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26 April 2017

Hydraulic Excavators

Hydraulic Excavator
Hydraulic Excavator is the most commonly used
construction machine. it has bucket with
specified volumetric capacity.
Hydraulic power is the key utility to operate the
hydraulic excavators.
Excavator can work above and under the ground
level where it rest.
It can work at all gradient and difficult terrain and
even under water excavation work where other
machine can not be used.
With various front attachments, it can be used for
diversified purposes.
Most excavators are mounted on track base, but
smaller model may be mounted on wheels base.
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Hydraulic Excavator: Main Parts


A hydraulic Excavator consists THREE major parts
1. Work Equipment 2. Upper Structure
This part consist This part consist engine, cabin
working tools for and holds components such as
digging and loading operators seat controlling
joysticks and monitoring gauges

3. Undercarriage
This part consist Crawler/
track chain or Wheel for
moving machine on the
ground.
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Work Equipment:
Work equipment is designed
to run by hydraulic cylinders

Piston

Force
= Oil Pressure Inside the
Pressure x Area cylinder is the key factor to
overcome require FORCE to
Rod Cylinder do work.

Arm Cylinder

Oil flow rate inside


cylinder is key factor to
move and speed up and
down of work equipment

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Upper Structure: Cabin Interior


Arm/Swing Controls (Left Joystick) Boom/Bucket Controls (Right Joystick)
move forward and backward to move Arm out and in move forward and backward to lower and raise boom
move left and right to control direction of swing move left and right to control bucket curl and dump

Depending on moving direction of control Joystick Boom, Arm or Bucket can


be moved for doing work or machine can swing to require degree of rotation

Machine monitoring units


Travel Levers
(Temp., Press. Gauges)
Depending on
moving direction Work equipment
of control Lever/ Work equipment
Pedals Machine control Joystick control Joystick
can move
straight or turn Engine starting
left or right.
switch

Travel Fuel gauge


Pedals
Operators Lights / Other
seat Cabin Interior
switches

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 5

Excavators: Swing mechanism


The outer race fixed at upper structure
turns with the Pinion that spins along with
the inner race fixed at the lower structure.
SWING CIRCLE
The part between the outer race and the
inner race turns smoothly on the ball
bearings.

Pinion Outer race

Inner race
This part enables an Ball bearings
hydraulic excavator to
Stick/Swing Controls (Left Joystick)
turn around
move forward and backward to move stick out
and in
move left and right to control direction of swing

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Lower Structure:
Undercarriage
Most are Crawler/ Track type.
Compared to the Wheel type, the
Crawler type has more part touching Can also be fitted
the ground. Which enables them to with dozing blade
work on muddy surface where Wheel . (Optional)
type can not be used.

Wheel type excavator


make use of supports/
Stabilizers during work.
CRAWLER / TRACK

WHEEL Seen from


the sides
(TYRE)

Seen from the


underneath

The part touching the


ground surface
26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 7

Hydraulic Excavators: How it Works ?


Hydraulic Power is the key utility to operate all Hydraulic Excavators

Arm Cylinder Control Valves

Hydraulic Pump

Boom Cylinder
Engine

Hydraulic Oil Tank


Bucket Cylinder Swing Motor
Travel Motors

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Excavators : Types
Based on feet mounted on undercarriage they
are classified as:
1. Crawler or Track type
2. Wheel type

Based on types of Bucket mounted or digging


motion of bucket they are classified as:
1. Shovel type
2. Hoe type

Both front SHOVEL type or HOE type Excavator can be


mounted on either on a Crawler or a Wheel tractor base.
26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 9

Hydraulic Excavator: Front Shovel


Basic Features:
An upward motion unit is know as
front shovel
Hydraulic front Shovel excavators
are used mainly for hard digging
above track level and for loading
hauling units.
A shovel develops breakout force
by crowding material away from
the machine.
The boom of a shovel swings
upward to load; so the machine
requires a material face above
the ground level

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Hydraulic Excavator: Hoe


Basic Features:
A downward arc unit is classified
as Hoe
Hydraulic Hoe excavators are used
primarily to excavate below natural
surface of the ground on which
machine rest
It develops excavation breakout
force by pulling the bucket towards
the machine and curling the bucket
inward.
The downward swing of a hoe
dictates usage for excavating
below the ground level at which
machine rest
26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 11

Hydraulic Excavator
The hydraulic excavators are fully hydraulically
control machine which provides:
Faster cycle time
Less noisy
Smoothness and ease of operation
High overall efficiency
Greater accuracy and precision
It is a versatile machine that can be used for
almost all kind of applications.
A quick coupler enables to quick change with
different type attachments and perform a
variety of tasks in rapid succession
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Model and Designation


