Hitachi EX2500 and EX3600 - Reference Material PDF

training
MNCO1027A
CONDUCT
EXCAVATOR/HYDRAULIC SHOVEL OPERATIONS
HITACHI EX2500 & EX3600

EXCAVATOR
EX2500
EX3600
LEARNING NOTES
Design & Development
by
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Phone:
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Version 01/06/05
MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

OPERATIONS
Hitachi EX2500/EX3600 Excavator
training
Worklearn
DISCLAIMER
Whilst a sincere effort has been made to ensure the accuracy of
the information described in this manual, Worklearn makes no
warranty, express or implied, with respect to the quality,
correctness, reliability, currency, accuracy or freedom from error
of this manual, or the products, procedures and process it
describes.
Worklearn makes no representation or warranty with respect to
the contents hereof and specifically disclaim any implied
warranties of fitness for any particular purpose.
Worklearn disclaims all lability for any direct, or indirect,
incidental or consequential, special or exemplary damages that
may result from the use of this manual, or from the use of any
products, procedures or processes described herein.
NOTE TO LEARNERS, FACILITATORS & ASSESSORS

This document is designed to align with the Performance Criteria from the Unit of
Competency MNCO1027A Conduct Hydraulic Shovel/Excavator Operations
However, in the interests of an easier learning sequence for learners, facilitators and
assessors we have placed Performance Criteria, EX 2.4 Conduct, Control & Monitor
Tasks (covers operation of controls ) before EX 2.3 Select Loading Method
Curragh Queensland Mining Pty Ltd is part of
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DOCUMENT CONTROL SHEET

Contact for Enquiries and Proposed Changes
If you have any questions regarding this document contact:
Name:
Steve Ward
Approved: ....
Designation:
RTO Coordinator
Phone:
49 869 247
Date:
Record of Issues
Issue No
001/06/05
Issue Date
June
Nature of Amendment
Initial Issue
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MNCO1027A
CONDUCT HYDRAULIC SHOVEL/EXCAVATOR OPERATIONS
EXPECTED OUTCOMES OF ASSESSMENT
Information for Assessors and Candidates
The skills assessment for this unit of competency must be conducted in the
workplace under controlled and/or real work conditions.
The assessment may be conducted over a period of time, as formative
assessment of the elements and not necessarily at one time (although this
may be possible). Competency requires that the operator will be capable of
carrying out expected day to day tasks operating an Excavator to the
required National Competency Standard (see above) and expected CQMPL
productivity standards.
Tasks that an Excavator operator will be expected to perform when assessed
as competent:
Start of shift walk around inspection using a provided check list
Start up, park-up and shut-down
Work with/in mobile plant and equipment teams; and
Direct trucks into position
Conduct loading operations including:

-
topsoil
overburden
coal
interburden or partings
Carry out loading:
- over the side

- through the gate
- drive by
- above trucks; and
- at the same level
Action alarms and communicating maintenance issues
Recognise and dealing with particular hazards associated with the

operation of the Excavator
Carry out operational servicing, lubrication and housekeeping
Provide support for major maintenance
Process records and reports
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Topic Abbreviations/Acronyms
Code
CT
EX25/36
Explanation
Mining Department Area Specific Induction
Hitachi EX2500 and EX3600 Excavator
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CONTENTS
OPEN CUT PRODUCTION COMPETENCIES

Section
Page
Competency Elements & Performance Criteria - Flow Chart
Element 1027.1 PLAN & PREPARE FOR OPERATIONS (Refer Mining Department
Area Specific Induction)
Element 1027.2 OPERATE HYDRAULIC SHOVEL/EXCAVATOR

CT 2.1
Resolve Coordination Activities with Others (Refer Mining Department

Area Specific Induction)
11
Walk-around Inspection Checklist
12
EX25/36 2.2 Carry Out Pre-start, Start Up , park-up and Shutdown Procedures
16
EX25/36 2.3 Select Loading Method for Excavator
46
2.3 & 2.4 are reversed in the

Learning Notes & Assessment
EX25/36 2.4 Conduct, Control and Monitor Dig Procedures
29
EX25/36 2.5 Act on or Report Monitoring Systems & Alarms
53
EX25/36 2.6 Recognise & Respond to Hazardous & Emergency Situations
59
CT 2.7
69
Complete Work to Planned Outcomes (Refer Mining Department Area

Specific Induction)
Formative Assessment
Element 1027.3 RELOCATE EXCAVATOR

CT 3.1
Receive & Confirm Route & Location Plan (Refer Mining Department Area
Specific Induction)
71
EX25/36 3.2 Complete and/or Follow Ground Preparation
72
CT 3.3
72
Resolve Co-ordination Issues, Support Equipment & Personnel (Refer

Mining Department Area Specific Induction)
EX25/36 3.4 Relocate Excavator
73
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CONTENTS (Continued)
OPEN CUT PRODUCTION COMPETENCIES

Section
Page
Element 1027.4 CARRY OUT OPERATOR MAINTENANCE

EX25/36 4.1 Carry Out Inspections & Fault Finding
75
EX25/36 4.2 Carry Out Routine Operational Servicing, Lubrication, Maintenance &
Housekeeping
76
EX25/36 4.3 Carry Out Minor Maintenance
78
EX25/36 4.4 Provide Support for Major Maintenance
81
CT 4.5
81
Process Maintenance Records (Refer Mining Department Area Specific

Induction)
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MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR OPERATIONS

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HITACHI EX2500/EX3600 EXCAVATOR

1027.1
1027.2
1027.3
1027.4
PLAN & PREPARE FOR

OPERATIONS
OPERATE EXCAVATOR
RELOCATE EXCAVATOR
OPERATOR MAINTENANCE
CT 1.1
Obtain, Interpret & Clarify
Work Requirements
CT 2.1
Resolve Co-ordination Requirements
with Others
CT 3.1
Receive & Confirm Route &
Location Plan
EX25/36 4.1
Carry out Inspections & Fault
Finding
EX25/36 2.2
Carry out Pre-start, Start Up, Park-up
& Shutdown Procedures
EX25/36 3.2
CT 1.2
Access, Interpret & Apply
Geological & Survey Data
CT 1.3
Access & Apply Safety
Information
CT 1.4
Co-ordinate Preparation of
Work Area
EX25/36 4.2
Complete and/or Follow
Ground Preparation
Carry out Routine Operational

Servicing, Maintenance,
Lubrication & Housekeeping
CT 3.3
Resolve Co-ordination
Issues, Support Equipment &
Personnel
Carry out Minor Maintenance
EX25/36 3.4
EX25/36 4.4
Provide Support for Major
Maintenance
EX25/36 2.3
Select Loading Method
EX25/36 2.4
Conduct, Control & Monitor Dig
Procedures
2.3 & 2.4 are reversed

in the Learning Notes
& Assessment
Relocate Excavator
EX25/36 2.5
Act on or Report Monitoring Systems
& Alarms
EX25/36 2.6
Recognise & Respond to Hazardous
and Emergency Situations
WHITE sections coded CT

relates to Mining
Department Area Specific
Induction
EX25/36 4.3
CT 4.5
Process Maintenance
Records
CT 2.7
Complete Work to Agreed
Planned Outcomes
GREEN sections coded :

EX25/36 relates to the Hitachi EX2500 and EX3600
EXCAVATOR
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PLAN & PREPARE FOR OPERATIONS
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MNCO1027A Conduct Hydraulic Shovel/Excavator Operations

Element 1027.1
Plan and Prepare for Operations
Performance Criteria
1027.1.1
Obtain, interpret and clarify/confirm work requirements in the form of

shift briefings, handover details or work orders before proceeding.
1027.1.2
Access, interpret and apply basic geological and survey data required
to complete the allocated task in accordance to site procedures.
1027.1.3
Access and apply safety information and procedures throughout the

work.
1027.1.4
Coordinate work area preparation, including floor clean up and level

and grade requirements with others and carry out to job specifications.
CT 1.1
OBTAIN, INTERPRET & CONFIRM WORK REQUIREMENTS

(Refer Mining Department Area Specific Induction)
CT 1.2
ACCESS, INTERPRET & APPLY GEOLOGICAL AND SURVEY

DATA
CT 1.3
ACCESS & APPLY SAFETY INFORMATION

CT 1.4
PREPARE WORK AREA

Mining Department Area Specific

Induction Assessment
must be completed before continuing.
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OPERATE EXCAVATOR
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Element 1027.2
Operate Excavator/Hydraulic Shovel
1027.2.1
Resolve coordination activities with others at the site prior to

commencement of, and during, the work activity.
1027.2.2
Carry out pre-start, start-up, park-up and shutdown procedures in

accordance with manufacturers and site procedures.
1027.2.3
Select required loading method, single-sided, double sided or other

appropriate method and position the equipment and trucks to meet this
requirement.
1027.2.4
Conduct, control and monitor dig procedures, fill and load in accordance
with manufacturers instructions and site procedures including those
covering truck loading.
1027.2.5
Act on or report monitoring systems and alarms are in accordance with

manufacturers instructions and site procedures.
1027.2.6
Recognise and respond to hazardous and emergency situations are in

accordance with manufacturer instructions and site procedures.
1027.2.7
Complete work in accordance with the agreed plan and outcomes and
within the operating capacities of the allocated equipment.
CT 2.1
CO-ORDINATE ACTIVITIES WITH OTHERS

