Hitachi Ex2500 & Ex3600 Excavator Technical Operations Manual

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MNCO1027A CONDUCT EXCAVATOR/HYDRAULIC SHOVEL OPERATIONS

HITACHI EX2500 & EX3600 EXCAVATOR

EX2500 EX3600

LEARNING NOTES Design & Development by www.

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61 7 3869 0220

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DISCLAIMER Whilst a sincere effort has been made to ensure the accuracy of the information described in this manual, Worklearn makes no warranty, express or implied, with respect to the quality, correctness, reliability, currency, accuracy or freedom from error of this manual, or the products, procedures and process it describes.

Worklearn makes no representation or warranty with respect to the contents hereof and specifically disclaim any implied warranties of fitness for any particular purpose.

Worklearn disclaims all lability for any direct, or indirect, incidental or consequential, special or exemplary damages that may result from the use of this manual, or from the use of any products, procedures or processes described herein.

NOTE TO LEARNERS, FACILITATORS & ASSESSORS This document is designed to align with the Performance Criteria from the Unit of Competency MNCO1027A Conduct Hydraulic Shovel/Excavator Operations However, in the interests of an easier learning sequence for learners, facilitators and assessors we have placed Performance Criteria, EX 2.4 Conduct, Control & Monitor Tasks (covers operation of controls ) before EX 2.3 Select Loading Method

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DOCUMENT CONTROL SHEET

Hitachi EX2500/EX3600 Excavator Contact for Enquiries and Proposed Changes If you have any questions regarding this document contact: Name:

Steve Ward

Approved: ………..……………..

Designation:

RTO Coordinator

Phone:

49 869 247

Date: ……………………………

Record of Issues

Issue No

001/06/05

Issue Date

June

Nature of Amendment

Initial Issue

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MNCO1027A CONDUCT HYDRAULIC SHOVEL/EXCAVATOR OPERATIONS EXPECTED OUTCOMES OF ASSESSMENT Information for Assessors and Candidates The skills assessment for this unit of competency must be conducted in the workplace under controlled and/or real work conditions.

The assessment may be conducted over a period of time, as formative assessment of the elements and not necessarily at one time (although this may be possible). Competency requires that the operator will be capable of carrying out expected day to day tasks operating an Excavator to the required National Competency Standard (see above) and expected CQMPL productivity standards.

Tasks that an Excavator operator will be expected to perform when assessed as competent: •

Start of shift walk around inspection using a provided check list

•

Start up, park-up and shut-down

•

Work with/in mobile plant and equipment teams; and

•

Direct trucks into position

•

Conduct loading operations including: -

topsoil overburden coal interburden or partings

•

Carry out loading:

•

- over the side - through the gate - drive by - above trucks; and - at the same level Action alarms and communicating maintenance issues

•

Recognise and dealing with particular hazards associated with the operation of the Excavator

•

Carry out operational servicing, lubrication and housekeeping

•

Provide support for major maintenance

•

Process records and reports

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Topic Abbreviations/Acronyms Code CT EX25/36

Explanation Mining Department Area Specific Induction Hitachi EX2500 and EX3600 Excavator

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CONTENTS OPEN CUT PRODUCTION COMPETENCIES

Hitachi EX2500/EX3600 Excavator Section

Page

Competency Elements & Performance Criteria - Flow Chart

7

Element 1027.1 PLAN & PREPARE FOR OPERATIONS (Refer Mining Department Area Specific Induction)

9

Element 1027.2 OPERATE HYDRAULIC SHOVEL/EXCAVATOR CT 2.1

Resolve Coordination Activities with Others (Refer Mining Department Area Specific Induction)

11

Walk-around Inspection Checklist

12

EX25/36 2.2 Carry Out Pre-start, Start Up , park-up and Shutdown Procedures

16

EX25/36 2.3 Select Loading Method for Excavator

46

2.3 & 2.4 are reversed in the Learning Notes & Assessment

EX25/36 2.4 Conduct, Control and Monitor Dig Procedures

29

EX25/36 2.5 Act on or Report Monitoring Systems & Alarms

53

EX25/36 2.6 Recognise & Respond to Hazardous & Emergency Situations

59

CT 2.7

69

Complete Work to Planned Outcomes (Refer Mining Department Area Specific Induction) Formative Assessment

Element 1027.3 RELOCATE EXCAVATOR CT 3.1

Receive & Confirm Route & Location Plan (Refer Mining Department Area Specific Induction)

71

EX25/36 3.2 Complete and/or Follow Ground Preparation

72

CT 3.3

72

Resolve Co-ordination Issues, Support Equipment & Personnel (Refer Mining Department Area Specific Induction)

EX25/36 3.4 Relocate Excavator

73

Formative Assessment

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CONTENTS (Continued) OPEN CUT PRODUCTION COMPETENCIES

Hitachi EX2500/EX3600 Excavator Section

Page

Element 1027.4 CARRY OUT OPERATOR MAINTENANCE EX25/36 4.1 Carry Out Inspections & Fault Finding

75

EX25/36 4.2 Carry Out Routine Operational Servicing, Lubrication, Maintenance & Housekeeping

76

EX25/36 4.3 Carry Out Minor Maintenance

78

EX25/36 4.4 Provide Support for Major Maintenance

81

CT 4.5

81

Process Maintenance Records (Refer Mining Department Area Specific Induction) Formative Assessment

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HITACHI EX2500/EX3600 EXCAVATOR 1027.1

1027.2

1027.3

1027.4

PLAN & PREPARE FOR OPERATIONS

OPERATE EXCAVATOR

RELOCATE EXCAVATOR

OPERATOR MAINTENANCE

CT 1.1 Obtain, Interpret & Clarify Work Requirements

CT 2.1 Resolve Co-ordination Requirements with Others

CT 3.1 Receive & Confirm Route & Location Plan

EX25/36 4.1 Carry out Inspections & Fault Finding

EX25/36 2.2 Carry out Pre-start, Start Up, Park-up & Shutdown Procedures

EX25/36 3.2

CT 1.2 Access, Interpret & Apply Geological & Survey Data CT 1.3 Access & Apply Safety Information CT 1.4 Co-ordinate Preparation of Work Area

Formative Assessment

EX25/36 4.2 Complete and/or Follow Ground Preparation

Carry out Routine Operational Servicing, Maintenance, Lubrication & Housekeeping

CT 3.3 Resolve Co-ordination Issues, Support Equipment & Personnel

Carry out Minor Maintenance

EX25/36 3.4

EX25/36 4.4 Provide Support for Major Maintenance

EX25/36 2.3 Select Loading Method

EX25/36 2.4 Conduct, Control & Monitor Dig Procedures

2.3 & 2.4 are reversed in the Learning Notes & Assessment

Relocate Excavator EX25/36 2.5 Act on or Report Monitoring Systems & Alarms

Formative Assessment

EX25/36 2.6 Recognise & Respond to Hazardous and Emergency Situations

WHITE sections coded CT relates to Mining Department Area Specific Induction

EX25/36 4.3

CT 4.5 Process Maintenance Records

Formative Assessment

CT 2.7 Complete Work to Agreed Planned Outcomes

Formative Assessment

GREEN sections coded : EX25/36 relates to the Hitachi EX2500 and EX3600 EXCAVATOR

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PLAN & PREPARE FOR OPERATIONS

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MNCO1027A Conduct Hydraulic Shovel/Excavator Operations

Hitachi EX2500/EX3600 Excavator Element 1027.1

Plan and Prepare for Operations

Performance Criteria 1027.1.1

Obtain, interpret and clarify/confirm work requirements in the form of shift briefings, handover details or work orders before proceeding.

1027.1.2

Access, interpret and apply basic geological and survey data required to complete the allocated task in accordance to site procedures.

1027.1.3

Access and apply safety information and procedures throughout the work.

1027.1.4

Coordinate work area preparation, including floor clean up and level and grade requirements with others and carry out to job specifications.

CT 1.1

OBTAIN, INTERPRET & CONFIRM WORK REQUIREMENTS (Refer Mining Department Area Specific Induction)

CT 1.2

ACCESS, INTERPRET & APPLY GEOLOGICAL AND SURVEY DATA (Refer Mining Department Area Specific Induction)

CT 1.3

ACCESS & APPLY SAFETY INFORMATION (Refer Mining Department Area Specific Induction)

CT 1.4

PREPARE WORK AREA (Refer Mining Department Area Specific Induction)

Mining Department Area Specific Induction Assessment must be completed before continuing.

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OPERATE EXCAVATOR

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MNCO1027A Conduct Hydraulic Shovel/Excavator Operations

Hitachi EX2500/EX3600 Excavator Element 1027.2

Operate Excavator/Hydraulic Shovel

Performance Criteria 1027.2.1

Resolve coordination activities with others at the site prior to commencement of, and during, the work activity.

