height Adjustment The seat height is adjusted pneumatically by pulling or pressing the adjustment lever as required to obtain the position required. DO NOT operate the compressor unit for more than 1 minute continuously.

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Seat Cushion Angle Adjustment The angle of the seat cushion can be adjusted individually from the back. Lift the handle and exert pressure in the desired direction while seated. Release handle once the required position is achieved.

Seat Depth Adjustment The depth of the seat pan can be individually adjusted. Lift the handle and slide the seat pan forward or backwards to position. Release the handle when the desired position is obtained.

Armrest Adjustment The armrests can be adjusted to fit the individual needs of each operator or folded up and placed out of the way.

To adjust the armrest height loosen the manual friction knobs on the outboard side of the armrest allowing the armrests to pivot. Move the armrest to any desired position within its range and retighten when desired.

To raise the arm rests; lift at front and stow vertically.

Headrest Adjustment The headrest can easily be adjusted by lifting, or tilting, headrest to the desired position.

Lumbar Support The curvature of the backrest can be adjusted pneumatically by pressing the switches on the lower left rear of the backrest.

Backrest Adjustment The backrest is adjusted by lifting the lever and then releasing once the desired position is obtained.

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OPERATING CONTROLS The operator must become familiar with the machine and its operating controls. The preceding figure depicts the general location of controls on the machine.

The operating controls will be grouped as primary and secondary controls, depending upon their location. The primary controls are the controls located in the operator’s cab and the secondary controls are the controls located in the machinery house.

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

PRIMARY OPERATING CONTROLS

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CONTROLS ON THE LEFT CONSOLE LEFT JOYSTICK The Left Joystick controls the crowd/horn/dipper trip and propel. It is the vertical handle mounted on the left console of the operator’s seat. This joystick will spring return to neutral when released.

During normal operation, pushing the joystick forward will extend the dipper handle and dipper into the bank. Pulling the joystick rearward will retract the dipper handle and dipper toward the machine. The neutral position between the crowd and retract functions is defined by a detent that is easily felt. The rate of motion is controlled by varying the distance the joystick is moved from the neutral (center) position. Full forward or full rearward position provides maximum speed to the handle. Moving the joystick to neutral will cause a braking action slowing the crowding or retracting handle. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

With the propel transfer switch in the PROPEL position, pushing the joystick forward will cause the left crawler to move forward. Pulling the joystick to the rear will cause the left crawler to move in the reverse direction. The crowd/retract motion is locked out electrically when the machine is in the propel mode.

Refer to JOYSTICK CONFIGURATION in this section of the manual to view the standard and alternate configurations for the Right and Left Joysticks.

DIPPER TRIP The dipper trip is part of the left joystick function in the standard configuration. Moving the joystick to the right will activate the dipper trip mechanism which releases the dipper door latch. The dipper trip is operational throughout the entire range of the crowd motion.

SIGNAL HORN Moving the Left Joystick (in the standard configuration) to the left will activate the signal horn. The signal horn is operational throughout the entire movement range of the crowd motion.

RADIO The radio supplied with your machine is an AM/FM Stereo radio with the capability to play cassette tapes in the player incorporated. This is a quality piece of sound equipment and will provide long term operation.

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HOIST BRAKE A selector switch used to set or release the Hoist Brake.

CROWD BRAKE A selector switch used to set or release the Crowd Brake.

SWING BRAKE A selector switch used to set or release the Swing Brake.

PROPEL BRAKE A selector switch used to set or release the Propel Brake.

Left Control Console

CLIMATE CONTROL PANEL The Climate Control Panel contains a rheostat controller on the top portion of the panel which is used to tailor the temperature of the air delivered to the operator’s cab within the selected mode of operation.

The Mode switch is provided to set the basic mode of operation for the roof mounted air conditioning/ heater unit.

The Blower Speed switch controls the volume of air being moved by the unit.

WINDSHIELD WIPER SWITCH The windshield wiper switch controls the speed of the wipers, as well as the starting and stopping of the wipers.

WINDSHIELD WASHER SWITCH The windshield washer pushbutton controls the supply to the washer reservoir which powers the washers.

