Index Sec 1 Sec 2 Sec 3 Sec 4
SECTION 4
OPERATION
SCOPE
Due the many varied mining operations and mining
shovel applications, this manual does not attempt to
cover mining applications and/or mining shovel task
sequencing.
The purpose of this section is to describe the operation
of the individual motion controls and include some
suggested operating procedures that will aid the
operator in the safe, smooth and efficient operation of
this mining shovel.
These operating suggestions are offered as a reminder
rather than as an attempt to instruct, since the
Harnischfeger Corporation is well aware of the fact
that a mining shovel is not entrusted to anyone except
a fully qualified operator.
NOTICE
It is important to remember that improper op-
erating techniques cause down time due to ex-
cess wear and/or fatigue of parts.
When operating a mining shovel, the operator should:
1. Be aware of the operating limits of his mining shovel
at all times.
2. Ensure that the mining shovel is properly
maintained by performing the pre-start checks
described in the Pre-start topic on page 3-1.
GENERAL
The four basic shovel movements are hoist, swing,
crowd, and propel. Three of the motions are used for
digging and the other for moving the shovel.
The following material describes how individual and
combinations of controls move the shovel and dipper.
Digging and propelling procedures are covered later in
this section.
NOTICE
All brake systems are holding brakes only and
should not be used for stopping shovel move-
ment except in an emergency.
INDIVIDUAL CONTROL OPERATION
General
The following descriptions of control operation includes
references to the operator’s controls illustration as
shown in section 2.
Due to the varying styles and configurations of
controls, and for the purpose of clarity, only Figure 2-1
is used to reference console mounted controls in the
following procedures.
Hoist Control
! WARNING
DANGER
Excessive inclines (see Figure 4-2) can
cause unexpected shovel movementtipov-
er or runaway, resulting in severe person-
al injury, death and damage to equipment.
Do not perform any digging operations on
grades in excess of 5%. Always make sure
all motion brakes are properly main-
tained to insure maximum brake effec-
tiveness. If frequent operation on a 5%
grade may be necessary or if you have any
other related questions, consult your lo-
cal P&H representative.
4-1

Figure 4-1 Right Controller
The RIGHT CONTROLLER (Figure 4-1) raises and
lowers the dipper after the HOIST/CROWD push-
button (04, Figure 2-1) places the shovel in hoist/crowd
mode and the HOIST BRAKE RELEASE push-button
(26, Figure 2-1) releases the brake. It can perform two
operations at the same time, such as raising or
lowering while swinging the upper (only if swing
brakes have been manually released.
Raise or lower the dipper as follows:
1. Check the HOIST/CROWD green indicator light (04,
Figure 2-1) to be sure it is on indicating the shovel is in
the hoist/crowd mode.
2. Depress the HOIST BRAKE RELEASE push-button.
The HOIST BRAKE RELEASED light will light when
the hoist brake system is pressurized to the preset
brake release air pressure.
NOTICE
Equipment damage may occur if the hoist rope
equalizer is hoisted into the boom point
sheaves. Maintain control of the dipper posi-
tion at all times.
3. To hoist the dipper, gradually pull the RIGHT
CONTROLLER back from the neutral position until
the dipper starts to move. The speed of the dipper
4-2
hoisting movement is proportional to the distance the
RIGHT CONTROLLER is moved away from neutral.
4. To stop the hoisting movement, allow the RIGHT
CONTROLLER to return to the neutral (center)
position.
5. To lower the dipper, release the hoist brake if it is set,
and gradually push the RIGHT CONTROLLER lever
forward. The speed of the dipper is proportional to the
positioning of the right controller.
6. To stop the lowering dipper movement, allow the
controller to return to the neutral position.
NOTICE
Never leave the operator’s seat with the dipper
suspended. Place the dipper on the ground and
set all brakes. If it is necessary to suspend a
loaded dipper while waiting for a haulage unit,
bring the hoist motion to a complete stop using
the hoist controller, then set the hoist brake.
The exception to this rule is when a loaded dipper may
be suspended, hoist brake set, awaiting the proper
spotting of a haulage unit.
7. To hold the dipper position, leave the RIGHT
CONTROLLER in the neutral position and set the
hoist brakes by pushing the HOIST BRAKE SET push-
button (27, Figure 2-1).
Figure 4-2 Digging On Incline