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WALK-AROUND INSPECTION - GROUND

Commence the inspection, starting at the bucket and working in an anticlockwise direction.
Check boarding steps for Danger, Out of Service or Information Tags. Check for
the following:
Ground Level
q
Bucket, bucket teeth, adaptors and pins ( wear and damage)
q
Bucket cylinders, arms/arm cylinders (leaks and condition of hoses)
Level cylinder, arm and boom cylinder (leaks or damage)
Lights (damage lens, blown globes)
Front idler (wear)
Left track for correct adjustment (ie tracks resting on centre wear plate)
Track rollers and pins (wear and oil leaks)
Grousers (wear and/or loose bolts)
Chains ( wear or damage)
Boarding ladder (wear or damage)
Remote fire suppression activator
Position and function of emergency stop button
Rear sprocket (loose segments, wear and/or damage)
Track frame (dirt build up around carry rollers)
Slew ring (adequate grease)
Fuel tanks (leaks and/or damage)
Service point (damage and leaking hoses/connections)
Rear sprocket (loose segments, wear and/or damage)
Right track for correct adjustment (ie tracks resting on centre wear plate)
Track rollers and pins (wear and oil leaks)
Grousers (wear and/or loose bolts)
Chains (wear or damage)
Track frame (dirt build up around carry rollers)
Front idler (wear)
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Upper Level Inspection (Use three point access technique one hand/two feet, two hands/one foot)
q Rotary connection (leaks, wear and tear)
q Hydraulic oil level and condition of tank
q Engine oil level (top up if necessary)
q Engine bay (fluid leaks, rubbish, excessive dust)
q Pump drives (oil leaks)
q Alternator and fan belts (adjustment, wear and/or damage)
q Coolant level (top up if necessary)
WARNING
System pressurised; serious burns may result from releasing radiator

cap on hot engines.
q Hydraulic pumps (oil leaks)

q Windscreen washer reservoir level (top up if necessary)
q Automatic Fire Suppression reservoirs (above counterweight)
q Swing gear box (oil level and leaks/damage)
q Main valve block (leaks)
q Pre-cleaner (clean if necessary)
q Fuel tank (level and condition)
q Auto lube system
q Battery
q Radiator cores (leaks and/or trash build up)
q Clean offside mirror
q Emergency escape system ( worn/damaged rope, worn/damaged hanger or case)
q Hydraulic cylinders, valves and hydraulic lines around the main boom area (leaks)
q All boom grease lines (damage)
q Boom pins ( wear and lubrication)
Clean Test and Adjust as necessary
q
q
q
q
q
q
q
q
Operating controls, horn, gauges

Seat and seat belt
Air conditioner and filters
Mirrors and windows
Operating pedals
Floor
Fire Suppression System
Lights, two-way and instruments
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HITACHI EX2500/EX3600 EXCAVATOR
Emergency Escape Device Hangar

Swing Device
Cab
Lubricator
Boom
Hydraulic Oil Tank
Level Cylinder
By Pass Filter
Arm
High Pressure Strainer

Bucket
Oil Cooler
Bucket Cylinder
Control Valve
Arm Cylinder
Pump
Emergency Escape Device
Hydraulic Oil Tank
Centre Joint
Counterweight
Front Idler
Engine
Track Adjuster
Radiator
Upper Roller
Swing Device
Lower Roller
Accumulator
Side Frame
Swing Bearing
Travel Device
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HITACHI EX3600 EXCAVATOR
Boom Cylinder
Cab
Swing Device
Boom
Lubricator
Oil Cooler
Level Cylinder
Hydraulic Tank
Arm
Muffler
Bucket
Battery
Dump Cylinder
Air Cleaner
Bucket Cylinder
Pump
Arm Cylinder
Counterweight
Washer Tank
Fuel Tank
Engine
Front Idler
Control Valve
Track Adjuster
Radiator
Upper Roller
Accumulator
Side Frame
Travel Device
Ladder
Lower Roller
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EX25/36 2.2

OPERATIONS
training
CARRY OUT PRE-START, START-UP, PARK-UP AND SHUTDOWN

PROCEDURES
2.2.1 Pre-Start Procedure

It is recommended that you commence the inspection at the bucket and
move around the machine in an anticlockwise direction, carrying out the
checks. Check boarding ladder for Out of Service and/or Danger
tags and use three point boarding techniques.
The access ladder may be operated from either ground level or from the
upper level.
To lower from the upper level

pull the T handle up to release
the lock and gently push down on
the ladder until it locks into place.
To lower from ground level

stand clear of the ladder, pull down
on the hanging rings to release the
lock and gently pull down on the
handle until the ladder locks into
place.
Ensure body parts are kept clear of the path of the ladder
when raising the ladder from the upper level.
WARNING
The ladder may spring up after the lock is released.
To raise from the upper level stand clear of the ladder, pull the
T handle up and exert upwards pressure on the ladder until it locks
into place.
To raise from ground level pull down on the hanging rings as you
push the ladder up until it locks into place.
T Handle
Upper Level
Hanging Rings
Ground Level
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2.2.2 Walk Around Information
Check the Coolant (engine shut down)

Check the coolant at the reservoir located in the engine bay. Coolant
must be between the MIN and MAX marks located on the outside of
the container. If the coolant is below the MIN mark, top up the
coolant in the reservoir only.
To fill the radiator:
-
remove the radiator cap
top up with coolant
check the coolant level
check for any leaks
replace the cap securely
WARNING
Only remove the radiator cap when the engine is

cool.
Relieve any pressure by removing the cap slowly
Use PPE (ie gloves, glasses)
Use gloves; and
Cover the cap with heavy rag or other protection
EX2500
EX3600
Coolant Level
Gauge
Radiator Cap
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Engine Oil Level

Check the oil level before starting the engine or 15 minutes (or more)
after stopping the engine. This allows the oil to drain from the engine
cavities and provides a more accurate reading.
Check the level as follows:
EX2500
ensure the excavator is parked on a level surface
check the oil burn reservoir under the excavator (the level should
show at least half in the sight glass)
open the inspection door at the rear left of the unit
remove the dipstick in the first engine
wipe the dipstick with a clean rag
re-insert the dipstick
remove the dipstick
read the level (level should be between the two marks)
EX3600
Oil Filler Cap
Oil Dipstick
Dipstick
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Fuel Level (for pre start

inspection) Check using the
sight glass located on the side
of the fuel tank, add fuel as
necessary
Fuel
Swing Reduction Gearbox Oil Level Ensure the excavator is

parked on a level surface with the engine off:
-
remove dipstick
wipe the dipstick on a clean rag
reinsert the dipstick
remove dipstick again
check the oil level
The oil must be maintained between the upper and lower marks on
the dipstick.
EX2500
EX3600
Dipstick
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Hydraulic Oil Reservoir Level

Ensure the excavator is parked on a level surface
with the boom, stick and bucket in the position
shown in the photo opposite. The engine should
be stopped. Check the level using
the sight glass located on the
Sight Glass
wall beside the cab steps. The
oil level should be between the two marks, if the
level is below the bottom mark add oil. Do not
overfill.
2.2.3 Operators Seat
Back-rest Adjustment
Cushion Angle
Seat Damper
Console Fore/Aft
Adjustment
Seat Fore/Aft
Adjustment
Adjust Backrest
Pull the Back-rest Adjustment lever up while applying or relieving
pressure on the back-rest.
Cushion Angle
Both the front and rear sections of the base cushion can be adjusted
by either lifting or lowering the cushion angle lever eg:
-
to adjust the rear part of the cushion, pull the lever up while
either applying or relieving pressure on the rear of the seat base.
to adjust the front part of the cushion, push the lever down
while either applying or relieving pressure on the front of the seat
base.
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Suspension Adjustment (dampening)

To adjust the ride or dampening effect of the seat turn the Seat
Damper dial clockwise to increase the dampening effect, or anticlockwise to decrease the dampening effect. As a guide, you may
turn the dial to set your own body weight (in kilograms).
Console/Seat Fore/Aft adjustment

The seat and/or the seat and console (control levers and seat) may
be adjusted forward or backward to suit your needs.
-
to adjust the seat only, lift the Seat Fore/Aft Adjustment bar
while pushing or pulling the seat in the direction required.
to adjust the seat and console together, lift the Console

Fore/Aft adjustment lever while pulling or pushing the unit in the
direction required.
Lumbar Support Adjustment

Lower back lumbar support may be adjusted by turning the dial
located on the left side of the back rest. Turning the dial anticlockwise will increase lumbar support.
Headrest adjustment
The headrest can be adjusted both in angle and height.
to raise or lower the height of the headrest, grasp it firmly with

both hands and pull up or push down to the desired position.
to tilt the headrest, hold the headrest while tilting it forward or

backwards to suit your requirements.
Armrest Height adjustment

The height of the armrests may be adjusted by turning the dials
located on the underside of the armrest.
NOTE
Adjust the seat so that you can easily depress the foot
pedals.
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2.2.4 Seat Belt
Before fastening the seat belt, inspect
WARNING
The securing brackets and belt for abnormal

conditions.
The bolts and fittings on the chassis for tightness
Fasten the belt as follows:
Adjust the seat so that the brake pedal can be depressed all the way
with your back against the back rest
Position the seat belt across your body
Secure the belt by placing the tongue into the socket attached to the
seat
Check that there are no kinks in the belt.

