truck and loader dictionary

Truck andLoaderDictionary

Second Edition2013

Truck & Loader DictionaryPwC – Mining Intelligence and Benchmarking

Truck and LoaderDictionary

Second Edition2013

PwC Mining IntelligenceBenchmarking

T: +61 7 3257 5000Email: [email protected]

Truck and Loader

Mining Intelligence and




Published byPricewaterhouseCoopers, ABN 52 780 433 757Riverside Centre, 123 Eagle Street, BRISBANE QLD 4000, GPO Box 150,BRISBANE QLD 4001T: +61 7 3257 5000, F: +61 7 3257 5999, www.pwc.com.au

Liability limited by a scheme approved under Professional StandardsLegislation.

Copies available from publisherAdvertising enquiries refer to the publisher


PricewaterhouseCoopers, ABN 52 780 433 757, 123 Eagle Street, BRISBANE QLD 4000, GPO Box 150,

T: +61 7 3257 5000, F: +61 7 3257 5999, www.pwc.com.au

Liability limited by a scheme approved under Professional Standards

g enquiries refer to the publisher


Truck and LoaderDictionary

Second Edition2013

The First Edition of this Truck and Loader dictionary was started in 2010and first released in 2012. Many hours were spent sourcing photos andwriting information. It has proved to be very popular and was universallyrecognized as being a tremendous resource for anyone working in anycapacity in Truck and Loader operations.number of new people working in and around Truck and Loaderoperations not being familiar with the terminology and jargon.includes operators, supervisors, maintenance personnel, engineers,managers, contractors and consultants.

Special recognition is given for contribution of content to Jan EikeSapper, Trevor Trott, Graham Lumley and Mark Lewis for making thisdictionary possible.

There will always be variations in terminology across sites and it would beimpossible to capture all of these. We do however continue to encourageyour input. If there is something not includedsend us details and if possible [email protected]. Wherever we use information and/orphotos provided by people outside PwCentry is printed in future editions. Our aim is to produce the third Editionin 2015.

PwC's Mining Intelligence and Benchmarking is a PwC serviceoffering.

In September 2013 PwC acquired the GBI Mining Intelligencebusiness. This is core to PwC’s consulting bprovides mining clients with asset benchmarking, productivityand analytics services.

PwC’s Mining Intelligence and Benchmarking service offeringsare appended to the end of this publication.


Truck and Loader

The First Edition of this Truck and Loader dictionary was started in 2010Many hours were spent sourcing photos andproved to be very popular and was universally

recognized as being a tremendous resource for anyone working in anycapacity in Truck and Loader operations. We were motivated by thenumber of new people working in and around Truck and Loader

being familiar with the terminology and jargon. Thisincludes operators, supervisors, maintenance personnel, engineers,managers, contractors and consultants.

Special recognition is given for contribution of content to Jan Eikem Lumley and Mark Lewis for making this

There will always be variations in terminology across sites and it would beWe do however continue to encourage

If there is something not included in this dictionary pleasesend us details and if possible photos. Send to

Wherever we use information and/orPwC we will acknowledge this if theOur aim is to produce the third Edition

PwC's Mining Intelligence and Benchmarking is a PwC service

In September 2013 PwC acquired the GBI Mining Intelligencebusiness. This is core to PwC’s consulting business whichprovides mining clients with asset benchmarking, productivity

PwC’s Mining Intelligence and Benchmarking service offeringsare appended to the end of this publication.


This is an electronic copy of the publication.will continue to produce this as an electronic


of the publication. Like the Cat Handbook® weelectronic copy as an ongoing resource.


Contents

2 Way Radio – A Communication System ................................

3D Dig – Mine Planning Software................................

10/10/20 Rule................................................................

Access Ramp – Truck Entrance and Exit Road

Access Stairs – Stairway for entry onto the equipment

Adverse Conditions – Dusty, Wet, Inclement or poor visibility

Alternator – Converts Mechanical Energy to Electrical Energy

Ancillary Equipment – Equipment that is Associated with the Operation

ANSUL Automatic Fire Suppression – Extinguisher System

ANSUL Automatic Fire Suppression Emergency Switch

Air Filter – Filters Air for the Engine ................................

Air Horns – Signal Horns ................................

Backhoe ................................................................

Bail less attachment – Connects the hoist ropes to the dipper(bucket) on a ropeshovel ................................................................

Bail-less Connection at Rear of Dipper ................................

Bail Arm (or just Bail) – Connects the hoist ropes to the dipper (bucket)

Batter – The Slope of the High or Low Wall

Batter Cleaning – Cleaning of a highwall batter

Battery – Electric Energy Storage ................................

BCM/BCY – Bank Cubic Metre/Yard................................

Bench – A Levelled Area where Mining Equipment Operates

Bench Width................................................................

The Bench Grade – Grade of bench ................................

Example of working on a grade ................................

The Bench Height – Height of bench ................................

Benchmark Loading Unit – A Measure of Performance and Productivity

Benchmark for Truck Fleets – A measure of P

BER – Bucket Efficiency Ratio ................................

Berm – A Bund or mound of Material Placed near the Edges of an Excavat

BEST Practice – The Average of the Top 10% of Equipment in the PwC MiningProduction and Time Utilisation Database

The PwC database................................................................

Blasting – Controlled Firing of Explosives to Break Rock

Blast patterns – Designed to provide the correct broken rock s

Blind Spot – Areas where operator’s or driver’s visibility is blocked

Bogged equipment – Stuck................................

Boom point sheaves – The Pulleys that Guide the Hoist Ropes round the Top Endof the Boom................................................................

Bottom Loading – Truck Positioning ................................

Boom Jacking – Rope Shovel ................................


................................................................................. 1

..............................................................................................2

.............................................................................................3

Truck Entrance and Exit Road ......................................................................... 5

Stairway for entry onto the equipment ............................................................6

Dusty, Wet, Inclement or poor visibility ............................................... 7

Converts Mechanical Energy to Electrical Energy............................................... 7

Equipment that is Associated with the Operation...............................8

Extinguisher System....................................................9

ANSUL Automatic Fire Suppression Emergency Switch – Extinguisher System ....................9

....................................................................................... 10

......................................................................................................... 10

......................................................................................................11

Connects the hoist ropes to the dipper(bucket) on a rope.....................................................................................................11

.....................................................................................11

Connects the hoist ropes to the dipper (bucket) ............................. 12

The Slope of the High or Low Wall ............................................................................ 13

Cleaning of a highwall batter ...................................................................... 14

............................................................................................ 14

....................................................................................... 15

A Levelled Area where Mining Equipment Operates ............................................... 15

.............................................................................................. 16

..........................................................................................17

.................................................................................................17

....................................................................................... 18

A Measure of Performance and Productivity ............................. 19

A measure of Performance and Productivity .........................23

.................................................................................................28

A Bund or mound of Material Placed near the Edges of an Excavat ion ....................29

The Average of the Top 10% of Equipment in the PwC MiningProduction and Time Utilisation Database..........................................................................30

..................................................................................... 31

Controlled Firing of Explosives to Break Rock......................................................32

Designed to provide the correct broken rock size or break up coal .............32

Areas where operator’s or driver’s visibility is blocked ......................................33

.......................................................................................................34

The Pulleys that Guide the Hoist Ropes round the Top End...........................................................................................34

.......................................................................................35

...................................................................................................35


Bottom Loading @90° - Truck Positioning................................

Bottom Loading @45° – Over the Tail ................................

Box Cut – The initial excavation that is dug when opening up a new pit

Brakes................................................................

Brake Oil reservoir & Level indicator – Indicates oil level

Bucket – Loading/digging device ................................

Bucket Spotting Time – Digging ................................

Bucket Tooth – Cutting Tip that is pinned to the Adaptor

Bund/Rill/Berm – See Windrow................................

Cab - Operators Cabin ................................................................

Refer to Operators Cab in the Dictionary................................

Cable Access - Roadway for Cable ................................

Cable Crossing – Portable Power Cable Protection Equipment

Cable Layout – Storing excess cable ................................

Cable Plug Stands – Keeps Cable Plugs off the Ground

Cable – Power Lead that delivers Power to a Rope Shovel

Cable Reel Cable storage directly attached to some Electric Rope Shovels

Cable Towers - Cable trees................................

Capital Cost ................................................................

Carry Back – Material stuck in truck trays ................................

CAT 777 – Dump Truck ................................

CAT 785 – Dump Truck................................

CAT 789 – Dump Truck................................

CAT 793 – Dump Truck................................

CAT 795 – Dump Truck ................................

CAT 797 – Dump Truck ................................

CAT 992 – Front End Loader ................................

CAT 993K – Front End Loader ................................

CAT 994 – Front End Loader ................................

CAT5130B – Hydraulic Shovel/Excavator ................................

CAT5230B – Hydraulic Shovel/Excavator ................................

CAT6015 (RH40E) – Hydraulic Shovel/Excavator

CAT6030 (RH120E) – Hydraulic Shovel/Excavator

CAT6040 (RH170B) – Hydraulic Shovel/Excavator

CAT6050 (RH200) – Hydraulic Shovel/Excavator

CAT6060 (RH340B) – Hydraulic Shovel/Excavator

CAT6090 (RH400) – Hydraulic Shovel/Excavator

CAT (Unit Rig) MT3000 – Dump Truck................................

CAT (Unit Rig) MT3300 - Dump Truck ................................

CAT (Unit Rig) MT3600 - Dump Truck ................................

CAT (Unit Rig) MT3700 – Dump Truck ................................



..............................................................................36

.....................................................................................36

The initial excavation that is dug when opening up a new pit ............................... 37

........................................................................................................38

Indicates oil level ......................................................39

.............................................................................................40

.............................................................................................. 41

Cutting Tip that is pinned to the Adaptor ..................................................... 41

..............................................................................................42

..............................................................................42

.................................................................................42

............................................................................................43

Portable Power Cable Protection Equipment .............................................44

........................................................................................45

Keeps Cable Plugs off the Ground .........................................................46

Power Lead that delivers Power to a Rope Shovel .................................................... 47

Cable Reel Cable storage directly attached to some Electric Rope Shovels ............................48

........................................................................................................49

...............................................................................................49

..............................................................................50

............................................................................................................ 51

............................................................................................................52

............................................................................................................53

............................................................................................................54

............................................................................................................ 55

............................................................................................................56

................................................................................................... 57

................................................................................................58

...................................................................................................59

...............................................................................60

.............................................................................. 61

Hydraulic Shovel/Excavator .................................................................62

Hydraulic Shovel/Excavator...............................................................63

Hydraulic Shovel/Excavator ...............................................................64

lic Shovel/Excavator ................................................................65

Hydraulic Shovel/Excavator ..............................................................66

Hydraulic Shovel/Excavator ................................................................ 67

..................................................................................68

...................................................................................69

...................................................................................70

...................................................................................71

.................................................................................. 72



CAT (Unit Rig) MT5500 – Dump Truck ................................


CCTV – Machine cameras ................................

Circuit Control ................................................................

Clean-up Outside Swing Radius – Spillage ................................

Clean-up Inside Swing Radius – Spillage ................................

Climbing Up Work Benches – Procedure ................................

Controls – All Machines ................................

CPP/ CHPP – Coal (handling) preparation plant

Coal - A Fossil Fuel consisting of Carbonised Vegetable Matter.

Coal Edge – The Extent of the Exposed Coal on the Low Wall Side

Coal floor clean-up – Minimises coal contamination with unwanted spoil

Coal Mining – Digging, Loading and Transporting the Coal

Coal Recovery Measurement Trenches – Comparing geological predictions andactual coal seam thickness................................

Coal Reject Silo/ Bin – Storage area of unwanted wash plant material for removalby dump truck................................................................

Collision Avoidance – Minimum distance to be maintained between equipment

Collision Avoidance driving – Minimum distance between equipment

Compressed Air Tank – Holds the Supply of Compressed Air

Cooling fan motor – Electric motor cooling

Counterweight – Balance................................

Crowd – Force applied to load ................................

Cycle efficiency – Optimal cycle time efficiency

Cycle time (truck) – Time to complete a full cycle

Cycle time (loading unit) – Load time from truck to truck

Defect Reporting – Reporting of defects on machinery

Delay – Maintenance Delay Scheduled ................................

Delay – Maintenance Delay Unscheduled ................................

Delay – Standby................................................................

Demag H285 – Hydraulic Shovel................................

H285 Demag Hydraulic Shovel ................................

DER – Dipper Efficiency Ratio................................

Dig Face – Digging area................................

Dig Plan – How the pit will be dug................................

Dig Techniques (Sequence) – Common techniques

Diggability – Fragmentation analysis ................................

Dip – Slope of the Coal Seam ................................

Dilution – Contamination in a mineable seam.

Dipper – Rope Shovel Bucket ................................

Dipper Crowd – Electric rope shovel arm ................................


.................................................................................. 73

.................................................................................. 74

.................................................................................. 75

........................................................................................................ 76

.......................................................................................... 76

.............................................................................. 77

................................................................................78

................................................................................ 79

.......................................................................................................... 80

Coal (handling) preparation plant .................................................................... 81

consisting of Carbonised Vegetable Matter. ........................................... 81

The Extent of the Exposed Coal on the Low Wall Side .......................................82

Minimises coal contamination with unwanted spoil ...........................83

Digging, Loading and Transporting the Coal ..................................................84

Comparing geological predictions and....................................................................................................85

Storage area of unwanted wash plant material for removal.......................................................................................85

Minimum distance to be maintained between equipment .................86

Minimum distance between equipment .................................86

Holds the Supply of Compressed Air...............................................88

Electric motor cooling ............................................................................89

..........................................................................................................89

.................................................................................................90

ciency ......................................................................90

Time to complete a full cycle.................................................................. 91

Load time from truck to truck ..................................................... 91

Reporting of defects on machinery .........................................................92

....................................................................................93

...............................................................................93

........................................................................................95

.............................................................................................96

................................................................................................96

.................................................................................................96

............................................................................................................ 97

........................................................................................... 97

Common techniques ................................................................98

......................................................................................99

.................................................................................................100

Contamination in a mineable seam. ......................................................................101

................................................................................................. 102

.............................................................................. 103


Dipper Door – Rope Shovel Bucket Door ................................

Dipper Door Hinges – Dipper door pivots to open and close

Dipper Door locking mechanism – Rope Shovel Bucket Door Lock

Dipper Depth ................................................................

Dipper Height/width ................................................................

Distance from face ................................................................

Double benching – Loading technique ................................

Double Sided Loading – Loading with trucks either side

Downtime – Delay ................................................................

Dozer – A Tracked or Rubber Tyred Machine

Drill Rig – Device for drilling blast holes ................................

Drill and Blast Areas – Area prepared for blasting

Drive-by Loading – Sequence ................................

Drive-by observation on crest – Checking condition of tip head

Dump Area Maintenance – Keeping dumping area in good condition

Dump Area Sequence – Dump area strategy

Dump Site Maintenance ................................

Dumping – Unloading material ................................

Dumping Phase................................................................

Dump – Placing of waste into spoil piles ................................

Dust – Control of dust ................................................................

Electronic Monitoring System – EMS................................

Elephant Skid – Highwall Power Cable Protection Equipment

Emergency Steering Switch – Activates emergency steering pump

Emergency Stop – Excavator/Shovel ................................

Emergency Stop – Truck ................................

Engine Block – Engine ................................

Equivalent Annual Production ................................

Esco – Bucket and GET Manufacturer................................

Excavator – Controls ................................................................

N (Neutral): The machine stops ................................

Excavator – Loading unit ................................

Excavator – Schematic ................................

Excavator Boom – Boom attachment ................................

Excavator Bucket – Bucket attachment ................................

Excavator – Lock Lever ................................

Excavator Stick – Attachment ................................

Excavator Undercarriage – Walking mechanism

Exhaust Pipes – Exhaust outlet ................................

Face Maintenance/Clean-up – Floor clean up

Face Height – Optimal height ................................

Face Shovel................................................................


.............................................................................. 104

Dipper door pivots to open and close ............................................... 105

ope Shovel Bucket Door Lock..................................... 105

.......................................................................................... 106

.............................................................................. 106

.................................................................................. 107

..................................................................................108

Loading with trucks either side ..................................................... 109

...................................................................................110

A Tracked or Rubber Tyred Machine ........................................................................ 111

................................................................................112

Area prepared for blasting................................................................113

.................................................................................................114

Checking condition of tip head ...........................................115

Keeping dumping area in good condition .................................115

Dump area strategy ..........................................................................116

..........................................................................................................116

.............................................................................................. 117

........................................................................................ 117

................................................................................118

.............................................................................119

.....................................................................................119

Highwall Power Cable Protection Equipment ............................................ 120

Activates emergency steering pump ..................................... 120

......................................................................................121

.........................................................................................................121

........................................................................................................... 122

............................................................................................... 123

................................................................................... 124

.............................................................................. 125

............................................................................................. 125

....................................................................................................... 125

........................................................................................................... 126

.................................................................................... 126

................................................................................. 127

.......................................................................................................... 127

................................................................................................ 128

Walking mechanism .................................................................. 129

.............................................................................................. 130

Floor clean up....................................................................... 130

.................................................................................................131

.............................................................................................. 132


Face Width ................................................................

Failure – Unstable Wall or parts of it ................................

Fatigue................................................................

Fatigue Incident................................................................

Fault – A Fracture Zone in the Overburden

Fill................................................................................................

Fitness for work ................................................................

Fire suppression and emergency shut down

Fire Suppression Bottle – Storage container for fire suppressant

Float – Lowbed/Flatbed/Transporter................................

Fragmentation – How well the material is shot

Free Dumping – Block Tipping ................................

Freeboard ................................................................

Front End Loader – (FEL)................................

Front End Loader – Controls ................................

Below is an example of the controls. ................................

Front End Loader – Filling cycle ................................

Front End Loader – Loading from a stockpile

Front End Loader – Loading technique ................................

Front End Loader – Schematic ................................

Fuel Burn Rate – Rate of fuel burn on the T&L Fleet

Fuel Filter – Filters fuel (Truck)................................

Fuel Tank – Diesel Storage................................

Fuel Tank Sediment Drain Valve – Drain valve

PwC – Worldwide Productivity and Reliability Database

PwC – Productivity Philosophy ................................

Fill the bucket up & do it more often................................

Gear leaver – Trucks................................................................

Geology – The structure of the earth................................

Geotechnical hazards................................................................

Geotechnical failure – Geotechnical interpretation, cracks or previous fail

Geotechnical failure – Crest Failure................................

Geotechnical................................................................

Geotechnical failure – Foundation Failure ................................

G.E.T – Ground Engaging Tools ................................

GPS Antenna – Global Positioning System................................

Gravel – Surface Material for Roadways................................

Grease lines – Carry hydraulic fluid................................

Guide Post – Delineates Roadways ................................

Gyratory Crusher – Rock breaker ................................

Hang time – Wait vs. Queue time ................................

Hard Dumping – Dumping technique ................................


.............................................................................................. 133

..................................................................................... 134

..................................................................................................... 135

...................................................................................... 136

A Fracture Zone in the Overburden .......................................................................... 137

............................................................................ 138

...................................................................................... 138

Fire suppression and emergency shut down.......................................................................... 139

Storage container for fire suppressant ........................................ 139

.................................................................................... 140

How well the material is shot .....................................................................141

.............................................................................................. 142

................................................................................................ 142

...................................................................................................... 143

................................................................................................. 144

...................................................................................... 144

............................................................................................ 145

Loading from a stockpile....................................................................... 146

................................................................................. 147

.............................................................................................. 148

Rate of fuel burn on the T&L Fleet ........................................................... 149

............................................................................................. 150

..................................................................................................... 150

Drain valve .....................................................................151

Worldwide Productivity and Reliability Database .................................................... 152

.............................................................................................. 152

...................................................................................... 152

............................................................................... 153

...................................................................................... 153

.............................................................................. 154

Geotechnical interpretation, cracks or previous failure................... 155

....................................................................................... 156

............................................................................................ 156

............................................................................ 158

............................................................................................ 160

............................................................................ 160

.................................................................................161

........................................................................................161

........................................................................................ 162

.......................................................................................... 162

.......................................................................................... 163

................................................................................... 164


Hauling................................................................

Haul road – Crossfall ................................................................

Haul road – Design................................................................

Haul Road Maintenance – Strategy ................................

Haul road – Superelevation (Camber) ................................

Haul Road Undulation – Soft areas ................................

Hazard – Something which may result in injury or harm

Heel Wear (dipper) – Damage to the heel of a dipper caused by the tooth attackangle ................................................................

High wall – Wall left in undug overburden

High Wall failure – Unstable Wall or parts of it

Historical Data – Information from previous strips

Hitachi EH1600 – Dump Truck ................................



Hitachi EH3500 – Dump Truck................................


Hitachi EH4500 – Dump Truck................................


Hitachi EX1800 – Hydraulic Shovel/Excavator




Hitachi EX3600 - Hydraulic Shovel/Excavator



Hitachi R90 – Dump Truck................................

Hitachi R100 – Dump Truck ................................

Hitachi R120E – Dump Truck................................








Hoist Control Lever – Truck Tray Control ................................

Hoist Cylinder/ram – Raises Tray to Dump Position

Hoist Ropes – Control Vertical Bucket Movements (Rope Shovel)

Host Rock – Waste ................................................................

Hydraulic Drive – Propels the Tracks ................................

Hydraulic Filters – Clean Hydraulic Fluids


.................................................................................................... 165

.............................................................................. 166

................................................................................. 167

....................................................................................... 169

................................................................................... 170

........................................................................................ 171

Something which may result in injury or harm..................................................... 172

Damage to the heel of a dipper caused by the tooth attack.................................................................................................... 172

........................................................................... 173

Unstable Wall or parts of it .................................................................... 174

Information from previous strips............................................................. 174

..............................................................................................175

............................................................................................. 176

.............................................................................................177

............................................................................................. 178

............................................................................................ 179

.............................................................................................180

.............................................................................................181

Hydraulic Shovel/Excavator.................................................................... 182

Hydraulic Shovel/Excavator .................................................................... 183

Hydraulic Shovel/Excavator ................................................................... 184


Hydraulic Shovel/Excavator .................................................................... 186

Hydraulic Shovel/Excavator.................................................................... 187


.................................................................................................... 189

.................................................................................................. 190

.................................................................................................191

.................................................................................................. 192

.................................................................................................. 193

.................................................................................................. 194

.................................................................................................. 195

.................................................................................................. 196

.................................................................................................. 197

.................................................................................................. 198

............................................................................. 199

Raises Tray to Dump Position .......................................................... 200

rol Vertical Bucket Movements (Rope Shovel) ...................................... 201

................................................................................. 201

....................................................................................202

Clean Hydraulic Fluids ...........................................................................202


Hydraulic Face Shovel – Machine................................

Hydraulic Face Shovel – Bucket ................................

Hydraulic Face Shovel – Schematic ................................

Hydraulic Pump – Pressurises Hydraulic Fluid

Hydraulic Tank – Hydraulic Fluid Storage ................................

Idle Time – A stoppage when the operator fails to enter a delay into the monitor

Idler – Undercarriage ................................................................

Inclinometer – Measures angles ................................

Isolation Station – A System to Positively Remove Power

Joy Stick – Steering control................................

Komatsu 630E 685E 730E – Dump Truck ................................

Komatsu 830E-AC – Dump Truck ................................

Komatsu 860E – Dump Truck ................................



Komatsu (Demag) H285 – Hydraulic Shovel/Excavator



Komatsu HD465 – Dump Truck ................................




Komatsu PC1800 – Hydraulic Shovel/Excavator






Komatsu WA800 – Front End Loader ................................



KPI – Key Performance Metrics ................................

Kress Coal Hauler – Unit body coal truck................................

Letourneau L 950 – Front End Loader (Now owned by Joy

Letourneau L 1100 – Front End Loader (Now owned by Joy Global)







Liebherr 994 – Hydraulic Shovel/Excavator


..........................................................................................203

.............................................................................................204

.......................................................................................205

Pressurises Hydraulic Fluid ....................................................................206

............................................................................207

A stoppage when the operator fails to enter a delay into the monitor ..............207

............................................................................ 208

........................................................................................... 208

y Remove Power....................................................209

.................................................................................................... 210

.............................................................................211

......................................................................................... 212

............................................................................................... 213

............................................................................................... 214

............................................................................................... 215

Hydraulic Shovel/Excavator ...................................................... 216



............................................................................................ 219

............................................................................................220

............................................................................................ 221

..........................................................................................222

Hydraulic Shovel/Excavator..................................................................223






...................................................................................229

...................................................................................230

................................................................................. 231

.............................................................................................232

..............................................................................233

Front End Loader (Now owned by Joy Global)....................................234

Front End Loader (Now owned by Joy Global) ..................................235

Front End Loader (Now owned by Joy Global)...................................236

Front End Loader (Now owned by Joy Global) .................................. 237

Front End Loader (Now owned by Joy Global)..................................238



Front End Loader (Now owned by Joy Global) .................................. 241

Hydraulic Shovel/Excavator .........................................................................242








Liebherr KL2420 KL2450 KL2680 – Dump Truck

Liebherr T252 & T262 – Dump Truck ................................

Liebherr T282 – Dump Truck ................................

Liebherr TI 272 & TI274 – Dump Truck ................................

Lighting Plant................................................................

Load Position on Trucks ................................

Loading – Precautions................................................................

Loading Techniques – Sequences ................................

Lockout – Regulations................................................................

Low-Wall Scavenging – Coal recovery ................................

Low Wall – Spoil Side Wall of the Excavation

Lube System – Applies Lubricant ................................

Lubrication Chart – Machine specs ................................

Lubrication controller – Systems ................................

Matching – Truck matching to the shovel ................................

Mine strategy – Basic Strategies ................................

Minerals – Excavation of a Resource ................................

Mining – Excavation of a Resource ................................

Modified Drive-By Loading – Sequence ................................

Mounting and Dismounting – Getting on and off machinery

Near Side Loading – Loading on Driver Side

OEM – Original Equipment Manufacturer................................

Offside Loading – Loading on Blind Side ................................

Oil Sands – Tar Sands................................................................

On-board fires – All equipment ................................

Operator – Obligations and Roll ................................

Operators Cabin – Control Centre of an Excavator

Operating Cost ................................................................

Opportunity Cost ................................................................

Ore Body................................................................

Overextending crowd – Rope Shovel ................................

Overloading – Trucks ................................................................

P&H 2800 XPA – Rope Shovel ................................

P&H 2800 XPA rope shovel ................................

P&H 4100 A– Rope Shovel ................................

P&H 4100 XPB – Rope Shovel ................................




Hydraulic Shovel/Excavator.......................................................................245

Hydraulic Shovel/Excavator .......................................................................246

el/Excavator ......................................................................247

Hydraulic Shovel/Excavator ......................................................................248

Dump Truck...............................................................249

...................................................................................250

................................................................................................ 251

................................................................................252

..........................................................................................253

.........................................................................................................254

............................................................................ 255

..........................................................................................256

............................................................................ 257

................................................................................... 257

Spoil Side Wall of the Excavation .......................................................................258

..........................................................................................259

.......................................................................................259

...........................................................................................260

.............................................................................260

............................................................................................ 261

.....................................................................................262

........................................................................................262

................................................................................263

Getting on and off machinery...............................................264

Loading on Driver Side ........................................................................264

............................................................................265

..............................................................................265

.............................................................................266

.............................................................................................267

............................................................................................268

Control Centre of an Excavator ...............................................................269

........................................................................................269

....................................................................................270

.................................................................................................. 271

.....................................................................................272

............................................................................. 273

..............................................................................................274

...................................................................................................274

..................................................................................................... 275

...............................................................................................276


P&H 4100 XPC – Rope Shovel ................................

Park-up – Go – No Go lines ................................

Park Up Area Guide – Go – No Go line ................................

Parking – Waiting for water truck................................

Payload – The Amount of Material the tray carries to dump

Payload – Optimal load ................................

Payload – Sub-optimal load ................................

Payload Distribution – Truck Tray................................

Payload Indicator Lights – Payload lights ................................

Payload meter – Displays the weight of the loaded material in t

Payload weight display – Displays the weight of the loaded material

Pit Design – Pit planning................................

Pit Shape/Mine Planning Considerations................................

Pit Ramp – Roadway to Access the Pit................................

Pitch Braces – Dipper Tooth Attack Angle Adjuster

Pivot Point/Nip Point – FEL ................................

Plan and Prepare for Operations – Prior to conducting an

PLC – Engine Saver ................................................................

PPE – Personnel Protective Equipment................................

Pre-Shift Briefing /Tool Box Meetings – Safety

Pre-Split Drill Hole Barrel – Drill hole marks on the excavation wall after blasting

Pre-Start – During Shift and End of Shift Checks/Inspections

Pre-Strip – Removal of waste/overburden material

Procurement of buckets/dippers................................

Propelling Up and Down Haul Roads – Operation

Queuing – Waiting position ................................

Radiator – Heat Exchanger ................................

Radiator Header – Storage for cooling liquid

Ramps................................................................

Rated capacity – Designated capacity of buckets

Rehabilitation/Reclamation – Re-establishing the Waste Spoil Heaps to a Stableand Productive Landform................................

Relative Density – RD................................................................

Refer to Specific Gravity in this Dictionary................................

Reliability – How long the Loader/Truck keeps Running

Reject Bin gate opener – Opens Reject bin remotely

Report – To give Information.................................

Retarder – Braking lever ................................

Retard Grid – Cooler ................................................................

Retarder – Non-friction Braking System ................................

Returning Phase – Operational ................................

Right Hand Operators Console – Cab ................................


............................................................................................... 277

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The Amount of Material the tray carries to dump ................................................279

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Displays the weight of the loaded material in the truck ............................284

Displays the weight of the loaded material ..................................285

........................................................................................................286

..............................................................................286

...................................................................................287

Dipper Tooth Attack Angle Adjuster ............................................................ 288

................................................................................................. 288

Prior to conducting any work........................................289

................................................................................289

.................................................................................290

Safety ....................................................................290

Drill hole marks on the excavation wall after blasting ........... 291

During Shift and End of Shift Checks/Inspections ............................................292

Removal of waste/overburden material .............................................................292

............................................................................................293

Operation ...............................................................294

...................................................................................................295

....................................................................................................296

Storage for cooling liquid........................................................................297

......................................................................................................297

Designated capacity of buckets ..................................................................298

establishing the Waste Spoil Heaps to a Stable...................................................................................................299

............................................................................ 300

........................................................................... 300

How long the Loader/Truck keeps Running ................................................... 300

Opens Reject bin remotely ........................................................... 301

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Rill – Prevents truck from unwanted rolling

Rimpull – Force ................................................................