(Komatsu Excavator: Typical example)

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Excavator Specifications
Machine (Make/ Model/ Sr. No., overall dimension)
Operating Weight (kN) (with operator,
cabin and all standard items & accessories)
Engine (Make/ Model/ Sr. No./Type, Cly. No./stroke,
CI/SI, Torque/ RPM/ Cooling type
Flywheel Power (kW)
Undercarriage (Track shoe size type,
roller no., track length, ground pressure etc.)
Hydraulic System
Swing Mechanism (Speed/ Torque)
Drive System (Travel speed / Drawbar-pull)
Work Implements (Pressure, Cylinder type size)
Bucket (model, Cubic capacity)
Performance Data (Working range, Arm force/ Bucket force)
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Hydraulic Excavator: Application


Hydraulic hoe has evolved from a single purpose
excavating machine into a versatile multipurpose tool.
It is a versatile machine that can be used for almost all
kind of applications.
Typical general applications are:
Digging under or above the ground level
Canal/ Trench excavating and pipe laying
Loading hauling units
Lifting construction materials
A quick coupler enables the hoe to change attachments
and perform a variety of tasks in rapid succession. Some
common attachments are:
Hydraulic breaker - Crane
Clamshell - Rock driller
Impact hammer - Demolition jaw
Cutters - Land clearing grapple

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 16

Typical Applications

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Attachments

Various types of attachments

Building demolishing Handling Scrap materials


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Commonly used terminologies related to


shovel/ bucket size rating
Struck Capacity :
The volume actually enclosed
by the bucket with no
allowance for bucket teeth
Heaped Capacity:
Both PCSA and SAE uses a
1:1 angle of repose for
evaluating heaped Capacity.
CECE specifies 2:1 angle of
repose.

PCSA Power Crane and Shovel Association


SAE Society of Automotive Engineers
CECE Committee on European Construction Equipment

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Fill Factors
Fill factors:
The actual amount of material in a
bucket needed for shovel
production calculation. Fill factor
are express in percentage which
when multiplied by heaped
capacity, adjust the volume by
accounting for how specific
material will load into the bucket.

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 20

Cycle time
The sum of time required to load bucket, swing
loaded, dump and swing empty.
Typical cycle element times under average
conditions, for 2 to 4 cum shovels will be
Load bucket 7-9 sec. (depend on material type)
Swing with load 4-6 sec (depend on machine size)
Dump load 2-4 sec (depend on dumping target)
Return swing 4-5 sec (depend on machine size)

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Factor affecting production


Actual production of a shovel is affected
by the following factors:
Class of material
Height of cut
Angle of swing
Size of hauling units
Operator skill
Physical condition of the shovel

Production efficiency ranges from 30 to 45 min per hour

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 22

Effect of height of cut and Angle of swing


The effect of height of cut and Angle of Swing on
Shovel production published by PCSA from field
study can be used:

The percent of optimum height of cut, in the table, is


obtained by dividing the actual height of cut by the
optimum height for the given material and bucket, and
then multiplying the result by 100.

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Optimum height of cut


The optimum height of cut ranges from 30 to
50% of the maximum digging height.
30 % for a easy to load materials (i.e. load sand,
gravel etc.)
40% for common earth
50% for poorly blasted rock, or sticky clay
The ideal production of shovel is based on
operating at a 900 swing and optimum height of
cut.
The ideal production should be multiplied by the
proper correction factor in order to correct the
production for any given height and swing angle.
26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 24

Excavator Production
Steps for estimating production:
1. Bucket Size (Usually given), (If not given; Obtain the heaped
bucket load volume (lcm) from the manufacturer performance data).
2. Apply a bucket fill factor based on type material being
excavated.
3. Estimate a peak cycle time:
(Load bucket+ Swing with load+ Dump load+ Return swing)
4. Obtain the factor for angle of swing and height of cut
from the table (% of optimum depth vs angle of swing).
5. Apply a efficiency factor (usually 30 45 min per 60 min)
6. Conform the production units to desired volume or weight
(lcm to bcm) (lcm= bcm*(1+swell factor)
7. Estimate the Production rate per hour using the formula

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Performance data from manufacturer (typical example)


Model
Item Unit PC220-5 Custom If not given, Obtain heaped cubic capacity of bucket
Flywheel Horse Power HP /(at rpm) 153 / (at 2200 rpm) from manufacturers specification for given model
Bucket Capacity Range STEP-1
SAE Heaped m3 0.4 to 1.26 Bucket Size
CECE Heaped m3 0.33 to 1.10

Fill Factor for Front Shvel Buckets (Caterpillar Inc.)


