Beruflich Dokumente
Kultur Dokumente
MNCO1027A
CONDUCT
EXCAVATOR/HYDRAULIC SHOVEL OPERATIONS
EX2500
EX3600
LEARNING NOTES
Design & Development
by
www.
Worklea rn .com
Phone:
61 7 3869 0220
Version 01/06/05
training
Worklearn
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.
Wesfarmers Energy
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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
Wesfarmers Energy
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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:
topsoil
overburden
coal
interburden or partings
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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
Page
Element 1027.1 PLAN & PREPARE FOR OPERATIONS (Refer Mining Department
Area Specific Induction)
11
12
EX25/36 2.2 Carry Out Pre-start, Start Up , park-up and Shutdown Procedures
16
46
29
53
59
CT 2.7
69
Receive & Confirm Route & Location Plan (Refer Mining Department Area
Specific Induction)
71
72
CT 3.3
72
73
Formative Assessment
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CONTENTS (Continued)
OPEN CUT PRODUCTION COMPETENCIES
Page
75
EX25/36 4.2 Carry Out Routine Operational Servicing, Lubrication, Maintenance &
Housekeeping
76
78
81
CT 4.5
81
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1027.2
1027.3
1027.4
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
CT 3.3
Resolve Co-ordination
Issues, Support Equipment &
Personnel
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
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
EX25/36 4.3
CT 4.5
Process Maintenance
Records
Formative Assessment
CT 2.7
Complete Work to Agreed
Planned Outcomes
Formative Assessment
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Performance Criteria
1027.1.1
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
1027.1.4
CT 1.1
CT 1.2
CT 1.3
CT 1.4
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OPERATE EXCAVATOR
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Performance Criteria
1027.2.1
1027.2.2
1027.2.3
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
1027.2.6
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
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Left track for correct adjustment (ie tracks resting on centre wear plate)
Right track for correct adjustment (ie tracks resting on centre wear plate)
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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
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Cab
Lubricator
Boom
Level Cylinder
By Pass Filter
Arm
Control Valve
Arm Cylinder
Pump
Centre Joint
Counterweight
Front Idler
Engine
Track Adjuster
Radiator
Upper Roller
Swing Device
Lower Roller
Accumulator
Side Frame
Swing Bearing
Travel Device
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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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EX25/36 2.2
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Ensure body parts are kept clear of the path of the ladder
when raising the ladder from the upper level.
WARNING
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
Hanging Rings
Ground Level
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WARNING
EX2500
EX3600
Coolant Level
Gauge
Radiator Cap
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EX2500
check the oil burn reservoir under the excavator (the level should
show at least half in the sight glass)
EX3600
Oil Filler Cap
Oil Dipstick
Dipstick
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Fuel
remove dipstick
The oil must be maintained between the upper and lower marks on
the dipstick.
EX2500
EX3600
Dipstick
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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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to adjust the seat only, lift the Seat Fore/Aft Adjustment bar
while pushing or pulling the seat in the direction required.
Headrest adjustment
The headrest can be adjusted both in angle and height.
NOTE
Adjust the seat so that you can easily depress the foot
pedals.
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WARNING
Adjust the seat so that the brake pedal can be depressed all the way
with your back against the back rest
Secure the belt by placing the tongue into the socket attached to the
seat
WARNING
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alternator indicator
Call
Hydraulic Oil
Coolant
Engine Oil
NOTE
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2.2.7
training
Start-up (Normal)
Start the unit as follows:
Release the key once the engine has started, or after ten seconds
with out starting.
NOTE
Emergency Stop
Ignition Key
Check that the warning lights glow for approximately two seconds
after the ignition key is turned to the ON position
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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EX2500
WARNING
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)
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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
Relay Box
Pre-heat Indicator
NOTE
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Warm up the engine for no less than five (5) minutes, under no load
and at mid range engine speed
Run the engine under light load until the engine coolant and hydraulic
oil gauges are in the green or white range
Engine Stop
Alternator
Engine Oil
Pressure
Transmission Oil
Pump
Check for:
C
Coolloouurrlleessss oorr ffaaiinntt bblluuee: normal (proper
combustion)
abnormal vibration
abnormal noise
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Move the engine speed control lever to the slow idle position
NOTE
Ignition Key
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EX25/36 2.4
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2.4.1 Foot Controls. The foot/centre front hand controls are used to manage
the travel movements of the excavator.
NOTE
FORWARD
Left
Right
Footrest
Footrest
Neutral
Left
Right
REVERSE
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
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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
Right
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HIGH
LOW
Confirm that Pilot Control Shut Off lever is in the LOCK position
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 operators seat.
WARNING
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Slew
RIGH
T
Slew
LEF
T
Arm
IN
Boom
UP
Bucket
Roll
OUT
NEUTRA
L
Bucket
Roll
IN
Boom
DOWN
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Emergency Stop
NOTE
Starter Switch
WARNING
EX2500
EX3600
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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
-
Washer Button
WARNING
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EX2500
Auxiliary
EX3600
Preheat
Auto Idle
Entrance Light
Interior Light
Working Lights
Fast Fill
Travel Speed
Fast fill Switch operates the service point arm located under the
back of the excavator.