Figure 4-3 Left Controller
Swing Control
! WARNING
DANGER
Excessive inclines (see Figure 4-2) can
cause unexpected shovel movementtipov-
er or runaway, resulting in severe person-
al injury, death and damage to equipment.
Do not perform any digging operations on
grades in excess of 5%. Always make sure
all motion brakes are properly main-
tained to insure maximum brake effec-
tiveness. If frequent operation on a 5%
grade may be necessary or if you have any
other related questions, consult your lo-
cal P&H representative.
The RIGHT CONTROLLER (Figure 4-1) rotates
(swings) the shovel’s revolving (upper) frame on the
lower after the swing brake is released.
Swing the revolving frame as follows:
1. Release the swing brakes by pushing the SWING
BRAKE RELEASE push-button.
2. To swing right, push the RIGHT CONTROLLER
lever to the right. Swing acceleration is determined by
how far the lever is pushed from the center position.
3. To swing left, push the RIGHT CONTROLLER lever
to the left. Swing acceleration is determined by how far
the lever is pushed from the center position.
4. To decelerate or stop swing motion in either
direction, allow the RIGHT CONTROLLER to return
to the center (neutral) position and then push it in the
opposite direction to plug and/or stop the swing.
5. To secure the revolving frame, bring the revolving
frame to a complete stop using the swing controller,
then set the swing brakes by depressing the SWING
BRAKE SET push-button (07, Figure 2-1) or the ALL
BRAKES SET push-button (28, Figure 2-1).
NOTICE
Pressing the ALL BRAKES SET push-button
will set all the brakes including the swing
brake.
Crowd Control
! WARNING
DANGER
Excessive inclines (see Figure 4-2) can
cause unexpected shovel movementtipov-
er or runaway, resulting in severe person-
al injury, death and damage to equipment.
Do not perform any digging operations on
grades in excess of 5%. Always make sure
all motion brakes are properly main-
tained to insure maximum brake effec-
tiveness. If frequent operation on a 5%
grade may be necessary or if you have any
other related questions, consult your lo-
cal P&H representative.
The LEFT CONTROLLER (Figure 4-3) crowds and
retracts the dipper after the HOIST/CROWD push-
button (04, Figure 2-1) places the shovel in hoist/crowd
mode and the CROWD BRAKE RELEASE push-button
(08, Figure 2-1) releases the brake.
The crowd/retract motion is the movement of the
dipper along an imaginary line from the base of the
boom to a point under the boom point. Operating the
LEFT CONTROLLER extends and retracts the dipper
along this imaginary line, positioning the dipper for
digging and dumping.
Crowd or retract the dipper as follows:
4-3
 4100
Figure 4-4 Jacking the Boom
1. Check the HOIST/CROWD green indicator light to
be sure it is illuminated, indicating that the shovel is in
the hoist/crowd mode.
2. Depress the CROWD BRAKE RELEASE push-
button. The CROWD BRAKE RELEASE indicator light
(08, Figure 2-1) will light when the crowd brake air line
is pressurized to brake release pressure.
3. To crowd (extend) the dipper, gradually push the
LEFT CONTROLLER forward from the neutral
position until the dipper starts to move. The speed of
the dipper crowd movement is proportional to the
distance the controller is moved away from neutral. Be
careful not to overcrowd or overextend the dipper
handles.
4. To retract the dipper, pull the LEFT CONTROLLER
back from the neutral position. The speed of the dipper
movement is proportional to the amount of the lever
movement away from the neutral position. Avoid
retracting the dipper into the boom.
4-4
NOTICE
The crowd programmable limit switch will stop
further movement of the dipper handle when
the programmed crowd or retract limit has
been exceeded. Move the LEFT CONTROLLER
in the opposite direction to bring the dipper
handle back within the programmed limits to
regain both crowd and retract movement.
5. To stop the crowding or retracting movement of the
dipper, allow the LEFT CONTROLLER to return to the
neutral position.
6. To hold the dipper crowd/retract position, leave the
left (crowd) controller in the neutral position and set
the crowd brake by pressing the CROWD BRAKE SET
push-button (06, Figure 2-1).
7. To sound the shovel signal horn, move the LEFT
CONTROLLER to the left from the center position.
8. To operate the dipper trip assembly, move the LEFT
CONTROLLER to the right from the center position.
 4100
Figure 4-5 Overextending
This causes the dipper trip drum to increase the pull on
the trip cable, tripping the dipper door latch.
Propel Control
! WARNING
DANGER
Unexpected movement of the mining
shovel or its components due to propel-
ling on an incline (see Figure 4-6) can
cause shovel tipover or runaway, result-
ing in severe personal injury or death and
damage to the shovel and other equip-
ment. Do not propel the shovel up or down
a grade in excess of 20% grade or trans-
verse propel on a grade in excess of 10%.
Always make sure all motion brakes are
properly maintained to insure maximum
brake effectiveness. If frequent or contin-
uous propelling at or below the above
mentioned grades may be necessary or if
you have any other related questions, con-
sult your local P&H representative.
The RIGHT and LEFT CONTROLLERS (Figure 4-1
and Figure 4-3) move or propel the shovel after the
PROPEL push-button (05, Figure 2-1) places the shovel
in propel mode, releasing the propel brakes. The
controllers control the speed and direction of travel of
the crawler belts.
The direction of travel is determined by the direction
the RIGHT and LEFT controllers are moved from
neutral position. Each controller causes its side of the
propel drive system to independently drive the
associated crawler. The RIGHT CONTROLLER
c o n t r o l s t h e r i g h t c r aw l e r a n d t h e L E F T
CONTROLLER controls the left crawler.
Direction of travel (steering) can vary from straight
forward or reverse propelling to counter rotating,
depending on the positioning of the controllers as
described below.
Propel controllers operate as follows. See Figure 4-7,
Figure 4-3, and Figure 4-1.
4-5