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CONTROLS ON THE RIGHT CONSOLE RIGHT JOYSTICK The Right Joystick controls the hoist/swing and propel. It is a joystick mounted on the right console of the operator’s seat. The joystick is used to control the hoist, swing and right crawler motions of the machine. The position of the propel transfer switch will determine whether this joystick controls the hoist motion or the crawler motion.

With the propel transfer switch in the dig position, and during normal operation, pushing the joystick forward will lower the dipper. Pulling the joystick to the rear will hoist the dipper. The neutral position between the hoist and lower functions is defined by a detent that is easily felt.

The speed of moving the dipper is controlled by varying the distance the joystick is moved from the neutral (center) position. The full forward or full rearward position provides maximum speed to the dipper. Moving the joystick to neutral will cause a braking action slowing the hoisting or lowering motion. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

NOTE:

When the right joystick is used in the hoist/lower mode it is a spring returned switch.

That is, it will return to the neutral position when it is released.

Moving the joystick to the left from the neutral position will cause the machine to swing to the left.

Moving the joystick to the right will cause the machine to rotate to the right. The swing motion is operational throughout the entire movement range of hoisting or lowering the dipper. The swing rate of acceleration is controlled by varying the distance the joystick is moved from the neutral position. Moving the joystick to the neutral position will not stop the swing motion but will allow the machine to coast. To stop or change direction the control joystick is moved past the neutral point in the opposite direction. The rate of deceleration is controlled by varying the distance the joystick is moved from the neutral position in the opposite direction.

Refer to JOYSTICK CONFIGURATION in this section of the manual to view the alternate configurations for the Right and Left Joysticks.

With the propel transfer switch in the propel position, pushing the joystick forward will cause the right crawler to move forward. Pulling the joystick to the rear will cause the right crawler to move in the reverse direction. The hoist motion is locked out electrically when the machine is in the propel mode.

NOTE:

When the JOYSTICK is used in the swing mode the switch is a spring returned switch.

That is, it will return to the neutral position when it is released.

• DIG - activates the hoist, crowd, and swing drives; deactivates the propel drive; and automatically sets the propel brakes.

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CONTROL STOP PUSHBUTTON The control stop pushbutton is located on the right operator’s console. Normally it is used to deenergize controls after the machine has been safely stopped by placing motion controls in neutral.

Actuation of this pushbutton when motions are running will cause all motions to automatically electrically brake to a stop and, when the motion speed has reached less than 5% speed, set all mechanical brakes. If the motions are already stopped, the brakes will be set and power is removed immediately. A similar switch is located on the front panel of the PLC control cabinet that can be used during testing of the machine.

DANGER:

THE OPERATOR SHOULD NEVER LEAVE THE OPERATOR’S SEAT BEFORE PRESSING THE CONTROL STOP PUSHBUTTON. Setting only the mechanical brakes with individual switches is not a sufficient safeguard to prevent machine damage and/or personnel hazards.

CONTROL RESET PUSHBUTTON CAUTION:

This is not an automatic reset system. All controls must be returned to neutral before the control reset button is pushed.

Right Control Console

The control reset pushbutton is located on the right operator’s console. The reset pushbutton restores control to all motions if no additional faults exist. This pushbutton is inoperative until the main power start control has been actuated.

If a control fault occurs that shuts down a motion, all motions will automatically be shut down together.

At this time the operator should set all brakes. If the fault clears, the motion may be reset by pressing this pushbutton. If the fault does not clear, the unfaulted motions can be restarted by pressing this pushbutton to enable these motions to re-position themselves.

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DIG/PROPEL TRANSFER SWITCH The Dig/Propel Transfer Switch is used to switch between the two primary operating modes of the machine. The current mode of operation will be indicated on the Operator’s screen on the Operator’s Display.

IMPORTANT: • WHILE IN THE DIG MODE, THE PROPEL CONTROLS ARE DISABLED. • WHILE IN THE PROPEL MODE, THE DIG CONTROLS ARE DISABLED. The recommended procedure to transfer from dig to propel is to bring all motions to a controlled stop by the operator. Turn the hoist brake switch to the SET position and then press the control stop pushbutton. Turn the transfer switch from DIG to PROPEL. When the indicator on the Operator Display screen indicates that the transfer has been completed, turn the propel brake switch to release.

