hitachi ex2500 and ex3600 - reference material.pdf
TRANSCRIPT
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LEARNING NOTES
Design & Development
by
www.Worklleeaarrnn.com Phone: 61 7 3869 0220
training
MNCO1027A
CONDUCT
EXCAVATOR/HYDRAULIC SHOVEL OPERATIONS
HITACHI EX2500 & EX3600 EXCAVATOR
EX2500
EX3600
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Version 01/06/05 MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR
OPERATIONS Hitachi EX2500/EX3600 Excavator
training
Curragh Queensland Mining Pty Ltd is part of Wesfarmers Energy 1
Worklleeaarrnn
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
Designation: RTO Coordinator
Phone: 49 869 247
Approved: ....
Date:
Record of Issues
Issue No Issue Date Nature of Amendment
001/06/05 June 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 Explanation
CT Mining Department Area Specific Induction
EX25/36 Hitachi EX2500 and EX3600 Excavator
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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
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 Complete Work to Planned Outcomes (Refer Mining Department Area Specific Induction)
69
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 Resolve Co-ordination Issues, Support Equipment & Personnel (Refer Mining Department Area Specific Induction)
72
EX25/36 3.4 Relocate Excavator 73
Formative Assessment
CONTENTS
2.3 & 2.4 are reversed in the Learning Notes & Assessment
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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 Process Maintenance Records (Refer Mining Department Area Specific Induction)
81
Formative Assessment
CONTENTS (Continued)
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HITACHI EX2500/EX3600 EXCAVATOR
GREEN sections coded :
EX25/36 relates to the Hitachi EX2500 and EX3600 EXCAVATOR
WHITE sections coded CT relates to Mining
Department Area Specific Induction
1027.1 PLAN & PREPARE FOR
OPERATIONS
1027.3
RELOCATE EXCAVATOR
1027.2
OPERATE EXCAVATOR
CT 1.1 Obtain, Interpret & Clarify
Work Requirements
CT 1.2 Access, Interpret & Apply Geological & Survey Data
CT 1.3 Access & Apply Safety
Information
EX25/36 2.2 Carry out Pre-start, Start Up, Park-up
& Shutdown Procedures
EX25/36 2.5 Act on or Report Monitoring Systems
& Alarms
EX25/36 3.2
Complete and/or Follow Ground Preparation
CT 3.3 Resolve Co-ordination
Issues, Support Equipment & Personnel
EX25/36 3.4
Relocate Excavator
CT 2.1 Resolve Co-ordination Requirements
with Others
CT 2.7 Complete Work to Agreed
Planned Outcomes
Formative Assessment
Formative Assessment
Formative Assessment
CT 1.4 Co-ordinate Preparation of
Work Area
EX25/36 2.6 Recognise & Respond to Hazardous
and Emergency Situations
EX25/36 2.3
Select Loading Method
1027.4
OPERATOR MAINTENANCE
EX25/36 4.1 Carry out Inspections & Fault
Finding
EX25/36 4.2
Carry out Routine Operational Servicing, Maintenance,
Lubrication & Housekeeping
EX25/36 4.4 Provide Support for Major
Maintenance
CT 4.5 Process Maintenance
Records
EX25/36 4.3
Carry out Minor Maintenance
Formative Assessment
EX25/36 2.4 Conduct, Control & Monitor Dig
Procedures
CT 3.1 Receive & Confirm Route &
Location Plan
2.3 & 2.4 are reversed in the Learning Notes
& Assessment
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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 manufacturers 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 manufacturers instructions and site procedures including those covering truck loading.
1027.2.5 Act on or report monitoring systems and alarms are in accordance with manufacturers 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 anti-clockwise 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 Operating controls, horn, gauges q Seat and seat belt q Air conditioner and filters q Mirrors and windows q Operating pedals q Floor q Fire Suppression System q Lights, two-way and instruments
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Level Cylinder
Boom
Cab
Arm
Bucket
Bucket Cylinder
Arm Cylinder
Front Idler
Track Adjuster
Upper Roller
Lower Roller
Side Frame
Accumulator Swing Bearing
Swing Device
Travel Device
Radiator
Control Valve
Engine
Counterweight
Hydraulic Oil Tank
Pump
Oil Cooler
High Pressure Strainer
By Pass Filter
Hydraulic Oil Tank
Swing Device
Lubricator
Emergency Escape Device Hangar
Emergency Escape Device
Centre Joint
HITACHI EX2500/EX3600 EXCAVATOR
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Level Cylinder
Boom Cylinder
Boom Cab
Swing Device
Lubricator
Oil Cooler
Hydraulic Tank
Muffler
Battery
Arm
Bucket
Dump Cylinder
Bucket Cylinder
Arm Cylinder
Washer Tank
Fuel Tank
Front Idler
Track Adjuster
Upper Roller
Side Frame Accumulator
Ladder
Lower Roller
Travel Device
Radiator
Control Valve
Engine
Counterweight
Pump
Air Cleaner
HITACHI EX3600 EXCAVATOR
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EX25/36 2.2 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.