PROPELLING UP OR DOWN AN INCLINE
TRANSVERSE PROPELLING ON AN INCLINE
Figure 4-6 Propelling On An Incline
NOTICE
When propelling or steering the mining shovel,
always make sure that both crawlers are mov-
ing. Steering the mining shovel by propelling
with only one crawler belt moving will acceler-
ate the wear of propel components.
! WARNING
DANGER
Unexpected shovel travel can cause haz-
ardous conditions resulting in injury,
death or property damage. Before relocat-
ing the mining shovel use a signal person,
check for people, equipment, grade of
slope and ground support around or near
the mining shovel and travel path.
1. For normal propel operations, position the upper
frame with the boom assembly over the front of the
carbody and/or the operator’s cab facing front.
4-6
NOTICE
This is done so shovel travel will be in the same
direction as the movement of controllers. If the
operator’s coop is not facing over the front of
the carbody, consider carefully the direction the
shovel will travel in relation to the positioning
of the controller.
2. To propel straight forward, move both controllers at
the same time and by the same amount from the
neutral (center) position (Figure 4-7). Speed is
proportional to the amount the controllers are moved
from the vertical (neutral) position.
! WARNING
DANGER
Breaking or damaging the electrical tail
cable can result in electrocution injury,
death or property damage. Inspect the lo-
cation of the cable before beginning shov-
el operation. Use a signal person to avoid
damage to tail cable during shovel travel.
3. To reverse directions while propelling, allow the
controllers to stop in neutral for a slight pause prior to
shifting directions.
4. To propel straight “reverse” pull both propel
controllers straight back. Speed is proportional to the
amount the controller levers are moved from the
vertical (neutral) position. To prevent extra stress and
wear to the crawler components, keep reverse
propelling to a minimum and do not reverse propel up
inclines.
5. To steer right while propelling forward, push the
LEFT CONTROLLER forward from the neutral
position. Depending on the degree of turn, position the
RIGHT CONTROLLER slightly forward for a long
sweeping turn.
! WARNING
DANGER
Counter rotating may cause one of the
crawler belts to run over the trailing elec-
trical cable resulting in electrocution in-
jury, death and property damage. Always
use a signal person to spot the trailing ca-
ble when attempting a counter rotating
turn.
 Figure 4-7 Propel Controller Operation
For a counter rotating right turn, position the LEFT
C O N T R O L L E R f o r wa r d a n d p u l l t h e R I G H T
CONTROLLER back. This will cause a counter rotate
right turn (Figure 4-7).
NOTICE
Counter rotation steering should be avoided or
kept to a minimum turning angle of 15˚ to 20˚
on a loose or soft floor, otherwise the crawler
shoes and components will be fouled with rocks
and debris accelerating wear of propel compo-
nents. Propelling straight for short distances
between 15˚ or 20˚ increments should clean the
crawler components.
6. To steer left while propelling forward, push the
RIGHT CONTROLLER forward from the neutral
position and, depending on the degree of turn, position
the LEFT CONTROLLER slightly forward for a long
sweeping turn.
! WARNING
DANGER
Counter rotating may cause one of the
crawler belts to run over the trailing elec-
trical cable resulting in electrocution in-
jury, death and property damage. Always
use a signal person to spot the trailing ca-
ble when attempting a counter rotating
turn.
For a counter rotating left turn, position the RIGHT
C O N T R O L L E R f o r wa r d a n d p u l l t h e L E F T
CONTROLLER back. This will cause a counter rotate
left turn (Figure 4-7).
4-7