1027.2.2

Carry out pre-start, start-up, park-up and shutdown procedures in accordance with manufacturer’s and site procedures.

1027.2.3

Select required loading method, single-sided, double sided or other appropriate method and position the equipment and trucks to meet this requirement.

1027.2.4

Conduct, control and monitor dig procedures, fill and load in accordance with manufacturer’s instructions and site procedures including those covering truck loading.

1027.2.5

Act on or report monitoring systems and alarms are in accordance with manufacturer’s instructions and site procedures.

1027.2.6

Recognise and respond to hazardous and emergency situations are in accordance with manufacturer instructions and site procedures.

1027.2.7

Complete work in accordance with the agreed plan and outcomes and within the operating capacities of the allocated equipment.

CT 2.1

CO-ORDINATE ACTIVITIES WITH OTHERS (Refer Mining Department Area Specific Induction)

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WALK-AROUND INSPECTION - GROUND Hitachi EX2500/EX3600 Excavator Commence the inspection, starting at the bucket and working in an anticlockwise direction.

Check boarding steps for “Danger”, “Out of Service” or “Information Tags”. Check for the following: Ground Level q Bucket, bucket teeth, adaptors and pins ( wear and damage) q

Bucket cylinders, arms/arm cylinders (leaks and condition of hoses)

q

Level cylinder, arm and boom cylinder (leaks or damage)

q

Lights (damage lens, blown globes)

q

Front idler (wear)

q

Left track for correct adjustment (ie tracks resting on centre wear plate)

q

Track rollers and pins (wear and oil leaks)

q

Grousers (wear and/or loose bolts)

q

Chains ( wear or damage)

q

Boarding ladder (wear or damage)

q

Remote fire suppression activator

q

Position and function of emergency stop button

q

Rear sprocket (loose segments, wear and/or damage)

q

Track frame (dirt build up around carry rollers)

q

Slew ring (adequate grease)

q

Fuel tanks (leaks and/or damage)

q

Service point (damage and leaking hoses/connections)

q

Slew ring (adequate grease)

q

Rear sprocket (loose segments, wear and/or damage)

q

Right track for correct adjustment (ie tracks resting on centre wear plate)

q

Track rollers and pins (wear and oil leaks)

q

Grousers (wear and/or loose bolts)

q

Chains (wear or damage)

q

Track frame (dirt build up around carry rollers)

q

Front idler (wear)

q

Slew ring (adequate grease)

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Upper Level Inspection (Use three point access technique – one hand/two feet, two hands/one foot) q Rotary connection (leaks, wear and tear) q Hydraulic oil level and condition of tank q Engine oil level (top up if necessary) q Engine bay (fluid leaks, rubbish, excessive dust) q Pump drives (oil leaks) q Alternator and fan belts (adjustment, wear and/or damage) q Coolant level (top up if necessary)

WARNING

System pressurised; serious burns may result from releasing radiator cap on hot engines.

q Hydraulic pumps (oil leaks) q Windscreen washer reservoir level (top up if necessary) q Automatic Fire Suppression reservoirs (above counterweight) q Swing gear box (oil level and leaks/damage) q Main valve block (leaks) q Pre-cleaner (clean if necessary) q Fuel tank (level and condition) q Auto lube system q Battery q Radiator cores (leaks and/or trash build up) q Clean offside mirror q Emergency escape system ( worn/damaged rope, worn/damaged hanger or case) q Hydraulic cylinders, valves and hydraulic lines around the main boom area (leaks) q All boom grease lines (damage) q Boom pins ( wear and lubrication) Clean Test and Adjust as necessary q q q q q q q q

Operating controls, horn, gauges Seat and seat belt Air conditioner and filters Mirrors and windows Operating pedals Floor Fire Suppression System Lights, two-way and instruments

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HITACHI EX2500/EX3600 EXCAVATOR

Emergency Escape Device Hangar Swing Device

Cab

Lubricator

Boom

Hydraulic Oil Tank

Level Cylinder

By Pass Filter

Arm

High Pressure Strainer Bucket Oil Cooler Bucket Cylinder

Control Valve

Arm Cylinder

Pump

Emergency Escape Device

Hydraulic Oil Tank

Centre Joint

Counterweight

Front Idler

Engine

Track Adjuster

Radiator

Upper Roller

Swing Device

Lower Roller

Accumulator Side Frame

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HITACHI EX3600 EXCAVATOR

Boom Cylinder Cab

Swing Device Boom

Lubricator Oil Cooler

Level Cylinder

Hydraulic Tank Arm

Muffler

Bucket

Battery

Dump Cylinder

Air Cleaner

Bucket Cylinder

Pump

Arm Cylinder Counterweight

Washer Tank Fuel Tank

Engine

Front Idler

Control Valve

Track Adjuster Radiator

Upper Roller

Accumulator

Side Frame

Travel Device

Ladder Lower Roller

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CARRY OUT PRE-START, START-UP, PARK-UP AND SHUTDOWN PROCEDURES

2.2.1 Pre-Start Procedure It is recommended that you commence the inspection at the bucket and move around the machine in an anticlockwise direction, carrying out the checks. Check boarding ladder for “Out of Service” and/or “Danger” tags and use three point boarding techniques.

The access ladder may be operated from either ground level or from the upper level.

•

To lower from the upper level – pull the “T” handle up to release the lock and gently push down on the ladder until it locks into place.

•

To lower from ground level – stand clear of the ladder, pull down on the hanging rings to release the lock and gently pull down on the handle until the ladder locks into place.

Ensure body parts are kept clear of the path of the ladder when raising the ladder from the upper level.

WARNING

The ladder may spring up after the lock is released.

•

To raise from the upper level – stand clear of the ladder, pull the “T” handle up and exert upwards pressure on the ladder until it locks into place.

•

To raise from ground level – pull down on the hanging rings as you push the ladder up until it locks into place.

“T” Handle Upper Level

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2.2.2 Walk Around Information •

Check the Coolant (engine shut down) Check the coolant at the reservoir located in the engine bay. Coolant must be between the MIN and MAX marks located on the outside of the container. If the coolant is below the MIN mark, top up the coolant in the reservoir only.

To fill the radiator: -

remove the radiator cap

-

top up with coolant

-

check the coolant level

-

check for any leaks

-

replace the cap securely •

WARNING

• • • •

Only remove the radiator cap when the engine is cool.

Relieve any pressure by removing the cap slowly Use PPE (ie gloves, glasses) Use gloves; and Cover the cap with heavy rag or other protection

EX2500

EX3600

Coolant Level Gauge

Radiator Cap

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Engine Oil Level Check the oil level before starting the engine or 15 minutes (or more) after stopping the engine. This allows the oil to drain from the engine cavities and provides a more accurate reading.

Check the level as follows:

EX2500

-

ensure the excavator is parked on a level surface

-

check the oil burn reservoir under the excavator (the level should show at least half in the sight glass)

-

open the inspection door at the rear left of the unit

-

remove the dipstick in the first engine

-

wipe the dipstick with a clean rag

-

re-insert the dipstick

-

remove the dipstick

-

read the level (level should be between the two marks)

EX3600 Oil Filler Cap

Oil Dipstick

Dipstick

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Fuel Level (for pre start inspection) Check using the sight glass located on the side of the fuel tank, add fuel as necessary

Fuel

•

Swing Reduction Gearbox Oil Level Ensure the excavator is parked on a level surface with the engine off: -

remove dipstick

-

wipe the dipstick on a clean rag

-

reinsert the dipstick

-

remove dipstick again

-

check the oil level

The oil must be maintained between the upper and lower marks on the dipstick.

EX2500

EX3600

Dipstick

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Hydraulic Oil Reservoir Level Ensure the excavator is parked on a level surface with the boom, stick and bucket in the position shown in the photo opposite. The engine should be stopped. Check the level using the sight glass located on the Sight Glass wall beside the cab steps. The oil level should be between the two marks, if the level is below the bottom mark add oil. Do not overfill.

2.2.3 Operator’s Seat

Back-rest Adjustment Cushion Angle Seat Damper

Console Fore/Aft Adjustment

Seat Fore/Aft Adjustment

•

Adjust Backrest Pull the Back-rest Adjustment lever up while applying or relieving pressure on the back-rest.

•

Cushion Angle Both the front and rear sections of the base cushion can be adjusted by either lifting or lowering the cushion angle lever eg: -

to adjust the rear part of the cushion, pull the lever up while either applying or relieving pressure on the rear of the seat base.

-

to adjust the front part of the cushion, push the lever down while either applying or relieving pressure on the front of the seat base.

