Bi006779-04-00-En - CMPL - Omm

®
BI006779
July 2013
Operators Manual
7495 Electric Rope Shovel
OM11089-EN
SAFETY.CAT.COM
BI006779
Amendments and alterations to this publication are not subject

to notification. Caterpillar Global Mining LLC reserves all rights
to this publication. Its content is protected by copyright laws.
No part of this publication may be reproduced or transferred

in any way or form without the prior written approval of
Caterpillar Global Mining LLC.
Caterpillar Global Mining LLC declines any liability for direct or

indirect consequences of printing errors.
© 2012 Caterpillar Global Mining LLC.
LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.

Table of Contents
BI006779
Table of Contents
Table of Contents
SECTION 1 - INTRODUCTION
PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

SECTION 2 - SAFETY
SECTION 3 - OVERVIEW
SECTION 4 - OPERATOR’S STATION
SECTION 5 - OPERATOR CONTROLS AND DISPLAYS
SECTION 6 - PRE-START, START-UP & SHUTDOWN
SECTION 7 - MACHINE OPERATION
SECTION 8 - APPENDIX
OM11089-EN Electric Rope Shovel TOC – i

July 2013
Table of Contents
BI006779
TOC – ii Electric Rope Shovel OM11089-EN

July 2013
Revision History
BI006779
Revision History
Revision History
November, 2012

Removed CDA fault code messages from Appendix, Section 8.
October, 2012
Added common safety features to Section 2. Updated Section 8 with additional CDA fault codes.
January, 2013
Updated description for the Emergency Stop Button.
Added notation to keep machinery house and cab doors closed.
July, 2013
Added avoid tight-lining information to Machine Operation section for Crowd and Propel Motion
Control.
OM11089-EN Electric Rope Shovel REV – i

July 2013
Revision History
BI006779
REV – ii Electric Rope Shovel OM11089-EN

July 2013
BI006779

1 Introduction
Always refer to the safety section of this manual before starting any maintenance
procedure on this machine.
Introduction
1.1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.2 Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.3 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.4 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.5 Precautions and Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.6 Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
OM11089-EN Electric Rope Shovel 1–1

July 2013
Introduction
BI006779
1–2 Electric Rope Shovel OM11089-EN

July 2013
Introduction
BI006779 About This Manual
Introduction
1.1 About This Manual

1.1.1 Purpose

This manual is designed to assist in the operation of your machine. Inside, you will find the
following information: location and explanation of controls, instructions for machine operation,
and certain maneuvering techniques.
NOTES:
• This manual contains information for the Rope Crowd and HydraCrowd™ systems. While
both machines operate the same, some functional differences exist. (For example,
HydraCrowd™ machines do not have a crowd brake.) Where applicable, this manual
provides both versions. Typically, the differences appear on the cab display.
• This is not a maintenance manual. A separate, detailed maintenance manual for this machine
has been supplied with the machine.
1.1.2 Organization
• A main table of contents (TOC) is your guide to topics and subtopics. It is located at the front
of the manual. Main topics are listed as numbered Sections, with subtopics listed beneath
(and indented). Subtopics include the main topic's section number.
• Additionally, each section contains its own TOC.
• In the electronic version, all TOC items are hyperlinked to their respective topics.

July 2013
Introduction
About This Manual BI006779
1.1.3 Terminology
• 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.
• On the cover and at the bottom of each page there is an alphanumeric code to identify the
manual, formatted as follows:
XXnnnnnn-YY
• XX represents the manual type. Below is a list of all manual types.
• nnnnnn represents the serial number for machine-specific manuals, or a generic manual
number intended for several machines.
• YY represents the language code. Below is a list of common language codes.
Code Type Code Language
SM Service EN English
OM Operation ES Spanish
EM Electrical FR French
PM Parts book PT Portuguese
TM Troubleshooting
EM Electrical training
AM Addendum
VM Vendor
MM Miscellaneous
So, for example, manual code EM141455-ES is an electrical manual written in Spanish for
machine #141455.
1.1.4 Revisions
This manual may be revised without notice. The most recent electronic version is available
online.
1.1.5 Precautions and Disclaimers

• Carefully study and follow all procedures in this manual. Safe operation of the machine
minimizes production delays and costly damage to equipment.
• Safety guidelines are intended to prevent accidents and are provided in the interest of all
mine personnel. Overall safety depends on the use of good judgment and the alertness of the
entire mining crew.
• It is the owner/mine's responsibility to perform the necessary risk assessment to outline
proper safety precautions. A minimum of unplanned machine downtime and more reliable
machine operation should result when a systematic and thorough maintenance/service
procedure is adhered to for this machine.

July 2013
Introduction
BI006779 About This Manual
• It is the policy of the manufacturer to improve its products whenever possible and practical to
do so. The company reserves the right to make changes or add improvements to its
machines at any time. This will be without incurred obligations to install such changes on
machines sold previously. Due to this ongoing program of product research and development
some procedures, specifications and parts may be altered in a constant effort to improve our
machines.

1.1.6 Contact
For more information or factory service assistance, contact your regional service representative
or:
Caterpillar Global Mining LLC

6744 S. Howell Ave.
Oak Creek, WI, USA 53154
Telephone (+1) 414.768.4000

July 2013
Introduction
About This Manual BI006779

July 2013
BI006779

2 Safety
Safety
2.1 Safety Symbols And Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.1.1 Warning Signs And Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Electrical Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 General Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Operation Near Electrical Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.1 Fire Extinguisher Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.2 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.7 Common Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7.1 Emergency Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-1 Emergency Lighting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7.2 Mine Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Figure 2-2 Mine Signal Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Figure 2-3 Mine Signal Horn Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.7.3 Dual Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Figure 2-4 Right Side Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

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Safety
BI006779
2.7.4 Propel Warning Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Figure 2-5 Right Side Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.7.5 Propel Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Figure 2-6 Propel Back-up Horn Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.7.6 Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.7.7 Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Figure 2-7 Camera Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.7.8 Boarding Stairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 2-8 Right Side Boarding Stair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.7.9 Vertical Boarding Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.7.10 Man On Ground Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Figure 2-9 Left Side Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.8 Emergency Escape Chute (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.9 Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

July 2013
Safety
BI006779 Safety Symbols And Signal Words
Safety
2.1 Safety Symbols And Signal Words

The safety alert symbols displayed here and throughout this manual are used to call attention to
instructions concerning personal safety. Carefully read and follow these instructions and observe

all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.
Be certain that anyone servicing this machine is aware of these SAFETY SYMBOLS and their
definitions. If it is impossible to safely perform any of the enclosed maintenance and operational
procedures, contact your regional service representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the safety
alert signal is used.
This signal word denotes an item of required information pertaining to the equipment. A
loss of time, assets, or minor injury may result if the appropriate action is not taken.
This signal word serves as a reminder of safety practices, or directs attention to specific
safety practices which could prevent possible injury if precautions are not adhered to.
This signal word denotes an imminently dangerous hazard which will result in death,
serious bodily injury, or serious damage to equipment if not acknowledged and
appropriate action taken.
This signal word denotes an imminently dangerous electrical hazard which will result in
death, serious bodily injury, or serious damage to equipment if not acknowledged and
appropriate action taken.
Operating, maintaining or servicing this machine is dangerous unless performed properly. Each
person must satisfy himself and his employer that he is alert, has the necessary skills,
knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used
are safe and correct. Factory service representatives and specialists are available to provide
additional information or technical assistance. The operator must be alert, physically fit and free
from the influence of alcohol, drugs, or any medications that might impair his/her eyesight,
hearing or reactions.

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Safety
Warning Signs And Decals BI006779
Safety must always be paramount!

Consult your supervisor when safety is in doubt.
2.2 Warning Signs And Decals

The warning signs and decals located throughout the machine convey information to operators,
maintenance personnel, or anyone who will be on or near the machine. The information is
designed to help prevent situations which may result in injury to personnel or damage to the
machine.
Immediately replace any and all safety and warning placards if they are defaced or
removed from the machine.

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Safety
BI006779 Electrical Safety Precautions
2.3 Electrical Safety Precautions
This manual provides information and data for the maintenance and/or operation of this

machine. All electrical equipment must be serviced by qualified individuals who have
been properly trained to work with high voltage systems and variable frequency AC
drives. Failure to comply could result in personal injury or death.
Do not attempt mechanical or electrical maintenance on this machine without a full

understanding of each component’s operation and function. Components utilizing
electrical power, air pressure, hydraulic pressure and compression or tension springs for
operation must be deactivated and isolated prior to disassembly.
The FEEDER CABLE must contain a provision for a ground connection, especially
whenever 2,300 volts or greater are used. At the substation, the power line must terminate
(see paragraph on ground circuits) to a suitable permanent ground. At the machine, the
power line must securely terminate through a bolted connection to the machine frame.
This provides a constant ground for the machine and its electrical equipment. Failure to
provide this adequate ground endangers employees and equipment.
HIGH VOLTAGE!The need for a power line grounding circuit adequate for the machine
cannot be overemphasized. Without a good grounding system, high voltages exist
between the machine and the ground. The portable trail cable and power lines supplying
electric energy to the machine must have a ground wire, ample in capacity, running
parallel to the main wires over the entire distance from the transformer to the machine. A
suitable grounding system must be used at the transformer. Consult your local electrical
supplier for details.
Due to the inherent dangers in the operation of high voltage electrical equipment, a safe
grounding system is required that includes ground conductors in the cable, a neutral
grounding resistor, and related relays and switchgear. A ground continuity check system
is also required.

July 2013
Safety
General Safety Precautions BI006779
2.4 General Safety Precautions

• The employment of qualified maintenance personnel, through a scheduled
maintenance program, is the best way to minimize machine downtime and maximize
productivity of equipment.
• Keep hands, feet and clothing away from rotating parts.

• Wear a hard hat, safety shoes and protective lenses at all times.
• Wear hearing protection when required.
• Think before you act. Carelessness is one luxury the operator and service personnel
cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation.
In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material
and the suggested method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load
could slip off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don’t try to catch it.
• Keep your work area organized and clean. Wipe up oil or spills of any kind
immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall,
slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations
be sure all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
• Regularly inspect for any loose bolts or locking devices and properly secure them.
• Use extreme caution while working near any electrical lines or equipment whether it is
high or low voltage. Never attempt electrical repairs unless you are qualified.
• Check limit switches for proper operation.
• After servicing, be sure all tools, parts or servicing equipment are removed from the
machine and secured in an appropriate storage area.
• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion
(dynamic) brake in emergency situations only.
• Use proper interior and exterior lighting.
• Install and maintain proper grounding and ground fault protection systems.
• Allow electrical inspection and maintenance to be performed only by a qualified
electrician.

July 2013
Safety
BI006779 Operating Precautions
2.5 Operating Precautions

Wear hearing protection. It is recommended that operators wear hearing protection (ear plugs or
ear muffs) when they are exposed to noise levels of 90 dBa and above for any time duration.
Dual hearing protection (plugs and ear muffs) is recommended for any exposure to noise levels
of 105 dBa and above, for any time duration. Exposure to noise levels of 115 dBa and above, at

any time, requires dual hearing protection.
NOTE: The above recommendations are based upon U.S. Department of Labor, Mine Safety
and Health Administration requirements, Title 30 CFR 62.0, which includes time
weighted averages for exposure limits. At minimum, follow the requirements of your
appropriate federal regulatory agency or your employer; whichever is most restrictive
(most protects your hearing). Whenever in doubt about the noise level, wear approved
hearing protection.
• Keeping all doors closed helps to maintain pressurization. Keeping the cab door(s)
closed significantly reduces noise levels and exposure to air borne contaminants to
the operator.
• Do not attempt to get on or off the machine while it is in operation. Notify the operator
prior to any attempt to board/exit the machine.
• Always use proper communication methods (horn signals, radio, visual) to notify all
personnel of your intentions before any equipment movement, and after equipment
stop.
• Do not move or operate the machine without first knowing the location and purpose of
all personnel and test or support equipment on or near the machine.
• Do not allow unauthorized personnel on board the machine while in operation.
• Use audible signals to warn of machine movements. A signal horn button is provided
for this purpose.
• Do not propel until the travel route has been cleared of obstructions.
• Prevent trail cable from being dragged on the ground for long distances or at high
speeds.
• Limit the amount of cable being pulled by the machine. Pulling too much cable will
damage both the cable and the machine.
• Do not operate the machine on a slope greater than that specified in SLOPE
LIMITATIONS later in this manual.

July 2013
Safety
Operation Near Electrical Power Lines BI006779
2.6 Operation Near Electrical Power Lines
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.
• 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.
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.

July 2013
Safety
BI006779 Fire Prevention
2.7 Fire Prevention

2.7.1 Fire Extinguisher Locations
• Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and
service the extinguisher as indicated on its instruction plate.
• DO NOT smoke while handling flammables or when near batteries.
• Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended
torque.
• Repair or replace loose or damaged lines, tubes and hoses as soon as possible.
• Make certain all clamps, guards and shields are replaced correctly so as to prevent vibration
and the chafing of parts during operation.
• DO NOT carry flammable fluids such as gasoline or solvents on board the machine.
• DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged
lines, tubes, or hoses. Replace them immediately.

