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S2 Guia de Aplicación
S2 Guia de Aplicación
Loading Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
haul road conditions on project sites. Motor Graders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Track-type Tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
It contains practical benchmarks that
Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRUCKS
Exchange Time Good (target) 0.7 minutes (42 seconds)
Correct Loading Correct Loading
Acceptable 0.9 minutes (54 seconds) Incorrect Loading Incorrect Loading
Exchange time is the elapsed time from when
the loaded truck first moves until the next truck
receives its first load.
Things to Watch for Truck Position Spotted in correct position by loader operator
rather than where truck operator decides to stop.
Can be spotted by horn or by first pass.
Positioned to help facilitate faster cycles:
At 45° for wheel loaders
Optimum Bench Height Top of boom Just above boom/ Length of stick, or between Bucket hinge pin height
sheaves stick pivot truck siderail and ducktail at maximum lift
Cycle Times 28-32 seconds 27-30 seconds 24-28 seconds 30-40 seconds
(avg. 31 seconds) (avg. 28 seconds) (avg. 26 seconds) (avg. 38 seconds)
Most Efficient Pass Match 3-4 passes 4-6 passes 4-6 passes 4-6 passes
First pass must be a good pass (operator has entire truck exchange to get it FULL). Ensure truck is correctly ‘spotted’
by loader with first pass or the horn.
Favorable Site Conditions Working a single face of Selective digging: can Bench height (worth 10- Level, dry, smooth,
the correct height also efficiently mine 15% extra production firm floors
Stable/level floor multiple targets over too high) Sufficient crossfall and
Wide benches Tight load area with Truck below HEX drainage in high rainfall
(to facilitate truck tight material (worth 15-20% over areas to minimize tire
maneuverability) Can work in poor floor same-level loading) damage and slip
Well-shot material conditions Tight load area, with Well-fragmented
Multi-face loading
LOADING TOOLS
Things to Watch for
Rope Shovels 70–90° max. swing Power cable maintenance Hydraulic Too high a bench height reduces productivity, leads
Never operate a bare edge Backhoes (ME**) to poor floors and increases spillage.
Efficient support-machine activity to keep floor clean Keep a tight digging zone and swing no more than
60°. Ideally, work no more than 45° on either side of
Hydraulic Front When material allows load from the top down, strip the center (i.e. work over idlers).
Shovels the top, and load from the center. Finally, clean up
Remove farthest pass during truck exchange;
the floor.
maintain “key cut” (pass in fornt of inside track)
Keep a tight digging zone and minimize swing angle.
to establish straight wall.
Ideally, work no more than 45° on either side of the
Settingbackhoe perpendicular to the face provides
center (i.e.work over idlers).
good working area, but avoid digging too far into
Settingshovel perpendicular to the face provides
the face. This increases reach to truck, and puts the
good working area, but avoid digging too far into
machine close to the edge.
the face.
Settingbackhoe parallel to the face may reduce time
Setting
shovel parallel to the face may reduce
relocating, but keep cut in line with inside track and
time spent relocating, but watch for high, unstable
no more than 45° over outside track.
benches that might collapse and damage
Watch for a poorly blasted toe that increases time in
the machine.
Load
the face and accelerates GET wear.
over the left side of the truck, and only consider
double-side loading if truck operators can spot Wheel Loaders Enterpile straight-on with the bucket floor parallel
themselves with minimal delays. to the pit floor.
Avoidexcessive prying and corner loading; don’t Frame straight when digging
swing into the pile. Lift bucket before crowding
Maximize GET* tip contact and minimize bowl Bucket full when lift arms are horizontal
contact (boom up and curl bowl through material).
Keep time in face below 0.2 minutes (12 seconds)
Define and maintain dig pattern (right to left or
Only 1.5 wheel turns from face to truck
left to right).
Never operate a bare edge
MOTOR GRADERS
Things to Watch for
General Grade in second or third gear (6-11 km/h, 4-7 mph).
For 24H, maintain first gear for all major grading
work. Maintain first gear for ripping applications
in all machines.
Keep edges sharp for better penetration.
Ensure cutting edges maintain protection
of moldboard; change edges ahead of
moldboard damage.