WARNING
Ensure body parts are kept clear of the path of the ladder when raising the ladder from the upper level.
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.
Hanging Rings Ground Level
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
Radiator Cap
Coolant Level Gauge
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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:
- 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)
EX2500 EX3600
Oil Filler Cap
Oil Dipstick
Dipstick
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Fuel
Fuel Level (for pre start
inspection) Check using the sight glass located on the side of the fuel tank, add fuel as necessary
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.
EX3600
Dipstick
EX2500
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Sight Glass
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 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 Operators Seat
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.
Seat Fore/Aft Adjustment
Cushion Angle Seat Damper
Back-rest Adjustment
Console Fore/Aft Adjustment
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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 anti-clockwise 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 anti-clockwise 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
WARNING
Before fastening the seat belt, inspect
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
WARNING
Check that there are no kinks in the belt.
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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Hydraulic Oil
Coolant
Engine Oil
Pilot Control Shut Off
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
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. Call Maintenance for advice/assistance
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 operators console.
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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Pilot Control Shut
Engine Speed Control
Emergency Stop
Ignition Key
2.2.7 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.
Check that all levers are in NEUTRAL (N)
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 engine
Release the key once the engine has started, or after ten seconds with out starting.
NOTE
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
NOTE
Contact maintenance if any of the warning lights above fail to glow.
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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Ether Container Holder
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
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
NOTE
Ether is injected into the engine automatically.
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ON OFF
Pre-heat Cut Off Switch
Relay Box
Pre-heat Cover & Switch
Pre-heat Indicator
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 than 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. Remove the Relay Box
cover
Turn the preheat cut-off switch ON.
Turn the ignition key switch the ACC position.
Open the preheat switch cover
Turn the preheat switch ON (the preheat indicator will glow) to indicate:
- 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
WARNING
If the monitor lamps do not go out after starting the engine:
Stop the engine immediately Call Maintenance for assistance
Run the engine under light load until the engine coolant and hydraulic oil gauges are in the green or white range
Ensure the alternator monitor lamp is OFF
Ensure the transmission pump oil pressure lamp is OFF
Ensure the engine oil pressure lamp is OFF
Ensure the engine stop lamp is OFF
Operate the excavator controls with no load applied to circulate warm oil through the hydraulic system
Check for:
- normal exhaust colour
- abnormal vibration
- abnormal noise
Hydraulic Oil Temperature Engine Oil Temperature
Alternator
Transmission Oil Pump
Engine Oil Pressure
Engine Stop
Exhaust Gas Colour - Quick Check CCCooolllooouuurrrlll eeessssss ooorrr fffaaaiii nnnttt bbbllluuueee: normal (proper
combustion)
Black: abnormal (improper combustion)
WWhhiittee :: 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
WARNING
if you must park on a grade:
Thrust the bucket teeth into the ground
Block both tracks
Lower the bucket to the ground
Turn the auto-idle switch OFF
NOTE
The turbocharger may be damaged if the engine is not correctly shut down.
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
Ignition Key
Speed Control Lever Pilot Control Shut Off Lever
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EX25/36 2.4 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)
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.
WARNING
Avoid changing direction in high speed.
Before changing direction check for hazards and people. When driving over rough terrain, reduce engine speed to lessen possibility of undercarriage damage.
Neutral
FORWARD
REVERSE
Right Left
Footrest Footrest
Right Left
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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.
NEUTRAL
FORWARD
REVERSE
Left Right
Left Right
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Pilot Control Shut Off
Engine Speed Control Lever
Allows the operator to regulate speed of the engine.
To operate:
Move the lever FORWARD for LOW and BACKWARDS for HIGH
NOTE
The Engine Speed Control lever should be in the LOW (idle) position to start the engine.
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
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 lever down to the UNLOCK position
WARNING
Ensure that the Pilot Control Shut Off lever is moved fully into the lock position before leaving the operators seat.
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.
LOW HIGH
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2.4.3 Bucket Controls
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
NOTE
The lever will return to the HOLD/NEUTRAL position if released in any selected position.
Arm IN
Bucket Roll OUT
Slew RIGH
T
Arm OUT
Slew LEF
T
Bucket Roll IN
Boom UP
Boom DOWN
NEUTRAL
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Starter Switch
Emergency Stop
2.4.4 Buttons and Switches
Emergency Stop Switch (Cab) located on the back of the right hand bucket control, above the start keys.