July 2013
Safety
Fire Prevention BI006779
• DO NOT start the machine or move any of the controls if a warning tag is attached to the
controls or the start panel.
• Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.
• Keep all structural frame compartments, walkways and work areas clean and free of lubricant
residue.
• NEVER weld, burn, or perform service on the machine alone.
• If a motor or other component is running hot, shutdown the machine until it has cooled and
the cause is determined and repaired.
2.7.2 Fire Extinguishers
Replace fire extinguisher immediately with fully charged extinguishers after ANY
discharge is made from an extinguisher.
2 – 10 Electric Rope Shovel OM11089-EN

July 2013
Safety
BI006779 Common Safety Features
2.8 Common Safety Features

Most shovels can be equipped with the following safety features.
2.8.1 Emergency Lighting

In case of a power failure, there are 13 emergency lights and 3 self-luminating exit lights located
throughout the machinery house and near walkways similar to the figure below.
Figure 2-1 Emergency Lighting Locations
OM11089-EN Electric Rope Shovel 2 – 11

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Safety
Common Safety Features BI006779
2.8.2 Mine Signal

A mine signal switch is located on either side of the machine at the back of the ballast box. A pull
cord, which can be reached from the ground, activates an air horn located at the top of the lube
room.
Figure 2-2 Mine Signal Switch
Figure 2-3 Mine Signal Horn Location

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Safety
2.8.3 Dual Mirrors
Dual convex mirrors are mounted outside right and left hand side of the operator’s cab. Mirrors
can be mounted and adjusted for best operator’s viewing.

Figure 2-4 Right Side Mirror

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Safety
2.8.4 Propel Warning Lights

Propel warning lights will flash when the machine is in motion.The amber lights are usually
mounted on both sides of the machine, outside of the electrical room.
Figure 2-5 Right Side Warning Light

July 2013
Safety
2.8.5 Propel Back-up Alarm
In addition to propel warning lights, machines can be equipped with a propel back-up warning
alarm. The horn is usually mounted on the right side of the ballast box, bellow the deck
extension.

Figure 2-6 Propel Back-up Horn Location

July 2013
Safety
2.8.6 Emergency Stop Buttons

There are 5 Emergency Stop buttons on the Rope Crowd machines and 7 on HydraCrowd
machines.
• POEB1: Wall mounted behind the MCC facing inboard

• POEB2: On the front section of the MCC facing inboard
• POEB3: Operator's Console
• POEB4: LH front side of the Siemens Skid
• POEB5: RH side of the HydraCrowd Skid (not used on Rope Crowd machines)
• POEB6: LH side of the HydraCrowd Skid (not used on Rope Crowd machines)
• POEB7: Near Auxiliary Seat in the cab
Pressing any one of the Emergency Stop buttons will stop the machine under operational
emergency conditions. Pushing this button will provide immediate electrical and mechanical
braking simultaneously. Therefore, it 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.
Pressing the emergency stop button when any drive is in motion may result in component
damage.

July 2013
Safety
2.8.7 Cameras
There are 5 cameras located on the machinery house and boom. Video camera monitors are
located in the operator’s cab above the front windshield.

Figure 2-7 Camera Locations

July 2013
Safety
2.8.8 Boarding Stairs

A set of boarding stairs is attached to the machinery house platform - either on the left side of the
machine, the right side or both. These stairs must be in their raised and latched position to
enable the operator’s controls.
Figure 2-8 Right Side Boarding Stair
2.8.9 Vertical Boarding Ladder

The vertical boarding ladder is one of the means for boarding the machine, located on the left-
hand side of the machine, at the rear of the machinery house. When the ladder is not latched in
place the operator's controls are deactivated.

July 2013
Safety
2.8.10 Man On Ground Light
A rotating light is used to indicate to other mine personnel in the pit that a person is on the ground
in the vacinity of the shovel. This light is typically mounted to a handrail on the left side of the
machine.

Figure 2-9 Left Side Warning Light

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Safety
Emergency Escape Chute (Option) BI006779
2.9 Emergency Escape Chute (Option)

An emergency escape chute is located just outside the operator's cab side doorway.
For detailed operating instructions, always refer to the manufacturer's documentation.

Ensure all personnel have a thorough understanding of how the system works and under
what conditions the escape chute should and should not be deployed.
2.9.1 Overview
A brief description below describes the conceptual use of the vertical escape chute in order to
provide a basic understanding of this optional component. It does not in any way replace the
manufacturer’s documentation for installation, operation or use.
The emergency egress is a simple but highly effective method of quickly evacuating personnel
from the machine in an emergency situation. Immediately after being deployed the chute can be
used. The vertical escape chute is fitted with a polymer cassette which allows the user to control
the speed of descent.
• Activate the escape chute by lifting up on the gate and pushing outward.
• Sit on the edge with your feet and legs in the chute.
• While supporting your body weight with your hands, lower yourself into the chute.
• Once in the chute, push your hands and arms against the wall to slow descent.

July 2013
Safety
BI006779 Emergency Escape Chute (Option)
• Bending your legs at the hips will bring you to a stop.
• Relaxing the pressure against the wall will increase the speed of descent.
• When your feet touch the ground, extract your body from the chute and walk away!

July 2013
Safety
Cable Reel BI006779
2.10 Cable Reel

The optional cable reel assembly is mounted on the rear of the machine. It is a level winding
wheel used to retrieve and pay out trail cable to keep the length of the cable as short as practical.
During normal operation of the machine a certain level of tension is maintained on the trail cable
by a motor mounted on the cable reel. The motor drives the cable reel through a chain sprocket
arrangement which powers the level wind mechanism through an intermediate right angle
reducer.
Cable reels are not designed to pull trail cable over the ground. Severe damage to the
cable or the cable reel may result if this is attempted.

July 2013
BI006779

3 Overview
Overview
3.1 Boarding The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.1.1 Power Step – Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2 Operator Cab Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.1 Fire Extinguisher Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-1 Cab Interior Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.2 Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.3 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.4 Cabinets & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3 Exiting The Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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Overview
BI006779

July 2013
Overview
BI006779 Boarding The Machine
Overview
3.1 Boarding The Machine

Never attempt to board or leave a machine when it is operating. The swing, propel, and/or
crowd functions can crush a person. Always wait until the machine is parked before
attempting to board.
Always notify the shovel operator before using the stairway controls.
• If a person aboard the machine wants to leave the parked machine, the boarding stairway is
controlled by a handle operated valve, located on the exterior wall of the machinery house.
• If a person on the ground wants to board the parked machine, a warning alarm for the
operator can be activated by pulling one of the two mine signal switch cords hanging from the
shovel at the rear.
After boarding the machine, raise the stairway to the stored position using the handle operated
valve located on the machinery house wall.

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Overview
Boarding The Machine BI006779
3.1.1 Power Step – Option

The power step is another way to board the machine. Inspect that all pins and keepers are in
place before using the power step. Use the lock/release foot lever to release the power step.
Always secure the safety chain or lever on the basket before boarding or dismounting the
machine.
When raising the power step, engage the switch in the up position and hold until the unit is fully
raised. To lower the power step, engage the switch in the down position and hold until the unit is
fully extended to the ground.

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Overview
BI006779 Operator Cab Interior
3.2 Operator Cab Interior

The operator's cab extends from the right front corner of the machine. The insulated cab provides
a controlled environment for the operator, crew, and electronic equipment. A combination heater/
air conditioning unit is mounted on the roof of the cab and provides warmed or cooled air as set
using the HVAC digital controller. Keeping all doors closed helps to maintain pressurization.

Keeping the cab door(s) closed significantly reduces noise levels and exposure to air borne
contaminants to the operator. For more specific information regarding operator controls, refer to
Section 4 ~ OPERATOR'S STATION later in the manual.
There are three unique seats in the cab:
Operator’s Seat — Auxiliary Seat — Swing Seat
3.2.1 Fire Extinguisher Location

There are two fire extinguishers shown in the locations above. Both are wall mounted. One fire
extinguisher is located inside the cab directly behind the auxiliary seat, the second is located just
outside the rear door.

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Overview
Operator Cab Interior BI006779
Figure 3-1 Cab Interior Amenities
3.2.2 Refrigerator
Setting Temperature:
The refrigerator is fitted with a manually operated thermostat. The control knob (located inside
the refrigerator) is turned clockwise to reduce temperature and counter-clockwise to both
increase temperature and activate the on-off switch at the end position. A certain spring
resistance is recognized at the off position.
Maintenance:
The refrigeration system has a closed cooling system and does not require any maintenance or
refilling of refrigerant. Periodically clean the inside surfaces using lukewarm water and a mild
detergent.

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Overview
BI006779 Operator Cab Interior
3.2.3 First Aid
A first-aid kit is stored inside the top drawer above the refrigerator.

3.2.4 Cabinets & Storage
The fire suppression cabinet is located above the electrical equipment cabinet at the rear of the
cab. Four personal storage lockers are located next to the cab’s right-side door.

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Overview
Exiting The Cab BI006779
3.3 Exiting The Cab

There are two doors in the cab. The rear door is best suited for emergency exit. There is a
second door located on the right side of the cab, just behind the operator's station. This door
opens onto the cab walkway and could also be used in an emergency.

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BI006779

4 Operator’s Station
Operator’s Station
4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.1.1 Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-1 Low Profile Fore and Aft Isolator Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.2 Adjustable Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-2 Right Hand Grate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.1.3 Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.1.4 Armrest & Joystick Pod Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1.5 Joystick Pod Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Figure 4-3 Standard Configuration – Button Locations . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.1.6 Operator Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.1.7 Display Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.1.8 Operator’s Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-4 Operator’s Console Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.1.8.1 Emergency Stop Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.1.8.2 Window Shade Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.1.8.3 Wiper Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.1.8.4 Console Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.1.8.5 Flood Light Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.1.8.6 Heated Mirror Switch – Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.1.8.7 Front Ceiling Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.1.8.8 Back Ceiling Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

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BI006779
4.1.8.9 Man On Ground Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.1.8.10 HVAC A/B Switch – Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.1.8.11 HVAC Digital Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Figure 4-5 HVAC Digital Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.1.8.11.1 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.8.11.2 Auto Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.8.11.3 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4.1.8.11.4 Up & Down Arrows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.8.11.5 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.8.11.6 Air Circulation Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.1.8.11.7 Defog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.1.8.11.8 Celsius / Fahrenheit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.1.9 Ground Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.1.10 Stereo AM/FM Receiver/CD Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.1.11 USB Stereo Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.1.12 Motorized Window Shades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.1.13 Task Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.1.14 Ethernet & USB Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.1.15 Telephone Handset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.1.16 Swing Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Figure 4-6 Swing Seat in the Stored Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.1.17 Video Camera Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

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BI006779 General Information
4.1 General Information

The operator’s station consists of the operator’s seat, operator console, two display monitors (not
shown). The operator console contains a bank of rocker switches, HVAC controller, radio/CD

player, ground test switch and an Emergency Stop button.
Before operating the machine, the operator should read and carefully study the information and
instructions outlined in this manual. The operator should become thoroughly familiar with the
location and purpose of each component within the operator’s station.
The descriptions listed should familiarize the operator with each of the 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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General Information BI006779
4.1.1 Seat Adjustment

The operator’s seat can be adjusted in a variety of ways.
For armrest’s refer to ARMREST ADJUSTMENTS, for pod’s refer to JOYSTICK POD
ADJUSTMENT later in this manual.
To raise the seat assembly:

Push in on the push/pull button at center of the seat.
To lower the seat assembly:
Pull out on the push/pull button at center of seat.

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To tilt the seat back:
Pull up on the seat tilt lever located on left side of the seat (where the seat back meets the seat
cushion).
To increase lumbar support:
Pump the squeeze bulb several times. This will add air and increase support in the lumbar

region of the seat back.
To reduce lumbar support:
Release air by opening the valve located on the bulb.
To adjust the back of the seat cushion height:

Lift up on lever to release the back of the seat cushion. Adjust the seat up and down as needed,
then release the lever to lock into position. The operator may need to shift their weight fore and
aft to allow the lever to release from the locked position.
To adjust the front of the seat cushion height:
Press down on lever to release the front of the seat cushion. Adjust up and down as needed,
then release the lever to lock into position. The operator may need to shift their weight fore and
aft to allow the lever to release from the locked position.

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Figure 4-1 Low Profile Fore and Aft Isolator Assembly
The low profile fore and aft isolator assembly is designed to handle substantial loads without
slack. The design is based on two long linear ball bearings. Each isolator dampens vibrations
and shocks with a stroke of ±40 mm. Dampening characteristics are adjustable in six levels and
can be locked out when isolation is not needed or wanted.

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4.1.2 Adjustable Footrest
The right hand grate acts as an adjustable footrest for the operator.
To adjust the incline of the grate, push the latch mechanism forward with your foot to release.
The unit’s gas spring will push the grate upward. Adjust accordingly. Once the grate is in the

desired position, take your foot off of the latch mechanism to reengage the latch.
Figure 4-2 Right Hand Grate Assembly
4.1.3 Seat Belts

The operator’s and auxiliary seat are both equipped with seat belts.
To fasten the lap belt:
Insert the belt tongue into the buckle until you hear it snap and feel it latch.
Always keep the lap belt snug and low across the hips.
To unfasten the lap belt:
Push the release button and remove the tongue from the buckle.