An example of a Rimpull Chart ................................

Rock Ejector – Removes rocks caught between tyres

Roll – Material build up from the digging process

Roll levelling – Levelling bench ................................

Rolling Resistance – Resistance created by the interaction between the trucks tyresand the haulroad................................................................

ROM Area – Run-of-Mine ................................

ROM Stockpile – Run-of-Mine Buffer ................................

Rope Shovel A-Frame – The anchor for the boom

Rope Shovel Boom – Attachment ................................

Rope Shovel Boom Suspension Ropes – The Wire Ropes tBoom and Load.................................................................

Rope Shovel – Fill Cycle ................................

Rope Shovel – Forces applied ................................

Rope Shovel – Machine ................................

Rope Shovel – Schematic ................................

Rope Shovel Tracks – Travelling device................................

Roster – A Truck and Loader Crew’s Working Arrangement

Safety Zone/Collision Avoidance – Safety ................................

Scaling Batters – Removing loose material from a wall

Scale Shovel – 1:7th RB22 ................................

Selecting the “Right” Trucks for a Mine ................................

What is the problem?................................................................

Variation in Truck and Loader Performance

Service Roads – Light vehicle access................................

Service refill fittings rack – Lube ................................

SG – Specific Gravity ................................................................

Shale – Fine grained material usually found as an intraseam. ................................................................

Shift – A Crew Working a Roster ................................

Shot ground – Blasted Overburden ................................

Shovel Dipper Modelling ................................

Simulator – A Test Device that Simulates Actual Conditions

Single Side Loading – Techniques ................................

Single Bench – Loading technique ................................

Soft Dumping Techniques – Techniques ................................

Specification Sheet – Machine ................................

Speed Limits – Safety ................................................................

Spillage ................................................................

Split Benching – Loading technique ................................


Prevents truck from unwanted rolling .........................................................................306

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Removes rocks caught between tyres .......................................................... 308

Material build up from the digging process ................................................................309

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Resistance created by the interaction between the trucks tyres................................................................................. 310

...................................................................................................... 312

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The anchor for the boom ................................................................ 314

.......................................................................................... 315

The Wire Ropes that Hold and Support the.................................................................................. 316

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....................................................................................................... 319

................................................................................. 319

A Truck and Loader Crew’s Working Arrangement ...............................................320

............................................................................. 321

Removing loose material from a wall ........................................................322

.......................................................................................................323

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Variation in Truck and Loader Performance .........................................................................324

......................................................................................325

...........................................................................................326

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Fine grained material usually found as an intra-seam or on top of a coal................................................................................................... 327

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Device that Simulates Actual Conditions ...............................................330

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Spoil – All Material removed from above a mineable seam

Spotting – Precautions ................................

Spotting – Techniques................................................................

Spotting for Top Loading @ 45° – Techniques

Spotting at 45˚ – Techniques ................................

Reason same as loading 45 ................................

Spotting at 90˚ – Techniques ................................

Spotting at 90˚ – Incorrect Positioning ................................

Start-up Procedure ................................................................

Steering system................................................................

Stockpile stacking/accumulation – Building manageable stockpile

Stoppages – Productivity................................

Strategy ................................................................

Strike length................................................................

Stripping – Removing of overburden waste or spoil

Stripping Ratio................................................................

Struck capacity................................................................

Stub Line –A Feeder Power Line................................

Suspension – Shock Absorber (truck)................................

Swell –The Enlargement of the Insitu Overburden after Blasting

Swell Factor – The Percentage of Enlargement of the Insitu Overburden afterBlasting ................................................................

Swing Arc Efficiency ................................................................

Swing Clearance................................................................

Swing Drive ................................................................

Swinging Phase ................................................................

Swinging Rack and Roller Assembly – swing bearing and revolving frame

Switchbacks – Zigzag................................................................

Tags ................................................................

Talpac – Truck & Loader Productivity Estimation Software

Tail gate – Stops spillage and increases body capacity

Terex (Dart) 3100 33100 – Dump Truck ................................

Terex (Dart) 3311 – Dump Truck ................................

Terex (Dart) 4150 4160 – Dump Truck................................

Terex (Titan) 3315C 3315D – Dump Truck ................................

Terex TR100/100DD – Dump Truck ................................

Tip head edge/ Tip head stability ................................

TKPH – Tonne Kilometre per Hour ................................

Toe – The Bottom of a Batter or Face ................................

Tooth Adaptor – Fitted to the Nose of the Bucket

Tooth attack angle................................................................

Tooth Coverage – Percentage of the lip which is made up of teeth


ll Material removed from above a mineable seam ..................................................339

...........................................................................................................340

............................................................................340

Techniques...................................................................... 341

.................................................................................................342

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Building manageable stockpile.....................................346

........................................................................................................347

...................................................................................................348

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Removing of overburden waste or spoil .............................................................350

........................................................................................ 351

........................................................................................ 351

............................................................................................ 351

....................................................................................352

The Enlargement of the Insitu Overburden after Blasting ........................................352

The Percentage of Enlargement of the Insitu Overburden after...............................................................................................353

...............................................................................353

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swing bearing and revolving frame ......................... 357

.............................................................................. 357

.........................................................................................................358

Truck & Loader Productivity Estimation Software................................................360

Stops spillage and increases body capacity.......................................................... 361

...............................................................................362

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Fitted to the Nose of the Bucket .................................................................370

................................................................................... 371

Percentage of the lip which is made up of teeth ...................................... 371


Top Loading ................................................................

Topsoil – The Dirt on the Surface that Grows Vegetation

Tracks (Continuous tracks or machine tracks)

Trainee – Person Learning to Operate a Machine

Tramming – Moving the loader ................................

Truck & Loader Operations ................................

Truck – Controls ................................................................

Truck Optimisation................................................................

Truck Payload ................................................................

Trucking – Truck matching to the shovel ................................

Truck Air Filter Indicators – Indicates the filter condition

Truck Forces – Forces on the Truck in operation

Truck parking bay ................................................................

Truck PLM (Payload Meter) – Measures the loaded Material

Truck Positioning................................................................

Truck Spotting guide – A device to assist truck drivers

Truck Tow Pin................................................................

Truck Tray (Bed) – Carries Material on the chassis

Truck Tray – Capacity................................................................

Truck tray cleaning – Reducing carry back................................

Truck Tray Hoist Ram Pivot Point ................................

Tyres ................................................................

Tyre Damage ................................................................

Tyre management reports ................................

Tyre Overheating ................................................................

Tyre Rim................................................................

Tyre Safety................................................................

Tyre Tread – Maintains traction with haulroad

Ultra Class Trucks................................................................

Undercarriage – bottom deck................................

Undercutting a Face above the bench ................................

Undercutting a Face below the bench ................................

Vienna Test System................................................................

Vital Information Management System (VIMS)

Volume – The Amount of waste in an area ................................

Void (dipper) – Volume in bucket which is not filled

Wait On Truck (Hang Time) – Reporting ................................

Wait On Loader (reporting)................................

Walk Around Inspection................................

Wash bay – Machine................................................................

Wheel lock ring ................................................................

Windrow/Berm – Physical Barrier ................................


............................................................................................ 372

The Dirt on the Surface that Grows Vegetation.................................................... 373

Tracks (Continuous tracks or machine tracks) – Providing motion traction .......................374

Person Learning to Operate a Machine ................................................................. 375

............................................................................................. 375

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.........................................................................................379

.............................................................................. 381

Indicates the filter condition..................................................382

Forces on the Truck in operation.................................................................383

...................................................................................383

Measures the loaded Material .............................................383

....................................................................................384

A device to assist truck drivers ........................................................385

.........................................................................................386

Carries Material on the chassis ..............................................................386

.............................................................................386

........................................................................... 388

.........................................................................................389

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...........................................................................................390

...................................................................................................... 391

....................................................................................392

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Maintains traction with haulroad ....................................................................395

...................................................................................396

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....................................................................................397

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Vital Information Management System (VIMS)................................................................... 400

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Volume in bucket which is not filled............................................................ 401

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.............................................................................. 406

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Wire rope – Consists of several strands laid together like a helix

Witches Hats – Reflective Safety Cones for Demarcation

Working Zones................................................................


Consists of several strands laid together like a helix.........................................407

Reflective Safety Cones for Demarcation ................................................... 408

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2 Way Radio – A Communication System

Two way radios are used extensively on a mine site. Most Truckoperations have hand held 2 ways with a dedicated channel for the Truckpersonnel to use for local communication. Some of these 2 ways are UHFand some VHF, both either one with a dedicated channel are a very usefuland necessary means for the crew to keep in contact with each otherduring operations. Safety issues was the main instigator to having handheld radios available to the crew, as in large mines, the tradios are exceptionally heavy, and with this means of communicating,especially with crew downsizing, more positive contact is available.

Portable orHand-held 2Way Radio

Fixed 2 WayRadio

T: +61 7 3257 5000Email: [email protected] 1

A Communication System

Two way radios are used extensively on a mine site. Most Truckoperations have hand held 2 ways with a dedicated channel for the Truckpersonnel to use for local communication. Some of these 2 ways are UHF

th either one with a dedicated channel are a very usefuland necessary means for the crew to keep in contact with each otherduring operations. Safety issues was the main instigator to having handheld radios available to the crew, as in large mines, the traffic on theradios are exceptionally heavy, and with this means of communicating,especially with crew downsizing, more positive contact is available.


3D Dig – Mine Planning Software

3dDig is a software program for three dimensional planning of minoperations. It has a unique rilling algorithm which allows Digital TerrainModels (DTM’s) to be dug (modified in the computer) and the spoildumped. It is marketed by Earth Technology Pty Ltd.


Mine Planning Software

3dDig is a software program for three dimensional planning of miningIt has a unique rilling algorithm which allows Digital Terrain

Models (DTM’s) to be dug (modified in the computer) and the spoilIt is marketed by Earth Technology Pty Ltd.


10/10/20 Rule

Some truck OEM’s will push the 10/10/20 rthat the average payload won’t exceed the nominal OEM stated payload;no more than 10% of the loads will be more than 10% above average andnone (0%) will be more than 20% over the nominal load.

A genuine attempt to conform to this rule will result in average payloadsbeing well below the nominal payload.

Technically, any overload could adversely affect component life, tyres,chassis, and potentially affect steering & braking performance. Thequestion is, “What is the relationship between fatigue life and loading?”Fatigue life is a fixed amount and is continually used. The higher theloading, the quicker fatigue life is used (and micro cracks become macrocracks which become life-limiting). If the overloading is severe ethe truck may be unsafe to operate.

Some Cat research demonstrates that component life decreasedsignificantly when overloaded 10% to 20%. The rate at which componentlife decreased as a result of overloading is greater than the rate at whichcomponent life increased as a result of underloading. Cat provide a fewbasic rules of thumb related to component life vs. payload. First, enginelife is directly related to fuel burn. If payload is increased, the truck getsheavier creating a higher duty cycle resulting in greater fuel burn andshorter life. The torque converter and transmission life are related totorque and again as payload is increased the truck gets heavier. Moretorque is required to move a heavier truck resulting in shorter torqueconverter and transmission life. The lower powertrain life is related toload and speed. A heavier truck puts more load on the lower powertrainand again the results is a decrease in component life.

The unclear and unstated issue is the impact of factors such ascharacteristics, operator characteristics, load positioning, etc. Certainly,with draglines, where there is the most data and analysis, damage isheavily impacted by what the operator is doing and not so much by theload being carried. There appears to be a likelihood that the same willapply with trucks. Consequently, there is some doubt that the impact ofminor overloading is significant compared with what the truck is doingand by extension the relevance of the 10/10/20 rule to damage and sHowever, it is part of some purchase contracts which means it is relevantand you have to consider it.


Some truck OEM’s will push the 10/10/20 rule. The 10/10/20 rule meansthat the average payload won’t exceed the nominal OEM stated payload;no more than 10% of the loads will be more than 10% above average andnone (0%) will be more than 20% over the nominal load.

to this rule will result in average payloadsbeing well below the nominal payload.

Technically, any overload could adversely affect component life, tyres,chassis, and potentially affect steering & braking performance. The

tionship between fatigue life and loading?”Fatigue life is a fixed amount and is continually used. The higher theloading, the quicker fatigue life is used (and micro cracks become macro

limiting). If the overloading is severe enough,

Some Cat research demonstrates that component life decreasedsignificantly when overloaded 10% to 20%. The rate at which componentlife decreased as a result of overloading is greater than the rate at which

nent life increased as a result of underloading. Cat provide a fewbasic rules of thumb related to component life vs. payload. First, enginelife is directly related to fuel burn. If payload is increased, the truck gets

e resulting in greater fuel burn andshorter life. The torque converter and transmission life are related totorque and again as payload is increased the truck gets heavier. Moretorque is required to move a heavier truck resulting in shorter torque

ter and transmission life. The lower powertrain life is related toload and speed. A heavier truck puts more load on the lower powertrainand again the results is a decrease in component life.

The unclear and unstated issue is the impact of factors such as haul roadcharacteristics, operator characteristics, load positioning, etc. Certainly,with draglines, where there is the most data and analysis, damage isheavily impacted by what the operator is doing and not so much by the

ppears to be a likelihood that the same willapply with trucks. Consequently, there is some doubt that the impact ofminor overloading is significant compared with what the truck is doingand by extension the relevance of the 10/10/20 rule to damage and safety.However, it is part of some purchase contracts which means it is relevant


The fact is that some suppliers are using the 10/10/20 policy in support ofwarranty considerations and maintenance and repair contracts (MARC’s)for Mining Trucks.

A genuine attempt to conform to this rule will result in average payloadsnot achieving the nominal payload. This is because the distribution ofpayload is inevitably flatter than what is required to meet this rule andachieve average payload.

Consider the following real worldwide statistics for mining trucks

22% of trucks exceed OEM nominated payload on average

63% of trucks fail the 10% overload rule (ie. they have more than10% of payloads more than 10% over nominal payload)

91% of trucks fail the 20% overload rule (ie. they have recordedpayloads more than 20% over nominal payload)

Only 7% pass 10% and 20% rules but these 7% achieve averagepayloads 14% below OEM nominated payload.

So what should a mine do? The options are;

1. Make a genuine attempt to conform to 10/10/20 rule. The resultwill be that you will probably end up more than 10% belownominal payload on average. Now this is OK if you know and youcan specify your equipment around this knowledge; but mineshaven’t known

Currently, potential warranty and/or MARC issues for 93% oftrucks.

2. Ignore the 10/10/20 rule. The result of this approach is that youwill probably end up voiding warranty and MARC arrangements.You also place yourself in some legal difficulty if a truck haccident (and there are potential safety issues) and you can beshown to have not conformed to the 10/10/20 rule.

The industry needs a rethink on trucks and how they are designed andspecified. Mines currently have the option of taking a hit on peand costs or voiding warranties and MARC contracts and even ending upin court.

Each mine purchasing trucks and loaders must consider this issue veryseriously.


The fact is that some suppliers are using the 10/10/20 policy in support ofwarranty considerations and maintenance and repair contracts (MARC’s)

A genuine attempt to conform to this rule will result in average payloadsnot achieving the nominal payload. This is because the distribution ofpayload is inevitably flatter than what is required to meet this rule and

Consider the following real worldwide statistics for mining trucks

22% of trucks exceed OEM nominated payload on average

63% of trucks fail the 10% overload rule (ie. they have more than10% of payloads more than 10% over nominal payload)

trucks fail the 20% overload rule (ie. they have recordedpayloads more than 20% over nominal payload)

Only 7% pass 10% and 20% rules but these 7% achieve averagepayloads 14% below OEM nominated payload.

So what should a mine do? The options are;

genuine attempt to conform to 10/10/20 rule. The resultwill be that you will probably end up more than 10% belownominal payload on average. Now this is OK if you know and youcan specify your equipment around this knowledge; but mines

rrently, potential warranty and/or MARC issues for 93% of

Ignore the 10/10/20 rule. The result of this approach is that youwill probably end up voiding warranty and MARC arrangements.You also place yourself in some legal difficulty if a truck has anaccident (and there are potential safety issues) and you can beshown to have not conformed to the 10/10/20 rule.

The industry needs a rethink on trucks and how they are designed andspecified. Mines currently have the option of taking a hit on performanceand costs or voiding warranties and MARC contracts and even ending up

Each mine purchasing trucks and loaders must consider this issue very


Access Ramp – Truck Entrance and ExitRoad

This enables trucks, light vehicles anloading and digging areas.


Truck Entrance and Exit

This enables trucks, light vehicles and other machinery to access the


Access Stairs – Stairway for entry ontothe equipment

There are a number of access stairs in and around mining equipment. Thestairs used most are the access from the ground to the operator’sSome are air or electrically operated and some are fixed.employees responsibility to learn the mine’s procedures for getting on andoff and follow them at all times.

Access Stairs


Stairway for entry onto

There are a number of access stairs in and around mining equipment. Thestairs used most are the access from the ground to the operator’s cabin.Some are air or electrically operated and some are fixed. It is everyemployees responsibility to learn the mine’s procedures for getting on and


Adverse Conditions – Dusty, Wet, Inclementor poor visibility

There are times and circumstances when adverse driving conditionsrequire you to take extra care.

Adverse conditions including rain, snow, ice, and fog affect your visibility.In these conditions vehicles become difficult to control on curves or evenon straight stretches when the surface is slippery. Braking distances arealso increased due to sub optimal road conditions. If conditions areunsafe, follow your site procedures, park up in a safe way and wait forconditions to improve or wait for furthersupervisor.

Alternator – Converts Mechanical Energy toElectrical Energy


Dusty, Wet, Inclement

There are times and circumstances when adverse driving conditions

Adverse conditions including rain, snow, ice, and fog affect your visibility.In these conditions vehicles become difficult to control on curves or even

n straight stretches when the surface is slippery. Braking distances arealso increased due to sub optimal road conditions. If conditions areunsafe, follow your site procedures, park up in a safe way and wait forconditions to improve or wait for further instructions from your

Converts Mechanical Energy to


Ancillary Equipment –Associated with the Operation

Ancillary equipment is any machine, vehicle or equipment that the Truckand loading equipment requires to do its job. Example:

The dozer/ grader assists with the ground work for the operation. The cable handling tractor is a tool for pulling and positioning the

cable for electric powered face shovels, when necessary. Transportation to and from the excavator, rope or hydraulic shovel is

by light vehicle. The cable reeler is a machine for routing cable as required. The reel is

usually mounted on an older front end loader.


– Equipment that isAssociated with the Operation

Ancillary equipment is any machine, vehicle or equipment that the Truckequipment requires to do its job. Example:

The dozer/ grader assists with the ground work for the operation.The cable handling tractor is a tool for pulling and positioning thecable for electric powered face shovels, when necessary.

d from the excavator, rope or hydraulic shovel is

The cable reeler is a machine for routing cable as required. The reel isusually mounted on an older front end loader.


ANSUL Automatic Fire SuppressionExtinguisher System

The automatic fire suppression system is designed to extinguish a fire inthe engine bay when activated by removal of the pin and depression of theknob. This is normally situated both inside and outside of the machine foreasy access.

ANSUL Automatic Fire SupEmergency Switch – Extinguisher System

The automatic Fire suppression system will extinguish an engine fire,when activated by removal of the pin and depression of the knob. This isnormally situated in the Operators Cabin.

Warning Panels

Most equipment is fitted with warning control modules containing LEDindicators and an audio alarm to provide a continuous update of systemstatus.


Automatic Fire Suppression –

omatic fire suppression system is designed to extinguish a fire inthe engine bay when activated by removal of the pin and depression of theknob. This is normally situated both inside and outside of the machine for

ANSUL Automatic Fire SuppressionExtinguisher System

The automatic Fire suppression system will extinguish an engine fire,when activated by removal of the pin and depression of the knob. This isnormally situated in the Operators Cabin.

ipment is fitted with warning control modules containing LEDindicators and an audio alarm to provide a continuous update of system


Air Filter – Filters Air for the Engine

This is a unit that filters air through a fine fibrous material. The filtremoves most fine particles such as dust. It prevents abrasive particulatematter from entering the engine's cylinders.

Air Horns – Signal Horns

Air horns are usually mounted on the front and rear of a machine. Thesehorns are used by the operator to indicate to others his intentions.

1. Short blast = Truck STOP.

2. Short blasts = Truck GO/ forward

3. Short blasts = Reverse


Filters Air for the Engine

This is a unit that filters air through a fine fibrous material. The filterremoves most fine particles such as dust. It prevents abrasive particulatematter from entering the engine's cylinders.

Signal Horns

Air horns are usually mounted on the front and rear of a machine. Theseindicate to others his intentions.

Short blasts = Truck GO/ forward


Backhoe

A backhoe is one of two configurations which an hydraulic excavator maybe set up as. The backhoe arrangement is where the buckeand to ward the machine to fill the bucket.

Bail less attachment –ropes to the dipper(bucket) on a rope shovel

The concept of bail vs. bail-less is more a function of where the connectionis made to the dipper. With a Bail less attachment, the connection is madedirectly to the rear of the dipper.

Bail-less Connection at Rear of Dipper


A backhoe is one of two configurations which an hydraulic excavator maybe set up as. The backhoe arrangement is where the bucket digs downand to ward the machine to fill the bucket.

– Connects the hoistropes to the dipper(bucket) on a rope shovel

less is more a function of where the connectionBail less attachment, the connection is made


Bail Arm (or just Bail)ropes to the dipper (bucket

The location of the bail arm can impact payload significanconnected part way along the dipper then it can impede material flow intothe dipper. When the bail is connected on the rear of the bucket or there isno bail arm and the hoist ropes connect directly onto the bucket, averagepayload is higher.


Bail Arm (or just Bail) – Connects the hoistbucket)

The location of the bail arm can impact payload significantly. If it isconnected part way along the dipper then it can impede material flow into

When the bail is connected on the rear of the bucket or there isno bail arm and the hoist ropes connect directly onto the bucket, average


Batter – The Slope of the High or Low Wall

The batter is the term given to the angle of a face of material measured asthe angle between the horizontal and the face.(undug material) are normally steeper than on the low walmaterial), as high walls, being in virgin ground, are usually of morecompetent material. The batter angle may vary from mine to mine,however it is usually the competency of the overburden that dictates thebatter angles. Most mines in Australia usdegrees). In some mines around the world a vertical batter is used onhighwalls. This is not the predominant practice due to the potential forfailure of the highwall. The batter on low walls is generally equal to theangle of repose although it is not unusual to “undercut” the lower part ofthe batter to 1:1 or even steeper.


The Slope of the High or Low Wall

The batter is the term given to the angle of a face of material measured asthe angle between the horizontal and the face. The angles on a high wall(undug material) are normally steeper than on the low wall (dugmaterial), as high walls, being in virgin ground, are usually of morecompetent material. The batter angle may vary from mine to mine,however it is usually the competency of the overburden that dictates the

Most mines in Australia use a 2:1 batter (approx. 63.4In some mines around the world a vertical batter is used onThis is not the predominant practice due to the potential for

failure of the highwall. The batter on low walls is generally equal to therepose although it is not unusual to “undercut” the lower part of


Batter Cleaning – Cleaning of a highwallbatter

In some operations, excavators are utilised to clean and prepare thehighwall by removing loose or hanging material on the highwall.

Battery – Electric Energy Storage

Converts stored chemical energy into electrical energy.

The battery is used as a power source to start up the engine or to allowelectric devices to operate without the engine running.

Most batteries contain an electroyte which is an acid. It can cause injury ifcomes in contact skin or eyes.

Always wear protective equipment when working with batteries.


Cleaning of a highwall

In some operations, excavators are utilised to clean and prepare theging material on the highwall.

Electric Energy Storage

Converts stored chemical energy into electrical energy.

The battery is used as a power source to start up the engine or to allowthe engine running.

t batteries contain an electroyte which is an acid. It can cause injury if

Always wear protective equipment when working with batteries.


BCM/BCY – Bank Cubic Metre/Yard

The quantity of spoil that occupies 1 cubic metre/cubic yard of spacebefore being disturbed by a blast.

The quantity of spoil moved by loading units is usually defined in terms ofBCM (metric – Australia & Africa) or BCY (imperial

BCM or BCY are calculated by taking the weight of spoil moved anddividing by the in-situ specific gravity (or density).

Sample Metric Calculation (SG = 2.2 t/CuM).

Number of cycles in a Day

Average Payload

Total Movement

Sample Imperial Calculation (SG = 3,750 lbs/CuYd).

Number of cycles in a Day

Average Payload

Total Movement

Bench – A Levelled Area where MiningEquipment Operates

A bench is a level area created as part of the miniequipment requires stable flat ground from which to operate. Excavator,hydraulic and rope shovel as well as FEL benches or floor conditions needto be level (refer to OEM for specific working angle limitation).


Bank Cubic Metre/Yard

f spoil that occupies 1 cubic metre/cubic yard of space

The quantity of spoil moved by loading units is usually defined in terms ofAustralia & Africa) or BCY (imperial – US).

king the weight of spoil moved andsitu specific gravity (or density).

Sample Metric Calculation (SG = 2.2 t/CuM).

1,000

100 tonnes

1000 * 100/2.2 = 45,454 BCM

Calculation (SG = 3,750 lbs/CuYd).

1,000

220,000 lbs

1000 * 220000/3750

58,667 BCY

A Levelled Area where Mining

A bench is a level area created as part of the mining process. Miningequipment requires stable flat ground from which to operate. Excavator,hydraulic and rope shovel as well as FEL benches or floor conditions needto be level (refer to OEM for specific working angle limitation).


Bench Width

The width of the bottom bench is imperative. The Excavator should be ±2m from the edge of the bench. If the machine is too close to the edge, thematerial can subside causing the machine to fall.

When the bottom bench is too wide, the Excavator operator cannot rethe floor to clean up spillage. Loading of the trucks correctly is alsoaffected.

Be mindful not to dig too much out in front of the excavator (and the digtrench) as you can easily get caught in nomachine cannot reach the face in front to pull material down and you havenothing to bridge out with)


of the bottom bench is imperative. The Excavator should be ±2m from the edge of the bench. If the machine is too close to the edge, thematerial can subside causing the machine to fall.

When the bottom bench is too wide, the Excavator operator cannot reachthe floor to clean up spillage. Loading of the trucks correctly is also

Be mindful not to dig too much out in front of the excavator (and the digtrench) as you can easily get caught in no-man’s land. (Hole too large and

h the face in front to pull material down and you have


The Bench Grade – Grade

Most benches are not level but are normally planar and established withfairly gently slopes of around 1 to 2% to facilitate drainage.

In some coal mines, the grade of the bench is fixed by the slope of theseam within the limits of operation of the type of equipment used. Attimes, digging at steeper grades is necessitated for ramp construction andsump digging.

Most operations utilise GPS systems to manage and conform to RL gradespecifications however some operations still use sighting rods or survey toassist.

Example of working on a grade


Grade of bench

level but are normally planar and established withfairly gently slopes of around 1 to 2% to facilitate drainage.

some coal mines, the grade of the bench is fixed by the slope of theseam within the limits of operation of the type of equipment used. Attimes, digging at steeper grades is necessitated for ramp construction and

systems to manage and conform to RL gradespecifications however some operations still use sighting rods or survey to


The Bench Height – Height of bench

The height of the bench needs to be considered to optimise p

With a lower bench height.

Lower Payload per Bucket. Higher frequency of Multi passes. Longer face establishment times. Longer Cycle time for total operation.

Having the optimal bench height.

Maximum Payload per dipper. Faster turnaround times of trucks due to a faster filling time on the

shovel. Less waiting on face preparation


Height of bench

The height of the bench needs to be considered to optimise productivity:

Higher frequency of Multi passes.Longer face establishment times.Longer Cycle time for total operation.

of trucks due to a faster filling time on the

Less waiting on face preparation


Benchmark Loading UnitPerformance and Productivity

Benchmarking is a widely accepted business tool to identify your positionand performance against yourself and the rest of the world. It is theprocess of seeking out and studying the best internal practices thatproduce superior performance to:

Identify strengths and weaknesses; Support continuous improvement; and Measure and monitor the effectiv

Every operation is different. Some dig deep and others are shallow. Somedig ore and some dig prestrip. Some have hard digging and others softdigging. Some have long hauls and some are short.answer all your questions. In fact it will raise quite a few questions whichthe mine will need to answer.

The key to benchmarking trucks and loaders is to take the “glass halfattitude. What can I learn about areas for improvement?achieving which I should be able to do?time benchmark results and justify it through “But my operation isdifferent”. These mines are consigned to mediocrity.“What can I do to improve?” inevitably do improve through theprocess of simply focussing on performance.on top of attitude-based improvements.

The following pages outline how PwCunits and the key outputs and KPIs that we have found to be paramidentifying areas of improvement.

There are a number of different KPI’s and analysis that should be takeninto account when benchmarking machines. We must take into accountspecific digging conditions and this can be as simple as benchmarkingagainst a specific geographical subset.


Benchmark Loading Unit – A Measure ofPerformance and Productivity

Benchmarking is a widely accepted business tool to identify your positionst yourself and the rest of the world. It is the

process of seeking out and studying the best internal practices that

Identify strengths and weaknesses;Support continuous improvement; andMeasure and monitor the effectiveness of change programs.

Some dig deep and others are shallow. SomeSome have hard digging and others soft

Some have long hauls and some are short. Benchmarking won’tIn fact it will raise quite a few questions which

The key to benchmarking trucks and loaders is to take the “glass half-full”What can I learn about areas for improvement? What are others

should be able to do? Many mines are shocked by firsttime benchmark results and justify it through “But my operation is

These mines are consigned to mediocrity. Those mines that say“What can I do to improve?” inevitably do improve through the intangibleprocess of simply focussing on performance. Process improvements come

based improvements.

PwC performs benchmarking for loadingunits and the key outputs and KPIs that we have found to be paramount in

There are a number of different KPI’s and analysis that should be takeninto account when benchmarking machines. We must take into accountspecific digging conditions and this can be as simple as benchmarking

st a specific geographical subset.


When benchmarking, PwC takes a standard approach and when definingthe Best Practice where all data is ranked by ‘total annual output’(tonnes/BCMs moved). Best Practice is therefore made up of the averageof the top 10% of machines for a specified model.