-
NOTE
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
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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.
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.
ON press the button IN. (The interior light comes on when the
switch is depressed)
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Warning Lights
Test
Fluid Level Check
Buzzer Stop
Dimmer
press the Warning Lights Test switch and check that the
remainder of the lights are glowing
Buzzer Stop Switch - use this button to reset the warning buzzer
after an alarm event. The buzzer will sound again at the next event.
NOTE
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Horn Button
Turn the park brake switch to OFF (to release the park brake)
Sound the horn (twice (2) for forward) (three (3) times for reverse)
pause five (5) seconds
NOTE
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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
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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%
WARNING
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60
80
70
60
50
50
40
40
30
30
20
20
10
10
0
Degrees
Percent
Degrees
Percent
Degrees
Percent
1.8
16
28.7
31
60.0
3.5
17
30.6
32
62.5
5.2
18
32.5
33
64.9
7.0
19
34.4
34
67.4
8.8
20
36.4
35
70.0
10.5
21
38.4
36
72.7
12.3
22
40.4
37
75.4
14.0
23
42.4
38
78.1
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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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.
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EX25/36 2.3
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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:
Ensuring the truck is positioned for safe, easy and productive loading
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Develop a plan of how to work the face and the loading method to be
employed (eg drive by, through the gate)
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.
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Bench height
Material stability
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The excavator raises the load and positions it at right angles to the
face
The excavator sounds the horn when the truck is in the correct
position or has reversed back sufficiently
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The excavator raises the load and positions it next at about 45o from
the cut line
The excavator sounds the horn when the truck is in the correct
position or has reversed back sufficiently
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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
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WARNING
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 excavator sounds the horn when the truck is in the correct
position or has reversed back sufficiently
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EX25/36 2.5
2.5.1
training
Oil Temperature
Water Temperature
Fuel
Tachometer
Fuel Level
Alternator
Fuel Gauge
Indicates the amount of fuel in the fuel tank.
The E mark indicates there is less than 250 litres in
the tank.
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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
Pump Transmission Oil Pressure Indicator (Warning) Indicator will glow red on low pressure. Stop the engine and
immediately contact Maintenance.
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Auto Idle
training
Download
Entrance Light
Coolant Level
Pre-lube
Auto-lube
Pump Contamination
(Warning)
Engine Warning
Stop Valve
(Warning)
Air Cleaner
Restriction
(Warning)
NOTE
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NOTE
ii)
iii)
iv)
WARNING
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check the coolant system for leaks and the coolant level.
If the red indicator comes ON and the buzzer continues sounding for
120 seconds, the engine will stop automatically.
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EX25/36 2.6
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the
red
ALARM
indicator should glow
TEST
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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Stop
the
engine
(to
minimise the addition of
fuel)
Call for help and stand watch over the excavator until help arrives.
(Even though the fire may be out, re-ignition could occur)
NOTE
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2.6.3
training
Fight the fire, using the fire extinguishers on your equipment (usually
located inside the cab, outside the cab and on the access stairs)
NOTE
Emergency Evacuation
NOTE
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2.6.5
training
Face towards the cab (as long as you hold the two ropes the
emergency escape device will not operate.)
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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
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2.6.7
training
WARNING
2.6.9
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Factors that will affect the type (grade) of incline you should attempt
include:
Direction of travel
To maintain a smooth surface, clean any spillage from the floor after
each truck where possible or contact grader/dozer to assist
WARNING
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2.6.11
training
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 reversing
2.6.13
WARNING
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2.6.15
training
Coolant (radiator)
Battery Acid
2.6.16
Mask/goggles
Gloves
Protective clothing
NOTE
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CT 2.7
training
Conduct
Formative Assessment
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RELOCATE EXCAVATOR
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Relocate Excavator
Performance Criteria
1027.3.1
1027.3.2
1027.3.3
Resolve coordination
personnel.
1027.3.4
CT 3.1
issues,
including
support
equipment
and
Hazards/risks
Environmental issues
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EX25/36 3.2
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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
Level - if necessary
using a grader for the
final finish
WARNING
CT 3.3
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EX25/36 3.4
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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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Operator Maintenance
Performance Criteria
1027.4.1
1027.4.2
1027.4.3
1027.4.4
Provide operator support during preparation for, and conduct of, major
maintenance tasks in accordance with site requirements.
1027.4.5
EX25/36 4.1
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EX25/36 4.2
4.2.1
training
Fluid levels
Instrumentation monitoring
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:
Position the excavator so that the fuel,oil and grease hoses can
reach the fast-fill compartment
NOTE
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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)
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
4.3.1
training
WARNING
4.3.2
WARNING
i)
ii)
iii)
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
Punch out the pins using a short drift to start the pin moving and
then a longer drift to complete the task
Strike the teeth on the flat face with the hammer to release them
from the adaptor
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4.3.3
training
By Work Request
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
training
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
Conduct
Formative Assessment
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