Hydraulic Excavator Operations - Guide

Hydraulic Excavator
Operations
Resource Manual
Hydraulic Excavator Operations
Table of Contents
1 Session Preliminaries.............................................................................................................7
1.1 Purpose of this Resource Manual...............................................................................................7
1.2 Safety Requirements....................................................................................................................7
1.3 Training Requirements...............................................................................................................7
1.4 Assessment Requirements...........................................................................................................7
1.1 Prerequisite..................................................................................................................................7
1.2 Getting Help.................................................................................................................................8
2 Introduction............................................................................................................................9
2.1 Scope.............................................................................................................................................9
2.2 Hydraulic Excavator Familiarisation........................................................................................9
2.2.1 Overview.............................................................................................................................. 9
2.2.2 Excavator Functions.......................................................................................................... 10
2.2.3 Hydraulic Excavator Variants............................................................................................. 11
2.2.4 Identifying the Excavator’s Main Components and Functions...........................................13
2.2.4.1 Excavator Views and Components............................................................................13
2.2.4.2 Operator Station........................................................................................................ 18
2.2.4.3 Excavator Systems.................................................................................................... 20
2.3 Operating Authority..................................................................................................................28
3 Operate an Hydraulic Excavator........................................................................................29
3.1 Operator Responsibilities..........................................................................................................29
3.2 Identifying Safe Operating Practices.......................................................................................31
3.2.1 Operating Standards.......................................................................................................... 31
3.2.2 Regular Checks................................................................................................................. 31
3.2.3 Additional PPE................................................................................................................... 32
3.2.4 Operating Plan Safety Elements........................................................................................ 32
3.2.5 Ground Condition Safety................................................................................................... 32
3.3 Fire Suppression System Components and Operation..........................................................33
3.4 Walk-Around Inspections.........................................................................................................35
3.4.1 Overview............................................................................................................................ 35
3.4.2 Driver Changeover............................................................................................................ 35
3.4.3 Pre-Inspection Checks....................................................................................................... 36
3.4.4 Operator’s Inspection Form............................................................................................... 37
3.4.5 Walk-Around Inspection..................................................................................................... 38
3.4.5.1 Introduction................................................................................................................ 38
3.4.5.2 Inspection Start.......................................................................................................... 38
Printed copy is UNCONTROLLED. The training web site has the latest version of this document
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3.4.5.3 Undercarriage Assembly – All Around.......................................................................40

3.4.5.4 Front Attachment Assembly.......................................................................................40
3.4.5.5 Lower Superstructure – All Around............................................................................41
3.4.5.6 Upper Superstructure – All Around............................................................................42
3.4.5.7 Cabin......................................................................................................................... 43
3.5 Start Up Procedure....................................................................................................................44
3.5.1 Final Pre-Start Checks....................................................................................................... 44
3.5.2 Start Up Process............................................................................................................... 44
3.5.3 Post Start Up Checks........................................................................................................ 45
3.6 Moving Off.................................................................................................................................46
3.6.1 Basic Steering................................................................................................................... 46
3.6.2 Basic Position.................................................................................................................... 46
3.6.3 Standard Operating Movements........................................................................................47
3.6.4 Continuing Checks............................................................................................................ 47
3.7 Operational Hazards and Emergencies...................................................................................48
3.7.1 Night Operating and Tramming......................................................................................... 48
3.7.2 Emergency Procedures..................................................................................................... 49
3.7.2.1 Overview.................................................................................................................... 49
3.7.2.2 Emergency Stop........................................................................................................ 49
3.7.2.3 Breakdown................................................................................................................. 50
3.7.2.4 Bogged...................................................................................................................... 50
3.7.2.5 Excavator Rollover.................................................................................................... 51
3.7.2.6 Excavator Fires.......................................................................................................... 52
3.8 Driving the Excavator...............................................................................................................54
3.8.1 Dash Indicators and warnings...........................................................................................54
3.8.2 Visibility.............................................................................................................................. 54
3.8.3 Clearances........................................................................................................................ 55
3.8.4 Horn Signals...................................................................................................................... 55
3.8.4.1 Starting and Moving Off............................................................................................. 55
3.8.4.2 Loading Trucks.......................................................................................................... 55
3.8.5 Hand Signals..................................................................................................................... 56
3.8.6 Spotting............................................................................................................................. 56
3.8.7 Power Mode Options......................................................................................................... 57
3.8.8 Tramming.......................................................................................................................... 58
3.8.8.1 General Tramming Procedures.................................................................................58
3.8.8.2 Steering Methods...................................................................................................... 58
3.8.8.3 Travelling Short Distances......................................................................................... 59
3.8.8.4 Travelling Long Distances......................................................................................... 60
3.8.8.5 Travelling Under Obstructions...................................................................................63
3.8.8.6 Travelling on Inclines................................................................................................. 64
3.8.8.7 Changing Bench Levels............................................................................................. 65
3.8.9 Operating Controls............................................................................................................ 67
3.8.9.1 Left Joystick............................................................................................................... 67
3.8.9.2 Right Joystick............................................................................................................ 67
3.8.9.3 Joystick Multi-functions.............................................................................................. 68

3.8.9.4 Slewing...................................................................................................................... 68
3.8.10 Positioning the Excavator................................................................................................ 70
3.8.10.1 Pre-Operations Inspections.....................................................................................70
3.8.10.2 Establishing Operating Positions.............................................................................70
3.8.10.3 Operating in Water.................................................................................................. 71
3.8.11 Operational Cycles.......................................................................................................... 72
3.8.11.1 Swing Angles........................................................................................................... 72
3.8.11.2 Work Phases........................................................................................................... 73
3.8.12 Digging Techniques......................................................................................................... 77
3.8.12.1 General Digging Guidelines.....................................................................................77
3.8.12.2 Face Digging........................................................................................................... 79
3.8.12.3 Bench Digging......................................................................................................... 81
3.8.12.4 Drop Cuts Digging................................................................................................... 88
3.8.13 Loss of Ground Engaging Tools (GET) When Digging....................................................88
3.8.14 Loading............................................................................................................................ 89
3.8.14.1 Introduction.............................................................................................................. 89
3.8.14.2 Considerations and Precautions..............................................................................89
3.8.14.3 General Loading Techniques...................................................................................90
3.8.14.4 Drive By Loading..................................................................................................... 91
3.8.14.5 Top Loading............................................................................................................. 92
3.8.14.6 Drive By Top Loading.............................................................................................. 94
3.8.14.7 Bottom Loading....................................................................................................... 94
3.8.14.8 Double Bench Loading............................................................................................ 97
3.8.15 Oversize Loading............................................................................................................. 98
3.8.16 Working Near Edges........................................................................................................ 99
3.8.17 Cleaning Up the Work Area............................................................................................. 99
3.8.17.1 Overview.................................................................................................................. 99
3.8.17.2 Clean-up Outside Swing Radius............................................................................100
3.8.17.3 Clean-up Inside Swing Radius...............................................................................101
3.8.18 Battering........................................................................................................................ 102
3.8.18.1 Overview................................................................................................................ 102
3.8.18.2 Pulling Batters....................................................................................................... 103
3.8.18.3 Scaling Batters...................................................................................................... 103
3.8.18.4 Pit Wall Assessment.............................................................................................. 104
3.8.18.5 Scaling Procedure................................................................................................. 104
3.8.18.6 Scaling Area Clean-up........................................................................................... 105
4 Perform Post-Operational Procedures.............................................................................107

4.1 Parking and Shutdown Procedures.......................................................................................107
4.2 End of Shift...............................................................................................................................108
4.3 Maintenance.............................................................................................................................109
4.3.1 Preventative Maintenance............................................................................................... 109
4.3.2 Defect Reporting.............................................................................................................. 110
4.3.3 Breakdowns..................................................................................................................... 111

4.3.4 Troubleshooting............................................................................................................... 111
4.3.5 Fluid Levels..................................................................................................................... 112
4.4 Field Refuelling and Servicing................................................................................................113
4.5 Field Jacking for Maintenance...............................................................................................114
4.6 Washing the Excavator...........................................................................................................115
5 Activities..............................................................................................................................116
5.1 Section 3 Operate an Hydraulic Excavator Activities..........................................................116
Activity 1................................................................................................................................... 116
Activity 2................................................................................................................................... 116
Activity 3................................................................................................................................... 116
Activity 4................................................................................................................................... 117
Activity 5................................................................................................................................... 118
Activity 6................................................................................................................................... 118
Activity 7................................................................................................................................... 119
Activity 8................................................................................................................................... 119
5.2 Section 4 Perform Post-Operational Procedures Activities.................................................120
Activity 1................................................................................................................................... 120
Activity 2................................................................................................................................... 120
Activity 3................................................................................................................................... 121
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Section 1 Session Preliminaries
1 Session Preliminaries
1.1 Purpose of this Resource Manual

The purpose of this Resource Manual is to provide detailed information and instructional
material for the subject matter of this training module. Where appropriate the content covers the
standards, procedures, safety and operational requirements for the workplace and tasks
described.
This Resource Manual is a key document in a suite of documents for the learning and
assessment requirements of this module.
1.2 Safety Requirements

If you demonstrate unsafe behaviour or perform a task without the necessary care or
confidence, the Trainer must direct you to cease work and terminate the training immediately.
1.3 Training Requirements

This Training module is conducted in accordance with the Training and Assessment Standard
and will be delivered in a variety of work situations and conditions appropriate to the role or task
to reinforce the required learning and repeated over a suitable time frame.
The Trainer will explain the training format, process and the progression to the assessment
requirements.
The content of this Resource Manual satisfies the training material requirements for this module.
Although you can keep this manual, the Activities at the end of each Section must be completed
and a copy of the Activities given to the Trainer.
1.4 Assessment Requirements

On completion of this training module an assessment will be conducted, which must be
successfully completed to attain an assessment of Competent for the material covered by this
module.
The assessment requirements are:
 A knowledge based test
 Practical demonstrations to establish a satisfactory understanding of the required
task/s and the associated safety requirements
 Workplace evidence completed by the Participant demonstrating competency in all the
required tasks
1.5 Prerequisite
Completing the training for the Generic Health, Safety and Environment Requirements and
being assessed as Competent, is a mandatory prerequisite for attending the training for this
module.
Information covered in the Generic Health, Safety and Environment Requirements Resource
Manual that is also applicable to hydraulic excavator operations is not duplicated in this
resource manual. If necessary, review the HSE manual to assist you with the full understanding
required for hydraulic excavator operations.
Section 1 Session Preliminaries
1.6 Getting Help

See your Line Manager or Supervisor to obtain further assistance with the subject matter in this
training module.
Section 2 Introduction
2 Introduction
2.1 Scope
This training module is aligned with the requirements of the unit of competency, RIIMPO310A
Conduct hydraulic excavator operations.
This Resource Manual discusses generic hydraulic excavator operations and is to be used in
conjunction with the relevant Original Equipment Manufacturer (OEM) manual for the specific
hydraulic excavator model and type that you will be operating at your mine site.
The topics include planning and preparing for operations, operating the hydraulic excavator and
carrying out post-operational procedures.
There is also relevant information covering the HSE and legislative requirements for the
functions associated with operating an hydraulic excavator. This safety information is extremely
important and is discussed in detail with all related subject matter, as required, throughout this
manual.
2.2 Hydraulic Excavator Familiarisation
2.2.1 Overview
Hydraulic excavators, also called diggers, are used for a variety of applications, e.g. road
construction, pipelines and digging holes and ditches. They are a high performance machine
equipped with a hydraulically operated arm and bucket also making them highly suitable for
various mining operations. The tracked hydraulic excavator is able to work on the soft and
uneven ground of the shot surfaces in strip mining.
The hydraulic excavator use diesel engines to power hydraulic pumps for supplying oil at high
pressure (up to 5000 psi) for the rams, slew motor, track motors, and accessories. There are
lower pressure pumps (approximately 700psi) for operating the Pilot Control for the spool
valves.
The two main sections of an excavator are the undercarriage and the house. The undercarriage
includes the blade (if fitted), tracks, track frame and final drives, which have a hydraulic motor
and gearing providing the drive to the individual tracks, and the house includes the operator
cab, counterweight, engine, fuel and hydraulic oil tanks. The house attaches to the
undercarriage with a centre pin allowing the machine to slew 360° unhindered.
Hydraulic excavators in action can be compared to the movements of a human arm. The boom
portion of the equipment acts very much like the upper portion of the arm, including the elbow
and the shoulder. The arm portion behaves similarly to the portion of an arm that starts at the
elbow and ends at the wrist. The bucket portion can be compared to a cupped hand.
Excavators are manufactured in a range of sizes for the many specialised purposes. The largest
Caterpillar model weighs 85 tonnes and has a 383 kilowatt (513hp) engine. The largest
excavator available is the Bucyrus RH400 weighing approximately 98 tonnes with a 3355
kilowatt (4500hp) engine and has a bucket size of about 52.0 m³.
An Example of an Hydraulic Excavator – The Liebherr Model R 994
This photograph shows the excavator in the correct park up configuration.
An Example of an Hydraulic Excavator Dimensions using a Liebherr Model R 994
2.2.2 Excavator Functions

An excavator may be required to perform the following tasks:
 Digging and loading material onto trucks, both from a bench and from ground level
 Side casting over benches
 Cutting limits and final wall batters
 Digging trenches and drains
2.2.3 Hydraulic Excavator Variants

There are several different makes and models of hydraulic excavator currently used throughout
the Leighton / HWE mine sites. The following images illustrate two examples of these
excavators.
Liebherr Model R 9350
Hitachi Model EX 1200
Terex O&K RH170 Excavator
2.2.4 Identifying the Excavator’s Main Components and Functions

The following photographs and supporting descriptions provide a general understanding of an
hydraulic excavator, its basic configuration and components.
The Excavator has three main structural sections.
1. Front Attachment
2. Superstructure
3. Undercarriage
These sections are described below.

