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Fire Extinguisher Locations
from CAT Electric Rope Shovel 495HD MIINIINNG SHOVEL MAINTENANCE and OPERATION MANUAL - PDF DOWNLOAD
SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT
BALLAST BOX SUPPORT
Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface.
Any mining shovel field work that requires the removal or lowering of the boom must incorporate additional support of the ballast box. The supports may be wooden cribbing or steel structures. Two supports positioned side-by-side on level ground are recommended. These supports are intended to accept vertical loads only. To prevent machine rotation use the swing brakes, cable stays, welded ties, etc. Refer to SWING RESTRAINT in this section of the manual.
When electric-powered, cable-style mining shovels are properly ballasted and operational, the center of gravity for the machine's upper works lies within the roller circle area. This assumes that the boom is attached to the machine and in its elevated, working position. As such, the machine should not be prone to tipping.
Boom removal or lowering will cause the center of gravity to shift toward the ballast box, decreasing machine stability. Stability is further dependent on the orientation of the upper works relative to the undercarriage. The machine may tip more easily over one of the four quadrants of the crawler mounting than it may over others.
Normally the machine is more likely to tip over the rear-most lower-roller than over the side of a crawler. Therefore, with the boom removed and the ballast box sitting over the rear of the crawlers, the machine may be unstable. Because ballast quantities differ from machine to machine and model to model, it is recommended that the ballast box be supported before beginning any procedure to lower and/or remove the boom.
SWINGING RESTRAINT
Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface. A small ground slope is enough to cause the machine to freely rotate if the brakes are not set or other restraints are not used. Once moving, it will keep going.
The following shows the relation between an out-of-level or slope and the resulting difference in elevation over a 14 ft. swing rack:
Difference in Slope % Elevation
0.25o
1.0o
5.0o 0.4% 0.75” 1.7% 2.9” 8.7% 14.7”
Where possible, all work on the swing brakes, motors, gearcases, or rack pinions should occur with the dipper attached to the machine and the full weight of the dipper on the
ground. If the dipper is not resting firmly on the ground, then an external means of preventing machine upper works rotation is required. Tie the upper works to the lower works using the preferred method mentioned below.
Mining shovels rotate using multiple swing units. Power is transferred from electric motors through individual gearcases, to pinions and into a fixed swing rack. Electric motor control prevents inadvertent machine rotation during operation. Should machine electric power be lost, spring-set brakes on the swing drive motors lock the geartrain to prevent machine rotation.
When working on the brakes, motors, or geartrains, it is an accepted practice to set the dipper on the ground. The weight of the dipper and handle will prevent machine rotation. EVEN IF ALL BRAKES, MOTORS, AND OR SWING GEARCASES ARE REMOVED, the machine should not rotate.
In certain circumstances it may not be possible to rest the full weight of the dipper firmly on the ground. For instance, the dipper, handle or the boom may not be attached to the machine.
To prevent machine rotation, with any of the major structures removed, two swing motor brakes should be set. A single brake in good operational condition is acceptable. However, a minimum of two brakes is recommended due to the possibility that the proper operation of a single brake may be unknown.