WARNING
Check that the belt has locked by pulling it
Unbuckle the seat belt as follows:
Depress the red button on top of the seatbelt socket
Allow the seat belt to retract
WARNING
If the seat belt is scratched or frayed or if any of the

fittings are broken or deformed or loose. Contact
Maintenance
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2.2.5 Pre Start Instrument Check
Place pilot control shut-off lever in the LOCK

position
Check that all control levers are in neutral (N)
Turn the ignition switch ON
Check that the following lights are ON:

-
alternator indicator
pump transmission oil pressure indicator
engine warning indicator
engine stop indicator
Pilot Control Shut Off
Press indicator light check switch; AND
Hold (indicator light check switch)
Check that all monitor lamps are ON
If any indicator fails to light, the bulb may be burned out.

Maintenance for advice/assistance
Call
2.2.6 Fluid Level Check

Wait 15 seconds after the
ignition has been switched
ON and check the fluid levels
using the test switch on the
operators console.
Hydraulic Oil
Coolant
Engine Oil
The fluid level lights will

glow if the fluids are
at operating levels.
All
three
lights
should glow before
you start the
engines.
NOTE
The level check function does not replace the need

for operator pre-start checks.
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2.2.7

OPERATIONS
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Start-up (Normal)
Start the unit as follows:
Adjust the operators seat
Check that the Pilot Control Shut Off lever is in the

LOCK position.
Pilot Control Shut
Check that all levers are in NEUTRAL (N)

Engine Speed Control
Place the Engine Speed Control in LOW
Sound horn once (wait five seconds)
Turn the ignition key to the ON position
Check warning lights
Turn the ignition key to the START position
Crank the e ngine
Release the key once the engine has started, or after ten seconds
with out starting.
NOTE
Emergency Stop
Ignition Key
Crank engine for a maximum of 15 seconds.

If the engine does not start, wait for three minutes before
attempting another start.
Check that the warning lights glow for approximately two seconds
after the ignition key is turned to the ON position
Contact maintenance if any of the warning lights above

fail to glow.
NOTE
Ensure that all the monitor lamps on the operator control panel go
out. If any lights fail to go out, stop the machine and check for the
cause (Refer 2.5 - Act on or Report Monitoring Systems & Alarms).
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2.2.8 Starting In Cold Weather
EX2500
Install an ether container on

holder located in the engine
room
Move the engine speed

control lever to the LOW
position.
Turn the ignition switch to

START; AND
Crank the engine
Ether Container Holder
WARNING
Starting fluid (ether) is highly flammable.
The container may explode if not handled

correctly.
Keep the container away from heat, sparks, and

open flame.
Contents of the starting fluid container are

pressurized. Do not puncture or incinerate the
container.
Remove container from the excavator if the engine

does not need starting fluid.
The Pre-lube indicator will glow and the starter will rotate to start the
engine , approximately 3 seconds after the pre-lube indicator light goes
out. A shot of ether will be injected into the engine.
Release the ignition key after the engine starts (It will return to the
ON position)
Remove the ether container after the engine has started
Ether is injected into the engine automatically.

NOTE
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Starting In Cold Weather
EX3600
When the preheat switch is turned ON, preheating is continuously
performed for approximately one (1) minute with the ignition key in the
ACC position. If the ignition key is turned to a position other tha n the
ACC position before preheating is complete, preheating will be
automatically stopped (the preheat indicator will go out). If preheating is
operated for longer than one (1) minute, the preheat indicator will go out,
automatically switching off preheating.
ON
OFF
Remove the Relay Box

cover
Turn the preheat cut-off switch

ON.
Turn the ignition key switch the

ACC position.
Pre-heat Cover & Switch
Open the preheat switch

cover
Turn the preheat switch

ON (the p reheat indicator
will glow) to indicate:
Pre-heat Cut Off Switch
Relay Box
Pre-heat Indicator
preheating of the engine intake air
setting the fuel injection for starting in cold weather.
Wait one minute after starting the preheating
Turn the ignition key to the START position
Crank the engine until it starts (Maximum 10 seconds). Preheating

will automatically be complete and preheat indicator will go out
NOTE
The preheating system will only operate if the ignition

key is in the ACC position.
If preheating is required again:
Turn the preheat switch OFF
Wait for 5 minutes
Turn the preheat switch ON
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2.2.9 After Start-up Checks
Warm up the engine for no less than five (5) minutes, under no load
and at mid range engine speed
Check the monitor lamps for operation

If the monitor lamps do not go out after starting the
engine :
WARNING
Stop the engine immediately

Call Mainte nance for assistance
Run the engine under light load until the engine coolant and hydraulic
oil gauges are in the green or white range
Hydraulic Oil Temperature
Engine Oil Temperature
Engine Stop
Alternator
Engine Oil
Pressure
Transmission Oil
Pump
Ensure the alternator monitor lamp is OFF
Ensure the transmission pump oil pressure lamp is OFF
Ensure the e ngine oil pressure lamp is OFF
Ensure the e ngine stop lamp is OFF
Operate the excavator controls with no load applied to circulate warm

oil through the hydraulic system
Check for:
Exhaust Gas Colour - Quick Check
normal exhaust colour
C
Coolloouurrlleessss oorr ffaaiinntt bblluuee: normal (proper
combustion)
abnormal vibration
Black: abnormal (improper combustion)
abnormal noise
W hite : abnormal (worn oil rings, or

coolant leakage into cylinder)
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2.2.10 Park Up and Shut Down
Check the distance from other plant/equipment
Park the excavator on a level surface
if you must park on a grade:

WARNING
Thrust the bucket teeth

into the ground
Block both tracks
Lower the bucket to the ground
Turn the auto -idle switch OFF
The turbocharger may be damaged if the engine is

not correctly shut down.
NOTE
Move the engine speed control lever to the slow idle position
Run the engine for 5 minutes to cool the Engine
Turn the ignition key to OFF
Pull the pilot control shut-off lever to the LOCK position
Close the windows, roof vent, and cab door
NOTE
Protect electrical components in the cab from bad

weather. Always close windows, roof vent and cab
door when parking the excavator
Pilot Control Shut Off Lever
Speed Control Lever
Ignition Key
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EX25/36 2.4

OPERATIONS
training
CONDUCT, CONTROL & MONITOR DIG PROCEDURES
2.4.1 Foot Controls. The foot/centre front hand controls are used to manage
the travel movements of the excavator.
NOTE
The travel directions below are described with the

track idlers positioned at the front of the excavator and
the travel motors at the rear. (If the tracks are facing in
the opposite direction the control movements must be
reversed)
FORWARD
Left
Right
Footrest
Footrest
Neutral
Left
Right
REVERSE
The Travel Direction Pedals operate as follows :

-
Forward Push the top of both pedals down
Reverse Push the bottom of both pedals down
Turn Right Push the top of the left pedal down
Turn Left Push the top of the right pedal down
Turn on Track Radius Push the top of the right pedal down
while pushing down on the bottom of the left pedal, or vice versa.
Avoid changing direction in high speed.
WARNING
Before changing direction check for hazards and people.