The excavator example used is the Liebherr model R 994.
2.2.4.1 Excavator Views and Components
2.2.4.1.1 Left Side Full View with the Front Attachment
1 Front Attachment 6 Work lights

See the diagram on the following
page for descriptions of the
components
2 Operator’s Cabin 7 Platform
3 Engine Compartment 8 Hydraulic Tank
4 Access ladders 9 Pre-Air Cleaner
5 Service Deck 10 Portable Fire Extinguishers
Front Attachment
The front attachment consists of three main components.
1. Boom
2. Stick
3. Bucket
The front attachment assembly and its components are illustrated in the following diagram.
These assemblies are connected with hardened steel pivot and joint pins and hardened alloy
bushes. All these mechanical linkages are lubricated by the integrated grease system.
The front attachment is controlled by hydraulic rams and cylinders powered by the excavator
engine’s hydraulic system.
The bucket functions like a backhoe and is constructed of high tensile steel plates and grouser
bars for wear resistance. The bucket’s teeth are connected to a cast steel bucket lip with
adapters.
Replaceable wear or lip shrouds are attached to the lip between each tooth / adapter unit. The
replaceable wing shrouds are fitted on the bucket’s sides. To assist crowding of the bucket, an
additional link may be used for connection to the stick.
2.2.4.1.2 Right Side Superstructure and Undercarriage View
1 Hydraulic System Cooling Fans 6 Work Lights

There are also more lights on the Boom
outside the scope of this photo
2 Final Drive 7 Centre Girder
The main undercarriage support frame
3 Track Side Frame 8 Track Rollers
4 Front Idler 9 Carrier Rollers
5 Boom Cylinders 10 Tracks
Superstructure
The superstructure is the body of the excavator and is mounted on the undercarriage slew ring.
The superstructure consists of the:
 Engine/s – there is a second engine on some models
 Hydraulic system
 Fuel tank
 Operator’s cabin
 Front attachment mountings
 Counterweight
Undercarriage
The undercarriage consists of two trackframe assemblies, each holding a trackbelt and a
superstructure that joins the two trackframe assemblies and supports the slew ring for the
superstructure.
Each trackbelt is constructed of induction hardened cast steel track pads interconnected with
floating, heat-treated pins.
2.2.4.1.3 Rear View
1 Counterweight 3 Flashing beacons

There are several of these light around
the superstructure
2 Exhaust 4 Work lights
2.2.4.2 Operator Station

A typical example of an Operator cabin in a modern hydraulic excavator
There is also a Ladder Access Control Box and a Service panel Control Box that is nor shown in
the above diagram.
Refer to the relevant OEM documentation for the excavators make/s and model/s at you site for
instructions on using the operational controls in the cabin/s of the equipment.
Cabin layout, instrumentation and controls vary between different models and makes of
hydraulic excavators.
2.2.4.2.1 Cabin
The Operator’s cabin provides a safe, healthy working environment while allowing efficient
excavator operations. Specific design characteristics are:
 Falling Object Protection Structure (FOPS) – Attached to the top of the Operator’s
cabin and the excavator’s structure to protect the Operator from rocks falling on
the cabin
 Built-in roll over protective structure (ROPS) – This provides protection to the
driver during loading operations and in the event of an excavator rollover.
 Cabin suspension to help provide vibration isolation
 Air suspension seat to help isolate the driver from vibration

 Sound suppression
 Heat and air-conditioning – some excavators have pressurised cabins
 Ergonomically designed seats
 Passenger / training seat – only in some models
 Window guards
 Inertia reel retractable belts
Cabin door
If the cab door cannot be opened during an emergency, the front window can be used as an
alternative exit by breaking the window glass with the special tool stored below the fire
extinguisher.
2.2.4.2.2 Operator’s Seat

The Operator’s seat provides a fully adjustable cushioned ride for the Operator’s comfort and
ease of operation.
To help reduce fatigue, periodically readjust the seat and backrest for additional comfort. The
seat’s air adjustment may vary between excavators due to site modifications. Ask if required.
The following images are examples of the seats that are typically installed in hydraulic
excavators.
Hitachi Seat Terex Seat
2.2.4.3 Excavator Systems

The excavator has seven separately identifiable systems.
1. Engine/s Systems
2. Drive systems
3. Swing System
4. Hydraulic System
5. Air System
6. Electrical System
7. Fire Suppression System
Engine/s Systems
The engine/s in the excavator used in this example are water-cooled, fuel injected,
turbocharged, 12 cylinder Cummins diesels with a power output of 840kW at 1800rpm.
The engine/s (if there are two) are housed in separate engine compartments.
The engines drive and supply power for all the excavator systems.
Radiators and oil coolers are installed at the front of each engine. The radiator cap is accessed
from the service deck, with a sight glass on the side of the tank to indicate coolant level.
The engine air cleaner is a two-stage filter with a dust ejector. A water-cooled aftercooler is
installed between the turbocharger and the engine to cool the airflow.
The exhaust gas driven turbocharger operates at speeds up to 80,000rpm.
The exhaust system is mounted on the back of the service deck over the counterweight.
The fuel system is electrically controlled to supply each engine with the required level and
pressure of fuel.
Engine speed is managed through a remote control system. Auto idle and each engine speed is
independently controllable from the Operator’s seat with the fuel levers.
An idle down timing device is connected to each engine, to help prolong engine life and prevent
turbocharger damage. Both are set for a predetermined run down, but can be overridden in the
event of an emergency.
Engine Compartment
Fuel System
Drive Systems
Each trackbelt is driven by a final drive tumbler at the rear of the trackframe and supported at
the front by a free turning front idler. Lower (load) rollers and opposed dual type upper (carrier)
rollers are also fitted onto each trackframe for trackbelt support and tracking control.
Each drive tumbler is powered by a separate drive train with each consisting of a travel motor
and a corresponding travel reduction device.
The hydraulically operated travel motors are fitted on the outside cover of each travel reduction
device and the motor drive shaft is splined to the pinion gear.
Output torque transfers to the drive shaft and tumbler through gearing in the travel reduction
device.
A spring set and hydraulically released multiple disc travel park brake is incorporated into each
travel motor. This brake engages automatically when the propel controls are in the neutral
position. There is also a travel motion alarm device.
Final Drive
Front Idler
Swing System
The swing system consists of a substantial swing bearing assembly that is installed between the
superstructure and the undercarriage allowing a 360° rotation of the superstructure.
The superstructure revolves around the centre joint and undercarriage through the rotation of
pinion gears against the swing bearing. The pinion gears are driven by swing drive units
consisting of a drive shaft, gearbox and hydraulically driven motor.
A swing lock valve is incorporated into each swing motor to brake the rotation of the
superstructure when the swing controls are released into the neutral position.
There is a triple-row roller bearing between the inner and outer races of the swing bearing to
support radial and axial forces. The bearing’s outer race is bolted to the superstructure and
rotates around the inner race, which is bolted to the undercarriage.
The pinion gears and the swing bearing are grease-bath lubricated through the Auto-lube.
The swing drive units are oil lubricated through their own reservoirs.
Oil level dipsticks and fill up points are provided on each unit.
Swing Mounting on Undercarriage
Swing Drive Planetary Gears
Hydraulic System
Hydraulic pumps are fitted to the engine/s that power the front attachment, and the travel and
swing motors.
The output power from each engine is transferred to the hydraulic system through the pump
drive transmissions and main pumps to the control valves and then to the main hydraulic lines
for each circuit. Various types of hydraulic filters are included in all circuits.
The pump drive transmissions are designed to enable an equal distribution of power to each
hydraulic function at all times allowing either independent or combined operation of the pumps.
Control of the front attachment and the swing and travel motors is through the pilot hydraulic
system via the joystick control levers and foot pedals in the Operator’s cabin.
When a control lever or pedal is operated, the oil pressure in the pilot system activates the
corresponding main hydraulic control valve, which results in the operation of the relevant
hydraulic function.
When the excavator’s park position is selected, the pilot pressure is not supplied and all front
attachment and travel functions will not operate. The Swing lock and travel motor park brake is
also applied.
Accumulators are provided in the pilot circuit to supply pressure for pilot valves after the engine
has stopped, which can be used for lowering the bucket and releasing the remaining pressure in
the actuator lines.
Hydraulic Pumps
Simple Hydraulic System
Air System
An air compressor is built into the engine/s and an air receiver is in the superstructure to supply
air pressure for the auto-lubrication system, the horn, the fast fill panel and to pressurise the
hydraulic tank.
The auto-lubrication system is a centralised, air powered system, which distributes grease to the
swing bearing, centre joint and all front attachment joint pins and bushes.
Auto-lube cycles are controlled with a timer allowing the greasing and pause cycle times to be
adjusted. The Auto-lube can also be manually operated with a button in the cabin. This can be
used for checking the system, adjusting the track tension or for manual lubrication with a
separate hose reel fitting.
The Fast Fill panel is a device used to refill the excavator’s fluid requirements conveniently from
ground level.
The excavator has an air-powered horn for normal use. It is also fitted with a separate electric
horn for emergency use if the air pressure is not available.
Electrical System
The electrical system consists of four main and two safety 12-volt batteries configured to supply
a 24-volt power source.
An engine driven alternator supplies the battery charging current.
Warning : The batteries give off hydrogen fumes that can explode.
24 Volt Battery Supply
Example of a Battery Isolation Switch on a Terex RH170 Excavator
Batteries can be isolated using a battery isolation switch. This prevents power from being
inadvertently feed to any of the excavator systems.
Never select the OFF position when the excavator is operating as this can damage the electrical
system.
Fire Suppression System

The excavator is fitted with an automatic and integrated fire suppression system.
The system consists of three major components.
1. Containers for storage of suppressant material.
2. Actuation and detection devices.
3. Delivery system.
There are two modes of system operation.

1. Manual
2. Automatic
Manual fire extinguishers are provided on the catwalk above the boom and at the rear of the
Operator’s cabin id required for extra fire suppression support.
2.3 Operating Authority

To operate an hydraulic excavator under any circumstances you must:
 Be at least 18 years of age
 Complete the relevant site induction/s
 Must be trained and deemed competent to operate by site training requirements
If you are unsure about your authority to operate or what authorisation is required, seek advice
from your Supervisor.
Section 3 Operate an Hydraulic Excavator
3 Operate an Hydraulic Excavator

Important Note
Due to the various makes and models of hydraulic excavators used across Leighton mining
sites, the following procedures for walk-around checks start up and general excavator
operations are generic. You must refer to your mine site’s procedures and the excavator’s OEM
documentation for the specific excavator that you will be operating for the full inspection and
operational requirements.
3.1 Operator Responsibilities

Operating an hydraulic excavator is a skilled task that requires significant training and an on-
going discipline to manage and operate this highly specialised and unique vehicle.
While operating the excavator, there are critical parameters that must not be exceeded, with
constant monitoring of systems and surrounds for alarms and hazardous situations.
The excavator is to be operated in accordance with the manufacturer’s instructions and adhere
to your site’s safety and operating procedures.
It is part of the Operator’s responsibility to help maintain the safe and efficient operation of the
excavator. This is achieved by following the required operating procedures.
These procedures are:
 Studying the OEM operations and maintenance documentation thoroughly before
operating or working on the excavator to become familiar with the location, purpose
and use of all instruments, controls, indicator lights, safety devices and emergency
devices
 Ensuring that you read and understand any additional information pertaining to special
attachments for the excavator
 Ensuring that you understand all warning and caution signs / labels / decals, checking
if all the warning signs are on the excavator and ensure they are all legible – notify the
Supervisor if any signs are damaged or missing
 Taking part in shift change-over procedures
 Conducting walk-around inspections and pre-start checks
 Only operate the controls while the engine is running as damage to some components
can occur and / or leave some functions in an unsafe setting causing unexpected
movement when systems are powered up
 Reporting defects in or on the excavator using approved defect-reporting forms or
procedures – never operate the excavator if you consider it unsafe to do so
 Operating the excavator safely and productively
 Operating the excavator to suit the ground conditions
 Not operating the excavator when warning lights are on or flashing
 Being aware of all machinery, light vehicles and personnel in the vicinity of the
excavator
 Always using the correct horn signals and checking the area around excavator before
starting or moving the machine
 Being aware of the possibility of rocks falling from the structure of the excavator
 Stopping the excavator if distracted
 Operating the excavator with due care, so as not to reduce its service life or cause
unnecessary damage to it or to other machinery
 Not slewing the superstructure of the excavator while any portions of the tracks are
unsupported
 Never using the excavator as a crane as there are no restrictive valves in the hydraulic
circuits
 Not allowing anybody to stand beneath a raised bucket or allow the bucket to pass
over any Operator’s cab
 Never carrying passengers in the excavator unless authorised by the Supervisor and
the excavator is fitted with an approved passenger seat and seatbelt
 Never leaving the Operator’s seat or allowing anybody to board / leave the excavator
without first grounding the Ground Engaging Tool (GET) and applying the park brake
 Ensuring the excavator is available for use whenever it is required
 Ensuring that preventative maintenance is performed when scheduled
 Parking the excavator in secure locations or designated areas
 Ensuring that high standards of housekeeping are maintained
 Observing shutdown procedures
 Requesting the assistance of an experienced operator if you are required to perform
an unfamiliar task
 Never performing any changes, additions or modifications on the excavator, which
could influence the safety, without obtaining the permission from the manufacturer
 Ensure that the excavator will not be damaged or made unsafe by any actions that
you may take
The excavator must be operated with lights on to assist with mine site safety. This is mandatory.
If you correctly perform all checks and operate within prescribed handling parameters, the
operation of the excavator is always a safe task.
The Operator’s excavator care responsibilities may vary depending on site regulations.
3.2 Identifying Safe Operating Practices
3.2.1 Operating Standards

You must perform frequent pre-operational and operational checks and inspections on the
excavator. The purpose of these inspections is to discover and locate any adjustments that may
be required before operating the excavator and to find any defects before they become
significant problems that may cause injury and equipment or environmental damage.
Ensure a high level of excavator maintenance, safety and operating standards by:
 Carrying out quality walk-around inspections
 Performing the required pre-start checks at the beginning of each shift and before
starting the excavator after a shutdown
 Ensuring that before operating the excavator that you are aware of the location of
underground services and get a site permit to dig before proceeding, if required
 Avoiding damage to the excavator by being aware of the its capabilities and
surroundings
 Ensuring that all procedures are followed if there is a need to move under overhead
power lines
 Do not work closer than 10 metres (fully extended) from a power line
 Not digging within 10 metres of a suspected misfire
Move the excavator clear and notify your Supervisor of the situation immediately.
 Detailed and conscientious reporting of defects
 Ensuring all routine servicing and any other preventative functions are carried out as
scheduled
 Operating the excavator within its limits in a safe manner
 Keeping the excavator clean
Warning : Do not operate the excavator if you believe it to be in an unsafe condition.

Report your concern and either get it cleared as safe to operate or report it for
repair.
3.2.2 Regular Checks

Monitoring the excavator’s operational status includes regularly checking:
 Temperature gauges
 Fluid level gauges
 All controls and switches
 Pressure gauges
 Alarms and indicator lights
 Drive and swing controls
 Braking systems
 Hydraulic systems
3.2.3 Additional PPE

PPE equipment for operating an excavator in addition to your site’s basic requirements can
include:
 Hearing protection
 Skin protection (when required)
 Torch – for use during the hours of darkness
 All tags and personal Isolation lock
 Gloves, face shields and fall protection devices must be worn when carrying out some
tasks
3.2.4 Operating Plan Safety Elements

Always include safety in your operating plan by:
 Monitoring personnel and equipment in the excavator operating area
 Monitoring all truck Operators for any signs or symptoms that could indicate Operator
fatigue.
 Constantly inspecting ground conditions around the excavator, with particular attention
to unstable shot ground and faces
 Using the excavator’s controls wherever possible to avoid visual problems and
potential strain injuries to your neck and back
3.2.5 Ground Condition Safety

The ground conditions can have a dramatic affect on Operator safety and comfort.
Some conditions to be aware of are:
 Watching for falling rocks
 Undulations and edges
 Any power troughs
 Climbing and descending faces
 Windrows
3.3 Fire Suppression System Components and Operation

Equipment Description
Excavators are equipped with an on-board Fire Suppression System (FSS) that when activated
controls a fire in the engine module.
The FSS consists of:
 Two nitrogen pressurised main canisters (typically blue) holding the suppressant foam
 Several CO2 pressurised actuator cylinders (typically red)
 The necessary connecting lines, valves and spray heads
The actuator cylinders are positioned at various locations on the excavator – typically:
 In the operators cab
 Upper deck next to engine well ladder
 Beneath excavator counterweight
Testing the Fire Suppression System

Use the following procedure to check and test the FSS.
1. Turn on the ignition.
If the FSS:
 Is charged and ready, the green ON light on the instrument panel lights up
 Has low pressure or has been discharged, the alarm lamp lights up and the alarm
sounds
Allowing the pressure in the FSS to fall below its operational range activates a system
alarm that will not allow excavator to be started. If this occurs report the problem to
maintenance facility.
2. Start the engine

3. Allow the air pressure build up after starting
4. Press the FSS test button on control panel
5. Ensure that the alarm sounds and the light flashes
Press Mute to silence the alarm.
6. Ensure that the engine shuts down.
7. Press the test button.
8. Press the reset button for system reset.
9. Restart the excavator.
If you don’t reset the system, the excavator will shut down again shortly after the restart.
Manual Operation
If you notice smoke or suspect that there is a fire in the excavator:
1. Press the emergency fire button
This activates the:
 Audible alarm
 Visual alarm
 FSS foam spray suppressant
2. Stop the excavator as soon as possible and park as per park-up / shutdown procedures, if
possible. The excavator engine will stop after a predetermined time from when the FSS is
activated.
3. Mute the alarm and initiate an emergency response call.
If the electrical system in the excavator fails (this would be very rare) the FSS must be manually
activated by removing the safety pin from:
 Any actuator cylinder and striking the knob – Some actuators are enclosed in a cover
or
 The lever on top of either one of the main canisters and then pulling the lever up
Automatic Activation
Some excavators have a device positioned above the engine that can automatically discharge
the FSS if the temperature in the engine compartment rises above a preset limit. This system
also activates audible and visual alarms.
If a fire occurs, Operators are not to rely on this device and always manually discharge the
system if it has not started when you suspect a fire.
Fire Extinguishers
There are also portable fire extinguishers located on the excavator.
Note : Do not operate the excavator if it does not have an appropriately located and fully
charged fire extinguisher.
3.4 Walk-Around Inspections
3.4.1 Overview
The primary reasons for a pre-start walk-around excavator inspection are to identify any
maintenance concerns before they become serious problems and to identify any potential safety
issues before they become serious hazards.
A walk-around inspection must be performed:
 At the beginning of every shift
 Before operating any other excavator during a shift
 After repairs and scheduled maintenance
 After a hot seat changeover occurs
Perform a brief walk-around inspection whenever the opportunity arises, i.e. after refuelling and
when you have been absent from cabin for any length of time, e.g. lunch and other breaks.
3.4.2 Driver Changeover