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
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
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 Switches
EX2500
Engine Emergency Stop
EX3600
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Microphone Button
Microphone
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
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.
OFF (engine)
ACC (horn, radio etc)
ON (Engine electrical)
START (engine)
IGNITION SWITCH
EMERGENCY STOP
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Wiper Switch
Wiper Delay Switch
Washer Button
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 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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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.
Working Lights
Fast Fill
Auto Idle
Travel Speed
Entrance Light
Engine Room Light
Interior Light
EX2500 Auxiliary
EX3600 Preheat
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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 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.
Warning Lights Test
Fluid Level Check
Buzzer Stop
Dimmer
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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
WARNING
Always stop the excavator before changing the travel mode speed. To decrease the travel speed, for travelling on a slope or in a tight space, press the switch to the turtle position.
NOTE
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 its 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 27 Off Horizontal 51%
3:1 Slope 18 Off Horizontal 32.5%
4:1 Slope
14 Off Horizontal 24.9%
WARNING
Avoid travelling across (right angles) a slope.
If you must walk across a slope: Keep the bucket close to the ground (.5 1 metre) Do not swing downward on a slope
2 M
1 M
3 M
1 M
4 M
1 M
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DEGREES PERCENT - SLOPE
Degrees Percent Degrees Percent Degrees Percent
1
2
3
4
5
1.8
3.5
5.2
7.0
8.8
16
17
18
19
20
28.7
30.6
32.5
34.4
36.4
31
32
33
34
35
60.0
62.5
64.9
67.4
70.0
6
7
8
9
10
10.5
12.3
14.0
15.8
17.6
21
22
23
24
25
38.4
40.4
42.4
44.5
46.6
36
37
38
39
40
72.7
75.4
78.1
81.0
83.9
11
12
13
14
15
19.4
21.3
23.1
24.9
26.8
26
27
28
29
30
48.8
51.0
53.2
55.4
57.7
41
42
43
44
45
86.9
90.0
93.3
96.6
100.0
100
90
80
70
60
50
40
30
20
10
0
90 80
70 60
50
40
30
20
10
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.
WARNING
Avoid working across a slope (eg at right angles). If you must work across a slope:
Start at the top
Maintain a windrow on the low side of the excavator to provide stability
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EX25/36 2.3 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.
NOTE
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
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 over 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 operators 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 excavator 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, only 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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EX25/36 2.5 ACT ON OR REPORT MONITORING SYSTEMS AND ALARMS
2.5.1 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.
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.
Fuel
Oil Temperature Water Temperature
Tachometer
Fuel Level
Engine Oil Pressure Overheat
Pump Transmission Oil Pressure
Alternator
Hydraulic Oil Level
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E N G I N E
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.
WARNING
To prevent damage to the engine: Stop excavator to reduce load on the engine; and Run engine at slow idle
DO NOT stop the engine when the needle enters the red zone, this will cause the temperature to increase.
Tachometer-Indicates engine speed in min-1x1000
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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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.
Download
Engine Oil Level
Hydraulic Oil Level (Warning)
Coolant Level
Travel Mode (Fast)
Travel Mode (Slow)
Pre-lube
Entrance Light
Engine Room Light Auto Idle
Coolant Level (Warning)
Auto-lube
Engine Stop (Warning)
Engine Warning
Ladder Position (Warning)
Fast Fill (Warning)
Emergency Engine Stop (Warning)
Pump Contamination (Warning)
Stop Valve (Warning)
Air Cleaner Restriction (Warning)
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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.
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.
WARNING
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
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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.
WARNING
As soon as the warning light comes ON, stop the engine. 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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EX25/36 2.6 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 equipments 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 TEST indicator should glow
- 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.
NOTE
A fault condition can occur if the battery voltage drops below the required supply voltage
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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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2.6.3 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.
WARNING
You should only fight fires if you are not in any personal danger.
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 operators cab door doesnt open in an emergency, escape in the following methods:
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.
WARNING
Wear safety glasses before breaking the window glass.
Emergency Evacuation Tool
Emergency Exit Decal
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2.6.5 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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2.6.7 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.
WARNING
Avoid sideways operation on inclines. Excavators can easily tip under these circumstances.
As you descend, avoid engine overspeed.
WARNING
Always carry the load forward up an incline.
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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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2.6.11 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)
WARNING
Always sound your horn: Once (1) Pause 5 seconds: Before starting Twice(2) Pause 5 seconds: Before moving forward Three times (3) Pause 5 seconds: Before reversing
2.6.12 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 dont 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 plants 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
Dont park under a fault (e.g. changeover)
Dont 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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Three Point Access
2.6.15 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.
Mask/goggles
Gloves
Protective clothing
2.6.16 Slippery steps and handrails operators still fall off
equipment when mounting or dismounting. Slippery steps and handra