When driving over rough terrain, reduce engine speed to
lessen possibility of undercarriage damage.
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Working Lights Dip Switch - A dip

switch has been fitted to the
excavator to allow the operator to turn
off the lower work lights when trucks
are approaching. The switch is
located on the side of the operator
cabinet, adjacent to the left foot rest.
2.4.2 Hand Controls

The Travel Directional Levers Follow the operation of the pedals as
follows:
Forward Push both levers forward
Neutral Centralise the levers
Reverse Pull both levers back
Turn Right Push the left lever forward
Turn Left Push the right lever forward
Turn on Track Radius Push the right lever forward while pulling
back on the left lever, or vice versa.
Left
FORWARD
Right
NEUTRAL
Left
REVERSE
Right
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Engine Speed Control Lever

Allows the operator to regulate
speed of the engine.
To operate:
HIGH
LOW
Move the lever FORWARD for

LOW and BACKWARDS for
HIGH
The Engine Speed Control lever should be in the LOW

(idle) position to start the engine.
NOTE
Pilot Control Shut Off Lever prevents the accidental operation of

controls when leaving the operators seat or cab
To activate the Pilot Control Shut Off Lever
When stopping the excavator:
-
park the excavator on a firm, level surface
lower the bucket to the ground
place all controls NEUTRAL
shut down the engine.
pull the Pilot Control Shut Off lever up into the

LOCK position
Pilot Control Shut Off
Before starting the excavator:

-
Confirm that Pilot Control Shut Off lever is in the LOCK position
After starting the engine:

-
confirm that all control levers and pedals are in NEUTRAL
confirm that no part of the machine is in motion
push the Pilot Control Shut Off le ver down to the UNLOCK
position
Ensure that the Pilot Control Shut Off lever is moved fully
into the lock position before leaving the operators seat.
WARNING
Shut down the excavator and Contact Maintenance if any

part of the machine (any actuator) moves when the Pilot
Control Shut Off lever is lowered to the UNLOCK
position.
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OPERATIONS
training
2.4.3 Bucket Controls

Arm
OUT
Slew
RIGH
T
Slew
LEF
T
Arm
IN
Boom
UP
Bucket
Roll
OUT
NEUTRA
L
Bucket
Roll
IN
Boom
DOWN
Left Hand Control (Upper Deck)

-
Slew LEFT Move the top of

the lever left
Slew RIGHT Move the top of

the lever right
Arm (stick) OUT Push the

top of the lever forward
Arm (stick) IN Pull the top of

the lever back
Right Hand Control (Bucket)

-
Boom UP Push the lever

forward
Boom DOWN Pull the lever

back
Bucket ROLL OUT Move

the top of the lever left
Bucket ROLL IN Move the top of the lever right
The lever will return to the HOLD/NEUTRAL position if

released in any selected position.
NOTE
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2.4.4 Buttons and Switches
Emergency Stop Switch (Cab) located on the

back of the right hand bucket control, above the
start keys.
Emergency Stop
To stop the engine in an emergency, turn the

emergency stop switch from NORMAL to
EMERGENCY STOP. This will stop the engine
and the Emergency Engine Stop monitor lamp
will glow.
Other emergency stop switches are located in
the pump room and at the bottom of the main
access ladder.
NOTE
Starter Switch
Return the emergency stop switches to the normal position

before trying to restart engines.
Emergency stop switches are also located in the:

-
EX2500 (Engine and Hydraulic Pump Compartments)
EX3600 (Engine, Pump, Oil Cooler and Radiator Compartments)
When the engine stop switch is turned to the EMERG. STOP

position, the engine will not start with the ignition key. The Engine
Emergency Stop indicator will glow and a buzzer will sound.
WARNING
Engine Emergency Stop

Switches
The engine will stop when the switch is turned to

EMERG. STOP. HOWEVER, air pressure will not be
purged from the hydraulic oil tank.
Engine Emergency Stop
EX2500
EX3600
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OPERATIONS
training
Engine Ignition (Starter) Switch used to start the engine and

activate the electrical circuits. There are four (4) positions:
-
START turn the key(s) to this position to start the engine(s).

The key(s) will return to the ON position when released.
ACC - supplies power to the radio, horn and two-way
ON - after starting, the engine(s) will continue to run with the

key(s) in this position
OFF - turns the engine(s) off and isolates the electrical systems
EMERGENCY STOP
OFF (engine)
ACC (horn,
radio etc)
IGNITION SWITCH
ON (Engine
electrical)
START (engine)
Two Way Radio The microphone on the two way radio is controlled
by the button on top of the left hand bucket control lever.
To talk on the radio:
DEPRESS the button on top of the control and HOLD down until you
have finished speaking.
Microphone
Microphone Button
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Wiper Switch
-
OFF - wipers are parked.
INT - wipers operate intermittently
LO - wipers operate at a slow speed (continuously)
HI - wipers operate at a high speed (continuously)

Wiper Switch
Wiper Delay Switch
Washer Button
Wiper Delay Selector activated when the wiper switch is turned to

INT. The Wiper Delay Selector switch allows the delay to be
adjusted to one of four settings:
-
SHORT - allows a delay period of approximately four (4) seconds

between wiper operation
Position TWO - allows a delay period of approximately eight (8)

seconds between wiper operation
Position THREE - allows a delay period of approximately fifteen

(15) seconds between wiper operations
LONG - allows a delay period of approximately twenty-five (25)

seconds between wiper operations
Washer depress the button to operate the windscreen washers.

The wiper will operate for approximately four (4) seconds after the
button is released.
WARNING
Damage will occur to the washer system if operated for

periods longer than twenty (20) seconds or if operated
continuously while the reservoir is empty.
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OPERATIONS
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EX2500
Auxiliary
EX3600
Preheat
Auto Idle
Entrance Light
Interior Light
Working Lights
Fast Fill
Travel Speed
Engine Room Light
Auxiliary Switch spare
Fast fill Switch operates the service point arm located under the
back of the excavator.
-
OUT (normal position) service point is stowed.
IN (light on) service point is in the down position
NOTE
The excavator will not slew while the service point is

down.
Auto Idle Switch has two (2) positions:

-
ON - press the button IN. The engine speed will drop to idle after
the bucket controls have been neutralised for four seconds.
OFF press the button a second time to release the switch and
turn off the AUTO IDLE.
An indicator light will glow while the AUTO IDLE system is activated.
NOTE
Before stopping the engines, turn the AUTO IDLE switch

OFF.
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Travel Speed Switch a two position switch used to control the

speed of the excavator when travelling. An indicator lamp will glow to
identify the speed selected:
-
IN position slow speed (turtle indicating light)
OUT position fast speed (rabbit indicating light)
Entrance Light Switch two (2) positions:

- ON press the button in
-
OFF press the button a second time
The entrance light (located externally at the top rear of the cab)
comes on when the entrance light switch is depressed. An indicator
light will glow while the button is in the ON position. To switch the
light OFF, press the button a second time.
Engine Room Light Switch two (2) positions:

-
ON press the button IN. (The engine room light comes on when
the switch is depressed). An indicator light will glow while the
button is in the down position.
Interior Light Switch Two (2) positions:

-
ON press the button IN. (The interior light comes on when the
switch is depressed)
Working Lights Switch Two (2) positions:

-
ON press the button IN. (When this button is depressed all

exterior working lights will come on and the instrument gauge
backlights and air conditioner illumination will glow)
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OPERATIONS
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Warning Lights
Test
Fluid Level Check
Buzzer Stop
Dimmer
Warning Lights Test Switch (fault monitor lamps)

To check the operation of the fault monitor lamps:
turn the key switches to ON
check that the alternator, transmission pump pressure, engine

stop, engine warning and engine protection lights are glowing
(nine lights).
press the Warning Lights Test switch and check that the
remainder of the lights are glowing
Fluid Level Check Switch

To check that the fluid levels are adequate for operation:
-
press the Fluid Level Check switch. The corresponding light on

the display will glow for each fluid level checked and correct
Buzzer Stop Switch - use this button to reset the warning buzzer
after an alarm event. The buzzer will sound again at the next event.
Dimmer Switch (instrument cluster) dial type switch used to

change the intensity of the instrument back lighting
-
turn the switch clockwise to increase the intensity of the back

lighting
turn the switch anticlockwise to decrease the intensity of the

back lighting
NOTE
The Fluid Level Check switch is not a substitute for

manual/visual pre start checks.
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Air Conditioner Controls

The air conditioner system fitted to the EX2500/EX3600 is split into
three separate systems each controlled separately. The three
systems are Rear, Side and Front.
The air conditioner controls for each system operate as follows :

-
Fan Control - the fan speed is

adjusted up or down by pushing the
black buttons shown below. The
status of the fan will be shown by a
LED behind the corresponding fan
speed (OFF, I, II, III).
Air Conditioner On/Off - the air conditioner may be

switched off independently of the fan to allow for fan
only operation without cooling. The on/off button for
this feature is the blue button marked AC. The status of
the air conditioner will be shown by an LED glowing
behind the snowflake emblem.
Temperature Control - The temperature output of the air

conditioner can be adjusted by pressing the black buttons shown
below. The temperature setting will be shown by an LED glowing
above the colour scale.
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OPERATIONS
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Horn Button
Horn Button is located on top of

the left hand bucket control lever. To
sound the horn press down on this
button for the duration required.
2.4.5 Move the Excavator