A hot seat changeover is a method of safely changing Operators of mobile equipment with a
minimum of disruption to the hauling cycle.
Hot seat changeovers generally occur at change of shift and involve many Operators. However,
hot seat changeovers can also occur under other circumstances that only involve the two
Operators, e.g. lunch, fatigue breaks, refuelling or other break in the normal haul cycle.
Changeovers are usually pre-arranged with designated Operators of light vehicles meeting with
mobile equipment at designated changeover areas.
The hot seat operator changeover procedures may vary according to site regulations and
excavator makes and models. Refer to your sites procedures for site and excavator variations.
Observe the general safe procedures for a hot seat operator changeover by:
 Contacting the excavator Operator on the two-way radio clearly stating the intention to
change Operators before proceeding into the work area
 Standing in a safe location clear of the excavator’s operating cycle
 Remaining clearly visible until the excavator has been safely parked and isolated on
solid flat ground with the GET lowered to ground
 Only approaching the excavator after the current Operator leaves the cabin
The handover can occur on the deck of the excavator or on the ground near the
excavator.
 Communicating with the out-going Operator regarding any concerns about the
excavator serviceability, hazards, work plans and any other site conditions as
necessary
 Completing a walk around inspection if changing during a shift and a pre-start
inspection when changing from one shift to another or at fuel up
 Ensuring the out-going Operator is clear of the required area
The current Operator remains in the excavator until the changeover Operator arrives. The
current Operator must not leave the excavator unattended during a hot seat changeover.
Excavator operations must not resume in the area until personnel / light vehicles have left the
exclusion zone and the all clear given by the light vehicle Operators via two-way radio and
acknowledged.
3.4.3 Pre-Inspection Checks

Before starting the inspection, ensure:
 Excavator is parked on stable and level ground in an appropriate place
 Excavator cannot move and is not to close to an overhanging face
 Nobody is in or around the cab area before approaching
 That you always approach the excavator from a position allowing vision to the cabin
 Park brake is on and the transmission is in neutral
 There are no tags or locks establishing a condition of unserviceability
Conduct a full walk around inspection outside the footprint of the excavator, checking for
obvious damage, ground conditions and if any persons within the area of the excavator.
Isolating the Excavator

Isolate the excavator with a personal danger tag and lock before conducting a pre-start
inspection or for servicing / cleaning.
Complete the following procedure to isolating the excavator:
1. Complete the required risk assessment.
2. Isolate the battery by turning the isolation switch to the OFF position to disconnect the
electrical system.
3. Tag the battery isolator with a Personnel Danger tag and lock
4. Ensure that the correct park up procedures have been applied.
5. Ensure that the excavator is parked in a safe position on level ground with the GET
lowered to ground.
6. Test the isolation by turning the ignition key to the start position to ensure the excavator will
not start.
a. If the test is successful (i.e. engine does not start), turn the ignition key back to the
OFF position.
or
b. If the test fails, i.e. engine starts:
 Turn off the engine
 Remove isolation tags and locks
 Turn the isolation switch to the OFF position
 Apply an Out of Service tag to the excavator
 Report problem to the Supervisor
Note : Never turn the battery isolator switch off with the engine running as serious damage can
occur to the engine and electrical system.
3.4.4 Operator’s Inspection Form

The Operator’s pre-start safety inspection checks form must be completed during the
walk-around to record any faults or damage to the excavator before commencement of your
shift. The information you record on this form can also protect you against being accountable for
any previous damage to the excavator.
The following image is an example of the typical pre-start inspection forms used for
driver-operated equipment at Leighton’s mine sites. The form used at your site may not be
exactly the same.
As these forms are typically not equipment specific or totally comprehensive, ensure that you
have with you during the walk-around some method of recording any other concerns resulting
from the inspection that are not listed on this form.
The forms typically have three fault categories for the repair actions required (see above form).
The following points specify your responsibilities as the Operator for each of these categories.
1. Do Not Operate – Report the fault to your Supervisor for repairs.
2. Authorisation Required – Report the fault to your Supervisor and obtain authority to
operate.
3. Corrective Action Required – Report the fault to your Supervisor and if the fault is not
corrected before the end of the shift, it must be recorded in the backlog defect list.
Note : All fire extinguishers on the excavator must be operational and you must have
at least one operational hand held fire extinguisher available before operating
the excavator.
3.4.5 Walk-Around Inspection
3.4.5.1 Introduction
The Liebherr R944 Excavator is used as an example to describe the required pre-start checks.
The location of some functions and items may vary on some of the hydraulic excavators at your
site. However, the important factor is that all points specified for inspection on your excavator
are checked.
If any system needs to be checked with the engine running, the Operator must remain in the
cabin while a second person checks the equipment.
Warning : Before commencing the inspection, check the engine start switch and the battery
disconnect switch to ensure there are no DANGER or OUT OF SERVICE TAGS
attached to the excavator. If there are do not use the excavator.
3.4.5.2 Inspection Start

A walk-around inspection can be performed in either direction around the excavator provided
the procedure you use is methodical and complete.
Commence walk-around by:
1. Isolating the electrical system using the battery isolation switch.
Example of a Battery Isolation Switch and location
2. Starting at a logical position, e.g. at the entrance ladder (1) as illustrated in the diagram on
next page
Warning : A walk-around inspection of the excavator must be conducted outside the

footprint of the equipment. However, it is acceptable to enter inside the
footprint to place Isolation after a Take 5 is conducted.
The following diagram illustrates a walk-around example in one direction.
1. Left side 2. Front Attachment 3. Right side

Undercarriage and Lower Undercarriage and
Superstructure Lower Superstructure
4. Rear 5. Upper Superstructure 6. Cabin
Undercarriage and Lower
Superstructure
Fluid Levels
All fluid levels are to be checked during walk-around inspections.
These are:
 Hydraulic fluid
 Engine oil
 Steering oil
 Fuel
 Coolant
Only use the sight glasses on the superstructure to check the various fluid levels. The locations
of the sight glasses vary depending on the make and model of the excavators at your mine site.
Refer to the OEM documentation for the excavator that you will be operating.
Warning : You are not to remove the caps of fluids that operate under pressure and high
temperatures, i.e. radiator, hydraulic tank and steering oil reservoir caps.
3.4.5.3 Undercarriage Assembly – All Around

Check:
 Track tension for the correct amount of slack between the carry roller and the idler –
refer to OEM specifications
 Track pads for damage, cracks or wear
 Track rollers and carry rollers for damage, oil leaks and signs of wear
 Track guides and plates missing or worn
 Track chain pins for wear and signs of movement and missing grouser plates
 Idlers and Sprockets for damage, wear and signs of oil and grease leaks
Leaks indicate damage or wear
 Pins and bushes for grease, wear, damage and security
 Track frame mounting bolts for security
 Lower superstructure for structural or accident damage
 Slew ring bolts for security
 Final drives, propel motors and guards for damage, wear and oil leaks
 Grease and hydraulic lines and clamps for damage, leaks or signs of rubbing, fraying
 Rotary connection and all hoses for leaks or damage
 Around and under excavator for oil or fuel leaks or any accumulation of grease
 Any other obvious abnormalities or damage
3.4.5.4 Front Attachment Assembly

Check:
 Bucket for damage, wear, structural cracks and missing hardware
 Bucket teeth and adapters for wear and missing pins
 Bucket shrouds for wear and missing pins
 Cutting edges (lip shrouds) for wear
 Bucket cheek guards for security and wear
 Bucket, pivot and cylinder pins for lubrication, security and damage
 Hydraulic cylinder rams and seals for rod damage and oil leaks
 Grease, pilot and hydraulic lines and hoses, clamps and valves for security, damage,
leaks or signs of rubbing, fraying
Any accumulation of grease could indicate a broken line or a lubrication fault.
 Pins and bushes for grease, wear and security
 All points are receiving grease
 For any loose or missing bolts, keeper plates and associated fittings
 Work lights and mountings
 Any other structural cracks or damage to the boom, stick or bucket
3.4.5.5 Lower Superstructure – All Around

Check:
 Emergency stop button is off and operates correctly
 Centre girder for damage
 For structural cracks, missing plates or bolts
 Boarding steps, handrails, catwalks and guardrails are in place, secure, undamaged
and free of grease and debris
 Front access ladder for debris, damage and security
 Position of the Fast Filling panel is correct
 Oil, water or fuel leaks from coolers or tank
 Oil leaks from under the cab or hydraulic pump room
 Ground area around and under the machine for oil, grease, fuel or coolant leaks
 All covers on the excavator are closed
 All working lights secure and undamaged
 Ensure all handrails and walkways are undamaged, secure and clear of grease and
debris
 Fire suppression bottles for charge and security
 Oil level in engine/s using dipsticks
 Radiator/s and fan blades from the top for damage or rubbish build up
 Belts (fan, A/C and alternator) for damage, fraying and adequate tension
 Hydraulic oil cooling fans and motors for any oil leaks, damage and rubbish build up
 Hydraulic pumps for leaks and worn or damaged hoses
 Autolube panel for leaks and damaged hoses
 Grease tank level using Indicator
 Left and Right pump drive gearboxes for leaks and correct oil levels
 Header tank coolant levels using sight glasses
 Hydraulic oil level using sight glass
For an accurate hydraulic oil level reading, the excavator must be shut down, boom
and stick must be fully extended out and the bucket fully crowded in and grounded.
 Ensure all engine compartment doors are securely closed
Use the emergency stop switches when inspecting in the engine and hydraulic pump
room, and ensure that all isolation points are clear of tags, other than isolation tags for
pre-inspection.
 Check the general engine and pump areas for oil, fuel or coolant leaks and any
rubbish build up
It is important that a visual check is conducted around the turbo or engine bay areas
for the potential for leaking combustible fluids onto hot parts which may result in the
ignition of resultant vapours.
 Engine room fire suppression systems for loose or broken hoses and blocked or
covered spray heads
 Engine air cleaner hoses are secure and undamaged
 Turbocharger oil feed lines and air cleaner hoses for condition and security
 Swing motor oil levels using dipsticks

 Boom and main hydraulic control valves and lines for damage, security, leaks or signs
of rubbing or fraying
 Batteries – security, cleanliness/corrosion , security of terminals
3.4.5.6 Upper Superstructure – All Around

Check:
 Ensure that all handrails and walkways are undamaged, secure and clear of grease
and debris
 Upper deck air filtering assemblies for damage
 Air cleaner indicator restriction gauges
 Inspect all fire suppression equipment
 Main fire bottles (blue) for security, loose or broken brackets and lines
 Main fire bottles (blue) gauges for charge indicator
 Actuator cylinders and lines are secure, undamaged and the safety pins are in
place
 Portable fire extinguishers are securely in place, undamaged, safety pin and
sealing tie in place and the gauges are in the green zone
Shake the cylinder to prevent settling of contents.
 Revolving light for damage and security
 Deck for oil and fuel leaks
 Arch hoses for wear, security and oil leaks
 Ensure that the emergency ladder or rope ladder is serviceable
 Exhaust stacks for damage and security
 Work lights and mountings for damage and security
 All doors, hatches and electrical cabinets must be closed
 Cracks in welds, joints and other frame and body structures
 Any other obvious abnormalities or damage
3.4.5.7 Cabin
Check:
 Cab mounting bolts for security
 FOPS for security and damage
 Door and window latches close and operate correctly
 Door and window seals undamaged and cab seals against dust
 Operator’s cab reasonably clean with no loose or heavy articles in the cabin or
unsecured
 The floor is cleared of anything that could become lodged behind the foot pedals
 Operator’s seat and seatbelt are in good condition and adjustable and ensure all
mountings are secure
 All instruments including emergency stop button, windscreen wipers, horn, air
conditioner and instrument panel are undamaged and in working order
 Fire Suppression System actuator cylinder and line are secure, undamaged and
safety pin is in place
 Windows and mirrors are clean, undamaged and mirrors adjusted to suit
Extreme care must be taken when cleaning windows and cleaning and adjusting
mirrors. Be careful, watch your footing and use adequate lighting at night.
 Console adjusted to suit
 Propel, boom, stick and bucket controls are undamaged and in proper working
condition
 Two-way radio is turned on and operational
3.5 Start Up Procedure
3.5.1 Final Pre-Start Checks

Prior to entering the cabin to start your shift, ensure that:
 Any issues found during the pre-start inspection are resolved and that the appropriate
signatures have been obtained
 Check the immediate area to ensure that personnel and equipment are clear of the
excavator
 The isolation switch is in the on position
After entering the cabin:

 Adjust the seat and mirrors
 Fasten the seatbelt
 Turn on the two-way radio and check that it is operating correctly
 Ensure the fire suppression system is active
 Check that the doors and windows are secure
 Ensure that the propel pedals can be comfortably operated with your back against the
seat
3.5.2 Start Up Process

Use the following sequence to start the excavator.
1. Ensure the speed selector lever is in the P (Park) position.
2. Ensure all control levers / pedals are in the neutral position.
3. Ensure the slew and travel brakes on.
4. Ensure the fuel levers are in the low idle position.
5. Ensure the auto Idling switch is in the correct position.
6. Turn the ignition key to the ON position – battery charge and all oil pressure lamps should
light.
7. Push the lamp check button – if any warning or OK lamp does not light have the problem/s
investigated.
8. Push the fluid level test button to check the fluid levels – if any of the green lamps do not
light, check the respective fluid levels, as they could be low.
This button gives an indication only. Fluid levels need to be checked visually during the
pre-start check. If the excavator is not level, an incorrect indication may be given.
9. Complete a last visual check around the excavator from the cabin to ensure that all is clear
to start and sound the horn, then wait 5 seconds.
10. Turn the ignition key to the START position and crank the engine.
If the engine does not start after 10 seconds, turn the key back to the OFF position before
trying again. Otherwise fuel will not be supplied and starting will not be possible, even
though the starter cranks the engine.
If the excavator does not start after two attempts, notify the Supervisor and allow two
minutes for the starter motor to cool down.
11. Release the key as soon as the engine starts.