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Suspension Adjustment (dampening) To adjust the ride or dampening effect of the seat turn the Seat Damper dial clockwise to increase the dampening effect, or anticlockwise to decrease the dampening effect. As a guide, you may turn the dial to set your own body weight (in kilograms).

•

Console/Seat Fore/Aft adjustment The seat and/or the seat and console (control levers and seat) may be adjusted forward or backward to suit your needs.

-

to adjust the seat only, lift the Seat Fore/Aft Adjustment bar while pushing or pulling the seat in the direction required.

-

to adjust the seat and console together, lift the Console Fore/Aft adjustment lever while pulling or pushing the unit in the direction required.

•

Lumbar Support Adjustment Lower back lumbar support may be adjusted by turning the dial located on the left side of the back rest. Turning the dial anticlockwise will increase lumbar support.

•

Headrest adjustment The headrest can be adjusted both in angle and height.

•

-

to raise or lower the height of the headrest, grasp it firmly with both hands and pull up or push down to the desired position.

-

to tilt the headrest, hold the headrest while tilting it forward or backwards to suit your requirements.

Armrest Height adjustment The height of the armrests may be adjusted by turning the dials located on the underside of the armrest.

NOTE

Adjust the seat so that you can easily depress the foot pedals.

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2.2.4 Seat Belt

Before fastening the seat belt, inspect

WARNING

•

The securing brackets and belt for abnormal conditions.

•

The bolts and fittings on the chassis for tightness

Fasten the belt as follows: •

Adjust the seat so that the brake pedal can be depressed all the way with your back against the back rest

•

Position the seat belt across your body

•

Secure the belt by placing the tongue into the socket attached to the seat

Check that there are no kinks in the belt.

WARNING •

Check that the belt has locked by pulling it

Unbuckle the seat belt as follows: •

Depress the red button on top of the seatbelt socket

•

Allow the seat belt to retract

WARNING

If the seat belt is scratched or frayed or if any of the fittings are broken or deformed or loose. Contact Maintenance

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2.2.5 Pre Start Instrument Check •

Place pilot control shut-off lever in the LOCK position

•

Check that all control levers are in neutral (N)

•

Turn the ignition switch ON

•

Check that the following lights are ON: -

alternator indicator

-

pump transmission oil pressure indicator

-

engine warning indicator

-

engine stop indicator

Pilot Control Shut Off

•

Press indicator light check switch; AND

•

Hold (indicator light check switch)

•

Check that all monitor lamps are ON

If any indicator fails to light, the bulb may be burned out.

Maintenance for advice/assistance

Call

2.2.6 Fluid Level Check Wait 15 seconds after the ignition has been switched ON and check the fluid levels using the test switch on the operator’s console.

Hydraulic Oil Coolant Engine Oil

The fluid level lights will glow if the fluids are at operating levels.

All three lights should glow before you start the engines.

NOTE

The level check function does not replace the need for operator pre-start checks.

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Start-up (Normal) Start the unit as follows: •

Adjust the operators seat

•

Check that the Pilot Control Shut Off lever is in the LOCK position.

•

Pilot Control Shut

Check that all levers are in NEUTRAL (N) Engine Speed Control

•

Place the Engine Speed Control in LOW

•

Sound horn once (wait five seconds)

•

Turn the ignition key to the ON position

•

Check warning lights

•

Turn the ignition key to the START position

•

Crank the e ngine

•

Release the key once the engine has started, or after ten seconds with out starting.

NOTE •

Emergency Stop Ignition Key

Crank engine for a maximum of 15 seconds.

If the engine does not start, wait for three minutes before attempting another start.

Check that the warning lights glow for approximately two seconds after the ignition key is turned to the ON position

Contact maintenance if any of the warning lights above fail to glow.

NOTE •

Ensure that all the monitor lamps on the operator control panel go out. If any lights fail to go out, stop the machine and check for the cause (Refer 2.5 - Act on or Report Monitoring Systems & Alarms).

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2.2.8 Starting In Cold Weather

EX2500 •

Install an ether container on holder located in the engine room

•

Move the engine speed control lever to the LOW position.

•

Turn the ignition switch to START; AND

•

Crank the engine

Ether Container Holder

WARNING

•

Starting fluid (ether) is highly flammable.

•

The container may explode if not handled correctly.

•

Keep the container away from heat, sparks, and open flame.

•

Contents of the starting fluid container are pressurized. Do not puncture or incinerate the container.

•

Remove container from the excavator if the engine does not need starting fluid.

The Pre-lube indicator will glow and the starter will rotate to start the engine , approximately 3 seconds after the pre-lube indicator light goes out. A shot of ether will be injected into the engine.

•

Release the ignition key after the engine starts (It will return to the ON position)

•

Remove the ether container after the engine has started

Ether is injected into the engine automatically.

NOTE

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Starting In Cold Weather

EX3600 When the preheat switch is turned ON, preheating is continuously performed for approximately one (1) minute with the ignition key in the ACC position. If the ignition key is turned to a position other tha n the ACC position before preheating is complete, preheating will be automatically stopped (the preheat indicator will go out). If preheating is operated for longer than one (1) minute, the preheat indicator will go out, automatically switching off preheating.

ON

OFF

•

Remove the Relay Box cover

•

Turn the preheat cut-off switch ON.

•

Turn the ignition key switch the ACC position.

Pre-heat Cover & Switch

•

Open the preheat switch cover

•

Turn the preheat switch ON (the p reheat indicator will glow) to indicate:

Pre-heat Cut Off Switch

Relay Box

Pre-heat Indicator

-

preheating of the engine intake air

-

setting the fuel injection for starting in cold weather.

•

Wait one minute after starting the preheating

•

Turn the ignition key to the START position

•

Crank the engine until it starts (Maximum 10 seconds). Preheating will automatically be complete and preheat indicator will go out

NOTE

The preheating system will only operate if the ignition key is in the ACC position.

If preheating is required again: •

Turn the preheat switch OFF

•

Wait for 5 minutes

•

Turn the preheat switch ON

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2.2.9 After Start-up Checks •

Warm up the engine for no less than five (5) minutes, under no load and at mid range engine speed

•

Check the monitor lamps for operation If the monitor lamps do not go out after starting the engine : WARNING

•

• •

Stop the engine immediately Call Mainte nance for assistance

Run the engine under light load until the engine coolant and hydraulic oil gauges are in the green or white range

Hydraulic Oil Temperature

Engine Oil Temperature

Engine Stop Alternator

Engine Oil Pressure

Transmission Oil Pump

•

Ensure the alternator monitor lamp is OFF

•

Ensure the transmission pump oil pressure lamp is OFF

•

Ensure the e ngine oil pressure lamp is OFF

•

Ensure the e ngine stop lamp is OFF

• Operate the excavator controls with no load applied to circulate warm oil through the hydraulic system •

Check for:

Exhaust Gas Colour - Quick Check

-

normal exhaust colour

C Coolloouurrlleessss oorr ffaaiinntt bblluuee: normal (proper combustion)

-

abnormal vibration

Black: abnormal (improper combustion)

-

abnormal noise

W hite : abnormal (worn oil rings, or coolant leakage into cylinder)

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2.2.10 Park Up and Shut Down •

Check the distance from other plant/equipment

•

Park the excavator on a level surface

if you must park on a grade: WARNING

• Thrust the bucket teeth into the ground • Block both tracks

•

Lower the bucket to the ground

•

Turn the auto -idle switch OFF

The turbocharger may be damaged if the engine is not correctly shut down.

NOTE •

Move the engine speed control lever to the slow idle position

•

Run the engine for 5 minutes to cool the Engine

•

Turn the ignition key to OFF

•

Pull the pilot control shut-off lever to the LOCK position

•

Close the windows, roof vent, and cab door

NOTE

Protect electrical components in the cab from bad weather. Always close windows, roof vent and cab door when parking the excavator

Pilot Control Shut Off Lever

Speed Control Lever

Ignition Key

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CONDUCT, CONTROL & MONITOR DIG PROCEDURES

2.4.1 Foot Controls. The foot/centre front hand controls are used to manage the travel movements of the excavator.

NOTE

The travel directions below are described with the track idlers positioned at the front of the excavator and the travel motors at the rear. (If the tracks are facing in the opposite direction the control movements must be reversed)

FORWARD Left

Right Footrest

Footrest

Neutral

Left

Right REVERSE

•

The Travel Direction Pedals operate as follows : -

Forward – Push the top of both pedals down

-

Reverse – Push the bottom of both pedals down

-

Turn Right – Push the top of the left pedal down

-

Turn Left – Push the top of the right pedal down

-

Turn on Track Radius – Push the top of the right pedal down while pushing down on the bottom of the left pedal, or vice versa.

Avoid changing direction in high speed.