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4.1.4 Armrest & Joystick Pod Adjustments

The armrests are attached to the seat assembly so they will stay properly adjusted when raising
or lowering the seat itself. The armrests are easily adjusted in various directions for operator
comfort.
Each armrest utilizes friction joints to allow side to side adjustment and armrest rotational
adjustment. The friction joints do not lock the armrest in place, therefore no amount of tightening
will lock these joints! Tighten the joint snuggly and test the amount of resistance to side
movement with and without weight on the armrests. The armrest should adequately hold their
position when the operator rests their arms and the added weight creates addition friction.
NOTE: The armrests are designed to allow for movement in the friction joint if exposed to high
forces. Simply re-orient armrests after movement occurs.

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Joystick pods can be moved into the best position for the operator. Hold firmly and move in the
direction desired to overcome the friction joint until it is located in the proper position.
NOTE: Adjustment tools for the pod are located in the headrest.
To reduce fatigue and improve comfort while operating, bring the armrests and joystick pods in
over your legs as shown below. This position allows operators to more easily view the crawlers.

This may take a little practice to begin with but will help to reduce fatigue and makes operation
easier. It generally takes 3-4 shifts to feel comfortable operating with the pods pulled inward over
your legs.
NOTE: If the armrests seem to be short, the operator can adjust the tilt of the seat pan which
will extend the armrest.

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4.1.5 Joystick Pod Buttons

The left pod houses three unique buttons.
The yellow Auto Dig button can be accessed using the left thumb. When the joysticks are in the
neutral position, this allows one-touch transfer from Propel to Dig. For more information, refer to
PROPEL/DIG CYCLE later in this manual. The left pod is also fitted with a spare and a Truck
Counter button which is located at the front edge of the pod. Pressing the button after each load
captures tonnage and load information when the optional AccuLoad™ system is utilized.
Figure 4-3 Standard Configuration – Button Locations
The right pod houses three unique buttons.

The blue Auto Propel button can be accessed using the right thumb. When the joysticks are in
the neutral position, this allows one-touch transfer from Dig to Propel. For more information, refer
to PROPEL/DIG CYCLE later in this manual. The right pod is also fitted with a spare and an
Alarm Silence button which is located at the front edge of the pod. This button silences the
audible CDA (Cab Displayed Alarm).

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4.1.6 Operator Displays
Two touch screen displays are used in the operator’s station. The displays come with pre-
installed software.
If the green power indicator light is illuminated, the power is on. DO NOT shut off power to the

operator displays. They should be left on at all times.
Adjust the brightness as needed.
There are two primary operator displays.

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The standard default configuration is described below:

The left-hand unit displays STATUS screens that provide the operator with information on the
status of the machine (air pressure, grade, lubrication, etc).
The right-hand unit displays CONTROL screens that allow the operator to control the machine
(set or release brakes, turn the drive power on or off, etc).
The CONTROL screens are essential for machine operation; the STATUS screens are not. In the
unlikely event that the right hand unit would fail, its CONTROL screen can be swapped to display
on the left hand unit so production can continue. For more information, refer to DISPLAY
INTERCHANGEABILITY later in this manual.

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4.1.7 Display Interchangeability
In the unlikely event that the right hand display would fail, its CONTROL screen can be swapped
to temporarily display on the left hand unit so production can continue.
To transfer screens follow the procedure outlined below:

1. On the Status screen, press the SETTINGS icon (graphic showing a wrench) which is
located at the bottom of the screen.
2. Press the Operator Display icon (graphic showing a computer screen) which is located in
the lower left side of the screen.
3. Under the heading “SWITCH DISPLAYS” select “Switch to Control Screen”.
4. A yellow screen will appear asking if you want to proceed. Press the green checkmark to
proceed.
5. This completes the screen transfer process. Operation of the machine can resume.
Immediately notify the mine electrical maintenance that you have experienced an operator
display failure.
NOTE: This is a temporary fix. A new operator display should be installed as soon as possible.
The screens should then be returned to the standard configuration.

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4.1.8 Operator’s Console

The operator’s console is located to the right of the operator’s seat.
Figure 4-4 Operator’s Console Layout

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4.1.8.1 Emergency Stop Button

The emergency stop pushbutton is used to stop the machine under operational emergency
conditions. Pushing this button will provide immediate electrical and mechanical braking
simultaneously. Therefore, this button should only be used if the operator intends the harshest
damage.
4.1.8.2 Window Shade Switches
There are three window shade switches used to raise and lower the left, right and front window
shades. In the unlikely event that electrical control should fail, the shades can be manually raised
and lowered by rotating the cassette by hand.
4.1.8.3 Wiper Switches
There are two switches used to operate the front windshield wiper. One switch controls the
starting and stopping as well as the speed of the windshield wiper.
The second switch activates the washer fluid pump while pressed, pumping washer fluid onto the
front glass as needed.
NOTE: Pressing the washer fluid switch will also initiate the wiper motion and eliminates the
need to press both switches.

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4.1.8.4 Console Dimmer Switch

The console dimmer switch allows the operator to adjust the brightness of the console lights.
4.1.8.5 Flood Light Switches
Two on/off light switches are used to power two cab roof floodlights facing forward and one cab
floodlight facing left.
4.1.8.6 Heated Mirror Switch – Option
This switch is used to activate the heating mechanism in operator’s cab outside mirrors.
4.1.8.7 Front Ceiling Light Switch
This switch controls the overhead light located in the front of the operator’s cab. This is a
dimmable light controlled with the console and wall mounted light switch (dimmer).

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4.1.8.8 Back Ceiling Light Switch

This switch controls the overhead light located in the rear of the operator’s cab. This is a
dimmable light controlled with the console and wall mounted light switch (dimmer).
4.1.8.9 Man On Ground Light Switch
This switch turns the rotating light on and off. This light is typically mounted to a handrail on the
left side of the machine. When this light is on, it indicates to other mine personnel in the pit that a
person is on the ground in the vicinity of the shovel.
4.1.8.10 HVAC A/B Switch – Option
This two position switch allows the operator to switch between the primary or secondary HVAC
units on the machine (only one unit can operate at a time).
4.1.8.11 HVAC Digital Control Unit

This digital controller is used to operate the heating and air conditioning operation within the cab.
Figure 4-5 HVAC Digital Control Unit

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4.1.8.11.1 Heater
Press to activate the heating mode. In this mode the heaters will cycle on or off based on the
thermostat set point. The fans will continue to run even if the heaters are cycled off.
4.1.8.11.2 Auto Climate Control
Press to activate automatic temperature control mode. Use UP and DOWN arrows to increase or
decrease the desired temperature set point. In this mode the system will automatically go in to
the heat mode or the cooling mode as required to maintain the desired set point.
4.1.8.11.3 Air Conditioner
Press to activate the cooling mode. In this mode the cooling circuit will cycle on or off based on
the thermostat set point. The fans will continue to run even if cooling is not required.
4.1.8.11.4 Up & Down Arrows
Press the UP and DOWN arrows to increase or decrease desired temperature set point.
4.1.8.11.5 Power
Press once to provide power to the digital controller, press again to turn the power off.

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4.1.8.11.6 Air Circulation Fan

Press to activate air circulation fan. Use UP and DOWN arrows to increase or decrease the
desired fan speed.
4.1.8.11.7 Defog
In this mode, one bank of heaters as well as the cooling circuit will be energized to aid in clearing
the cab glass of fog. The heaters will run regardless of the current thermostat set point, however
the cooling circuit will cycle as normal using the current set point.
4.1.8.11.8 Celsius / Fahrenheit Setting
Press to switch between Fahrenheit and Celsius digital readout.

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4.1.9 Ground Test Switch

The Ground Test Switch is used to trip the breaker that supplies power to the machine. This is
accomplished since pushing the Ground Test Switch opens up the pilot wire in the trail cable
circuit.
This pushbutton should be used to shut down the machine only when removal of power to the
machine is required or to test the pilot trip circuit.
The Ground Test Switch has a hasp on it so that the pilot circuit can be padlocked open.

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4.1.10 Stereo AM/FM Receiver/CD Player
The stereo unit is an AM/FM receiver that can also play MP3, WMA, WAV, and AAC files on
compact disc. It has the capability to play digital files from the USB port as well. The unit is
equipped with a 3-band Equalizer.

For more detailed information, refer to the manufacturer’s instruction manual.
4.1.11 USB Stereo Port

(Not Shown)
This USB port can be used to play digital music files through the stereo receiver.

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4.1.12 Motorized Window Shades

Motorized window shades are installed on the right, left and front windows of the cab. The
shades travel along guide rods for smooth operation. Each shade is raised and lowered with its
own rocker switch located on the operator’s console. In the unlikely event that electrical control
should fail, the shades can be manually raised and lowered by rotating the cassette by hand.
There is no maintenance or lubrication required for the shades. However, upon initial set-up the
upper and lower limits (where the shade stops when raising or lowering) can be adjusted. Each
shade is adjusted individually. A small flat screwdriver and/or an allen wrench are required.
To adjust the limits:
The upper limit is always the limit located closer to the window regardless of the motor side.
Motor mounted on the left side of the shade is standard.
NOTE: One full revolution of the screw will move the shade approximately 0.25 inch (6.35 mm).

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4.1.13 Task Lights
There are two TouchLED Task Lights located in the operator’s cab. The flexible gooseneck
allows for easy positioning. The lights have no mechanical switches.

The center red LED performs the ON/OFF switching and serves as the nightlight function as well.
The nightlight function is activated automatically when it becomes dark. It will transform from its
dim stand-by mode to a full on red light mode which is bright enough for reading in the dark. By
quickly touching the center red LED you can switch ON/OFF the white LEDs. Nightlight function
automatically deactivates during the day.
The red nightlight function can be deactivated if it is not desired. This is achieved by one long
touch (min. 3 seconds) to the center red LED. In this case, the center-red LED will remain in its
stand-by mode, giving off a very subtle glow; just enough to allow one to locate the touch spot
should it be necessary to turn on the light in the dark. Any change in operation mode is initiated
by a brief quick flashing of the center red LED.

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4.1.14 Ethernet & USB Ports

Two port enclosures are located to the right of the operator’s seat. The Ethernet ports are used
for service personnel to connect a laptop for troubleshooting or monitoring purposes. This allows
access into the PLC, operator displays or maintenance station programs.
The USB ports are normally used by service personnel to connect a mouse or keyboard to
monitor or program the operator displays.

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4.1.15 Telephone Handset

To make a page announcement:
1. Lift the telephone handset from the cradle.
2. Depress and hold the handset pressbar.
3. Speak directly into the microphone to broadcast your announcement over the
loudspeakers.
4. Release the handset pressbar, and if requested, wait for a response. The paged
individual(s) responds by picking up a station handset.
NOTE: Audio adjustments can be made by removing the cover of the remote amplifier located
at the foot of the swing seat. Use a small standard screwdriver to adjust the receiver
volume, sidetone and microphone gain.

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Audio Adjustments:
• Microphone Gain: adjusts the gain level from the microphone signal to the page or party
lines.
• Receiver Sidetone: adjusts the signal transmitted from the microphone to the receiver of a
handset.
• Receiver Volume: adjusts the gain level from a party line to the receiver.

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4.1.16 Swing Seat
A retractable swing seat is located directly behind the operator’s station.

Figure 4-6 Swing Seat in the Stored Position

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4.1.17 Video Camera Monitors

Five video camera monitors are located above the front windshield.
In a standard configuration, the cameras are setup to monitor:

• Dipper
• Hoist Drum
• Left Side Facing Front
• Left Side Facing Rear
• Center Facing Rear*
The monitor settings should not require any adjustment. However, each unit can be adjusted
accordingly.
Brightness Adjustment
Press the Brightness button on the face of the monitor. Use the plus (+) or
minus (-) buttons to select the desired brightness.
Contrast Adjustment
Press the Contrast button on the face of the monitor. Use the plus (+) or
minus (-) buttons to select the desired contrast.
* To invert or “mirror” the image (reverse left and right) sent from the rear facing camera, the
service menu of the appropriate monitor will need to be accessed.

July 2013
To access or open the Service Menu:

Press the plus, minus and camera selection buttons at the same time.
• With the “CAMERA SETTINGS” highlighted, press the Enter button.
• Highlight the “MIRROR” option and toggle to ON (box checked).
• Press the Enter button again to store the new setting.

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BI006779

5 Operator Controls and Displays
Operator Controls and Displays
5.1 Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Figure 5-1 Standard Default Configuration Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 Control Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3 Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-2 HOME Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-3 Primary Icons used to navigate Status Screens . . . . . . . . . . . . . . . . . . . . 5-6
5.3.1 Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Permissives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.1 E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.2 1 Start Within 2 Minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.3 2 Starts Within 5 Minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.4 Drive Ready (No AFE Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.5 Drive Cabinet Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.6 Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.7 Auxiliary Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.8 Incomplete Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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5.4.9 Joysticks Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4.10 Joysticks In Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.11 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.12 Boarding Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.13 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

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BI006779 Joysticks
5.1 Joysticks
The operator’s station contains two joystick controllers (Left and Right).
For detailed information about transferring from DIG to PROPEL mode; refer to either AUTO

PROPEL - DIG CYCLE or MANUAL PROPEL - DIG CYCLE later in the manual.
Figure 5-1 Standard Default Configuration Shown
For detailed information explaining hoist, swing, crowd and propel motion controls; refer to
MACHINE OPERATION later in the manual.