After the engine has been started allow 5 minutes (minimum) warm up.
To move the excavator:
Check that all the warning lights have gone out
Unlock the Pilot Control Shut Off lever
Lift the bucket
Turn the park brake switch to OFF (to release the park brake)
Select travel speed using the Travel Speed Switch. Slow

speed (turtle) or fast speed (rabbit) can be selected by
pushing the travel speed switch regardless of engine
speed.
Sound the horn (twice (2) for forward) (three (3) times for reverse)
pause five (5) seconds
Always stop the excavator before changing the

travel mode speed.
WARNING
NOTE
To decrease the travel speed, for travelling on a slope

or in a tight space, press the switch to the turtle
position.
Select a route that is as flat as possible. Steer the

excavator as straight as possible making small,
gradual changes in direction.
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Select the direction of travel as follows:
Forward Travel - Push down on the front of both pedals or, push
forward on both of the travel levers
Reverse Travel - push down on the rear of both pedals or, pull back
on both of the travel levers
Neutral Position - when the travel pedals or, levers are placed in the
neutral (central) position, the travel brakes will automatically stop
and/or hold the machine
Left Turn - push down on the front of the left pedal or, push the left
travel lever forward
Right Turn - push down on the front of the right pedal or, push the
right travel lever forward
Short (spin) Turn - push down on the front of one pedal and the
rear of the other or, alternatively push/pull both travel levers in
opposite directions
WARNING
The travel directions above are described with the

track idlers positioned at the front of the excavator
and the travel motors at the rear. (If the tracks are
facing in the opposite direction the control
movements must be reversed)
Be sure to confirm the position of the travel motors
before travelling
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2.4.6 Filling the bucket

Before moving the bucket into
the face it should be levelled
and lowered to the floor. The
bucket can be levelled by
pulling/pushing the bucket
control lever to the left or to
the right.
Once the bucket has reached
a point where the floor of the
bucket is of a similar angle to
that of the material being
excavated, lower the bucket to
the floor and check the bucket
level, adjust the level if
required.
With the bucket
levelled and lowered to the
floor, move the bucket arm
towards the face to the point
where the excavator has
started to labour, at this stage pull the bucket control back towards the
operator seat to start to roll (tilt) the bucket slowly until its full whilst
slowly raising the boom(hoist).
Always keep the bucket floor parallel to the face when digging. When the
bucket is full, continue to hoist to the required level while also slewing
towards the loading position.
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2.4.7 Working on Inclines (Slopes)

It is usually safer and more efficient to work from the tops of an incline to
the bottom (rather than from the bottom up to the top). The weight of the
excavator (and gravity) will assist in pushing the load ahead of the blade.
You will need to communicate and understand the angle of an incline
before you can work on it. Inclines are generally referred to in ratios (e.g.
2:1, 4:1).
2:1, means that if you walk for two metres up an incline you will rise one
metre from your starting point. A ratio will also relate to the angle of the
incline. The drawings below show the relative steepness of inclines and
approximate angle in degrees.
At Curragh, ramp angles are usually referred to in percentages (e.g.
most pit ramps are 8%. Dragline ramps are 10% maximum). Highwalls
are usually referred to in ratios (i.e. 1:1 or 1:2)
2:1 Slope
1M
27 Off Horizontal
2M
51%
3:1 Slope
1M
18 Off Horizontal
32.5%
3M
4:1 Slope
1M
4M
14 Off Horizontal
24.9%
Avoid travelling across (right angles) a slope.
WARNING
If you must walk across a slope:

Keep the bucket close to the ground (.5 1 metre)
Do not swing downward on a slope
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training
DEGREES PERCENT - SLOPE

100
90
80
70
90
60
80
70
60
50
50
40
40
30
30
20
20
10
10
0
Degrees
Percent
Degrees
Percent
Degrees
Percent
1.8
16
28.7
31
60.0
3.5
17
30.6
32
62.5
5.2
18
32.5
33
64.9
7.0
19
34.4
34
67.4
8.8
20
36.4
35
70.0
10.5
21
38.4
36
72.7
12.3
22
40.4
37
75.4
14.0
23
42.4
38
78.1
15.8
24
44.5
39
81.0
10
17.6
25
46.6
40
83.9
11
19.4
26
48.8
41
86.9
12
21.3
27
51.0
42
90.0
13
23.1
28
53.2
43
93.3
14
24.9
29
55.4
44
96.6
15
26.8
30
57.7
45
100.0
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Excavators may tip forward when travelling up or down a slope (dip)

always keep the bucket low to the ground (500mm to 1 metre)
Avoid turning on slopes. If you must turn ensure the ground is firm and
the slope angle is not excessive. Never traverse slopes of more than 15
degrees longitudinally or 15 degrees across the fall.
It is important to select the correct digging technique with regard to the

steepness of the slope.
Avoid working across a slope (eg at right angles).

If you must work across a slope:
WARNING
Start at the top
Maintain a windrow on the low side of the

excavator to provide stability
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EX25/36 2.3

OPERATIONS
training
SELECT LOADING METHOD
2.3.1 Loading Tasks includes both haulers and rear dump trucks.
There may also be times when loading is in conjunction with other type
of loading units eg loader.
Loading materials may include:
Topsoil
Overburden
Coal
Interburden or partings
Whatever type of unit you are loading, you must work with the operator
as part of a team by:
Maintaining communication with the operator of the equipment being

loaded. This may be via two way radio, by horn signals (eg one horn
signal by the excavator operator to tell the truck to stop) or visually
using hand signals
Ensuring the truck is positioned for safe, easy and productive loading
2.3.2 Loading Preparation

Carry out an inspection of the area where loading is to be carried out
for any hazards
Communicate your movements to any other operators in the area
Contact grader/dozer to clean floor in preparation for truck loading.
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2.3.3 Loading Operation

Study the area that the loading operation will be carried out and decide
on the best approach to loading eg:
Develop a plan of how to work the face and the loading method to be
employed (eg drive by, through the gate)
Inspect the area/material to be loaded and decide if any additional

preparation is required (eg grader/dozer to prepare floor/bench)
Set up the loading bench. Check the following as you go:
keep the bench height as close as possible to the stick length or

equal to the gate height of the truck.
set the angle of the bench to suit the material being excavated.
Loose material will need a lower angle while compacted earth
may stand near vertical.
Load trucks using the most productive method (eg drive by, over the
side)
When trucks are fully loaded and the area is clear of other traffic, sound
the horn once to signal that loading is completed.
Some rear dump trucks have a load weight system,

as the excavator operator you should familiarise
yourself with the system fitted to the trucks you are
loading. The Komatsu system fitted is as follows:
One Green light for a load between 56-67 ton
Two Green lights for a load between 67-85 ton
NOTE
Three Green lights for a load between 85-91 ton

One Yellow light for a load between 91-96 ton
One Red light for a load o ver 96 ton
Do Not Overload
Komatsu 785 Rear Dump Trucks
are rated at 85 ton (three green lights)
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2.3.4 Positioning Trucks/Loading Techniques

The excavator operator is the spotter and it is his/her role to direct the
truck to the loading position. The excavator operator usually has the
bucket full and in position so that the truck can reverse under it for
loading.
Loading may be carried out using a number of techniques to satisfy
safety, job or production needs. Some of the more common techniques
include:
Over the side
Off the same level
Through the gate
Drive by
Factors to consider when setting up for loading include:
Bench height
Material stability
The area required for positioning of trucks (confined/floor type etc)
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2.3.5 Loading Over the Side

The excavator is positioned parallel to the face with the right track lined
up along the cut line.
Trucks are positioned at right angles to the face or they may also be
positioned at an angle to the face (see diagram below)
The excavator swings from the dig zone to the left carrying the bucket
over the side (rails) of the truck before placing the material in the body of
the truck.
The basic operation for loading over the side is as follows:
The excavator raises the load and positions it at right angles to the
face
The truck operator backs under the bucket
The excavator sounds the horn when the truck is in the correct
position or has reversed back sufficiently
The excavator tips the load from the bucket.
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2.3.6 Through the Gate Loading

Trucks are positioned at an angle to the bench face and facing away to
the left of the excavator.
through the gate of the truck before placing the material in the truck
body.
The basic operation for through the gate loading is as follows:
The excavator raises the load and positions it next at about 45o from
the cut line
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2.3.7 Drive By Loading

Trucks are positioned parallel to the bench face, preferably with the
operators cabin on the excavator side. It is the responsibility of the
excavator operator to ensure that the truck is positioned so that the
counter weight clears the truck when the excavator is swinging.
through the trucks gate or over the side before placing the material in the
truck body.
The basic operation for through drive by loading is as follows:
The truck operator drives into position along the bench with the truck
about 2.5 metres from the crest of the face
The e xcavator sounds the horn when the truck is in the correct
position
The excavator raises the load and swings it over the trucks side
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OPERATIONS
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2.3.8 Loading Trucks Off the Same Level

The excavator is positioned at floor level. Tracks can be facing either
directly into the heap or at an angle across the face depending on the
width of the bench.
Trucks are positioned at an angle to the to the bench face (if conditions
allow).
The excavator swings from the dig zone to left and right carrying the
bucket through the gate before placing the material in the truck body.
WARNING
Although truck loading can be carried out from either

side, to prevent the excavator counter weight striking
a truck, o nly one truck at a time should be positioned
The basic operation for loading trucks off the same level is as follows:
The excavator raises the load and positions it to the left or right of the
digger as close to the face as possible. Excavator operator must
ensure that the truck is not in the path of the excavators counter
weight when slewing
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EX25/36 2.5
2.5.1
training
ACT ON OR REPORT MONITORING SYSTEMS AND ALARMS