WARNING

Before changing direction check for hazards and people.

When driving over rough terrain, reduce engine speed to lessen possibility of undercarriage damage.

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Working Lights Dip Switch - A dip switch has been fitted to the excavator to allow the operator to turn off the lower work lights when trucks are approaching. The switch is located on the side of the operator cabinet, adjacent to the left foot rest.

2.4.2 Hand Controls The Travel Directional Levers – Follow the operation of the pedals as follows: •

Forward – Push both levers forward

•

Neutral – Centralise the levers

•

Reverse – Pull both levers back

•

Turn Right – Push the left lever forward

•

Turn Left – Push the right lever forward

•

Turn on Track Radius – Push the right lever forward while pulling back on the left lever, or vice versa.

Left

FORWARD

Right

NEUTRAL

Left

REVERSE

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Engine Speed Control Lever – Allows the operator to regulate speed of the engine.

To operate:

HIGH

LOW

Move the lever FORWARD for LOW and BACKWARDS for HIGH

The Engine Speed Control lever should be in the LOW (idle) position to start the engine.

NOTE •

Pilot Control Shut Off Lever – prevents the accidental operation of controls when leaving the operators seat or cab To activate the Pilot Control Shut Off Lever When stopping the excavator: -

park the excavator on a firm, level surface

-

lower the bucket to the ground

-

place all controls NEUTRAL

-

shut down the engine.

-

pull the Pilot Control Shut Off lever up into the LOCK position

Pilot Control Shut Off

Before starting the excavator: -

Confirm that Pilot Control Shut Off lever is in the LOCK position

After starting the engine: -

confirm that all control levers and pedals are in NEUTRAL

-

confirm that no part of the machine is in motion

-

push the Pilot Control Shut Off le ver down to the UNLOCK position Ensure that the Pilot Control Shut Off lever is moved fully into the lock position before leaving the operator’s seat.

WARNING

Shut down the excavator and Contact Maintenance if any part of the machine (any actuator) moves when the Pilot Control Shut Off lever is lowered to the UNLOCK position.

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2.4.3 Bucket Controls Arm OUT

Slew RIGH T

Slew LEF T

Arm IN

•

•

Boom UP

Bucket Roll OUT

NEUTRA L

Bucket Roll IN

Boom DOWN

Left Hand Control (Upper Deck) -

Slew LEFT – Move the top of the lever left

-

Slew RIGHT – Move the top of the lever right

-

Arm (stick) OUT – Push the top of the lever forward

-

Arm (stick) IN – Pull the top of the lever back

Right Hand Control (Bucket) -

Boom UP – Push the lever forward

-

Boom DOWN – Pull the lever back

-

Bucket ROLL OUT – Move the top of the lever left

-

Bucket ROLL IN – Move the top of the lever right

The lever will return to the HOLD/NEUTRAL position if released in any selected position.

NOTE

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2.4.4 Buttons and Switches •

Emergency Stop Switch (Cab) – located on the back of the right hand bucket control, above the start keys.

Emergency Stop

To stop the engine in an emergency, turn the emergency stop switch from NORMAL to EMERGENCY STOP. This will stop the engine and the Emergency Engine Stop monitor lamp will glow.

Other emergency stop switches are located in the pump room and at the bottom of the main access ladder.

NOTE

Starter Switch

Return the emergency stop switches to the normal position before trying to restart engines.

Emergency stop switches are also located in the: -

EX2500 (Engine and Hydraulic Pump Compartments)

-

EX3600 (Engine, Pump, Oil Cooler and Radiator Compartments)

When the engine stop switch is turned to the EMERG. STOP position, the engine will not start with the ignition key. The Engine Emergency Stop indicator will glow and a buzzer will sound.

WARNING

Engine Emergency Stop Switches

The engine will stop when the switch is turned to EMERG. STOP. HOWEVER, air pressure will not be purged from the hydraulic oil tank.

Engine Emergency Stop

EX2500

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Engine Ignition (Starter) Switch – used to start the engine and activate the electrical circuits. There are four (4) positions: -

START – turn the key(s) to this position to start the engine(s).

The key(s) will return to the ON position when released.

-

ACC - supplies power to the radio, horn and two-way

-

ON - after starting, the engine(s) will continue to run with the key(s) in this position

-

OFF - turns the engine(s) off and isolates the electrical systems EMERGENCY STOP OFF (engine)

ACC (horn, radio etc)

IGNITION SWITCH

ON (Engine electrical)

START (engine)

•

Two Way Radio – The microphone on the two way radio is controlled by the button on top of the left hand bucket control lever.

To talk on the radio: DEPRESS the button on top of the control and HOLD down until you have finished speaking.

Microphone

Microphone Button

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Wiper Switch -

OFF - wipers are parked.

-

INT - wipers operate intermittently

-

LO - wipers operate at a slow speed (continuously)

-

HI - wipers operate at a high speed (continuously) Wiper Switch

Wiper Delay Switch

Washer Button

•

•

Wiper Delay Selector – activated when the wiper switch is turned to INT. The Wiper Delay Selector switch allows the delay to be adjusted to one of four settings: -

SHORT - allows a delay period of approximately four (4) seconds between wiper operation

-

Position TWO - allows a delay period of approximately eight (8) seconds between wiper operation

-

Position THREE - allows a delay period of approximately fifteen (15) seconds between wiper operations

-

LONG - allows a delay period of approximately twenty-five (25) seconds between wiper operations

Washer – depress the button to operate the windscreen washers.

The wiper will operate for approximately four (4) seconds after the button is released.

WARNING

Damage will occur to the washer system if operated for periods longer than twenty (20) seconds or if operated continuously while the reservoir is empty.

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EX2500 Auxiliary EX3600 Preheat

Auto Idle

Entrance Light

Interior Light

Working Lights

Fast Fill

Travel Speed

Engine Room Light

•

Auxiliary Switch – spare

•

Fast fill Switch – operates the service point arm located under the back of the excavator.

-

OUT (normal position) service point is stowed.

-

IN (light on) service point is in the down position

NOTE •

The excavator will not slew while the service point is down.

Auto Idle Switch – has two (2) positions: -

ON - press the button IN. The engine speed will drop to idle after the bucket controls have been neutralised for four seconds.

-

OFF – press the button a second time to release the switch and turn off the AUTO IDLE.

An indicator light will glow while the AUTO IDLE system is activated.

NOTE

Before stopping the engines, turn the AUTO IDLE switch OFF.

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Travel Speed Switch – a two position switch used to control the speed of the excavator when travelling. An indicator lamp will glow to identify the speed selected: -

IN position – slow speed (turtle indicating light)

-

OUT position – fast speed (rabbit indicating light)

Entrance Light Switch – two (2) positions: - ON – press the button in -

OFF– press the button a second time

The entrance light (located externally at the top rear of the cab) comes on when the entrance light switch is depressed. An indicator light will glow while the button is in the ON position. To switch the light OFF, press the button a second time.

•

•

•

Engine Room Light Switch – two (2) positions: -

ON – press the button IN. (The engine room light comes on when the switch is depressed). An indicator light will glow while the button is in the down position.

-

OFF – press the button a second time

Interior Light Switch – Two (2) positions: -

ON – press the button IN. (The interior light comes on when the switch is depressed)

-

OFF – press the button a second time

Working Lights Switch – Two (2) positions: -

ON – press the button IN. (When this button is depressed all exterior working lights will come on and the instrument gauge backlights and air conditioner illumination will glow)

-

OFF – press the button a second time

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Warning Lights Test Fluid Level Check

Buzzer Stop

Dimmer

•

Warning Lights Test Switch (fault monitor lamps) To check the operation of the fault monitor lamps:

•

-

turn the key switches to ON

-

check that the alternator, transmission pump pressure, engine stop, engine warning and engine protection lights are glowing (nine lights).

-

press the Warning Lights Test switch and check that the remainder of the lights are glowing

Fluid Level Check Switch To check that the fluid levels are adequate for operation: -

press the Fluid Level Check switch. The corresponding light on the display will glow for each fluid level checked and correct

•

Buzzer Stop Switch - use this button to reset the warning buzzer after an alarm event. The buzzer will sound again at the next event.

•

Dimmer Switch (instrument cluster) – dial type switch used to change the intensity of the instrument back lighting -

turn the switch clockwise to increase the intensity of the back lighting

-

turn the switch anticlockwise to decrease the intensity of the back lighting

NOTE

The Fluid Level Check switch is not a substitute for manual/visual pre start checks.

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Air Conditioner Controls The air conditioner system fitted to the EX2500/EX3600 is split into three separate systems each controlled separately. The three systems are Rear, Side and Front.