Material Fill Factor *(F) (%)
Bank clay earth 100 to 110 Select the suitable Fill factor (F) for
Rock-earth mixture 105 to 115
STEP-2
type of material to be excavated.
Rock-poorly blasted 85 to 100
Fill factor
Rock-well blasted 100 to 110
Shale, sandstone-standaning back 85 to 100
* % of Heaped bucket capacity
Estimate the pick cycle time base on machine
size, materials type and dumping condition.
Typical cycle element times under average conditions, for -Load time, for easy loading material take lower
2 to 4 cum shovels value (7sec) and higher value for difficult (9 sec)
Load bucket 7-9 sec. (Based on materials) -Swing time, take lower value(4sec)for smaller m/c
Swing with load 4-6 sec (Based on size of m/c) STEP-3
Dump load 2-4 sec (Base on hauling unit) Cycle and for higher(6sec) value for bigger size m/c.
Return swing 4-5 sec (Based on size of m/c) time --Dump time, for dumping in a hauling unit take
higher value and lower value for free dumping.
Factors for Height of Cut and Angle of Swing Effect on Shovel
Percent Obtain AS:D from the table.
Angle of Swing (degree)
Optimum
Depth (%) 45 60 75 90 120 150 180
maximum depth of cut from manufacturers
40 0.93 0.89 0.85 0.80 0.72 0.65 0.59 specification and multiply it by a factor within
60 1.10 1.03 0.96 0.91 0.81 0.73 0.66
STEP-4 range of 0.3 0.5. Take lower value (0.3) for
80 1.22 1.12 1.04 0.98 0.86 0.77 0.69 easy to load material and higher value (0.5)
Swing
100 1.26 1.16 1.07 1.00 0.88 0.79 0.71
Angle & for very difficult material
120 1.20 1.11 1.03 0.97 0.86 0.77 0.70
Depth of
140 1.12 1.04 0.97 0.91 0.81 0.73 0.66 Average height of cut
Cut factor
160 1.03 0.96 0.90 0.85 0.75 0.67 0.62 % of optimum depth 100
Optimum height of cut
Optimum depth of cut 30% of maximum digging height (for easy to load material)
50% of maximum degging height (for difficult blasted rock etc)
40% of maximum digging height (for common averge material)
26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 26

Working time (WT) (min/hr)


STEP-5 Find Efficiency Factor (EF) EF
60
STEP-6. Convert to required unit LCM BCM * (1 SF )

STEP-7 Compute the production rate, using following formula.


3600 Q F ( AS : D) WT
P (lcm/hr)
t 60
3600 Q F ( AS : D) WT 1
P (bcm/hr)
t 60 1 S.F.

Where;
P (lcm/hr) = Production in loose cubic meter (volume) per hour
P (bcm/hr) = Production in bank cubic meter (volume) per hour
P (ton/hr) = Production in tons (weight) per hour
Q = Heaped bucket capacity (lcm)
F = Bucket fill factor
AS:D = Angle of swing and depth (height) of cut correction factor
t = Cycle time in seconds
E F= Efficiency minutes per hour (take WT 30-45 if not given)
S.F. = Swell Factor
WT = Working time (min, in one hour)

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Example-1
A 3.8 cu.m. shovel having a maximum digging height of 10.4m is being
used to load poorly blasted rock. The face being worked is 3.7m high and
the haul units can be positioned so that the swing angle is only 600. What
is the adjusted ideal production if the ideal cycle time is 21 sec.
Bucket size (Q)= 3.8 m 3 (Given)
Bucket fill factor = 0.9 (taken from the table, for poorly blasted 85-100%)
Ideal Cycle time (t) = 21 sec. (Given)
Optimum height = 0.5 x 10.4 = 5.2m (Taken highest %, for poorly blasted rock) (3050%)
Working height) 3.7
% of optimum height 100 100 71.15%
0
Optimum height 5.2
Angle of Swing = 60
Angle of Swing and depth (AS:D) =1.08 (by interpolation)
(from the table 1.03+(71.15-60)*(1.12-1.03)/(80-60)
3600 Q F ( AS : D) WT Assuming Efficiency factor,
P (lcm/hr) EF= 45/60
t 60
3600 3.8 0.9 1.08 45
P (lcm/hr) 475 (lcm / hr )
21 60
26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 28