Figure 4-8 Bank Penetration
NOTICE
Counter rotation steering should be avoided or
kept to a minimum turning angle of 15˚ to 20˚
on a loose or soft floor, otherwise the crawler
shoes and components will be fouled with rocks
and debris. Propelling straight for short dis-
tances between 15˚ or 20˚ increments should
clean the crawler components.
7. To steer left or right while propelling in reverse,
position the controller as shown in Figure 4-7. Reverse
propelling should be kept to a minimum to prevent
extra stress and wear to the crawler components.
8. To stop the propelling motion, allow the controllers to
return to neutral, allow the shovel to stop moving and
change mode of operation by pushing the CROWD/
HOIST push-button (04, Figure 2-1), which will
automatically set the propel brakes. In an emergency,
press the shovel STOP push-button (02, Figure 2-1).
4-8
NOTICE
Bring the propel motion to a complete stop be-
fore transferring to the CROWD/HOIST mode
of operation. Pushing the crowd/hoist button
while the shovel is moving will cause the propel
brakes to set in a dynamic condition and cause
premature wear of propel brake components.
DIGGING CYCLE
! CAUTION
DANGER
Unexpected movement of mining shovel
components due to performing digging
operations on an incline (see Figure 4-2)
can cause shovel tipover or runaway, re-
sult in personal injury, death and equip-
ment damage. Do not perform any digging
operations on grades in excess of 5%. Al-
ways make sure all motion brakes are
properly maintained to insure maximum
brake effectiveness. If frequent operation
on a 5% grade may be necessary or if you
have any other related questions, consult
your local P&H representative.
General
A safe, efficient shovel digging operation requires
coordinated manipulation of the crowd, hoist, and
swing controls in a smooth flowing sequence of steps.
For the purposes of this manual, this sequence is
divided into digging, swinging, dumping, and returning
phases. In addition to operating suggestions, each
phase includes information and precautions considered
important for the operator to know before operating.
Digging Phase
1. The digging phase includes crowding the dipper into
the bank, hoisting the dipper to fill the dipper, and
retracting the dipper from the bank.
2. Crowd motion gives thrust, which forces the dipper
into the bank at the start of the digging phase and gives
the required thrust to force the dipper teeth under
enough material to make effective use of the available
bail pull.
 Figure 4-9 Digging Conditions
NOTICE
Proper adjustment of the crowd/retract limit
switches must be maintained at all times.
3. Hoist motion during the digging phase is the shovel
movement that provides the bail pull on the dipper.
4. The type and weight of material being dug effects the
hoist motion (bail pull) and the swing motion when
digging. Four digging conditions are as follows (Figure
4-9).
A. EASY DIGGING applies to all loose, free running
materials of granular form such as natural sand
and gravel deposits free of boulders. Easy digging
also includes stock pile materials such as coal,
finely crushed stone, and ore concentrate.
B. MEDIUM DIGGING applies to materials dug from
natural beds without blasting, such as: dry earth
a n d cl ay, c l ay g r av e l w i t h s o m e b o u l d e r s,
unclassified excavation, ore not requiring blasting,
and coal. The dipper usually obtains a full load,
with filling aided by the natural tendency of the
material to flow when fragmented by the digging
lip.
C. HARD DIGGING applies to materials requiring
blasting. Blasting gives good fragmentation, but
results in chunks of such size as to cause many
empty spaces. Some ores requiring light blasting
are: limestone, gypsum, shale, and cemented
gravel. Hard digging also applies to wet earth and
clay. The dipper averages less than a full load under
these conditions because of the voids and/or
difficulty in digging.
Removing face material at the base of the bank of
hard material results in shallow or no bank
penetration. The dipper literally bounces off the
hard base material. This results in partially filled
dippers and additional passes to load a haulage
unit.
D. VERY HARD DIGGING applies to materials that
blast into interlocking chunks and fines that are
difficult to pull loose from the bank. Such material
is taconite, granite, trap rock, laminated shale,
some forms of limestone, and conglomerate
overburden. The dipper averages considerably less
than a full load because of the many larger chunks
which block fill and hinder pick-up of smaller
available pieces.
PRECAUTIONS
1. Do not attempt to lift the entire bank. Material must
be shaved off the bank (Figure 4-8).
2. Maintain a clean pit floor. Clean the floor before
moving forward into the bank. If necessary, propel the
shovel backward a few feet to effectively remove
material in front of the crawlers or carbody.
3. Crawler shoes and lower boom plating can be
extensively damaged by dipper impact. Do not dig
4-9
 4100