EMERGENCY STOP PUSHBUTTON The machine stop/emergency stop pushbutton is located on the right operator’s console. It is used to remove power from the machine motions after the motions have been stopped in the normal manner. A second purpose of the pushbutton is to stop the machine under operational emergency conditions. Pushing this button will provide electrical and immediate 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.

CAUTION:

PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY RESULT IN COMPONENT DAMAGE.

A second pushbutton that also provides the functions as described above is located in the remote start console and is labeled “machine stop.”

MAIN POWER OFF PUSHBUTTON The main power off pushbutton is located on the right operator’s console. It is used only to immediately remove power from the drives in case of an electrical emergency involving component failure or fire.

CAUTION:

Sept. 2010

PUSHING THE “POWER OFF” PUSHBUTTON WHILE IN MOTION WILL IMMEDIATELY SET THE MECHANICAL BRAKES AND REMOVE INCOMING HIGH VOLTAGE FROM THE DRIVES. THIS ACTION MAY RESULT IN COMPONENT DAMAGE. It will also result in the inability to power the DC bus voltage down to a low value. This voltage will decay slowly, taking several minutes.

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EARTH CONTINUITY LOCKOUT PUSHBUTTON The earth continuity lockout pushbutton is used to trip the breaker that supplies power to the machine.

When the machine is operating, this pushbutton should be used to shutdown the machine only when removal of power to the machine is required.

TELEPHONE A telephone is located at the rear of the right control console. This telephone is connected to other phone stations throughout the machine.

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AUXILIARY CONTROLS

REMOTE START CONSOLE The remote start panel contains the following switches and indicator lights used to initially start the machine.

Phase Sequence Light This green indicator light, when lit, indicates that incoming power sequence is correct. If the light is OFF, have electrical maintenance change the trail cable phase sequence.

Drive Cabinets Temperature Light This green indicator light, when lit, indicates that the drive electronic cabinets are at the correct operating temperature. Too low or too high cabinet temperatures will not allow the machine to start.

PLC Power On Light This green indicator light, when lit, indicates that PLC and drive control power is on.

System Ready Light This green indicator light, when lit, indicates the system is ready to start. When the system run pushbutton is pressed and the system successfully started, this light will go out.

Auxiliary Ground Fault Light This green indicator light, when lit, indicates that no auxiliary power ground fault exists. If the light is OFF, alert an electrician as soon as possible.

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Incomplete Sequence Light This red indicator light, when lit, indicates the automatic start-up sequence did not complete in a preset time period. Have an electrician troubleshoot the sequence. If this indicator does not light up, the start-up sequence is progressing properly and machine start-up can continue.

System Run Pushbutton This pushbutton will energize the drive system when pressed if the system ready light is on.

Ladder Down Horn When the boarding ladder is not latched in place, the operator's controls are deactivated.

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AIR PANEL

1.

The upper air pressure gauge indicates the air system operating pressure of 120 PSI (689 Kpa).

CAUTION:

IF THE SYSTEM PRESSURE IS BELOW 100 PSI, OR ABOVE 120PSI, SHUT THE MACHINE DOWN AND CORRECT THE PROBLEM. Failure to heed this caution could result in machine damage.

2.

Crowd Clutch Regulator - The crowd machinery is fitted with a clutch which will slip and protect the machinery from impact loads that may occur when digging.

3.

Adjust the air regulator to obtain an air pressure of 80 PSI in the lower gauge. Further adjustment may be required due to digging conditions and friction material. Once set, no additional adjustment is required.

NOTE: The air supply line at the crowd clutch is equipped with a check valve that permits air flow into the clutch but not out. This check valve is there to prevent inadvertent loss of clutch action by accidentally exhausting air and possibly letting the dipper handle move in the boom yoke blocks without motor or brake control. This check valve is located inside the guard over the clutch. To exhaust air from the crowd clutch, the air supply line must be closed, the clutch guard removed and the air line to the clutch loosened to reduce the air pressure.

DANGER!

