1. Operation
GENERAL INFORMATION
This section of the manual will assist in the operation of this machine. It provides the operator
with the location and explanation of the controls, instructions for machine operation and certain
maneuvering techniques. Throughout this section and the remainder of the manual, the use of
the terms “LEFT, RIGHT, FRONT and REAR” refer to machine locations as viewed by the
operator sitting in the operator’s seat in the cab.
Safe operation of the machine minimizes production delays and costly damage to equipment.
Carefully study and follow all recommended procedures in this manual. Safety guidelines are
intended to prevent accidents from occurring and are provided in the interest of all mine
personnel. Overall safety depends upon the use of good judgment and the alertness of the
entire mining crew. Refer to Section 1 in this manual for specific safety precautions.
OPERATION NEAR ELECTRICAL LINES
DANGER: HIGH VOLTAGE! The following precautions shall be complied
with whenever operating around or near electrical distribution and
transmission lines.
Working in the vicinity of electrical power lines presents a very serious hazard and special
precautions must be taken. For purposes of this manual we are considering the entire machine
or its load, in any position, that can reach to within the minimum distance specified by local,
state and federal regulations.
Safe operating practices require that you maintain the maximum possible distance from the
lines and never violate the minimum clearances.
Before working in the vicinity of power lines, always take the following precautions:
• Always contact the owners of the power lines or the nearest electric utility before
beginning work.
• You and the electrical utility representative must jointly determine what specific
precautions must be taken to ensure safety.
• It is the responsibility of the user and the electric utility to see that necessary precautions
are taken.
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2. • Consider all lines to be power lines and treat all power lines as energized even though it
is known that the power is shut off and the line is visibly grounded.
• Slow down the operating cycle. Reaction time may be too slow and distances may be
misjudged.
• Caution all ground personnel to stand clear of the machine at all times.
• Use a signal person to guide the machine into close quarters. The sole responsibility of
the signal person is to observe the approach of the machine to the power line. The
signal person must be in direct communication with the operator and the operator must
pay close attention to the signals.
DANGER: HIGH VOLTAGE! Death or injury could result should any part of
the machine approach the minimum distance of an energized
power line specified by local, state and federal regulations.
CONTROLS
The operator must become familiar with the machine and its operating controls before operating
the machine.
The operating controls will be grouped as primary and secondary controls, depending upon their
location. The primary controls are the controls located in the operator’s cab and the secondary
controls are the controls located in the machinery house.
The descriptions listed should familiarize the operator with each control’s location and functional
use. The terms left, right, forward and reverse indicate directions with the operator seated in the
cab and facing forward, and with the boom extending over the front of the crawlers.
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3. Figure 2-1: Operator’s Cab
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4. PRIMARY OPERATING CONTROLS
Figure 2-2: Operator’s Control Consoles in Cab
CONTROLS ON THE LEFT CONSOLE
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5. Figure 2-3: Left Control Console
LEFT JOYSTICK
The left joystick controls the crowd/horn/dipper trip and propel. It is the vertical handle mounted
on the left console of the operator’s seat. The switch will spring return to neutral when released.
During normal operation, pushing the joystick forward will extend the dipper handle and dipper
into the bank. Pulling the joystick rearward will retract the dipper handle and dipper toward the
machine. The neutral position between the crowd and retract functions is defined by a detent
that is easily felt. The rate of motion is controlled by varying the distance the joystick is moved
from the neutral (center) position. Full forward or full rearward position provides maximum
speed to the handle. Moving the joystick to neutral will cause a braking action slowing the
crowding or retracting handle. Reversing the joystick will cause the motion to stop and if the
joystick is held in this position, it will change the direction of the motion.
With the propel transfer switch in the PROPEL position, pushing the joystick forward will cause
the left crawler to move forward. Pulling the joystick to the rear will cause the left crawler to
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6. move in the reverse direction. The crowd/retract motion is locked out electrically when the
machine is in the propel mode.