Check Monitors
When the ignition is turned ON the monitoring system will self-test.
Monitoring lamps will glow for about two seconds except for the
alternator and pump transmission indicators, these two will stay on until
the engine has started.
Oil Temperature
Water Temperature
Fuel
Tachometer
Fuel Level
Alternator
Hydraulic Oil Level
Pump Transmission Oil Pressure

Overheat
Engine Oil Pressure
Fuel Gauge
Indicates the amount of fuel in the fuel tank.
The E mark indicates there is less than 250 litres in
the tank.
Hydraulic Oil Temperature Gauge

Green zone indicates normal operating range. If the
needle goes into the red zone, stop operation and run
the engine at LOW IDLE until the needle returns to
the green zone.
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OPERATIONS
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Water Temperature
Start the engine. Run at slow idle until the needle
enters the green zone, indicating normal operating
temperature.
If the needle enters the red zone, reduce the load
immediately and run the engine at slow idle. If the problem continues,
contact Maintenance.
To prevent damage to the engine:
Stop excavator to reduce load on the engine; and
Run engine at slow idle
WARNING
DO NOT stop the engine when the needle enters the

red zone, this will cause the temperature to increase.
Tachometer-Indicates engine speed in min1

x1000
Alternator Indicator - Glows red when the alternator output

is low. Contact Maintenance
Pump Transmission Oil Pressure Indicator (Warning) Indicator will glow red on low pressure. Stop the engine and
immediately contact Maintenance.
Engine Oil Pressure (Warning) - Indicator will glow red on

low pressure. Stop the engine and immediately contact
Maintenance.
Overheat Indicator - Indicates overheating of mechanical

components. Stop the engine and immediately contact
Maintenance.
Hydraulic Oil Level Indicator - Indicates that the hydraulic

oil level is low
Fuel Level Indicator - will glow red when approximately 250

litres remain in the fuel tank.
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OPERATIONS
Hydraulic Oil Level (Warning)
Auto Idle
training
Engine Room Light
Download
Entrance Light
Coolant Level
Pre-lube
Engine Oil Level
Travel Mode (Slow)
Travel Mode (Fast)

Coolant Level (Warning)
Ladder Position (Warning)

Fast Fill (Warning)
Auto-lube
Emergency Engine Stop

(Warning)
Engine Stop (Warning)
Pump Contamination
(Warning)
Engine Warning
Stop Valve
(Warning)
Air Cleaner
Restriction
(Warning)
Engine Oil Level Indicator - When the level check switch is

pushed, the green indicator will light if the engine oil level is
adequate for operation.
NOTE
This check does NOT take the place of manual daily

inspection.
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OPERATIONS
training
Coolant Level Indicator - When the level check switch is

pushed, the green indicator will light if the engine coolant
level is adequate for operation.
NOTE
This check does NOT take the place of manual daily

inspection.
If you need to remove the radiator cap when the coolant

is hot, take the following precautions, as hot coolant
may spurt out:
i)
Use Personal Protective Equipment (PPE) (eg

gloves, face shield)
ii)
Cover the radiator cap with a rag
iii)
Release the pressure slowly (some caps have a

pressure release button)
iv)
If fitted, fill via the expansion tank
WARNING
Download Indicator - The green indicator comes ON if the

system memory is fully occupied. If the indicator comes ON,
download the data.
Hydraulic Oil Level Indicator (Warning)

Red light glows and buzzer sounds to indicate low hydraulic
oil level. If this light is activated stop the engine immediately
and contact Maintenance.
Auto Idle - Glows when the auto -idle device is turned ON
Engine Room Light Indicator - Glows when the lights in the

engine room and pump room are switched on.
Entrance Light Indicator - Glows when the entrance lights

are switched on.
Pre-lube Indicator - When the ignition is turned to the

START position, the pre-lube pump is operated between five
and 45 seconds before the engine starts. The indicator
glows during the pre-lube pump operation.
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OPERATIONS
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Travel mode Indicator Slow speed - Lights up when slow

travel speed is selected.
Travel mode indicator Fast speed - Lights up when fast

travel speed is selected
Coolant Level (Warning) - If the coolant level is lower than the

recommended level, the red indicator light comes ON and
the buzzer sounds.
-
stop the engine immediately
check the coolant system for leaks and the coolant level.
refill the coolant as necessary.
If the red indicator comes ON and the buzzer continues sounding for
120 seconds, the engine will stop automatically.
As soon as the warning light comes ON, stop the

engine.
WARNING
If the engine is operated with the coolant level lower

than the recommended level, damage to the engine
and/or radiator may result.
Auto Lubrication Indicator - Glows red to indicate faults in

the auto grease circuit. The indicator will also light if the
grease mode switch in the battery compartment is turned to
MANUAL or OFF.
Engine Stop (Warning) - Glows red if any abnormality in

the engine or systems occur. The engine may also stop
automatically, or slow, depending on the severity of the
fault. If this monitor lights up, park the machine and contact
Maintenance.
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OPERATIONS
Engine Warning Indicator - Glows yellow if any abnormality

in the engine(s) or system(s) occur. The excavator may be
operated while the yellow light is glowing, however, engine
performance may be restricted. Contact Maintenance if this
indicator comes on.
Air Cleaner Restriction Indicator - Glows red when the air

flowing through the filters is restricted. Contact Maintenance.
Pump Contamination Indicator - Indicates faults within any

of the six pumps required for equipment operation. Contact
Maintenance if the indicator glows.
Emergency Stop Indicator - This indicator will glow when

any of the engine stop switches, located in either the cab or
pump room, have been turned to EMERG STOP position.
Indicator will go out once the switch/s return to the NORMAL
position.
Ladder Position Indicator - Any time the ladder is down or

partially down the Ladder Position indicator will glow red and
the machine slew will be disabled.
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EX25/36 2.6

OPERATIONS
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RECOGNISE & RESPOND TO HAZARDOUS AND EMERGENCY

SITUATIONS
2.6.1 Fire Check the following at

the beginning of every shift:
All extinguishers are fully

charged
Automatic Fire Suppression

Warning System is working
2.6.2 Fire Suppression System

operates the mobile equipments fire control system.
An indicator panel is mounted in the cab and provides an audible and
visual indication of any fire.
If a fire is detected the, engine will automatically shutdown after 10
seconds.
The panel should be tested daily, as follows:
Check that the green, power ON light, is lit (NORMAL)
Press the ALARM TEST button:
the
red
ALARM
indicator should glow
TEST
after a short alarm verification

delay the red FIRE indication
will flash
the audible alarm will sound
after the time delay period the

engine will shut down
Press the ISOLATE and RESET button twice after the test. To return
the panel to normal.
The ISOLATE button will silence the audible alarm during a test or an
alarm but will not extinguish the alarm FIRE indicator. By pressing the
RESET button during a test or an alarm the 10 seconds delay will start
again.
A fault condition can occur if the battery voltage drops
below the required supply voltage
NOTE
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Auxiliary Fire System Attachment (Deluge System)

Additional foam/water can be supplied to
the system through the attachment of a fire
hose to the mobile equipment that is
connected to the fire/rescue unit.
Fire Suppression System Operating
Procedure
In the event of a fire, fire suppression system will actuate automatically if
the fire is in the protected area. The fire suppression system can be
manually operated as follows:
Park the excavator
Stop
the
engine
(to
minimise the addition of
fuel)
Remove the safety pin

from the remote actuator
Strike the knob firmly
Evacuate the area and take

a hand held fire extinguisher with you if possible.
Call for help and stand watch over the excavator until help arrives.
(Even though the fire may be out, re-ignition could occur)
NOTE
i. Leaving the engine running may add fuel to the fire

or restart the fire
ii. React quickly so that the fire is caught before it
gets too large.
iii. Leave the immediate area to reduce the risk of
being burnt by wind-blown flames or explosions
iv. Someone should observe the excavator, at a safe
distance, until the danger of re-ignition has
passed.
v. After a fire the excavator should be serviced and
cleaned the fire investigated and the fire
suppression system recharged.
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2.6.3

OPERATIONS
training
Fire Emergency Procedure
Park the unit
Shut down engine
Call Emergency, emergency, emergency, fire (give your unit number

and location) on the two way radio (as per emergency procedure)
Fight the fire, using the fire extinguishers on your equipment (usually
located inside the cab, outside the cab and on the access stairs)
NOTE
Fight the fire by aiming the fire extinguisher at the base

of the fire.
You should only fight fires if you are not in any

personal danger.
WARNING
2.6.4
Emergency Evacuation
NOTE
The emergency exit instructions are applied as decals

to the left window, located near the front side on left
console.
If the operators cab door doesnt open in an emergency, escape in the

following methods:
Emergency Exit Decal
Open the left window

Escape through the window
If the left window is difficult to open
Locate the Emergency Evacuation Tool

Break the left window glass
Escape through the broken window.
Emergency Evacuation Tool
Wear safety glasses before breaking the window glass.