The air conditioner controls for each system operate as follows : -

Fan Control - the fan speed is adjusted up or down by pushing the black buttons shown below. The status of the fan will be shown by a LED behind the corresponding fan speed (OFF, I, II, III).

-

Air Conditioner On/Off - the air conditioner may be switched off independently of the fan to allow for fan only operation without cooling. The on/off button for this feature is the blue button marked AC. The status of the air conditioner will be shown by an LED glowing behind the snowflake emblem.

-

Temperature Control - The temperature output of the air conditioner can be adjusted by pressing the black buttons shown below. The temperature setting will be shown by an LED glowing above the colour scale.

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Horn Button

•

Horn Button – is located on top of the left hand bucket control lever. To sound the horn press down on this button for the duration required.

2.4.5 Move the Excavator After the engine has been started allow 5 minutes (minimum) warm up.

To move the excavator: •

Check that all the warning lights have gone out

•

Unlock the Pilot Control Shut Off lever

•

Lift the bucket

•

Turn the park brake switch to OFF (to release the park brake)

•

Select travel speed using the Travel Speed Switch. Slow speed (turtle) or fast speed (rabbit) can be selected by pushing the travel speed switch regardless of engine speed.

•

Sound the horn (twice (2) for forward) (three (3) times for reverse) – pause five (5) seconds

Always stop the excavator before changing the travel mode speed.

WARNING

NOTE

To decrease the travel speed, for travelling on a slope or in a tight space, press the switch to the turtle position.

Select a route that is as flat as possible. Steer the excavator as straight as possible making small, gradual changes in direction.

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Select the direction of travel as follows: •

Forward Travel - Push down on the front of both pedals or, push forward on both of the travel levers

•

Reverse Travel - push down on the rear of both pedals or, pull back on both of the travel levers

•

Neutral Position - when the travel pedals or, levers are placed in the neutral (central) position, the travel brakes will automatically stop and/or hold the machine

•

Left Turn - push down on the front of the left pedal or, push the left travel lever forward

•

Right Turn - push down on the front of the right pedal or, push the right travel lever forward

•

Short (spin) Turn - push down on the front of one pedal and the rear of the other or, alternatively push/pull both travel levers in opposite directions

WARNING

The travel directions above are described with the track idlers positioned at the front of the excavator and the travel motors at the rear. (If the tracks are facing in the opposite direction the control movements must be reversed) Be sure to confirm the position of the travel motors before travelling

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2.4.6 Filling the bucket Before moving the bucket into the face it should be levelled and lowered to the floor. The bucket can be levelled by pulling/pushing the bucket control lever to the left or to the right.

Once the bucket has reached a point where the floor of the bucket is of a similar angle to that of the material being excavated, lower the bucket to the floor and check the bucket level, adjust the level if required.

With the bucket levelled and lowered to the floor, move the bucket arm towards the face to the point where the excavator has started to labour, at this stage pull the bucket control back towards the operator seat to start to roll (tilt) the bucket slowly until it’s full whilst slowly raising the boom(hoist).

Always keep the bucket floor parallel to the face when digging. When the bucket is full, continue to hoist to the required level while also slewing towards the loading position.

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2.4.7 Working on Inclines (Slopes) It is usually safer and more efficient to work from the tops of an incline to the bottom (rather than from the bottom up to the top). The weight of the excavator (and gravity) will assist in pushing the load ahead of the blade.

You will need to communicate and understand the angle of an incline before you can work on it. Inclines are generally referred to in ratios (e.g.

2:1, 4:1).

2:1, means that if you walk for two metres up an incline you will rise one metre from your starting point. A ratio will also relate to the angle of the incline. The drawings below show the relative steepness of inclines and approximate angle in degrees.

At Curragh, ramp angles are usually referred to in percentages (e.g. most pit ramps are 8%. Dragline ramps are 10% maximum). Highwalls are usually referred to in ratios (i.e. 1:1 or 1:2)

2:1 Slope 1M

27° Off Horizontal 2M

51%

3:1 Slope 1M

18° Off Horizontal 32.5%

3M

4:1 Slope 1M

4M

14° Off Horizontal 24.9%

Avoid travelling across (right angles) a slope.

WARNING

If you must walk across a slope: • Keep the bucket close to the ground (.5 – 1 metre) • Do not swing downward on a slope

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DEGREES – PERCENT - SLOPE 100 90 80 70 90

60

80 70 60

50 50 40

40

30

30 20

20

10

10 0

0

Degrees

Percent

Degrees

Percent

Degrees

Percent

1

1.8

16

28.7

31

60.0

2

3.5

17

30.6

32

62.5

3

5.2

18

32.5

33

64.9

4

7.0

19

34.4

34

67.4

5

8.8

20

36.4

35

70.0

6

10.5

21

38.4

36

72.7

7

12.3

22

40.4

37

75.4

8

14.0

23

42.4

38

78.1

9

15.8

24

44.5

39

81.0

10

17.6

25

46.6

40

83.9

11

19.4

26

48.8

41

86.9

12

21.3

27

51.0

42

90.0

13

23.1

28

53.2

43

93.3

14

24.9

29

55.4

44

96.6

15

26.8

30

57.7

45

100.0

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Excavators may tip forward when travelling up or down a slope (dip) always keep the bucket low to the ground (500mm to 1 metre)

Avoid turning on slopes. If you must turn ensure the ground is firm and the slope angle is not excessive. Never traverse slopes of more than 15 degrees longitudinally or 15 degrees across the fall.

It is important to select the correct digging technique with regard to the steepness of the slope.

Avoid working across a slope (eg at right angles).

If you must work across a slope: WARNING

•

Start at the top

•

Maintain a windrow on the low side of the excavator to provide stability

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SELECT LOADING METHOD

2.3.1 Loading Tasks – includes both haulers and rear dump trucks.

There may also be times when loading is in conjunction with other type of loading units eg loader.

Loading materials may include: • Topsoil • Overburden • Coal • Interburden or partings Whatever type of unit you are loading, you must work with the operator as part of a team by: •

Maintaining communication with the operator of the equipment being loaded. This may be via two way radio, by horn signals (eg one horn signal by the excavator operator to tell the truck to stop) or visually using hand signals

•

Ensuring the truck is positioned for safe, easy and productive loading

2.3.2 Loading Preparation • Carry out an inspection of the area where loading is to be carried out for any hazards • Communicate your movements to any other operators in the area • Contact grader/dozer to clean floor in preparation for truck loading.

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2.3.3 Loading Operation Study the area that the loading operation will be carried out and decide on the best approach to loading eg: •

Develop a plan of how to work the face and the loading method to be employed (eg drive by, through the gate)

•

Inspect the area/material to be loaded and decide if any additional preparation is required (eg grader/dozer to prepare floor/bench)

• Set up the loading bench. Check the following as you go:

•

-

keep the bench height as close as possible to the stick length or equal to the gate height of the truck.

-

set the angle of the bench to suit the material being excavated.

Loose material will need a lower angle while compacted earth may stand near vertical.

Load trucks using the most productive method (eg drive by, over the side)

When trucks are fully loaded and the area is clear of other traffic, sound the horn once to signal that loading is completed.

Some rear dump trucks have a load weight system, as the excavator operator you should familiarise yourself with the system fitted to the trucks you are loading. The Komatsu system fitted is as follows: One Green light for a load between 56-67 ton Two Green lights for a load between 67-85 ton NOTE

Three Green lights for a load between 85-91 ton One Yellow light for a load between 91-96 ton One Red light for a load o ver 96 ton Do Not Overload Komatsu 785 Rear Dump Trucks are rated at 85 ton (three green lights)

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2.3.4 Positioning Trucks/Loading Techniques The excavator operator is the ‘spotter’ and it is his/her role to direct the truck to the loading position. The excavator operator usually has the bucket full and in position so that the truck can reverse under it for loading.

Loading may be carried out using a number of techniques to satisfy safety, job or production needs. Some of the more common techniques include: • Over the side • Off the same level • Through the gate • Drive by Factors to consider when setting up for loading include: •

Bench height

•

Material stability

•

The area required for positioning of trucks (confined/floor type etc)

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2.3.5 Loading Over the Side The excavator is positioned parallel to the face with the right track lined up along the cut line.

Trucks are positioned at right angles to the face or they may also be positioned at an angle to the face (see diagram below) The excavator swings from the dig zone to the left carrying the bucket over the side (rails) of the truck before placing the material in the body of the truck.

The basic operation for loading over the side is as follows: •

The excavator raises the load and positions it at right angles to the face

•

The truck operator backs under the bucket

•

The excavator sounds the horn when the truck is in the correct position or has reversed back sufficiently

•

The excavator tips the load from the bucket.

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2.3.6 Through the Gate Loading The excavator is positioned parallel to the face with the right track lined up along the cut line.