Example-2
A 2.3 cu.m. shovel having a maximum digging height of 9.1 m, will be
used on a highway project to excavate well-blasted rock. The average
face height is expected to be 6.7 m. Most of the cut will require an
average 1200 swing of the shovel in order to load the haul unit. Determine
the estimated production in cubic meter bank measure. Take efficiency 30
min in 60 minute.
Bucket size (Q)= 2.3 m3 (Given)
Bucket fill factor (F)= 1 (taken from the table, for well-blasted 100-110%)
Ideal Cycle time (t) = (Load + Swing loaded + Dump + Swing empty)
= 9 + 4+ 4 + 4 = 21 sec
Assuming: Typical cycle element times under
average conditions, for 2 to 4 cum
Load = 9 sec (Taken maximum value, as material is rock difficult to load) shovels:
Swing loaded = 4 sec (Taken smaller value, as being smaller sized m/c) Load bucket 7-9 sec.
Dump = 4 sec (Taken maximum value, as it is to be loaded into haul units) Swing with load 4-6 sec
Swing empty = 4 sec (Taken smaller valve, as being smaller sized m/c) Dump load 2-4 sec
Return swing 4-5 sec

Optimum height = 0.5 x 9.1= 4.55m (Taken highest %, for poorly blasted rock) (3050%)
Working height) 6.7
% of optimum height 100 100 147%
Optimum height 4.55

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Example-2 (/contd)
Angle of Swing = 1200
Angle of Swing and depth (AS:D)= 0.79 (by interpolation)
(from the table 0.81- [{(0.81-0.75)/(160-140)}*(147-140)]
Efficiency Factor (EF) = 30/60 (Given)
% Swell = 60% (From the table for well blasted rock)

3600 Q F ( AS : D) WT 1
P (bcm/hr)
t 60 1 swell
3600 2.3 1 (0.79) 30 1
P (bcm/hr) 97.3
21 60 1 0.6

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 30

Hydraulic Hoe: Production Estimating


The same elements that affect shovel production
are applicable to hoe excavation operation.
Hoe cycle times are approximately 20% longer
than similar size shovel and work.
The optimum depth of cut for hoe is usually in the
range of 30 to 60%.
Standard data for Cycle time based on bucket
size and average conditions (30-600 swing angle,
hauling unit at same level etc. is available).
No standard data and factors based on angle of
swing and depth of cut is available.

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 31

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Hydraulic Hoe: Production Estimating


Step-1: Bucket size
(From the (lcm)
manufacturer specification for the size of bucket to be
used. Many different size buckets will fit the same
machine. Interested in heaped capacity).
Step-2: Fill Factor:
(From the table for
corresponding type of material. Heaped capacity is base
on 1:1 material angle of repose. It must be adjusted
based on the characteristics of material being handled).
[Bucket volumetric capacity (lcm) = Heaped capacity *Fill Factor]

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 32

Hydraulic Hoe: Production Estimating


Step-3: Cycle time (sec) (Load + Swing load + Dump +
Swing empty).
Typical excavation cycle times based on machine (bucket) size

The cycle times


must be increased
when loads are
dumped into a
smaller haul units.
Small machine
swing faster than
large ones.

Depth of cut: 40 to 60%


Swing angle = 30 600
Loading haul units on the same level

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Hydraulic Hoe: Production Estimating


Step-4: Depth of cut (Obtain maximum dig depth from manufacturers
data and check for optimum depth of cut within the range of 30% to 60%.)

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 34

Hydraulic Hoe: Production Estimating


Step-5: Efficiency Factor:
Bunching (In actual operation cycle time is never constant. When loading haul
unit they will sometime bunch. The effect of bunching is a function of the no. of
haul units.
Operator efficiency: (Skill of operator)
Equipment availability (Haul units availability x% of the time)

Machines working range based on size of machine (bucket) fitted with


standard items (Boom, Arm etc.)

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Step-6: Compute production rate, using following formula.

3600 Q F WT
P (lcm/hr)
t 60
3600 Q F WT 1
P (bcm/hr)
t 60 1 S.F.

Where;
P (lcm/hr) = Production in loose cubic meter (volume) per hour
P (bcm/hr) = Production in bank cubic meter (volume) per hour
P (ton/hr) = Production in tons (weight) per hour
Q = Heaped bucket capacity (lcm)
F = Bucket fill factor
t = Cycle time in seconds
EF = Efficiency minutes per hour (take WT, 30-45 if not given)
S.F. = Swell Factor
WT = Working time (min, in an hour)