Sept. 2010

RELEASE THE AIR LINE PRESSURE BEFORE REDUCING AIR PRESSURE TO THE CLUTCH. DO NOT ATTEMPT TO REMOVE ANY FITTINGS UNTIL THE AIR PRESSURE HAS COMPLETELY BLED OFF. FAILURE TO USE CAUTION COULD RESULT IN PERSONAL INJURY.

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PRE-START CHECKS 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, suspension 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. Section 4 of this manual contains checklists to assist in record keeping and ensure that adequate inspection standards are met.

WALKAROUND GROUND LEVEL INSPECTION Check the following areas daily during a general walkaround inspection: 1.

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.

2.

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.

3.

Check the swing rack 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.

DANGER:

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

4.

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

5.

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

6.

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

7.

Inspect the dipper door, hardware and bumpers for damage and excessive wear.

8.

Inspect fulcrum attachment points, slide blocks and spacers, and dipper handle for damage, excessive wear and evidence of adequate lubrication.

9.

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

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10.

Inspect Dipper Bail Assembly for damage, wear and evidence of adequate lubrication.

11.

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

ON-BOARD INSPECTION Check the following areas daily on board the machine: 1.

Visually inspect the swing, crowd and hoist gearcases for oil levels and leaks. Repair or service as required.

2.

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

3.

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

4.

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

5.

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

Check the lubricant supply and refill tanks if required.

6.

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

7.

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.

8.

Clean windows of operator’s cab.

9.

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

10.

Ensure ladder(s), steps and/or man basket are raised and properly stowed.

11.

Perform the manual lubrication points detailed in Sections 3 and 4 of this manual.

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MACHINE START-UP, OPERATION AND SHUTDOWN START-UP 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.

1.

Perform all pre-start checks listed in PRE-START CHECKS in this section of the manual.

2.

Raise the LH boarding stair and RH boarding ladder, making sure they are secured in the raised position. The limit switch at the top of the ladder and the back of the stair will not activate and the controls will not energize if the stair and ladder are not in the fully-raised position.

Start-Up Control Locations

3.

In the operator’s cab check that all brake switches are in the SET position and that the joysticks are in the neutral position. Then go to the electrical area at the rear of the machinery house.

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4.

At the AC control cabinet verify that the uninterruptable breaker is in the ON position. At the motor control cabinet, verify that all breakers are in the ON position.

5.

At the remote starting console in the operator’s cab, use the following sequence to start the machine: a.

Verify that the green AUXILIARY GROUND FAULT light is lit.

CAUTION:

b.

NOTE:

6.

IF THE AUXILIARY GROUND FAULT LIGHT IS OFF, ALERT AN ELECTRICIAN AS SOON AS POSSIBLE. The machine may be operated with one fault but a second fault could cause damage to the machine and/or become a safety hazard. The fault should be cleared as soon as possible.

Verify that the green PHASE SEQUENCE light is lit. This indicates that the incoming power sequence is correct. If not, the light will be out and the machine will not start.

Electrical maintenance personnel must correct the problem.

This PHASE SEQUENCE light also indicates auxiliary power phase unbalance, phase loss or under-voltage. Any of these faults occurring while the machine is running will produce an alarm. In the event of such an alarm an electrician should be notified, however the machine may be operated.

c.

Verify that the PLC and drive cabinets’ green temperature lights are lit. If the cabinet temperature is too low or too high, the machine cannot be started.

d.

Verify that the green PLC POWER ON light is lit. This light should be on about 20 seconds after the UPS motor is started.

e.

Turn the AIR COMPRESSOR RUN switch to the run position. It is located on the air compressor.

f.

Verify that the green SYSTEM READY light is lit on the start console.

g.

Press the SYSTEM RUN pushbutton. When this button is pressed, the system ready light will go out and the drive system will automatically power up.

h.

Verify that the red INCOMPLETE SEQUENCE light is out. If lit, call the electrician to troubleshoot the sequence.

In the operator’s cab, verify that the air pressure displayed on the operator’s display is correct.

The machine cannot be operated until the air pressure is at the specified rating.

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7.

Verify that the brake switches are in the set position and the joysticks are in the neutral position. Sound the signal horn and be sure all personnel are clear of machine.

8.

