Index Sec 1 Sec 2 Sec 3 Sec 4
SECTION 3
PRE-START, START-UP, SHUTDOWN
GENERAL
This section contains information describing the
preliminary equipment checks and the starting and
shutdown procedures for this mining shovel.
Check lists are provided to aid the operator in setting
up a routine for checking the required items. Blank
spaces have been provided on the individual lists so
that additional checks may be added by the user to
accommodate local operating conditions and/or
environment. The check lists can be duplicated on a
copy machine.
NOTICE
The pre-start checks, start-up and shutdown
procedures are written on the basis that the
mining shovel is completely shutdown at the
end of the day. The procedures may vary de-
pending on the operation and state of readiness
in which the mining shovel is kept after each
work period.
PRESTART
Perform the pre-start procedures at the beginning of
each work day, prior to initial start-up. If an item is
checked and found incorrect, remedy the problem prior
to start-up to ensure proper operation of the shovel.
1. Be sure the tail cable is secure and free from damage.
2. Be sure the crawler belt assemblies are free from
abnormalities and are proper adjusted.
3. Check and ensure that the daily (single point)
lubrication is completed. Refer to the Lubrication topic
in the Shop Manual.
A. Check the oil levels in the swing transmissions. The
oil level dipsticks are located in fill pipes on the side
of the swing transmissions.
B. Check the oil level in the propel transmission by
viewing the level sight gauges.
C. Check the oil level of the air compressor. The oil level
must be maintained between the two marks on the
dipstick. Never allow it to fall below the lower
mark.
D. Check the oil level in the hoist gear case with the
dipstick.
E. Ensure that the automatic lubrication system sumps
and reservoirs are at the proper levels. Check the
sumps and reservoirs daily.
F. Check the air system lubricator sightglass for the
proper lubricant level.
G. Check the oil level in the crowd transmission.
4. Check that the hoist and swing brake assemblies are
free from oil or grease.
5. Check the condition of the hoist ropes and
suspension ropes. Be sure the ropes are laying straight
in the lagging and that an overspool condition does not
exist on the hoist drum. Report any visual evidence of
rope degradation, such as:
• Severe abrasion, scrubbing, peening, kinking, or
broken outer wires.
• Crushing, or other damage that distorts the rope’s
structure.
• Severe reduction in rope diameter or an observable
increase in rope lay.
• Evidence of severe corrosion, particularly in the
vicinity of attachments.
• Lack of lubrication
6. Check that the shovel house area is clear of loose
tools, rags, and equipment.
! WARNING
DANGER
Electrical hazard exposed by open electri-
cal cabinets can result in accidental con-
tact causing severe personal injury or
3-1
 death. Keep electrical cabinet doors or
covers closed during operation. Use au-
thorized and qualified electrical person-
nel for any inspection or work on the
mining shovel’s electrical systems.
7. Close all cabinet doors and secure locking devices.
8. Ensure that the switches and controllers in Table 3-
2 are positioned as shown.
! CAUTION
DANGER
To avoid potential equipment damage or
personal injury, never force circuit break-
ers to stay in the ON position. An immedi-
ate trip indicates equipment or circuit
problems.
A. Circuit breakers in the auxiliary cabinet should be
in the positions indicated in Table 3-2.
F. Place all branch feeder breakers in the 120/100 load
panel in the ON positions.
G. Be sure the Reactive Power Compensation (RPC)
breakers are in the ON position.
9. Visually inspect the dipper handle, rack and shipper
shaft pinions for proper lubrication.
10. Check the condition of the dipper trip assembly,
hoist ropes, saddle blocks, and crowd shovel to ensure
that they are clear for operation.
11. Check that there is no oil or grease contamination
on the disc brakes.
12. Refer to start-up procedures.
START-UP
The following procedure includes references to the
control configuration listed in Section 2.

NOTICE
NOTICE
The following start-up procedure assumes that
All circuit breakers provide overcurrent protec-
the operation is the initial start-up of the day,
tion. If the breaker automatically returns to
and that the electrical system has been checked
the TRIP position, wait a short period of time
out by qualified electrical personnel and func-
and reset the breaker to the ON position. If the
tions properly.
breaker returns to the TRIP position a second
time, a problem exists and an electrician 1. Ensure that the pre-start checks are performed.
should be notified. Problems should be correct-
2. Ensure that all electrical cabinet doors are closed
ed before resuming operation.
and locked.
B. Place the main auxiliary breaker on the load panel
in the ON position.
C. Place the field supply breakers in the ON position.
These breakers are on the field transformer.
D. Place the control and relay supply breakers in the
ON position. These breakers are in the control
cabinet.