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 36

Example-3
A crawler hoe having a 2.8 cu.m bucket is being considered for use on a
project to excavate dry clay from a borrow pit. The clay will be loaded in
trucks having a loading height of 3m. Soil-boring information indicates that
below, average 2.5 m, the material changes to an unacceptable silt
material. What is the estimated production of the hoe in cubic meter bank
measure, if the efficiency factor is equal to a 50-min hour.?
Step-1: Size of Bucket (Q)= 2.8 cu.m
Step-2: Bucket fill factor (F)= 85% (taken average of 80-90 from the table,
. for hard clay)
Step-3: Cycle times (t) = 22 sec (from the table, for nearest bucket size 3 cum)
Step-4: Optimum depth of cut to be within 30% to 60%
From the table maximum depth of cut 7 8.2 m
Average depth of cut = 2.5 m
2.5
* 100 35.7%
7 Checking for optimum depth of
2.5 cut range 30% to 60%.
* 100 30.4%
8.2

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Example-3 /.contd
Step-5: Efficiency factor (EF)= 50 min per hour (given)
Working time (WT) (min/hr)
EF
60

Step-6: Production rate Calculation

3600 Q F WT
P (lcm/hr)
t 60

3600 2.8 0.85 50


P (lcm/hr) 324.5 (lcm/hr)
22 60
Swell factor = 35% for type of materials from the table
P (lcm/hr) 324.5
P (bcm/hr) 240.37
1 Swell factor 1 0.35

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 38

PRODUCTIVITY OF HYDRAULIC EXCAVATOR:


(Quick Method)
The hourly production of hydraulic excavator can also be
calculated as :-
3600 Q E 3600 (q k ) E
P (lcm/hr)
Ct (t F )
Where;
P (lcm/hr) = Production in loose cubic meter (volume) per hour
Q = Bucket Production (cu.m)
= (q*K) Bucket Factor (k)
q = bucket heaped capacity (cu.m) Material Bucket factor (K)
K = Bucket factor Moist loam or sandy clay 1.0 - 1.1
E= Job Efficiency factor Common soil 0.9 - 1.0
t = Standard Cycle time in seconds Sand and gravel 0.85 0.95
F = Time factor
Hard tough clay 0.8 - 0.9
Ct = Cycle time in seconds =(t*F)
Rock well blasted 0.6 - 0.75
Rock poorly blasted 0.4 - 0.5

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Standard Cycle time (t)= excavating time + swing time


loaded+ dumping time +swing time empty

OR

Actual cycle time = standard cycle time * time factor

Time Factor (F) Cycle Time (t)


Standard cycle time based on bucket
Dumping Conditions
Capacity
Digging
NORMAL RATHER Swing Angle /Time (Sec)
Conditions EASY DIFFICULT BUCKET
(Average) DIFFICULT
CAPACITY
40 - 90 90 -180
BELOW 40 % 0.7 0.9 1.1 1.4 0.25 13 -15 15 -17
40 % - 75 % 0.8 1.0 1.3 1.6 0.4 13 -15 15 -17
0.45 14 -16 16 -18
OVER 75 % 0.9 1.1 1.5 1.8 0.7 16-18 18 21
Digging condition= (Digging depth/ Max. depth of cut)*100 0.9 18 - 20 20 23
Easy = Dump onto spoil pile
1.2 20 - 22 22 - 25
Normal = Large dump target
Rather difficult = Small dump target
Difficult = Small dump target requiring maximum reach.

26 April 2017 NEC/MS-MCPE: Hydraulic Excavators : by Ashok K. Shrestha 40

Example-4
A contractor has a project to construct a large office building with an underground parking
garage. He has decided to use a Hydraulic excavator to excavate for the parking garage
and load the excavated material into a dump trucks. The maximum digging depth of the
excavator is 6m and it is equipped with a 1.2 cum bucket size. The material to be
excavated is a tough clay at average depth of cut 3m and job condition are considered to
be average. Angle of swing 600 and work an average of 50 min per hour. What is the
estimated productivity in bank Cum per hour if the swell of the excavated material is 35%.
Bucket size (q) = 1.2 cum
Bucket factor (k) = 0.85 (taken average value of 0.8 and 0.9)
Digging condition = (3/6)*100 = 50%
Time Factor (F) = 1.3 (for digging and rather difficult dumping condition (dump truck))
Standard time (t) = 22 sec (1.2cum bucket size and 60 0 angle of swing)
Job Efficiency (E) = (50/60)=0.83
36001.2 0.85 0.83
P (lcm/hr) 106.5
(22 1.3)
106.5
P (bcm/hr) 78.9 (For given 35% of swell)
1.35

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