Trucks are positioned at an angle to the bench face and facing away to the left of the excavator.

The excavator swings from the dig zone to the left carrying the bucket through the gate of the truck before placing the material in the truck body.

The basic operation for through the gate loading is as follows: •

The excavator raises the load and positions it next at about 45o from the cut line

•

The truck operator backs under the bucket

•

The excavator sounds the horn when the truck is in the correct position or has reversed back sufficiently

•

The excavator tips the load from the bucket.

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2.3.7 Drive By Loading The excavator is positioned parallel to the face with the right track lined up along the cut line.

Trucks are positioned parallel to the bench face, preferably with the operator’s cabin on the excavator side. It is the responsibility of the excavator operator to ensure that the truck is positioned so that the counter weight clears the truck when the excavator is swinging.

The excavator swings from the dig zone to the left carrying the bucket through the trucks gate or over the side before placing the material in the truck body.

The basic operation for through drive by loading is as follows: •

The truck operator drives into position along the bench with the truck about 2.5 metres from the crest of the face

•

The e xcavator sounds the horn when the truck is in the correct position

•

The excavator raises the load and swings it over the trucks side

•

The excavator tips the load from the bucket.

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2.3.8 Loading Trucks Off the Same Level The excavator is positioned at floor level. Tracks can be facing either directly into the heap or at an angle across the face depending on the width of the bench.

Trucks are positioned at an angle to the to the bench face (if conditions allow).

The excavator swings from the dig zone to left and right carrying the bucket through the gate before placing the material in the truck body.

WARNING

Although truck loading can be carried out from either side, to prevent the excavator counter weight striking a truck, o nly one truck at a time should be positioned

The basic operation for loading trucks off the same level is as follows: •

The excavator raises the load and positions it to the left or right of the digger as close to the face as possible. Excavator operator must ensure that the truck is not in the path of the excavators counter weight when slewing

•

The truck operator backs under the bucket

•

The excavator sounds the horn when the truck is in the correct position or has reversed back sufficiently

•

The excavator tips the load from the bucket.

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ACT ON OR REPORT MONITORING SYSTEMS AND ALARMS Check Monitors When the ignition is turned ON the monitoring system will self-test.

Monitoring lamps will glow for about two seconds except for the alternator and pump transmission indicators, these two will stay on until the engine has started.

Oil Temperature

Water Temperature

Fuel

Tachometer

Fuel Level

Alternator

Hydraulic Oil Level

Pump Transmission Oil Pressure Overheat

Engine Oil Pressure

•

Fuel Gauge Indicates the amount of fuel in the fuel tank.

The E mark indicates there is less than 250 litres in the tank.

•

Hydraulic Oil Temperature Gauge Green zone indicates normal operating range. If the needle goes into the red zone, stop operation and run the engine at LOW IDLE until the needle returns to the green zone.

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Water Temperature Start the engine. Run at slow idle until the needle enters the green zone, indicating normal operating temperature.

If the needle enters the red zone, reduce the load immediately and run the engine at slow idle. If the problem continues, contact Maintenance.

To prevent damage to the engine: • Stop excavator to reduce load on the engine; and • Run engine at slow idle WARNING

DO NOT stop the engine when the needle enters the red zone, this will cause the temperature to increase.

•

Tachometer-Indicates engine speed in min1 x1000

•

Alternator Indicator - Glows red when the alternator output is low. Contact Maintenance

•

Pump Transmission Oil Pressure Indicator (Warning) Indicator will glow red on low pressure. Stop the engine and immediately contact Maintenance.

•

Engine Oil Pressure (Warning) - Indicator will glow red on low pressure. Stop the engine and immediately contact Maintenance.

•

Overheat Indicator - Indicates overheating of mechanical components. Stop the engine and immediately contact Maintenance.

•

Hydraulic Oil Level Indicator - Indicates that the hydraulic oil level is low

•

Fuel Level Indicator - will glow red when approximately 250 litres remain in the fuel tank.

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Hydraulic Oil Level (Warning)

Auto Idle

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Engine Room Light

Download

Entrance Light

Coolant Level

Pre-lube

Engine Oil Level

Travel Mode (Slow)

Travel Mode (Fast) Coolant Level (Warning)

Ladder Position (Warning) Fast Fill (Warning)

Auto-lube

Emergency Engine Stop (Warning)

Engine Stop (Warning)

Pump Contamination (Warning)

Engine Warning

Stop Valve (Warning)

•

Air Cleaner Restriction (Warning)

Engine Oil Level Indicator - When the level check switch is pushed, the green indicator will light if the engine oil level is adequate for operation.

NOTE

This check does NOT take the place of manual daily inspection.

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Coolant Level Indicator - When the level check switch is pushed, the green indicator will light if the engine coolant level is adequate for operation.

NOTE

This check does NOT take the place of manual daily inspection.

If you need to remove the radiator cap when the coolant is hot, take the following precautions, as hot coolant may spurt out: i)

Use Personal Protective Equipment (PPE) (eg gloves, face shield)

ii)

Cover the radiator cap with a rag

iii)

Release the pressure slowly (some caps have a pressure release button)

iv)

If fitted, fill via the expansion tank

WARNING

•

Download Indicator - The green indicator comes ON if the system memory is fully occupied. If the indicator comes ON, download the data.

•

Hydraulic Oil Level Indicator (Warning) Red light glows and buzzer sounds to indicate low hydraulic oil level. If this light is activated stop the engine immediately and contact Maintenance.

• Auto Idle - Glows when the auto -idle device is turned ON

•

Engine Room Light Indicator - Glows when the lights in the engine room and pump room are switched on.

•

Entrance Light Indicator - Glows when the entrance lights are switched on.

•

Pre-lube Indicator - When the ignition is turned to the START position, the pre-lube pump is operated between five and 45 seconds before the engine starts. The indicator glows during the pre-lube pump operation.

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Travel mode Indicator Slow speed - Lights up when slow travel speed is selected.

•

Travel mode indicator Fast speed - Lights up when fast travel speed is selected

•

Coolant Level (Warning) - If the coolant level is lower than the recommended level, the red indicator light comes ON and the buzzer sounds.

-

stop the engine immediately

-

check the coolant system for leaks and the coolant level.

-

refill the coolant as necessary.

If the red indicator comes ON and the buzzer continues sounding for 120 seconds, the engine will stop automatically.

As soon as the warning light comes ON, stop the engine.

WARNING

If the engine is operated with the coolant level lower than the recommended level, damage to the engine and/or radiator may result.

•

Auto Lubrication Indicator - Glows red to indicate faults in the auto grease circuit. The indicator will also light if the grease mode switch in the battery compartment is turned to MANUAL or OFF.

•

Engine Stop (Warning) - Glows red if any abnormality in the engine or systems occur. The engine may also stop automatically, or slow, depending on the severity of the fault. If this monitor lights up, park the machine and contact Maintenance.

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Engine Warning Indicator - Glows yellow if any abnormality in the engine(s) or system(s) occur. The excavator may be operated while the yellow light is glowing, however, engine performance may be restricted. Contact Maintenance if this indicator comes on.

•

Air Cleaner Restriction Indicator - Glows red when the air flowing through the filters is restricted. Contact Maintenance.

•

Pump Contamination Indicator - Indicates faults within any of the six pumps required for equipment operation. Contact Maintenance if the indicator glows.

•

Emergency Stop Indicator - This indicator will glow when any of the engine stop switches, located in either the cab or pump room, have been turned to EMERG STOP position.

Indicator will go out once the switch/s return to the NORMAL position.

•

Ladder Position Indicator - Any time the ladder is down or partially down the Ladder Position indicator will glow red and the machine slew will be disabled.

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RECOGNISE & RESPOND TO HAZARDOUS AND EMERGENCY SITUATIONS

2.6.1 Fire – Check the following at the beginning of every shift: •

All extinguishers are fully charged

•

Automatic Fire Suppression Warning System is working

2.6.2 Fire Suppression System – operates the mobile equipment’s fire control system.

An indicator panel is mounted in the cab and provides an audible and visual indication of any fire.

If a fire is detected the, engine will automatically shutdown after 10 seconds.

The panel should be tested daily, as follows: •

Check that the green, power ON light, is lit (NORMAL)

•

Press the ALARM TEST button:

•

-

the red ALARM indicator should glow

TEST

-

after a short alarm verification delay the red FIRE indication will flash

-

the audible alarm will sound

-

after the time delay period the engine will shut down

Press the ISOLATE and RESET button twice after the test. To return the panel to normal.

The ISOLATE button will silence the audible alarm during a test or an alarm but will not extinguish the alarm FIRE indicator. By pressing the RESET button during a test or an alarm the 10 seconds delay will start again.