! WARNING
DANGER
Abnormal shovel performance can occur
when test/run selector switch position is
changed while shovel is energized. Unex-
pected shovel movement or performance
can result in severe personal injury or
property damage. Only change test/run
selector switch position after shovel is
shutdown.
E. Ensure that the TEST/RUN selector switch is in the Figure 3-1. Air Compressor
RUN position.

3-2
CHECK DAILY REMARKS

Propel transmission oil level.

Tail cable secure and free of damage.

Check for cracked pads, keepers and pin retainers on the crawler belt
assemblies.

Daily single point lubrication completed.

Swing transmission oil level (dipstick).

Air compressor oil level (dipstick).

Hoist gear case oil level (dipstick).

Air lubricator oil level (sight glass).

Swing, hoist, and crowd brakes free of contamination.

Hoist ropes not crossed on drum and free from damage.

Automatic lubrication system reservoirs level (dipstick)

No loose tools, rags, or equipment in the machinery house.

All electrical cabinet doors closed and locked.

Switches and controls in proper position (see electrical pre-start check

list on the following page).

Crowd gear case oil level (dipstick).

Dipper handle and rack, and shipper shaft pinion lubrication.

Dipper trip assembly, hoist ropes, saddle blocks, and crowd machinery
clear for operation.

Check that all guards are in place.

Check Suspension ropes.