Turn the propel transfer switch to the DIG position. When the Operator Display lights indicate that the process is complete, press the control reset pushbutton to activate the controls.

9.

Turn the hoist, crowd, swing and propel brake switches to their RELEASED position.

10.

Briefly actuate swing, crowdand hoist controls to make sure each motion is operational.

RESTARTING AFTER AN ELECTRICAL FAULT To restart the machine after the electrical control system has gone into a fault condition, proceed as follows: NOTE:

Before any or all motions can be reset, the following conditions must be met:

a.

No operator’s monitor special screens should be activated.

b.

For hoist/propel motion the hoist/propel transfer switch is in the position called for by the operator’s mode selector switch.

c.

The joystick for the motion being reset must be in the neutral position.

d.

The motion mechanical brake selector switch must be in the released position.

1.

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.

2.

For a boom jacking fault, the crowd motion will stop but the controls will remain active. Put both joysticks in neutral. Reversing the left joystick will remove the fault and allow continued operation.

3.

If the RH boarding ladder or LH 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.

Once the ladder is back in position, the motions may be restarted by pressing the control reset pushbutton.

4.

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

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OPERATION Efficient operation is essentially the result of understanding and applying the basic techniques related to each machine motion, to achieve fast, smooth and safe load cycles. The interrelated coordination of the hoist, swing and crowd motions results in efficient machine operation.

Each motion is described in the following paragraphs. The operator should thoroughly learn each motion, its purpose and how this knowledge can be applied in becoming a better operator.

When learning to handle the operator controls, be sure that all personnel are clear of the machine and that there is ample clearance with no danger spots around the machine, such as culverts, ditches or embankments and that the machine is not too close to the digging face or overhanging ledges and large rocks.

Use the Operator Display panel, in the operator’s cab, to assist in the operation of the machine.

The monitor allows a large number of messages to be sent to the operator from all portions of the control system. These messages fit into four basic categories: 1.

Normal routine operational messages.

2.

Alarm only.

3.

Delayed shutdown messages.

4.

Immediate faults and shutdowns.

This monitor also allows the setting of certain operating parameters for the machine. Refer to OPERATOR’S DISPLAY in this section of the manual for detailed descriptions of the Operator Display monitor screens and how they relate to the proper operation of the machine.

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STOPPING THE MACHINE 1.

Return left and right joysticks to their center positions and set all brake switches.

2.

After all motions are stopped and brakes are set, press the CONTROL STOP pushbutton.

This action will remove power to the control units and set the brakes. The controls will become inoperative.

3.

To stop the machine completely and remove power from the drives, press the MACHINE STOP Pushbutton on the right operator’s console.

MACHINE SHUTDOWN When shutting down the machine at the end of a shift proceed as follows: 1.

Park the machine on firm ground in a position where it cannot be damaged by a slide, falling rocks or flooding.

2.

Place the dipper firmly on the ground.

3.

Make sure left and right joysticks are in their center positions.

4.

Make sure all brake switches are in their SET positions.

5.

Press the CONTROL STOP pushbutton. All primary controls should be de-energized.

6.

To de-energize the DC bus, press the MACHINE STOP pushbutton on the remote start console or the MACHINE STOP/EMERGENCY STOP pushbutton on the operator’s console.

7.

Close all windows in the cab and lock all cab doors.

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GROUND PREPARATION Ground preparation is very important. The mining shovel requires a properly prepared ground base for operation. The crawler shoes must have full contact with the ground when the machine is digging. With the machine weight distributed over the crawler shoes minimum ground bearing pressure is obtained and the machine components are less stressed.

For optimum operation, the ground supporting a mining shovel must be as near level as possible and firm. Sharp rocks and boulders cause point loading which will damage the propel machinery and crawler structures and should be removed if possible. Where this is impractical, cover the working area with fill dirt to a sufficient depth that will eliminate the effects of the rocks.

The mining shovel design incorporates a calculated balance between boom length, boom angle, allowable dipper load, machine weight, and ballast used. During normal digging cycles, the center of gravity shifts from the front to the rear within a specific distance. If, for any reason, the digging radius or load increases to cause the center of gravity to extend beyond this specific distance the machine will become unstable.