A fault condition can occur if the battery voltage drops below the required supply voltage NOTE

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Auxiliary Fire System Attachment (Deluge System) Additional foam/water can be supplied to the system through the attachment of a fire hose to the mobile equipment that is connected to the fire/rescue unit.

Fire Suppression System Operating Procedure In the event of a fire, fire suppression system will actuate automatically if the fire is in the protected area. The fire suppression system can be manually operated as follows: •

Park the excavator

•

Stop the engine (to minimise the addition of fuel)

•

Remove the safety pin from the remote actuator

•

Strike the knob firmly

•

Evacuate the area and take a hand held fire extinguisher with you if possible.

•

Call for help and stand watch over the excavator until help arrives.

(Even though the fire may be out, re-ignition could occur)

NOTE

i. Leaving the engine running may add fuel to the fire or restart the fire ii. React quickly so that the fire is caught before it gets too large. iii. Leave the immediate area to reduce the risk of being burnt by wind-blown flames or explosions iv. Someone should observe the excavator, at a safe distance, until the danger of re-ignition has passed. v. After a fire the excavator should be serviced and cleaned the fire investigated and the fire suppression system recharged.

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Fire Emergency Procedure •

Park the unit

•

Shut down engine

•

Call “Emergency, emergency, emergency, fire (give your unit number and location)” on the two way radio (as per emergency procedure)

•

Fight the fire, using the fire extinguishers on your equipment (usually located inside the cab, outside the cab and on the access stairs)

NOTE

Fight the fire by aiming the fire extinguisher at the base of the fire.

You should only fight fires if you are not in any personal danger.

WARNING 2.6.4

Emergency Evacuation

NOTE

The emergency exit instructions are applied as decals to the left window, located near the front side on left console.

If the operator’s cab door doesn’t open in an emergency, escape in the following methods: Emergency Exit Decal

• •

Open the left window Escape through the window

If the left window is difficult to open • • •

Locate the Emergency Evacuation Tool Break the left window glass Escape through the broken window.

Emergency Evacuation Tool

Wear safety glasses before breaking the window glass.

WARNING

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Emergency Escape Device The Emergency Escape Device is provided in a case located outside, on the left of the cab. To use the (EED): •

Unlock the latch on the case

•

Open the cover

•

Hang the hook onto the cab upper-left surface hanger

•

Drop the rope wound reel

•

Fasten the life belt around your chest

•

Hold the two ropes; and

•

Climb over the fence

•

Face towards the cab (as long as you hold the two ropes the emergency escape device will not operate.)

•

Release the ropes (you should commence to descend slowly)

•

Push against the excavator (gently) to prevent your body from turning

When you reach the ground: •

Remove the life belt; and

•

Evacuate to a safe place

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2.6.6 Accidents – All accidents, incidents and near hits must be reported.

If you are involved in an accident, make an emergency call and stay with your equipment until your supervisor reaches you.

The accident will be investigated by an open cut examiner, your supervisor and the safety department.

NOTE

Your co-operation is essential in identifying causes and to help in preventing a similar accident happening again.

Near miss/Hazard Reports are particularly important as they indicate potential accidents. (The only real difference between an accident and an incident/near miss is the result, in an accident someone is injured and/or equipment damaged, in an incident/near miss the causes may be the same as an accident but there is no obvious loss – i.e. injury/damage)

(Refer to the Health and Safety Department or your site induction booklet for details of Reports and reporting).

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Wet Conditions may be environmental (e.g. rain) or man-made (e.g. water truck)

WARNING

Due to their low ground pressure, trucks are usually unpredictable in wet conditions Allowances need to be made for the safe positioning of trucks in wet conditions

Manufacturers have a Permissable Water depth (PWD) for equipment operation (Check the Manufacturers’ Manual). The PWD for the EX2500/EX3600 is just below the upper surface of the top rollers (1500 mm) to avoid water entering into any oil reservoirs.

2.6.8

Boggy Conditions – it is possible to get bogged in muddy conditions. If you think the excavator is becoming bogged down avoid spinning the tracks (this will only make the situation worse).

You may be able to gain traction by using the bucket to help pull the machine from the bog.

Although it may be embarrassing call for assistance BEFORE you get in too deep.

2.6.9

Inclines can often be very dangerous for heavy mobile equipment.

Avoid sideways operation on inclines. Excavators can easily tip under these circumstances.

WARNING As you descend, avoid engine overspeed.

Always carry the load forward up an incline.

WARNING

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Factors that will affect the type (grade) of incline you should attempt include: •

Condition of the ground

•

Direction of travel

When ascending an incline: • Maintain high engine revolutions • Extend the bucket forward • Carry the bucket low to the ground If the slope is too steep, the excavator may develop a jerky, bucking motion, that can turn into a slide.

If the excavator begins to slip sideways, turn into the downgrade as quickly as possible.

If the engine stalls while working or travelling on an incline, lower the bucket immediately and stop the excavator. Restart the engine.

2.6.10

Rough Conditions – You should always keep work areas as level as possible. This will provide you with: •

A surface easier to operate over

•

Less fatigue for you and the truck operators

•

Less damage to the excavator and/or trucks

To maintain a smooth surface, clean any spillage from the floor after each truck where possible or contact grader/dozer to assist

WARNING

Avoid excessive spinning/screwing of the tracks.

Spinning can cause ruts that may possibly tip or other equipment

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Light Vehicle Interaction – Although you are seated high off the ground on an excavator your vision is restricted because of blind spots.

While “it is the responsibility of drivers of light vehicles to ensure their own …..safety”…, you also have a responsibility to ensure the safety of yourself and others.

Operators of a light vehicle are required to ask your permission before parking within 30 metres of your excavator. (Refer to Mine Traffic Rules) Always sound your horn: Once (1) Pause 5 seconds: Before starting WARNING

2.6.12

Twice(2) Pause 5 seconds:

Before moving forward

Three times (3) Pause 5 seconds:

Before reversing

Heavy Equipment Interaction – Normal traffic conventions governing right of way apply at CQMPL as prescribed in the Transport Operations (Road Use Management) Act. For details refer to the Mine Traffic Rules issued at your site induction.

2.6.13

Overhead Obstructions – All mobile equipment must maintain a safe working distance of at least three (3) metres vertical and six (6) meters horizontal from any power lines (Refer to SOP FMP002).

If power line contact occurs: •

Stay where you are

•

Keep everyone away

•

Do not allow anyone to touch the crane or load

•

Move the crane off the wire if possible

•

If you have to get out, JUMP don’t step down

WARNING

It is not necessary for mobile plant to touch a power line or power source to become electrified. Electricity can jump or arc across to the plant’s structure or load.

Stay away from mobile plant if it working close to power lines. The plant may become electrified and deadly.

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2.6.14 Faulted High Walls – You must assess the risk under any faulted high walls because each situation will be different.

As a general rule follow the precautions below: •

Maintain a safe distance from the fault and the wall itself

•

Don’t park under a fault (e.g. changeover)

•

Don’t drive underneath a fault they can collapse at anytime

•

Assess the risk constantly (e.g. falling overburden)

•

Warn others of any danger

If you are working on the top of a faulted high wall you must carry out a visual inspection for any faults (or developing faults along the edge).

If there is any evidence of faulting (e.g. cracks along the wall edge) contact your supervisor and/or the Open Cut Examiner (OCE).

If faulting has been marked out (e.g. witches hats and/or stakes), seek advice on safe operation.

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Dangerous Fluids - You may be exposed to dangerous fluids particularly when equipment is at operational temperature e.g.: •

Oil (engine, transmission, hydraulic)

•

Coolant (radiator)

•

Battery Acid

Be sure to wear/use the appropriate Personal Protective Equipment (PPE) when checking fluids e.g.

2.6.16

•

Mask/goggles

•

Gloves

•

Protective clothing

Slippery steps and handrails – operators still fall off equipment when mounting or dismounting. Slippery steps and handrails are dangerous and difficult to avoid in some circumstances. When you have to mount or dismount equipment: •

Always face the equipment

•

Climb all the way to the ground (don’t jump!)

•

Use the “three point technique” by ensuring that three of your four limbs are in contact with the equipment at all times. (i.e. two feet or one hand or two hands and one foot). This technique provides you with support and reduces the risk of falling if you do slip.

Three Point Access

2.6.17 Stopping Engine for Electrical Malfunction •

Turn the engine start switches to OFF

If the engines do not stop: •

Depress the emergency stop button at the rear steps

NOTE

DO NOT operate the excavator until checked by maintenance.