Why not take the top machine? PwCan average of the top machines as we can find that sometimes a machinemay perform exceptionally well for a single year but this is often notsustainable.

There can also be specific idiosyncrasies for a single machines yearlyoutput and this can be misunderstood when not related back to theoriginal machine and its specific environment. By taking the top 10% of


takes a standard approach and when definingthe Best Practice where all data is ranked by ‘total annual output’(tonnes/BCMs moved). Best Practice is therefore made up of the average

10% of machines for a specified model.

PwC believes that it is important to takean average of the top machines as we can find that sometimes a machinemay perform exceptionally well for a single year but this is often not

There can also be specific idiosyncrasies for a single machines yearlyoutput and this can be misunderstood when not related back to theoriginal machine and its specific environment. By taking the top 10% of


machines we reduce the impact of tha general picture of what we calculate to be a ‘Best Practice’ machine.


machines we reduce the impact of these idiosyncrasies and help to providea general picture of what we calculate to be a ‘Best Practice’ machine.


When Benchmarking PwC compares a number of key factors:

Scheduled Time: How does your machine compare against BestPractice machines for the amount of time it was scheduled to work.Depending on the specific time model of the mine this can identifyimprovement areas such as industrial action, public holidays or simplytime in which the machine was parked up.

Availability: How does your machinemachines for the amount of time it was available to work in the scheduledtime. This KPI identifies where breakdowns or preventative maintenancemay be hindering the machines productivity and gives a starting pointwith which to look into this area of improvement in more detail.

Utilisation: Of the Available time how effective was your machine atperforming production related tasks? This KPI identifies if operationaldelays are an area that needs more investigation. For exampleoperational delays being pushed up due to factors such as Wait on Truckon Wait on Dozer?

Dig Rate: This KPI identifies the productivity of the machine for theallocated production time. So using this information we can look furtherinto what is causing a lower than (or higher than) Best Practice resultit a lower payload or are the operators simply taking too long to fill thebucket?

By identifying the major factors that are directly affecting the total outputof the machine it is possible to ‘drill down’ into more detailed analysis anddiscussion amongst mine site personnel to identify how to improve eachmachines performance.


compares a number of key factors:

does your machine compare against Bestamount of time it was scheduled to work.

Depending on the specific time model of the mine this can identifyimprovement areas such as industrial action, public holidays or simplytime in which the machine was parked up.

achine compare against Best Practicemachines for the amount of time it was available to work in the scheduledtime. This KPI identifies where breakdowns or preventative maintenancemay be hindering the machines productivity and gives a starting point

to look into this area of improvement in more detail.

able time how effective was your machine atperforming production related tasks? This KPI identifies if operationaldelays are an area that needs more investigation. For example are youroperational delays being pushed up due to factors such as Wait on Truck

KPI identifies the productivity of the machine for theallocated production time. So using this information we can look further

causing a lower than (or higher than) Best Practice result – isit a lower payload or are the operators simply taking too long to fill the

By identifying the major factors that are directly affecting the total outputo ‘drill down’ into more detailed analysis and

discussion amongst mine site personnel to identify how to improve each


Benchmark for Truck FleetsPerformance and Productivity

Benchmarking is a widely accepted business toand performance against yourself and the rest of the world. It is theprocess of seeking out and studying the best internal practices thatproduce superior performance to:

Identify strengths and weaknesses; Support continuous improvement; and Measure and monitor the effectiveness of change programs.

Can you accurately benchmark mining trucks?

Every operation is different. Some dig deep and others are shallow. Somedig ore and some dig prestrip. Some have hard digging and otherdigging. Some have long hauls and some are short.answer all your questions. In fact it will raise quite a few questions whichthe mine will need to answer.

The key to benchmarking trucks and loaders is to take the “glass halfattitude. What can I learn about areas for improvement?achieving which I should be able to do?time benchmark results and justify it through “But my operation isdifferent”. These mines are consigned to m“What can I do to improve?” inevitably do improve through the intangibleprocess of simply focussing on performance.on top of attitude-based improvements.

The following pages outline how PwCunits and the key outputs and KPIs that we have found to be paramount inidentifying areas of improvement.

When benchmarking PwC takes a standard approach and when definingthe Best Practice where all data is ranked by ‘total an(tonnes/BCMs moved). Best Practice is therefore made up of the averageof the top 10% of machines for a specified model.

Why not take the top machine? PwCan average of the top machines as we can find thamay perform exceptionally well for a single year but this is often notsustainable. There can also be specific idiosyncrasies for a single machinesyearly output and this can be misunderstood when not related back to theoriginal machine and its specific environment. By taking the top 10% of


Benchmark for Truck Fleets – A measure ofPerformance and Productivity

Benchmarking is a widely accepted business tool to identify your positionand performance against yourself and the rest of the world. It is theprocess of seeking out and studying the best internal practices that

Identify strengths and weaknesses;improvement; and

Measure and monitor the effectiveness of change programs.

Can you accurately benchmark mining trucks?

Some dig deep and others are shallow. SomeSome have hard digging and others soft

digging. Some have long hauls and some are short. Benchmarking won’tIn fact it will raise quite a few questions which

The key to benchmarking trucks and loaders is to take the “glass half-full”What can I learn about areas for improvement? What are others

achieving which I should be able to do? Many mines are shocked by firsttime benchmark results and justify it through “But my operation is

These mines are consigned to mediocrity. Those mines that say“What can I do to improve?” inevitably do improve through the intangibleprocess of simply focussing on performance. Process improvements come

based improvements.

PwC performs benchmarking for loadingunits and the key outputs and KPIs that we have found to be paramount in

takes a standard approach and when definingthe Best Practice where all data is ranked by ‘total annual output’(tonnes/BCMs moved). Best Practice is therefore made up of the averageof the top 10% of machines for a specified model.

PwC believes that it is important to takean average of the top machines as we can find that sometimes a machinemay perform exceptionally well for a single year but this is often notsustainable. There can also be specific idiosyncrasies for a single machinesyearly output and this can be misunderstood when not related back to the

ine and its specific environment. By taking the top 10% of



An important factor taken into account byBenchmarks is the Haul Distance. It is not a fair comparison to compare atruck fleet performing a 3km total haul to a truck fleet performing a 6kmhaul. Based on this PwC is able to identify the total cycle time of the trucksand split out the specified travel portion. By adjusting this portion toreflect a specific cycle distance we can then adjust the number of cycleseach fleet/truck can perform in the available total cycle time.

Using this process we can compare the trucks on a like fgive a true indication of best practice based on a mines specific hauldistances without altering the other portions of the cycle (load time, queuetime etc.).

When Benchmarking PwC compares a number of key factors:



An important factor taken into account by PwC when performing TruckBenchmarks is the Haul Distance. It is not a fair comparison to compare atruck fleet performing a 3km total haul to a truck fleet performing a 6km

is able to identify the total cycle time of the truckst the specified travel portion. By adjusting this portion to

reflect a specific cycle distance we can then adjust the number of cycleseach fleet/truck can perform in the available total cycle time.

Using this process we can compare the trucks on a like for like basis andgive a true indication of best practice based on a mines specific hauldistances without altering the other portions of the cycle (load time, queue

compares a number of key factors:


Scheduled Time: How does your machine compare against BestPractice machines for the amount of time it was scheduled to work.Depending on the specific time model of the mine this can identifyimprovement areas such as industrial action, public holidays or simplytime in which the machine was parked up.

Availability: How does your machine compare against Best Practicemachines for the amount of time it was available to work in the scheduledtime. This KPI identifies where breakdowns or preventative maintenancemay be hindering the machines productivity and gives a starting pointwith which to look into this area of improvement in more detail.

Utilisation: Of the Available time how effective was your machine atperforming production related tasks. This KPI identifies if operatiodelays are an area that needs more investigation. For example are youroperational delays being pushed up due to factors such as Wait on Loaderor Waiton Dozer?

Dig Rate: This KPI identifies the productivity of the machine for theallocated production time. So using this information we can look furtherinto what is causing a lower than (or higher than) Best Practice resultit a lower payload or are the operators simply taking too long to positionthe truck?

By identifying the major factors that aof the machine it is possible to ‘drill down’ into more detailed analysis anddiscussion amongst mine site personnel to identify how to improve eachmachines performance.


does your machine compare against BestPractice machines for the amount of time it was scheduled to work.Depending on the specific time model of the mine this can identifyimprovement areas such as industrial action, public holidays or simply

h the machine was parked up.

does your machine compare against Best Practicemachines for the amount of time it was available to work in the scheduledtime. This KPI identifies where breakdowns or preventative maintenance

the machines productivity and gives a starting pointwith which to look into this area of improvement in more detail.

e Available time how effective was your machine atperforming production related tasks. This KPI identifies if operationaldelays are an area that needs more investigation. For example are youroperational delays being pushed up due to factors such as Wait on Loader

his KPI identifies the productivity of the machine for then time. So using this information we can look further

into what is causing a lower than (or higher than) Best Practice result – isit a lower payload or are the operators simply taking too long to position

By identifying the major factors that are directly affecting the total outputof the machine it is possible to ‘drill down’ into more detailed analysis anddiscussion amongst mine site personnel to identify how to improve each






BER – Bucket Efficiency Ratio

Bucket Efficiency Ratio is a measure of what weight of spoil a bucket of aparticular capacity will carry. As such it is a measure of the digging(getting the spoil into the bucket) and shape (holding spoil in the bucket)efficiency of the bucket. It is found by dividing the average payload by theratedbucket capacity.

BER – Payload/Bucket Rated Capacity

While BER provides a measure of bucket performance irrespective of size, itsmost useful function is in the calculation of optimum bucket capacity in selectnew bucket.

BER (t/m3) – Bucket Payload/Bucket Rated Capacity

Rope Shovel - 2.16 t/cu.m (Ave 1.87 t/

Backhoe - 2.00 t/cu.m (Ave 1.74 t/cu.m

Face Shovel & FEL – 2.07 t/ cu.m (Ave 1.82 t/

**Valid at time of going to press


Bucket Efficiency Ratio

et Efficiency Ratio is a measure of what weight of spoil a bucket of aAs such it is a measure of the digging

(getting the spoil into the bucket) and shape (holding spoil in the bucket)by dividing the average payload by the

While BER provides a measure of bucket performance irrespective of size, itsmost useful function is in the calculation of optimum bucket capacity in selecting a

Bucket Rated Capacity

(Ave 1.87 t/cu.m)

cu.m)

(Ave 1.82 t/ cu.m)


Berm – A Bund or mound of Material Placednear the Edges of an Excavation

A berm or bund should be placed around any excavation. The heightvaries. The mining regulations state “the berm must be half the height ofthe largest wheeled machine that uses the area” It isthe pit edge during service days and allow safe access for vehicles.


ound of Material Placedear the Edges of an Excavation

A berm or bund should be placed around any excavation. The heightvaries. The mining regulations state “the berm must be half the height ofthe largest wheeled machine that uses the area” It is also used to identifythe pit edge during service days and allow safe access for vehicles.


BEST Practice – The Average of the Top 10%of Equipment in the PwCand Time Utilisation Database

Best Practice means, for each individual prodtime utilisation KPI, the average for that KPI calculatedfrom the top 10% of machine years for loading units inan agreed benchmark population when ranked by totalannual output. That is, the machine years for loadingunits in the agreed benchmark population are ranked bytotal annual output, the top 10% of machine years areselected and separated out and the average of eachindividual production KPI and time utilisation KPIscalculated for the selected machine years only.

Important note: A particular production or time utilisation KPI,calculated as the average of that KPI recorded by the top 10% of machineyears for loading units in an agreed benchmark population when rankedby total annual output, may be lower than what is achieved for the samKPI when considered in isolation. There is no machine in the PwCdatabase which achieves the best result in each individual KPI. Further, anumber of KPIs in combination are counterpractice filling times (lower is better) r(larger is better).


The Average of the Top 10%PwC Mining Production

Database

Best Practice means, for each individual production ortime utilisation KPI, the average for that KPI calculatedfrom the top 10% of machine years for loading units inan agreed benchmark population when ranked by totalannual output. That is, the machine years for loading

ark population are ranked bytotal annual output, the top 10% of machine years areselected and separated out and the average of eachindividual production KPI and time utilisation KPIscalculated for the selected machine years only.

icular production or time utilisation KPI,calculated as the average of that KPI recorded by the top 10% of machineyears for loading units in an agreed benchmark population when rankedby total annual output, may be lower than what is achieved for the sameKPI when considered in isolation. There is no machine in the PwCdatabase which achieves the best result in each individual KPI. Further, anumber of KPIs in combination are counter-productive. For example, bestpractice filling times (lower is better) rarely provide best practice payloads


The PwC database

The PwC mining equipment database has been gathering production datafrom trucks, electric rope shovels, frontbackhoes, draglines, drills and ancillary equipment since 1992. Thedatabase maintains more than 12,000 machine years of miningequipment data. The following tableof the data in the PwC database.


The PwC mining equipment database has been gathering production datafrom trucks, electric rope shovels, front-end loaders, hydraulic excavators,

ncillary equipment since 1992. Thedatabase maintains more than 12,000 machine years of mining

The following table and pie chart provide a breakdown


Blasting – Controlled Firing of Explosives toBreak Rock

Overburden blasts are common on a mine site. Explosive products are putinto the drill holes and fired to fracture the overburden. The quantity ofexplosive or powder factor used in each hole depends on the hardness ofthe overburden being blasted.

Blast patterns – Designed to provide thecorrect broken rock size

Square Pattern: The easiest type of drill pattern to layout and maintainis the square pattern. This pattern is primarily used in shallow groundwhere holes are spaced closely together.


Controlled Firing of Explosives to

Overburden blasts are common on a mine site. Explosive products are putinto the drill holes and fired to fracture the overburden. The quantity ofexplosive or powder factor used in each hole depends on the hardness of

Designed to provide thecorrect broken rock size or break up coal

The easiest type of drill pattern to layout and maintainThis pattern is primarily used in shallow ground

closely together.


Staggered Pattern: A staggered pattern provides better distribution ofthe energy provided by the shot, but requires greater care by the drilloperator when laying out the holes.

Blind Spot – Areas where operator’s ordriver’s visibility is blocked

The areas in blue mark are an example of the blind spot a truck. Theoperator cannot see these areas from his position while driving.


A staggered pattern provides better distribution ofthe energy provided by the shot, but requires greater care by the drill

Areas where operator’s ory is blocked

The areas in blue mark are an example of the blind spot a truck. Theoperator cannot see these areas from his position while driving.


Bogged equipment – Stuck

Never attempt to remove a stuck or bogged piece of equipment withoutthe right responsible persons present. Follow your sites procedures.

Boom point sheaves –the Hoist Ropes round the Top End of theBoom

On a rope shovel, boom point sheaves guide the hoist ropes around the tipof the boom and are made to swivel and oscillate so they always align withthe direction of the ropes. It is important that the operator is smooth sothat the ropes don’t jump the sheave grooves.


Stuck

Never attempt to remove a stuck or bogged piece of equipment withoutresponsible persons present. Follow your sites procedures.

The Pulleys that Guidethe Hoist Ropes round the Top End of the

On a rope shovel, boom point sheaves guide the hoist ropes around the tipswivel and oscillate so they always align with

the direction of the ropes. It is important that the operator is smooth sothat the ropes don’t jump the sheave grooves.


Bottom Loading – Truck Positioning

Bottom loading is defined as the excavator operatinbench, and the truck being positioned on the floor below the excavator.The excavator operator can position the truck at 45° or 90° depending onground conditions and pit configuration.

The bottom loading technique maximizes excavatorfaster cycle times, giving better productivity output than top loading.

For efficient bottom loading, the bench height for general operationsshould beoptimized as follows:

For stable or consolidated materials, the optimum benchshould be four metres or approximately equal to the stick length.

For unstable materials, the bench height should be slightly less thanthe stick length.

Boom Jacking – Rope Shovel

Boom jacking is the direct consequence of overcrowding by the opera(pushing out too much), during the dipper filling cycle. As a result of theoperator’s action, the boom is raised in reference to its normal workingposition causing the suspension ropes to become slack and often rockingthe shovel.

The dipper loading cycle stops when the boom is displaced; causing losttime and minimising production because the boom “falls “on recoveryafter being raised, major structural stresses and loads are caused.


Truck Positioning

Bottom loading is defined as the excavator operating from the top of thebench, and the truck being positioned on the floor below the excavator.The excavator operator can position the truck at 45° or 90° depending onground conditions and pit configuration.

The bottom loading technique maximizes excavator efficiency by ensuringfaster cycle times, giving better productivity output than top loading.

For efficient bottom loading, the bench height for general operations

For stable or consolidated materials, the optimum bench heightshould be four metres or approximately equal to the stick length.For unstable materials, the bench height should be slightly less than

Rope Shovel

Boom jacking is the direct consequence of overcrowding by the operator(pushing out too much), during the dipper filling cycle. As a result of theoperator’s action, the boom is raised in reference to its normal workingposition causing the suspension ropes to become slack and often rocking

cycle stops when the boom is displaced; causing losttime and minimising production because the boom “falls “on recoveryafter being raised, major structural stresses and loads are caused.


Bottom Loading @90°

The haul truck should be positioned with the end of the truck body belowthe boom/stick hinge point.

The most common technique is loading at 90° over the side.excavator is placed on a bench above the truck and digs to the same levelas the truck’s driving surface. This technhoist than other methods to clear the side of the truck body, and calls forgreater accuracy when unloading the bucket.

Truck waiting/ queuing safety distances vary from mine site to mine site.

Bottom Loading @45°

Loading through the rear at 45° is similar to the 90° bottom side loadingmethod, except that the truck is positioned at 45° to the excavator.

This technique allows smoother bucket unloading when coming inthrough the rear of the truck body and requtheside loading.


Bottom Loading @90° - Truck Positioning

positioned with the end of the truck body below

The most common technique is loading at 90° over the side. Theexcavator is placed on a bench above the truck and digs to the same level

This technique requires you to use morehoist than other methods to clear the side of the truck body, and calls forgreater accuracy when unloading the bucket.

Truck waiting/ queuing safety distances vary from mine site to mine site.

– Over the Tail

Loading through the rear at 45° is similar to the 90° bottom side loadingmethod, except that the truck is positioned at 45° to the excavator.

This technique allows smoother bucket unloading when coming inthrough the rear of the truck body and requires less hoisting than 90° over


Box Cut – The initial excavation that is dugwhen opening up a new pit

The first excavation in a new pit in a coal mine is called a Box Cut, as thereare no open faces. Box cuts incur large volumes ofoperation. They tend to have bends in the pit as they follow the LOX (lineof oxidation) line of the coal seam.

A large number of box cuts are initially exposed by means of Truck andLoader work.


The initial excavation that is dugwhen opening up a new pit

The first excavation in a new pit in a coal mine is called a Box Cut, as thereare no open faces. Box cuts incur large volumes of rehandle in a draglineoperation. They tend to have bends in the pit as they follow the LOX (line

A large number of box cuts are initially exposed by means of Truck and


Brakes

Brakes are used to slow down or stop a truck as required. The main formsof brakes in modern trucks are disc brakes. Disk brakes are actuated byhydraulic oil.


own or stop a truck as required. The main formsof brakes in modern trucks are disc brakes. Disk brakes are actuated by


Brake Oil reservoir & Level indicatorIndicates oil level

Allows operators to check oil level and if necessary rrequired level.

The sight glass allows operators to visually check rather than the oldfashioned dip stick method.


Brake Oil reservoir & Level indicator –

Allows operators to check oil level and if necessary refill oil to the

The sight glass allows operators to visually check rather than the old


Bucket – Loading/digging device

Refer to sections:

Hydraulic Shovel - Bucket Excavator - Bucket Rope Shovel - Dipper Front End Loader- Bucket


digging device


Bucket Spotting Time

This is the time taken to correctly engage the material being dug followingthe dumping into a truck. Operators should know where the nextbucketful is to be placed for optimal engage as part of the

Bucket Tooth – Cutting Tip that is pinned tothe Adaptor

The tooth on the bucket is the main cutting edge when digging.various tooth styles and manufacturers in the market, so each mine has topick teeth that meet their requirements.adaptors and are pinned to allow removal when they are worn out.

Some mines have the tips of the teeth hard surfaced to get longer wear outof them and thus lower ground engaging tool (G.E.T.) costs.


– Digging

This is the time taken to correctly engage the material being dug followingthe dumping into a truck. Operators should know where the nextbucketful is to be placed for optimal engage as part of the sequence

Cutting Tip that is pinned to

The tooth on the bucket is the main cutting edge when digging. There arevarious tooth styles and manufacturers in the market, so each mine has topick teeth that meet their requirements. The teeth are mounted onadaptors and are pinned to allow removal when they are worn out.

Some mines have the tips of the teeth hard surfaced to get longer wear outof them and thus lower ground engaging tool (G.E.T.) costs.


Bund/Rill/Berm – See Windr

The safety berms must be at least half the height of the tyre of thelargest vehicle

Berms and windrows are a safety feature which are designed for haulvehicles and other mine vehicles to prevent them accidently running overthe edge of elevated sections such as ramps or dumps.

There are at least three principle berm/windrow designs that are commonwithin the mining industry.

Edge Berm/Windrow Central Berm/Windrow for lane separation Safety or Runaway Berm/Windrow

Regular inspections must be planned

Cab - Operators Cabin

Refer to Operators Cab in the Dictionary


See Windrow

The safety berms must be at least half the height of the tyre of the

Berms and windrows are a safety feature which are designed for haulvehicles and other mine vehicles to prevent them accidently running over

ons such as ramps or dumps.

There are at least three principle berm/windrow designs that are common

Central Berm/Windrow for lane separationSafety or Runaway Berm/Windrow

Regular inspections must be planned.

Operators Cabin

Refer to Operators Cab in the Dictionary


Cable Access - Roadway for Cable

Cable access needs to be prepared to allow safe entry of ancillaryequipment/trucks and light vehicles. The access is required to be wideenough for the largest equipment to pass through safely.

Cable Access beside roadway


Roadway for Cable

Cable access needs to be prepared to allow safe entry of ancillarytrucks and light vehicles. The access is required to be wide

largest equipment to pass through safely.

Cable Access beside roadway


Cable Crossing – Portable Power CableProtection Equipment

Various means and methods are used to protect portable power cablesfrom damage and allow truck access in and around shovels and haulroads. Reflective topped safety cones mark unprotected cables.


Portable Power CableProtection Equipment

Various means and methods are used to protect portable power cablesfrom damage and allow truck access in and around shovels and haul

e topped safety cones mark unprotected cables.


Cable Layout – Storing excess cable

“Cable loops” refers to the way excess cable is looped when it is stored onthe ground.

Cables must be laid out conducive to the type of loadingsequence required.

Cable moves must be pre-planned and laid out prior to shovel moves,so as to minimize excessive down times.

Cables should be positioned in such a way out of the blasting areaif applicable.

Cables should be hoisted up on cable towers to allow easier accesstrucks and ancillary equipment, for cleaning the face and doublesided loading.

For deadheading to new a new area, cable layout should be donebefore the walk begins to minimize delays.


Storing excess cable

“Cable loops” refers to the way excess cable is looped when it is stored on

Cables must be laid out conducive to the type of loading

planned and laid out prior to shovel moves,so as to minimize excessive down times.Cables should be positioned in such a way out of the blasting area

Cables should be hoisted up on cable towers to allow easier access fortrucks and ancillary equipment, for cleaning the face and double

For deadheading to new a new area, cable layout should be donebefore the walk begins to minimize delays.


Cable Plug Stands – Keeps Cable Plugs offthe Ground

Cable Plug Stands are used to keep cable plugs above the ground. Cableplug halves are connected with a rubber seal in the middle to keepmoisture out. However it is a requirement that they do not becomeimmersed in water. Therefore stands are used to raise themground. There are as many different styles of stand as there are mines.

Cable Plug


Keeps Cable Plugs off

Plug Stands are used to keep cable plugs above the ground. Cableplug halves are connected with a rubber seal in the middle to keepmoisture out. However it is a requirement that they do not becomeimmersed in water. Therefore stands are used to raise them off theground. There are as many different styles of stand as there are mines.

Cable Stand


Cable – Power Lead that delivers Power to aRope Shovel

The cable is like an extension lead that brings the power from thesubstation to the rope shovel. The new cablmetres or 500 metres and can be ~8it has to endure the rigors of being moved around the rope shovel. Thecore is made up of 3 cables and a continuity wire encased in heavy rubber.


Power Lead that delivers Power to a

The cable is like an extension lead that brings the power from thesubstation to the rope shovel. The new cable comes in lengths of 300metres or 500 metres and can be ~8-10cm in diameter. It is very robust asit has to endure the rigors of being moved around the rope shovel. Thecore is made up of 3 cables and a continuity wire encased in heavy rubber.


Cable Reel - Cable storage directly attachedto some Electric Rope Shovels


storage directly attachedto some Electric Rope Shovels


Cable Towers- Cable trees

Cable Towers/trees are used for lifting cables above roadways to allowvehicles to safely pass under. There are a number of designs and itimportant that they are stable and when raising the cable with the liftropes. No personnel should be positioned below the cable in the event thatit might fall.

Capital Cost

Capital is a one-time setup cost of plant (equipment) or a project, afterwhich there will only be recurring operational or running costs.

Loaders may now cost up to $50M and Trucks >$7M.

Capital costs include Buckets, motors, structure, etc.

By capitalising these costs the mine can spread the cost over the expectedlife.

In any capital application you will be asked to:

Justify the investment of the money Internal rate of return Payback period Net present value

Generally needs to be approved in the 6year starting

Capital costs should include cost of engineering in th

Design work


Cable trees

trees are used for lifting cables above roadways to allowvehicles to safely pass under. There are a number of designs and it

hey are stable and when raising the cable with the liftNo personnel should be positioned below the cable in the event that

time setup cost of plant (equipment) or a project, afterbe recurring operational or running costs.

now cost up to $50M and Trucks >$7M.

Capital costs include Buckets, motors, structure, etc.

By capitalising these costs the mine can spread the cost over the expected

you will be asked to:

Justify the investment of the money

Generally needs to be approved in the 6-9 months prior to the financial

Capital costs should include cost of engineering in the capital for example:


Physical modelling Engineering

Carry Back – Material stuck in truck trays

Carry back occurs when material hangs up at the tail, front or sidesections of a haul road truck with the consequence of the piece ofequipment carrying material back to the loading site and reducing theactual load the truck dumps. This is dependent on type of material beingcarried and the condition of it ie. Wet or dry. A further cause can be thetype of tray depending on material being used andmore prone than other to have carry back.

There are many ways in which to combat this reoccurring problem,however some are costly.

Teflon lining in pan Various tumble boards Kick plates Exhaust system

Each operation has to solve the problem, and make its staff aware of thecosting and losses; however the simplest and cheapest method is to usethe excavator if available.

The dump dozer operator and/or the loading unit operator can inform thetruck when there is carry back present.


Material stuck in truck trays

Carry back occurs when material hangs up at the tail, front or sidesections of a haul road truck with the consequence of the piece of

rrying material back to the loading site and reducing theactual load the truck dumps. This is dependent on type of material beingcarried and the condition of it ie. Wet or dry. A further cause can be thetype of tray depending on material being used and design some try aremore prone than other to have carry back.

There are many ways in which to combat this reoccurring problem,

roblem, and make its staff aware of thecosting and losses; however the simplest and cheapest method is to use

The dump dozer operator and/or the loading unit operator can inform thetruck when there is carry back present.


CAT 777 – Dump Truck

CAT 777 SeriesCAT777

EngineGross Power (kW) 648.8

Net Power (kW)

Transmission Max. Speed (kph)

WeightEmpty (kg) 56428

Loaded (kg) 133540

OperatingSpecifications

Capacities(m3)

Struck

Heaped

Rated Payload (kg) 77,111

Fuel Capacity (L)

Dimensions

Overall Length (m)

Overall Width (m)

Overall Height (m)


Dump Truck

CAT777

CAT777B

CAT777C

CAT777D

CAT777F

648.8 686 745.7 758

649 649 699.5 700

58.3 60 60 60.4 64.5

56428 60055 61800 70306.8 73976.4

133540 146966 148000 161030 163293

36.3 36.4 42 41.9

51 51 52 61 60

77,111 86,183 86,200 90,400 90,719

947 946 1137 1136

9.8 9.79 9.79 9.78 10.54

3.51 5.46 5.13 6.1 6.49

4.9 4.9 5.02 5 5.17



CAT 785

EngineGross Power (kW)

Net Power (kW)

Transmission

Max. Speed (kph)

WeightEmpty (kg)

Loaded (kg)


Capacities (m3)Struck

Heaped

Rated Payload (tonnes)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Dimensions

Overall Length (mm)

Overall Width (mm)

Overall Height (mm)


Dump Truck

CAT785

CAT785B

CAT785C

CAT785D

1029 1029 1082 1082

962 962 1005 1005

56 54.8 54.8 54.8

96353 94922 95725106218-117597

249433 249480 249480 249476

57 57 57

78 78 78 78-85

136 118-136 136 131-143

1893 1893 1893 1893

11200 11207 11207 11809

15 15.2 15.2

11020 11022 11024 11548

6630 6277 6274 7061

5770 5769 5769 5679



CAT 789 Series


Net Power (kW)


WeightEmpty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped

Rated Payload (kg)

Fuel Capacity (L)

Dimensions

Overall Length (m)

Overall Width (m)

Overall Height (m)


Dump Truck

CAT789

CAT789B

CAT789C

CAT 789D

1342.3 1342 1417 1566

1271.4 1272 1320 1468

54 54.4 52.6 57.2

121922 121922 135670 135012

317460 300000 317515 324319

73 92 108SAE 2:1105 104.6 105

176901 177000 176901 181000

3222 3222 2082

12.18 12.18 12.18 12.7

7.34 7.34 7.67 6.5

6.15 6.15 6.18 5.51



CAT 793 SeriesCAT793

Engine

Gross Power (kW)

Net Power (kW) 1534

Transmission Max. Speed (kph) 53.6

Weight

Empty (kg)15799

Loaded (kg)37499


Capacities (m3)

Struck

Heaped

129.2

Rated Payload (kg)21700

Fuel Capacity (L)

Dimensions

Overall Length (m) 12.87

Overall Width (m) 7.41

Overall Height (m) 6.43


Dump Truck

CAT CAT793B

CAT793C

CAT793D

CAT 793F

1715.1

1801 1976

1534 15341615.