Blade
Position
Tip Angle Top of the moldboard should typically be
50 mm (19.6 in.) ahead of the cutting edge (i.e., blade
tipped forward and edge at 90° to road surface).
Maintaining a constant tip angle in operation
minimizes cutting edge wear.
Blade Angle Use widest possible pass width but
increase blade angle if material flows
around leading edge.
When using the graderbit system
or a serrated edge, use a blade
angle of 10° maximum.
For further information, consult
H-series Motor Grader Application
Guide AEGQ0945.
MNINGUID5.QXD 8/29/01 2:13 PM Page 9
TRACK-TYPE TRACTORS
Things to Watch for
General Blade
Operation Excessive tramming between jobs. Position On dual-tilt machines, begin cut with blade tilted forward for
Loose or missing track hardware. better penetration, then begin to lay blade back when about
half full. Continue to fill blade while laying back until blade is
Ripping full and racked fully back.
General Rip downhill wherever possible.
When ripping for scrapers, rip in the same direction, GET Penetration ripper tip reinforcing ribs must face upward;
as the scrapers will load. they ship on the shank with the rib down.
Generally, speeds of 1.5-2.5 km/hr (.9-1.5 mph) at 2/3 throttle Ensure GET pins, retainers and bolts are installed correctly
will give the most economical production, with reduced and are not missing.
speeds in shock/impact conditions. Never operate a bare shank.
For further information, consult The Handbook of Ripping
Ripper AEDK0752.
Position Begin pass with ripper tip rearward, then pull tip
forward/under the tractor after tip penetrates ground.
Ripper shank should always be lying backwards SCRAPERS
when ripping.
Excessive track slippage and blunt tips are good indicators Loading
that ripper position is not correct. Time Good: 0.4-0.5 minutes (24-30 seconds)*
Dozing Average 0.6-0.7 minutes (36-43 seconds)*
General Use slot dozing wherever possible, and doze from the front of * Open bowl/push-loaded Wheel-Tractor Scraper (shorter
the cut. Work to the rear, moving back 11⁄2 to 2 machine lengths time for tandem, longer time for single-powered)
each additional pass. Consult publications for self-loading
Slot depth to be a maximum of 2/3 blade height. (elevating/auger) and push-pull machines.
Take advantage of any available slope. For further information, consult Making the
Steer with the blade when dozing, not the steering clutches. Most of Scraper Potential AEGQ2380 and
Track slap in the middle of a cut is a good indicator that the Optimum Scraper Load Time AEGC0195.
clutches are being used rather than blade controls.
Minimize corner loading and prying and impact; maintain
a steady dozing pressure.
MNINGUID5.QXD 8/29/01 2:13 PM Page 10
The primary controls of a drill rig are pulldown force and rotational speed. Rates of penetration and rotation torque are functions
of ground conditions and these settings.
Typical Machines Driltech DK25, DK40 Driltech DK55 Driltech DK75, Driltech Gator
in this Class Ingersoll-Rand DM30, DM45 Ingersoll-Rand DM50, DML DK90, DK1190 Ingersoll-Rand ECM 370,
Reedrill SK30, SK45 Reedrill SK50 Ingersoll-Rand DM-M2, ECM 470, ECM 580, ECM 660,
DM-M3, DM-H, Pit Viper 35 ECM 680, ECM 690, CM 695
P&H 250XP, 100XP Tamrock (most models)
Depths Up to 40 m/43 yd Up to 60 m/65.6 yd Up to 100 m/109 yd Up to 50 m/54 yd
multi-pass multi-pass multi-pass multi-pass
10-12 m/11-13 yd 12-16 m/13-17 yd 14-18 m/15-19 yd 8-10 m/8.75-10.9 yd
single pass single pass single pass single pass
Hole Sizes (Generic) 100-200 mm/3.9-7.8 in 150-250 mm/5.9-9.8 in 200-350 mm/7.8-13.7 in Up to 150 mm/5.9 in
Rotation Speeds: Coal 120-150 rpm 100-130 rpm 80-110 rpm 80-120 rotary
Rotation Speeds: 100-120 rpm 80-110 rpm 70-90 rpm Up to 40 rpm hammer
Hard Rock (up to 40 rpm hammer)
Penetration: Coal* 40-60 m/hr/ 40-80 m/hr/ 40-100 m/hr/ 30-50 m/hr/
43.7-65.6 yd/hr 43.7-87.4 yd/hr 43.7-109.4 yd/hr 32.8-54.6 yd/hr
Penetration: Hard Rock + 10-30 m/hr/ 10-40 m/hr/ 10-50 m/hr/ 10-30 m/hr
10.9-32.8 yd/hr 10.9-43.7 yd/hr 10.9-54.6 yd/hr 10.9-32.8 yd/hr
DRILLS
Things to Watch for
Excessive Chip/Cutting
Vibration The drill bit is bouncing off the bottom of the Size Chip/cutting size gives the best indication of
hole, which may knock out the carbide tips on drilling function. Cuttings may vary from pea
the cones, causing excessive wear. to golf ball size, depending on drill size and
rock type. Fine powder indicates grinding
Drill rather than cutting.