CAUTION:

Sept. 2010

OPERATION OF AN UNSTABLE MACHINE COULD RESULT IN DAMAGE TO THE SHOVEL, TRUCKS OR SUPPORT EQUIPMENT.

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MACHINERY MOTIONS HOIST MOTION In standard configuration, Hoist motion is controlled by the operator’s right joystick. Set the propel transfer switch in the DIG mode. The crawlers should be positioned so that the digging is done over the front of the crawlers. Move the joystick between 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.

CAUTION:

NOTE:

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

The following represents the standard configuration.

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CROWD MOTION In standard configuration, Crowd motion is controlled by the operator’s left joystick. Move the joystick to crowd and retract the dipper handle until a “feel” is developed for the limits and speed of the motion.

CAUTION: NOTE:

This joystick also controls the signal horn and dipper trip.

The following represents the standard configuration.

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 are achieved.

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PROPEL MOTION Propel motion is controlled by placing the propel transfer switch in the propel mode and actuating the left or right joystick. To propel in a straight forward direction, push forward on both the left and right joysticks at the same time. The speed is increased as the levers are displaced farther from neutral. To propel straight in reverse, pull equally both joysticks to the rear.

NOTE:

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

DANGER:

THE HOIST BRAKE MUST BE SET WHENEVER IN THE PROPEL MODE.

Propel - Straight Forward/Reverse

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SWING MOTION In standard configuration, 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.

NOTE:

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

DANGER:

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 machine, the hoist and swing motions are electrically locked out.

NOTE:

The following represents the standard configuration.

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

DANGER:

EXTENSIVE DAMAGE TO THE DIPPER HANDLE AND DIPPER CAN OCCUR IF THE MACHINE IS ROTATED 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.

DANGER:

Manual No. 10955

THE DIPPER SHOULD NEVER BE POSITIONED 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 open the door on an empty dipper and lower the dipper to a point that permits moving without striking the ground.

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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° increased the output to 126 percent. Therefore, a swing arc of 90° or less should usually be used.

Haul units should be positioned so their center line 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.

DANGER:

“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 SWEEPING. A bulldozer or loader should be used to help the machine operator maintain a clean pit floor in conjunction with the shovel.

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.

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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° should be used to minimize material build up on the crawler belt roller path.

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COUNTER-ROTATION TURNS 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 associated propel components.

To make a sharp right turn, move the LEFT joystick forward and pull the RIGHT joystick to the rear.

To make a sharp left turn, move the RIGHT joystick forward and pull the LEFT joystick to the rear.

CAUTION:

NOTE:

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

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 bogdown.

CAUTION:

The propel brakes are released when either joystick is moved from neutral. The propel brakes are set when both joysticks are returned to neutral.

When moving the machine in a straight line, propel forward, which is in the direction of the take-up axle to reduce strain on the crawler belts and propel mechanism. When not possible and propelling to the rear, make sure the trail cable is clear of the machine and follow the signals given by the helper. The machine should be rotated in a position to allow 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 loadings of haul units.

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

POSITIONING THE MACHINE There are two basic methods for positioning the machine at the working face of the bank: the “back-up method” and the “drive-by method”. Both methods are acceptable and effective.

BACK-UP METHOD When using the back-up method, position the machine at the bank with the front of the machine facing the digging face. The haul units are spotted on both sides of the machine. The bank can be excavated until a 180° circular area of material has been removed from the bank. Once the material is removed, a 90° or greater swing will be required in order to load the haul units, requiring the machine to be moved.

To reposition the machine, propel to the rear, away from the bank, at an approximate 45° angle to the bank. When the machine is centered in-line with the untouched edge of the previous excavation, propel straight toward the bank and position the machine for further digging.

The back-up method will minimize the swing arc and reduce moving time, produce less bank toe area clean up and simplify handling of the trail cable, cable standard and trail cable boat.

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DRIVE-BY METHOD NOTE:

If mine conditions or equipment prevent the use of the following procedures, use the “Back-up Method” instead.

Position the machine crawlers parallel to the bank with the outer set of crawler tracks directly in line with the bank toe.