Table 3-1 Mechanical Pre-start Checklist

3-3
 CHECK DAILY REMARKS

Supply and lighting transformer breakers. ON

Hoist blowers. ON

Swing blowers. ON

Crowd blowers ON

Propel blowers ON

Hoist lubrication pump. ON

RPC blower. ON

Converter cabinet blowers. ON

Dipper trip motor. ON

RPC blower. ON

Machinery cab blowers. ON

Main auxiliary circuit breaker. ON

Air compressor circuit breaker. ON

Heater receptacle. ON when used

Control supply circuit breaker. ON

Relay supply circuit breaker. ON

240V supply circuit breaker. ON

RPC Capacitor bank circuit breakers ON

Lube PLC circuit breaker. ON

Mode selector switch. ON

110-120-240 branch circuit breakers. ON

Control cabinet fan. ON

Suppression circuit breakers. ON

Field supply circuit breakers. ON

Main lighting circuit breaker. ON

All light circuit breakers. ON when used

Table 3-2 Electrical Pre-start Checklist

3-4

Figure 3-2. Hoist Gear Case Filter Indicator
3. Check the lubrication indicator panel in the cab for
lube faults. Press the FAULT RESET pushbutton on
the PLC lube controller in the lubrication room or
console and eliminate faults as required.
4. Check the hoist gear lubrication system filters for the
proper indication (see Figure 3-2).
5. If necessary, position the air compressor ON-OFF
control to the ON position and check the air compressor
as follows:
A. Check that the air compressor is operating properly.
The compressor oil pressure gauge should indicate
15 to 20 psi (1.03 to 1.38 bars).
! CAUTION
DANGER
Escaping compressed air may cause eye
or ear injury. Use eye and ear protection
when operating the receiver safety valve.
B. Manually operate the compressor and receiver
safety relief valves to ensure that each safety valve
operates properly.
C. Check that air pressure is building in the receiver.
For the shovel to start, there must be a pressure
equal to the amount of air pressure required for
releasing the propel brakes and crowd brake.
6. Check the fault indicator light (14, Figure 2-1). If the
fault indicator light is illuminated, press the fault reset
button (14, Figure 2-1) before pressing the STOP
pushbutton.
7. Momentarily press the STOP pushbutton (02, Figure
2-1).
! CAUTION
DANGER
Activating the START button causes shov-
el electrical and automatic systems to
function or operate. Unexpected move-
ment, lube pressure or electrical power
while personnel are on or near the mining
shovel can cause injury and property
damage. Before pressing the START but-
ton be sure all machinery is reassembled,
all guards are in place and that personnel
and tools are clear of moving or energized
parts.
8. After the STOP button is released, push and release
the START button. The green SYSTEM ON indicator
will illuminate when the shovel completes the
electrical start sequence and is ready for normal
operation. The shovel electrical system automatically
selects the HOIST/CROWD mode at start-up. If
PROPEL mode is desired, press the PROPEL mode
pushbutton.
9. Select the desired mode of operation with the
HOIST/CROWD (04, Figure 2-1) or PROPEL mode
pushbuttons (05, Figure 2-1).
! CAUTION
DANGER
Releasing of the brakes can cause person-
al injury or property damage due to shov-
el movement. Be aware of and control this
movement IMMEDIATELY.
10. Depress the required HOIST BRAKE RELEASE
(26, Figure 2-1) or CROWD BRAKE RELEASE (08,
Figure 2-1) pushbutton while in the HOIST/CROWD
mode to release the brakes. The propel brakes are
released and the crowd and hoist brakes are set
automatically when the PROPEL mode pushbutton is
actuated. Manual setting of HOIST/CROWD brakes is
preferred prior to transferring to the propel mode.
11. Check that the BRAKE RELEASED indicator(s)
are illuminated.
NOTICE
In the PLC lube controller enclosure is an audi-
ble fault alarm, three illuminated pushbuttons
for resetting faults and starting a manual lube
cycle, a pushbutton for silencing the lube fault
audible alarm, and a timer/counter control for
3-5
 monitoring or changing the lube cycle times
(Figure 2-4).
12. If the GROUND FAULT indicator illuminates,
correct the fault and press the GROUND FAULT
RESET button (14, Figure 2-1).
NOTICE
A single ground fault may not effect shovel op-
eration. A succeeding fault may initiate shovel
shutdown. Mine practices concerning ground
faults should be adhered to. Clear all faults as
soon as possible.
13. If the FAULT PANEL indicator illuminates, have
an electrician correct the fault, then press the FAULT
PANEL INDICATOR RESET button.
14. If the DC MOTOR THERMAL OVERLOAD
indicator illuminates, there is a sustained high DC
c u r r e n t d r aw o n o n e o f t h e D C m o t o r s. T h i s
illumination is accompanied by an audible alarm.
The shovel should be safely parked and brakes set, but
should be left running so blowers continue to run,
cooling the motor(s).
PARKING FACING UP OR DOWN AN INCLINE
PARKING SIDEWAYS (TRANSVERSE) ON AN INCLINE
Figure 3-3 Parking On An Incline
3-6
15. If the shovel fails to start, or shuts down during
normal operation, the operator should attempt three
starts before notifying maintenance personnel. Each
start must be preceded by depressing the STOP button
and FAULT RESET button before depressing the
START button (13, Figure 2-1). Fault indicators must
be observed after each shutdown prior to attempting a
start.
NOTICE
The system will not function until proper air
pressure and oil flow is established.
16. Exercising caution, start the shovel and slowly
operate the crowd and hoist motions while checking to
be certain that the limits are properly adjusted and
completely functional.
NOTICE
Damage to the shovel can occur if the mechan-
ical limits are exceeded.
SHUTDOWN PROCEDURES
Leaving Control Station
! CAUTION
DANGER
Unexpected movement of the mining
shovel or its components due to parking
the shovel on an incline (see Figure 3-3)
can cause shovel tipover or runaway, re-
sulting in severe personal injury or death
and damage to the shovel and other
equipment. Do not park the shovel facing
up or down a grade in excess of 20% or
sideways (transverse) on a grade in excess
of 10%. Always make sure all motion
brakes are properly maintained to insure
maximum brake effectiveness. If frequent
or continuous parking at or below the
above mentioned grades may be neces-
sary or if you have any other related ques-
tions, consult your local P&H
representative.
1. Make sure the mining shovel is on level ground.
2. Lower the dipper until it is resting on the ground.
3. Set all the brakes by pressing the ALL BRAKES SET
pushbutton (28, Figure 2-1).
4. Press the ST OP button (02, Figure 2-1). It
automatically de-energizes the electrical motors.
Extended Shutdown
! CAUTION
DANGER
Unexpected movement of the mining
shovel or its components due to parking
the shovel on an incline (see Figure 3-3)
can cause shovel tipover or runaway, re-
sulting in severe personal injury or death
and damage to the shovel and other
equipment. Do not park the shovel facing
up or down a grade in excess of 20% or
sideways (transverse) on a grade in excess
of 10%. Always make sure all motion
brakes are properly maintained to insure
maximum brake effectiveness. If frequent
or continuous parking at or below the
above mentioned grades may be neces-
sary or if you have any other related ques-
tions, consult your local P&H
representative.
Index Sec 1 Sec 2
Use the following procedure whenever the shovel is to
be out of operation for any extended period of time:
1. Make sure the mining shovel is on level ground.
NOTICE
Park the shovel on solid, level ground. Ensure
the shovel is safe from rock slides and water,
which may accumulate from heavy rain. Do not
allow the shovel to stand in mud or water if
there is a possibility of freezing. Move the shov-
el to high ground or onto timbers to prevent
tracks from freezing to the ground.
2. Lower the dipper until it is resting on the ground.
3. Set all the brakes by pressing the ALL BRAKES SET
pushbutton (28, Figure 2-1).
4. Press the ST OP button (02, Figure 2-1). It
automatically de-energizes the electrical motors.
5. Place the field supply breakers and all control
breakers to the OFF positions.
3-7
Sec 3 Sec 4