Refer to JOYSTICK CONFIGURATION in this section of the manual to view the standard and
alternate configurations for the right and left joysticks.
DIPPER TRIP
The dipper trip is part of the left joystick function. Moving the left joystick to the right will activate
the dipper trip mechanism which releases the dipper door latch. The dipper trip is operational
throughout the entire range of the crowd motion.
SIGNAL HORN
Moving the left joystick to the left will activate the signal horn. The signal horn is operational
throughout the entire movement range of the crowd motion.
RADIO
The radio supplied with your machine is an AM/FM Stereo radio with cassette player. This is a
quality piece of sound equipment and will provide long term operation.
HOIST BRAKE
A selector switch used to set or release the hoist brake.
CROWD BRAKE
A selector switch used to set or release the crowd brake.
SWING BRAKE
A selector switch used to set or release the swing brake.
PROPEL BRAKE
A selector switch used to set or release the propel brake.
CLIMATE CONTROL PANEL
The climate control panel contains a rheostat controller on the top portion of the panel which is
used to tailor the temperature of the air delivered to the operator’s cab within the selected mode
of operation.
The mode switch is provided to set the basic mode of operation for the roof mounted air
conditioning/heater unit.
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7. The blower speed switch controls the volume of air being moved by the unit.
WINDSHIELD WIPER SWITCH
The windshield wiper switch is located on the operator display monitor console at the left of the
left operator’s console. It controls the speed of the wipers, as well as the starting and stopping
of the wipers.
WINDSHIELD WASHER SWITCH
The windshield washer switch is located with the windshield wiper switch on the operator
display monitor console. It controls the supply to the washer reservoir which powers the
washers.
CONTROLS ON THE RIGHT CONSOLE
Figure 2-4: Right Control Console
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8. RIGHT JOYSTICK
The right joystick controls the hoist/swing and propel. It is a joystick mounted on the right
console of the operator’s seat. The joystick is used to control the hoist, swing and right crawler
motions of the machine. The position of the propel transfer switch will determine whether this
switch controls the hoist motion or the crawler motion.
With the propel transfer switch in the dig position, pushing the joystick forward will lower the
dipper. Pulling the joystick to the rear will hoist the dipper. The neutral position between the
hoist and lower functions is defined by a detent that is easily felt. The speed of moving the
dipper is controlled by varying the distance the joystick is moved from the neutral (center)
position. The full forward, or full rearward position provides maximum speed to the dipper.
Moving the joystick to neutral will cause a braking action slowing the hoisting or lowering
motion. Reversing the joystick will cause the motion to stop and if the joystick is held in this
position, it will change the direction of the motion.
NOTE: When the right joystick is used in the hoist/lower mode the switch is a spring returned
switch. That is, it will return to the neutral position when it is released.
Moving the right joystick to the left from the neutral position will cause the machine to swing to
the left. Moving the joystick to the right will cause the machine to rotate to the right. The swing
motion is operational throughout the entire movement range of hoisting or lowering the dipper.
The swing rate of acceleration is controlled by varying the distance the joystick is moved from
the neutral position. Moving the joystick to the neutral position will not stop the swing motion but
will allow the machine to coast. To stop or change direction the control joystick is moved past
the neutral point in the opposite direction. The rate of deceleration is controlled by varying the
distance the joystick is moved from the neutral position in the opposite direction.
Refer to JOYSTICK CONFIGURATION in this section of the manual to view the alternate
configurations for the right and left joysticks.
With the propel transfer switch in the propel position, pushing the lever forward will cause the
right crawler to move forward. Pulling the lever to the rear will cause the right crawler to move in
the reverse direction. The hoist motion is locked out electrically when the machine is in the
propel mode.
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9. NOTE: When the right joystick is used in the swing mode the switch is a spring returned
switch. That is, it will return to the neutral position when it is released.
CONTROL STOP PUSHBUTTON
The control stop pushbutton is a pushbutton located on the right operator’s console. Normally it
is used to de-energize controls after the machine has been safely stopped by placing motion
controls in neutral.