12. Repeat step 10 for the second engine (if applicable)
Always start each engine separately.
13. Warm the engine/s at low idle for about three minutes.
To prevent damage and to prolong serviceable life, turbocharged engines need to be
warmed up at low revs before being operated and then idled down before being shut off.
14. Ensure that all alert indicators, except for the park brake, should go out.
15. Ensure oil pressure is normal.
If it does not register within 10 seconds or any other warning lights / buzzers don’t go out /
off, stop the engine and notify the maintenance facility to investigate the warnings.
3.5.3 Post Start Up Checks

Complete the following checks after the engine starts.
1. Ensure that all gauges, instruments and controls are functioning correctly.
2. Check that the air pressure, oil pressure and coolant temperature gauges are normal.
3. Ensure that no warning lamps are on.
4. Ensure that all panel lights, work lights and wipers / washers are working.
5. Check air cleaner gauge readings – needles must be in the normal range at high rpm.
6. Ensure lights are on.
7. Raise engine RPM and check all boom / stick / bucket / swing and travel functions.
This function also assists warm up the hydraulic oil.
Do not extend or retract the hydraulic rams to full stroke during the warm up.
8. Ensure that the GET is at the correct elevation to avoid any obstacles or hazards.
9. Slew excavator at least 360 at the start of each shift to relocate slew ring roller bearings for
even wear and grease distribution.
10. Report any faults or abnormalities immediately and never operate an unsafe or damaged
excavator.
11. Set up the excavator to commence work.
12. Sound horn and wait 5 seconds before starting operating.
The safety lever that controls servo pressure for the excavator hydraulics only functions when
the Operator is in their seat. This lever must be lowered to engage the excavator functions and
raised to disengage the excavator functions.
Simultaneously with the operation of the safety lever, the travel and swing brakes are applied. If
the safety lever is raised, the travel and swing brakes cannot be released by the respective
switches.
When changing the safety lever back to the lower position, the brakes are returned to the same
condition they were in before the lever was raised, i.e. released or applied.
3.6 Moving Off
3.6.1 Basic Steering

The excavator steering is controlled by manipulating the pressure on the right and left travel
pedals for forward and reverse motion and turning right or left. Each pedal is connected to the
drive system for one of the tracks. (Steering techniques are comprehensively described later in
this section.)
If the upper structure is slewed past its basic forward position by more than 90°, the machine
may move in the opposite direction to that which you have anticipated. If you are unsure about
the position of the upper structure and the undercarriage, the travel pedals should be depressed
slightly to check the direction of travel.
3.6.2 Basic Position

Always travel with the excavator in the basic position. This means the superstructure in line with
the tracks and the final drives / motors at the rear.
The following diagram illustrates the basic position.
Travelling in this manner:

 Centralises the excavator’s centre of gravity
 Keeps the track pads taut on the bottom
 Produces the most effective transfer of power
 Subjects the rollers and pads to the least wear
 Correspond with the travel pedal directions
Always check the position of the final drives / motors before pressing the travel pedals.
3.6.3 Standard Operating Movements

Always be aware of other equipment operating in the area.
Monitor track position at all times.
The excavator may be moved with the final drives at the front without causing serious wear for
the occasional short moves, e.g. repositioning at the face.
Ensure that you have a clear line of vision in the direction of travel and be able to see both
tracks. Angle the superstructure slightly to the tracks to achieve this keeping the slewing to a
minimum while travelling.
Always apply the slew brake while travelling. If the boom or GET position needs to be altered
during a move, stop the excavator first, reposition and recommence travelling.
Never travel with a loaded bucket.
Whenever possible always drive on firm and level ground; select the travel speed to suit the
conditions and travel in straight lines. Take extra care on slippery ground.
The excavator is equipped with two-speed travel. Only select High speed for travelling along flat
haul roads and benches. Low speed must be selected for rougher areas and when travelling up
or down inclines.
Do not change the travel speed setting while moving. Stop the excavator first, select the
required range and recommence travelling.
It may be necessary to clear the tracks of dirt or debris before beginning a move.
Alert all personnel via the two-way radio and give details of any major move. If it is required to
travel along a haul road, an escort must be used.
Be careful not to hit the drive motors by driving over obstructions or straddling large rocks. Know
the underside clearances before tramming over rough ground.
The travel brake applies automatically when the travel pedals are released.
If any problems are encountered, park the excavator safely, stop the engine, isolate and report
to Supervisor to have maintenance investigate the problem before continuing operation.
If the excavator becomes unstable or starts slipping or rocking while travelling, release the travel
pedals immediately and ground the bucket.
3.6.4 Continuing Checks

Throughout start-up and operation of the excavator you need to continue your checking and
safety vigilance by using all your senses to monitor the excavator’s performance. This approach
can be summarised as follows.
Look: for unusual occurrences, e.g. oil or coolant leaks, obstructions, poor road
conditions, deterioration of components
Listen: for unusual noises, e.g. bearing failures, engine over-speed, warning alarms,
transmission and drive train failures
Smell: for burning and overheated oils, electrical equipment, engine or transmission
Feel: for unusual vibrations, from engine, transmission, drive train, bearings and
hydraulic controls
3.7 Operational Hazards and Emergencies
3.7.1 Night Operating and Tramming

The reduced visibility at night presents hazards that require you to exercise a greater level of
caution than during daylight hours.
You must also ensure you have an adequate amount of sleep before starting a night shift. If you
are fatigued, take a rest break or contact your Supervisor.
Adjust your normal procedures and techniques at night to include:
 Conducting a thorough walk-around check of the excavator using a torch ensuring all
windows and lights are clean and serviceable
 Taking extra care and attention to detail when operating at night
 Being more careful of potential safety concerns due to the blind spot areas of the
excavator
 Looking for the lights of other vehicles
 Using the turn signal indicators when tramming and making turns to give ample
warning to other vehicles
 Avoiding sudden changes of direction at night
 Checking the lights at regular intervals and cleaning any that have become obscured,
particularly rear lights and indicators
 Keeping to the known roads and tracks and avoiding going into unfamiliar areas
3.7.2 Emergency Procedures
3.7.2.1 Overview
It is not possible to anticipate every possible circumstance that may lead to an emergency.
The following procedures are provided as a guide for reacting to potential mine site emergency
situations. Use your judgement for each situation and attempt to prioritise actions to avoid:
 Personal injury
 Equipment damage
 Environmental damage
 Loss of production
3.7.2.2 Emergency Stop

Only use the emergency stop procedure in an emergency or if the ignition switch malfunctions.
If you have control of the emergency stop:
 Cease operations immediately
 Lower the GET to the ground
 Press the emergency stop button
 Turn off the ignition
 Use the two-way radio to notify the relevant emergency response crew using the site’s
emergency communications procedure
 Leave the cabin if save to do so
There are several emergency stop switches on an excavator that can be used to immediately
shutdown the engine/s in an emergency situation or to render the excavator inoperable to carry
out inspections or maintenance.
The switches are typically located:
 In Operator’s cab
 Inside engine room
 Beneath the counterweight
When any Emergency Stop Switch is activated:

 Fuel relays are turned off
 Fuel solenoid valves are de-energised stopping both engines
 An air solenoid valve is energised to immediately dump the pressurised air out of the
hydraulic tank
 A swing emergency stop solenoid valve is energised to stop the swing function
 The cabin monitor lamp lights up and a buzzer sounds
 The fire suppression system may be activated
Note : When any Emergency Stop switch is ON, the engines can be cranked but will not start.
3.7.2.3 Breakdown
The Operator must assess situation, perform an excavator risk assessment if necessary and
follow the breakdown procedure.
1. Stop the excavator, and if possible, apply the correct park up procedure as soon as
practicable in the nearest safest location.
2. Apply the brakes.
3. Take appropriate action in accordance with the breakdown situation, e.g. oil leak – shut off
engine.
4. Leave on or turn on lights.
5. Notify the Supervisor using the two-way radio of the location and problem.
6. Notify control to ensure all traffic is aware of your location.
7. If safe, stay in the cabin and wait for assistance unless advised to vacate by the Supervisor
or maintenance personnel.
If the excavator breaks down and must to be parked in an operational area, a windrow barrier,
cones and flashing lights must be placed around the excavator.
3.7.2.4 Bogged
If the excavator becomes bogged or wedged in shot ground and is not safe to move under its
own power, immediately contact the Supervisor. Do not attempt to recover a bogged excavator
without the appropriate equipment or assistance, as the risk of serious injury and further
equipment damage is high.
Your Supervisor will assess the situation and take the appropriate action to recover the
excavator.
3.7.2.5 Excavator Rollover

When excavators are operated correctly, the chances of a rollover are minimal. However, there
is no room for complacency because rollovers have and can occur with reduced awareness.
There are several conditions either, separately or in combination, that can cause rollovers.
These are:
 Too close to edges
 Large rocks
 Rough and / or shot ground
 Excessive load
 Incorrect tramming on ramps
In the event of a rollover, follow the recommended precautions and procedures as much as
practicable in an attempt to prevent or minimise injury.
Brace firmly in the Operator’s seat with both feet firmly on the floor to minimise body movement
during the rollover. You should already be wearing your seat belt.
When the excavator has stopped moving, if there is no immediate danger, exit the cabin if you
can do it safely. If there is a possibility of the excavator moving again remain in the cabin until
assistance arrives.
Warning : Never attempt to jump clear while the excavator is moving in a rollover
situation.
At the earliest opportunity:

 Shut down the engine
 Radio for assistance
 Shut down all electrical systems
Note : Always maintain a high standard of housekeeping in the cabin as serious injury
can occur from loose objects during a rollover.
3.7.2.6 Excavator Fires
3.7.2.6.1 Introduction
Working excavators develop a high range of operating temperatures and the potential for fire is
always present. Although excavator fires are a rare occurrence, when they do occur, they can
cause significant levels of destruction and threat to personal safety.
No fire is the same. If you notice a fire remain calm as the information that you give is vital to the
emergency response.
Safety and speed are the two most important factors in fighting fires.
3.7.2.6.2 Operator Fire Response Procedures

If there is a fire on the excavator use the following procedure.
1. Bring the excavator operation to an immediate stop parking it as safely as possible.
If possible, park to allow the water truck easy access to the area affected by fire.
2. Position the bucket on the ground.
3. Select neutral.
4. Move fuel levers to idle position.
5. Apply the park brake.
6. Lock the hydraulic controls.
7. Turn the ignition off.
If necessary, activate the idle-timer override switch (if equipped) to shut down the
excavator immediately or shut down engine/s with emergency stop switch.
8. Activate the Fire Suppression System if the fire is in or near the engine/s.
9. Notify your position and emergency details using the site’s two-way radio emergency
procedure advising if the fire control system has been activated.
10. Leave the operator cabin and dismount at the safest exit point.
11. If possible and safe (i.e. do not risk personal injury) fight fires outside the engine area using
a portable fire extinguisher.
If fire cannot be controlled evacuate the excavator immediately.
Ensure your escape route, as it can become engulfed in flames by a shift in wind direction
or further rupturing of fuel / oil lines.
12. Once the extinguisher is discharged, move away from the excavator to a safe location.
3.7.2.6.3 Fire Prevention

If oil and fuel spills are cleaned up as they occur and rubbish build up is eliminated, the risk of
fire is greatly reduced.
Actions that can be taken by Operators to avoid or minimise fire hazards are:
 Always turning off the engine while refuelling the excavator
 Shutting down the excavator immediately a blown hose is noticed
 Never smoking or allowing an open flame in refuelling areas, where batteries are
being charged or where batteries and flammable materials are stored
 Always starting the engine as described in the OEM documentation and / or site
procedures
 Checking the electrical system regularly and frequently
 Ensuring that all defects (e.g. loose connections, burnt out fuses and bulbs, burnt or
damaged cables) are repaired immediately by maintenance personnel
 Never storing flammable fluids on the excavator except in storage tanks intended for
the machine's operation
 Inspecting all components, lines, tubes and hoses for oil and fuel leaks and / or
damage, and then replacing or repair any damaged components immediately
 Ensuring that all clamps, guards and heat shields are installed
These components prevent vibration, rubbing, chafing and heat build-up.
Install tie wraps to fasten hoses and wires, as required.
3.8 Driving the Excavator
3.8.1 Dash Indicators and warnings

Operators need to be familiar with all the indicators on the dash as this allows you to take timely
corrective action for any problems while operating and to report all the information required by
maintenance crews for repair.
Always refer to the relevant OEM manual for your excavator model and type, as the dash
indicators may be different.
3.8.2 Visibility
Visibility from the cabin of an excavator is severely restricted because the elevated position of
the Operator and the physical features of the excavator create blind spots.
The Operator must use caution and be alert at all times.
The Operator must be aware of clean up equipment and any other vehicles entering the work
area. Always obtain a positive response from clean-up equipment before the Operator
commences any clean up.
When working in close proximity with other mobile equipment, do not assume that Operators of
the other equipment are not affected by visibility limitations. Be prepared to take evasive action
if necessary.
When visibility drops below a safety level due to excessive dust, mist, rain or sun, extreme
caution must be used. Operate to suit the conditions.
If at any time the tracks, front attachment, face or haul truck is not visible, STOP operating and
wait for visibility to improve.
Do not attempt to judge these positions and continue digging and loading. The chances of an
accident occurring are greatly increased.
The periods of dawn and dusk can greatly affect the visibility and extra care must be taken
during these times.
Remain alert for the masking affects of shadows cast by the excavator and other equipment or
other work area features. Approach shadowed areas with caution.
If the work lights fail, especially at night, notify the Supervisor and cease operating until there is
sufficient light to resume operations safely.
Clean all windows, mirrors and lights at the start of your shift and as necessary throughout the
shift.
Visibility can also be improved or impaired depending upon the operations of the Excavator, i.e.
up or down ramps, turning circle left or right and blind corners.
Visibility from the excavator is even more restricted when reversing. Ensure that you have
sufficient clearances from faces, other equipment and personnel before reversing. If there is any
doubt, use a Spotter.
3.8.3 Clearances
It is the Operator’s responsibility to ensure the excavator has sufficient clearance whenever it is
in operation.
Be aware of clearances when:
 Tramming
 Swinging
 Parking
 Turning – slow down and avoid making contact with bund walls / windrows
 Operating in tight areas around other equipment, overhead power lines, near cables,
lighting plants and park up areas
If in doubt when entering into an area for the first time, seek clarification and guidance from the
Supervisor.
In relation to visibility from vehicles, a blind spot is defined as a line of sight obscured by a
window column or other obstruction.
3.8.4 Horn Signals
3.8.4.1 Starting and Moving Off

Operators of mobile equipment in the mine operational areas use horn signals to indicate the
three main vehicle actions.
These are:
 One blast indicates the equipment is about to start
 Two blasts indicate the equipment is going to move forward
 Three blasts indicate the equipment is going to reverse
3.8.4.2 Loading Trucks

Loading unit operators direct the movement of trucks in the loading area with horn signals.
These are:
 One short blast to stop the truck under the shovel / bucket
 One long blast to indicate that the truck is loaded
 Two long blasts to indicate that the truck is in the wrong position
 One short blast before raising the bucket – this also applies when the bucket has been
sitting in the face waiting
 One long or continuous blast when moving to reposition or when slewing to the right or
executing a 360° turn
3.8.5 Hand Signals

In some situations it may be necessary for the Operator to receive signals from a person on the
ground, e.g. maintenance personnel.
Where possible a two-way radio should be used. If this is not possible, the Signaller and the
Operator agree on what hand signals are used for the job. It is important that the Operator only
receive hand signals from one person.
Some Basic Hand Signals
3.8.6 Spotting
Introduction
Spotting in the pit area under normal working condition can only be performed by a person
seated in another machine provided that person has clear a vision of both the approach to the
excavator and the entire path of the excavator. The Spotter must keep an open communication
on the two-way radio and only releasing the communication link when the manoeuvre that
required spotting is complete.
Spotting in other situations (e.g. breakdowns and workshops) must be performed using the
appropriate procedure for the lighting conditions.
Spotting From the Ground by Day

Spotting from the ground is only performed when absolutely necessary due to the danger of
falling rocks and tyre explosions.
The Spotter instructs the Operator of the requirement by radio (preferred) or in person using
approved site signals.
The Operator keeps the Spotter in full view at all times and if he / she loses site of the Spotter or
signals are not clear; stop immediately and resolve the problem.
Spotting From the Ground by Night

Radio communication is preferred and encouraged, however a torch can be used.
The Spotter is to be clearly visible to the Operator and have an operational torch.
The Spotter uses approved site signals to guide the Operator.
The Operator keeps the Spotter in full view at all times and if he / she loses site of the Spotter or
signals are not clear or the torch fails, stop immediately and resolve the problem.
A Spotter must always be used when tramming an excavator into and out of a workshop and to
act as a third party when it is necessary for an Operator to remain in the cabin while a fitter
cannot be seen by the Operator.
3.8.7 Power Mode Options

Four different operating modes can be selected with the power mode switch. For each of these
modes, a microcomputer automatically selects the best combination of engine speed and
hydraulic pump flow rate.
The digging power does not vary with each setting, only the speed changes.
Mode Selected Function
L Low Power For high accuracy / less noise, e.g. setting up for maintenance,
positioning in workshop and jacking up excavator
E Economy power For travelling and when the priority is on fuel cost rather than work
speed
P Power General operating mode
S Super power High operating mode
3.8.8 Tramming
3.8.8.1 General Tramming Procedures

Ensure that the roads, access ramps, incline of grades and new work area have been prepared
according to expectations, and safety and site requirements before moving the excavator.
Plan and coordinate any required safety signage placements and support equipment operations
along the designated route and at the new work area.
You must constantly monitor the excavators operating and warning indicators while tramming
and be aware of unusual changes in performance.
If conditions allow, always tram with boom fully raised, the arm fully retracted and the bucket in
the closed position. This distributes the weight of the excavator evenly on the lower rollers.
Always position the front attachment in a safe position to avoid overhead obstructions. Be aware
of the surrounding conditions and move in a safe manner to suit conditions.
3.8.8.2 Steering Methods