WARNING
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2.6.5

OPERATIONS
training
Emergency Escape Device

The Emergency Escape Device is provided in a case located outside, on
the left of the cab. To use the (EED):
Unlock the latch on the case
Open the cover
Hang the hook onto the cab upper-left surface hanger
Drop the rope wound reel
Fasten the life belt around your chest
Hold the two ropes; and
Climb over the fence
Face towards the cab (as long as you hold the two ropes the
emergency escape device will not operate.)
Release the ropes (you should commence to descend slowly)
Push against the excavator (gently) to prevent your

body from turning
When you reach the ground:
Remove the life belt; and
Evacuate to a safe place
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2.6.6 Accidents All accidents, incidents and near hits must be reported.
If you are involved in an accident, make an emergency call and stay with
your equipment until your supervisor reaches you.
The accident will be investigated by an open cut examiner, your
supervisor and the safety department.
NOTE
Your co-operation is essential in identifying causes

and to help in preventing a similar accident
happening again.
Near miss/Hazard Reports are particularly important as they indicate

potential accidents. (The only real difference between an accident and
an incident/near miss is the result, in an accident someone is injured
and/or equipment damaged, in an incident/near miss the causes may
be the same as an accident but there is no obvious loss i.e.
injury/damage)
(Refer to the Health and Safety Department or your site induction

booklet for details of Reports and reporting).
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2.6.7

OPERATIONS
training
Wet Conditions may be environmental (e.g. rain) or man-made (e.g.

water truck)
WARNING
Due to their low ground pressure, trucks are usually

unpredictable in wet conditions
Allowances need to be made for the safe positioning
of trucks in wet conditions
Manufacturers have a Permissable Water depth (PWD) for equipment

operation (Check the Manufacturers Manual). The PWD for the
EX2500/EX3600 is just below the upper surface of the top rollers (1500
mm) to avoid water entering into any oil reservoirs.
2.6.8
Boggy Conditions it is possible to get bogged in muddy conditions. If

you think the excavator is becoming bogged down avoid spinning the
tracks (this will only make the situation worse).
You may be able to gain traction by using the bucket to help pull the
machine from the bog.
Although it may be embarrassing call for assistance BEFORE you get in
too deep.
2.6.9
Inclines can often be very dangerous for heavy mobile equipment.
Avoid sideways operation on inclines. Excavators

can easily tip under these circumstances.
WARNING
As you descend, avoid engine overspeed.
Always carry the load forward up an incline.

WARNING
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training
Factors that will affect the type (grade) of incline you should attempt
include:
Condition of the ground
Direction of travel
When ascending an incline:

Maintain high engine revolutions
Extend the bucket forward
Carry the bucket low to the ground
If the slope is too steep, the excavator may develop a jerky, bucking
motion, that can turn into a slide.
If the excavator begins to slip sideways, turn into the downgrade as
quickly as possible.
If the engine stalls while working or travelling on an incline, lower the
bucket immediately and stop the excavator. Restart the engine.
2.6.10
Rough Conditions You should always keep work areas as level as

possible. This will provide you with:
A surface easier to operate over
Less fatigue for you and the truck operators
Less damage to the excavator and/or trucks
To maintain a smooth surface, clean any spillage from the floor after
each truck where possible or contact grader/dozer to assist
WARNING
Avoid excessive spinning/screwing of the tracks.

Spinning can cause ruts that may possibly tip or
other equipment
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2.6.11
training
Light Vehicle Interaction Although you are seated high off the ground
on an excavator your vision is restricted because of blind spots.
While it is the responsibility of drivers of light vehicles to ensure their
own ..safety, you also have a responsibility to ensure the safety of
yourself and others.
Operators of a light vehicle are required to ask your permission before
parking within 30 metres of your excavator. (Refer to Mine Traffic Rules)
Always sound your horn:
Once (1)
Pause 5 seconds: Before starting
WARNING
2.6.12
Twice(2)
Pause 5 seconds:
Before moving forward
Three times (3)

Pause 5 seconds:
Before reversing
Heavy Equipment Interaction Normal traffic conventions governing

right of way apply at CQMPL as prescribed in the Transport Operations
(Road Use Management) Act.
For details refer to the Mine Traffic Rules issued at your site induction.
2.6.13
Overhead Obstructions All mobile equipment must maintain a safe

working distance of at least three (3) metres vertical and six (6) meters
horizontal from any power lines (Refer to SOP FMP002).
If power line contact occurs:
Stay where you are
Keep everyone away
Do not allow anyone to touch the crane or load
Move the crane off the wire if possible
If you have to get out, JUMP dont step down
WARNING
It is not necessary for mobile plant to touch a power line

or power source to become electrified. Electricity can
jump or arc across to the plants structure or load.
Stay away from mobile plant if it working close to power
lines. The plant may become electrified and deadly.
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2.6.14 Faulted High Walls You must assess

the risk under any faulted high walls
because each situation will be different.
As a general rule follow the precautions
below:
Maintain a safe distance from the

fault and the wall itself
Dont park under a fault (e.g.

changeover)
Dont drive underneath a fault they

can collapse at anytime
Assess the risk constantly (e.g. falling overburden)
Warn others of any danger
If you are working on the top of a

faulted high wall you must carry out a
visual inspection for any faults (or
developing faults along the edge).
If there is any evidence of faulting (e.g.
cracks along the wall edge) contact
your supervisor and/or the Open Cut
Examiner (OCE).
If faulting has been marked out (e.g.
witches hats and/or stakes), seek
advice on safe operation.
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2.6.15
training
Dangerous Fluids - You may be exposed to dangerous fluids

particularly when equipment is at operational temperature e.g.:
Oil (engine, transmission, hydraulic)
Coolant (radiator)
Battery Acid
Be sure to wear/use the appropriate Personal Protective Equipment

(PPE) when checking fluids e.g.
2.6.16
Mask/goggles
Gloves
Protective clothing
Slippery steps and handrails operators still fall off

equipment when mounting or dismounting. Slippery
steps and handrails are dangerous and difficult to
avoid in some circumstances. When you have to
mount or dismount equipment:
Always face the equipment
Climb all the way to the ground (dont jump!)
Use the three point technique by ensuring that

three of your four limbs are in contact with the
equipment at all times. (i.e. two feet or one hand
or two hands and one foot). This technique
provides you with support and reduces the risk of
falling if you do slip.
Three Point Access
2.6.17 Stopping Engine for Electrical Malfunction
Turn the engine start switches to OFF
If the engines do not stop:
Depress the emergency stop button at the rear steps
NOTE
DO NOT operate the excavator until checked by

maintenance.
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CT 2.7

OPERATIONS
training
COMPLETE WORK TO PLANNED OUTCOMES

Conduct
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OPERATIONS
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RELOCATE EXCAVATOR
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Element 1027.3
Relocate Excavator
1027.3.1
Receive and confirm, route and location plan if necessary by site

inspection.
1027.3.2
Complete and/or follow ground preparation including pads, roads and

ramp according to site requirements.
1027.3.3
Resolve coordination
personnel.
1027.3.4
Relocate excavator in accordance with manufacturers and/or site

requirements.
CT 3.1
RECEIVE & CONFIRM ROUTE & LOCATION PLAN

issues,
including
support
equipment
and
Routes are determined by supervisors and/or operators. To do this

they may utilise survey maps, production plans and planning meetings
to identify the best possible path.
Excavator operators may be required to check out the proposed route
and alert the supervisor to any concerns that they may have including:
Hazards/risks
Obstacles that may create problems when preparing or moving the

excavator
Environmental issues
The excavator operator should be prepared to offer any solutions they

may have to overcome their concerns.
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EX25/36 3.2
training
COMPLETE AND/OR FOLLOW GROUND PREPARATION
3.2.1 The excavator needs to be level when working to provide the operator
with a base that allows the tub to swing freely from the pick up area to
the loading area without needing to adjust the height of the bucket up
or down.
There are a few ground rules to observe when constructing a work
pad/area for the excavator:
Assess the area check the area from the excavator and from
ground level, on foot
Identify hazards when you locate any hazards carry out a risk
assessment and agree on corrective actions
Cleared - of mud/rubbish and backfilled with good, dry soil

(particularly in low areas). Leaving mud underneath dry soil fill will
cause the excavator to tip and create imbalance, this can cause
mechanical wear issues and in extreme cases cause the excavator
to tip on its side.
Do not bury mud under any circumstances

NOTE
Level - if necessary
using a grader for the
final finish
Flat - to provide access

to the material being
shifted as quickly as
possible
Free of Rocks, Stumps

and Bulldust any
bulldust must be graded off before operating the excavator.
Bulldust will cause the excavator to dry bog
Watered to reduce dust and increase visibility
WARNING
CT 3.3
Too much water is dangerous (and wasteful) and may

cause the excavator to slide, sink or bog
RESOLVE CO-ORDINATION ISSUES, SUPPORT EQUIPMENT &

