Hitachi EX2500 and EX3600 - Reference Material.PDF

LEARNING NOTES

Design & Development

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www.Worklleeaarrnn.com Phone: 61 7 3869 0220

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MNCO1027A

CONDUCT

EXCAVATOR/HYDRAULIC SHOVEL OPERATIONS

HITACHI EX2500 & EX3600 EXCAVATOR

EX2500

EX3600

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


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


CONTENTS

2.3 & 2.4 are reversed in the Learning Notes & Assessment



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OPEN CUT PRODUCTION COMPETENCIES


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


CONTENTS (Continued)

Version 001/06/05 MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR OPERATIONS Hitachi EX2500/EX3600 Excavator training

Curragh Queensland Mining Pty Ltd is part of Westfarmers Energy 7

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




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


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


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


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 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)




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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

Documents

Hitachi EX2500 and EX3600 - Reference Material.PDF