Figure 4-10 Digging Operation

4100

Figure 4-11 Stalled Condition

4-10
 4100
Figure 4-12 Maximum Hoisting Force
material so close to the front of the shovel that the
dipper strikes the crawlers, side frames, or the
underside of the boom.
4. Do not reach for material or haulage units. The
crowd motion should be controlled at the beginning of
the pass and as the dipper is raised through the bank.
If necessary, move closer to the working face so the
major portion digging is performed under the boom
point or only slightly beyond as shown in Figure 4-10.
5. Do not crowd or retract the dipper handles beyond
their operating limits. If the limits are exceeded, the
crowd limit switches will electrically stop the crowd/
retract motion until the LEFT CONTROLLER is
placed in the opposite position.
6. Do not overcrowd or jack the boom. Overcrowding is
the use of excessive crowd thrust while the dipper is
engaged in the bank. This results in the jacking of the
boom as shown in Figure 4-4. Repeated or excessive
jacking of the boom stretches the suspension cables,
resulting in premature failure of related components.
7. Engage the bank with the dipper at a point
approximately in line under the boom point. The rise of
the digging dipper should be as vertical as possible.
Proper engagement of the bank results in maximum
force in line with the cut (Figure 4-10).
8. Do not dig too close to the crawler. Digging attempted
too close to the crawlers, or with the dipper handles
extended beyond the boom point, dissipates bail pull
when the hoist force opposes the crowd force. Lift the
dipper straight up to fill (Figure 4-10).
9. AVOID STALL CONDITIONS at all times as shown
in Figure 4-11. Effective and productive life of the hoist
machinery and hoist cables depends upon the
operator’s skill in avoiding stall condition situations.
10. Carefully control the desired depth of cut and the
hoist power demands. Often the hard and very hard
digging conditions (Figure 4-9) require hoist and crowd
motion maneuvering around oversized or firmly lodged
obstructions in the bank rather than attempting to lift
the entire bank.
11. Extensive crusher damage will result if a dipper
tooth, adapter, or any sizable metal object is hauled to
the crusher and dumped. Watch closely what material
is entering the dipper.
4-11
 12. Operating a dipper in the bank with a tooth missing
results in a seriously worn dipper lip or tooth adapter.