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Control Screens BI006779
5.2 Control Screens

Control screens allow the operator to control the machine (set or release brakes, turn the drive
power on or off, etc) and are essential for machine operation.
In the screen above all the brakes are currently set. Note the “release” icons are grayed out. The
machine is currently in the dig mode, control is in the stop position and the drive power is off. At
the bottom of the screen the current configuration for the joystick and pod buttons is displayed.

July 2013
BI006779 Status Screens
5.3 Status Screens

As the name implies, status screens display the current status of the machines components
(boarding ladders, air pressures, etc). Status screens also help the operator monitor current
conditions and can display a record of past events (faults, alarm history, etc).
Figure 5-2 HOME Screen

July 2013
Status Screens BI006779
With proper authorization, the specific machine settings can be displayed and modified by
qualified personnel. Not all screens are accessible by the machine operator.
Figure 5-3 Primary Icons used to navigate Status Screens
5.3.1 Home
Selecting the HOME icon will allow the operator to display the current status of the machines
handle lube, air pressure, boarding ladder position, intake fans, and other components. Access
to Adaptive Control and Accuload Control falls under the HOME icon.
5.3.2 Monitoring
Selecting the MONITORING icon will allow the operator to view the component operating
temperatures, current side to side incline, front to back incline, machine hours and fault counter.
The temperature monitoring feature is an option.
5.3.3 Alarms
Selecting the ALARMS icon will allow access to the machines active alarms as well as the alarm
history.
5.3.4 Settings
Selecting the SETTINGS icon will allow the operator access to:
• Setting Limits
• Rope Reeving & Pintle Tightening
• Joystick Calibration
• Lube Setup and Test
• Motivator (Option)
• Operator Display Setup
• Switch Displays
• Security

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BI006779 Permissives
5.4 Permissives
Selecting PERMISSIVES displays the machines current readiness for startup.

5.4.1 E-Stop
Green check mark indicates that none of the emergency stop buttons have been pressed.
5.4.2 1 Start Within 2 Minutes

This contact detects whether the DC bus has been pre-charged within the past two minutes. The
DC bus cannot be pre-charged more than once within the past two minutes. The green check
mark indicates that the bus has not been pre-charged within the two minute timeframe.

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Permissives BI006779
5.4.3 2 Starts Within 5 Minutes

This contact detects whether the DC bus has been pre-charged twice within the past five
minutes. The DC bus cannot be pre-charged more than twice within the past five minutes. The
green check mark indicates that the bus has not been pre-charged twice within the five minute
timeframe.
5.4.4 Drive Ready (No AFE Fault)

There is no drive fault. The AFE drive is ready for startup.
5.4.5 Drive Cabinet Temperature

The green check mark indicates that the drive cabinet temperature is within an acceptable range.
5.4.6 Phase Sequence

AC phase sequence check. The red “X” mark indicates that the sequence is NOT proper.
5.4.7 Auxiliary Ground Fault

Auxiliary ground fault check. The red “X” mark indicates that there is a ground fault.

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5.4.8 Incomplete Start-up Sequence
The green check mark indicates that the sequence for start-up was complete.

5.4.9 Joysticks Calibrated
The green check mark indicates that the joysticks are calibrated.
5.4.10 Joysticks In Neutral

Checks if both joysticks are in the neutral position. The green check mark indicates that both
joysticks are in neutral.

July 2013
5.4.11 Brakes
The red “X” marks indicate that the brakes have not been released.
5.4.12 Boarding Ladder

Detects if any of the boarding ladders are down or in the process of being lowered. The green
check mark indicates that all ladders are up.

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5.4.13 Information
Selecting the INFORMATION icon will display:
• Machine Type & Serial Number
• PLC Filename

• Operator Station Filename
• WinCC Version Number

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6 Pre-start, Start-up & Shutdown
Pre-start, Start-up & Shutdown
6.1 Pre-start Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.2 Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6-1 Machine Start-up Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6-2 Machine Start-up Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 Compressor Startup & Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.3.1 Normal Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.3.2 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4 Normal Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Figure 6-3 Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.5 Emergency Shut-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Figure 6-4 Emergency Stop Buttons Inside the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.6 Restarting After An Electrical Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

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July 2013
BI006779 Pre-start Inspections
6.1 Pre-start Inspections

Before starting, inspect the machine to ensure it is ready to be put into operation. Failure to make
such a routine check could result in unnecessary downtime. For example: an undetected oil leak

could result in a dry gearcase, eventually leading to excessive gear wear or destruction, seized
bearings or other mechanical problems. Broken strands in the hoist ropes, crowd rope, retract
rope or structural strands could, if undetected, result in serious injury or damage to the machine
or haulage unit. A few minutes spent inspecting the machine often results in considerable
savings in time and machine efficiency.
Check the following areas daily during a general walk-around inspection:
1. Check the areas under and around the crawlers for signs of oil leaks. If single droplets are
noticed, leakage is minimal. Determine the point of leakage and make a note of it on the log
sheet. If pooling of oil is noticed, determine the source and take corrective action
immediately. Determine if loose hardware, a defective gasket, a combination of both, or a
similar problem is responsible. Tighten hardware or replace defective gaskets.
2. Inspect the crawler belts for missing links or lock pins, excessive belt sag, cracked shoes or
other deterioration. Check the oil level in the propel planetary gearcase. Add oil as required.
3. Check the swing rack and pinion guards for rocks, dirt and other debris that will interfere
with the operation of the machine. Inspect the swing rack gear and rollers for the proper
lubricant film.
HIGH VOLTAGE!THE MACHINE TRAIL CABLE CARRIES A LETHAL VOLTAGE. Handle

the cable in an approved manner with appropriate hot gloves and insulated hooks or
tongs.
4. Visually inspect the trail cable for cuts, abrasions and other damage.
5. Visually inspect exterior of machinery house for damage or evidence of internal leakage.
6. Inspect the dipper trip mechanism, rope and associated hardware for damage, adjustment
and wear.
7. Inspect the dipper door, hardware and bumpers (if equipped) for damage and excessive
wear.
8. Inspect fulcrum attachment points, take up cylinders and spacers and dipper handle for
damage, excessive wear and evidence of adequate lubrication.
9. Inspect boom bumper (if equipped) for security and damage.
10. Inspect the dipper teeth and tooth adapters for tightness and excessive wear.
11. Inspect padlocks for damage, wear and evidence of adequate lubrication.
12. Check both the running ropes and the boom structural strands for broken strands and loose
sockets.
Check the following areas daily on board the machine:
1. Visually inspect the swing, crowd (if equipped) and hoist gearcases for oil levels and leaks.
Repair or service as required.

July 2013
Pre-start Inspections BI006779
2. Visually inspect all machinery for loose bolts, nuts, clamps or unusual deterioration. Repair
as required.
3. Visually inspect the open gears of the swing, crowd (if equipped) and hoist machinery for
proper lubricant film and evidence of adequate lubrication from the automatic lubricant
dispensing system.
4. Visually inspect hoist and crowd*ropes for wear, lubrication and evidence of birdcaging near
the drum attachment beckets. Check that the ropes are properly seated in the drum
grooves.
5. Check the oil level in the air compressor. Add oil if required.
6. Check lubricant supply level in the air system lubricator and lube system lubricators.
7. Inspect the automatic lubrication central pumping stations for any signs of malfunctioning.
Check the lubricant supply and refill tanks if required.
8. Visually inspect swing, crowd and hoist brake assemblies for damage, wear and evidence
of an overheated condition.
9. Check the operator’s cab for cleanliness and visual condition of controls and location of
special equipment that may be required by the mine site. Check all operating controls for
freedom of movement. Controls should move freely without binding.
10. Clean windows of operator’s cab using the machine’s windshield wiper system. If the wiper
blades need replacement, refer to the maintenance manual.
11. Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a
safety hazard.
12. Ensure all external stairways and/or ladder(s) and optional power step are raised and
properly stowed.
*.Crowd ropes are not used with HydraCrowd machines

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BI006779 Start-up Procedure
6.2 Start-up Procedure

Whether starting the machine for the first time, or starting after the machine has been in service
for some time, the procedures are essentially the same.
1. Perform all pre-start inspections. For a detailed list, refer to PRE-START INSPECTIONS

earlier in the manual.
2. Ensure the air compressor has
been started and is running with
adequate operating pressure.
Navigate to the “home” screen to
verify the compressors operating
pressure. If the air compressor
(located in the left side of the
machinery house) is not running,
it will need to be manually started.
Refer to COMPRESSOR
STARTUP & SHUTDOWN later in
this section of the manual.
3. On the left-hand operator display, the Permissives screen will appear by default. Verify the
items A through L below are ready for start-up.
Figure 6-1 Machine Start-up Permissives

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Start-up Procedure BI006779
a. Verify that the E-Stop icon indicates a green check mark. This means that no Power
Off or Emergency Stop buttons have been detected as being pressed.
b. Verify that the”1 Start Within 2 Minutes” icon indicates a green check mark. This
means that the DC bus has not been pre-charged within the past two minutes.
c. Verify that the”2 Starts Within 5 Minutes” icon indicates a green check mark. This
means that the DC bus has not been pre-charged twice within the past five minutes.
d. Verify that the Drive Ready icon indicates a green check mark. This means that there
is currently no drive fault and the AFE drive is ready for start-up.
e. Verify that the Drive Cabinet Temperature icon indicates a green check mark. This
means that the drive cabinet temperature is within operating range.
f. Verify that the Phase Sequence icon indicates a green check mark. This means that
the phase sequence is proper.
Figure 6-2 Machine Start-up Permissives
g. Verify that the Auxiliary Ground Fault icon indicates a green check mark. This means
that there is no ground fault detected.
h. Verify that the Incomplete Start-up Sequence icon indicates a green check mark. This
means that the start-up sequence is complete. If all start-up indicators are checked,
the machine is ready to start.
i. Verify that the Joysticks Calibrated icon indicates a green check mark. This means
joysticks are properly calibrated.
j. Verify that the Joysticks in Neutral icon indicates a green check mark. This means that
both joysticks are in the default (neutral) position.

July 2013
BI006779 Start-up Procedure
k. Verify that all brake icons indicate a red “X” mark. This means that the brakes are SET.

l. Verify that the Boarding Ladder icon indicates a green check mark. Ensure that all
boarding stairs and/or ladders are in the raised and latched position. If all the control
permissives are indicated with a green check mark, the machine is able to operate.
4. Press the Drive Power ON button.
If the button is not active (faded in appearance), press the Control RESET button (shown
below), then press the Drive Power ON.
5. Monitor the air pressure using the appropriate status screen on the left-hand operator
display.
6. Address any CDA Faults that arise after start-up.
7. Sound the signal horn and be sure all personnel are clear of the machine.

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Start-up Procedure BI006779
8. Ensure the joysticks are in the neutral position. Select the DIG Mode.
When the process is complete, press the Control RESET to activate the controls.
9. RELEASE the brakes using the control screen.

10. Briefly actuate the swing, crowd and hoist controls to make sure each motion is operational.
11. Perform a pre-operational check of the propel motion before operating the propel.
12. Before operation, verify that hoist and crowd limits are set properly and operational.

July 2013
BI006779 Compressor Startup & Shutdown
6.3 Compressor Startup & Shutdown

The air compressor is located along the left side wall of the machinery house.
A brief description of the compressor startup and shutdown process is included in order to guide
the user through the processes. It is not intended to replace the manufacturer’s documentation. If
you are not familiar with the proper and safe operation of the air compressor, read the
manufacturer’s operator’s manual before proceeding.
To start the air compressor:
1. Verify that the shut-off valves are fully open.
2. Verify that the main power is on.
3. Press the START button. The electronic controller may delay the starting process under
certain conditions. Once the compressor begins startup, monitor the digital display until the
set operating pressure is achieved.
4. When the digital display reads STANDBY RUN ON, run the compressor through a number
of load/unload cycles and check for consistent, smooth operation.

July 2013
Compressor Startup & Shutdown BI006779
6.3.1 Normal Shutdown
Never assume that the compressor has completely stopped, even if the compressor does
not appear to be running. The compressor may have stopped in STANDBY mode and may
restart at any time!
To shut down the air compressor:

Press the STOP button on the digital display. The compressor will begin a delayed stop
sequence STOP RUN ON along with the remaining time in seconds until compressor stop. The
compressor will stop automatically after the delayed stop period.
NOTE: If during the stop delay period the START button is pressed, the STOP RUN ON timer
function will be cancelled and the compressor will run normally loaded/unloaded as
necessary to maintain system pressure.
6.3.2 Emergency Shutdown
Press the EMERGENCY STOP button on the front of the compressor. DO NOT use the
emergency stop button for normal shutdown!