Actuation of this pushbutton when motions are running will cause all motions to automatically
electrically brake to a stop and, when the motion speed has reached less than 5% speed, set all
mechanical brakes. If the motions are already stopped, the brakes will be set and power is
removed immediately. A similar switch is located on the front panel of the PLC control cabinet
that can be used during testing of the machine.
DANGER: THE OPERATOR SHOULD NEVER LEAVE THE OPERATOR’S
SEAT BEFORE PRESSING THE CONTROL STOP PUSHBUTTON.
Setting only the mechanical brakes with individual switches is not
a sufficient safeguard to prevent machine damage and/or
personnel hazards.
CONTROL RESET PUSHBUTTON
CAUTION: This is not an automatic reset system. All controls must be
returned to neutral before the control reset button is pushed.
The control reset pushbutton is a pushbutton located on the right operator’s console. The reset
pushbutton restores control to all motions if no additional faults exist. This pushbutton is
inoperative until the main power start control has been actuated.
If a control fault occurs that shuts down a motion, all motions will automatically be shut down
together. At this time the operator should set all brakes. If the fault clears, the motion may be
reset by pressing this pushbutton. If the fault does not clear, the unfaulted motions can be
restarted by pressing this pushbutton to enable these motions to reposition themselves.
DIG/PROPEL TRANSFER SWITCH
The dig/propel transfer switch is used to switch between the two primary operating modes of the
machine. The current mode of operation will be indicated on the Operator’s screen on the
Operator’s Display.
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10. IMPORTANT!
• WHILE IN THE DIG MODE, THE PROPEL CONTROLS ARE DISABLED.
• WHILE IN THE PROPEL MODE, THE DIG CONTROLS ARE DISABLED.
The recommended procedure to transfer from hoist to propel is to bring all motions to a
controlled stop by the operator. Turn the hoist brake switch to the SET position and then press
the control stop pushbutton. Turn the transfer switch from DIG to PROPEL. When the indicator
on the Operator Display screen indicates that the transfer has been completed, turn the propel
brake switch to release.
EMERGENCY STOP PUSHBUTTON
The machine stop/emergency stop pushbutton is located on the right operator’s console. It is
used to remove power from the machine motions after the motions have been stopped in the
normal manner. A second purpose of the pushbutton is to stop the machine under operational
emergency conditions. Pushing this button will provide electrical and immediate mechanical
braking simultaneously. Therefore, this button should only be used if the operator intends the
harshest braking of all motions. If the machine is in motion, power will remain on the motions in
order to provide electrical braking for a few seconds. If the machine is in motion or stopped, this
button will power the DC bus to approximately zero voltage quickly after the time delay.
CAUTION: PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY
RESULT IN COMPONENT DAMAGE.
MAIN POWER OFF PUSHBUTTON
The main power off pushbutton is located on the right operator’s console. It is used only to
immediately remove power from the drives in case of an electrical emergency involving
component failure or fire.
CAUTION: PUSHING THE “POWER OFF” PUSHBUTTON WHILE IN MOTION
WILL IMMEDIATELY SET THE MECHANICAL BRAKES AND
REMOVE INCOMING HIGH VOLTAGE FROM THE DRIVES. THIS
ACTION MAY RESULT IN COMPONENT DAMAGE. It will also result
in the inability to power the DC bus voltage down to a low value.
This voltage will decay slowly, taking several minutes.
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11. EARTH CONTINUITY LOCKOUT PUSHBUTTON
The earth continuity lockout pushbutton is used to trip the breaker that supplies power to the
machine. When the machine is operating, this pushbutton should be used to shutdown the
machine only when removal of power to the machine is required.
TELEPHONE
A telephone is located at the rear of the right control console. This telephone is connected to
other phone stations throughout the machine.
HEATED MIRRORS
The heated mirror switch is a 2-position switch located on the right control console. It is used to
activate the heating mechanism in the operator’s cab outside mirrors.
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