The haul units must approach the machine from the front, making a turn away from the machine as the unit’s front wheel approaches the outside crawler. Haul units then stop in a position to allow backing toward the point of the bank for loading.

During the load cycle, swing arc is to one side only and should not exceed 90°. The cycle time from one full haul unit to the next empty unit should not exceed the cycle time between successive dipper loads to each unit.

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.

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

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.

Force the Dipper Lip into the Bank

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, requiring additional passes to fill the haulage unit

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

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

Digging should take place under the boom point for maximum shovel 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.

Variations on Dipper Penetration

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

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.

Dig with the Dipper Beneath the Boom Point

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.

Make Effective Use of the Hoist Effort

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.

Hoist Force Opposes Crowd Force

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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.

DANGER:

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.

Do 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.

DANGER:

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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COMPONENT WEIGHTS Quantity Weight Each (U.S. Pounds)

Shoe with Pins ................................................................ 102 ............... 490 Crawler Assembly .............................................................. 2 .......... 68,110 Front Idler ...................................................................... 2 ............ 2,500 Front Idler Shaft ............................................................ 2 ............... 330 Load Roller ................................................................. 16 ............... 720 Load Roller Shaft ........................................................ 16 ............... 190 Rear Idler ...................................................................... 2 ............... 980 Rear Idler Shaft ............................................................. 2 ............... 220 Sprocket ........................................................................ 2 ............ 4,500 Sprocket Shaft Assembly ............................................... 2 ............ 1,600 Propel Gearcase ........................................................... 2 ............ 6,620 Propel Motor ................................................................. 2 ............ 1,770 Propel Brake ................................................................. 2 ............... 470 Truck Frame Assembly ....................................................... 1 .......... 73,620 Truck Frame Structure ................................................... 1 .......... 55,120 Rotating Gear................................................................ 1 .......... 12,440 Center Journal .............................................................. 1 ............ 4,740 Roller Circle .................................................................. 1 ............ 6,600 Rotating Frame Assembly .................................................... 1 .......... 68,760 Structure ....................................................................... 1 .......... 58,840 Drum Shaft Pedestal - Left ............................................ 1 ............ 3,210 Drum Shaft Pedestal - Right .......................................... 1 ............ 2,860 Left Deck Extension ...................................................... 1 ............ 4,710 Right Deck Extension .................................................... 1 ............ 4,330 Ballast Box .................................................................... 1 .......... 30,730 Hoist Machinery: Hoist Drum Shaft Assembly ........................................... 1 .......... 19,620 Hoist Intermediate Shaft ................................................ 1 ............ 1,060 Hoist Motor Pinion Shaft ............................................... 1 ............... 300 Hoist Motor ................................................................... 1 ............ 7,500 Hoist Brake ................................................................... 1 ............... 600

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

Quantity Weight Each (U.S. Pounds)

Hoist Rope Winch ......................................................... 1 ............... 120 Swing Gearcase ................................................................. 2 ............ 6,210 Swing Motor .................................................................. 2 ............ 1,770 Swing Brake .................................................................. 2 ............... 390 Main Rotating Shaft ...................................................... 2 ............ 1,730 Main Rotating Pinion ..................................................... 2 ............... 165 Gantry Front Leg ................................................................. 1 ............ 5,030 Back Leg ....................................................................... 2 ............ 1,730 House Filter/Fan Unit .......................................................... 2 ............ 1,370 Operator's Cab .................................................................... 1 ............ 6,840 Air Compressor ............................................................. 1 ............... 500 Boom Assembly .................................................................. 1 .......... 53,900 Boom Structure ............................................................. 1 .......... 33,870 Boom Point Sheave Assy. ............................................. 1 ............ 6,070 Shipper Shaft Assembly ...................................................... 1 ............ 8,160 Yoke Block .................................................................... 4 ............... 640 Shipper Shaft Gear ....................................................... 1 ............ 1,550 Shipper Shaft Pinion ..................................................... 2 ............... 380 Shipper Shaft ................................................................ 1 ............ 1,720 Intermediate Crowd Gear .............................................. 1 ............... 920 Intermediate Crowd Shaft .............................................. 1 ............... 450 Crowd Motor ................................................................. 1 ............ 1,770 Crowd Brake ................................................................. 1 ............... 470 Crowd Clutch ................................................................ 1 ............... 560 Dipper Handle ..................................................................... 1 .......... 26,880 Dipper Assembly ................................................................. 1 .......... 32,090 Dipper Structure ............................................................ 1 .......... 20,900 Dipper Bail .................................................................... 1 ............ 2,250 Equalizer Sheave .......................................................... 1 ............ 1,150 Dipper Door Assembly ................................................... 1 ............ 7,780 Pitch Brace, each .......................................................... 1 ............... 330