July 2013
BI006779 Normal Shutdown Procedure
6.4 Normal Shutdown Procedure

When shutting down the machine proceed as follows:
1. Park the machine on firm ground in a position where it cannot be damaged by a slide, falling
rocks or flooding, and where the next operator can safely conduct their pre-operational

inspection. In cold climates, be sure the crawler belts will not freeze into the ground.
2. Place the dipper firmly on the ground.
Figure 6-3 Control Screen
3. Make sure all brakes are SET.

4. Press the Control Stop button.
5. Press the Drive Power Off button. This shuts down the drive.
NOTE: The house and motor blowers will continue to operate to ensure the drive components
have cooled down sufficiently. Once the drives are cool, the house blowers will shut-
down automatically.
DO NOT use the Emergency Stop button for normal shutdown! The emergency stop
pushbutton is used to remove power and stop the machine under emergency conditions.
Pushing this button will immediate set all brakes. Therefore, this button should only be
used if the operator intends the harshest braking of all motions.

July 2013
Emergency Shut-down BI006779
6.5 Emergency Shut-down

Pressing any one of the Emergency Stop buttons will stop the machine under operational
emergency conditions. Pushing this button will provide immediate electrical and mechanical
braking simultaneously. Therefore, it should only be used if the operator intends the harshest
damage.
Figure 6-4 Emergency Stop Buttons Inside the Cab

July 2013
BI006779 Restarting After An Electrical Fault
6.6 Restarting After An Electrical Fault

To restart the machine after the electrical control system has gone into a fault condition, proceed
as follows:
NOTE: Before any or all motions can be reset, the following conditions must be met:

a. For hoist/propel motion the hoist/propel transfer switch is in the position called for by
the operator’s mode selector switch.
b. The joystick for the motion being reset must be in the NEUTRAL position.
c. The motion mechanical brake selector button must be in the SET position.
1. For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the
controls will remain active. Reversing the joystick will remove the fault and allow continued
operation.
2. For a boom jacking fault, ALL motions will stop but the controls will remain active. Reversing
the crowd joystick will remove the fault and allow continued operation. Gently retract the
dipper handle until the boom is completely lowered. You can then resume normal operation.
3. If the boarding ladder and/or stairs are pulled down while the machine is in operation, an
alarm message will be sent to the operator, and swing and propel motions will be shut
down. The hoist and crowd motions will remain active.
a. Once the ladder and/or stairs are back in position, the motions may be restarted by
pressing the control reset pushbutton.
4. For most other faults, the machine will be shut down and brakes set. In these situations, the
controls cannot be reset until the fault has been corrected by an electrician.

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Restarting After An Electrical Fault BI006779

July 2013
BI006779

7 Machine Operation
Machine Operation
7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.1.1 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Auto Propel - Dig Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Manual Propel - Dig Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.4 Hoist Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5 Swing Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6 Proper Swing Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.7 Crowd Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8 Propel Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.8.1 Recommended Handle Position During Propel . . . . . . . . . . . . . . . . . . . . . . 7-15
7.9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.10 Counter-rotation Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.11 Positioning The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.11.1 Back-up Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

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BI006779
7.11.2 Drive-by Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7.12 Start Of The Dig Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Figure 7-1 Force the Dipper Lip into the Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Figure 7-2 Variations on Dipper Penetration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Figure 7-3 Dig with the Dipper Beneath the Boom Point . . . . . . . . . . . . . . . . . . . . . 7-23
7.13 Engaging The Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Figure 7-4 Engage the Bank Under the Boom Point. . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Figure 7-5 Hoist Force Opposes Crowd Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Figure 7-6 Make Effective Use of the Hoist Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.14 Slope Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

7.15 Excavating Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7.16 Operation Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.17 Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

July 2013
Machine Operation
BI006779 Introduction
Machine Operation
7.1 Introduction
The purpose of this section is to describe the operation of the individual motion controls and
include some recommended operating procedures and practices that will aid the operator in the

safe, smooth and efficient operation of the machine.
Due to the many varied mining conditions, situations may arise which are not directly
discussed in detail in this manual. When such situations arise; past experience,
availability of equipment, and common sense play a large part in what steps should be
taken. General safe practices for working machines must be followed as well as safe
operating practices. However, it is impossible to foresee all such conditions, and it must
remain the responsibility of the mining company and the operator to anticipate and avoid
any unsafe conditions not described in detail in this manual. Safety rules within individual
mining companies vary. If a conflict exists, the rules of the company take precedence over
the suggestions contained within this manual.
7.1.1 Operator Responsibilities

• The operator must read and understand the operator's manual and be familiar with all
instructions and signs on the machine.
• The operator must see that the machine is in proper order before starting to work each
shift. Refer to PRE-START INSPECTIONS for details. Check with mine maintenance and
operations management to see that periodic maintenance and inspections have been
performed and all necessary repairs made.
• Refer to START-UP PROCEDURE for detailed instructions on starting the machine.

July 2013
Machine Operation
Auto Propel - Dig Cycle BI006779
7.2 Auto Propel - Dig Cycle
It is strongly recommended that the manual transfer process be utilized whenever

performing maintenance functions to avoid releasing brakes (which the auto transfer
process will do).
Transferring from DIG to PROPEL mode and back again can be done using the control screen or
the transfer process can be accomplished (often quicker) using the buttons located on the left
and right joystick pod. When using this auto transfer method, it is important that both joysticks
remain in the NEUTRAL position until the transfer is complete.
NOTE: In the short time the auto transfer is in process, the following occur automatically:
• The applicable brakes are set
• The Control is stopped
• The transfer occurs
• The Control is reset
• The applicable brakes are released
To transfer from PROPEL to DIG:

• Push the (yellow) Auto Dig button on the left-hand pod to initiate the process.
• Control screen icons associated with the transfer will flash on and off during the transfer.
Once the transfer is complete the icons will go solid green.
To transfer from DIG to PROPEL:
• Push the (blue) Auto Propel button on the right-hand pod to initiate the process.

July 2013
Machine Operation
BI006779 Auto Propel - Dig Cycle

• Control screen icons associated with the transfer will flash on and off during the transfer.
Once the transfer is complete the icons will go solid green.

July 2013
Machine Operation
Manual Propel - Dig Cycle BI006779
7.3 Manual Propel - Dig Cycle

Transferring from DIG to PROPEL mode and back again can be done using the control screen.
This manual transfer is strongly recommended whenever performing maintenance functions to
avoid releasing the brakes (which the auto transfer process will do).
To manually transfer from PROPEL to DIG using the control screen:

1. Press to set the appropriate brakes; All Brakes or Propel.
3. Press the DIG button. Allow time for the transfer to be completed.
4. Press the Control Reset button. When the button is pressed, it turns to blue (as shown
below). When this button is released, it turns back to black.
5. Press to release the appropriate brakes; All Brakes or Hoist and Crowd.
To manually transfer from DIG to PROPEL using the control screen:

July 2013
Machine Operation
BI006779 Manual Propel - Dig Cycle
1. Press to set the appropriate brakes; All Brakes or Hoist and Crowd.

3. Press the PROPEL button. Allow time for the transfer to be completed.
4. Press the Control Reset button. When the button is pressed, it turns to blue (as shown
below). When this button is released, it turns back to black.
5. Press to release the appropriate brakes; All Brakes or Propel.

July 2013
Machine Operation
Hoist Motion Control BI006779
7.4 Hoist Motion Control

Hoist motion is controlled by the operator’s right joystick. To transfer to the DIG mode, refer to
PROPEL-DIG CYCLE for more information. The crawlers should be positioned so that the
digging is done over the front of the crawlers. Move the joystick between the hoist and lower until
a “feel” is developed for the height, depth range and speed at which the dipper moves. Practice
the hoist function until movement can be stopped smoothly.

NOTE: The speed of the hoist movement is proportional to the distance the joystick is moved
away from neutral. There are slowdown and stop limits at both ends of each stroke.
Stop movement by moving the joystick to the neutral (center) position. The joystick is
spring loaded and will return to the neutral position when released.
The right joystick also controls the swing motion through left and right motions.
NOTE: The standard (default) configuration is shown above. The hoist and lower directions can
be inverted.

July 2013
Machine Operation
BI006779 Swing Motion Control
7.5 Swing Motion Control

Swing motion is controlled by the operator’s right joystick. To swing in either direction, move the
joystick lever in the direction of swing. Practice swinging in each direction until a “feel” is
developed for start-up and stopping. The speed of the swing movement is proportional to the
distance the joystick is moved away from neutral. Unlike other motion controls, swing movement

does not stop when the joystick is returned to the neutral (center) position. The operator must
counter swing to stop.
NOTE: The joystick also controls the hoisting and lowering of the dipper through forward and
backward motions.
Each motion - hoist or swing - is fully operational throughout the complete movement of
the other motion.
NOTE: When this joystick is used for propelling the right track of the machine, the hoist and
swing motions are locked out.

July 2013
Machine Operation
Proper Swing Motion BI006779
7.6 Proper Swing Motion

Proper swing motion means smooth control and an efficient swing cycle. The swing motion
begins toward the haulage unit when the dipper is filled and is clear of the bank.
Extensive damage to the dipper handle and dipper can occur if the machine is swung
before the dipper clears the bank.
The swing motion begins with acceleration to an optimum point at which the excavator is brought
to a stop over the haulage unit. Maximum efficiency and minimum swing machinery wear are
direct results of mastering the swing motion.
NOTE: Improper swing motion results in erratic control, and an inefficient swing cycle.
The dipper should never be swung over personnel, trail cables, related electrical
equipment or other equipment. When the dipper is loaded, accidental tripping of the
dipper door could result in death or serious injury to personnel, and extensive damage to
equipment. Empty dippers may contain small fragments of material that can be extremely
dangerous when dropped from a considerable height. On long moves it’s best to have the
door open on an empty dipper and the dipper lowered to a point that permits moving
without striking the ground.

July 2013
Machine Operation
BI006779 Proper Swing Motion
Time is required to accelerate any motion from zero to working speed, and also to decelerate
from working speed back to zero. The time expended for accelerating and decelerating the swing
represents the major part of the entire dig cycle. Therefore, the swing arcs must be kept to a
minimum to obtain maximum operating efficiency. As an example: assuming that a 90° swing
results in 100 percent of the maximum output, increasing the swing arc to 180° reduces output to
70 percent, while decreasing the swing arc to 45° increases the output to 126 percent. Therefore,

a swing arc of 90° or less should usually be used.
Haulage units should be positioned so their centerline is approximately under or not more than
slightly outside the swing path of the boom point. This substantially reduces the amount of dipper
maneuvering required of the operator when positioning the dipper for dumping. Positioning of the
haulage unit inside or outside the boom point makes it necessary to retract or crowd the dipper
handle and dipper, which breaks the operator’s natural rhythm.
A clean, level pit floor must be maintained. A good operator will always clean the floor before
moving into the bank. A clean and level floor grade is a requisite to safe and stable machine
operation, and reduces damage to crawler links and related components.
“Sweeping” should never be attempted with the machine. Sweeping consists of lowering
the dipper to the ground and using the swing motion of the machine to move the dipper
from side-to-side and “sweep” the pit floor. The dipper, dipper handle and boom
structures can be damaged by this tactic. A bulldozer or loader should be used to help the
machine operator maintain a clean pit floor in conjunction with the machine.

July 2013
Machine Operation
Crowd Motion Control BI006779
7.7 Crowd Motion Control

Crowd motion is controlled by the operator’s left joystick. Transfer to the DIG mode, refer to
PROPEL-DIG CYCLE for more information. Move the joystick forward to crowd and backward to
retract the dipper handle until a “feel” is developed for the limits and speed of the motion.
NOTE: The speed of the crowd movement is proportional to the distance the joystick is moved
away from neutral. There are slowdown and stop limits at both ends of each stroke.
Stop movement by moving the joystick to the neutral (center) position. The joystick is
spring loaded and will return to the neutral position when released.
Practice the crowd and retract functions until the movement can be stopped smoothly. Combine
the crowd and hoist functions and practice until smooth coordinated motions and subsequent
machine effectiveness is achieved.

July 2013
Machine Operation
BI006779 Crowd Motion Control
NOTE: On HydraCrowd machines, avoid “tight-lining”.

“Tight-lining” occurs when the dipper is pulled up close to the underside of the boom when the
handle extension is less than 4.5 m (15 feet). Routinely placing the dipper in this position will
adversely affect cylinder life and could lead to premature cylinder failure.

July 2013
Machine Operation
Propel Motion Control BI006779
7.8 Propel Motion Control

Prior to moving the machine, position the dipper in the recommended position. Avoid “tight-
lining”. See topic “Recommended Handle Position During Propel”.
To propel, transfer to the PROPEL mode. Refer to either AUTO PROPEL-DIG CYCLE or
MANUAL PROPEL-DIG CYCLE for more information.
THE HOIST BRAKE MUST BE SET WHENEVER IN THE PROPEL MODE.
To propel in a straight forward direction, move both joysticks forward slightly past neutral and
pause until the slack in the crawler belts and drive tumblers is taken up and motion begins. This
will reduce potential damage to the crawlers and tumblers. Then push the joysticks farther in the
direction of travel for more speed. The speed is increased as the joysticks are displaced farther
from neutral.
To propel straight in reverse, pull equally on both joysticks to the rear, just past neutral to
eliminate the crawler belt / tumbler slack. Then pull both joysticks back farther for more propel
speed.
When propel motion is complete, reverse the direction of the joysticks just past neutral to relieve
any crawler belt / tumbler tension, then return the joysticks to neutral to stop.
NOTE: The control stop pushbutton must be pressed before the propel transfer switch can be
activated.