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COMPLETE WORK TO PLANNED OUTCOMES (Refer Mining Department Area Specific Induction)

Conduct Formative Assessment

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RELOCATE EXCAVATOR

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MNCO1027A Conduct Hydraulic Shovel/Excavator Operations

Hitachi EX2500/EX3600 Excavator Element 1027.3

Relocate Excavator

Performance Criteria 1027.3.1

Receive and confirm, route and location plan if necessary by site inspection.

1027.3.2

Complete and/or follow ground preparation including pads, roads and ramp according to site requirements.

1027.3.3

Resolve coordination personnel.

1027.3.4

Relocate excavator in accordance with manufacturer’s and/or site requirements.

CT 3.1

RECEIVE & CONFIRM ROUTE & LOCATION PLAN (Refer Mining Department Area Specific Induction)

issues,

including

support

equipment

and

Routes are determined by supervisors and/or operators. To do this they may utilise survey maps, production plans and planning meetings to identify the best possible path.

Excavator operators may be required to check out the proposed route and alert the supervisor to any concerns that they may have including: •

Hazards/risks

•

Obstacles that may create problems when preparing or moving the excavator

•

Environmental issues

The excavator operator should be prepared to offer any solutions they may have to overcome their concerns.

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COMPLETE AND/OR FOLLOW GROUND PREPARATION

3.2.1 The excavator needs to be level when working to provide the operator with a base that allows the tub to swing freely from the pick up area to the loading area without needing to adjust the height of the bucket up or down.

There are a few ‘ground’ rules to observe when constructing a work pad/area for the excavator: •

Assess the area – check the area from the excavator and from ground level, on foot

•

Identify hazards – when you locate any hazards carry out a risk assessment and agree on corrective actions

•

Cleared - of mud/rubbish and backfilled with good, dry soil (particularly in low areas). Leaving mud underneath dry soil fill will cause the excavator to tip and create imbalance, this can cause mechanical wear issues and in extreme cases cause the excavator to tip on its side.

Do not bury mud under any circumstances NOTE •

Level - if necessary using a grader for the final finish

•

Flat - to provide access to the material being shifted as quickly as possible

•

Free of Rocks, Stumps and Bulldust – any bulldust must be graded off before operating the excavator.

Bulldust will cause the excavator to ‘dry bog’

•

Watered – to reduce dust and increase visibility

WARNING CT 3.3

Too much water is dangerous (and wasteful) and may cause the excavator to slide, sink or bog

RESOLVE CO-ORDINATION ISSUES, SUPPORT EQUIPMENT & PERSONNEL (Refer Mining Department Area Specific Induction)

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RELOCATE EXCAVATOR

3.3.1 Before you begin to tram the excavator, you must determine the direction that the tracks are facing.

FRONT

The travel motors are designed to be at the rear of the track assembly during forward travel, so that when you press down on the front of the travel pedals, the excavator will move forward.

When travelling, select a route that is as flat as possible and allows maximum travel distance without turns. When turning, make small incremental changes in direction rather than sharp turns.

Conduct Formative Assessment

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OPERATOR MAINTENANCE

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MNCO1027A Conduct Hydraulic Shovel/Excavator Operations

Hitachi EX2500/EX3600 Excavator Element 1027.4

Operator Maintenance

Performance Criteria 1027.4.1

Carry out excavator/shovel inspections and fault finding in accordance with the manufacturer’s instructions and site requirements.

1027.4.2

Carry out routine operational servicing, lubrication and housekeeping tasks in accordance with manufacturer’s instructions and site authorised procedures and practices.

1027.4.3

Carry out minor maintenance to manufacturer’s instructions and site requirements.

1027.4.4

Provide operator support during preparation for, and conduct of, major maintenance tasks in accordance with site requirements.

1027.4.5

Process records in accordance with site requirements.

EX25/36 4.1

CARRY OUT INSPECTIONS & FAULT FINDING

4.1.1 Excavator Inspections It is the operator’s responsibility to carry out Pre-operational Checks and In Operational Checks on the Excavator prior to operation (Refer to checklists at front of 2.2 Carry Out Pre-Start, Start-Up, ParkUp & Shutdown Procedures) Any faults wear or damage should be reported to your Supervisor or Maintenance. A Work Request Form is available for this purpose. Safe operation issues should be reported immediately.

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CARRY OUT ROUTINE OPERATIONAL SERVICING, LUBRICATION, MAINTENANCE & HOUSEKEEPING Running Checks •

Running repairs to minor components and attention to defects prevent the condition becoming worse

•

Running Checks involve the ongoing checks of:

•

Fluid levels

•

Control and switch functions

•

Instrumentation monitoring

•

Audible changes that indicate malfunctions

Daily Servicing Daily servicing involves the replenishing of lubricants and/or filters to ensure long-term mechanical operation. Servicing / refuelling may be carried out in the field by the Service Truck, or in the Lube Bay. When you take the excavator in for a daily service to the Lube Bay, the following procedure must be observed: •

Proceed to the lube bay

•

Stop before entering

•

Select low idle

•

Enter the service bay slowly

•

Position the excavator so that the fuel,oil and grease hoses can reach the fast-fill compartment

•

Park according to the park-up prodedures

•

Apply the park brake

•

Lower the bucket

•

Set the Pilot Control Shut Off lever to LOCK

NOTE

When the bucket needs to be in the raised position they must be securely supported by blocks.

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Shutdown the engines using the correct procedure (Refer to 2.2 Carry Out Pre-Start, Start-Up, Park-Up & Shutdown Procedures)

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Top up fluid levels as necessary (refer to the pre-start check-list)

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Top up oil, fuel and grease levels

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Disconnect all hoses when servicing is finished

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Restart the engine using the correct procedure (Refer to 2.2 Carry Out Pre-Start, Start-Up, Park-Up & Shutdown Procedures)

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Give two blasts on the horn and wait 5 seconds, (to warn personnel that you are about to move out of the lube bay)

Preventative maintenance Preventative maintenance involves the inspection of components by analysis and oil sampling. This provides the ability to forecast the life of that component.

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EX25/36 4.3

CARRY OUT MINOR MAINTENANCE

4.3.1

training

Maintenance items are carried out by the Maintenance Department either in the field, on call out or, in the workshop. It is the responsibility of the operator to contact and report any maintenance repair needs at the beginning, during and at the conclusion of the shift.

If fuses are frequently blown or if there are traces of short circuit on the electrical wiring, contact maintenance to carry out repair.

WARNING

Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause fire, so always check and remove such material.

Keep the top surface of the battery clean and' check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.

Operators are only to carry out minor maintenance when authorised to do so.

WARNING

4.3.2

Replace bucket teeth Teeth on the bucket have to be replaced to maintain efficiency. The process is as follows:

WARNING

i) ii) iii)

Refer to SOP, WP and/or WI Use Personal Protective Equipment Ensure the tools you use are safe and in good condition

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Locate new set of teeth (warehouse)

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Locate tools equipment eg: -

hammer drift (short and long) screw driver

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Lower the bucket to the ground with the teeth at an angle suitable for the crew to swing the hammer at knee height and hit the drift to punch out the pins holding the teeth

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Punch out the pins using a short drift to start the pin moving and then a longer drift to complete the task

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Strike the teeth on the flat face with the hammer to release them from the adaptor

DO NOT strike the teeth on the sharp edge with the hammer WARNING

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Clean the surface of the adaptor

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Rest the snap rings in place

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Slide the new tooth over the adaptor

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Hammer the pins home

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4.3.3

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR OPERATIONS Hitachi EX2500/EX3600 Excavator

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Reporting Defects and Hazards A prime step in good maintenance is the prompt reporting of equipment defects. Defects that can be noted and repaired will lead to a safer and more efficient work environment.

Report to Maintenance: •

Verbally, to your supervisor or maintenance

•

By Work Request

•

TAGGING (Out of Service, Information, Danger)

To work safely means being able to manage hazards and not allow hazards to generate incidents.

Until a hazard is eliminated it is essential that all operators are aware of the accident potential associated with the hazard. Near Miss/Hazard Reports must be completed if you identify a hazard in the workplace or on the unit.

Equipment inspection and reporting of defects and hazards is an operator's responsibility.

Near Miss/Hazard reports must be lodged with your Supervisor.

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EX25/36 4.4

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR OPERATIONS Hitachi EX2500/EX3600 Excavator

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PROVIDE SUPPORT FOR PREPARATION & CONDUCT OF MAJOR MAINTENANCE

4.4.1 There will be the occasion where maintenance technicians will need assistance to locate and/or repair a fault or maintenance item. The operator is ofte n the best person to assist.

In the case of a major repair or maintenance the operator may be called upon to help to carry out housekeeping and cleanup of the Excavator and operate the Excavator in particular environments (e.g. for troubleshooting)

CT 4.5

PROCESS MAINTENANCE RECORDS (Refer Mining Department Area Specific Induction)

Conduct Formative Assessment

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