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

TYPICAL MACHINE SPECIFICATIONS This specification describes the principal mechanical features of a standard Bucyrus International, Inc. 182M Mining Shovel. The machine is fully revolving, crawler mounted and equipped to operate from an alternating current power source.

NOTE: These are typical machine specifications.

WEIGHTS

US

Metric

Shipping Weight

Lbs.660,000

Kgs.299,400

Working Weight

Lbs.780,000

Kgs.353,800

Ballast (Furnished by Purchaser)

Lbs.80,168.8

Kgs.36,364

Lbs./Cu.Ft.250

Kgs.4005

40'-2"

12.24 Meters

54"

1.37 Meters

Boom Foot Pin to Shipper Shaft

16'-9"

5.10 Meters

Dipper Handle Length

27'-0"

8.23 Meters

Cu.Yds.13

10 Cu. Meters

Hoist Motor

710 hp @ 1400 V

1.4 kW

Swing Motors, Two

195 hp @ 1400 V

1.4 kW

Propel Motors, Two

195 hp @ 1400 V

1.4 kW

Crowd Motor

195 hp @ 1400 V

1.4 kW

Swing Speed

2.9 rpm.

2.9 rpm.

Travel Speed

1.0 mph.

1.61kph.

Minimum Weight of Ballast BOOM - HANDLE - DIPPER Boom Length Boom Sheave Diameter - Pitch Diameter

Dipper Capacity ELECTRICAL EQUIPMENT

Complies with the Indian Electricity Rules 1956 as amended.

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WORKING RANGES~Without Limits

A - Boom Angle B - Dumping Height - Maximum C - Dumping Radius @ Maximum Height D - Dumping Height @ Maximum Radius E - Dumping Radius - Maximum F - Cutting Height - Maximum G - Cutting Radius @ Maximum Height H - Cutting Height @ Maximum Radius J - Cutting Radius - Maximum K - Radius of Clean-up L - Clearance Radius - Outside Boom Point Sheave M - Clearance Height - Over Boom Point Sheave N - Crawler Length O - Crawler Width P - Belt Width Bearing Pressure, Lbs.per Sq. In. Q - Clearance Under Lower Frame R - Clearance Under Crawler Gearcase S - Clearance Radius - Rear End T - Clearance Under Frame U - Clearance Height - Gantry V - Clearance Height - Filter House W - Eye Level - Operator's Cab, Standard X - Clearance Width - Machinery House Hoist Drum - Pitch Diameter Hoist Rope Diameter (Double Line) Boom Support Rope Diameter (Twin Dual)

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US 45° 26'-6" 47'-1" 18'-0" 48'-10" 42'-9" 50'-10" 22'-9" 56'-9" 36'-5" 39'-2" 41'-1"

Metric 45° 8.08 14.35 5.49 14.90 13.04 15.51 6.93 17.30 11.10 11.94 12.52

Std.~ Opt. 29'-9" ~ 29'-9" 22'-6" ~ 24'-1" 39" ~ 59" 36.4 ~24.3 2'-0" ~ 2'-0" 19" ~ 19" 24'-6" 6'-9" 29'-9" 25'-3" 25'-2" 20'-5" 40" 2" 2"

Std.~ Opt. 29'-9" ~ 29'-9" 6.86 ~ 7.34 1.00 ~ 1.50 2.56 ~ 1.71 0.61 ~ 0.61 0.48 ~ 0.48 7.47 2.05 9.07 7.69 7.67 6.22 1.02 51.0 mm 51.0 mm

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Bucyrus International, Inc. 182M-AC Electric Mining Shovel

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