July 2013
Machine Operation
BI006779 Propel Motion Control
7.8.1 Recommended Handle Position During Propel
During propel, the handle should be horizontal and the hoist ropes should be vertical. This will
ensure the forces on the handle are minimal.

July 2013
Machine Operation
Steering BI006779
7.9 Steering
• To make a gradual forward right turn, move the LEFT joystick (crowd) forward and leave
the right joystick (hoist) in neutral.
• To make a gradual forward left turn, move the RIGHT joystick (hoist) forward and leave
the left joystick (crowd) in neutral.
Whenever possible, gradual turns should be made in short increments of 15° to 20° maximum.
Propel straight for a short distance (usually 1/2 the length of the crawler belts) to clear the crawler
belts of stone and other debris; then make another 15° to 20° turn. Continue until the turn is
completed.
NOTE: When steering in soft material such as sand, clay, etc., increments of less than 15° to
20° might be used to minimize material build up on the crawler belt roller path. A single
sharp turn should be avoided to minimize material build up on the crawler belt roller
path and subsequent high loading of crawler belt and associated propel components.

July 2013
Machine Operation
BI006779 Counter-rotation Turns
7.10 Counter-rotation Turns

To make a sharp right turn:
Move the LEFT joystick forward (just past neutral) and pull the RIGHT joystick to the rear (just
past neutral) to take up the slack in the respective crawler belts and drive tumblers before moving
the joysticks to full travel and faster propel speed.
To make a sharp left turn:
Move the RIGHT joystick forward (just past neutral) and pull the LEFT joystick to the rear (just
past neutral) to take up the slack in the respective crawler belts and drive tumblers before moving
the joysticks to full travel and faster propel speed.
NOTE: When the turn is completed, reverse the direction of the joysticks slightly past neutral to
relieve any tension on the crawler belts and drive tumblers. Then return the joysticks to
neutral to stop.
Although possible, a single sharp turn should be avoided to minimize material build up on the
crawler belt roller path. This results in high loading of the crawler belt and increased stress on the
propel components. Therefore, counter-rotation turns should be limited to 15° to 20° increments.
When using the counter-rotation method for turning, use a helper to ensure that the trail
cable does not get fouled and/or torn from the machine.

July 2013
Machine Operation
Counter-rotation Turns BI006779
NOTE: The ability of the machine to turn sharply is dependent on the surface on which the
machine is setting. A soft surface will cause the crawlers to dig-in and machine to bog
down.
When moving the machine in a straight line, always propel forward (in the direction of the take-up
axle) to reduce strain and wear on the crawler belts and propel mechanism. This is especially
important in long propels or in deadheading back to the beginning of a cut. When not possible to
propel forward, and propelling to the rear is required, make sure the trail cable is clear of the
machine and follow the signals given by the helper. For increased safety the machine’s upper
works should be rotated in a position that allows the operator to face the direction of travel.
NOTE: Turning when propelling to the rear requires that the joystick be positioned in a direction
opposite the actual direction in which the turn takes place. The machine should be
moved close to the bank in short and frequent moves to maintain digging efficiency.
Movement should occur between the loading of haul units.

July 2013
Machine Operation
BI006779 Positioning The Machine
7.11 Positioning The Machine

There are two basic methods for positioning an excavator at a bank working face. The first
method is the “back-up method”. The second method is the “drive-by method”. Both methods are
acceptable and effective when set up correctly.

7.11.1 Back-up Method
When using the back-up method, the excavator is placed in the bank with the front of the
machine turned directly toward the digging face. The haulage units are spotted on both sides of
the machine. The bank is worked until a 180° semicircle has been excavated. When the point is
reached where a 90° swing to either side is required to load haulage units, the excavator is
moved to a new cut.
Work the machine from right to left along the bank. To move over, the operator should back up,
turning the machine gradually until the crawlers are at a 45° angle to the original digging path.
Then, back the machine straight until the right crawler crosses the corner of the excavated
semicircle.
Then, propel forward, turning the crawlers gradually to the left. When the right crawler is aligned
with the corner of the semicircle, move forward to the digging face and proceed to load the
haulage units. The back-up method will minimize the swing arc and reduce moving time. Other
advantages are less bank toe area clean up and simplified handling of the trail cable, cable
towers and trail cable boat.

July 2013
Machine Operation
Positioning The Machine BI006779
7.11.2 Drive-by Method

NOTE: If the machine and haulage units cannot be set up as described below, the drive-by
method should be avoided.
Position the machine crawlers parallel to the bank with the inside edge of the outer set of crawler
tracks directly in line with the bank toe. The trucks must approach the machine from the front
making a turn away from the machine as the front wheel approaches the outside crawler. The
truck should stop in a position to allow backing toward the point of the bank for loading. During
the load cycle, the swing arc should not exceed 90°. The time between finishing one truck to the
first digging cycle of the next should not exceed that of any cycle during a load.

July 2013
Machine Operation
BI006779 Start Of The Dig Cycle
7.12 Start Of The Dig Cycle

The crowd motion forces the dipper lip into the bank at the start of the digging cycle. It is the
crowd thrust which enables the dipper lip and front opening to get into a column of material of
sufficient cross section to fill the dipper rapidly.

Figure 7-1 Force the Dipper Lip into the Bank
There is a direct relationship between crowd depth of bank penetration and the distance the
dipper must rise in the bank to fill the dipper. The deeper the “bite” the quicker the dipper will be
filled, providing the hoist force is sufficient to cut the column of material. Do not attempt to lift the
entire bank with each pass. As soon as the dipper is full, retract it from the bank and swing the
machine to fill the truck.
Crowd penetration should be rapid just at the arc of entry and rise as the dipper enters the bank.
This will permit as much digging as possible near the base of the bank. This is of particular
advantage when digging loose or blasted material. The greater the hoist force and crowd thrust,
the faster the dipper filling time of the dig cycle. The crowd thrust should be maintained to hold
the dipper in the bank while it is being hoisted. An added benefit of proper crowd thrust and hoist
force is that the opposing vertical resistance of the bank material tends to have a “ramming”
effect in the dipper front opening, minimizing voids and producing larger dipper loads.
It is important that the full cutting surface of the dipper contact the bank on each pass. A full face
cut combined with deep bank penetration will result in a full dipper for the least amount of hoist. A
partial cut, even with deep bank penetration, requires a greater rise, and tends to leave voids in
the dipper. This could necessitate additional passes to fill the haulage unit.

July 2013
Machine Operation
Start Of The Dig Cycle BI006779
Shallow bank penetration of the arc of entry and rise is ineffective and inefficient. A shaving cut
dribbles material into the dipper resulting in voids and making additional passes necessary while
accelerating dipper lip wear.
NOTE: A deeper bite = quicker fill times
Figure 7-2 Variations on Dipper Penetration

July 2013
Machine Operation
BI006779 Start Of The Dig Cycle
Digging should take place under the boom point for maximum machine effectiveness. If
necessary, the machine should be moved closer to the bank face, rather than extending the
dipper handle. Reaching for material results in a partially filled dipper and excessive crowd and
retract time. Use caution not to damage the boom point sheaves when operating close to the
high wall.

Figure 7-3 Dig with the Dipper Beneath the Boom Point
Overcrowding with the dipper lowered can result in lifting the boom. This jacking action can result
in damaged components. Overcrowding the dipper in the bank slows up the dipper loading
process, thereby reducing machine efficiency.

July 2013
Machine Operation
Engaging The Bank BI006779
7.13 Engaging The Bank

To make maximum use of the hoist rope pull, the dipper rise should be as close to vertical as
possible. The dipper should enter the bank approximately under and behind the boom point. The
actual cut should start a few degrees behind an imaginary vertical line from the front of the boom
point sheaves. Proper bank engagement results in maximum hoisting force in line with the cut.
When the dipper is too far forward, bank penetration will be minimal, and the hoist and crowd
forces will oppose each other rather than working together.
Figure 7-4 Engage the Bank Under the Boom Point
An excavator dipper capacity rating is the struck measure cubic yard capacity. When digging, a
load greater or less than the rated capacity may be obtained, depending on the type of material.
An efficient operation can be measured by the number of dipper loads required to load a haulage
unit. When the dipper capacity is efficiently sized to the truck capacity, not less than three or
more than five dippers full should be required to load a unit. Other factors such as improper
sizing of haulage units to dipper, improper material fragmentation, etc. also must be considered.
In all types of digging the skilled operator must carefully control the desired depth of cut, and
control the hoist power requirements. Often, digging situations are encountered which require
hoist and crowd motions to maneuver around oversize or lodged obstructions in the bank, rather
than attempting to lift the entire bank.
Figure 7-5 Hoist Force Opposes Crowd Force

July 2013
Machine Operation
BI006779 Engaging The Bank
Maintain a digging face which avoids any major slides which could cause an accident.
Examine the digging face for large boulders, large rocks, or frozen material which could
slide and cause an accident. Avoid overhanging material.

The experienced operator does not repeatedly stall the dipper in the bank, nor maintain a stall
condition. The life expectancy of the hoist machinery and hoist ropes is directly related to the
operator’s skill in avoiding stalling. Whenever stall conditions are encountered, back off on the
hoist motion, retract the dipper, or do both. Avoid stall conditions at all times.
Figure 7-6 Make Effective Use of the Hoist Effort
Do not suspend a loaded or empty dipper in the air with the brakes set for long time
periods. Lower the dipper to the ground if the machine is to be idle or unattended for any
length of time. Failure to comply can result in personal injury or death of anyone beneath
the dipper.
For most efficient production, the dipper should be loaded from the most remote point while
waiting for a truck. When the truck is positioned, excavating should begin close to the haulage
unit, progressively working away from the unit. This technique saves time by allowing smooth,
short dig cycles, and eliminates excessive swing, crowd and retract motions.

July 2013
Machine Operation
Slope Limitations BI006779
7.14 Slope Limitations

It is important to remember the difference between slope percent and degrees!
It is strongly recommended that the machine dig and propel on level ground for the greatest
possible productivity and the longest component life.
DO NOT operate the machine on a slope greater than specified below:
Limit the machines propel operation to a maximum of 13 degrees (23%) slope.
Limit the machines digging operation to a maximum of 4.5 degrees (8%) slope.
DO NOT EXCEED THE SLOPE LIMITATIONS SPECIFIED FOR THIS MACHINE. Failure to
operate the machine within the specified limits could result in serious bodily injury or
death.

July 2013
Machine Operation
BI006779 Slope Limitations

July 2013
Machine Operation
Excavating Material BI006779
7.15 Excavating Material

It is important that the operator not only know the controls, but also recognize other aspects of
the mining operation. Chief among these is the type of material to be excavated. It plays a great
part in the overall efficiency of the machine.
Materials can be roughly divided into four categories:

1. Easy digging. This category includes all loose, free-flowing materials, such as sand and
gravel deposits, stock pile materials such as finely crushed stone, ore fines, coal fines and
any other similar materials. The dipper will usually obtain a heaped load.
2. Medium digging. This category includes only materials which can be excavated from their
natural beds without blasting, and which break up in bulk with some voids. Such material
includes clay, dry earth, clay-gravel mixtures, gravel with some boulders, certain types of
ores, and coal. The dipper will usually obtain a full load, with filling augmented by the
material’s natural tendency to break apart when it encounters the dipper lip and teeth.
3. Hard digging. Included in this category are materials that require blasting, resulting in good
fragmentation, but leaving large chunks which develop voids. Limestone, gypsum shale,
cemented gravel, wet earth, clay and certain types of ore and overburden all fall within this
category. The dipper will average less than a full load because of the resistance of the
material against flow and voids due to blocky material.
4. Very hard digging. This category includes all materials that require heavy blasting and give
irregular fragmentation. Taconite, granite, laminar shale, certain types of limestone, and
conglomerate overburden fall into this category. The dipper will average considerably less
than a full load, because of the large chunks and interlocking action of the material which
block fill.

July 2013
Machine Operation
BI006779 Operation Checks
7.16 Operation Checks

During machine operation there are several things to consider relative to safe, efficient machine
operation.
1. Check the motors for unusual noise, loss of power or failure to respond to controls.

2. Check hoist, crowd, swing and propel machinery for unusual sounds and overheating of
bearings.
3. Avoid slack hoist ropes which could allow the ropes to become crossed on the drum, or skip
a groove.
4. Frequently check the air pressure readout on the “home” screen (shown below). Investigate
immediately if there is a drop in air pressure. Correct all air leaks.
5. When propelling, check the engagement of the drive tumblers on the crawler belt links and
adjust the belts to correct any improper alignment.
6. When operating auxiliary functions, such as steering, note any tendency of the controls to
jam or hang up. Check and correct any problems at the earliest opportunity.