NOTICE
Never operate a shovel with a dipper tooth
missing. To effectively cut the bank material, a
dipper must have all teeth intact.

13. If possible, avoid digging on a slope. This type of

digging increases the wear of the swing circle
components and is not recommended.

NOTICE
The maximum incline for up or down propelling
is an 20% grade. Propelling in reverse up or
down inclines is not recommended. Also, re-
verse propelling on level surfaces should be
minimized due to increased stresses on the
crawler components.

OPERATING SUGGESTIONS. Refer to, Figure 2-1,

Figure 4-13 Swing Motion Figure 4-1, and Figure 4-3 when using the following
procedure.

Figure 4-14 Sweeping

4-12
1. Ensure that the shovel is in the hoist/crowd mode of
operation and the hoist, crowd and swing brakes are
released. If the shovel is in the propel mode, push the
HOIST/CROWD and the BRAKE RELEASE push-
buttons.
2. Ensure the HOIST/CROWD light and the hoist,
crowd and swing BRAKE RELEASED lights are on.
Excessive jacking of the boom stretches the suspension
cables, resulting in premature failure of related
components. Use care not to overcrowd and jack the
boom as shown in Figure 4-4.
3. Operate the RIGHT and LEFT CONTROLLERS to
position the dipper teeth and lip into the bank. The
actual digging should take place in a zone close behind
or in front of a vertical line through the boom point.
Proper engagement of the bank occurs when maximum
force is in line with the cut.
If the boom is jacked while engaging the bank, one of
two things happen:
Figure 4-15 Swing Arc Production Ratio
Figure 4-16 Swing Path
• If the boom is jacked slightly, it contacts the first stage
of the boom limit switch and crowding action stops.
For example: if the controller handle is in crowd
position and the boom jacks, crowd motion is inhibited,
even if the controller handle is held in crowd position.
When the boom returns to its normal position by
retracting, and the limit switch is clear, the controller
reverts back to its normal function.
• If the boom is jacked or snaps back suddenly, beyond
the first stage of the boom limit switch, a second stage
is contacted and the shovel will shut down completely
electrically. If this occurs, depress and hold the START
push-button to recycle the shovels electrical system.
Still holding the START push-button, press the
HOIST/CROWD BRAKE RELEASE push-button
allowing the boom to return to its normal position.
After the boom limit switch has reset, release both
push-button.
4. Manipulate both controllers to effectively engage the
bank. Hoist the dipper until it is full (Figure 4-10).
5 . U p o n fi l l i n g t h e d i p p e r, r e t u r n t h e R I G H T
CONTROLLER to neutral and retract the dipper slightly,
using the LEFT CONTROLLER. As the dipper clears the
bank, manipulate the RIGHT CONTROLLER to start
swing motion in the direction desired.
! WARNING
DANGER
Falling or spilling load can cause injury,
death, or property damage. Never swing a
loaded or empty dipper over personnel,
trail cables, related electrical gear or other
equipment. Avoid abrupt movements that
4-13
 can result in spillage. Establish a method
for loading haulage units to prevent
swinging the loaded bucket over cabs,
people or equipment.
Swinging Phase
! CAUTION
DANGER
Swinging upper and dipper can contact
unexpected equipment or obstructions re-
sulting in equipment damage and injury.
Check for swing clearances and never
side load the dipper by swinging into
rocks or obstructions. Establish job site
procedures for loading haulage units, re-
stricting unauthorized personnel or vehi-
cles near the mining shovel, and
maintaining swing clearance from walls.
See Figure 4-14.
4100
Figure 4-17 Carry Position
4-14
Information
1. The swinging phase is the second phase of the
digging cycle. It begins when the dipper clears the
bank. Operation during this phase includes:
• controlling the position of the dipper on a planned
swing arc (path) and dump height, and
• controlling the swing motion of the revolving frame
until the dipper is over the haulage unit as shown in
Figure 4-13.
2. A 90˚ swing arc is considered standard for maximum