The information in the following table describes the steering methods for a tracked excavator.
Direction of Travel Steering Methods
Forward Push down on the top of both pedals at the same rate.
Speed is proportional to the distance the pedals are moved from the
stop position.
Forward Left Push down on the top of the right pedal and release the pressure on
the left pedal.
The greater the difference in the pedal positions, the tighter the turn.
Forward Right Push down on the top of the left pedal and release the pressure on the
right pedal.
The greater the difference in the pedal positions, the tighter the turn.
Pivot Turn Left Push fully down on the top of the right pedal and leave the left pedal in
neutral.
See the next page for extra information about pivot turning.
Pivot Turn Right Push fully down on the top of the left pedal and leave the right pedal in
neutral.
Spin Turn left Push fully down on the top of the right pedal and push fully down on
the bottom of the left pedal.
Spin Turn Right Push fully down on the top of the left pedal and push fully down on the
bottom of the right pedal.
Reverse To travel in a straight direction in reverse, push down on the bottom of
both pedals at the same rate.
Speed is proportional to the distance the pedals are moved from the
stop position.
When reversing do not position the GET over the final drives.
Reverse Left To steer to the left while travelling in reverse, push the bottom of the
right pedal.
Depending on the degree of turn required, position the left pedal at
neutral for cornering or slightly forward for a sweeping turn.
Direction of Travel Steering Methods
Reverse Right To steer to the right while travelling in reverse, push the bottom of the
left pedal.
Depending on the degree of turn required, position the right pedal at
neutral for cornering or slightly forward for a sweeping turn.
Select hard, level or raised ground for steering wherever possible and avoid turning in dips or
depressions.
When turning over 90° at one time, complete the turn in increments of 20° to 25° with the
excavator being propelled for a short distance between each direction change, especially in soft
or boggy ground. This reduces stress on the tracks and track frame components and stops the
build-up of material in and around the tracks.
Pivot Turning, Counter-Rotating or Spragging

Pivot turning, counter-rotating or spragging accelerates turning and can be used to reposition
the excavator in a small area.
The excavator is capable of spragging 360° on the spot.
To assist spragging, the bucket heel can be placed on the ground with a light down-pressure to
raise the front of the tracks slightly off the ground. This reduces weight and tension allowing the
tracks to be repositioned with less effort.
Operate the slew control lever to release the swing lock when performing this procedure.
Example: To sprag to the left, raise the tracks as described above. Then operate the slew lever
to the right, press the left pedal back and the right pedal forward all at the same time. This
rotates the car body anticlockwise under the stationary superstructure.
It is important to lift only the excavator just enough to take the weight off the front idlers. Do not
lift the tracks high off the ground as this places extreme loads on the final drives, slew bearing,
slew bolts and other drive components causing premature wear and failure of the excavator
drive system.
Turning or spragging on a slope can make the excavator unstable. If unavoidable, select the
firmest ground with minimal degrees.
Ensure there is sufficient track tension before attempting to sprag the excavator. If the tracks
are too loose, the rollers may ride up over the track shoes.
3.8.8.3 Travelling Short Distances

When moving the excavator short distances around the work area, keep the stick about vertical
with the bucket heel facing the ground and ready to help reposition the excavator as shown in
the following illustration.
3.8.8.4 Travelling Long Distances

Tramming
When travelling on level ground for some distance, the front attachment position shown in the
following illustration is to be used, provided there are no overhead obstructions. This position
gives you maximum visibility and, due to the weight shift; the excavator is easier to turn.
When travelling for longer distances, track roller temperatures need to be monitored, as
excessive heat builds up in the undercarriage, which must be regularly cooled down.
Overheating can occur more often on cambered roads and uneven ground due to excessive
side thrust. Always keep the excavator in the centre of the road.
If tramming time exceeds 15 minutes, stop for 15 minutes to allow undercarriage to cool down.
Arrange for a water truck to spray the rollers during the 15-minute stop.
If necessary use a heat gun to check the temperature of the rollers near the duo cone seals.
Temperatures must not exceed 15° above ambient.
If surface is rough decrease engine speed and avoid sudden changes in direction.
Rotate undercarriage direction every 30 minutes.
Transporting
If an excavator has to be moved long distances, it can be more efficient and less stressful on
the equipment to use a low loader / float transport vehicle.
The following diagram illustrates the correct method for tramming an excavator on to a low
loader / float transport vehicle.
The following procedures are to be used when loading an excavator on to a transport vehicle.
1. Select a suitable location.
2. If necessary, remove part of the attachments before loading.
3. Remove all dirt and mud from track components.
4. Secure the superstructure to the undercarriage with the locking pin.
5. Ensure the low loader breaks are applied.
6. Lower the loading ramps ensuring that the ramp incline is no more than 30°.
7. Cover the ramps with wooden planks to help prevent skidding.
8. Ensure hand controls are fitted to the travel pedals.
9. Have a Spotter ready to guide and signal the excavator Operator.

10. Retract the attachment as far as possible and lower the attachment as close as possible to
the loading surface.
11. Commence manoeuvring slowly in a low gear towards the loading ramps.
12. Ensure the excavator is correctly centred with respect to the ramps.
13. Walk the machine slowly up the ramps.
14. Take care at the overbalance point.
15. Position the excavator so that its centre of gravity is as close as possible to the load centre
of the low loader.
16. When the excavator is on the trailer the Operator secures the machine by:
 lowering the front attachment
 Releasing the hydraulic pressure
 Shutting down the engine
 Removing the ignition key
 Locking the cabin
 Isolating the excavator
 Securing all doors and covers
17. Carefully secure the excavator to the low loader with chains, wedges and blocks to prevent
slipping.
18. Raise the ramps.
19. .Review the transport route to ensure that the width, height and weight allowances are
within the permitted limits, e.g. bridges, underpasses, utility lines and tunnels.
Unloading
Unloading the excavator from the transport vehicle is essentially the reverse of the loading
process with the same precautions.
1. Park the transport vehicle on flat and level ground.
2. Remove the excavator tie downs.
3. Position the ramps.
4. Start the excavator as per OEM guidelines.
5. Use a Spotter to guide the excavator Operator.
6. Follow site procedures for an unloaded excavator before tramming.
3.8.8.5 Travelling Under Obstructions

Where there are overhead obstructions along the route travel with the front attachment as
illustrated in the following diagram. Keep the boom high enough to ensure the bucket link does
not hit the ground when travelling in this mode, especially if the excavator starts rocking.
When a low overhead obstruction is reached (e.g. power lines), it may be necessary to move
the front attachment to the position illustrated in the following diagram to maximise clearance. A
Spotter is to be used to help guide the excavator under low obstructions.
This position should also be used when climbing steep hills.
3.8.8.6 Travelling on Inclines

When operating the excavator on an incline, the following precautions must be observed to
ensure safety and stability.
Always use a slow speed when tramming up or down any inclines, e.g. ramps and
workbenches.
Keep the bucket on the uphill side of the incline approximately half to one metre from the
ground. This means that the final drives are always on the downhill side while travelling up or
down an incline as shown in the following illustration.
Never walk an excavator up or down a slope that has an incline over 30° or across a slope that
is over 15°.
Dig out a ramp before tramming up or down inclines of more than 30°.
Do not swing downward on a slope greater than 15° as the excavator may roll over.
Where possible, always travel straight up or down slopes and not across. Traversing slopes
puts great stress on the track components, and can make the excavator unstable.
Always position the front attachment to suit conditions.
Never reposition the travel speed selector lever whilst moving, especially downhill, it may cause
the excavator to start slipping or run away.
If the excavator becomes unstable or starts slipping or rocking while travelling, release the travel
pedals immediately and ground the bucket.
Always stop the excavator first, before changing direction on a slope.
If the excavator stalls on a slope, ground the bucket and restart the engine.
Always ground the bucket if the excavator is to be stopped or parked on the slope even for a
short time.
Due to the increased load on the undercarriage when travelling uphill, monitor the hydraulic oil
temperature. If the oil temperature gets too high, stop the excavator and run the engine at high
idle to cool it down. It is preferable to do this before the hydraulic oil temperature warning light
illuminates.
Be careful not to damage the drive motors by riding over obstructions or straddling large rocks.
3.8.8.7 Changing Bench Levels

During excavators operations you will regularly need to move from one bench to another for
various reasons, e.g. safety, efficiency and work plans.
Moving Up a Bench
When the excavator needs to move up a bench level, use the techniques illustrated in the
following diagram to ensure safety and prevent equipment damage.
When the excavator needs to move up

to another level, material is pulled down
from the top of the bench to form a
ramp that the excavator can climb.
Approach the bench at a 90° angle and
use the bucket to pull the top section
down to lessen the angle of the climb.
Do not exceed a maximum angle of 30°
or 60%.
To take stress off the tracks and drive
motors, reach the bucket out and use it
to assist the excavator to climb the
ramp.
Stop and reposition the bucket as
necessary until level ground is reached.
Coordinate pulling the stick in and

walking the excavator to climb the
bench.
When nearing the top of the bench,

start lifting the bucket to just clear of the
surface.
When at the top of the bench, push the

stick out to maintain balance.
If a ramp has been built from part of the face the excavator is digging out, it will need to be
removed before continuing operations. It may sometimes be necessary for a dozer to assist in
the construction and removal of these access ramps.
Moving Down a Bench

When the excavator needs to move down from a bench level, use the techniques illustrated in
the following diagram to ensure safety and prevent equipment damage.
When walking off benches, always travel with the drive motors to the front.
When the excavator needs to move

down to another level, a ramp is built
by cutting out the top corner of the
bench edge and placing the material
at the bottom to form a steady decline
for the excavator to walk down.
Approach the bench at a 90° angle.
Select low speed and fully depress the
pedals to enable the travel retarder
valve to operate properly.
Push the edge of the bench over and
place the bucket on the pit floor to
help support the excavator when
repositioning it to a lower level.
Never support the full weight of the
excavator with the front attachment
when using this method.
Serious damage, including cracking of
the boom and running the engines out
of oil can occur if this type of
procedure is not done correctly.
Walk the excavator to the edge and
start the decline from the bench,
keeping the tracks at a 90° angle to
the bench. A maximum angle of 30° or
60% must not be exceeded.
While descending the ramp, keep the
bucket out low, ready to be grounded
if the excavator runs away or
becomes unstable.
Walk down the decline slowly, keeping
the weight on the boom and stick.
When approaching the bottom of the

bench ensure that the bucket clears
the surface.
Remember to start raising the boom
as the bucket nears the bottom of the
ramp.
3.8.9 Operating Controls

There is a joystick on the left and right side consoles for controlling the operation of the
excavator’s swing and front attachment functions.
3.8.9.1 Left Joystick

The left joystick controls the:
 Stick’s roll in and roll out movements
 Upper structure’s left or right swing movements
The left joystick controls are illustrated in the following diagram.
When the joystick is released, it automatically returns to the neutral position stopping the
function.
3.8.9.2 Right Joystick

The right joystick controls the:
 Boom’s raising and lowering movements
 Bucket’s crowd and dump movements
The right joystick controls are illustrated in the following diagram.
3.8.9.3 Joystick Multi-functions

Diagonal movement of the joystick combines the movements of the front attachment’s functions.
When the swing function is activated, all working movements are possible without affecting the
swing movement.
During travel all front attachment movements are possible with swing movement taking priority.
When swing is activated travel movement is reduced.
3.8.9.4 Slewing
3.8.9.4.1 General Operation and Precautions

When slewing an excavator the following procedures and precautions must be observed.
Always check the swing working range to ensure there is adequate clearance before slewing.
Warning : Never slew the front attachment over any person, equipment or the cabin of a haul truck,
even if the bucket is considered to be empty.
Small rock fragments are extremely dangerous when dropped from a considerable height.
Always attempt to slew to the left (anti-clockwise), due to restricted vision on the right (blind)
side of the excavator when performing a slew inspection of an area. If slewing to the left is not
possible, use a continuous horn blast to indicate that the excavator is slewing to the right
(clockwise).
Warning : Ensure that you never allow the GET to make contact with the cabin of any equipment
as this can easily result in serious injury or death to the occupant.
Keep slewing to a minimum when the excavator is on an angle. If this movement is necessary,
take extra precautions as the slew responses will be different to those normally expected. The
slew motors, slew components and centre joint are also placed under additional load and stress
in these conditions.
Swinging heavy loads to the side of the tracks may cause the excavator to tip.
Do not swing the bucket downhill with a load.
Do not apply side forces to the bucket.
The superstructure should be rotated at least 360° about every four hours of operation to
relocate the roller bearings for even wear and grease distribution.
Do not shift rocks, clean the floor or attempt to clean walls using the slew function. Ensure all
swing motion has stopped before engaging the face and ensure the bucket has disengaged the
face before commencing to slew.
Good slew control means a safe and efficient digging and loading cycle. Maintain a smooth
swing motion and avoid jerky movements when starting and stopping. Maximum efficiency,
minimal slew component damage and minimal spillage are the direct result of smooth swing
control.
Keep swing distances as short as possible while loading. The slew time taken in the digging
cycle represents the greater part of the entire cycle time. Keeping the slew arc at 90° or less,
contributes toward more efficient and productive loading.
Complying with the above procedures will greatly reduce wear on all slew components and all
front attachment pins and bushes.
3.8.9.4.2 Braking Operation

The braking function for slewing operations is controlled by a hydraulic service brake or a
mechanical parking brake.
Hydraulic Service Brake

The slewing motors of the upper structure can be decelerated by moving the left joystick back to
the neutral position after the slewing movement has been initiated.
To achieve maximum hydraulic braking, move the left joystick through the neutral position in the
opposite slewing direction to which the upper structure is moving.
Mechanical Parking Brake

The mechanical parking brake is an hydraulically activated disk brake integrated into the
slewing gear.
The brake enables the slewing mechanism to be locked in any position.
The slewing brake is activated with a button on the engine control panel. When the brake is
applied, the accompanying red light on the switching unit is illuminated.
Warning : The slewing brake must only be activated when the upper structure is stationary.
3.8.10 Positioning the Excavator
3.8.10.1 Pre-Operations Inspections

Prior to commencing work you must inspect the work area and consider all potential hazards
that may affect the excavator or the haul trucks.
The inspection considerations include:
 The level and condition of the floor
 The height and stability of the face
 The presence of potentially dangerous rocks or overhangs
 The proximity to roads, bench edges, blast patterns and auxiliary equipment
 Overhead lines or underground cables or pipes
 Sun, dust and wind direction
 Adequate room for the excavator to slew
 Adequate room for haul trucks to safely turn around
 Any area considered to be unsafe
If it is not possible to make the area safe, the excavator is moved away from the unsafe
conditions and the Supervisor notified.
The excavator’s stability, track angle and the positioning of haul trucks also need to be
considered.
Setting up properly is a pre-requisite to safe efficient loading and helps maintain stability, power
and bench levels. It will also reduce Operator fatigue.
Study the work area, noting the type of material and any hazardous or unstable sections.
Determine the best digging position and method of operation.
Always perform a risk assessment and notify the Supervisor before digging near the edge of a
bench. If there is a chance of material falling down and endangering either personnel or
equipment below, access to the area is to be closed off.
3.8.10.2 Establishing Operating Positions