July 2013
Machine Operation
Operating Tips BI006779
7.17 Operating Tips

The following tips are reminders of the do’s and don’ts related to excavator operation:
• Engage the bank properly.
• Load with the successive pass technique.
• Maintain a clean pit floor.

• Use proper hoist control.
• Make effective use of the hoist pull.
• Use proper crowd control.
• Force the dipper lip into the bank at the arc of entry.
• Crowd the dipper into the bank for deep penetration.
• Make full face cuts for faster loading cycles.
• Dig under the boom point.
• Make smooth, safe swing cycles.
• Keep swing arcs within 90°.
• “Spot” the haulage units properly.
• Keep the working faces free of projections.
• Propel forward whenever possible rather than backward.
• Move up to the bank frequently.
• Dig over the take-up axle end of the crawlers whenever possible.
• Make gradual turns when propelling.
• Do not suspend a loaded dipper for an extended time or set the hoist brake on a suspended
load (except in an emergency situation).
• Do not operate too close to material.
• Do not operate with missing dipper teeth.
• Do not stall hoist or crowd motions.
• Do not reach for material.
• Do not reach for haulage units.
• Do not overcrowd and jack the boom or machine.
• Do not make partial face cuts.
• Do not make shallow bank penetration.
• Do not make erratic swings.
• Do not swing until dipper is clear of the bank.
• Do not swing loaded or unloaded dippers over personnel or equipment.
• Do not “sweep” the pit floor with the dipper.
• Do not make sharp turns when propelling. Maximum turn is 15° to 20° at a time.
• Do not make long inefficient moves.
• Do not exceed swing arc of 90°.
• Do not spot haulage units inside or outside the boom point swing arc.

July 2013
Machine Operation
BI006779 Operating Tips
• Maintain adequate clearance between digging face and point sheaves.
• Do not allow the dipper to contact the crawler belts.
• On HydraCrowd machines, avoid “tight-lining”. “Tight-lining” occurs when the dipper is pulled
up close to the underside of the boom with the handle extension less than 4.5 m (15 feet).

July 2013
Machine Operation
Operating Tips BI006779

July 2013
BI006779

8 Appendix
Appendix
8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.2 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.2.1 Touch Screen And Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.2.2 File Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.3 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.4 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.5 Display Configuration And Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.6 Opening The Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.3 Software Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.3.1 Bootup (Power Up). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.3.2 Navigation, Program Control And Data Entry . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.3.3 Icon Help Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.3.4 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Figure 8-1 Security Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Figure 8-2 Password Entry Pop Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.3.5 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.3.5.1 Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.3.5.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.3.5.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.3.5.4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

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BI006779
8.3.6 Permissives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.3.6.1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.3.6.2 Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Figure 8-3 Home Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.3.7 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.3.7.1 Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Figure 8-4 Temperature Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.4 HydraCrowd Warm-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.4.1.1 Stage 1A: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.4.1.2 Stage 1B: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.4.1.3 Stage 1C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.4.1.4 Stage 2A: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.4.1.5 Stage 2B: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.4.1.6 Stage 2C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.4.1.7 Stage 3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.4.2 Alarms & Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Figure 8-5 Active Alarms Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Figure 8-6 Alarm History Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

Figure 8-7 Settings Main Screen (Password Protected) . . . . . . . . . . . . . . . . . . . . . . 8-30
8.5.1 Setting Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.5.2 Rope Reeving & Pintle Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.5.3 Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
8.5.4 Lube Setup & Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.5.5 Motivator (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.5.6 Hydracrowd Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Figure 8-8 Hydracrowd Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8.5.7 HydraCrowd Hose Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Figure 8-9 HydraCrowd Hose Flushing Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.5.8 HydraCrowd Pump Trending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Figure 8-10 HydraCrowd Pump Trending Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.5.9 Operator Display (HMI) Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.5.10 Security Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8.6 Permissives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
8.6.1 E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
8.6.2 1 Start Within 2 Minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
8.6.3 2 Starts Within 5 Minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8.6.4 Drive Ready (No AFE Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8.6.5 Drive Cabinet Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

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BI006779
8.6.6 Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

8.6.7 Auxiliary Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8.6.8 Incomplete Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8.6.9 Joysticks Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8.6.10 Joysticks In Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8.6.11 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

8.6.12 Boarding Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

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BI006779

July 2013
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BI006779 Overview
Appendix
8.1 Overview
The operator displays are designed to assist the operator in efficient operation. It gives the user
machine data, indicators, and alarms. Machine setup parameters and user options are entered

through the display.
All servicing of this display system is to be done only by qualified service personnel.
This manual is written to help the user understand the workings of the display information system
as it pertains to the operation of the machine and troubleshooting the control system. Some
objects referred to as “options” in this manual are only enabled where that particular feature has
been purchased. On other systems those options will either be non-functioning “grayed out”
screen objects or inaccessible.
NOTE: The graphics and descriptions in this manual are for reference only. Actual screens may
differ depending upon software version and purchased options. Actual screen colors
may be different due to differences in printing and display technologies. The values
shown are examples and may not exactly match those on your display.

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Hardware BI006779
8.2 Hardware
The operator display terminal consists of an industrial hardened computer running a proprietary
operating system. The color touch screen was specifically chosen to provide optimum viewing in
bright sunlight.
8.2.1 Touch Screen And Keyboard

This display has a touch screen. This means that for normal operation it is designed to be used
exclusively by simply choosing objects on the screen and touching them with your finger. DO
NOT use anything other than your finger for selecting screen objects. Items such as pens,
pencils, screwdrivers, etc. will damage screen and should never be used.
Certain functions for troubleshooting the display or for initial setup may require the use of a
keyboard (supplied by manufacturer). Any standard USB keyboard from a desktop computer
may be used. The USB ports are located near the operator’s seat. It is mounted below the
display stand on the back of the left console. There are two ports here for a mouse and a
keyboard.

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BI006779 Hardware
8.2.2 File Storage
The complete operating system and application files are stored on a solid state hard drive
mounted in an adapter, accessible on the side of the unit. If required, program updates may be
delivered by exchanging the old hard drive for a new one. If this is done, please remember to
return the old hard drive to the manufacturer as soon as possible.

To remove the hard drive, first remove power from the display. This is done by turning off the
appropriate circuit breaker. Then press the small button located immediately left of the drive to
eject it. Put the new drive in, making sure it faces the same way that the old drive did. Make sure
the drive is pushed all the way in, but do not force it.
8.2.3 Ethernet Communication

Communication is established to the PLC through Ethernet. An Ethernet port exists on the side of
the operator display. This can also be used for programming the unit.
8.2.4 Power
Power is supplied to a three-pin connector on the side of the display. Only 24VDC is allowed,
regardless of the configuration of the machine.
8.2.5 Display Configuration And Setup

All configuration and setup functions are done through software. Please refer to the Software
section of this manual for a summary of these features.
8.2.6 Opening The Display

The internal components of the operator display are not user-serviceable. It is not recommended
that the user open the display for any reason, unless directed to by the manufacturer. If problems
are serious enough to open the unit, it should be replaced or repaired by trained personnel.

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Software Overview BI006779
8.3 Software Overview

The application software for the operator display was created using a proprietary development
tool, supplied by the manufacturer of the display. Most screens have been custom designed for
the machine. However, certain features such as the alarm screens and the display configuration
utilities are “pre-made” screens which are standard for the hardware being used.
Some of the screens have security attached to them, meaning that only personnel who enter the
proper password may access that screen. These passwords are defined in the Setup Screen.
NOTE: The Administrator has access to all screens. User1 has access to all screens except
the Setup screen.
8.3.1 Bootup (Power Up)

The operator display will automatically boot (power up) whenever power is applied to the unit.
The entire bootup process, from power-on until the unit is ready for use usually takes
approximately five minutes. DO NOT TOUCH THE TOUCH SCREEN DURING THIS TIME.
Once the boot process is finished, communication between the display and the PLC is
established and the Status Screen appears. The display is now ready for use. If a yellow banner
appears at the top of the display stating “PLC COMMUNICATION LOST,” this is an indication
that communication with the PLC has failed. Refer to the Troubleshooting section of this manual
for help.
Once the display is powered up, DO NOT shut off the power. The displays should be left
on at all times.
8.3.2 Navigation, Program Control And Data Entry

For normal operation, the operator display is controlled exclusively with the touch screen. To
change screens or choose an object, simply touch it with your finger. Do not use anything other
than your finger for selecting screen objects. Items such as pens, pencils, screwdrivers, etc. will
damage the screen and should never be used.

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BI006779 Software Overview
Screens are changed by touching the on-screen button associated with the desired screen. Most
screens or sections can be accessed from the Main Menu. Almost all screens have direct access
to the Status Screen, and the Main Menu is located at the bottom of almost every screen.
When it is necessary to enter a number, a pop-up keypad will appear on the screen. Simply
touch the keys on the keypad as you would with an actual keypad. Press <ENTER> when
finished or <X> to abort the entry. With the keypad, errors are corrected with the delete key

<del>.
8.3.3 Icon Help Screen

Many of the screens have a “HELP!” button in the upper right corner which is indicated with a “?.”
Pressing this key will bring up a separate screen that displays and describes all the different
icons that may be encountered throughout the program. When finished, press a button from the
Main Menu at the bottom of the screen that corresponds to the desired function.

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8.3.4 Security
Figure 8-1 Security Settings Screen
Since some of the screens contain setup parameters that may impact performance of the
machine, it is not always desirable for all users to access all screens. Therefore, the parameter
screens that are not required for day to day operation are protected by a three to five digit
security code. The Administrator password has access to all screens. User 1 has access to all
screens except the Setup screen. When a user attempts to access a secure screen, the
Password Entry window will pop up.
Figure 8-2 Password Entry Pop Up

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In order for the secure screen to open up, a specific code must be entered using this keypad. The
user enters the password with the pop-up keypad. If the code is correct, the desired screen will
appear. If the code is not correct, the Password Entry window will remain with a message
indicating an invalid password. If the user decides not to enter the correct password, he can
return to the previous screen by pressing the “X” button in the upper right corner.

Since all machines are shipped with the same set of default passwords, mine supervision
should change these passwords as soon as possible to prevent unauthorized screen
accesses or updates.
8.3.5 Main Menu

The Main Menu is the primary area from which the other screens are selected. The Main Menu is
located across the bottom of many screens. Simply press the icon button at the bottom of the
screen that you wish to call.
8.3.5.1 Home
to Adaptive Control and AccuLoad Control falls under the HOME icon.
8.3.5.2 Monitoring
Selecting the MONITORING icon will allow the operator to view the component operating
temperatures, current side to side incline, front to back incline, machine hours and fault counter.
The temperature monitoring feature is an option.
8.3.5.3 Alarms
Selecting the ALARMS icon will allow access to the machines active alarms as well as the alarm
history. For more detailed information, refer to ALARMS & FAULTS later in this section of the
manual.

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8.3.5.4 Settings
Selecting the SETTINGS icon will allow the operator access to:
Setting Limits
• Switch Displays
• Security
8.3.6 Permissives
8.3.6.1 Information
Selecting the INFORMATION icon will
display:
• Machine Type & S/N
• PLC Filename
• Operator Station Filename
• WinCC Version Number

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Appendix
8.3.6.2 Home
to Adaptive Control and AccuLoad Control falls under the HOME icon.
At startup, once the DC bus has been activated the HOME screen (shown below) automatically

appears. If the PLC determines that a warm-up period is required prior to startup, the appropriate
screen will appear prior to the HOME screen.
Figure 8-3 Home Screen
A — Dipper Handle Manual Lube Button: Pressing button initiates manual lubrication of the
dipper handle.
B — Air Compressor Operating Pressure: Displays the current operating pressure of the air
compressor.
C — Boarding Ladder Status: If the ladder symbol is in the UP position (as shown) all ladders
are in the raised position. If the ladder symbol is solid red and appears below the machinery
house, one or more ladders have been lowered or have not yet been fully raised.
D — Intake Fan Status: If the fan symbol appears gray (as shown) the fans are ON. The fan
symbol appears solid red when one or more of the intake fans are OFF.
E — Boom Status: If the boom symbol is solid red, this indicates a boom jack fault.
F — AccuLoad: Displays the current load per truck and is reset to zero when the NEW TRUCK
button is pressed.

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Appendix
G — Dipper Load: Displays the current weight of the material loaded in the dipper.
H — Adaptive Control: Activates adaptive control feature when pressing the ON button. If the
PLC accepts the command the button will turn blue.
J — AccuLoad: The operator presses the NEW TRUCK button to tell the AccuLoad system that
a truck has left. The current truck load is added to the Shift Total then reset to zero. The PAUSE
button temporarily disables the AccuLoad counter without clearing them. This is useful when
using the shovel to perform cleanup tasks and not actively loading trucks.
K — Inclination Status: Displays the current incline in degrees or a percentage value. If the
slope limits have been exceeded*, the background behind the value will flash yellow and gray. *
In DIG mode, any value >4.5° (8%). In PROPEL mode, any value >13° (23%).
L — Crowd/Retract Limit Indicator: The dipper handle will turn solid yellow when a Slow Limit
has been entered on either end. The dipper handle will turn solid red when a Stop Limit has been
reached at either end.
M — Truck Count: Displays the running total of loaded trucks during the current shift.
N — Hoist/Lower Limit Indicator: The hoist rope will turn solid yellow when a Slow Limit has
been entered on either end. The hoist rope will turn solid red when a Stop Limit has been
reached at either end.