output. Increasing the swing arc to 180˚ decreases the
production output to about 70% of maximum.
Decreasing the swing arc to 45˚ increases production
output as shown in Figure 4-15.
3. Material weight influences swing acceleration and
deceleration times. Excessive material or dipper
weight effects stability, but does not effect overall
shovel production.
Precautions
1. To gain maximum operating efficiency, keep the
swing arcs to a minimum. Time expended in the swing
phase represents the greatest part of the entire cycle
time.
2. Position haulage units carefully. Spot them initially
by positioning the dipper over the desired location.
Positioning of these units effects swing time. Position
them as shown in Figure 4-16, so their center lines are
approximately under the swing path of the boom point.
NOTICE
To minimize dipper maneuvering required to
position the dipper to dump, position the haul-
age unit carefully.
3. Keep the working face clear of projections.
NOTICE
Never swing the shovel if the swing arc path of
the boom point is obstructed in any way.
4. Keep the pit floor level and clean. A level and clean
floor provides safe and stable shovel operation and
minimizes crawler shoe and related component
damage. It also increases output. If necessary, the
operator should request assistance of a dozer.
NOTICE
Equipment damage will occur if the dipper is
used to sweep the pit floor clean (Figure 4-14).
Never use the dipper to sweep the pit floor.
OPERATING SUGGESTIONS. Refer to Figure 2-1,
Figure 4-1, and Figure 4-3. when using the following
procedure.
1. Select the hoist/crowd mode when digging. The
HOIST/CROWD indicator will illuminate.
NOTICE
The revolving frame rotates (swings) in propel
or hoist/crowd mode of operation.
2. If necessary, release the swing brakes by pushing the
swing BRAKE RELEASE push-button. Wait until the
BRAKE RELEASED light is on.
NOTICE
Extensive dipper handle and other damage can
occur if the revolving frame is swung before the
loaded dipper is clear of the bank. Clear the
bank before swinging a loaded dipper.
3. When the dipper clears the bank, vertically and
horizontally, begin the swing toward the haulage unit.
Gradually push the RIGHT CONTROLLER from
neutral (center) in the direction of the desired swing
(right or left).
4. Hold the controller in position until the swing
reaches an optimum point (Figure 4-13). Then return
the controller to the neutral position and start plugging
(decelerating) before reaching the haulage unit.
5. To plug (slow down) or stop the swing of the revolving
frame, push the CONTROLLER from neutral in the
direction opposite of the swinging motion. If the
swinging motion is left, push the controller right. If the
motion is right, push the controller left.
Dumping Phase
INFORMATION. The dumping phase begins before the
loaded dipper passes over the end of the haulage unit
and finishes as the swing motion stops and reverses.
OPERATING SUGGESTIONS. Refer to Figure 2-1,
Figure 4-1, and Figure 4-3 when using the following
procedure:
1. When the dipper is over the box of the haulage unit,
push the LEFT CONTROLLER right. This takes up the
slack in the dipper trip rope and opens the dipper. So as
to minimize impact in the haulage unit, have the
dipper height such that the door swing just clears the
unit or the top of the load. Time the action so that the
latch trips and the dipper door opens just after the
dipper passes over the end of the haulage unit (Figure
4-13).
NOTICE
Release the LEFT CONTROLLER and allow it
to return to the neutral (center) position imme-
diately after the door opens.Holding the LEFT
CONTROLLER in the “dipper trip” position
longer than necessary will shorten the life of
the dipper trip motor and resistors
4-15
2. Manipulate the RIGHT CONTROLLER in the
opposite direction of the swing motion to slow, stop, or
reverse the swing before the dipper passes over the bed
of the haulage unit.
Returning Phase
INFORMATION. The returning phase includes:
swinging the upper frame back to the dig site, lowering,
and releasing the dipper trip assembly so when the