21743 1848

53.6 53.6 53.6 54.3 60

157992

157992

113510

159662

159207-163289

374992

374992

376490

383749

386007-390089

96 96 112-142

129.2 129.2 129 129159-190SAE 2:1

217000

217000

223168

217724

226800

3790 4354 2839/4922

12.87 12.87 12.87 12.86 13.7

7.41 7.41 7.41 7.68 8.3

6.43 6.43 6.43 9.49 6.53



CAT 795

Engine Gross Power (kW)


WeightEmpty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (tonnes)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Dimensions

Overall Length (mm)

Overall Width (mm)

Overall Height (mm)


Dump Truck

CAT 795F AC

2536

64

202270

570678

Struck 121.5-211

SAE 2:1 181-252

Rated Payload (tonnes) 313

3596

15445

26

15146

9449

7800



CAT 797 Series


Net Power (kW)


WeightEmpty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped

Rated Payload (kg)

Fuel Capacity (L)

Dimensions

Overall Length (m)

Overall Width (m)

Overall Height (m)


Dump Truck

CAT 797 CAT 797B CAT 797F

2535.4 2648 2983

2406.4 2513 2828

64 67.6 67.6

231313 265000 260810

557900 623690 623690

173 188-213

Heaped 220 220240-267SAE 2:1

326587 360000 363000

6813 6813.7 3785

14.53 14.53 15.09

9.15 9.15 9.53

7.24 7.58 6.53


CAT 992 – Front End Loader

Caterpillar


Flywheel Power (kW)


Rated Payload (metric ton)

Operating Weight (kg)

BucketsCapacities

Heaped (m3)

Struck (m3)

Transmission

MAX Speed-Forward (kph)

MAX Speed-Reverse (kph)

HydraulicSystem

Raise Time (sec)

Dump Time(sec)

Lower Time(sec)

Dimensions

MAX Overall Length(m)

Height To Top Of Cab (m)

Reach At Max Lift AndDump (m)

OthersPass Match with Trucks(CAT)


Front End Loader

992C 992D 992G 992K

548.1 548.1 656 674.1

514.5 514.5 597 597.3

21.8 21.7

85180 89158 94927 97498.8

9.6 10.7 11.5 12.2

8.2 8.9 9.5 10.7

21.1 21 21.8 20.6

23.3 22.9 24 22.4

12 11.4 9.1 9.4

2.5 3.4 3.2 1.8

4 3.7 3.5 3.7

12.72 13.15 15.59 15.74

8.74 5.49 5.59 5.68

2.08 2.31 2.32 2.33

777D/785C

775/777/785


CAT 993K – Front End Loader

Caterpillar


Flywheel Power (kW)




Buckets CapacitiesHeaped (m3)

Struck (m3)

TransmissionMAX Speed-Forward (kph)


Hydraulic System

Raise Time (sec)

Dump Time(sec)

Lower Time(sec)

Dimensions

Length with Bucket on Ground (m)


Reach At Max Lift And Dump (m)

Others Match Trucks (CAT)


Front End Loader

993K

Gross Power (kW) 782

Flywheel Power (kW) 708

Rated Payload (metric ton) 22.7

erating Weight (kg) 133637

13

10

Forward (kph) 21.9

Reverse (kph) 24.2

Raise Time (sec) 2.4

Dump Time(sec) 9.4

Lower Time(sec) 2.1

th Bucket on Ground (m) 15.21

Height To Top Of Cab (m) 6

Reach At Max Lift And Dump (m) 2.5

Match Trucks (CAT)777(Std)/

785(High lift)


CAT 994 – Front End Loader

Caterpillar


Flywheel Power (kW)




BucketsCapacities

Range (m3)

TransmissionMAX Speed-Forward (kph)


Hydraulic System

Raise Time (sec)

Dump Time(sec)

Lower Time(sec)

Dimensions

Overall Length(m)


Reach At Max Lift And Dump(m)

Others Pass Match with Trucks (CAT)


Front End Loader

994 994D 994F

996 1027 1176

932 933 1092

Rated Payload (metric ton) 3134.5(Std.)/

31(HL)35(Std.)/

32(HL)

177037

191200 195434

17.6 15-31 14-36

Forward (kph) 24 24

Reverse (kph) 25.6 25.6

12.5 11.3

3.4 3.1

4 3.5

16.81(Std.)/

17.59(HL)

16.88(Std.)/

17.52(HL)

Height To Top Of Cab (m) 6.71 6.74

Reach At Max Lift And Dump2.26 2.31

Pass Match with Trucks (CAT)785C, 789C(Std.)/

789C, 793C(HL)


CAT5130B – Hydraulic Shovel

CAT 5130

BackhoeBucket

EngineGross power (kW)

Flywheel Power (kW)

WorkingRange

Max. Digging Depth (m)

Max. Cutting Height (m)

Max. Loading Height(m)

Max Digging Reach (m)



Buckets

Capacities (m3)

Boom Length (mm)

Stick Length (mm)

Dimensions(mm)

Overall Height (To Cab)

Overall Length (NoBucket)

Overall Width



Hydraulic Shovel/Excavator

5130 5130B

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

600 600 641 641

555 555 597 597

8.4-9.7 3.2

14.3-14.9 13.3

9.1-9.6 8.3-9.1

14.9-16.2 12.4

175000 170000 182000 181000

3.3 3.3

7.8 10.5 8.5-18.3 9.0-11.0

8560 6401

5258 4928

6550 6550

8885 8885

6620 6620

777D,775D,773D


CAT5230B – Hydraulic Shovel

CAT 5230

BackhoeBucket

EngineGross power (kW)

Flywheel Power (kW)

WorkingRange

Max. Digging Depth(m)

Max. Cutting Height(m)

Max. Loading Height(m)

Max Digging Reach(m)

Operating Weight (kg) 314793

Transmission

Max. Speed (kph)

Buckets

Capacities (m3)

Boom Length (mm)

Stick Length (mm)

Dimensions(mm)

Overall Height (ToCab)


Overall Width




5230 5230B

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

1096.2 1096.2 1232 1232

1081 1081 1140 1140

9.4 9.5 3.8

15.1 15.2

9.8 9.8 10.3

17.2 17.8 14.9

314793 328100 327000

2.5 2.5-3.4 2.5-3.4

17 16 17

9.5 6.9

4.5 4.7

7455

10000 10300 10300

6296

785, 789, 793


CAT6015 (RH40E) – HydraulicShovel/Excavator

CAT 6015 (RH40E) CAT6015

BB

Engine Net Power (kW)

Working Range



Max. Dumping Height(m)




Buckets

Capacities (m3)

SAE 1:1

SAE 2:1

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height

Overall Length(No Bucket)

Overall Width

Notes: BB = Backhoe Bucket; SB = Shovel Bucket


Hydraulic

CAT6015 RH40E

BB SB BB SB

522 522 453 453

7.3 2.2 7.3 2.1

11 10.9

13 8.8 12.8 8.8

13.5 10.5 13.5 10.5

105600 105200 103200 103600

2.7 2.7 2.34 2.34

6 8.1 6 8.1

5.2 7 5.2 7

7.8 5.05 7.8 5.05

3.3 3.55 3.3 3.55

5250 5250 5250 5250

7355 7355 7355 7355

5340 5340 4740 4740



CAT6030 (RH120E) –Shovel/Excavator

CAT 6030 (RH120E)


WorkingRange



Max. Dumping Height (m)




Buckets

Capacities(m3)

SAE 1:1

SAE 2:1

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height


Overall Width

Others Match Trucks



Hydraulic

CAT6030 RH120E

BB SB BB SB

1140 1140 1044 1044

6.1 2.5 6.1 2.5

14.5 13.9 14.4 13.9

10.7 10.7

15.1 13.7 15.3 13.7

289700 287000 287100 284100

1.4-2.7 1.4-2.7 1.4-2.7 1.4-2.7

17 19 17 19

15.3 16.5 15.3 16.5

8.5 6.2 8.5 6.2

4 4.4 4 4.4

7600 7600 7600 7600

10270 10270 10270 10270

6390 6390 6390 6390

136 tonnes truck



CAT6040 (RH170B) –Shovel/Excavator

CAT 6040 (RH170B and 170) CAT6040

BB

Engine Net Power (kW) 1516

WorkingRange



16.8



17.7

Operating Weight (kg)3970

00

Transmission

Max. Speed (kph)1.52.5

Buckets

Capacities (m3)

SAE 1:1 22

SAE 2:1 19.5

Boom Length (m) 9.5

Stick Length (m) 4.6

Dimensions(mm)

Overall Height 7870


1103

Overall Width 7200

Others Match Trucks



Hydraulic

CAT6040 RH170B RH170

SB BB SB BB SB

1516 1516 1516 1516 1516 1516

7 2.6 7 2.6 7 2.6

16.8 14.4 17 14.4 17 14.4

10.9 10.9 10.9

17.7 15.4 17.7 15.4 17.7 15.4

397000

397400

393800

394400

1.5-2.5

1.5-2.5

1.6-2.6

1.6-2.6

1.6-2.6

1.6-2.6

22 25.3 20 25.3 20

19.5 22 17.7 22 17.7 21

9.5 7.3 7.3 9.5

4.6 4.6 4.6 4.5

7870 7870 7870 7870 7870 7870

11035

11035

11035

11035

11035

11035

7200 7200 7200 7200 7200 7200

172 tonnes truck



CAT6050 (RH200) – Hydraulicshovel/Excavator

CAT 6050 (RH200)


WorkingRange






Transmission

Max. Speed (kph)

Buckets

Capacities (m3)

SAE1:1

SAE2:1

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height


Overall Width

Others Match Trucks



Hydraulic

CAT6050 RH200

BB SB BB SB

1880 1880 1880 1880

9.2 2.4 9.2 2.4

16.8 15.3 17 15.3

11.8 11.8

19.5 16.2 19.4 16.2

534000 525000 537000 525000

1.6-2.3 1.6-2.3 1.6-2.3 1.6-2.3

SAE28 30.5 28 30.5

SAE24.6 26 24.6 26

10.5 8 10.5 8

5.5 5.1 5.5 5.1

8760 8760 8760 8760

11850 11850 11850 11850

8730 8730 8100 8100

218 tonnes truck



CAT6060 (RH340B) –Shovel/Excavator

CAT 6060 (RH340 and340B)

CAT6060

BB SB

Engine Net Power (kW) 2240 2240

WorkingRange

Max. DiggingDepth (m)

8.9 2.7

Max. CuttingHeight (m)

15.9 15.5

Max. DumpingHeight (m)

11.6

Max DiggingReach (m)

18.9 16.4

OperatingWeight (kg)

56450056230

0

Transmission

Max. Speed(kph)

1.4-2.0 1.4-2.0

Buckets

Capacities (m3)

SAE1:1

34 39.5

SAE2:1

30.3 34

Boom Length(m)

10.5 8

Stick Length(m)

5 5.1

Dimensions(mm)

Overall Height 8770 8770


12570 12570

Overall Width 8730 8730

Others Match Trucks



– Hydraulic

CAT6060E RH340B RH340

BB SB BB SB BB SB

1800 1800 2240 2240 1880 1880

8.9 2.7 8.9 2.7 8.9 15.4

15.9 15.5 15.9 15.5 15.9 15.4

11.6 11.6 11.5

18.9 16.4 18.9 16.4 18.9 16.3

545500

542300

567500

566600

547000

552000

1.4-2.0 1.4-2.0 1.5-2.0 1.5-2.0 1.5-2.0 1.5-2.0

34 39.5 34 39.5 34 39.5

30.3 34 30.3 34 30.3 34

10.5 8 10.5 8 10.5 8

5 5.1 5 5.1 5 5.1

8770 8770 8770 8770 8770 8770

12195 12195 12570 12570 12195 12195

8730 8730 8100 8100 8250 8250

218 tonnes truck MT4400



CAT6090 (RH400) – HydraulicShovel/Excavator

Caterpillar (O&K)

Engine Rate Power (kW)

Working Range






Payload (tonnes)


Buckets

Capacities(m3)

SAE 1:1

SAE 2:1

Boom Length (m)

Stick Length (m)

Dimensions(mm)


Overall Length (No Bucket)

Overall Width


Hydraulic

CAT 6090 RH400

Shovel Bucket Shovel Bucket

3360 3360

2.3 2.3

20.2 20.2

Max. Dumping Height (m) 14.5 14.5

19 19

980000 980000

90

1.6-2.2 1.7-2.2

SAE 1:1 59.8 (Std. rock) 52 (oil sand)

SAE 2:1 52 (Std. rock) 45 (oil sand)

9.5 9.5

5.8 5.6

9990 10175

Overall Length (No Bucket) 13545 13490

9070 9780


CAT (Unit Rig) MT3000

CAT (Unit Rig)


Net Power (kW)


WeightEmpty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Dimensions

Overall Length (mm)

Overall Width (mm)

Overall Height (mm)


CAT (Unit Rig) MT3000 – Dump Truck

MT3000


Max. Speed (kph) 50

97470

206470

Struck

Heaped 2:1 76

Rated Payload (kg) 109000

Fuel Capacity (L)

Dump Height (mm)

25

Overall Length (mm) 12200

dth (mm) 6300

Overall Height (mm) 6300



CAT (Unit Rig)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Dimensions Overall Length (mm)

Overall Width (mm)

Overall Height (mm)


CAT (Unit Rig) MT3300 - Dump Truck

MT3300 MT3300AC

1007 1286

1171

53 64

104890 112880

240890 248934

Struck 59

Heaped 2:1 87 90

136000 136000

2271

10800-11900

29 20

12200 12300

6300 7100

6100 6400



CAT (Unit Rig)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


CAT (Unit Rig) MT3600 - Dump Truck

MT3600 MT3600B

1343 1286.3

1174.5

56 56.4

105053 116348

277053 270569

Struck 62

Heaped 2:1 98 98

172000 154221

2877

11800

27 31

12700 13100

6700 7300

6800 6800



CAT (Unit Rig)


Net Power (kW)


WeightEmpty (kg)

Loaded (kg)


Capacities (m3)

Struck

Heaped2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Dimensions

Overall Length (mm)

Overall Width (mm)

Overall Height (mm)



MT3700 MT3700B MT3700AC

1492 1286.3 1510

1174.5 1398

55 55 65

120869 131065 149660

306809 317037.9 335600

Struck 77 92

Heaped105 111 123

185940 185972.9 186000

2877 2877

11900 12000

27 19 22

12700 13100 13100

6700 7300 7300

6800 6900 6900



CAT (Unit Rig)


Net Power (kW)


WeightEmpty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Dimensions

Overall Length (mm)

Overall Width (mm)

Overall Height (mm)



MT4000

kW) 1641

Net Power (kW)

Max. Speed (kph) 50

138034

357034

Capacities (m3)

Struck

Heaped 2:1 140


Fuel Capacity (L)

Dump Height (mm)

27


Overall Width (mm) 7160




CAT (Unit Rig)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3) Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)



MT4400 MT4400AC

1865 2014

1706 1855

48 64

160998 170975

390930 392290

Struck 100 100

Heaped 2:1 144 144

236000 218000

3028 3028

12800 12700-13900

22 22

13900 14100

8000 8000

7200 7100



CAT (Unit Rig)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)



MT5500 MT5500AC

2014 2712

1847

65 65

216780 216780

543311 543311

Struck 158 158

Heaped 2:1 218 218

326000 326000

3028 3028

13440 13440

28 28

14780 14780

9450 9450

7670 7670



CAT (Unit Rig)


Net Power (kW)


WeightEmpty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Dimensions

Overall Length (mm)

Overall Width (mm)

Overall Height (mm)



MT6300AC

2796

2610

64

235828

598640

Struck

Heaped 2:1

363000

13440


9540



CCTV – Machine cameras

Cameras assist the operators to observe in the blind spot of the machine.These are a valuable safety feature installed on many typ

Circuit Control

Communicate and take control:

Responsibility rests with the loader operator. Truckies informed as to what is needed and given lead time. Positive and negative feedback. Everyone must inform the loading unit about an

the circuit flow. Help each other to keep the trucks cycling at equal intervals.


Machine cameras

Cameras assist the operators to observe in the blind spot of the machine.These are a valuable safety feature installed on many types of equipment.

Responsibility rests with the loader operator.Truckies informed as to what is needed and given lead time.

Everyone must inform the loading unit about anything that will affect

Help each other to keep the trucks cycling at equal intervals.


Clean-up Outside Swing Radius

The clean-up dozer pushes material up to maximum reach of theexcavator without interfering with the excavato

Once the area outside the swing radius is clean, the dozer needs to wait forpermission from the excavator operator to enter the swing radius area.


up Outside Swing Radius – Spillage

up dozer pushes material up to maximum reach of theexcavator without interfering with the excavator’s swing radius.

Once the area outside the swing radius is clean, the dozer needs to wait forpermission from the excavator operator to enter the swing radius area.


Clean-up Inside Swing Radius

Cleaning inside the swing radius is whenup inside the bucket swing arc. Before entering the area, the cleanupmachine operator should obtain permission from the excavator operator.

A safe practice is:

The excavator operator stops digging, grounds the bucket and sets thebrakes before allowing the cleanup machine to continue.

No vehicle is to go between the excavator and the truck being loaded. No vehicle shall be permitted to go within the splash zone, which is

behind, beside or in front of the truck being loaded.


up Inside Swing Radius – Spillage

Cleaning inside the swing radius is when machines are required to cleanBefore entering the area, the cleanup

machine operator should obtain permission from the excavator operator.

The excavator operator stops digging, grounds the bucket and sets thebrakes before allowing the cleanup machine to continue.No vehicle is to go between the excavator and the truck being loaded.No vehicle shall be permitted to go within the splash zone, which isbehind, beside or in front of the truck being loaded.


Climbing Up Work Benches

Approach the bench at a 90° angle and use the bucket to pull the topsection down to lessen the angle of the climb.must not be exceeded

Push the stick out and place the bucketon top of the bench.

When nearing the top of the bench,start lifting the boom to just clear of thesurface.

Once at the top of the bench, push thestick out to maintain balance.


bing Up Work Benches – Procedure

Approach the bench at a 90° angle and use the bucket to pull the topsection down to lessen the angle of the climb. A maximum angle of 30%

Co-ordinate pulling the stick in andwalking the excavator to climb thebench.

Select Low Speed and fully depress thepedals to enable the travel retardervalve tooperate properly.


Controls – All Machines

Refer to Excavator or Truck controls in the Dictionary of youroperator’s manual.

Push the edge of the bench over andplace the bucket on the pit floor.

Walk down the decline slowly, keepingthe weight on the boom and stick.


All Machines

Refer to Excavator or Truck controls in the Dictionary of your

Walk the excavator to the edge andstart the decline from the bench,keeping the tracks at a 90° angle to thebench. A maximum angle of 30% mustnot be exceeded.

When approaching the bottom of thebench, commence lifting the bucket toclear the surface. Continue walking offthe bench, raising the bucket to clearthe surface.


CPP/ CHPP – Coal (handling) preparationplant

Coal Handling and Preparation PlantPlant (CPP).

Coal - A Fossil Fuel consisting of CarbonisedVegetable Matter.

A fossil fuel consisting of carbonized vegetable matter deposited in theCarboniferous period and altered through the actions of heat andpressure.

The coal seam is compressed vegetable matter laid down in horizontallayers. Some mines have multiple seams that they mine.

Coal Seams are varied and of different qualities.


handling) preparation

Coal Handling and Preparation Plant, another term for Coal Preparation

A Fossil Fuel consisting of Carbonised

A fossil fuel consisting of carbonized vegetable matter deposited in theCarboniferous period and altered through the actions of heat and

The coal seam is compressed vegetable matter laid down in horizontallayers. Some mines have multiple seams that they mine.

Coal Seams are varied and of different qualities.


Coal Edge – The Extent of the Exposed Coalon the Low Wall Side

The coal edge is the low wall side of the exposed coal seam. Mostoperations prefer to dig a bucket width down to the bottom of the coalseam to allow cleaner extraction of the coal.cost of extra rehandle as the low wall has to be movmaintain the correct angle and for the toe to meet the trench floor.

Coal Edge


The Extent of the Exposed Coal

oal edge is the low wall side of the exposed coal seam. Mostoperations prefer to dig a bucket width down to the bottom of the coalseam to allow cleaner extraction of the coal. This procedure comes at acost of extra rehandle as the low wall has to be moved further out tomaintain the correct angle and for the toe to meet the trench floor.


Coal floor clean-up – Minimisescontamination with unwanted spoil

The easiest way to prevent/ reduce coal contamination is for loaderleave a thin layer of coal in the digging area for the dozers to clean upmore accurately than the loaders can.equipment that is operating in the digging area from churning up theboundary between the coal and the spostockpile of the “cleaned up” coal in the pit which is then loaded intotrucks.

The result is greater volume of good quality coal with less or no wastedcoal at the wash plant. This reduces the running cost of the coal waplant and as well an increasing the efficiency of the operation.

Caution: Clean up the floor and remove any over spillage after filling thetruck on a regular basis. Uneven Coal/ pit floors can damage the trucktyres.


Minimises coalcontamination with unwanted spoil

The easiest way to prevent/ reduce coal contamination is for loaders toleave a thin layer of coal in the digging area for the dozers to clean upmore accurately than the loaders can. The aim is to prevent the miningequipment that is operating in the digging area from churning up theboundary between the coal and the spoil underneath. The dozers create astockpile of the “cleaned up” coal in the pit which is then loaded into

The result is greater volume of good quality coal with less or no wastedcoal at the wash plant. This reduces the running cost of the coal washingplant and as well an increasing the efficiency of the operation.

Clean up the floor and remove any over spillage after filling thetruck on a regular basis. Uneven Coal/ pit floors can damage the truck


Coal Mining – Digging, LoadiTransporting the Coal

Coal mining consists of digging, loading and transporting the coal to thewash plant. Most times the coal seam is blasted to break up the hard coalseam to make it easier to dig.

Digging & Loading: There are many machines for dthe coal. Mines that have large coal seams mostly use Trucks and Shovelextraction.

Mines with smaller seams tend to use excavators andloaders.

Truck fleets can include bottom (belly) dumpers and rear dumpers. Someeven use conveyor systems.

Some of the smaller mines use road trucks to haul the coal.


Digging, Loading andTransporting the Coal

Coal mining consists of digging, loading and transporting the coal to thewash plant. Most times the coal seam is blasted to break up the hard coal

There are many machines for digging and loadingthe coal. Mines that have large coal seams mostly use Trucks and Shovel

Mines with smaller seams tend to use excavators and/or front end

Truck fleets can include bottom (belly) dumpers and rear dumpers. Some

Some of the smaller mines use road trucks to haul the coal.


Coal Recovery Measurement TrenchesComparing geologicalactual coal seam thickness

A coal recovery measurement trench is dug across a strip to measure thethickness of a coal seam. A measurement is then made from the top ofcoal to the bottom of the seam and is compared with the predictedgeology. If the measurement varies from the predicted thickness of theseam, a variance from the predicted amount of coa

Coal Reject Silo/ Bin –unwanted wash plant material for removalby dump truck


Coal Recovery Measurement Trenches –geological predictions and

actual coal seam thickness

A coal recovery measurement trench is dug across a strip to measure thethickness of a coal seam. A measurement is then made from the top ofcoal to the bottom of the seam and is compared with the predicted

If the measurement varies from the predicted thickness of theseam, a variance from the predicted amount of coal will result.

– Storage area ofunwanted wash plant material for removal


Collision Avoidance –be maintained between equipment

Distances vary from mine site to mine site. Check regulations for ymine. Most mines are investigating collision avoidance systems to assistin preventing incidents as well as minimising interaction between lightvehicles and heavy equipment.

Collision Avoidance drivingdistance between equipment

Distances vary from mine site to mine site. Check regulation for yourmine.

The minimum safety distance between two trucks was implemented toallow the driver sufficient time to react and apply the brakes withoutrunning the risk of not to having enough distance to


Minimum distance tobe maintained between equipment

Distances vary from mine site to mine site. Check regulations for yourmine. Most mines are investigating collision avoidance systems to assistin preventing incidents as well as minimising interaction between light

Collision Avoidance driving – Minimumdistance between equipment

vary from mine site to mine site. Check regulation for your

The minimum safety distance between two trucks was implemented toallow the driver sufficient time to react and apply the brakes withoutrunning the risk of not to having enough distance to stop.




Compressed Air TankCompressed Air

The air tank is a large pressure vessel that holds the supply of compressedair. Loaders and trucks are generally fitted with some kind of storage tankfor compressed air to assist in the breaking, starting and ancillarysystems. Air tanks are being constantly refilled during operation but, intrucks, if brakes are constantly applied the air compressor might not beable to refill the tank sufficiently to maintain working pressure. Loss ofbraking power may occur.

Air tanks are subject to statutory testing periodically.

CompressedAir Tank


Compressed Air Tank – Holds the Supply of

The air tank is a large pressure vessel that holds the supply of compressedair. Loaders and trucks are generally fitted with some kind of storage tank

breaking, starting and ancillarysystems. Air tanks are being constantly refilled during operation but, intrucks, if brakes are constantly applied the air compressor might not beable to refill the tank sufficiently to maintain working pressure. Loss of

Air tanks are subject to statutory testing periodically.

CompressedAir Tank


Cooling fan motor – Electric motor cooling

These are used to cool electric motors on some equipment.

Counterweight – Balance

Counterweights are designed to balancebucket/dipper including the weight of all attachments and spoilcontained. The reasoning for this is to control centre of gravity on themachine.


Electric motor cooling

These are used to cool electric motors on some equipment.

alance

Counterweights are designed to balance the weight of a fully ladendipper including the weight of all attachments and spoil

contained. The reasoning for this is to control centre of gravity on the


Crowd – Force applied to load

The crowd gear/motor provides extra power and forcshovel to push the dipper into the bank. This action in conjunction withthe hoist loads the bucket.

Cycle efficiency – Optimal cycle timeefficiency

The key to maximising efficiency is to minimise the work cycle.one or two seconds on each load cycle can increase efficiency over arelatively short period.


Force applied to load

motor provides extra power and force to enable a ropepush the dipper into the bank. This action in conjunction with

Optimal cycle time

to maximising efficiency is to minimise the work cycle. A saving ofwo seconds on each load cycle can increase efficiency over a


Cycle time (truck) – Time to complete afull cycle

Truck cycle time consists of travelling, waiting time, queuing, spotting,dumping and loading. Measured from a specisame point in the next cycle.

Cycle time (loading unit)truck to truck

Cycle time includes truck spotting time, digging, swinging and loadingtime. It is again defined as the time from a specified point in othe same point in the next cycle.

DigSwingFull

Spotting Dump

Phase Delay Phase

One Cycle


Time to complete a

Truck cycle time consists of travelling, waiting time, queuing, spotting,dumping and loading. Measured from a specified point in one cycle to the

Cycle time (loading unit) – Load time from

Cycle time includes truck spotting time, digging, swinging and loadingIt is again defined as the time from a specified point in one cycle to

DumpSwingEmpty

DigSwingFull

Phase

New Cycle


Defect Reporting – Reporting of defectson machinery

Defects or faults should be looked for and will from time to time beobserved during pre-shift inspections, walk around checks, duringoperation orother activities.

If an observed defect is such that the equipment is unsafe to operate:

The operator must attach an Out of Service tag to the appropriateposition to ensure that either the faulty component or the wholemachine (as applicable) is not operate

Report this to your supervisor immediately. The defect or fault is either repaired or reported by tearing off the

bottom of the tag and/or filling out a defect report, then forwarding itto the maintenance department through the appropriate channels.

If a defect is observed that is not a Safety hazard and the machine cancontinue to work safely:

The operator must attach an Information tag to the appropriateposition to ensure that other operators are aware of this issue.

Report this to your supervisor during or at the end of your shift. Forwarding it to the maintenance department through the

appropriate channels.