“Plunging” Drill “plunging” occurs when the pulldown
hydraulics enter into an oscillation. This Correctly Leveled
can be eliminated by better control of Machine and
pulldown pressure. Level Floors A correctly leveled drill and a flat floor are
vital to ensure all holes are drilled parallel
Excessive and collar elevations are maintained. Every
Pulldown one degree of tilt/roll moves the toe of the
Pressures Excessive pulldown causes damage to the drill hole by 1 m per 10 m drilled/1.1 yd per 11 yd
bit by overloading, and wears items such as drilled. Over a 50 m/55 yd hole, the toe can be
pulldown chains, ropes, cylinders, motors, the out by up to 5 m/5.5 yd. This has a huge effect
mast structure and rotation motors. on fragmentation when blasted, particularly in
the toe area which can seriously affect ease of
Excessive digging, GET wear and machine productivity.
Rotation
Speeds Excessive rotation speeds can cause premature
wear of the drill bit from overheating.
Bailing
Velocity Bailing velocity is often incorrect, but should be
set between 1500-2500 m/min/1640-2734 yd/hr.
Cross-slopes On Flats Apply the minimum slope to maintain drainage for expected rainfall conditions.
If rainfall and site profile allow, consider a 2% constant crossfall with loaded
trucks running on the uphill side of the road. This is recommended ahead of
centerline crowning as it helps maintain tire load sharing.
If expected rainfall demands a slope greater than 2%, or the site profile does
not allow constant crossfall, use a centerline crowned road profile. A crowned
profile allows better control of rainfall and erosion, and maintains safe operating
conditions when the haulroad is wet and slippery.
On Grades Minimal cross-slope is required unless rainfall is very heavy,
as drainage is provided by downgrade. 2° constant crossfall
Correct Incorrect
Corners Radii Use maximum practical corner radius and keep the radius as smooth and
consistent as possible.
Super-
elevation Employ if speeds exceed 15 km/h/9.3 mph as per Performance Handbook (PHB)
recommendations (see Tables section). Super elevation greater than 10% should
be used with caution due to the danger of side slippage in wet conditions.
MNINGUID5.QXD 3/14/02 9:34 AM Page 13
Safety Berms All locations Berm should be a minimum 1⁄2 wheel height at
(windrows) the dump edge and along all haul road/highwall
edges. Check against local mining regulations.
Drainage
MNINGUID5.QXD 8/29/01 2:13 PM Page 14
Analysis Tools ASA Use ASA analysis to assess machine Fleet Use FPC to compare actual cycle times with
(Application application severity: Production theoretical values.
Severity To identify locations/features on the road and Cost (FPC) Are trucks achieving predicted speed on grades?
Analysis) for improvement. Are trucks cycling in predicted cycle times?
To quantify the severity of the haul from strut
Are truck wait times at the loader in the
pressure data.
predicted range?
To illustrate transmission shift frequency and
gear on grade. If not, investigate possible causes:
To identify brake/retarder application Rough/slippery roads causing operators to slow.
(frequency and location). Higher rolling resistance than planned/expected.
Vital Use VIMS to help manage machine application: Tight corners forcing machine to slow.