PERSONNEL
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EX25/36 3.4

OPERATIONS
training
RELOCATE EXCAVATOR
3.3.1 Before you begin to tram the excavator, you must determine the
direction that the tracks are facing.
FRONT
The travel motors are designed to be at the rear of the track assembly
during forward travel, so that when you press down on the front of the
travel pedals, the excavator will move forward.
When travelling, select a route that is as flat as possible and allows
maximum travel distance without turns. When turning, make small
incremental changes in direction rather than sharp turns.
Conduct
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OPERATOR MAINTENANCE
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OPERATIONS
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Element 1027.4
Operator Maintenance
1027.4.1
Carry out excavator/shovel inspections and fault finding in accordance

with the manufacturers instructions and site requirements.
1027.4.2
Carry out routine operational servicing, lubrication and housekeeping

tasks in accordance with manufacturers instructions and site authorised
procedures and practices.
1027.4.3
Carry out minor maintenance to manufacturers instructions and site

requirements.
1027.4.4
Provide operator support during preparation for, and conduct of, major
maintenance tasks in accordance with site requirements.
1027.4.5
Process records in accordance with site requirements.
EX25/36 4.1
CARRY OUT INSPECTIONS & FAULT FINDING
4.1.1 Excavator Inspections

It is the operators responsibility
to carry out Pre-operational
Checks and In Operational
Checks on the Excavator prior
to
operation
(Refer
to
checklists at front of 2.2 Carry
Out Pre-Start, Start-Up, ParkUp & Shutdown Procedures)
Any faults wear or damage
should be reported to your
Supervisor or Maintenance. A
Work
Request
Form
is
available for this purpose. Safe
operation issues should be
reported immediately.
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EX25/36 4.2
4.2.1

OPERATIONS
training
CARRY OUT ROUTINE OPERATIONAL SERVICING, LUBRICATION,

MAINTENANCE & HOUSEKEEPING
Running Checks
Running repairs to minor components and attention to defects

prevent the condition becoming worse
Running Checks involve the ongoing checks of:
Fluid levels
Control and switch functions
Instrumentation monitoring
Audible changes that indicate malfunctions
Daily Servicing
Daily servicing involves the replenishing of lubricants and/or filters to
ensure long-term mechanical operation. Servicing / refuelling may be
carried out in the field by the Service Truck, or in the Lube Bay.
When you take the excavator in for a daily service to the Lube Bay,
the following procedure must be observed:
Proceed to the lube bay
Stop before entering
Select low idle
Enter the service bay slowly
Position the excavator so that the fuel,oil and grease hoses can
reach the fast-fill compartment
Park according to the park-up prodedures
Apply the park brake
Lower the bucket
Set the Pilot Control Shut Off lever to LOCK
NOTE
When the bucket needs to be in the raised position

they must be securely supported by blocks.
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Shutdown the engines using the correct procedure (Refer to 2.2

Carry Out Pre-Start, Start-Up, Park-Up & Shutdown Procedures)
Top up fluid levels as necessary (refer to the pre-start check-list)
Top up oil, fuel and grease levels
Disconnect all hoses when servicing is finished
Restart the engine using the correct procedure (Refer to 2.2 Carry
Out Pre-Start, Start-Up, Park-Up & Shutdown Procedures)
Give two blasts on the horn and wait 5 seconds, (to warn
personnel that you are about to move out of the lube bay)
Preventative maintenance
Preventative maintenance involves the inspection of components by
analysis and oil sampling. This provides the ability to forecast the life of
that component.
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EX25/36 4.3
CARRY OUT MINOR MAINTENANCE
4.3.1
training
Maintenance items are carried out by the Maintenance Department

either in the field, on call out or, in the workshop. It is the responsibility of
the operator to contact and report any maintenance repair needs at the
beginning, during and at the conclusion of the shift.
If fuses are frequently blown or if there are traces of
short circuit on the electrical wiring, contact
maintenance to carry out repair.
WARNING
Accumulation of flammable material (dead leaves,

twigs, grass, etc.) around the battery may cause fire,
so always check and remove such material.
Keep the top surface of the battery clean and' check
the breather hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap to clear the
breather hole.
Operators are only to carry out minor maintenance

when authorised to do so.
WARNING
4.3.2
Replace bucket teeth

Teeth on the bucket have to be replaced to maintain efficiency. The
process is as follows:
WARNING
i)
ii)
iii)
Refer to SOP, WP and/or WI

Use Personal Protective Equipment
Ensure the tools you use are safe and in good
condition
Locate new set of teeth (warehouse)
Locate tools equipment eg:

-
hammer
drift (short and long)
screw driver
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Lower the bucket to the ground with the teeth at an angle suitable
for the crew to swing the hammer at knee height and hit the drift to
punch out the pins holding the teeth
Punch out the pins using a short drift to start the pin moving and
then a longer drift to complete the task
Strike the teeth on the flat face with the hammer to release them
from the adaptor
DO NOT strike the teeth on the sharp edge with the

hammer
WARNING
Clean the surface of the adaptor
Rest the snap rings in place
Slide the new tooth over the adaptor
Hammer the pins home
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4.3.3

OPERATIONS
training
Reporting Defects and Hazards

A prime step in good maintenance is the prompt reporting of equipment
defects. Defects that can be noted and repaired will lead to a safer and
more efficient work environment.
Report to Maintenance:
Verbally, to your supervisor or maintenance
By Work Request
TAGGING (Out of Service, Information, Danger)
To work safely means being able to manage hazards and not allow
hazards to generate incidents.
Until a hazard is eliminated it is essential that all operators are aware of
the accident potential associated with the hazard. Near Miss/Hazard
Reports must be completed if you identify a hazard in the workplace or
on the unit.
Equipment inspection and reporting of defects and hazards is an
operator's responsibility.
Near Miss/Hazard reports must be lodged with your Supervisor.
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EX25/36 4.4

OPERATIONS
training
PROVIDE SUPPORT FOR PREPARATION & CONDUCT OF MAJOR

MAINTENANCE
4.4.1 There will be the occasion where maintenance technicians will need
assistance to locate and/or repair a fault or maintenance item. The
operator is ofte n the best person to assist.
In the case of a major repair or maintenance the operator may be called
upon to help to carry out housekeeping and cleanup of the Excavator
and operate the Excavator in particular environments (e.g. for
troubleshooting)
CT 4.5
PROCESS MAINTENANCE RECORDS

Conduct
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training

HITACHI EX2500 & EX3600

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

NOTE TO LEARNERS, FACILITATORS & ASSESSORS

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

DOCUMENT CONTROL SHEET

Hitachi EX2500/EX3600 Excavator

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

Start of shift walk around inspection using a provided check list

Start up, park-up and shut-down

Work with/in mobile plant and equipment teams; and

Direct trucks into position

Conduct loading operations including:

Carry out loading:

- over the side

Recognise and dealing with particular hazards associated with the

Carry out operational servicing, lubrication and housekeeping

Provide support for major maintenance

Process records and reports

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

Hitachi EX2500/EX3600 Excavator

Competency Elements & Performance Criteria - Flow Chart

Element 1027.2 OPERATE HYDRAULIC SHOVEL/EXCAVATOR

Resolve Coordination Activities with Others (Refer Mining Department

Walk-around Inspection Checklist

EX25/36 2.3 Select Loading Method for Excavator

2.3 & 2.4 are reversed in the

EX25/36 2.4 Conduct, Control and Monitor Dig Procedures

EX25/36 2.5 Act on or Report Monitoring Systems & Alarms

EX25/36 2.6 Recognise & Respond to Hazardous & Emergency Situations

Complete Work to Planned Outcomes (Refer Mining Department Area

Element 1027.3 RELOCATE EXCAVATOR

EX25/36 3.2 Complete and/or Follow Ground Preparation

Resolve Co-ordination Issues, Support Equipment & Personnel (Refer

EX25/36 3.4 Relocate Excavator

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

Hitachi EX2500/EX3600 Excavator

Element 1027.4 CARRY OUT OPERATOR MAINTENANCE

EX25/36 4.3 Carry Out Minor Maintenance

EX25/36 4.4 Provide Support for Major Maintenance

Process Maintenance Records (Refer Mining Department Area Specific

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR OPERATIONS

HITACHI EX2500/EX3600 EXCAVATOR

PLAN & PREPARE FOR

Carry out Routine Operational

Carry out Minor Maintenance

2.3 & 2.4 are reversed

WHITE sections coded CT

GREEN sections coded :

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

PLAN & PREPARE FOR OPERATIONS

Curragh Queensland Mining Pty Ltd is part of

MNCO1027A CONDUCT HYDRAULIC SHOVEL /EXCAVATOR

MNCO1027A Conduct Hydraulic Shovel/Excavator Operations