Always position the drive motors to the rear of the digging area to prevent rock damage or
material being pulled into them.
Avoid digging at right angles to the tracks, as this can pull the excavator sideways and create
stresses in the tracks and track frame components. The excavator is not designed to take this
type of operational stress. It can also destabilise the excavator and cause excessive wear to the
slew components.
Do not position the excavator too far away from the digging or too close to the edge.
Keep a stable platform and level footing with both tracks in full contact with the ground. Never
operate with a track on top of a rock. Inclined working positions have a negative affect on
excavator stability and accelerate wear.
An unstable platform can cause unexpected instability of the excavator due to the centre of
gravity shifting during slewing.
Sprag the tracks alternately from side to side to wriggle the excavator into a more settled
position. If necessary, drop some material in front of the track/s and reposition the excavator. A
stable excavator maximises break out and slewing speed.
The recommended position at all times while loading from a bench is to place the tracks at a 45°
angle to the digging face as illustrated in the following diagram.
Never dig with the tracks parallel to a bench edge which is soft or falling away. It is possible that
the outside track could drop down, severely affecting the excavator’s stability and making it
difficult to reposition to safe ground.
Having the tracks at 45° allows greater track ground contact for the machine to walk back out of
difficulty if the edge face falls away.
Be careful not to hit the excavator tracks with the bucket teeth when digging at an angle to the
tracks.
After excavating all the immediately accessible material, reverse back and re-position the tracks
at 45° ready to begin the new cut.
Position the excavator so the bucket edge is square to the dig line. This helps create a straight
face with minimum rill at the base allowing future trucks to back right up close.
When positioning haul trucks, place the bucket where they can reverse up parallel to the stick
and boom.
Position trucks to minimise slew angles, but not over rocks, up the face or where they may in
danger of being hit by falling rocks or trapped by the face falling down.
Do not operate the excavator within 8 metres of a blast pattern.
Do not operate the excavator within 10 metres (fully extended) of power lines.
3.8.10.3 Operating in Water

If necessary, it is possible to have the excavator in water, but only up to the height of the tracks.
First ensure that the submerged ground level is flat, as water contact with the slew components
must be avoided.
If the swing circle, swing pinion or the centre joint is immersed in water or mud by mistake,
abnormal wear results if the excavator continues to be operated.
Immediate lubrication and maintenance are necessary.
3.8.11 Operational Cycles
3.8.11.1 Swing Angles

The correct positioning of the excavator is essential to enable a safe and efficient operation.
The following diagram illustrates the operational efficiency as it directly relates to the arc that the
excavator must swing through to load and empty the bucket.
Maximum efficiency is achieved when the excavator’s operational swing zone is limited to 15°
either side of the centreline, which is approximately equal to the width of the undercarriage.
The recommended digging range is about a 90° angle in front of the excavator. This angle
represents the maximum stability range.
3.8.11.2 Work Phases

The excavator’s operation consists of four phases.
1. Dig
2. Swing
3. Dump
4. Return
3.8.11.2.1 Dig Phase
Filling the Bucket

The dig phase requires you to control the positioning of the bucket to ensure the correct dig
angle and prevent overloading and stalling. To ensure maximum efficiency during the digging
phase, the following diagrams illustrate the bucket penetration techniques to be used by
excavator.
Do not position the bucket too far

out, as it is difficult to keep a level pit
floor and it is more time consuming
to bring the bucket to maximum
mechanical advantage.
Do not position the bucket too far in,

as the point of penetration is lost by
dragging the bottom of the bucket.
This is the ideal position for keeping

the pit floor level, as it gives
optimum penetration of the bucket
using maximum mechanical
advantage when the teeth enter the
material.
Raising the Bucket

When the bucket is full, use the techniques illustrated in the following diagrams to raise the
bucket to minimise material spillage and equipment damage.
If the bucket is not curled in

sufficiently, material will fall over the
bucket teeth.
If the bucket is curled in too far,

material will fall over the back of the
bucket and crush between the
bucket and the stick.
The ideal position for lifting and

carrying is curling the bucket to
enable maximum fill while avoiding
material spillage.
3.8.11.2.2 Swing Phase

The correct swing motion results in smooth and efficient swing control. The swing motion starts
as the excavator swings the boom towards the truck when the bucket is full and is clear of the
bench. Smoothly accelerate the boom to an optimum point and stop over the truck.
Improper swing motion results in erratic control and an unsafe, inefficient swing cycle.
If the cycle begins with fast acceleration and maximum speed is maintained to the dump spot, it
will be necessary to stop the swing very suddenly resulting in a jerky swing motion and
unnecessary spillage onto the excavator and pit floor.
Positioning of the excavator also affects the swing time. Trucks must be positioned along the
swing path with their centre lines approximately under or slightly inside the swing path of the
boom / stick pivot point.
The following diagram illustrates the correct positions for the excavator and truck and the
correct swing motion.
3.8.11.2.3 Dump Phase

The dump phase starts just before the loaded bucket passes over the edge of the excavator and
finishes as the swing motion stops and reverses.
The dump phase is the:
 Controlling the swing of the bucket by slowing
 Stopping and reversing the swing direction
 Controlling the bucket to dump the load at the correct position on the truck
3.8.11.2.4 Return Phase

The return phase is the:
 Returning of the empty bucket to the dig position
 Lowering and crowding the bucket to commence the dig cycle
The return phase of the swing cycle, with the bucket empty, can be accomplished at full rated
speed.
Coordinate the lowering of the bucket to the digging position simultaneously with the return
swing.
Note : Do not use the bucket as a hammer as damage will be caused to the bucket and other
frontend attachments.
3.8.12 Digging Techniques

There are different digging methods to suit the various operational requirements. These
methods include:
 Face digging
 Bench digging
 Drop cuts digging
3.8.12.1 General Digging Guidelines

The following information covers digging procedures and precautions common to most digging
methods.
These include:
 Always dig with the excavator in the basic position, i.e. idlers facing the digging and
final drives at the rear
 The travel speed selector lever must be in low position while digging, ensuring that all
the repositioning of the excavator is done at a low speed
 Maintain a stable platform and a level floor to maximise digging efficiency and reduce
wear
Warning : Do not operate on a gradient if the stability of the excavator is

adversely affected.
 Fill the bucket as much as possible on every pass

 The hardness of the material determines the length and depth of each dig
In harder material, dig using shorter shallower cuts
 Ideally, the heel of the bucket does not contact the floor during the digging cycle
 Use hydraulic power for digging hard material
Never use the inertia force of the bucket or the mechanical life of the front attachment
(mainly bucket) will be shortened
 When digging toe, it is often more efficient to engage with just one or two teeth to help
breakout the material
 Regularly monitor the condition of the bucket hardware, especially when digging in
hard or abrasive material
 Under no circumstances is the propel function to be used to help the excavator dig
 Do not lift the front of the excavator off the ground with the stick and bucket while
digging
Operating with a jacked up excavator does not increase the excavator’s digging ability,
but puts excessive strain on many components which may damage or cause
premature component failure
 Never attempt to break rocks or hammer with the bucket
 When digging deeply, be careful not to hit the ground or tracks with the bucket cylinder
hoses or the lower side of the boom
 Never dig under the excavator
This practice can undercut and de-stabilise the excavator
 Take care not to pull material into the tracks

 Operate all hydraulic functions with smooth and consistent movements
Wrenching or pulling hard on the control levers does not improve performance, it just
bends or breaks the lever
 Lower the boom slowly, especially when loaded
Stopping it suddenly causes significent shock and stress to the excavator
 Avoid working on the cylinder limits or crowding the bucket back onto the stops
Example of Correct Ground Level Digging

To maximise excavator power and material breakout, maintain grade and fill the bucket
efficiently, correct digging angles and technique need to be used.
1. Begin the digging cycle by lowering the boom with the stick at approximately 45° to the
ground, with the bucket positioned slightly over vertical.
2. Pull the stick in towards the excavator and maintain the correct bucket cutting position by
manipulating the bucket control lever simultaneously with the stick control lever.
3. Adjust the boom as required, to maintain the level and to stop the heel of the bucket
contacting any material.
4. As the bucket progresses through its normal arc of travel, commence curling it and raising
the boom as the stick reaches the vertical position.
Power is lost when the stick is brought back past the vertical.
3.8.12.2 Face Digging

Standard Face
The best method to work a digging face with an excavator depends on various factors and
conditions.
These are:
 The length of the face
 The height of the face
 The shape of the face
 The stability of the face
 How freely the material digs
 The amount of working space
 The number of contact zones for different ore types, if any
 The affects of the sun, dust and wind direction
Take care when working in the vicinity of high faces as they can collapse. Very high or unstable
faces must be dozed down to a workable height.
Warning : Vibration and sometimes even the engine noise from a machine can be enough to cause a
face to collapse. A potential face collapse is usually indicated by a trickle of loose
material.
Never park or sit idling next to a high face.
When working a face, the excavator must be positioned at approximately 45° to the face with
the drive motors pointing away from the face.
Work the face from right to left, with the trucks positioned on the left of the excavator to avoid
blindside loading. This also means that the trucks will not be running over ground that has been
roughed up by the excavator tracks.
Warning : If it is necessary to load on the off side or blindside, vision of the truck is restricted by the
stick and boom. Therefore care must be taken to ensure that the bucket is high enough to
clear the tray before slewing.
Haul truck drivers need to line up the excavator’s cabin in their rear vision mirror when they
reverse up for a load. So when positioning haul trucks, place the bucket where they can reverse
up parallel with the stick and boom.
Sound the horn to indicate when the truck is in position. The horn also activates the revolving
light, which is necessary, because quite often the drivers cannot hear the horn, but they will see
the light flash.
Dig the face at the same height as the back of the haul truck’s tray. This means no time is lost in
lifting the bucket to clear the tray reducing loading time.
Overhanging material or rocks that can’t be dug down safely must be reported to the Supervisor
to have them dozed down.
Leave rilled material in front of the tracks to protect them from rocks rolling down from the face.
As loading continues it is necessary to remove material from lower down the face.
During the loading cycle, do not slew the excavator until the bucket is clear of the face and do
not swing the bucket into the face or the load in the tray to help slow down the slew motion.
Stockpile Face
One of the most important things to consider when digging a stockpile face is the safety
windrow at the top.
A regulation height windrow or other approved barrier must be in position at the top of all
stockpiles at all times.
If there is no natural rill, the windrow must be positioned a minimum of the regulation distance
back from the edge.
Existing stockpile windrows are dug out as material is removed from the base. To avoid
dangerous situations occurring, a new windrow is to be built at least the regulation distance
back from the top edge, before starting to load out from the bottom.
This must be monitored before the job is commenced, during the shift and before the excavator
leaves the area.
Digging tapes may also be required.
3.8.12.3 Bench Digging
3.8.12.3.1 Overview
The various types of bench digging include:
 Single bench digging
 Double bench digging
 End of bench digging
The best techniques to use for bench digging depend upon various conditions and
circumstances that include the:
 Shape of the shot
 Length of the face
 Type and resistance of the material being dug
 Positioning options available for both the excavator and the haul trucks
 Dust and wind direction also need to be considered
3.8.12.3.2 Starting a Bench

To start the bench:
 Walk the excavator to the face
 Stay on the floor level and start to dig into the face as you load trucks (top loading)
 Ensure that you do not undercut the excavators tracks while digging
 Ensure the excavator is kept at a safe distance from the face
This ensures the excavator can just reach the face with the boom, stick and bucket
fully extended.
 Wherever possible, work the high material first and avoid digging down low on face
 Remove large rocks and overhangs with caution and according to site procedures
Warning : Be aware of loose material and fault lines that may potentially
collapse onto the excavator.
 Pull dirt towards the excavator as you load out the trucks to establish a pad for
climbing
 Level the pad to ensure excavator remains stable
 Ensure that there is room to swing the excavator after climbing onto the pad
 Load out trucks from the bench
 Dig a catch trench to pull down the face as you advance
 When you need to move forward push the floor into the trench
3.8.12.3.3 General Bench Operating Procedures

The capacity of the material supporting the excavator must be constantly assessed and the
height of the digging face adjusted to ensure the excavator is working in a safe environment.
Bench Heights
Optimum bench height is about the height of a haul truck tray. This height enables the excavator
to maintain power when reaching to the bottom of the cut, to reach spillage in the loading area
and to maintain a level floor. A consistent bench height is essential.
High benches create restrictions in the ability to keep a level floor, especially if toe is present. It
can make the excavator unstable by having to work too close to the face causing overreaching.
High benches can also make truck positioning difficult and to clear rill or rocks from the truck
turning area.
A backhoe type excavator is usually most efficient when loading from a bench level above that
of the haul truck.
A bench height that is too low is unproductive because the excavator must stopping regularly to
reposition.
A correct bench height is important to establish a neat and tidy digging face and for not creating
pockets or slots where truck positioning can be made difficult.
Using the Bucket

Excavate in layers. Begin digging at the top of the bench and move down progressively. This
shortens the digging cycle. Don’t go to the bottom of the bench each time and rake the bucket
up the face.
Ensure that the haul trucks are positioned as close as possible to the material being dug out to
minimise slew time.
Always attempt to fill the bucket. A full bucket on every pass is far more efficient than a quicker
cycle with a partially loaded bucket.
Remove the bucket from the face and start slewing as soon as it is full. Manipulate slew control
to ensure that the bucket has sufficient height to clear the truck.
As a bench is progressively dug out, the excavator is eventually sitting on top of the last
remaining section of material that needs to be removed. This can be completed with a frontend
loader, but depending on the machine availability, the excavator may be required to dig it out,
which requires advance planning.
When digging at ground level care must always be taken not to pull material into the excavator.
Begin digging from the farthest edge of the mound and work back toward the excavator. The
material in front of the tracks acts as a barrier and is removed last.
To safely remove this last section, dig deeper than ground level during the last part of the job,
until there is a hole approximately the same size as the remaining material. Push this material
into the hole with the bucket and tidy up as much as possible.
In some situations you may be required to double bench or flitch into a high face.
Ore Work
If working with ore, check with the ore grader Operator before completing the above.
3.8.12.3.4 Single Bench Digging

When performing single bench digging, use the techniques illustrated in the following diagrams
to maintain efficiency and safety.
When starting a bench, position the

excavator by calculating distances
so that the travel arc includes the
key cut and the front of the
excavator.
Start by digging the first bucket load

of material from the key and
dumping it in the front of the truck’s
tray.
Dig the second bucket load from the

outside of the bench and dump it
into the front of the truck’s tray.
Dig a third bucket load working

towards the centre of the key and
dumping it into the front of the
truck’s tray.
Continue digging the material as

illustrated and dump it progressively
toward the rear of the truck’s tray.
The last bucket load is taken from

behind the first key cut.
3.8.12.3.5 Double Bench Digging

When performing double bench digging, use the techniques illustrated in the following diagram
A double bench is approximately twice the width of a single bench.