dipper is lowered, the dipper door will shut and the
latch will engage.
OPERATING SUGGESTIONS. Refer to Figure 2-1,
Figure 4-1, and Figure 4-3 when using the following
procedure:
1. Return the dipper to the dig site at full rated speed
lowering the dipper simultaneously to digging position.
NOTICE
Swing the upper 360˚, in the same direction,
once each hour. This prolongs the life of the roll-
er circle rollers and lubricates the center gud-
geon.
2. Manipulate the RIGHT CONTROLLER to swing the
upper frame in the desired direction and at the same
time push it forward to lower the dipper into the
digging position.
3. Center the LEFT CONTROLLER allowing the
dipper latch to engage.
4. Manipulate the LEFT CONTROLLER back and
forward to retract or crowd the dipper into the digging
position.
5. Repeat the digging cycle as desired.
PROPELLING OPERATING SUGGESTIONS
! CAUTION
DANGER
Unexpected shovel travel can cause haz-
ardous conditions resulting in injury,
death, and property damage. Before relo-
cating shovel use a signal person, check
for people, equipment, grade of slope and
ground support around or near shovel
and travel path.
4-16
1. Have a location in mind as to where the shovel is
going.
2. Ensure that the propelling surface is free of soft
spots, uneven places, and rocks that may fracture a
crawler shoe.
NOTICE
REMEMBER: the maximum incline for up or
down propelling is an 20% grade and maximum
incline for transverse propelling is an 10%
grade. Propelling in reverse up or down inclines
is not recommended. Also, reverse propelling
on level surfaces should be minimized due to
increased stresses on the crawler components.
3. Set up communications with the ground crew.
Establish a signal code for planned operations.
4. If necessary, perform the pre-start check on page 3-1
and start-up procedures on page 3-2.
5. Align the revolving frame with the boom over the
front of the carbody.
NOTICE
This is done so shovel travel will be in the same
direction as the movement of controllers. If the
operator’s coop is not facing over the front of
the carbody, consider carefully the direction the
shovel will travel in relation to the positioning
of the controller.
6. Set the swing brakes.
7. Position the dipper in a carry position (Figure 4-17).
Refer to “Hoist Control” on page 4-1 and “Crowd
Control” on page 4-3.
8. Set the hoist and crowd brakes.
9. Push the PROPEL push-button and wait for the
PROPEL light to go on.
NOTICE
Selecting the propel mode releases the propel
brakes and sets up the propel circuitry to re-
ceive input from the propel controller.
10. Warn the ground crew, using the mine signal code.
! WARNING
DANGER
Breaking or damaging electrical trailing
cable can result in electrocution injury,
death or property damage Inspect the lo-
cation of the cable before beginning shov-
el operation. Use a signal person to avoid
damage to trailing cable during shovel
travel.
11. Move the CONTROLLER(S) in the desired
direction of travel. The propel direction is related to
control lever movement as described in the propel
control topic on page 4-5.
NOTICE
Shovel speed is proportional to the amount of
controller displacement from the vertical (neu-
tral) position. Controller positioning should be
smooth with a slight pause in neutral when
changing from forward-to- reverse or reverse-
to-forward positions.
Index Sec 1 Sec 2
12. To stop the shovel propel movement, position the
CONTROLLER(S) to the vertical position.
NOTICE
Propel brakes are holding (parking) brakes
only and should not be engaged while traveling.
Emergency stopping to prevent personal injury,
death, or property damage is done by pushing
the STOP push-button on the control console.
13. When the shovel is stopped, push the HOIST/
CROWD SET push-button to set the propel brakes. The
shovel is ready for the digging mode.
14. If the shovel is going to dig, signal the ground
personnel that the shovel is about to be swung. Wait for
an “all clear” signal back from the ground personnel
prior to swinging the shovel or starting to dig.
15. If the shovel is to be shut down, refer to the mining
shovel shutdown procedures on page 3-6.
4-17
Sec 3 Sec 4