Information Datalogger data (export to ASA) to quantify haul Poor visibility due to dust or obscured views.
Management road conditions. Pinch points, STOP signs at intersections, etc.
System (VIMS) Better payload management to optimize speed
on grade.
Check event logs for high brake temps., engine
overspeeds, etc.
MNINGUID5.QXD 8/29/01 2:13 PM Page 15
Loading Zone The floor should be smooth, with adequate water removal,
kept clear of rock debris fallen from the face and from trucks
as they leave the zone. Ensure trucks are not backing up
onto rocks fallen from the face or driving off over rocks
spilled during loading as this damages tires and powertrain
components and adversely affects payload accuracy.
Avoid tight, high speed turns as trucks return to the
load area.
Can the truck leave the loading zone under full and
continuous acceleration, or is the loading zone too
tight, too rough or too congested with other machines
to allow this to occur?
Loading Zone
Main Haul Road The haul road should be well-maintained and smooth with
sufficient drainage and free from potholes, ruts and gullies. It
should also have a smooth/constant grade. Is there adequate
passing room (road width) and corner radius (super-elevated if
necessary) etc., that allows safe and reliable operation at the
highest possible road speed?
Is spillage that falls from moving trucks removed quickly?
Are there signs of rubber being deposited on tight or
rocky turns?
Are operators applying high braking forces to negotiate corners?
Can the truck achieve expected road speeds for all segments?
Dump Zone The floor should be smooth, allowing trucks to maintain high
speed until they reach the dump zone, entering parallel to the
edge and braking in a straight line before turning and stopping
to reverse to the dump.
Safety berms of regulation height along the entire edge.
MNINGUID5.QXD 8/29/01 2:13 PM Page 16
Miscellaneous 12
MANAGEMENT
STRATEGIES
Present machine application issues to mine Use Cat® Software Tools [FPC (Fleet Production and Cost),
management in a language they understand; EMF (Earth Moving Fundamentals software), DOZSIM
i.e. Productivity (lost or gained), and Cost per Ton. (Dozer productivity simulation software)] and others to:
Compare theoretical with actual:
Identify the potential to improve productivity.
• Grade speeds
Better bucket fill factors through: • Cycle times
• Improved fragmentation
• Total machine/fleet productivity
• Correct GET selection and maintenance
Miscellaneous 13
Consider whether the most economic earthmoving system is being Tractors, Consider the benefits outlined in
used in the application. The following values are rules of thumb, ‘Management Strategies’ when
Wheel Dozers, correct use of support machines
but will vary with underfoot conditions, material type, required
production rate, and operator skill: Motor Graders and allows optimum machine
Water Trucks productivity, minimum impact on
major component lives,
maximum tire life, maximum haul
road life, and most importantly,
maximum operational safety.
Dozers: 0 to 100 m (0 to 350 ft)
Also consider that wheel dozers
are typically more cost-effective
than track-type tractors in lighter
applications such as haul road and
shovel clean-up, and offer greater
Load and Carry: 50 to 120 m (150 to 400 ft) speed for better coverage and
improved flexibility.
REFERENCES/FURTHER READING
Caterpillar Performance Handbook (PHB)
FPC — Fleet Production and Cost software
EMF — Earthmoving Fundamentals software
Load Study Forms — available upon request
Literature:
Handbook of Ripping AEDK0752
5130 / 5230 Applications Guide AEDK0128
H-series Motor Grader Application Guide AEGQ0945
994 Bucket Selection Guide AEDK0268
Making the Most of Scraper Potential AEGQ2380
Optimum Scraper Load Time AEGC0195
GET Inspection and Maintenance Guide PEXT8033
GET Service Guide PEGP7030
Videos:
24H Motor Grader Introduction TEVN3797
*24H Operating Techniques AEVN4741/AEVP4741
*5130B/5230 Front Shovel Application
Techniques AEVN4380/AEVP4380
*5130B/5230 ME Application Techniques AEVN4381/AEVP4381
994 Operating Tips AEVN2947
*GET Operating Tips PEVN4009/PEVP4009
* Denotes videos in PAL system format. Others are available in NTSC only.
www.CAT.com
© 2001 Caterpillar
Printed in U.S.A.
AEDK0391