Dig the first bucket load from the furthest point closest the face. This ensures that a safe
distance is maintained between the excavator counterweight and the face. It also enables the
excavator to move into position with no delays in the loading cycle.
Dig the second bucket load closest to the truck.
Continue digging the material as illustrated in the above diagram and dump it progressively
toward the rear of the truck’s tray as shown.
3.8.12.3.6 End of Bench Digging

When performing end of bench digging, use the techniques illustrated in the following diagrams
Ensure that the ground condition is

stable.
Start a new bench by pulling to the
centre of the excavator.
This provides a new key for the next dig
sequence, which is used to maintain a
straight bench.
Make gradual turns when nearing the

end of the bench.
Do not turn more than 25° before
moving forward and back to remove
material build up beside and in the
tracks.
Reposition the excavator to enable the

remainder of the bench to be removed
and position the excavator for correct
loading.
Remove the last of the material from

the corner, remembering to clean up
material back to the bench to allow
excavator access for the next pass.
Recommence the cycle.
3.8.12.3.7 Digging the Last Bench

When digging the last bench, use the set up illustrated in the following diagram to maintain
efficiency and safety.
When digging the second last bench, set up the last bench width by fully extending the boom
and stick to touch the slope.
This gives you a dig bench of approximately 15 metres.
Allow 3 metres clearance between the rear of the excavator and the wall and leave 2 metres
from the tracks on the edge of the bench.
3.8.12.4 Drop Cuts Digging

A drop cut is the technique used when the pit floor needs to be dug out to begin a new bench on
a lower level.
A drop cut involves a decline being progressively dug at a 10% angle until a vertical depth of 5
metres is reached. This decline becomes the main haul road ramp to the lower bench. Dozers
are normally made available to assist with maintaining the 10% angle.
The excavator begins digging and loading at ground level from the base of an existing ramp and
then progressively digging deeper and deeper as it moves back as illustrated in the following
diagram.
When the desired depth of 5 metres is reached, the decline is levelled out and normal digging
and loading operations are recommenced.
All haul road ramps are constructed at a minimum width of 25 metres.
Note : As an excavator Operator you must remember that the haul trucks are operating on an
angle during drop cut operations.
The bucket must always be positioned to ensure that it has a safe and adequate turning
circle and reversing path.
3.8.13 Loss of Ground Engaging Tools (GET) When Digging

The haul truck Operator is responsibility for ensuring the excavator GET is inspected before
loading of the truck commences. Completing this inspection between each truck ensures that
any missing GET items are identified and immediate controls instigated to prevent a piece of
GET entering the crusher.
If a piece of GET is identified as missing and not visible at digging face, you must notify the
crusher Operator immediately to stop feed to crusher until the missing GET is located. The
crusher Operator then notifies the Operator’s of all loaded haul trucks on the way to the crusher
not to tip in to the crusher. Loads run out for inspection.
Visible GET lost in the face must be removed to a safe position where a clean up machine can
move it without the risk of falling rocks.
Warning : Personnel must not remove GET items from the digging face.
If the lost GET has not been found and is suspected to be lost in the digging face, the next two
trucks are to be loaded from the immediate material at the toe line by the excavator. These
loads are then to be run out for inspection.
3.8.14 Loading
3.8.14.1 Introduction
Loading techniques vary according to the dig site location and circumstances, and the size of
the haul trucks.
The three main loading techniques are:
 Drive by loading
 Top loading
 Bottom loading
3.8.14.2 Considerations and Precautions

Before commencing loading ensure the ground is:
 Level
 Free of spillage
 Suitable on which for trucks to drive
Your loading technique must always ensure that there is minimum risk of injury to the truck
Operator and damage to equipment. The risks of injury or damage are higher for the first bucket
load of material dumped in the truck.
Safe and efficient loading of haul trucks requires:
 Coordinated manipulation of the boom, stick, bucket and slew functions in a smooth
flowing sequence of steps
 Correct spotting of haul trucks ensuring that they do not reverse over spillage / rocks
or up the face
 Positioning haul trucks to minimise slew distances
 Allow the bucket to be easily crowded out
 Reversing the haul trucks back as far as possible
Poor haul truck positioning:

 Breaks the Operator’s rhythm
 Adds to swing cycle time
 Can create spillage
 Can cause off centre loads
 Creates unnecessary manoeuvring of the front attachment
Note : You should have visual contact with the truck Operator at all times during the loading
process.
When the face is not free rilling, the haul truck must stand off the digging face.
Ensuring that haul truck Operators stay within the cabin of the truck while being loaded.
Never slew the excavator bucket, unloaded or loaded, over the front of the haul truck or over
any other machinery or personnel working in the area.
Attempt to keep the loading area floor as level and clear of spillage as possible. Call for
clean-up machines as necessary.
Watching for up or down movement in the haul truck tray as it reverses in as this can help you
to judge the condition of the lower floor level.
Whenever the excavator is sitting and waiting for trucks, the bucket should be grounded to avoid
unnecessary strain on the hydraulic system.
Haul truck Operators are advised to be alert for, and report any, fluid leaks, smoke or general
damage on the excavator while they are in the pit working around it because they are in a better
positioned to notice problems than what you are while Operating the excavator.
Never leaving the controls with a bucket suspended.
3.8.14.3 General Loading Techniques

Bottom loading diagrams are used to illustrate the general loading techniques.
When emptying the bucket, start at about the tray position to allow sufficient room to crowd out
as illustrated in the following image.
Don’t crowd out any further than necessary for the material to drop out. This leaves the bucket
positioned ready for the next digging cycle as illustrated in the following image.
When loading a haul truck, the first bucket should be dropped from about 1 metre above the
tray. Don’t dump material into the haul truck material from too high.
Centralise the load, don’t overload or under load and avoid spillage as much as possible.
Control the last bucketful to help centralise the load.
Off centre loads make haul trucks unstable, especially around corners. This also causes one-
sided overstressing of axles, tyres, suspension and hoist cylinders.
Under loading is unproductive while overloading causes over stressing of rear axles and tyres,
and spillage off the truck. Additionally, an overloaded truck may not be able to hoist its tray high
enough to tip the load.
Observe the trucks load weight indicator lights for more accurate load sizing.
If rocks are to be loaded, the tray must be lined with smaller material first. Always notify the
driver before loading a large rock.
Irrespective of the weight, the load must always be kept several centimetres below the
sideboards of the tray to reduce spillage. Do not balance large rocks on top of the load.
Observe the material is entering the tray to avoid sending any foreign objects to the crusher.
3.8.14.4 Drive By Loading

Align the truck with the bucket raised to a position parallel with the excavator tracks. As the
excavator approaches, swing the bucket to place the load in the excavator. The truck is
positioned to minimise the load cycling time.
Ensure that the bucket height is sufficient to clear the edge of the tray with the bucket in the load
position. The excavator is positioned to allow the load to be aligned in the centre of the truck
body.
When using the bottom or top drive-by loading technique, the risk of truck tyre damage due to
the truck being located too close to the excavator can be a problem. Arrange for the loading
area to be cleaned as required.
3.8.14.5 Top Loading

Top Loading at 90 Degrees
The top loading technique is generally used when the cut is too deep to dig with one pass.
Top loading can also be used when the trucks are experiencing difficulty moving out from the
face or when the material is unsuitable for the trucks to drive over. Due to the increase in swing
and lift time as compared to other methods, top loading is not an efficient method and is only
used when necessary.
To improve efficiency, ensure that the bucket is positioned for optimum penetration and material
spillage is minimised by crowding the bucket to the correct position.
Top Loading at 45 Degrees

Depending on the bench height, 45° loading can be safe and productive. With this technique,
the excavator is able to swing over the rear of the truck body.
3.8.14.6 Drive By Top Loading

Drive-by loading on a low bench occurs when the truck moves along the bench with the
excavator while loading.
The truck Operator can lose sight of the excavator unless this approach is very carefully
controlled. Therefore, this method is considered to be unsafe and is generally not permitted.
3.8.14.7 Bottom Loading

Bottom Loading from the Rear at 90 Degrees
The bottom loading technique maximises excavator efficiency by ensuring faster cycle times.
For efficient bottom loading, the bench height for general operations is configured for:
 Stable or consolidated materials
The optimum bench height is four metres or approximately equal to the stick length
 Unstable materials
The bench height is slightly less than the stick length
The excavator is positioned with the end of the truck body below the boom and stick hinge point.
The most common technique is loading at 90° over the side. The excavator is placed on a
bench above the truck and digs to the same level as the truck’s driving surface. This technique
requires you to use more hoist than other methods to clear the side of the truck body and
demands greater accuracy when unloading the bucket.
There are two positions for trucks to wait while loading, depending on the location of the bench
and ramp, as illustrated in the following diagrams.
Haul Truck Loading and Approach from the Left
Haul Truck Loading and Approach from the Right
Bottom Loading at 45 Degrees

Loading through the rear at 45° is similar to the 90° bottom side loading method, except that the
truck is positioned at 45° to the excavator.
This technique allows smoother bucket unloading when coming in over the rear of the truck
body and requires less hoisting than 90° over the side loading.
3.8.14.8 Double Bench Loading

When double benching the bottom bench must be at least 4.5 metres high and top wall (high
wall) must not be any higher than the height of the top of the excavator cabin. These general
guidelines for the bench heights reduce the possibility of excavator damage.
A catch drain must be left on the high wall side of the bench to catch any material that falls from
the wall. The width of the bench must be wide enough for the excavator to turn around with the
boom and stick out and the bucket crowded in without touching the wall.
When loading at the face take the first bucket from where the truck’s rear wheels will be located
to keep the area clear of rocks and debris to avoid tyre damage.
Do not allow the truck to back:
 Over debris or rocks
 Up the wall or side of the bench
Be prepared to modify the bench and face heights depending on material types.
Notify the Supervisor of any:
 Known geological faults in the immediate work area, e.g. fault planes, cracking,
bedding planes or any other geological feature which may affect excavation
 Situation within their area that they feel is unsafe or unproductive
When picking up the bottom bench leave one-bucket width of the bench behind along the face.
This ensures that when digging the top bench a small catchment area can be dug before
collapsing the face at rear of the truck. This decreases the risk of rock damage to rear of truck.
3.8.15 Oversize Loading

If oversize material is being loaded, notify the truck Operator, who has the option of staying in
the cabin or leaving.
If the truck Operator elects to leave, ensure that they are clear of the truck before loading
commences.
If you advise the truck Operator to leave the cabin, do so before loading starts. While on the
ground, the truck Operator must remain in clear view and remain at a safe distance from the
truck.
If large rocks or any oversized is to be loaded, the haul truck tray must be lined with fine
material before loading the oversize material. Particular care must be taken to ensure the truck
is stable.
Good control of all functions must be maintained while picking up and loading rocks to prevent
them falling off the bucket and / or striking the sides of the truck.
If there is any chance that you may lose control of a rock while placing it in the tray or it is too
large to load, leave it for a dozer to relocate.
Do not balance large rocks on top of the haul truck’s load. If loading ore, notify the driver to tip
on the stockpile.
Never attempt to move large rocks with the excavator’s travel function or side swipe them with
the bucket.
Avoid spilling rocks and other material onto the headboard.
If a large rock is exposed in the face, reposition the excavator to one side of the obstruction and
further back from the edge with both tracks facing toward the rock before attempting to undercut
or remove it. This method removes the excavator from the rocks path if the rock falls.
Warning : Removing large rocks from above the excavator can cause the rock or face to fall onto
the excavator.
Removing large rocks from below the excavator can cause the face to collapse and
destabilise the excavator.
Remove material from each side of the rock until it is sufficiently exposed for prising or pushing
free. Do not allow the back of the excavator to lift up. After removing the rock, ensure that the
face is stable and not undercut before moving the excavator forward.
Ensure all other vehicles are clear of the face before attempting this procedure.
Do not direct the truck to leave if there is any chance of rocks moving during the haul to the
dump.
Sound one short blast on the horn to signify that the Operator can return to the truck.
Place the bucket on the ground and wait for the truck to depart the loading bay before
continuing operations.
3.8.16 Working Near Edges

Material is not to be dumped, pushed, dislodged or blasted over any edge where there are
people working below or where there is access to vehicles until there is compliance with the
following conditions.
If it is expected that material will fall after being dislodged or there is a requirement for material
to be dumped over any edge, the area around and below must be inspected by a Supervisor
before the work commences.
Access to these hazardous areas is restricted and controlled by:
 Windrows across roads
 Barricades and / or hazard cones
 Signage
 Spotter to control traffic at key access points
Operators must also establish that the area is safe to dump or dislodge material before the work
commences.
3.8.17 Cleaning Up the Work Area
3.8.17.1 Overview
The work area is to be cleaned up with a minimum loss of production and without compromising
safety.
The clean up dozer are requested whenever there is excess spillage or rocks in the haul trucks
turning and loading area or if the area becomes excessively rough.
The clean-up dozer Operator and you must work together as a team with good communications
being essential. You must be aware of the location of the clean-up dozer at all times while it is in
their work area.
The clean-up dozer Operator must contact you by two-way radio and wait for your permission
before entering the work area. Maintain clear two-way radio or visual communications while the
dozer is working inside the swing radius of the excavator. Never assume the clean-up dozer
Operator is fully aware of your plans.
Note : The excavator bucket must be grounded while the clean-up equipment is inside the swing
radius.
You are required to advise all other personnel that a clean-up is in progress and place a delay in
the company recording system.
The clean-up dozer can also work in conjunction with the excavator to assist with maintaining:
 Bench levels
 Limits work
 Construction of access ramps
 Drop cuts
 Moving oversize rocks
For the above work both Operators discuss the plans and requirements before work
commences.
An acknowledgment is made between the clean up dozer and you when the dozer is leaving the
area and before you recommence excavator operations.
3.8.17.2 Clean-up Outside Swing Radius

The clean-up dozer must only push material up to the swing radius of the excavator.
Note : Never use the bucket of the excavator to slew sweep the floor for clean-up purposes.
When the area outside the swing radius has been cleaned, the dozer cleans within the swing
radius area after receiving your authorisation.
3.8.17.3 Clean-up Inside Swing Radius

When a clean-up dozer is required to work inside the bucket swing radius, stop digging, ground
the bucket and set the brakes before allowing the clean-up dozer to commence operations.
Vehicles are not permitted to go within the splash zone, which is behind, beside or in front of the
truck being loaded.
3.8.18 Battering
3.8.18.1 Overview
The face must be regularly cleared as excavator operations progress to help avoid the risk of
walls collapsing.
The possibility of material slides increase as the height and steepness of the batter increases.
The type of material used in the construction of the batter affects the stability of the face. It is
very important for you to know how to construct batters in varying soil conditions and
understand how to use the different materials.
Changes in material moisture content affect the internal friction of the soil particles and the total
weight of the material mass. An increase in moisture can help to bind the soil and make it
marginally safer, but it can also cause the material mass to become too heavy for the angle of
the face.
The slope is not to be over-excavated at any time. Batters need to be cut, not filled, if they are to
withstand the affect of any prevailing capable of causing batter failure, e.g. wind and water
erosion.
Digging operations commence at the top of the cut and are completed progressively as the level
of the work area is lowered.
The outer edge of the batter is identified by survey pegs. Work close to the pegs, without
disturbing them, as they are your reference point for the duration of the excavation and battering
process.
Continue to work level to the batter wall and step out with each successive cut. The depth of the
step out depends on the angle that is required for the batter, e.g. for slope of 45° each step is
excavated to a depth of 150 mm.
Catch berms must be cleaned off before or as the next bench is being cut. Leaving excess
material on catch berms creates unnecessary hazards. This situation can deteriorate as the pit
deepens.
3.8.18.2 Pulling Batters

When pulling batters the bench must have a catch drain the on high wall side of the bench to
catch any material that falls from the batter. The batter must not be any higher than the top of
the excavator cabin to minimise any risk of damage to the excavator.
ANY operation outside these parameters must have a risk assessment approved by the
appropriate mine site authority.
3.8.18.3 Scaling Batters

Ground conditions in the mine can vary from competent solid rock to poor ground. Competent
ground can be fired to a clean face. Half barrels from the drill holes are a good sign the unfired
ground has not been seriously damaged.
Poor ground or poor firings may result in shattered and loose rock sitting in the exposed face,
especially at the crest. While this rock sits in the face it is a hazard to personnel and equipment
working below.
High Wall Cleaning
Poor ground is usually associated with geological features, i.e. faults and shear zones. These
can be planar in nature and depending on their orientation can present a serious hazard where
large amounts of material can slide into the open pit.
Discuss the controlling geological features in the wall with your Supervisor or a Geologist to
ensure that you are fully aware of the hazards that may be present at the dig site.
Note : Discuss the job with your Supervisor before proceeding if you are unsure about the
ground conditions.
3.8.18.4 Pit Wall Assessment

To assess the pit wall, estimate the:
 Size of the rocks to be dislodged
 Reach required to dislodge the loose material
 Amount of loose material that may come down with the dislodged rocks
 Impact on the surrounding work area
 Security of the wall above the area to be scaled
Identify the risks associated with scaling the wall and apply the appropriate controls to reduce
the risk to an acceptable level.
3.8.18.5 Scaling Procedure

1. Install witches hats or flagging to outline the excavator work area.
2. Prepare a clear and level work area that is of sufficient height to access safely the loose
material to be scaled before commencing.
3. Clear the area of other personnel and equipment.
4. When scaling the wall, pay particular attention to the crests, as most loose material is
situated in the top section of the face.
Rocks falling down an inclined surface will attain a horizontal velocity that can carry them to
the cabin or undercarriage of the excavator.
5. Build a mound rather than working too close to the face where falling rocks may damage
the cabin or cause injury to you.
6. Construct a safety berm of adequate height at the toe of the wall being scaled to prevent
material coming into contact with the excavator.
Never work inside the bermed area unless a pad of adequate height and width has been
constructed to allow for safe progress and there is a catch trench between the wall being
scaled and the excavator.
7. If working from a platform use the slew to avoid falling rocks rather than backing off the
mound with an extended boom.
8. Work progressively across the face.
9. When working from a pad on the pit floor, access the pad from the side away from the pit
wall.
10. Work the excavator towards an area where the loose material can be readily loaded onto
the trucks. Alternatively, a dozer can be used to clean up the scaled material.
11. Excavator tracks are to face towards the wall with drive motors to the rear for protection.
12. Do not undercut the face or remove unstable material that may leave a higher unstable
block that is out of reach.
13. The wall must be scaled right to the floor to reduce the reach required for scaling the next
lift.
14. Every wall that has been scaled must be washed.
15. After washing the wall, the batter trimmings must be pulled away from the wall so that it is
ready for inspection.
16. Do not push cleaned up material against the final wall.
3.8.18.6 Scaling Area Clean-up

When scaling operations have been completed, arrange for a dozer to push up scaled material
ready for loading into trucks.
If production is to start from the area, ensure the excavator has sufficient clearance from
stockpiled material.
When parking the excavator in the pit, park it well clear of the walls on level and stable ground.
Vibration from firings in the pit can cause loose material to fall and damage equipment parked
too close to walls.
If there is no suitable parking area in the pit, tram and park the excavator at the nearest safe
location.
Section 4 Perform Post-Operational Procedures
4 Perform Post-Operational Procedures
4.1 Parking and Shutdown Procedures

The following procedure details the method for stopping and shutting down the excavator.
1. If the GET is a bucket, ensure that it is empty.
2. Move the excavator away from the working face to a safe, level and practical position in a
designated area with sufficient clearance on both sides.
If this is not possible, park with the man hoist or ladder facing away from the face to protect
personnel from falling rocks.
3. Slowly move the travel pedals to the stop position.
4. Park the excavator.
When parking on a bench, be aware of traffic flow, high faces, open edges, rocks and
obstacles.
5. Align superstructure with the tracks and position the Operator’s cabin above the idlers.
Move slightly forward to relieve tension on the idlers.
6. Lower attachments to the ground with the boom and stick extended out and the bucket
crowded in.
This gives an accurate hydraulic oil level reading.
7. Return the control levers to the neutral position.
8. Ensure the speed selector lever is in the P (Park) position.
Never put the speed selector lever in Park until the excavator has come to a complete stop.
9. Place all locks in the ON position, e.g. safety and control levers.
10. Idle down engines (or set idle timers) for 5 minutes and lower the Fast Fill panel
or
Turn the ignition key to the OFF position.
This activates the turbo timer (if fitted) – the excavator automatically shuts down after the
pre-set time has elapsed.
The excavator must not be left unattended while running on the turbo timer. The engine
must be shut down before leaving.
Note : Never stop the engine until the bucket is grounded and never stop the engine suddenly
from full load, except in an emergency.
See the Idler Down Timer information below.