Reporting of defects

Defects or faults should be looked for and will from time to time beshift inspections, walk around checks, during

If an observed defect is such that the equipment is unsafe to operate:

The operator must attach an Out of Service tag to the appropriateposition to ensure that either the faulty component or the wholemachine (as applicable) is not operated.Report this to your supervisor immediately.The defect or fault is either repaired or reported by tearing off thebottom of the tag and/or filling out a defect report, then forwarding itto the maintenance department through the appropriate channels.

a defect is observed that is not a Safety hazard and the machine can

The operator must attach an Information tag to the appropriateposition to ensure that other operators are aware of this issue.

uring or at the end of your shift.Forwarding it to the maintenance department through the


Delay – Maintenance Delay

Air Systems

Axle Repairs

Brake Repairs

Cab Repairs

Cleaning for Maintenance

Cleaning to Repair

Cooling System Repairs

Daily Service

Engine Repairs

Hydraulic Repairs

Inspection

Light Vehicle Check

Maintenance Checks

Major Cab Clean

Major Service

Major Shutdown

Service Break

Delay – Maintenance Delay

2-Way Radio

Accident Damage

Accidental Damage

Air Filters

Air Intake System

Awaiting Diagnosis

Awaiting Maintenance

Backup Alarm

Battery

Bearings

Blade/Bucket/Bowl/Ripper

Blade/Cutting Edges

Body/Frame Chassis

Body/Tray


Maintenance Delay Scheduled

Suspension Repairs

Tyre Inspection

Tyres Scheduled

Tyres, Tracks or Frames

Fire Suppression

Lube System Repair

Maintenance Inspection

Maintenance Service

Planned Repairs

PM Air System

PM Brakes

PM Cooling System

PM Fire Sup Sys

PM Steering

PM Wash-down

Pre- Maintenance Inspect

Accidental Equipment Damage

Maintenance Delay Unscheduled

Fire Suppression

Frame/Structure Front Axle

Front Strut

Fuel Filters

Fuel Injectors

Fuel Pump

Fuel Sys

Fuel Tank

Gear Shifting

General Electrical

Hydraulic Cylinders

Hydraulic Oil Cooler

Hydraulic Oil Level Leaks

Hydraulic Pump - Main


Brake Pump

Brake Test

Brakes System

Breakdown - Electrical

Breakdown - FMS

Breakdown - Mechanical

Bucket

Bucket General

Bucket Welding

Cab/Walkways

Cab Equipment

Cabin

Cabin Controls

Cabin/Decks

Chassis/Body

Control System

Coolant System

Dispatch System

Drive Brakes

Drive Cooling Sys. Radiator

Lights/Indicators

Elec E Stop

Elec Fail To Start

Elect General

Electrical Fault - 24 Volt

Engine System

Unplanned Electrical

Unplanned Mechanical

Filter System

Filters


Hydraulic Valves

Hydraulic Filters

Hydraulic Pump

Hydraulic Cylinders

Hydraulic General

Lighting

Lube System

Lube System Electrical

Lube System Mechanical

Main Gear Boxes

Maintenance Inspections

Maintenance Delay

Park Brake

Power Loss

Retarder

Rock Ejectors

Rock/Tyre Management

Starting System

Structural Damage

Suspension

Suspension Cylinders

Tray

Truck Box Cleaning

Tyre Change

Tyres Unscheduled

Undercarriage

Unscheduled Maintenance

Wait Electrician

Wait Fitter

Wash-down Equipment


Delay – Standby

Accident

Blast Misfire

Blasting

Blocked Access

Crib

Dust/No Water Cart

Electrical Storm

Env/Coal Fires

Environmental

Environmental Incident

Equipment Not Required

Floor Cleanup

Fuel

Holidays(Shutdown)

Idle

Idle -Safety

Illness

Industrial Action

Loader Delay

Long Term Standby

No Avail Crushers

No Avail Dumps

No Avail Shovels(Auto)

No Avail Shvl Call Disp

No Available Dump

No Available Employee

No Available Face

No Available Hopper

No Available Shovel

No Heavy Hauler

No Labour Available

No Loading Unit

No Oper - Hot Seating


No Operator

No Operator - Other Duties

Off Shift Due To Roster Structure

Operational/Talk To Supervisor

Operator Travel

Power Down

Power Outage Site

Public Holiday

Return From Maintenance

Safety/Meetings

Safety Shutdown

Scheduled Down

Scheduled Off Shift

Shift Change

Site Emergency

Smoke

Snow

Standby

Stby No Production

Stby Parked

Stopped For Emergency

Stop-Work Meeting

Talk To Supervisor

Toilet Break

Tool Box/Safety Talk

Total Operation Shutdown

Union Meeting

Upub Special Public Holiday

Wait On Blast

Wait On Dust

Weather

Wet Roads

Work Instructions


Demag H285 – Hydraulic Shovel

H285 Demag Hydraulic Shovel

DER – Dipper Efficiency Ratio

Dipper Efficiency Ratio is a measure of what weight of spoil a bucket of aparticular capacity will carry. As such it is a measure of the digging(getting the spoil into the bucket) and shape (holding spoil iefficiency of the bucket. It is found by dividing the average payload by theratedbucket capacity.

DER = payload/capacity in t/cu.m

DER increases with tooth attack angle between 50continue to a point where the interaction of the heel of the bucket and the spoilrestricts tooth penetration and subsequent payload.

Different dipper shapes achieve differenta function of the shape of the dipper and the volume of the rear of the buckettaken up with voids. This void is shown in the picture.


Hydraulic Shovel

Dipper Efficiency Ratio

Dipper Efficiency Ratio is a measure of what weight of spoil a bucket of aAs such it is a measure of the digging

(getting the spoil into the bucket) and shape (holding spoil in the bucket)It is found by dividing the average payload by the

DER increases with tooth attack angle between 50˚ and 70˚. This is expected to continue to a point where the interaction of the heel of the bucket and the spoilrestricts tooth penetration and subsequent payload.

Different dipper shapes achieve different payloads (for the same capacity). This isa function of the shape of the dipper and the volume of the rear of the buckettaken up with voids. This void is shown in the picture.


Dig Face – Digging area

Dig area where operator engages and fills the bucket

Dig Plan – How the pit will be dugThe dig plan is the communication plan given to operatorswhat needs to be dug/removed and according to specific designparameters.


Digging area

Dig area where operator engages and fills the bucket/dipper.

How the pit will be dugThe dig plan is the communication plan given to operators/supervisors of

removed and according to specific design


Dig Techniques (Sequence)techniques

There are a number of different Dig methods or sequences a site coulduse, below are a few of the most used:

Single approach loading method. Double Approach Loading Method. Drive by Method, (normally Back Hoe). Underhand Method (normally Back Hoe). Single Bench Loading with a Front-end Loader Split Bench Split Bench Face Heights Split Benching Method Ramping Down

Refer to individual pages on specific dig techniques in this dictionary.


(Sequence) – Common

number of different Dig methods or sequences a site coulduse, below are a few of the most used:

Single approach loading method.Double Approach Loading Method.Drive by Method, (normally Back Hoe).Underhand Method (normally Back Hoe).

end Loader

Split Benching Method Ramping Down

Refer to individual pages on specific dig techniques in this dictionary.


Diggability – Fragmentation analysis

Optimal Fragmentation is essential for trucDiggability is a term used to describe how easy the material can be dug bythe loading unit. The best measure of diggability is the Specific DigEnergy.

SDE = Payload/Energy to Fill

As digging gets harder the payload goes down anup. Hence the SDE goes down, and vice versa.

Example of optimal fragmentation.


Fragmentation analysis

Optimal Fragmentation is essential for truck and loader productivity.Diggability is a term used to describe how easy the material can be dug by

The best measure of diggability is the Specific Dig

As digging gets harder the payload goes down and the energy to fill goesHence the SDE goes down, and vice versa.


Dip – Slope of the Coal Seam

The dip/slope of a product i.e. coal or other specific body of orefor extraction.


Slope of the Coal Seam

slope of a product i.e. coal or other specific body of ore


Dilution – Contamination inseam.

Dilution of the coal is the percentage of overburden or waste materialmixed with the coal. There is, at times, dilution within the coal seam itself.The actions of the operators when removing the overburden from the topof coal can have a major effect on dilution. Keeping the bucket off top ofcoal is one way of reducing dilution. The dozer can clean the last halfmetre down to the coal seam.

Dilution can also be caused by loading the coal into the spoil causingcontamination.


Contamination in a mineable

Dilution of the coal is the percentage of overburden or waste materialat times, dilution within the coal seam itself.

The actions of the operators when removing the overburden from the topa major effect on dilution. Keeping the bucket off top of

coal is one way of reducing dilution. The dozer can clean the last half

Dilution can also be caused by loading the coal into the spoil causing


Dipper – Rope Shovel Bucket


Rope Shovel Bucket


Dipper Crowd – Electric rope shovel arm


Electric rope shovel arm

Crowd


Dipper Door – Rope Shovel Bucket


Rope Shovel Bucket Door


Dipper Door Hinges –open and close

Dipper Door locking mechanismShovel Bucket Door Lock


– Dipper door pivots to

Dipper Door locking mechanism – RopeShovel Bucket Door Lock


Dipper Depth

Dipper depth is defined as the distance from top (teeth end) to bottom(door end). These depths have been expressed as a percentage of thewidth (distance across the mouth of the dipper).demonstrates the depth.

Depth

Dipper Height/width

Dipper height is defined as, when looking into the mouth of the dipper,the distance from top to bottom. These heights are normally expressed asa percentage of the width (distance across the mouth of the dipper).following figure demonstrates the definition of height and width.


Dipper depth is defined as the distance from top (teeth end) to bottomThese depths have been expressed as a percentage of the

width (distance across the mouth of the dipper). The following figure

Dipper height is defined as, when looking into the mouth of the dipper,These heights are normally expressed as

a percentage of the width (distance across the mouth of the dipper). Thetrates the definition of height and width.


Distance from face

Retract the dipper handle until the top end protrudes approximately 3mbeyond the shipper shaft. Bring the dipper up to about 20° and crowdforward until the dipper teeth contact the bank. Alltuck the dipper in front of the crawlers to begin each digging cycle.

Be mindful not to dig too much out in front of the excavator (and the digtrench) as you can easily get caught in nomachine cannot reach the face in front to pull material down and you havenothing to bridge out with)

When positioned correctly, the excavator operator can easily reach the topbench face and dig in the downwards pulling motion.


Retract the dipper handle until the top end protrudes approximately 3mbeyond the shipper shaft. Bring the dipper up to about 20° and crowdforward until the dipper teeth contact the bank. Allow enough clearance totuck the dipper in front of the crawlers to begin each digging cycle.

Be mindful not to dig too much out in front of the excavator (and the digtrench) as you can easily get caught in no-man’s land. (Hole too large and

ot reach the face in front to pull material down and you have

When positioned correctly, the excavator operator can easily reach the topbench face and dig in the downwards pulling motion.


Retract the shovel dipper handle until the top end protrudesapproximately 3m beyond the shipper shaft.20° and crowd forward until the dipper teeth contact the bank.enough clearance to tuck the dipper in front of the crawlers to begin eachdigging cycle.

Double benching – Loading technique

Refer to Split Benching in this Dictionary.


til the top end protrudesapproximately 3m beyond the shipper shaft. Bring the dipper up to about20° and crowd forward until the dipper teeth contact the bank. Allowenough clearance to tuck the dipper in front of the crawlers to begin each

Loading technique

Refer to Split Benching in this Dictionary.


Double Sided Loadingeither side

Double-sided loading is used whenever possible, because it is consideredthe most productive system of operation.

The shovel is positioned with the tracks at 90° to the face and advanceddirectly into the face as material is removed. This operation is particularlysuited to high face heights and a large number of trucks, with little or noshovel relocation over the shift. With trucks positioned on each side of themachine, the shovel can load with virtually no interruption and not exceed90° of swing for each truck. Clean-ups are done only once the shovel hasparked with the bucket on the ground.

Trucks are normally required to spot without the aid of the shovel and areusually positioned below the boom point swing path within 90° of shovelswing. Inefficiency can affect the high productivity normally achieved withthis system if the haul trucks spot either inside orpoint swing path.


Double Sided Loading – Loading with trucks

sided loading is used whenever possible, because it is consideredthe most productive system of operation.

The shovel is positioned with the tracks at 90° to the face and advanceddirectly into the face as material is removed. This operation is particularlysuited to high face heights and a large number of trucks, with little or no

ift. With trucks positioned on each side of themachine, the shovel can load with virtually no interruption and not exceed

ups are done only once the shovel hasparked with the bucket on the ground.

required to spot without the aid of the shovel and areusually positioned below the boom point swing path within 90° of shovelswing. Inefficiency can affect the high productivity normally achieved withthis system if the haul trucks spot either inside or outside of the boom


Downtime – Delay

Any time the machine (Truck or Loading unit) is not operational oravailable.

Downtime can be classed as either Scheduled or Unmaintenance or operational delay.

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Key Delay and Downtime Activities


Any time the machine (Truck or Loading unit) is not operational or

Downtime can be classed as either Scheduled or Un-scheduled

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Key Delay and Downtime Activities


Dozer – A Tracked or Rub

A dozer is a necessary ancillary tool around a truck and shovel operation.They are generally utilised for cleaning up of the loading area, spillagearound the loading area and on the haul route to minimise tyre damage tothe trucks.

Dozers can also be used to push and establish benches as well as pushingdown high faces for loading. (Dozer Assist).


A Tracked or Rubber Tyred Machine

A dozer is a necessary ancillary tool around a truck and shovel operation.They are generally utilised for cleaning up of the loading area, spillagearound the loading area and on the haul route to minimise tyre damage to

rs can also be used to push and establish benches as well as pushingdown high faces for loading. (Dozer Assist).


Drill Rig – Device for drilling blast holes


Device for drilling blast holes


Drill and Blast Areas –for blasting


– Area prepared


Drive-by Loading – Sequence

Drive-by loading is defined as the excavator operating from the top of thebench, and the truck being positioned on the floor below the excavator.

However the only time that this type of loading should be used is when theexcavator is in a tight spot and the bencoperations avoid this type of loading due to the added exposure of thetruck tyres to the bench face causing extra damage on the drive by.

When spotting for this type of loading the truck operator must alignhis/her left shoulder with the counterweight of the Excavator.excavator operator will indicate where to stop by sounding his beeperonce when the truck reaches the correct position.

Ensure that the bucket height is sufficient to clear the edge of the dumpbody with the bucket in the load position.positioned to allow the load to be aligned in the centre of the truck body.


Sequence

y loading is defined as the excavator operating from the top of thebench, and the truck being positioned on the floor below the excavator.

However the only time that this type of loading should be used is when theexcavator is in a tight spot and the bench is very narrow. Most miningoperations avoid this type of loading due to the added exposure of thetruck tyres to the bench face causing extra damage on the drive by.

When spotting for this type of loading the truck operator must alignder with the counterweight of the Excavator. The

excavator operator will indicate where to stop by sounding his beeperonce when the truck reaches the correct position.

Ensure that the bucket height is sufficient to clear the edge of the dumpe bucket in the load position. The excavator should be

positioned to allow the load to be aligned in the centre of the truck body.


Drive-by observation on crestcondition of tip head

This allows the driver to see the condition of the grounbefore reversing to dump. Minimum distances applyregulations.

Dump Area Maintenancedumping area in good condition

Correct dump area maintenance prevents unnecessary tyre damage andwear and tear. Tip head must be maintained to the correct heights

Drive by observation on crest

Correct Dump Site Maintenance


by observation on crest – Checking

This allows the driver to see the condition of the ground and bund wallbefore reversing to dump. Minimum distances apply - check mine

Dump Area Maintenance – Keepingdumping area in good condition

Correct dump area maintenance prevents unnecessary tyre damage andmaintained to the correct heights


Dump Area Sequence –

As a truck enters the dump location it should always dump according tothe strategy and according to where the previous truckload was dumped.The operator on the dozer will normalcommunicate with the truck operators as to where to dump.

Dump Site Maintenance

Proper dump site maintenance is designed to:

Prevent Tyre damage on Trucks Prevent damage to Trucks by ground falling or running away Prevent loss of life Ensure quicker cycle times Take into consideration, berms, width, demarcation, sequence,

ancillary equipment to be used to level and size (dozer, RTDDozer, etc.)

Berm Height as a rule of thumb must be at least half the size of the Tyused by the largest Truck dumping.


– Dump area strategy

As a truck enters the dump location it should always dump according tothe strategy and according to where the previous truckload was dumped.The operator on the dozer will normally control the dump strategy andcommunicate with the truck operators as to where to dump.

Dump Site Maintenance

Proper dump site maintenance is designed to:

Prevent damage to Trucks by ground falling or running away

Take into consideration, berms, width, demarcation, sequence,ancillary equipment to be used to level and size (dozer, RTD/Wheel

Berm Height as a rule of thumb must be at least half the size of the Tyre


Dumping – Unloading material

Material can be dumped from:

Truck Trays, Excavator and Loader Buckets, Shovel Dippers, Dragline Buckets.

Dumping Phase

The dumping phase of the digging cycle is part of the swing andphases. The dumping phase starts just before the loaded bucket passesover the edge of the haul truck and finishes as the swing motion stops andreverses. The dumping phase consists of swinging of the bucket, slowing,stopping and reversing the swing direction and, at the same time,controlling the bucket to dump the load at the correct position.


Unloading material

The dumping phase of the digging cycle is part of the swing and returnphases. The dumping phase starts just before the loaded bucket passesover the edge of the haul truck and finishes as the swing motion stops and

The dumping phase consists of swinging of the bucket, slowing,ng direction and, at the same time,

controlling the bucket to dump the load at the correct position.


Dump – Placing of waste into spoil piles

The dump area should be kept as level as possible in all directions andshould provide a stable dumping platfor

Dump sites with an uneven ground surface can produce instability andeven rollover risks when a full truckload is being hoisted to dumpingposition. The shift in the centre of gravity brought about when the wheelbase is inclined from the horizontal, maof the haul truck.

Do not hoist the body to the dump position whilst the wheels arepositioned on uneven ground.

Dumping uphill should be avoided as greater energy is required to liftthe load and high loads are imposedmachine frame.


Placing of waste into spoil piles

The dump area should be kept as level as possible in all directions andshould provide a stable dumping platform.

Dump sites with an uneven ground surface can produce instability andeven rollover risks when a full truckload is being hoisted to dumpingposition. The shift in the centre of gravity brought about when the wheelbase is inclined from the horizontal, may be sufficient to upset the balance

Do not hoist the body to the dump position whilst the wheels are

Dumping uphill should be avoided as greater energy is required to liftthe load and high loads are imposed on the body trunnions and


Dust – Control of dust

All haul routes should be managed to prevent dust. Dust can be controlledby frequent watering with Water bowsers or by applying a chemicalcompound mixed with water to bind fines causin

Dust is a major problem at some mines with significant periods of standbycaused by poor visibility caused by dust.

Electronic Monitoring System

The Electronic Monitoring System (EMS) consists of a fault alarm, a faultlight and a monitoring panel with individual indicators for each trucksystem listed on the panel.

The EMS is designed to alert the operator of an immediate or impendingproblem in one of the truck systems covered. All equipment includingtrucks, loading units and ancillary equipment has one form or anotherEMS.


Control of dust

All haul routes should be managed to prevent dust. Dust can be controlledby frequent watering with Water bowsers or by applying a chemicalcompound mixed with water to bind fines causing dust.

Dust is a major problem at some mines with significant periods of standbycaused by poor visibility caused by dust.

Electronic Monitoring System – EMS

The Electronic Monitoring System (EMS) consists of a fault alarm, a faultg panel with individual indicators for each truck

The EMS is designed to alert the operator of an immediate or impendingproblem in one of the truck systems covered. All equipment including

quipment has one form or another


Elephant Skid – Highwall Power CableProtection Equipment

Elephant Skids are used to facilitate moving shovels back and forth thelength of a mining pit. The Elephant Skid is often used in conjunction within-pit cable trees and/or cable crossings to help prevent damage to theelectrical power cable as the shovel advances.

Emergency Steering Switchemergency steering pump

This switch activates the emergency steering pump on a haul truck.emergency steering pump is activated once the button is pressed. It allowsthe steering to be operated at less than 5kph and for a maximum of 90seconds.


Highwall Power CableProtection Equipment

Elephant Skids are used to facilitate moving shovels back and forth thelength of a mining pit. The Elephant Skid is often used in conjunction with

le trees and/or cable crossings to help prevent damage to theelectrical power cable as the shovel advances.

Emergency Steering Switch – Activatesemergency steering pump

This switch activates the emergency steering pump on a haul truck. Thesteering pump is activated once the button is pressed. It allows

the steering to be operated at less than 5kph and for a maximum of 90


Emergency Stop – Excavator

Emergency stop pull cables are located at various locations around theloading unit. Operators should familiarise themselves with the location ofthese.

Emergency Stop – Truck

If you are faced with an emergency situation, where the operation of atruck has to be stopped immediately, the following procedure must befollowed.

Bring the truck to a complete stop as quickly as possible. Place the gear selection in neutral. Apply the park brake. Use the emergency engine shutdown switch/Emergency Stop button Turn the ignition key switch off. Notify the supervisor/OCE of your po

using the two way radio. Leave the operator cabin if safe to do so in a calm and cautious

manner and remove yourself to a safe location.

Conditions and circumstances of use is in case of a fire, engine run on,engine run away, or when normal shut down system is not working(ignition switch).


Excavator/Shovel

Emergency stop pull cables are located at various locations around theng unit. Operators should familiarise themselves with the location of

Truck

If you are faced with an emergency situation, where the operation of atruck has to be stopped immediately, the following procedure must be

Bring the truck to a complete stop as quickly as possible.Place the gear selection in neutral.

Use the emergency engine shutdown switch/Emergency Stop buttonTurn the ignition key switch off.Notify the supervisor/OCE of your position and emergency details

Leave the operator cabin if safe to do so in a calm and cautiousmanner and remove yourself to a safe location.

Conditions and circumstances of use is in case of a fire, engine run on,or when normal shut down system is not working


Engine Block – Engine

Fuel WaterSeparator

Brake OilFilter


Engine

Brake OilFilter

AdditionalExtra Low FuelSpec Filter

Engine OilFilter


Equivalent Annual Production

This is Annual production assuming full 7 day roster and no stoppageslonger than 7 days.

It is divided by in-situ SG to convert tonnes (weight) to volume.

Equivalent Annual Production =

Annual Swings * 365_________* Ave. Payload

(365 – Stoppage days > 7 days)


Equivalent Annual Production

This is Annual production assuming full 7 day roster and no stoppages

ert tonnes (weight) to volume.

* Ave. Payload


Esco – Bucket and GET Manufacturer

ESCO® is a manufacturer of a range of dragline/ hydraulic face shovel/excavator and dipper buckets, GET components and other alloy steel wearresistant products.


Bucket and GET Manufacturer

ESCO® is a manufacturer of a range of dragline/ hydraulic face shovel/r and dipper buckets, GET components and other alloy steel wear


Excavator – Controls

Travel Levers with Pedals - These levers are used to change the directionof travel between forward and reverse.

Forward: The lever is pushed forward, (The pedal is angled forward)

Reverse: The lever is pulled back (The pedal is angled back)

N (Neutral): The machine stops

Note: If the lever is shifted to the ForwardNeutral position, the alarm sounds to warn that the mto move.

Excavator – Loading unit

An excavator is a loading unit as can be seen below. Please refer to specificmakes and models as illustrated in this dictionary.set up as a backhoe (as shown) or face shovel.


These levers are used to change the directionof travel between forward and reverse.

rward, (The pedal is angled forward)

The lever is pulled back (The pedal is angled back)

Forward or Reverse position from theNeutral position, the alarm sounds to warn that the machine is starting

Loading unit

An excavator is a loading unit as can be seen below. Please refer to specificmakes and models as illustrated in this dictionary. An excavator may beset up as a backhoe (as shown) or face shovel.


Excavator – Schematic

Excavator Boom – Boom attachment

An excavators Boom is attached to the lower part of the machine deck andholds all the other parts from the Arm plus the weight of the spoil. TheBoom is driven by the two hydraulic cylinders (Beamresponsible for the vertical movements.

MachineryDeck

CounterWeight

CrawlerBelt/Track

PropelMachinery/ Sprocket

MachineryHouse

Boom

Roller


Schematic

Boom attachment

An excavators Boom is attached to the lower part of the machine deck andholds all the other parts from the Arm plus the weight of the spoil. TheBoom is driven by the two hydraulic cylinders (Beam cylinders). They areresponsible for the vertical movements.

HydraulicRams

Bucket

Dipper

Idler


Excavator Bucket – Bucket attachment

Excavator buckets are made of solid steel and generally present teethprotruding from the cutting edge, to disrupt hard material and avoidwear-and-tear of the bucket.

Excavator – Lock Lever

When this lever is in the upwards position as illustrated, the excavatorcannot be operated as it applies the same principle as the park brake on atruck or brakes on a shovel.

Once the operator is in the chair he canposition and continue work.


Bucket attachment

Excavator buckets are made of solid steel and generally present teethprotruding from the cutting edge, to disrupt hard material and avoid

Lock Lever

When this lever is in the upwards position as illustrated, the excavatorcannot be operated as it applies the same principle as the park brake on a

Once the operator is in the chair he can push the lever into the lower


Excavator Stick – Attachment

The Stick is attached to the Boom and is driven by one or two hydrauliccylinders (Arm cylinders) which are attached on the upper part of theBoom. They are used for the horizontal movement.

Stick


Attachment

The Stick is attached to the Boom and is driven by one or two hydrauliccylinders (Arm cylinders) which are attached on the upper part of the

the horizontal movement.


Excavator Undercarriagemechanism

The undercarriage gives the excavator the mobility and flexibility toensure that it can cope with constantly changingsurroundings/conditions. The major undercarriage components cthe crawler tracks; propel machinery and the track frame. The track frameparts consist of track line assembly, top roller, sprocket, bottom roller,idler and the track shoe (see picture below).

The tracks and frames are mounted on the undercarrexcavators, the track frame design is such that the tracks can be removedfor transportation.

Item Description

A Idler

B Track

C Top Roller

D Track Link assembly

E Track/Walking Frame

F Bottom Roller

G Sprocket

H Drive/Propel


Excavator Undercarriage – Walking

The undercarriage gives the excavator the mobility and flexibility toensure that it can cope with constantly changing

The major undercarriage components consist ofthe crawler tracks; propel machinery and the track frame. The track frameparts consist of track line assembly, top roller, sprocket, bottom roller,idler and the track shoe (see picture below).

The tracks and frames are mounted on the undercarriage. On most largeexcavators, the track frame design is such that the tracks can be removed


Exhaust Pipes – Exhaust outlet

Face Maintenance/Clean

Face maintenance/clean-up is done to:

To prevent tyre damage to Trucks To prevent an uneven loading surface for the trucks and the shovel To allow trucks to maneuver next to the

possible To prevent avoidable cable damage Increase production


Exhaust outlet

Face Maintenance/Clean-up – Floor clean up

up is done to:

To prevent tyre damage to TrucksTo prevent an uneven loading surface for the trucks and the shovelTo allow trucks to maneuver next to the loader as efficiently as

To prevent avoidable cable damage


Face Height – Optimal height

At any bench height greater than 30% of boom point height, a full payloadcould be achieved. The issue at the lower bench heights may bethat the shovel has to be moved more often so that the dipper can reachthe face.


Optimal height

At any bench height greater than 30% of boom point height, a full payloadThe issue at the lower bench heights may be the fact

that the shovel has to be moved more often so that the dipper can reach


Face Shovel

A face shovel is one of two configurations which an hydraulic excavatormay be set up as. The face shovel arrangement is where the bucket digsup and away from the machine to fill the bucket.


is one of two configurations which an hydraulic excavatorarrangement is where the bucket digs

the machine to fill the bucket.


Face Width

Face width depends on type of machine, the sequence utilised, the trucktype and by the available room.

It is also important for the face width to be constant over the length of thedig to maintain a consistent operation.

As a general rule the face width should be 3.3radius distance for single sided loading and double this for double sidedloading.

The following illustration is for an electric rope shovel (4100XPCpoint radius = 24 metres.


Face width depends on type of machine, the sequence utilised, the truck

It is also important for the face width to be constant over the length of thetain a consistent operation.

As a general rule the face width should be 3.3-3.5 times the boom pointradius distance for single sided loading and double this for double sided

The following illustration is for an electric rope shovel (4100XPC – boom


Failure – Unstable Wall or parts of it

A high wall is said to have failed (deep seated failure)falls into a previously dug out pit. Can be a major hazard when equipmentis working in the vicinity.

Skin Slippage is a failure of parts of the wall where for example blastinghas weakened or cracked rocks in the high wall


Unstable Wall or parts of it

(deep seated failure) when part of itCan be a major hazard when equipment

is a failure of parts of the wall where for example blastinghas weakened or cracked rocks in the high wall


Fatigue

This is a state of impaired mental and/or physical performance andlowered alertness arising as a result of hard physical and mehealth and psychological factors, inadequate restorative sleep or acombination of these factors. Fatigue can either be work or nonrelated or a combinationof both.

Operators are responsible for:

Presenting themselves at work in a fit stduties safely throughout their shift.

Use the opportunity for sleep provided to obtain adequate rest priorto commencing a rostered shift

Report any instances of fatigue or fatigue related incidents to theirsupervisor.

Understanding the effects of fatigue on safety and performance. Complying with the requirements of their site standards. Exercise particular care at critical times such as at shift change

the end of shifts. Actively participate if required to undergo a

individual plan.

(Life)

Engineers discovered that if you repeatedly applied and then removed anominal load to and from a metal part (known as a "cyclic load"), the partwould break after a certain number of loadmaximum cyclic stress level applied was much lower than the strength ofthe member. They discovered that as they reduced the magnitude of thecyclic stress, the part would survive more cycles before breaking. Thisbehaviour became known as "FATIGUE"that the metal got "tired". When you bend a paper clip back and forth untilit breaks, you are demonstrating fatigue behaviour.

On a Loader, the cyclical action of dig, swing, dump and return createsmany fatigue situations around the machine.

Fatigue life is a fixed quantity, and is always being used. The questionsare:

How fast is the available fatigue life being used?

What are critical crack lengths compared to inspection strategies?


This is a state of impaired mental and/or physical performance andlowered alertness arising as a result of hard physical and mental work,health and psychological factors, inadequate restorative sleep or acombination of these factors. Fatigue can either be work or non-work

Presenting themselves at work in a fit state to be able to conduct theirduties safely throughout their shift.Use the opportunity for sleep provided to obtain adequate rest prior

Report any instances of fatigue or fatigue related incidents to their

erstanding the effects of fatigue on safety and performance.Complying with the requirements of their site standards.Exercise particular care at critical times such as at shift change/and at

Actively participate if required to undergo a fatigue management

Engineers discovered that if you repeatedly applied and then removed anominal load to and from a metal part (known as a "cyclic load"), the partwould break after a certain number of load-unload cycles, even when themaximum cyclic stress level applied was much lower than the strength of

They discovered that as they reduced the magnitude of thecyclic stress, the part would survive more cycles before breaking. Thisbehaviour became known as "FATIGUE" because it was originally thoughtthat the metal got "tired". When you bend a paper clip back and forth untilit breaks, you are demonstrating fatigue behaviour.

On a Loader, the cyclical action of dig, swing, dump and return createsons around the machine.

Fatigue life is a fixed quantity, and is always being used. The questions

How fast is the available fatigue life being used?

What are critical crack lengths compared to inspection strategies?


Fatigue Incident

This is an accident, incident or error where fatigue is identified as asignificant contributing factor.

Reporting of Fatigue Incident Cases:

Personnel should be encouraged to report fatigue incidents and caseswithout fear of reprisal. Reported fatigue incidents and casesfollowed up by supervision to identify the cause of the fatigue.

Reporting of Fatigue Cases and Fatigue incidents whilst driving on publicroads is also encouraged, particularly those events that may be associatedwith commute travel to and fromany site.

Discussions with employees regarding fatigue incidents and cases shouldfocus on prevention and the individual taking responsibility for fatiguerelated risks. If the fatigue appears to be more than a oneemployee can be referred for further assessment and further referral ifrequired.

Each operation should record and track reported fatigue cases andincidents in the same way as the other Health & Safety incidents, howeverthe fatigue related incidents will be broken into specifimproved Health & Safety fatigue monitoring.


t, incident or error where fatigue is identified as a

Reporting of Fatigue Incident Cases:

Personnel should be encouraged to report fatigue incidents and caseswithout fear of reprisal. Reported fatigue incidents and cases should befollowed up by supervision to identify the cause of the fatigue.