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8.3.7 Monitoring
Selecting the MONITORING icon will allow the operator to view the machine hours / fault
counter, current side to side / front to back inclination, and optional temperature monitoring. A
warm-up sequence icon will appear on HydraCrowd machines.

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Appendix
8.3.7.1 Inclination
NOTE: When acceptable slope limits are exceeded, tilted background of screen will flash
between yellow and gray.

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Appendix
Figure 8-4 Temperature Monitoring

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Appendix
BI006779 HydraCrowd Warm-up Sequence
8.4 HydraCrowd Warm-up Sequence

The HydraCrowd Warm-up Sequence will come up anytime the PLC senses that the hydraulic
fluid has fallen below operating temperature. This typically happens at machine startup, but can
also occur when the machine is running but has sat idle for a period of time. Temperature
sensors are located in the upper hydraulic tank, lower hydraulic tank (power module) and the

cylinder control manifold. Hydraulic oil temperature throughout the system must be at least 95-
110° F (35-44° C).
During the warm-up sequence the operator needs to be present to monitor the progress
throughout the entire procedure. The PLC will prompt the operator at various stages to
turn the crowd control ON and OFF. The PLC displays the estimated time remaining to
complete the warm-up sequence.
8.4.1 Overview
The warm-up sequence typically begins at machine start-up. After all the permissives are met
and the Drive Power is turned ON, the PLC will determine if the hydraulic oil is up to operating
temperature. If not, the warm-up sequence will appear and the process will begin. As a rule,
components highlighted in red are in the warm-up process. Components in gray have not yet
begun warm-up. Individual components highlighted in green have reached operating
temperature. When all components are green the entire operating system is up to operating
temperature and the warm-up sequence is complete. The “home” screen will then appear.

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Appendix
HydraCrowd Warm-up Sequence BI006779
8.4.1.1 Stage 1A:

The hydraulic oil in the upper tank begins warm-up. The crowd control should be OFF.

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Appendix
8.4.1.2 Stage 1B:
The hydraulic oil in the upper tank has reached operating temperature. The circulation pump
begins operating at half speed as the lower tank begins warm-up.

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Appendix
8.4.1.3 Stage 1C:

The circulation pump begins operating at full speed as the lower tank continues to warm-up.

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Appendix
8.4.1.4 Stage 2A:
The main pump heating is ready to start. The operator will be prompted to energize the crowd
motor by pressing the Crowd Control ON button. Ensure the ON button appears solid green. The
hydraulic oil in the lower tank (power module) begins warm-up.

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Appendix
8.4.1.5 Stage 2B:

The four main pumps are operating and oil is circulating through the system with the exception of
the crowd cylinder manifold and the crowd cylinder. When 2B is complete, the operator will be
prompted to turn the crowd control OFF.

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Appendix
8.4.1.6 Stage 2C:
At this point, heating of the cylinder manifold will begin. The operator will be prompted to turn the
crowd control back ON. During this process, dipper handle motion may occur.

NOTE: Once Stage 2C is complete, the option to perform hose flushing and pump trending
operations becomes available. Those options are accessed through the HydraCrowd
Maintenance screen. When 2C is complete, the operator will be prompted to turn the
crowd control OFF.

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Appendix
8.4.1.7 Stage 3:
The operator will be prompted to turn the crowd control back ON. The operator will also be
prompted to extend and retract the dipper handle two full cycles to complete the process.
When all components are green the entire operating system is up to operating temperature and
the warm-up sequence is complete. The “home” screen will then appear.
8.4.2 Alarms & Faults

The operator display serves as a means of informing its users when various alarm or fault
conditions occur on the machine. It also records these conditions in a short-term history so the
user can see problems that may have occurred during the current operating session.
When a new alarm occurs, an alarm window pops up with an acknowledge button and an audible
alarm sounds. A yellow message banner will also appear at the top of the screen that displays
the alarm number and description of the most recent alarm. Other screens allow the user to see
all currently active alarms/faults, as well as the short-term history.

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Appendix
Alarms, faults, and messages are always referred to by their CDA (Cab Displayed Alarm)
number. If you are contacting the manufacturer about a specific message, make sure that you
know its exact CDA number.

Figure 8-5 Active Alarms Screen
The Active Alarm Screen lists all of the alarms and faults that are currently in the active state and
have not been cleared or reset.
The Alarm History Screen lists all of the alarms, faults, and messages currently recorded since
the display was powered up. By default, the most recent event is shown on top.
The first two columns list the time and date that the event occurred. The third column lists the
alarm number (CDA). This is the primary key to identifying the message. The fourth column lists
a brief description of the alarm. If the number of events is large enough, the Page Up and Page
Down buttons to the left of the list can be used to scroll through the list. This is a rolling history so
the oldest entries will be deleted when the limits are reached.

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Figure 8-6 Alarm History Screen
Alarms shown in red text are active.

Alarms shown in green text have been cleared.
The list of faults can be sorted in two ways:
a. Type in the three digit code in the CDA FAULT FILTER.
b. Type in the desired time range in the DATE/TIME FILTER.

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Settings BI006779
8.5 Settings
The Settings Screens are password protected.
Selecting the SETTINGS icon will allow the authorized personnel access to:
• Setting Limits

• Hydraulic Crowd Maintenance (HydraCrowd Only)
• Security Settings
Figure 8-7 Settings Main Screen (Password Protected)

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Appendix
BI006779 Settings
8.5.1 Setting Limits
This screen is used to set the slowdown and stop limits for:

• Crowd and Retract
• Hoist and Lower
For detailed information on Setting Limits, refer to Section 4 of the maintenance manual.

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Settings BI006779
8.5.2 Rope Reeving & Pintle Tightening

This screen allows authorized personnel to enter the hoist and crowd reeving modes or the
center pintle tightening mode. The meter along with the numeric display show the number of
degrees since one of the reeving modes was entered.
NOTE: The remote hoist and crowd reeving modes are optional. The crowd reeving modes are
not applicable for HydraCrowd machines. When remote reeving options are not
selected the icons are invisible. When the machine has HydraCrowd, the crowd reeving
icons are invisible.
For detailed information on Rope Reeving & Pintle Tightening, refer to Section 4 of the
maintenance manual.

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Appendix
BI006779 Settings
8.5.3 Joystick Calibration

This screen allows authorized personnel to calibrate the joysticks.
For detailed information on Joystick Calibration, refer to Section 4 of the maintenance manual.

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Settings BI006779
8.5.4 Lube Setup & Test

The Lube Setup Screen allows authorized personnel to set the lube intervals for various
components. The Lube Test Screen permits authorized personnel to initiate lube system tests
(allow injection operation, inspection and adjustment).

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Appendix
BI006779 Settings
8.5.5 Motivator (Option)

The Motivator Screen permits use of an off-board portable generator to propel the machine
instead of using trail cable power. It reconfigures some drive system software parameters for this
to happen properly.

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Appendix
Settings BI006779
8.5.6 Hydracrowd Maintenance

The HydraCrowd Maintenance Screen allows authorized personnel access to Pump Trending
and Hose Flushing operations. The latest Trending Data can be viewed by pressing the DATA
button. Warnings can be reset in this screen as well.
Figure 8-8 Hydracrowd Maintenance Screen

July 2013
Appendix
BI006779 Settings
8.5.7 HydraCrowd Hose Flushing
Pressing the FLUSHING button allows access to hose flushing operation. The estimated time
remaining to complete the hose flushing operation is displayed in minutes for convenience.

Figure 8-9 HydraCrowd Hose Flushing Screen

July 2013
Appendix
Settings BI006779
8.5.8 HydraCrowd Pump Trending

Pressing the TREND button allows access to manual or automatic pump trending operations.
After an automatic pump trending operation, the trend data will be displayed and stored for future
reference.
Figure 8-10 HydraCrowd Pump Trending Screen

July 2013
Appendix
BI006779 Settings
8.5.9 Operator Display (HMI) Setup

The HMI setup screen allows authorized personnel to set the format of the current time/date
Units of measure can be set individually or reset to exclusively metric or imperial units. The
“Switch To Control” button can be used to swap the CONTROL and the STATUS screens. For a
step-by-step procedure, refer to DISPLAY INTERCHANGEABILITY in Section 4 of this manual.

July 2013
Appendix
Settings BI006779
8.5.10 Security Settings

The Security Settings Screen allows the Administrator to change passwords.

July 2013
Appendix
8.6 Permissives

8.6.1 E-Stop
Green check mark indicates that none of the emergency stop buttons have been pressed.
8.6.2 1 Start Within 2 Minutes

This contact detects whether the DC bus has been pre-charged within the past two minutes. The
DC bus cannot be pre-charged more than once within the past two minutes. The green check
mark indicates that the bus has not been pre-charged within the two minute timeframe.

July 2013
Appendix
8.6.3 2 Starts Within 5 Minutes

This contact detects whether the DC bus has been pre-charged twice within the past five
minutes. The DC bus cannot be pre-charged more than twice within the past five minutes. The
green check mark indicates that the bus has not been pre-charged twice within the five minute
timeframe.
8.6.4 Drive Ready (No AFE Fault)

There is no drive fault. The AFE drive is ready for startup.
8.6.5 Drive Cabinet Temperature

The green check mark indicates that the drive cabinet temperature is within range for startup.
8.6.6 Phase Sequence

AC phase sequence check. The red “X” mark indicates that the sequence is NOT proper.
8.6.7 Auxiliary Ground Fault

Auxiliary ground fault check. The red “X” mark indicates that there is a ground fault.
8.6.8 Incomplete Start-up Sequence

The green check mark indicates that the sequence for start-up was complete.
8.6.9 Joysticks Calibrated

The green check mark indicates that the joysticks are calibrated.
8.6.10 Joysticks In Neutral

Checks if both joysticks are in the neutral position. The green check mark indicates that both
joysticks are in neutral.

July 2013
Appendix
8.6.11 Brakes
The red “X” marks indicate that the brakes have not been released.

8.6.12 Boarding Ladder
Detects if any of the boarding ladders are down or in the process of being lowered. The green
check mark indicates that all ladders are up.

July 2013
Appendix

July 2013
®
Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining
LLC reserves all rights to this publication. Its content is protected by copyright laws.
No part of this publication may be reproduced or transferred in any way or form without the prior written
approval of Caterpillar Global Mining LLC.
Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors.
© 2012 Caterpillar Global Mining LLC.
LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.

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Amendments and alterations to this publication are not subject

No part of this publication may be reproduced or transferred

Caterpillar Global Mining LLC declines any liability for direct or

© 2012 Caterpillar Global Mining LLC.

LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

SECTION 4 - OPERATOR’S STATION

SECTION 5 - OPERATOR CONTROLS AND DISPLAYS

SECTION 6 - PRE-START, START-UP & SHUTDOWN

SECTION 7 - MACHINE OPERATION

OM11089-EN Electric Rope Shovel TOC – i

TOC – ii Electric Rope Shovel OM11089-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

OM11089-EN Electric Rope Shovel REV – i

REV – ii Electric Rope Shovel OM11089-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

1.1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

OM11089-EN Electric Rope Shovel 1–1

1–2 Electric Rope Shovel OM11089-EN

1.1 About This Manual

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

OM11089-EN Electric Rope Shovel 1–3

1.1.5 Precautions and Disclaimers

1–4 Electric Rope Shovel OM11089-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

Caterpillar Global Mining LLC

OM11089-EN Electric Rope Shovel 1–5

1–6 Electric Rope Shovel OM11089-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

2.1 Safety Symbols And Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

OM11089-EN Electric Rope Shovel 2–1

2.7.4 Propel Warning Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Figure 2-7 Camera Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.8 Emergency Escape Chute (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2–2 Electric Rope Shovel OM11089-EN

2.1 Safety Symbols And Signal Words

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

OM11089-EN Electric Rope Shovel 2–3

Safety must always be paramount!

2.2 Warning Signs And Decals

2–4 Electric Rope Shovel OM11089-EN

2.3 Electrical Safety Precautions

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

Do not attempt mechanical or electrical maintenance on this machine without a full

OM11089-EN Electric Rope Shovel 2–5

2.4 General Safety Precautions

• Keep hands, feet and clothing away from rotating parts.

2–6 Electric Rope Shovel OM11089-EN

2.5 Operating Precautions

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

OM11089-EN Electric Rope Shovel 2–7

2.6 Operation Near Electrical Power Lines

2–8 Electric Rope Shovel OM11089-EN

2.7 Fire Prevention

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

OM11089-EN Electric Rope Shovel 2–9

2.7.2 Fire Extinguishers

2 – 10 Electric Rope Shovel OM11089-EN

2.8 Common Safety Features

2.8.1 Emergency Lighting

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 23, 2013

Figure 2-1 Emergency Lighting Locations