11. Turn OFF the lights, radios and air-conditioner
12. Switch off all electrical components.
13. Clean windows and mirrors.
14. Leave the cabin clean with the door / windows shut.
15. Dismount facing the excavator and maintaining three points of contact.
16. Be aware of uneven ground when dismounting.
17. Isolate excavator according to site procedures.
18. Complete a walk-around inspection and report any damage, leaks or excess wear on the
excavator.
Idle Down Timer

The excavator has an Idle Down Timer. This device helps to protect the engine turbochargers
from damage and unnecessary wear by forcing them stop immediately the power is cut to the
engine.
The Idle Down Timer keeps each engine idling until the pre-set time on the timer (e.g.
5-minutes) has lapsed after the ignition has been turned off.
The Idle Down Timer can be overridden by pressing the relevant Emergency Stop button on the
device or any other Emergency Stop switch on the Excavator.
4.2 End of Shift

The end of shift excavator checks and tasks include:
 Cleaning the cabin
 Removing any rubbish from the cabin
 Cleaning glass and mirrors
 Complete a final walk-around checking for:
 Damage
 Leaks
 Items requiring cleaning, e.g. lights, radiators and coolers
The Operator is responsible for excavator housekeeping.
Section 5 Activities
4.3 Maintenance
4.3.1 Preventative Maintenance

A strict definition of preventative maintenance is, maintenance tasks conducted at regular
scheduled intervals based on average statistical and anticipated lifetime to avoid failure.
In simple terms preventative maintenance is any action taken to prolong the life of equipment
and avoid unnecessary down time.
Typically, preventative maintenance includes:
 Equipment inspections
 Lubrication
 Adjustments
 Cleaning
 Non-destructive testing
 Statistical recording
 Fault reporting
 Minor replacements
Effective preventative maintenance programs are the result of a well-organised and carefully
executed effort among operational and maintenance personnel.
All preventative maintenance activities are to be conducted according to the site’s safety
guidelines and the equipment’s prescribed maintenance schedules.
Regular walk-around inspections are an important part of the site preventative maintenance
program.
The benefits of a comprehensive walk-around inspection include:
 Fewer equipment failures and emergency breakdowns
 More planned work completed
 Reduced labour costs and better labour utilisation
 Extended equipment life
 Improved equipment operation
 Less downtime and maximised production output
 Generally reduced maintenance costs
 Increased operational safety
 Decrease in unexpected breakdowns
This diagram illustrates the benefits of a proactive approach to maintenance by reacting

immediately to small problems before they become major repair issues.
4.3.2 Defect Reporting

Defects or faults are occasionally identified during walk-around checks or other inspection
activities. If a defect results in the equipment assessed as unsafe to operate, you must attach
an Out of Service tag to the appropriate location on the equipment to ensure that it is not
operated.
Note : Do not attach a Personal Danger Tag to equipment requiring maintenance.
Ensure that the defect / fault is either repaired or reported by filling out a defect report and then
forwarding it to the designated maintenance area.
4.3.3 Breakdowns
You are responsible for immediately reporting any faults or breakdowns of the excavator to
your, pit control, Supervisor or appropriate maintenance personnel. Do not leave it to the next
person or until it causes an accident or further damage.
If you must leave a broken-down excavator unattended, ensure that it does not cause a hazard.
Place lights or cones as necessary and leave the hazard lights on. Even if you think the problem
is obvious, leave an Out of Service tag attached to the main isolation control to make sure any
person checking the excavator is made aware of the problem.
4.3.4 Troubleshooting
Before reporting a fault, check that the problem cannot be resolved by investigating the
following possibilities. Also where possible consult OEM documentation and site procedures for
what you as an Operator can and cannot do with regards to troubleshooting.
If the excavator will not start, check that the:
 Emergency switch is ON
 Main battery isolator is switched OFF
 Brake is not set
 Travel speed selector lever is not in Park position
 Excavator has not started first time and the key has not been turned back to OFF
before trying again
If the excavator does not swing, check that:

 The Fast filling panel is down
 The ladder / man hoist is down
 The hydraulic oil level is low
 A monitor warning light has illuminated
 The slew brake is on
 Travel speed selector lever is in Park position
If the front attachment does not operate, check that the travel speed selector lever is in the Park
position.
If the excavator blows a hydraulic line while operating, use the following procedure.
1. Move away from the edge, ground the bucket and put the excavator in Park.
2. Move fuel lever/s to low idle position.
3. Turn ON the emergency switch in the cabin.
This shuts down the engine/s and releases the pressurised air in the hydraulic tank,
stopping excessive hydraulic oil being forced out of the ruptured hose.
4. Power off the excavator and notify the Supervisor of the situation.
The following phenomena are characteristics of the hydraulic excavator and not failures of the
machine:
 When operating the stick control lever, the stick may stop for a moment and then start
to move, especially near the vertical position
This is caused by the amount of discharged of oil from the pump not catching up with
the physical weight of the stick
 Noise is heard from the brake valve relief whenever swinging, travelling and starting /
stopping operations are performed
If there is an engine failure when the boom is raised:

 Turn on the ignition
 Turn on the servo control
 Lower the boom to the ground
 Turn off the ignition
4.3.5 Fluid Levels

Fluid measuring methods include:
 Sight-glasses
 Dipsticks
 Level plugs
 Instrumentation and other devices that signal low levels via audible and / or visual
warnings
It is essential that you accurately determine the fluid levels during your walk-around inspection
and constantly monitor them via cabin instrumentation.
The characteristics of the particular fluid containers concerned determine the consequences of
fluid level problems.
The general affects of incorrect fluid levels are summarised in the following table.
Low fluid levels lower than the recommended Fluid levels higher than the recommended
minimum maximum
Component seizure Aeration and overheating

Seal damage Fluid oxidation
Reduction in heat dissipating capability Lubrication problems
Concentration of contaminant Seal damage
4.4 Field Refuelling and Servicing

Important site safety procedures apply to the refuelling and servicing of excavators. Always
exercise caution during the whole process.
Warning : Smoking is prohibited during refuelling operations.
Equipment refuelling and servicing operations are conducted under mine site procedures
developed to prevent incidents occurring due to uncontrolled energy sources and fuel ignition.
Servicing and fuelling must only be carried out by competent personnel or under direct
supervision of competent personnel.
Competent personnel include:
 Mechanical tradesmen
 Competent and licensed equipment Operators
 Servicemen
Prepare the excavator for refuelling or maintenance using the following procedure.
1. Move the excavator to a safe level area clear of other operating equipment and hazards,
e.g. drop-offs and high walls
2. Apply correct park up procedures
3. Lower the GET to the ground
4. Acknowledge that it is safe for the refuelling truck or service vehicle to approach.
5. Leave the cabin and dismount the excavator before the refuelling truck or service vehicle
approaches.
6. Ensure the refuelling truck or service vehicle is parked at least three metres from the
excavator to allow maintenance personnel to move safely between the vehicles.
7. – Refuelling and maintenance personnel are responsible for isolate all excavator energy
sources and attaching their Personal Danger tags to the isolation points.
If the excavator is being serviced, a Service in Progress – Do Not Operate sign is placed at
the foot of each access point. Maintenance personnel are in charge of the equipment
during a live servicing operation.
8. Follow all instructions given by the refuelling or maintenance personnel.
If you are required to assist maintenance personnel, ensure that you have all the correct
PPE for the task and understand what is required of you.
9. You must not enter within the footprint of the excavator while being refuelled.
10. Do not enter the excavator without authorisation from refuelling or maintenance personnel.
11. Perform a walk-around inspection before starting and moving the excavator after the
refuelling or servicing has been completed.
Follow the site’s safe moving off procedures for the refuelling or maintenance vehicles and the
excavator, i.e. which vehicle moves off first and which Operator remains out of the cabin until
the other vehicle/s are clear.
4.5 Field Jacking for Maintenance

Use the site procedures and the following instructions for jacking up and excavator for field
maintenance.
The excavator can be jacked up onto one track using the front attachment:
 To check the track tension
 To clear the tracks of accumulated material when preparing for a move
 When the excavator cannot move under its own power because of sinking into soft
ground or clogging of material in the tracks
Use the following procedure to jack up the excavator.

1. Keep the front attachment at right angles to the tracks with the bucket heel on the ground.
2. Ensure the angle between the stick and boom is at about 90°.
3. Lower the boom to raise the track only just enough to clear the ground.
4. Check the track tension and / or remove the material off each track by rotating it back and
forth several times.
Take care when jacking in soft ground, as the grounded track could sink in further.
Never leave the Operator’s seat while the excavator is jacked up.
4.6 Washing the Excavator

Cleaning Process
Prepare the excavator for the entry to the workshop for maintenance by removing all the dirt
build up on and around the excavator, especially the track assembly, in accordance with the
service work to be performed. Also ensure the bucket is empty of any material.
Prior to washing, establish the extent of washing required, i.e. only the section of the excavator
requiring maintenance may need washing.
Park the excavator at the designated area for washing and arrange for a water truck to perform
the initial wash down.
Before washing commences, for reasons of safety and equipment damage, the:
 GET must be ground
 Engine must be shut down
 Excavator must be vacated
 All openings must closed
 Fire Suppression System must be Isolated
Following the removal of the bulk of the dirt, the excavator is taken to the workshop wash down
pad for the final clean.
Cleaning Precautions
Wear / use correct PPE when washing the excavator.
Take extra sealing precautions (e.g. masking tape) especially for electrical components if high
pressure or steam cleaning is to be used.
Make sure that the temperature sensors of the fire alarm and extinguishers system do not come
in contact with the hot cleaning fluids, which could trigger the fire extinguishing system.
Remove all coverings and masking material after completing the cleaning procedure.
Check all fuel lines, engine oil lines and hydraulic oil lines for leaks, loose connections, chafing
and / or damage.
Ensure any problems are fixed immediately.
Compressed air is not to be used for cleaning down the excavator.
5 Activities
5.1 Section 3 Operate an Hydraulic Excavator Activities
Activity 1
Complete a Take 5 assessment for placing the appropriate isolation on an hydraulic excavator
so as to allow a walk-around inspection inside the machine’s footprint.
Attach a copy of the completed Take 5 assessment to a copy of this Activities page.
Activity 2
Complete a start of shift Operator / Equipment Pre-Start Safety Inspection on an excavator at
your mine site.
Explain what you are checking and why to the Assessor as you go.
Attach a copy of the completed form to a copy of this Activities page.
Activity 3
What are the horn signals for:
1. Starting the excavator
2. Moving off
3. Loading trucks
Activity 4
The pre-start inspection is complete and you are in the cabin. Describe the start up process
sequence from sitting in the seat up to ready to move off.
Activity 5
What are five operational techniques that contribute to ensuring safety and maximum output of
materials when operating and loading?
Activity 6
Describe the correct procedure for moving an excavator up to another bench level.
Activity 7
What precautions must you be aware of when loading a truck and especially for the first bucket
load?
Activity 8
There are many things that you can do to increase safety and reduce the possibility of accidents
before and during excavator operations. List eight of what you consider to be the more
important considerations for hazard avoidance.
5.2 Section 4 Perform Post-Operational Procedures Activities
Activity 1
What is the main reason for applying good preventative maintenance practices to operating an
excavator?
Activity 2
If you identify a defect in an item of equipment that makes it unsafe to operate, what are the two
things that you must do and why?
Activity 3
There are important procedures for the parking and shutting down of an excavator at the end of
a shift. List the actions to be taken from when you dump the last bucket load to walking away
from the excavator.

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Hydraulic Excavator

3.4.5.3 Undercarriage Assembly – All Around.......................................................................40

3.8.9.3 Joystick Multi-functions.............................................................................................. 68

4 Perform Post-Operational Procedures.............................................................................107

4.3.3 Breakdowns..................................................................................................................... 111

1.1 Purpose of this Resource Manual

1.2 Safety Requirements

1.3 Training Requirements

1.4 Assessment Requirements

1.6 Getting Help

2.2 Hydraulic Excavator Familiarisation

An Example of an Hydraulic Excavator – The Liebherr Model R 994

This photograph shows the excavator in the correct park up configuration.

An Example of an Hydraulic Excavator Dimensions using a Liebherr Model R 994

2.2.2 Excavator Functions

2.2.3 Hydraulic Excavator Variants

Liebherr Model R 9350

Hitachi Model EX 1200

Terex O&K RH170 Excavator

2.2.4 Identifying the Excavator’s Main Components and Functions

These sections are described below.

2.2.4.1 Excavator Views and Components

2.2.4.1.1 Left Side Full View with the Front Attachment

1 Front Attachment 6 Work lights

2.2.4.1.2 Right Side Superstructure and Undercarriage View

1 Hydraulic System Cooling Fans 6 Work Lights

2.2.4.1.3 Rear View

1 Counterweight 3 Flashing beacons

2.2.4.2 Operator Station

 Air suspension seat to help isolate the driver from vibration

2.2.4.2.2 Operator’s Seat

Hitachi Seat Terex Seat

2.2.4.3 Excavator Systems

Swing Mounting on Undercarriage

Swing Drive Planetary Gears

Simple Hydraulic System

24 Volt Battery Supply

Example of a Battery Isolation Switch on a Terex RH170 Excavator

Fire Suppression System

There are two modes of system operation.

2.3 Operating Authority

3 Operate an Hydraulic Excavator

3.1 Operator Responsibilities

3.2 Identifying Safe Operating Practices

3.2.1 Operating Standards

Warning : Do not operate the excavator if you believe it to be in an unsafe condition.

3.2.2 Regular Checks

3.2.3 Additional PPE

3.2.4 Operating Plan Safety Elements

3.2.5 Ground Condition Safety

3.3 Fire Suppression System Components and Operation

Testing the Fire Suppression System

2. Start the engine

3.4 Walk-Around Inspections

3.4.2 Driver Changeover

3.4.3 Pre-Inspection Checks

Isolating the Excavator

3.4.4 Operator’s Inspection Form