Reporting of Fatigue Cases and Fatigue incidents whilst driving on publicroads is also encouraged, particularly those events that may be associated

Discussions with employees regarding fatigue incidents and cases shouldfocus on prevention and the individual taking responsibility for fatiguerelated risks. If the fatigue appears to be more than a one-off incident, the

ed for further assessment and further referral if

Each operation should record and track reported fatigue cases andincidents in the same way as the other Health & Safety incidents, howeverthe fatigue related incidents will be broken into specific categories forimproved Health & Safety fatigue monitoring.


Fault – A Fracture Zone in the Overburden

http://en.wikipedia.org/wiki/Geologic_fault

In geology a fault, or fault line, is a planarock on one side of the fracture has moved with respect to the rock on theother side. Large faults within the Earth's crust are the result ofdifferential or shear motion and active fault zones are the causal locationsof most earthquakes.

Since faults do not usually consist of a single, clean fracture, the term faultzone is used when referring to the zone of complex deformation that isassociated with the fault plane. The two sides of a noncalled the hanging wall and footwall. By definition, the hanging walloccurs above the fault and the footwall occurs below the fault.


A Fracture Zone in the Overburden

http://en.wikipedia.org/wiki/Geologic_fault

In geology a fault, or fault line, is a planar fracture in rock in which therock on one side of the fracture has moved with respect to the rock on theother side. Large faults within the Earth's crust are the result ofdifferential or shear motion and active fault zones are the causal locations

Since faults do not usually consist of a single, clean fracture, the term faultzone is used when referring to the zone of complex deformation that isassociated with the fault plane. The two sides of a non-vertical fault are

nging wall and footwall. By definition, the hanging walloccurs above the fault and the footwall occurs below the fault.


Fill

Fill refers to the period of time between the bucket engaging the materialand disengaging the material with a load prior to sdump.

The following figures demonstrate a backhoe filling.

Fitness for work

Management of fatigue is just one part of an overall Fitness for Worksystem. Each part of the system is interrelated and is likely to impact onthe other factors if not managed effectively. The components of a holisticFitness for Work system are as follows:

A Health & Safety Plan A Fitness for Work Policy A Fatigue Management Plan An Alcohol & Other Drugs management System A Psychological and Physical Impairmen A Health Management System; Medical Assessment (including assessment for potential sleep

disorders) Health Promotion & Health Programs Occupational hygiene Illness and Injury management


Fill refers to the period of time between the bucket engaging the materialand disengaging the material with a load prior to swinging ready for

The following figures demonstrate a backhoe filling.

Management of fatigue is just one part of an overall Fitness for Worksystem. Each part of the system is interrelated and is likely to impact on

rs if not managed effectively. The components of a holisticFitness for Work system are as follows:

An Alcohol & Other Drugs management SystemA Psychological and Physical Impairment Management System

Medical Assessment (including assessment for potential sleep

Health Promotion & Health Programs



Fire Suppression Bottlefor fire suppressant



e Suppression Bottle – Storage container


Float – Lowbed/Flatbed

A Float/Lowbed/Flatbed/Transporter is a large trailer that is used totransport large mining equipment.


Flatbed/Transporter

Transporter is a large trailer that is used to


Fragmentation – How welshot

Fragmentation is how well the overburden is fractured or broken up.Good fragmentation of the blasted overburden is when the dragline canfill the bucket easily with a good heap of spoil on the top. Overburden canat times be over fragmented and it will tend to flow out of the bucketwithout heaping.

Good Fragmentation is when the particle rock sizes range from fines up toaround half the width of the bucket.

An example of bad fragmentation is shown below.


How well the material is

Fragmentation is how well the overburden is fractured or broken up.Good fragmentation of the blasted overburden is when the dragline canfill the bucket easily with a good heap of spoil on the top. Overburden can

agmented and it will tend to flow out of the bucket

Good Fragmentation is when the particle rock sizes range from fines up to

An example of bad fragmentation is shown below.


Free Dumping – Block

When the haul truck operator is required to carry out block dumping indesignated areas or roadwork the following procedures should be carriedout.

The operator should observe the dumping site to ensure it is level,clear of obstruction and able to support the weight of the loaded haultruck.

Plan the approach and exit from the dump site. Liaise with the dozer or grader operator to determine the position in

which the load is to be dumped. Dump the material in a manner that allows access by the equi

required to spread or move the material.

Freeboard

Freeboard is the gap (usually deliberately) left between the material andthe top of the tray / box / bed. It is done in an attempt to control spillage.Mines should be careful in the amount ofreduce output.


Block Tipping

When the haul truck operator is required to carry out block dumping indesignated areas or roadwork the following procedures should be carried

The operator should observe the dumping site to ensure it is level,support the weight of the loaded haul

Plan the approach and exit from the dump site.Liaise with the dozer or grader operator to determine the position in

Dump the material in a manner that allows access by the equipmentrequired to spread or move the material.

board is the gap (usually deliberately) left between the material andthe top of the tray / box / bed. It is done in an attempt to control spillage.Mines should be careful in the amount of freeboard allowed as it can


Front End Loader – (FEL)

A Front End Loader is a loading unit as can be seen below. Please refer tospecific makes and models as illustrated in this dictionary.


(FEL)

A Front End Loader is a loading unit as can be seen below. Please refer tospecific makes and models as illustrated in this dictionary.


Front End Loader – Controls

Below is an example of the controls.


Controls


Front End Loader – Filling cycle

Below is the illustrated filling technique of a front end loader.


Filling cycle

Below is the illustrated filling technique of a front end loader.


Front End Loader – Loading from astockpile

When loading from a stockpile:

The operator should position the bucket parallel tothe ground.

Drive forward and engage the stockpile with the bucket in thesame position.

Raise the bucket lift control lever to raise the bucket while continuingto move forward into the material.

Tilt the bucket back with the tilt conthe material.

Return the lift control to Hold/Float positcrowd.

Adjust the wheel torque to prevent the wheels spinning. Once full, raise the bucket high enough to clear the material being

loaded. Reverse the loader away from the stockpile. When clear of the stockpile, move forward while lowering the bucket

to the carry position and proceed to the truck or dump area. Raise the bucket when near the dump area. Dump the material. Repeat the cycle.


Loading from a

The operator should position the bucket parallel to and just touching

Drive forward and engage the stockpile with the bucket in the

Raise the bucket lift control lever to raise the bucket while continuingto move forward into the material.Tilt the bucket back with the tilt control while moving up through

Float position to obtain additional

to prevent the wheels spinning.Once full, raise the bucket high enough to clear the material being

rse the loader away from the stockpile.When clear of the stockpile, move forward while lowering the bucketto the carry position and proceed to the truck or dump area.Raise the bucket when near the dump area.


Front End Loader – Loading technique

To ensure efficiency and safety when loading the haul truck, the front endloader should stand out from the face to enable the haul truck to reverseinto the correct position without obstructions.ready to dump the load by ensuring the bucket is fully raised to allow thetruck operator to reverse into position ensuring proper spotting.

The haul truck operator is to carefully reverse under the full bucketensuring that the haul truck is square to,from, the front wheels of the front end loader. Stop as the loader dumpsthe first bucket of material and remain in that position during loadinguntil given the signal to pull away.

Correct loading position for Near-Side Loading with a Front


Loading technique

To ensure efficiency and safety when loading the haul truck, the front endloader should stand out from the face to enable the haul truck to reverseinto the correct position without obstructions. The loader operator will beready to dump the load by ensuring the bucket is fully raised to allow thetruck operator to reverse into position ensuring proper spotting.

The haul truck operator is to carefully reverse under the full bucketensuring that the haul truck is square to, and approximately two metresfrom, the front wheels of the front end loader. Stop as the loader dumpsthe first bucket of material and remain in that position during loading

Side Loading with a Front-End Loader


Front End Loader – Schematic


Schematic


Fuel Burn Rate – Rate of fuel burn on theT&L Fleet

This methodology employed, is PwCbe employed by others without the express written permission ofuses a series of graphs where each individual cycle has key dependentvariables plotted against independent variables.

The dependent variables are load time, spot time, dump time and queuingtime. The independent variables are haul distance loaded and returndistance; for the velocity an average velocity was taken over each cycleperformed by the unit over the period analysed.by using fuel consumed over the time in rel

The Main KPI used by PwC when assessing Fuel efficiency isLitres/BCM/KM calculated as follows: ((Total Fuel/Cycle Count)Full Haul Distance/Cycle Count))/Average Payload

Using this KPI we can take into account not ontruck but also the distance travelled to ensure that trucks can bebenchmarked fairly against one another. The lower the Litres/BCM/KMvalue the more efficient the truck.

The following table shows the overall fuel efficiency fortruck for the years


Rate of fuel burn on the

PwC’s intellectual property and should notby others without the express written permission of PwC. It

uses a series of graphs where each individual cycle has key dependentvariables plotted against independent variables.

The dependent variables are load time, spot time, dump time and queuingThe independent variables are haul distance loaded and return

distance; for the velocity an average velocity was taken over each cycleperformed by the unit over the period analysed. Fuel burn rate is analysedby using fuel consumed over the time in relation to distance and velocity.

when assessing Fuel efficiency isLitres/BCM/KM calculated as follows: ((Total Fuel/Cycle Count)/(TotalFull Haul Distance/Cycle Count))/Average Payload

Using this KPI we can take into account not only the productivity of thetruck but also the distance travelled to ensure that trucks can bebenchmarked fairly against one another. The lower the Litres/BCM/KM

The following table shows the overall fuel efficiency for three models of


Fuel Filter – Filters fuel (Truck)

Fuel filters remove particles or other contamination from the fuel before itgets into the engine for combustion. This is an easy and cheap way tomake sure that the fuel is clean enough for the engine. Filters should bechecked on a regular base as stated in OEM manuals.

Fuel Tank – Diesel Storage


Filters fuel (Truck)

Fuel filters remove particles or other contamination from the fuel before itgets into the engine for combustion. This is an easy and cheap way to

enough for the engine. Filters should bechecked on a regular base as stated in OEM manuals.

Diesel Storage


Fuel Tank Sediment Drain Valvevalve

This valve is used to drain the fuel line of any sediment on some makesand models of trucks and loading units.

Fuel Tank sedimentdrain valve


Fuel Tank Sediment Drain Valve – Drain

This valve is used to drain the fuel line of any sediment on some makesof trucks and loading units.

Fuel Tank sedimentdrain valve


PwC – Worldwide Productivity andReliability Database

PwC has been building this warehouse of data since 1992 andspent thousands of hours in its development:

**Valid at time of going to Press.

PwC – Productivity Philosophy

Payload is critical. It is the most important metric and focus must beprovided to maintain payloads in loaders and trucks.

Fill the bucket up & do it more often


Worldwide Productivity and

has been building this warehouse of data since 1992 and PwC hasspent thousands of hours in its development:

ctivity Philosophy

Payload is critical. It is the most important metric and focus must beprovided to maintain payloads in loaders and trucks.

do it more often


Gear leaver – Trucks

The gear range can be selected with this lever to matconditions.

D position: This is used for normal travel. If the lever is placed in thisposition, the transmission is shifted automatically from 2nd to top gear tomatch the travel speed of the machine.shift lever is normally fixed at 1st. always lower the dump body whentraveling.

Geology – The structure of the earth

Geology is a region or stratum distinguished by composition or content ofthe overburden. The geology of the coal and overburden is very complextimes.


The gear range can be selected with this lever to match the travel

D position: This is used for normal travel. If the lever is placed in thisposition, the transmission is shifted automatically from 2nd to top gear tomatch the travel speed of the machine. If the dump body is raised, the

ver is normally fixed at 1st. always lower the dump body when

The structure of the earth

Geology is a region or stratum distinguished by composition or content ofthe overburden. The geology of the coal and overburden is very complex at


Geotechnical hazards

Any issues related to the material being moved either pre or post diggingare geotechnical hazards. Cracks and Sinkholes, Settlement cracks are notalways serious but should be filled in. Avoid letting water drain into cr

“Steps” formed across cracks may lead to failure. Tip short and doze to reestablish gradient and windrow. Sinkholesdamage or rollover. They can appear well behind the tip head.


Any issues related to the material being moved either pre or post diggingCracks and Sinkholes, Settlement cracks are not

always serious but should be filled in. Avoid letting water drain into cracks

“Steps” formed across cracks may lead to failure. Tip short and doze to re-establish gradient and windrow. Sinkholes – risk of tyre/suspensiondamage or rollover. They can appear well behind the tip head.


Geotechnical failure –interpretation, cracks or previous failure

Geotechnical failures are based on the results of geotechnicalinterpretation, cracks or previous failure. Geotechnical instability hazardscan comprise of uncontrolled, un-retained or poorly retained fill, slopeinstability (landslides/debris slides), cutting/excavation instability andboulders/rock falls. All operators should be aware of the mines Standards,Rules and Regulations pertaining to Geotechnical Hazards and actionrequired.


– Geotechnicalrpretation, cracks or previous failure

Geotechnical failures are based on the results of geotechnicalinterpretation, cracks or previous failure. Geotechnical instability hazards

retained or poorly retained fill, slopeability (landslides/debris slides), cutting/excavation instability and

boulders/rock falls. All operators should be aware of the mines Standards,Rules and Regulations pertaining to Geotechnical Hazards and action


Geotechnical failure –

Geotechnical


– Crest Failure


Trucks should be at least 4m from the edge of the dump. Define this distance using a windrow of sufficient height

high windrow. This assumes a 37 degree windrow slope angle. Windrows with steep

sides and short base length may be inadequate. 4m standoff assumes a stationary load. Truck hitting windrow increases load on crest. Need more than 4m = not practical. Procedures to prohibit using windrow as backstop.


Trucks should be at least 4m from the edge of the dump.Define this distance using a windrow of sufficient height – i.e. a 1.5m

This assumes a 37 degree windrow slope angle. Windrows with steeplength may be inadequate.

4m standoff assumes a stationary load.Truck hitting windrow increases load on crest.Need more than 4m = not practical.Procedures to prohibit using windrow as backstop.


Geotechnical failure –


– Foundation Failure


Increased risk:

Tipping weak material across dump face. Dump fails on weak plane.

Managing the risk:

Mix strong and weak material. Large amounts of weak material should go to a dedicated dump. Weak material can be paddock dumped across the dump to form a flat

layer. Avoid forming a continuous layer.


Tipping weak material across dump face.

Large amounts of weak material should go to a dedicated dump.Weak material can be paddock dumped across the dump to form a flat

Avoid forming a continuous layer.


G.E.T – Ground Engaging Tools

G.E.T are the replaceable/wearing parts that are on a bucketwhich interact with the ground.

These parts wear out relatively quickly as they are constantly in contactwith the overburden as the bucket is dragged through it.teeth, adaptors, lip shrouds and cheek shrouds.

GPS Antenna – Global Positioning System

Satellite based positioning unit which allows an accurate positioning ofthe truck/loading unit anywhere on the mine.


Ground Engaging Tools

wearing parts that are on a bucket/dipper

These parts wear out relatively quickly as they are constantly in contactrburden as the bucket is dragged through it. GET includes;

teeth, adaptors, lip shrouds and cheek shrouds.

Global Positioning System

Satellite based positioning unit which allows an accurate positioning ofn the mine.


Gravel – Surface Material for Roadways

Gravel is a stony mix of material used to surface roadways and preventexcessive surface break up under use of heavy traffic.similar hard igneous rocks are common roadway gravels used.

Grease lines – Carry hydraulic fluid


Surface Material for Roadways

Gravel is a stony mix of material used to surface roadways and preventexcessive surface break up under use of heavy traffic. Crushed basalt orsimilar hard igneous rocks are common roadway gravels used.

Carry hydraulic fluid


Guide Post – Delineates Roadways

Guide Posts are used on a mine site to delineate roadways.

Most guide posts used are various lengths of white PVC pipe withreflectors attached. 3 metre lengths of PVC are usedmake it easier for the large trucks to see the edges of the road.

Gyratory Crusher – Rock breaker

This is also known as a cone crushermachinery, using the gyratory sports in casing cone cavity ofcone to produce extrusion, fracturing and bending role to materials forcrushing ore or rock of various hardness.


Delineates Roadways

Guide Posts are used on a mine site to delineate roadways.

Most guide posts used are various lengths of white PVC pipe withreflectors attached. 3 metre lengths of PVC are used on some haul roads tomake it easier for the large trucks to see the edges of the road.

Rock breaker

/rock breaker. It is large crushingmachinery, using the gyratory sports in casing cone cavity of crushingcone to produce extrusion, fracturing and bending role to materials forcrushing ore or rock of various hardness.


Hang time – Wait vs. Queue time“Hang time” is the same as “Wait on truckunit versus the time lost by the trucks while queuing.

Mines should determine what the target is and set appropriate measuresin place to manage and achieve this.


Wait vs. Queue timeWait on truck” time experienced by a loading

by the trucks while queuing.

Mines should determine what the target is and set appropriate measures


Hard Dumping – Dumping techniqueHard dumping refers to reversing to a dump whilst loaded in normaloperating conditions, this being on a firm, compacted dry dump area.


Dumping techniqueHard dumping refers to reversing to a dump whilst loaded in normal

conditions, this being on a firm, compacted dry dump area.


Hauling

This is the transportation of resource or waste to another location bytruck.

During the hauling phase, the operator must observe the following toensure efficiency and safety are maintained at all times:

Follow the planned haul route to your destination. Always utilise your mirrors to ensure adequate visual awareness in

your surrounding areas. When exiting the pit, the truck will upshift automatically as the

ground speed increases. Always select the appropriate gear to prevent unnecessary gearing

down while going up steep ramps for maximum efficiency. Maintain a minimum safety distance between trucks, other equipment

and light vehicles (follow site rules). Keep on the correct side of the haul road away from the centre and

avoid going off the road. Keep to all speed directions and observe all signs. Keep a look out for road maintenance equipment and crews such as

graders, water trucks, sweepers etc. Practice positive communication wit

for overtaking and other activities. Always communicate your intent when entering or crossing a haul

circuit if in a light vehicle or any other equipment being added to thecircuit.


This is the transportation of resource or waste to another location by

During the hauling phase, the operator must observe the following toaintained at all times:

Follow the planned haul route to your destination.Always utilise your mirrors to ensure adequate visual awareness in

When exiting the pit, the truck will upshift automatically as the

Always select the appropriate gear to prevent unnecessary gearingdown while going up steep ramps for maximum efficiency.Maintain a minimum safety distance between trucks, other equipmentand light vehicles (follow site rules).

f the haul road away from the centre and

Keep to all speed directions and observe all signs.Keep a look out for road maintenance equipment and crews such asgraders, water trucks, sweepers etc.Practice positive communication with all vehicles on the haul circuitfor overtaking and other activities.Always communicate your intent when entering or crossing a haulcircuit if in a light vehicle or any other equipment being added to the


Haul road – Crossfall

Crossfall is the difference in elevation between the crest (crown) and theroad edge. It is a widely used technique that effectively drains water fromroad surfaces and is to be incorporated in all road designs.

Crossfall helps protect the road pavement from damage by wreducing pooling of water, mud and potholing. If water is allowed toaccumulate on the running surface, deterioration of the subwater saturation may occur. If the subdamage may also occur.

The rate of crossfall depends on a number of factors including the roadgradient, the road surface and the expected weather conditions. From anoperator’s point of view, a level driving surface is most preferred becausethis requires the least steering effort. However, to adrainage, crossfall must be applied and so the rate must accommodateboth a rapid removal of surface water and steerability.


e difference in elevation between the crest (crown) and theroad edge. It is a widely used technique that effectively drains water fromroad surfaces and is to be incorporated in all road designs.

Crossfall helps protect the road pavement from damage by water byreducing pooling of water, mud and potholing. If water is allowed toaccumulate on the running surface, deterioration of the sub-base due towater saturation may occur. If the sub-base becomes exposed, tyre

all depends on a number of factors including the roadgradient, the road surface and the expected weather conditions. From anoperator’s point of view, a level driving surface is most preferred becausethis requires the least steering effort. However, to allow adequatedrainage, crossfall must be applied and so the rate must accommodateboth a rapid removal of surface water and steerability.


Haul road – Design

To minimize or prevent damage to haul roads only suitable and drymaterials should be used in their construction. Make sure that there is nowet material beneath the road; a minimum of 4 metres, or preferably 5metres. A fully loaded truck generates vibrations which can penetrate upto 4 metres into the ground (depending on material).transform wet material into a very thick liquid

Design roads with a small slope to the side so that rain water can run offquick and easily to the side away from the road.on or beside road to avoid the water’ssurface and substrates.

The radii of haul road corners are important issues to be taken intoconsideration during the road planning stage.

To prevent overheating of truck tyres, the radius of a corner should be aswide as possible, particularly when the corner is at the end of a slope.wider corner does create as much heat and stress within the side wall of atyre especially when a truck is fully loaded.

Haul routes need to be well maintained and at an acceptable gramaximum of 10% (follow your sites regulations).


To minimize or prevent damage to haul roads only suitable and drytheir construction. Make sure that there is no

wet material beneath the road; a minimum of 4 metres, or preferably 5-6metres. A fully loaded truck generates vibrations which can penetrate upto 4 metres into the ground (depending on material). These vibrations cantransform wet material into a very thick liquid-like state.

Design roads with a small slope to the side so that rain water can run offquick and easily to the side away from the road. Remove any water puddleon or beside road to avoid the water’s eventual penetration into the road

The radii of haul road corners are important issues to be taken intoconsideration during the road planning stage.

To prevent overheating of truck tyres, the radius of a corner should be asas possible, particularly when the corner is at the end of a slope. A

wider corner does create as much heat and stress within the side wall of atyre especially when a truck is fully loaded.

Haul routes need to be well maintained and at an acceptable grade of amaximum of 10% (follow your sites regulations).




Haul Road Maintenance

If there is spillage (loose rock/material) on the haul road due tooverloading or aggressive cornering, the haul truck operator must contactthe supervisor or the road maintenance machine to come and cleanand repair the haul road.

Damage to tyres (side wall cuts) is mainly due to spillage in the face andon the haul roads. To enhance and speed up truck cycle time haul roadsshould be regularly maintained.

Pot-holes and undulations etc. should be filled to minimize wear andtear on the trucks.

To prevent excessive dust pollution, an allying compound should beused or water should be applied to the haul roads.

The width of the road should be wide enough for the bused on the site to pass each other with a suitable gap between them.

Also take into consideration the: grade, width, separation berms,corner camber, demarcation, weight of load & truck type, etc.


Haul Road Maintenance – Strategy

material) on the haul road due tooverloading or aggressive cornering, the haul truck operator must contact

e road maintenance machine to come and clean-up

Damage to tyres (side wall cuts) is mainly due to spillage in the face andon the haul roads. To enhance and speed up truck cycle time haul roads

holes and undulations etc. should be filled to minimize wear and

To prevent excessive dust pollution, an allying compound should beused or water should be applied to the haul roads.The width of the road should be wide enough for the biggest trucksused on the site to pass each other with a suitable gap between them.Also take into consideration the: grade, width, separation berms,corner camber, demarcation, weight of load & truck type, etc.


Haul road – Superelevation

Superelevation (camber) is a technique to assist vehicles in driving safelyaround corners. It allows the vehicle taking the corner to counteract forcestowards the outside of the curve, by directing the vehicle weight towardsthe centre of radius of the curve. The amount of superelevation on acorner is directly related to the radius of the corner and the desiredvehicle speed through the corner.

Superelevation is a particularly important design consideration forswitchbacks on pit ramps. On such corners, whichturn radius, superelevation is extremely important. On switchbacks thathave the centre of the curve located on the upchosen superelevation rate prevents material being spilled from loadedtrucks and also improves control.

The camber on some haul roads fall to the wrong side of the bend. Thiscauses an increase in tyre stress and damage as well as shifting the centreof gravity on the trucks. Incorrect camber reduces truck stability (safety),reduces tyre life (maintenance cost) and slows the trucks (production).

Incorrect superelevation.


Superelevation (Camber)

is a technique to assist vehicles in driving safelyaround corners. It allows the vehicle taking the corner to counteract forcestowards the outside of the curve, by directing the vehicle weight towards

The amount of superelevation on acorner is directly related to the radius of the corner and the desired

Superelevation is a particularly important design consideration forswitchbacks on pit ramps. On such corners, which typically have a smallturn radius, superelevation is extremely important. On switchbacks thathave the centre of the curve located on the up-side of the ramp, a well-chosen superelevation rate prevents material being spilled from loaded

The camber on some haul roads fall to the wrong side of the bend. Thiscauses an increase in tyre stress and damage as well as shifting the centre

Incorrect camber reduces truck stability (safety),e (maintenance cost) and slows the trucks (production).


Haul Road Undulation

This is generally caused by an insufficient foundation or wet spots on theroad. These areas must be maintained and repaired to minimiseto truck tyres and suspension.


Haul Road Undulation – Soft areas

This is generally caused by an insufficient foundation or wet spots on theroad. These areas must be maintained and repaired to minimise damage


Hazard – Something which may result ininjury or harm

Safety around an operation is paramount at all times. The identification ofhazards is critical in incident prevention. It is the responsibility of all mineemployees to identify and control hazards in the work place.

Hazards cause….

Heel Wear (dipper) – Damage to the heel ofa dipper caused by the tooth attack angle

Heel wear in conjunction with wear under the teeth, is affected andinfluenced by the tooth attack angle.more wear and tear the bucket will sustain.

Heel damage is likely to be an issue above 65° tooth attack angle.


Something which may result in

Safety around an operation is paramount at all times. The identification ofhazards is critical in incident prevention. It is the responsibility of all mineemployees to identify and control hazards in the work place.

Damage to the heel ofa dipper caused by the tooth attack angle

Heel wear in conjunction with wear under the teeth, is affected andattack angle. The higher the tooth attack angle, the

more wear and tear the bucket will sustain.

Heel damage is likely to be an issue above 65° tooth attack angle.


High wall – Wall left in undug overburden

The high wall is the advancing wall of the pitThe angle of the high wall (Batter) can vary at each mine site. Incompetent material the angle is usually 70 degrees, but it time can be laidback to 60 degrees. Some mines cut vertical high walls. This can create anissue with unstable material which creates a safety issue for peopleworking under it.

Some mines also presplit their high wall. When done correctly thispractice creates a very clean, stable wall.


Wall left in undug overburden

The high wall is the advancing wall of the pit left in undug overburden.The angle of the high wall (Batter) can vary at each mine site. Incompetent material the angle is usually 70 degrees, but it time can be laidback to 60 degrees. Some mines cut vertical high walls. This can create an

unstable material which creates a safety issue for people

Some mines also presplit their high wall. When done correctly thispractice creates a very clean, stable wall.


High Wall failure – Unstable Wall or partsof it

A high wall is said to have failed when part of it falls into a previously dugout pit. This can be a major hazard when equipment is working in thevicinity.

Historical Data – Information fromprevious strips

Significant knowledge is accumulated through experiencesoperation. Historical data is information gathered by various means andarchived for future reference. Data is gathered by machine productionmonitors, engineers and production personnel in hard or electronic copy,and is a very useful means of verifying what may have happened duringthe excavation of previous parts of the mine.

Sometimes historical data is lost due to the movement of key personnelaround site or to other sites and these needs to be planned for.


Unstable Wall or parts

aid to have failed when part of it falls into a previously dugThis can be a major hazard when equipment is working in the

Information from

Significant knowledge is accumulated through experiences at a particularHistorical data is information gathered by various means and

archived for future reference. Data is gathered by machine productionmonitors, engineers and production personnel in hard or electronic copy,

s of verifying what may have happened duringthe excavation of previous parts of the mine.

Sometimes historical data is lost due to the movement of key personnelaround site or to other sites and these needs to be planned for.


Hitachi EH1600 – Dump Truc

Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

EH1600

783

732

58.6

70920

160664

Struck 35

Heaped 2:1 57.1


1003

9780

12.8





Hitachi EH1700 – Dump Truck

Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

EH1700 EH1700-3

895 783

836 710

61.6 55.7

71736 68137

170100 163300

Struck 38.6 39.5

Heaped 2:1 60.3 60.4

98400 95200

1003 1136

9860 9820

12.8 12.8

10290 10540

6050 6250

5310 5170



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

EH3000

1398

1304

54.7

123489

278964

Struck 72.2

Heaped 2:1 101.9


2838

12600

17.9






Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

EH3500 EH3500ACII

1510 1491

1414 1398

55.7 56

134047 141000

324324 309000

Struck 79.9 74

Heaped 2:1 115.1 111

190000 168000

2838.8 2950

12630 12760

17.9 17.5

12240 13510

8126 8990

6370 6770



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

EH4000 EH4000ACII

1864 1864

1790 1771

48.4 56

157895 162000

385923 384000

Struck 92.9 106

Heaped 2:1 131.9 153

228028 222000

3785 2680

12520 13860

23 18

13510 14280

7870 9540

6860 7360



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

EH4500 EH4500-2 EH4500 AOS

2013 2014 2013

1973 1939 1963

62 66.9 58.6

180014 198096 195625

435456 480362 469153

105.4 108 90.81

Heaped 2:1 147.6 159 144.05

255442 282000 273528

3785 3785 3785

14250 14300 14400

22.2 22 22.2

14150 14300 14150

8150 9050 8760

7040 7240 7300



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

EH5000 EH5000ACII

2014 2014

1939 1896

66.9 60

213185 210000

528208 500000

Struck 143.6 156

Heaped 2:1 196.1 206

315000 290000

3785 4732

14280 14460

22 23

14420 15220

9050 9280

7170 8010


Hitachi EX1800 – HydraulicShovel/Excavator

Hitachi


WorkingRange






Transmission

Max. Speed (kph)

Buckets Capacities (m3) PCSA 1:1

PCSA 2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height


Overall Width

Others Match Trucks


Hydraulic

EX1800-2 EX1800-3

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

746 746 746 746

9.24 5.92 9.27 5.93

14.45 14.55 14.44 14.54

9.16 10.4 9.16 10.4

16.07 13.4 16.07 13.4

177000 177000 180000 180000

2.1-2.8 2.1-2.8 2.1-2.8 2.1-2.8

PCSA 1:1 4.3-14 10.3-14.5

4.4-14 10.5-14.5

PCSA 2:1 3.8-12.5 3.8-12.5

8.7 8.7

4 4

6115 6115 6910 6910

9750 9750 9760 9760

5770 5770 6200 6200

46, 77, 120 tonnes truck



Hitachi


Net Power (kW)

WorkingRange







Buckets Capacities(m3)

PCSA 1:1

PCSA 2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height


Overall Width

Others Match Trucks


Hydraulic

EX1900-5 EX1900-6

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

765 765 810 810

775 775

8.18 5.92 8.18 5.92

14.14 14.61 14.14 14.61

9.06 10.44 9.06 10.44

15.25 13.43 15.25 13.43

186500 185900 192000 191000

2.1-2.8 2.1-2.8 2.1-2.8 2.1-2.8

PCSA 1:1 4.4-12 4.4-12

PCSA 2:1 3.8-10.6 11.0-15

11.0-15

8.3 8.3

3.6 3.6

6820 6820 6990 6990

Overall Length (No Bucket) 9750 9750 9775 9775

6260 6260 6660 6660

EH1700



Hitachi EX2500

BackhoeBucket

ShovelBucket

Engine Gross Power(kW)

970

Net Power (kW) 935

Working

Range


8.57


16.16


10.36


16.5

Operating Weight(kg)

236000 238500



PCSA1:1

13.8

PCSA2:1

Boom Length (m) 9


Dimensions(m)

Overall Height 7.04


10.225 10.225

Overall Width 6.35


Hydraulic

EX2500-5 EX2500-6

ShovelBucket

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

970 1007 1007 1044 1044

935 971 971 994 994

3.72 8.57 3.72 8.6 3.72

15.01 16.16 15.01 16.06 15.01

10.35 10.36 10.35 10.33 10.35

14.06 16.5 14.06 17.08 14.06

238500 239000 242000 248000 249000

2.3 2.3 2.3 2.3 2.3

15 15

14 15-16.5

15-16.5

9 9

4.2 4.2

7.04 7.04 7.04 7.25 7.25

10.225 10.225 10.225 10.225 10.225

6.35 6.2 6.2 7.56 7.56



Hitachi


Net Power (kW)

WorkingRange








PCSA 1:1

PCSA 2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height


Overall Width

Others Match Trucks


Hydraulic

EX3500-2 EX3500-3

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

1312 1312 1312 1312

9.34 6.06 9.34 6.04

19.78 17.17 19.78 17.17

13.3 12.42 13.3 12.42

19.4 15.81 19.4 15.81

330000 330000 330000 334000

1.8-2.4 1.8-2.4 1.8-2.4 1.8-2.4

17-25 18-25 17-25 18-25

15-22 15-22

10 10

5 5

6850 6850 7750 7750

11130 11130 11130 11130

8240 8240 8240 8240

154 tonnes truck


Hitachi EX3600 - HydraulicShovel/Excavator

Hitachi EX3600

BackhoeBucket


Net Power (kW)

WoringRange






Transmission

Max. Speed (kph)

Buckets Capacities (m3)

PCSA1:1

PCSA2:1

Boom Length (m)

Stick Length (m)

Dimensions(m)

Overall Height


Overall Width


Hydraulic

EX3600-5 EX3600-6

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

1400 1400 1450 1450

1400 1400 1450 1450

8.58 3.91 8.58 4.16

17.69 16.3 17.69 16.56

11.59 10.99 11.59 10.99

18.19 15.22 18.19 15.47

348000 350000

359000

362000

2.2 2.2 2.2 2.2

22 22

21-23 21-23

9.6 9.6

4.5 4.5

7.75 7.75 7.83 7.83

11.13 11.13 11.13 11.13

9.03 9.03 9.42 9.42



Hitachi EX5500-1

BackhoeBucket

Engine Gross Power (kW) 1940

Net Power (kW)

Working

Range


9


20.6


13


20.9

Operating Weight(kg)

515000



PCSA 1:1 29

PCSA 2:1/CECE

26

Boom Length (m) 10.6


Dimensions(m)

Overall Height 8.5


12.425

Overall Width 9.85


Hydraulic

1 EX5500-5 EX5500-6

ShovelBucket

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

1940 2014 2014 2088 2088

1942 1942 1988 1988

4.55 9 4.55 9 4.55

18.9 20.6 18.9 20.6 18.9

13.1 13 13.1 13 13.1

16.6 20.9 16.6 20.9 16.6

515000 518000 518000 522000 522000

2.3 2.3 2.3 2.3 2.3

27 29 29

27/29/30.6

27

10.6 10.6

5.3 5.3

8.5 8.5 8.5 8.6 8.6

12.425 12.425 12.425 12.625 12.625

9.85 9.85 9.85 10.08 10.08



Hitachi


WorkingRange








PCSAheaped

Dimensions(mm)



Overall Width

Others Match Trucks (Hitachi)


Hydraulic

8000 8000-6 8000 E-6

ShovelBucket

ShovelBucket

ShovelBucket

2800 2900 2400

4.1 4.1 4.1

20.5 20.5 20.5

13.8 13.8 13.8

18.5 18.5 18.5

805000 811000 804000

1.4-2.0 1.4-2.0 1.3-1.9

40 40 40

9900 9900 9900

Overall Length (No Bucket) 13530 13530 13530

10670 10670 10670

EH5000 EH5000ACII EH5000


Hitachi R90 – Dump Truck

Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R90 R90C

690 690

650 650

57.55 54.8

63731 64410

149687 155129

Struck 35.7 35.7

Heaped 2:1 52.7 52.7

85756 90718

1003 1003

9730 9730

12 12

Overall Length (mm) 10260 10260

5440 5890

Overall Height (mm) 5180 5180



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R100


Net Power (kW) 746

Max. Speed (kph) 54.69

67541

158261

Capacities (m3) Struck 35.1

Heaped 2:1 55


Fuel Capacity (L) 1230.1

Dump Height (mm) 10240

Raise Time (s) 20





Hitachi R120E – Dump Truck

Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R120E


Net Power (kW) 783


81460

190320


Heaped 2:1 65.4


ty (L) 1930.4


Raise Time (s) 18






Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R130 R130B R130M

1007 1007 1007

895 895

38.5 49 59.8

79357 94761 79350

217700 226761 197286

50.3 50.3 50.3

Heaped 2:1 71.9 71.9 71.9

138371 132000 117936

1930.4 1930.4

10740 10740

20 12.8 20

11250 11230 11250

5840 6070 5840

5840 5770 5760



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


p Truck

R150


Net Power (kW) 895


98467

234467


Heaped 2:1 84.1


Fuel Capacity (L) 1930.4


Raise Time (s) 25






Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R170 R170C

1193 1343

1133 1264

55.4 54.7

106015 122000

261342 279000

Struck 68.4

Heaped 2:1 97

Rated Payload (kg) 154224 157000

1930.4 2838.8

11430 12320

25 17.9


Overall Width (mm) 6380 6550




Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R190 R190C

1342 1342

1230

52.6 55.4

114416 127252

286784 310652

Struck 77.7

Heaped 2:1 106.8 106.8

172368 183400

2854

11160

26 26


6680 7160




Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R220


wer (kW)

Max. Speed (kph) 56

133800

324310


Heaped 2:1 108.3


Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)

Overall Length (mm)

Overall Width (mm)

Overall Height (mm)



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R260

1864

1780

48.8

148644

385923

Struck 92.9

Heaped 2:1 131.9

237279

3785

12520

23

13510

7870

6860



Hitachi


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

R280 R280AC

2014 2013

1973

62 62

180000 147100

435000 435500

Struck

Heaped 2:1


3785

Dump Height (mm) 14250 14250

22


Overall Width (mm) 8150 8150



Hoist Control Lever –

This is the control used to raise, lower or float the truck tray.

Power Down

HoldLever


Truck Tray Control

This is the control used to raise, lower or float the truck tray.

Float Travelling PositionPower Down

RaiseHold


Hoist Cylinder/ram –Position

These cylinders raise the truck tray up for dumping or maintenance.


Raises Tray to Dump

These cylinders raise the truck tray up for dumping or maintenance.


Hoist Ropes – Control Vertical BucketMovements (Rope Shovel)

Host Rock – Waste

Host rock or waste is rock which serves as a host formaterial of an ore body or mineral deposits.an ore body may need to be removed in themine.


ontrol Vertical BucketMovements (Rope Shovel)

which serves as a host for or the surroundingor mineral deposits. Material above and around

may need to be removed in the mining process of an open cut


Hydraulic Drive – Propels the Tracks

These are the hydraulic motors that propel some machines.

Hydraulic Filters – Clean Hydraulic Fluids


Propels the Tracks

These are the hydraulic motors that propel some machines.

Clean Hydraulic Fluids


Hydraulic Face Shovel

A Hydraulic Face Shovel is a loading unit asopposed to the backhoe which digs towards itself, the face shovel digsaway from itself. Please refer to specific makes and models as illustratedin this dictionary.


Hydraulic Face Shovel – Machine

is a loading unit as can be seen below. Asopposed to the backhoe which digs towards itself, the face shovel digs

Please refer to specific makes and models as illustrated




Hydraulic Face Shovel – Bucket




Hydraulic Face Shovel – Schematic


Hydraulic Pump – Pressurises HydraulicFluid


Pressurises Hydraulic


Hydraulic Tank – Hydraulic Fluid Storage

Idle Time – A stoppage when the operatorfails to enter a delay into the monitor

Idle time is usually a failure on the part of the operator to enter a delayinto the production monitor. Not all monitors call it idle; some may call itstand-by or some form of unknown delay.for trucks and loaders as there is always a reason for a delay, and theoperator should ensure there is a delay entered.


Hydraulic Fluid Storage

A stoppage when the operatorfails to enter a delay into the monitor

Idle time is usually a failure on the part of the operator to enter a delayinto the production monitor. Not all monitors call it idle; some may call it

by or some form of unknown delay. There should never be idle timeas there is always a reason for a delay, and the

delay entered.


Idler – Undercarriage

Inclinometer – Measures

Inclinometers are used to determine the angle of operation on manyloading machines. Most loading units have designed cross fall and slopeangle limitations and must not be operated ploading unit on an angle increases damage to the machine.


Undercarriage

Measures angles

Inclinometers are used to determine the angle of operation on manyloading machines. Most loading units have designed cross fall and slopeangle limitations and must not be operated past these. Operating aloading unit on an angle increases damage to the machine.


Isolation Station – A System to PositivelyRemove Power

The rules regarding the application and locks and or tags to equipmentare there to protect you and your fellow workeor life-threatening incident. The general rules for tags and locks are:

No person shall attempt to start or operate any plant or equipmentthat has a personal locks, Danger tags (if required) or Out of Servicetags attached

Once tags have been used they must be destroyed


A System to Positively

The rules regarding the application and locks and or tags to equipmentare there to protect you and your fellow workers from a potentially serious

The general rules for tags and locks are:

No person shall attempt to start or operate any plant or equipmentthat has a personal locks, Danger tags (if required) or Out of Service

nce tags have been used they must be destroyed


Joy Stick – Steering control

An example of a Joy Stick steering control used on a Front End Loader isillustrated below.


Steering control

An example of a Joy Stick steering control used on a Front End Loader is


Komatsu 630E 685E 730E

Komatsu 630E 685E 730E


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (m)

Raise Time (s)

Dimensions Overall Length (m)

Overall Width (m)

Overall Height (m)


Komatsu 630E 685E 730E – Dump Truck

630E 685E 730E 730 E-7

1491

1271 1383 1388 1388

51 67 55.7 55.7

113559 128369 140592 140592

285559 309369 324322 324319

77 77

103 111 111 111

172000 181000 183730 185949

3217 3217

12.51 12.51

21 21

11.89 11.94 12.83 12.83

7.01 7.21 7.54 7.54

6.38 6.55 6.25 6.25


Komatsu 830E-AC – Dump Truck

Komatsu 830E Series


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)


Overall Width (m)

Overall Height (m)


Dump Truck

830E 830E-AC

1865 1865

1761 1761

48.8 64

162505 164200

385852 385848

Struck 117 117

Heaped 2:1 147 147


4542 4542

14.2 14.4

7.32 7.32

6.88 6.88


Komatsu 860E – Dump Truck

Komatsu 860E


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (m)

Raise Time (s)


Overall Width (m)

Overall Height (m)


Dump Truck

860E-1K

2014

1902

64.5

200351

454363

Struck 122

Heaped 2:1 169

254012

4542

14.04

22

14.93

9.39

7.3



Komatsu 930E Series 930E


Net Power (kW) 1865


Weight Empty (kg) 180440

190268

Loaded (kg) 462440

480567


Capacities (m3)

Struck

Heaped 2:1

161


290299

Fuel Capacity (L)

Dimensions Overall Length (m) 15.2




Dump Truck

930E 930E-2 930E-3 930E-4 930E-4SE

2014 2014 2014 2611

1865 1902 1902 1902 2558

64.5 64.5 64.5 64.5 64.5

180440-

190268

202232

211681

210187

215307

462440-

480567

498952

501974

501974

505755

171 171 171 171

161-184

211 211 211 211

282000-

290299

290000

290293

291790

290448

4542 4542 4542 5300

15.2 15.32 15.6 15.6 15.6

8.43 8.69 8.69 8.69 8.69

7.26 7.32 7.37 7.37 7.37



Komatsu 960E 960E_1


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Struck

Heaped2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (m)

Raise Time (s)


Overall Width (m)

Overall Height (m)


Dump Truck

960E_1 960E_1K 960E_2 960E_2K

2610 2610 2610 2610

2495 2495 2495 2495

64.5 64.5 64.5 64.5

249475 249475 249475 249475

576072 576072 576072 576072

149 149 149 149

214 214 214 214

326585 326585 326585 326585

5300 5300 5300 5300

14.1 15.51 14.1 15.51

24 23 24 24

15.6 15.34 15.6 15.34

9.6 10 9.6 10

7.37 7.67 7.37 7.67


Komatsu (Demag) H285Shovel/Excavator

Komatsu (Demag) Demag H285

BackhoeBucket

Engine Gross Power (kW) 1400

Net Power (kW) 1350

Working

Range


8





Transmission


Buckets Capacities (m3) 21

Boom Length (m) 9.65

Stick Length (m) 5

Dimensions(m)

Height To Top of Cab(m)

8.26


10.69

Overall Width 7.65


Komatsu (Demag) H285 – Hydraulic

Demag H285 Demag H285S Komatsu PC4000

ShovelBucket

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

1400 1400 1300 1300 1400 1400

1350 1350 1178.2 1178.2 1350 1350

8 2.8 3.15 8 2.8

17.5 15

12 12.7 12

14.7 17.5

301000 303000 335000

392000/397000

385000/

390000

2.1 2.1 1.9 1.9 2.1 2.1

21 16(Std)/24

17.3 29 (2:1)/32.7(1:1

)

29

9.65 7.15 6.3 9.75 7.15

5 4.9 4.3 4.5 4.9

8.26 8.26 7.81 7.81 8.3 8.3

10.69 10.69 14.2(W/B)

10.92 10.92

7.65 7.65 6.45 6.45 8.33 8.33



Komatsu (Demag) H485S

BB


WorkingRange




Operating Weight(metric ton)


Buckets Capacities (m3) Std.

Long

Boom Length (m)

Stick Length (m)

Dimensions(m)

Overall Height (To CAB)


Overall Width (Over tracks)




H485S H485SP H485/H655/H685SP

BB SB BB SB BB SB

2240-3000

2240-3000

2780 1592 1592

18-20.4 20.4 18

13-15 14 15

16-18 16-18 17

600-650

600-650

680-685

680-685

500-575

500-575

2.1/2.24 2.1/2.2 2.25 2.25 2.1 2.1

33 33 35 35 20 38

38 44

11.5 8.15

6.3 5.75

8.21 9.21 9.21 9.21 8.82 8.82

12.7-13.4 12.7-13.4

13.38 13.38 12.79 12.79

7.8/8.0 7.8/8.1 8.1 8.1 7.8 7.8




Komatsu


WorkingRange





Operating Weight(metric ton)

Transmission

Max. Speed (kph)


Long

Boom Length (m)

Stick Length (m)

Dimensions(m)

Overall Height (To CAB)


Overall Width (Overtracks)

Others Match Trucks




H485/H655/H685SP

H655S

BB SB BB SB

1592 1592 2769.5

2.7

18 20.5

15 14

17 16.8

500-575 500-575

685

2.1 2.1 2.1 2.1

20 38 33-35 33-35

38 44

11.5 8.15

6.3 5.75

8.82 8.82 9.61 9.61

12.79 12.79 13.42 13.42

7.8 7.8 7.8 7.8

CAT793F/EH4000/830E



Komatsu HD465 – Dump Truck

Komatsu HD465 Series HD4652


Net Power (kW) 506.3

Transmission

Max. Speed (kph) 65


Loaded (kg) 82555


Capacities (m3)

Struck

Heaped 2:1

34.2


Fuel Capacity (L) 780





Dump Truck

HD465- HD465-3

HD465-5

HD465-5QPAK

HD465-7/7R/7EO

551 551

506.3 524 533 533 533

65 65 70 70 70

36500 37770 42500 46700 43100

82555 83000 96100 100000

99680

25 25

34.2 34.2 34.2 40 34.2

46000 46000 55000 60000 55338

780 780 780 780

9 9 9.12/9.4 9.12 9.36

4.05 4.05 4.17/5.1 5.1 5.4

4.25 4.25 4.35/4.4 4.43 4.55



Komatsu 785 Series HD785-


Net Power (kW) 654



Loaded (kg) 129555


Capacities(m3)

Struck

Heaped2:1


Fuel Capacity (L) 1240

Dimensions Overall Length (m) 10.13

Overall Width (m)



Dump Truck

-1 HD785-2 HD785-3 HD785-5 HD785-7

895

654 654 753 753 879

70 65 68 64.7 65

55500 56000 60400 70490 72000

129555 134000 147400 166468 166000

40

52 52 53 60 60

78000 78000 87000 91000 91000

1240 1250 1308

10.13 10.13 10.1 10.49 10.29

5.7 5.7 5.5 5.66 6.89

4.99 4.92 4.92 5.05 5.05



Komatsu 985


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

HD985-3 HD985-5

783

753 753

70 70

73700 73700

178700 178775

Struck 45

Heaped 2:1 64

105000 105000

1250

10135

15 13

10610 10610

5865 5865

5120 5120



Komatsu HD1500


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

HD1500-5 HD1500-7

1108 1109

1048 1048

58 58

100462 105300

249462 249478

54 54

Heaped 2:1 78 78

149000 144100

2120

11440

15

11370 11370

6620 6890

5850 5850


Komatsu PC1800 – HydraulicShovel/Excavator

KomatsuPC1800

Engine Flywheel Power (kW)






Transmission

Max. Speed (kph)


Boom Length (m)

Stick Length (m)

Dimensions(m)

Overall Height

Overall Length (with Bucket)

Overall Width


Hydraulic

BackhoeBucket

ShovelBucket

lywheel Power (kW) 676 676

Max. Digging Depth (m) 9.265 3.22

Max. Cutting Height (m) 13.38 14.42


Max Digging Reach (m) 15.78 13.17

Operating Weight (kg) 180000-184120

180000-184120

d (kph) 2.7 2.7

5.6-12 11

Boom Length (m) 8.7 5.95

Stick Length (m) 3.9 4.45

6.745 8.18

Overall Length (with Bucket) 17.185 13.23

6.015 6.015


Komatsu PC2000 – HydraShovel/Excavator

omatsu


Net Power (kW)

Working Range Max. Digging Depth (m)







PCSA 1:1

PCSA 2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions (mm) Overall Height


Overall Width


Hydraulic

PC2000-8

BackhoeBucket

ShovelBucket

728 728

713 713




Digging Reach (m) 15.78 13.17

200000 195000

2.7 2.7

PCSA 1:1 12 11

PCSA 2:1/CECE 11

8.7 5.95

3.9 4.45

7030 7030


7550 7550



Komatsu


Net Power (kW)

WorkingRange






Transmission

Max. Speed (kph)


PCSA1:1

PCSA2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height


Overall Width

Others Match Trucks


Hydraulic

PC3000 PC3000-6

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

940 940 940 940

900 900 900 900

7.8 3.2 7.9 3.3

14.1 14 14.1 15.1

9 10.2 9 10.2

16.2 13.4 16.2 13.3

253000 250000 256000 252000

2.4 2.4 2.4 2.4

15 17.2 15-Jan

15 15

8.6 6 8.6 6

4 4.3 4 4.3

7485 7485 7485 7485

10435 10435 10365 10365

6800 6800 6800 6800

77-150 tonnes truck



Komatsu


Net Power (kW)

WorkingRange








PCSA 1:1

PCSA 2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions(mm)

Overall Height


Overall Width

Others Match Trucks


Hydraulic

PC4000 PC4000-6

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

1400 1400 1400 1400

1350 1350 1350 1350

8 2.8 8 2.8

14.6 16 15 16

9.6 12 9.6 12

17.5 15.2 17.5 15.2

390000 380000 392000 385000

2.1 2.1 2.1 2.1

22 25 22 25

22 22

9.75 7.15 9.75 7.15

4.5 4.9 4.5 4.9

8260 8260 8300 8300

10688 10688 10921 10921

7650 7650 7975 7975

150-231 tonnes 136-218 tonnes



Komatsu PC5500

BackhoeBucket


Net Power (kW)

WorkingRange







Buckets Capacities (m3) PCSA1:1

PCSA2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions(m)

Overall Height


Overall Width

Others Match Trucks (Komatsu)


Hydraulic

PC5500 PC5500-6

BackhoeBucket

ShovelBucket

BackhoeBucket

Shovel

Bucket

1880 1880 1880 1880

1800 1800 1800 1800

8.3 2.7 8.3 2.7

15.5 19.5 15.5 19.5

10.1 13.4 10.1 13.3

19.8 16.5 19.8 16.5

535000-549000

535000-549000

535239-548847

530703-544311

2.1 2.1 2.1 2.1

28 32 29

28 29

11 7.6 11 7.6

5.1 5.6 5.1 5.6

8.61 8.61 8.61 8.61

12.41 12.41 12.41 12.41

8.6 8.6 8.62 8.62

830E 860E-1K



Komatsu

Engine Power (Diesel Drive)(kW)

Power (Electric Drive)(kW)

WorkingRange







Buckets Capacities (m3) PCSA 1:1

PCSA 2:1/CECE

Boom Length (m)

Stick Length (m)

Dimensions(m)

Overall Height


Overall Width

Others Match Trucks


Hydraulic

PC8000 PC8000-6

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

3000 3000 3000 3000

2900 2900 2900 2900

8.09 8.4 3

18.3-19.5

14 13.9

19.73 15.8-17.2 19.9 16.1

700 700 710-720 700-710

2.2 2.2 2.4 2.4

38-42 44 38-42 48

38 42

11.5 8.15 11.5 8.15

5.5 5.75 5.5 5.75

9.5 9.5

14 14

9.07 9.07 10 10

CAT793F/EH4000AC/830E

60E-1K


Komatsu WA800 – Front End Loader

Komatsu


Flywheel Power (kW)



Buckets Std. Capacities (m3)

Transmission MAX Speed (kph)

HydraulicSystem

Raise Time (sec)

Dump Time(sec)

Lower Time(sec)

Dimensions MAX Overall Length(mm)

Height To Top Of Cab (mm)

Hinge-Pin Height (mm)

Width Outside Tires (mm)

Others Fuel Tank (L)


Front End Loader

WA800-3 WA800-3EO

636 636

603 603

98300 101900

11 11

28.3 28.3

11.2 11.2

2 2

4.8 4.8

MAX Overall Length(mm) 13730 13960

ab (mm) 5275 5275

6785 6785

Width Outside Tires (mm) 4585 4585

1425 1555



Komatsu


Flywheel Power (kW)





HydraulicSystem

Raise Time (sec)

Dump Time(sec)

Lower Time(sec)







Front End Loader

WA900-3 WA900-3EO

672 672

637 638

101550 107200

13 13

28.3 28.3

11.2 11.2

2.8 2

4.8 4.8

(mm) 14270 14490

Height To Top Of Cab (mm) 5275 5275

6950 6960


1430 1555



Komatsu


Flywheel Power (kW)





HydraulicSystem

Raise Time (sec)

Dump Time(sec)

Lower Time(sec)







Front End Loader

WA1200-3 WA1200-6

1280 1411

1165 1316

205200 216400

20 20

22.6 19.3

13.5 14.8

3 3.2

5 5.3

MAX Overall Length(mm) 18200 18310

Height To Top Of Cab (mm) 6970 6970

8830 8850


5100 5100


KPI – Key Performance Metrics

KPI’s are used to measure the performance of a truckan operator.

These KPI’s give the operator or the mine a measure of how they aretracking against pre-set targets.

KPI’s need to be recorded and managed on an Hourly, Shift or Day basis:

Fill Time. Total Loads. Truck Loading Time. Truck Travelling Time. Truck Idle Time. Shovel Idle Time (waiting on trucks). Shovel Utilization, (Other Delays blasting etc.) Truck Availability. Shovel Availability.

AP: 18.0

TT: -19.1

TP: -0.9

LT: 14.9

LP: -2.6

-40

-30

-20

-10

0

10

20

30

40

Vari

ati

on

[%]

This Month

KPI variation against Previous Period.For [785 Trucks, 789 Trucks]

AP: 5.4TT: 10.0

TP: 14.6LT: 7.8

LP: 2.3

-40

-30

-20

-10

0

10

20

30

40

Vari

ati

on

[%]

This Month

KPI variation against Previous Period.For [830E Trucks, 4400 Terex Trucks]


Key Performance Metrics

ure the performance of a truck/loader operation or

These KPI’s give the operator or the mine a measure of how they are

KPI’s need to be recorded and managed on an Hourly, Shift or Day basis:

Shovel Idle Time (waiting on trucks).Shovel Utilization, (Other Delays blasting etc.)

PR: -3.5

PR: 19.8


Kress Coal Hauler – Unit body coal truck

Originally built by the independent Kress Corporationdump trucks come in various sizes and have been built in 145 to 290tonne capacities. They have a high PER.


Unit body coal truck

by the independent Kress Corporation, these bottomdump trucks come in various sizes and have been built in 145 to 290tonne capacities. They have a high PER.


Letourneau L 950 – Front End Loaderowned by Joy Global)

Letourneau


Flywheel Power (kW)


Rated Payload (kg)




Hydraulic System Raise Time (sec)

Dump Time(sec)

Lower Time(sec)

Dimensions MAX Overall Length(m)


Hinge-Pin Height (m)

Width Outside Tires (m)


Pass Match with Trucks (tonnes)


Front End Loader (Now

L950

ower (kW) 783

Flywheel Power (kW)



Std. Capacities (m3) 13.76

MAX Speed (kph) 19.31

Raise Time (sec) 11

Dump Time(sec) 2

r Time(sec) 5

MAX Overall Length(m) 15.66

Height To Top Of Cab (m) 5.64

Pin Height (m) 6.91

Width Outside Tires (m) 4.98

Fuel Tank (L) 2384

Pass Match with Trucks (tonnes) 68-109



Letourneau


Flywheel Power (kW)


Rated Payload (kg)





Dump Time(sec)

Lower Time(sec)






Pass Match with Trucks (t



L1100


Flywheel Power (kW)





Raise Time (sec) 13

Dump Time(sec) 3

Lower Time(sec) 6.5



Pin Height (m) 7.67


1741




Letourneau


Flywheel Power (kW)


Rated Payload (kg)


Buckets Std. Capacities (m



Dump Time(sec)

Lower Time(sec)









L1150


Flywheel Power (kW)





Raise Time (sec) 13

Dump Time(sec) 3

Lower Time(sec) 5



Pin Height (m) 7.82


2384




Letourneau


Flywheel Power (kW)


Rated Payload (kg)





Dump Time(sec)

Lower Time(sec)









L1350


Flywheel Power (kW)





Raise Time (sec) 15

Dump Time(sec) 3

Lower Time(sec) 5



Pin Height (m) 8.71


3501




Letourneau


Flywheel Power (


Rated Payload (kg)





Dump Time(sec)

Lower Time(sec)









L1400



Rated Payload (kg)




Raise Time (sec) 14

Dump Time(sec) 4

Lower Time(sec) 6

all Length(m) 17.22


Pin Height (m) 8.89


3974



Letourneau L 1800 – Front End Loader(Now owned by Joy Global)

Letourneau


Flywheel Power (kW)




Buckets Capacities Range (m3)

Heaped (m3)

Combo (m3)


Dump Time(sec)

Lower Time(sec)

Dimensions Length with Bucket on Ground (m)

Overall Height (Bucket Raised) (m)

Overall Width (m)


Front End Loader(Now owned by Joy Global)

L1800



Rated Payload (metric ton) 45


21.4-42.1

25.2

34.4

c) 14

Dump Time(sec) 4

Lower Time(sec) 6

Length with Bucket on Ground (m) 17.8

Overall Height (Bucket Raised) (m) 11.9

Overall Width (m) 6



Letourneau


Flywheel Power (kW)


Rated Payload (kg)





Dump Time(sec)

Lower Time(sec)









L1850

Power (kW) 1491

Flywheel Power (kW)





Raise Time (sec) 16

Dump Time(sec) 4

ower Time(sec) 6



Pin Height (m) 9.4


3975



Letourneau L 2350 – Front End Loader(Now owned by Joy Global)

Letourneau


Flywheel Power (kW)


Rated Payload (kg)





Dump Time(sec)

Lower Time(sec)






Pass Match with Trucks (


Front End Loader(Now owned by Joy Global)

L2350


Flywheel Power (kW)





Raise Time (sec) 17

Dump Time(sec) 3

Lower Time(sec) 6



Pin Height (m) 9.91


4940



Liebherr 994 – Hydraulic Shovel

Liebherr 994

BackhoeBucket


WorkingRange








Std.

Other

Boom Length (m)

Stick Length (m)

Dimensions(m)

Overall Height (ToCab)


Overall Width



994 994B

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

937 937 1120 1120

8.7 3.7 9.5 3.7

15.6 14.8 15.4 16.2

10.3 10.9 10.2 11.2

16 12.9 17 14.6

229000 226400 296800 306500

2.6 2.6 2.3-3.0 2.3-3.0

13 13.5 18 18

4.5-20 10.5-18 15.3-18 15.3-18

9 9.3

4.2

7100 7100 7570 7570

9780 9780 10625 10625

6440 6440 7190 7190



Liebherr









Other

Boom Length (m)

Dimensions (m) Overall Height (To Cab)


Overall Width



995

BackhoeBucket

Shovel Bucket

1600 1600

8.6 4.4

16.3 18.3


18.5 16.15

439420 448500

2.7 2.7

26.5 26.5

Other 24 24

10

8820 8820


8230 8230



Liebherr 996

BackhoeBucket


WorkingRange








Std.

Other

Boom Length (m)

Stick Length (m)

Dimensions(m)



Overall Width

Others Match Trucks(Komatsu)



996 996B

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

2240 2240 2240 2240

8.8 3.8 8.11 3.3

16.6 16.56

10.5 14.3 10.67 12.9

20 17 20.2 16.5

668000 677000 672000 676000

2.2 2.2 2.2 2.2

30(Std)/33(Arctic)

34 36 34

25/30/33/36(Arctic)

25/29/36(Arctic)

32/34 31/32/36

12.5 8.65 12 8.65

7.5 5.62 7.5 5.62

9.07 9.07 9.26 9.26

12.8 12.8 12.6 12.6

8.25 8.25 8.08 8.08


Liebherr 9250 – HydraulicShovel/Excavator

Liebherr









O

Boom Length (m)

Stick Length (m)

Dimensions (mm) Overall Height (To Cab)


Overall Width


Hydraulic

9250/ 9250Arctic

BackhoeBucket

ShovelBucket

960 960

Digging Depth (m) 8.7 3.8


Max. Dumping Height (m) 10.3 11


250000 253500

2.1-2.7 2.1-2.7

Std. 15 15

Other 13-17 11.0-1711- Arctic

9 6.37

4 4.2

Overall Height (To Cab) 7250 7250


6800 6800



Liebherr


WorkingRange








Other

Boom Length (m)

Stick Length (m)

Dimensions(mm)



Overall Width


Hydraulic

9350/9530Arctic 9350E

BackhoeBucket

ShovelBucket

BackhoeBucket

ShovelBucket

1120 1120 1200 1200

9.5 3.8 9.5 3.8

15.4 16 15.4 16

10.2 11.2 10.2 11.2

17 14.6 17 14.6

302000 310000 314600 322500

2.5-3.3 2.5-3.3 2.2 2.2

18 18 18 18

15.3-20 15.3-20.5

15.3-18 15.3-18

9.3 6.75 9.3 6.75

4.2 4.2 4.2 4.2

7800 7800 7800 7800

10470 10470 10470 10470

7400 7400 7400 7400



Liebherr









Other

Boom Length (m)

Stick Length (m)

Dimensions (m) Overall Height (To Cab)


Overall Width

\


Hydraulic

9400

BackhoeBucket

Shovel Bucket

1250 1250

9.5 3.9

15.5 16


17 14.8

345000 353000

2.7 2.7

22 22

18-24 18-24

9.3 6.75

4.2 4.3

8343 8343


7900 7900



Liebherr


WorkingRange








Std.

Other

Boom Length (m)

Stick Length (m)

Dimensions(m)



Overall Width

Others Match Trucks


Hydraulic

9800

Backhoe Bucket Shovel Bucket

2984 2984

9 3.3

16.2 18.3

10.9 13.1

21.2 17.4

800000 810000

2.0-2.5 2.0-2.5

38-42 38-42

11.75 8.55

5 5.1

10338 10338


8880 8880

220, 290, 360 tonnes trucks


Liebherr KL2420 KL2450 KL2680Truck

Liebherr


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Liebherr KL2420 KL2450 KL2680 – Dump

KL2420 KL2450 KL2680

1492 1865 2238

55 62 65

129500 152000 190562

324500 370000 500000

95 134

Heaped 2:1 108 147 207

195000 218000 309438

12 9 12

13300 13300 14600

7100 7800 8500

6400 6700 7100


Liebherr T252 & T262

Liebherr


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Hea

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


– Dump Truck

T252 T262

1286-1510

1510-1864

51 51

148320 156940

331120 390090

Struck 76.5 84

Heaped 2:1 107.8 119

181000 218000

3140 3310

20 21

13300 13300

7500 7400

6400 6700


Liebherr T282 – Dump Truck

Liebherr


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities(m3)

Struck

Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

T282 T282B T282C

1864-2050

2725 2800

64 64.4 54

203300 187000 237000

566300 592000 600000

122

Heaped 2:1 183.5 212

364000 363000 363000

4730 4730 6813

13900 13300 15050

24 28

14500 14500 15690

8700 8400 9679

7400 7400 8294


Liebherr TI 272 & TI274

Liebherr


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


TI274 – Dump Truck

TI272 TI274

2014 2238

68 64

151500 170000

441900 460000

Struck

Heaped 2:1 175

290000 290000

4540

12300

21

13100

8500 8290

6900 8320


Lighting Plant

Lighting plants are used during night shifts or in low visibility toilluminate the work/dump area or hazardous areas.


Lighting plants are used during night shifts or in low visibility todump area or hazardous areas.


Load Position on Trucks

It is important that the load is positioit is off centre it can cause a multitude of problems.wear and damage to the struts on the trucks, spillage at the load face andspillage on the haul road. It also causes a lot of safety issuessafety problem is that when the load is to one sideare large rocks in the load it can cause problems at the dump when tippingthe load off.

Also when the truck is cornering a lot of spillage will occur which requa grader to clean. It reduces also the lifetime of the tyres when the trucksare cornering while driving down hill. The tyres are starting to overheatand in the worst case they can ignite.negative effect on correct load placement.

Load incorrectly positioned


Load Position on Trucks

positioned in the centre of the truck tray. Ifoff centre it can cause a multitude of problems. These include; undue

wear and damage to the struts on the trucks, spillage at the load face andon the haul road. It also causes a lot of safety issues. The primary

when the load is to one side, especially where thereare large rocks in the load it can cause problems at the dump when tipping

Also when the truck is cornering a lot of spillage will occur which requiresa grader to clean. It reduces also the lifetime of the tyres when the trucksare cornering while driving down hill. The tyres are starting to overheatand in the worst case they can ignite. The truck location can have a

placement.

Load incorrectly positioned


Loading – Precautions

When loading, truck and loading unit operators should observe thefollowing precautions:

Always remain inside the cab during loading operations, unlessotherwise instructed, e.g. when loading very large rocks. This wprevent material falling onto the operator and causing a potentialinjury.

Use the payload indicator to gain an understanding of the currentpayload and ensure you obtain targeted payload every cycle.

Do not overload, follow the 10/10/20 rule (or siteinstructions).

Do not drive off until instructed to by the loader operator. Always look for rocks, spillage and poor

that can damage tyres and the truck. Utilise reverse cameras on trucks where available and


Precautions

When loading, truck and loading unit operators should observe the

Always remain inside the cab during loading operations, unlessotherwise instructed, e.g. when loading very large rocks. This willprevent material falling onto the operator and causing a potential

Use the payload indicator to gain an understanding of the currentpayload and ensure you obtain targeted payload every cycle.Do not overload, follow the 10/10/20 rule (or site specific operating

Do not drive off until instructed to by the loader operator.Always look for rocks, spillage and poor/sub-standard road conditionsthat can damage tyres and the truck.Utilise reverse cameras on trucks where available and fitted.


Loading Techniques –

There are many different loading techniques associated with each type ofloading unit:

Hydraulic Excavator

Top Loading Top Loading @ 45° Top Loading @ 90° Bottom Loading @ 45° Bottom Loading @ 90° Drive-by Loading

Hydraulic/Electric Shovel

Near Side Loading Offside Loading Single Side Loading Double Side Loading Modified Drive-by Loading

Front –End Loader

Near-side Loading Off-side Loading Double Side Loading

There may be others…


– Sequences

There are many different loading techniques associated with each type of


Lockout – Regulations

The rules regarding the application and locks and or tags to equipmentare there to protect you and your fellow workers from a potentially seriousor life-threatening incident. The general rules for tags and locks are:

No person shall attempt to start or operate anythat has a personal locks, Danger tags (if required) or Out of Servicetags attached


Without using your personal lock at the isolation point and an additionalsigning at the Isolation point you are not allowed to access a machineduring maintenance days or during a shut down. This ensures that no onecan start any part of the machine or the machine itself before allmaintenance personnel are off the machine.

Low-Wall Scavenging

Scavenging coal from the low wall or highwall by different methods iswidely practiced. Before such activities, the operator must ensure that the


Regulations

egarding the application and locks and or tags to equipmentare there to protect you and your fellow workers from a potentially serious

The general rules for tags and locks are:

No person shall attempt to start or operate any plant or equipmentthat has a personal locks, Danger tags (if required) or Out of Service


Without using your personal lock at the isolation point and an additionalt you are not allowed to access a machine

during maintenance days or during a shut down. This ensures that no onecan start any part of the machine or the machine itself before allmaintenance personnel are off the machine.

Wall Scavenging – Coal recovery

or highwall by different methods iswidely practiced. Before such activities, the operator must ensure that the


risk is clearly understood. No untrained operator should perform thesetechniques due to the risk of low wall or highwall failure and the potentialfor greatcoal losses.

Low Wall – Spoil Side Wall of theExcavation

The low wall is the side of the pit where the dug spoil has been placed.

Low wall

Spoil

Piles


risk is clearly understood. No untrained operator should perform thesewall or highwall failure and the potential

Spoil Side Wall of the

The low wall is the side of the pit where the dug spoil has been placed.

Spoil

Piles


Lube System – Applies Lubricant

The lube system delivers automaticallyattached parts while the machine is running. This allows the parts to belubricated at a set interval without down time.

Applying lubricant is often most effective when it is dispensed in small,measured amounts over short, frequent time intervals.

Lubrication Chart – Machine specs


Applies Lubricant

cally a controlled amount of lubricant toattached parts while the machine is running. This allows the parts to belubricated at a set interval without down time.

Applying lubricant is often most effective when it is dispensed in small,er short, frequent time intervals.

Machine specs


Lubrication controller

Lubrication controllers provide control and feedback to the operator.

Matching – Truck matching to the shovel

Refer to Trucking – Truck matching t


Lubrication controller – Systems

Lubrication controllers provide control and feedback to the operator.

Truck matching to the shovel

Truck matching to the shovel in this Dictionary.


Mine strategy – Basic Strategies

1. Sell as much as possible2. Sell as little as possible3. Try to optimise output4. Sell as much as possible (>30%)

– Use when prices are high– Can usually get more coal exposure capacity

o Increased truck and loadero Increased contractorso Lower dragline horizon

– Bottleneck becomes washplant, stockpiles, railing capacity, etc.– Higher cost of incremental material movement is not such a

problem as margins are so high that total margin increases

5. Sell as little as possible (>60%)

– When price is low you want to lose as little money as possible– Just do enough to still be in business when price improves– There is a fixed cost just to have the mine operating– Just long term contracts– Can reduce coal uncovery capacity

o Send contractors awayo Dragline pullbacko Reduce hourso Optimise Sales (<10%)

6. Often this will be the same as 1. or 2.

– When price is average and you are making average profits theequation of optimising mine strategy is difficult

– If you increase sales you might need higher cost (lower margin)methods of uncovering the coal

– If you reduce sales then the fixed costs become a greaterpercentage of total costs and unit cost increases

– Luckily?? the coal industry is not often in this position.in a boom and bust industry and often mines only have to choosebetween 1. or 2.


Basic Strategies

Sell as much as possible (>30%)

Can usually get more coal exposure capacity

uck and loader

Lower dragline horizon

Bottleneck becomes washplant, stockpiles, railing capacity, etc.Higher cost of incremental material movement is not such aproblem as margins are so high that total margin increases

When price is low you want to lose as little money as possibleJust do enough to still be in business when price improvesThere is a fixed cost just to have the mine operating

Can reduce coal uncovery capacity

Often this will be the same as 1. or 2.

When price is average and you are making average profits theequation of optimising mine strategy is difficult

ght need higher cost (lower margin)methods of uncovering the coalIf you reduce sales then the fixed costs become a greaterpercentage of total costs and unit cost increasesLuckily?? the coal industry is not often in this position. We work

bust industry and often mines only have to choose


Minerals – Excavation of a Resource

A mineral is a naturally occurring solid chemical substance formedthrough biogeochemical processes, having characteristic chemicalcomposition, highly ordered atomic structure, and specific physicalproperties.

By comparison, a rock is an aggregate of minerals and/or mineraloids anddoes not have a specific chemical composition. Minerals range incomposition from pure elements and simple salts to very cowith thousands of known forms.

Reference: http://en.wikipedia.org

Mining – Excavation of a Resource

Mining is the extraction of valuable minerals from the earth, from an orebody, vein or (coal) seam.

Materials recovered by mining include base metals, precious metals, iron,uranium, coal, etc.


Excavation of a Resource

A mineral is a naturally occurring solid chemical substance formedthrough biogeochemical processes, having characteristic chemical

rdered atomic structure, and specific physical

By comparison, a rock is an aggregate of minerals and/or mineraloids anddoes not have a specific chemical composition. Minerals range incomposition from pure elements and simple salts to very complex silicates

Excavation of a Resource

Mining is the extraction of valuable minerals from the earth, from an ore

Materials recovered by mining include base metals, precious metals, iron,


Modified Drive-By Loading

The modified drive by loading system or parallel approach is a goodloading option without affecting production, if doubachievable. The advantage of this technique is being highly productivewith a low number of trucks with a low dozer clean up delay. Someconditions must be given to avoid damage to the trucks and a lowproduction.

The Shovel removes material at less than the maximum digging radius bytraversing the face. The trucks approach parallel to the bench and spot at45˚ to the shovel.

Due to the fact that shovel and the trucks operate in the opposite directionreduces the manoeuvring time of the trucks. During the fill of a truck thewaiting truck can move into position. As soon as the loaded truck driveson the waiting truck can start position for the next loading cycle.


By Loading – Sequence

The modified drive by loading system or parallel approach is a goodwithout affecting production, if double sided loading is not

achievable. The advantage of this technique is being highly productivewith a low number of trucks with a low dozer clean up delay. Someconditions must be given to avoid damage to the trucks and a low

s material at less than the maximum digging radius bytraversing the face. The trucks approach parallel to the bench and spot at

Due to the fact that shovel and the trucks operate in the opposite directionthe trucks. During the fill of a truck the

waiting truck can move into position. As soon as the loaded truck driveson the waiting truck can start position for the next loading cycle.


Mounting and Dismountingand off machinery

Injuries can result from incorrect mountingequipment. Injuries also occur wherematerial build up on steps. When mounting or dismounting themake sure of the following:

Mount and or dismount the machhandrails are provided.

Face the machine when mounting or dismounting Always maintain a three-point contact with the steps and handrails Never get on or off a moving machine. Never jump off the machine. Do not use machine controls as hand

the operator’s cab.

Near Side Loading – Loading on Driver Side

When near or left side loading, align the lay flats that hangs off the dipperarms along the side of the truck body, ensure to stay paralflat, while reversing into position. Place the transmission in neutral andapply the park brake. Once in the correct position the shovel operator willload the first dipper of material into the truck.


Mounting and Dismounting – Getting on

result from incorrect mounting and or dismounting mobilenjuries also occur where operators slip due to dirt and

steps. When mounting or dismounting the machine,

Mount and or dismount the machine only where ladders, steps and

mounting or dismounting.point contact with the steps and handrails.

get on or off a moving machine.

chine controls as hand-holds when entering or exiting

Loading on Driver Side

When near or left side loading, align the lay flats that hangs off the dipperarms along the side of the truck body, ensure to stay parallel with the lay

Place the transmission in neutral andapply the park brake. Once in the correct position the shovel operator willload the first dipper of material into the truck.


OEM – Original Equipment Manufactur

Examples of OEM’s are:

ETC…

Offside Loading – Loading on Blind Side

During offside or right side loading, the shovel is positioned on the righthand side of the haul truck. Align the teeth of the shovel dipper with theside of the truck body, (using your right hand mirror) whilposition. Place the transmission in neutral and apply the park brake. Oncein the correct position the shovel operator will load the first dipper ofmaterial into the truck.

Be extra careful when reversing the haul truck in on the off sidall blind spots are clear. Maintain a three metre gap between the truck andthe counter weight of the shovel.


Original Equipment Manufacturer

Loading on Blind Side

During offside or right side loading, the shovel is positioned on the rightAlign the teeth of the shovel dipper with the

side of the truck body, (using your right hand mirror) while reversing intoPlace the transmission in neutral and apply the park brake. Once

in the correct position the shovel operator will load the first dipper of

Be extra careful when reversing the haul truck in on the off side, ensuringMaintain a three metre gap between the truck and


Oil Sands – Tar Sands

Oil sands/tar sands are a type of petroleum ore deposit.

Oil sands are loose sand or partially consolidnaturally occurring mixtures of sand, clay, and water, saturated with adense and extremely viscous form of petroleum technically referred to asbitumen.


Tar Sands

tar sands are a type of petroleum ore deposit.

Oil sands are loose sand or partially consolidated sandstone containingnaturally occurring mixtures of sand, clay, and water, saturated with adense and extremely viscous form of petroleum technically referred to as


On-board fires – All equipment

A fire on any loading unit or haul truckserious situation; therefore, the following procedure must be adhered toand initiated quickly (refer to your specific mine site procedures).

Bring the machine operation to a stop as quickly as possible. Position the implements on the ground Reduce engine to low idle. Apply the park brake. Turn ignition to off position. Notify your position and emergency details using the two way radio if

safe to do so. (refer to your site emergency procedures). Activate the in cab Automatic Fire Suppression System by removing

the pin and striking the actuation nob (if fitted) Leave the operators cabin and dismount at the safest exit point. Use the hand-held extinguisher to control fire, ensuring not to place

yourself in a position where personal injury may result. Once the hand-held extinguisher is discharged, move away from the

machine to a safe location.

Note: Always follow your sites rules and regulations regarding emergencyprocedures


All equipment

A fire on any loading unit or haul truck has the potential to create aserious situation; therefore, the following procedure must be adhered toand initiated quickly (refer to your specific mine site procedures).

operation to a stop as quickly as possible.s on the ground if fitted (loading units).

Notify your position and emergency details using the two way radio if(refer to your site emergency procedures).

ate the in cab Automatic Fire Suppression System by removingthe pin and striking the actuation nob (if fitted).Leave the operators cabin and dismount at the safest exit point.

held extinguisher to control fire, ensuring not to placein a position where personal injury may result.

held extinguisher is discharged, move away from the

: Always follow your sites rules and regulations regarding emergency


Operator – Obligations and

Obligations

Do not endanger your or any persons Report all unsafe conditions, activities

injuries to your supervisor. Do not tamper with or deactivate any

procedures. Use the appropriate PPE. Report all damage and or defects. Do not attempt a task unless qualified,

and confident.

Roll

Attend all shift briefings, tool box talks Ensure you understand and have all relevant data available on

planned activities. Understand/analyse all information

your task. Use the correct equipment for the job Do the required walk around and pre Understand and apply the relevant Practice a high standard of housekeeping Operate the machine safely and in accordance with

manufacturer’s instructions. Assess and apply all site safety, environmental rules and regulations Operate as efficiently and cost effectively as possible.


Obligations and Roll

persons health and safetyunsafe conditions, activities, near misses, hazards or

tamper with or deactivate any health and safety devices or

s.Do not attempt a task unless qualified, authorised, competent

, tool box talks and shift handovers.Ensure you understand and have all relevant data available on your

information/instructions given and plan

the correct equipment for the job.walk around and pre-start/shift inspections.

and apply the relevant tagging procedures.high standard of housekeeping.

safely and in accordance with the

Assess and apply all site safety, environmental rules and regulations.Operate as efficiently and cost effectively as possible.


Operators Cabin – Control Centre of anExcavator

An operators Cabin/Cab houses the major and minor controls that anoperators needs to utilise to enable the functioning of the excavator.Besides all the controls, this will also house the operator’s seat platand most of the warning systems. This is basically the control room of thetruck, or loading unit.

Operating Cost

This is broken down into fixed costs

Fixed costs are the same regardless of what the T&L fleet does andinclude access to electricity grid, lease

Variable costs depend on hours operating anddone.

It is complex and difficult to compare the costs of different T&L fleets.

It is known that a T&L operation is generally the mostmove spoil compared to a dragline operation and the T&L cost is between$3.00 and $4.00/PBCM (This is the cost in operating the machine).


Control Centre of an

Cab houses the major and minor controls that anoperators needs to utilise to enable the functioning of the excavator.Besides all the controls, this will also house the operator’s seat platform

This is basically the control room of the

fixed costs and variable costs.

are the same regardless of what the T&L fleet does andaccess to electricity grid, lease payments, labour, etc.

depend on hours operating and/or number of cycles

It is complex and difficult to compare the costs of different T&L fleets.

It is known that a T&L operation is generally the most expensive way tomove spoil compared to a dragline operation and the T&L cost is between

PBCM (This is the cost in operating the machine).


Opportunity Cost

In any economic analysis this is the really important cost

What you really need to understand is what the value in moving moredirt or the opportunity cost of moving less

If you know this then you can make informed decisions on certainactions.

In any simple economic analysis follow the 3 step approach

Where draglines are involved convert all dragline material moved toprime

Calculate additional material that will be moved. Calculate the cost/value of moving that material

Use one of the following 3 methods

Two cost models (with T&L all have various subsets)

Direct cost savings

– Mine is constrained in what it does through coal sales or pitlayout, etc.

– No other prestrip or ancillary equipment to shut down first– Is usually used when considering moving fleets faster and

reducing scheduled time to operate, eg 7 day to 6 or 5– Difficult to quantify accurately

Incremental profit on coal available to be sold

– Mine can sell all coal produced– Additional coal usually has high profit margin.– How will you bank the gains– Need to know what incremental profit is


In any economic analysis this is the really important cost

understand is what the value in moving moredirt or the opportunity cost of moving less is.If you know this then you can make informed decisions on certain

ollow the 3 step approach:

onvert all dragline material moved to

Calculate additional material that will be moved.value of moving that material

Use one of the following 3 methods

Two cost models (with T&L all have various subsets)

is constrained in what it does through coal sales or pit

No other prestrip or ancillary equipment to shut down firstIs usually used when considering moving fleets faster and/orreducing scheduled time to operate, eg 7 day to 6 or 5

to quantify accurately

Incremental profit on coal available to be sold

Mine can sell all coal producedAdditional coal usually has high profit margin.How will you bank the gainsNeed to know what incremental profit is


Ore Body

An ore is a type of rock (spoil) that contains a valuable mineral withimportant elements including metals (copper, iron etc.). Ore is extractedthrough a mining process. Ore is then processed to extract the valuableelement.

Ore bodies are formed by a variety of geological processore formation is called ore genesis.


spoil) that contains a valuable mineral withimportant elements including metals (copper, iron etc.). Ore is extractedthrough a mining process. Ore is then processed to extract the valuable

Ore bodies are formed by a variety of geological processes. The process of


Overextending crowd

Do not over-extend the dipper handleshould be propelled closer to the loading

Overextending affects the hoist ropes, andcrowd motor.

Over extending the dipper handle results inhoist rope damage/stresses. Consequencelow availability and loss of production.


– Rope Shovel

handle to load the dipper. The equipmentloading face.

Overextending affects the hoist ropes, and causes overheating of the

results in overheating of the motors andonsequences are premature motor failure,

production.


Overloading – Trucks

Excessive overloading or badly loaded trucks put an immense pressure ontyres which are designed to hold only a specific weight. Any pressure overthe manufacture recommended load will have an impact on the tyre lifespan

The tyre stress will be even more, if that high speeds over rough surfaces and through corners.

As well the spillage caused will subsequently damage tyres to followingtrucks, if not removed from the haul road.

Solution:

Adjust loading to account for materi Adjust speed to haul road condition Report bad road and mine conditions


ive overloading or badly loaded trucks put an immense pressure ontyres which are designed to hold only a specific weight. Any pressure overthe manufacture recommended load will have an impact on the tyre life

The tyre stress will be even more, if the driver operates the haul road truckat high speeds over rough surfaces and through corners.

As well the spillage caused will subsequently damage tyres to followingtrucks, if not removed from the haul road.

Adjust loading to account for materialAdjust speed to haul road conditionReport bad road and mine conditions


P&H 2800 XPA – Rope Shovel

P&H 2800 XPA rope shovel


Rope Shovel


P&H 4100 A– Rope Shove

P&H

Max. Power DC (kW)

AC (kVA)





Operating Weight (tonne)

Nominal Payload (tonne)

Rated Suspended Load (tonne


Buckets Capacities (m3) SAE Struck

SAE 2:1

Dimensions (m) Overall Height (Over Gantry)




Rope Shovel

4100A 4100A/LR 4100TS

3400 3176 3773

9.19 15.42 9.7

20.85 25.04 20.85

1238.9 1223.5 1350.1

88 65.5 82.4

Rated Suspended Load (tonne)

SAE Struck 47.4 35.2 44.3

SAE 2:1

Overall Height (Over Gantry) 12.62 12.62 12.62

Overall Length (No Bucket) 15.24 15.24 15.24

Overall Width (Over tracks) 13.16 13.16 13.16


P&H 4100 XPB – Rope Shovel

P&H

Max. Power DC (kW)

AC (kVA)













Others Match Trucks size (tonne)


Rope Shovel

4100XPB

Max. Digging Depth (m) 1.93

Max. Cutting Height (m) 18.06

Max. Dumping Height (m) 10.44

Max Digging Reach (m) 23.8

Operating Weight (tonne) 1455

Nominal Payload (tonne) 104



Capacities (m3) SAE Struck 55.8

SAE 2:1

Overall Height (Over Gantry) 14.35

Overall Length (No Bucket) 14.33

th (Over tracks) 14.35

Match Trucks size (tonne) 172-363


P&H 4100 XPC – Rope Shovel

P&H

Max. Power DC (kW)

AC (kVA)













Others Match Trucks size (tonne)


Rope Shovel

4100XPC-DC 4100XPC-AC

2*1860

4640



. Dumping Height (m) 9.5 9.5


Operating Weight (tonne) 1489 1535

Nominal Payload (tonne) 99.8-108.9 99.8-108.9

Rated Suspended Load (tonne) 195 195

SAE Struck 53.5-62.7 53.5-62.7

SAE 2:1 67.6 67.6

Overall Height (Over Gantry) 14.7 14.7


Overall Width (Over tracks) 14.4 14.4

Match Trucks size (tonne) 172-363 172-363


Park-up – Go – No Go lines

The go, no-go line is where the trucks commence their shift from andreturn for crib breaks and shift changes. Operators should be cautious ofwater tankers watering/dust allying the area.

Trucks should enter and exit the designated parking area in a oneflow. This is to minimise interaction between the trucks and other traffic.

Other traffic (light vehicles etc.) should not enter this area. Speed should be minimised in this area. Trucks should be Fundamentally Parked over the hump

to minimise the possibility of involuntary movement

Park Up Area Guide –

Some areas have indicative lines for trucks to park in. This is to assistoperators park safely and in such a manner that they minimise interactionwith other machines and trucks in the area.

Hard Park / Truck Stand Correct Flow


No Go lines

go line is where the trucks commence their shift from andreturn for crib breaks and shift changes. Operators should be cautious of

dust allying the area.

Trucks should enter and exit the designated parking area in a one-wayflow. This is to minimise interaction between the trucks and other traffic.

Other traffic (light vehicles etc.) should not enter this area.Speed should be minimised in this area.Trucks should be Fundamentally Parked over the hump/berm/ridge

the possibility of involuntary movement/run away.

Go – No Go line

Some areas have indicative lines for trucks to park in. This is to assistoperators park safely and in such a manner that they minimise interaction

s and trucks in the area.


Parking – Waiting for water truck

If areas are deemed to be too dusty and unsafe to operate, truck operatorsmust stop and wait for the dust to be controlled, usually through watering.

Payload – The Amount of Material the tracarries to dump

Payload is one of the most important factors in Truck and Loaderproductivity. All operators of loadersrequired/targeted and ensure that they


Waiting for water truck

If areas are deemed to be too dusty and unsafe to operate, truck operatorsmust stop and wait for the dust to be controlled, usually through watering.

The Amount of Material the tray

Payload is one of the most important factors in Truck and Loaderof loaders should understand what is

targeted and ensure that they load this consistently.


Payload – Optimal load


Optimal load


Payload – Sub-optimal load


optimal load


Payload Distribution –

Incorrect distribution in the truck tray increases wear and tearthe truck and reduces tyre life.

Incorrect placement and payload distribution.

Correct distribution of payload.


– Truck Tray

Incorrect distribution in the truck tray increases wear and tear/damage to

Incorrect placement and payload distribution.


Payload Indicator Lights

Some Truck types are fitted with Payload indicator lights.

The payload lights are an indicator to the loader operator as to the currentstatus of the payload. While loading, the Red indicator light will beilluminated until the payload has been reached (when the Green indicatorlight become illuminated).


Indicator Lights – Payload lights

Some Truck types are fitted with Payload indicator lights.

The payload lights are an indicator to the loader operator as to the currentstatus of the payload. While loading, the Red indicator light will be

l the payload has been reached (when the Green indicator


Payload meter – Displays the weight of theloaded material in the truck

In some trucks, the payload meter is incorporated into the speedometerdial or on the dash.

The Payload meter records Payload weight along with other operatinginformation.


Displays the weight of theloaded material in the truck

In some trucks, the payload meter is incorporated into the speedometer

The Payload meter records Payload weight along with other operating


Payload weight displayweight of the loaded material

Some Truck types are fitted with Payload indicator displays.

The payload display is an indicator to tstatus of the payload. While loading, the display will indicate the payload.


Payload weight display – Displays theweight of the loaded material

Some Truck types are fitted with Payload indicator displays.

The payload display is an indicator to the loader operator as to the currentstatus of the payload. While loading, the display will indicate the payload.


Pit Design – Pit planning

Pit Shape/Mine Planning Considerations

Location of pit limits Final pit outline Pit Shape Optimisation Destinations/dump designs and locations for in In-pit Bench/strip geometry Ore/coal access The pit progress process/sequencing Pit slope/highwalls/lowalls geometry Final pit slope angles Design and placement of roads

– Spiral roads – inside the wall– Spiral ramps – outside the wall– Switchbacks– Perpendicular lowall ramps– Parallel lowall ramps

Road construction

– Section designs– Curve designs– Berm designs– Haul road gradients

Stripping ratios Geometric sequencing


Pit planning

Mine Planning Considerations

dump designs and locations for in-pit materials

sequencinglowalls geometry

inside the walloutside the wall


Pit Ramp – Roadway to Access the Pit

Access to the bottom of the pit is gained via a pit ramp. The ramp isusually dug by an excavator when opening up the new pit area. Rampgrade and width is governed by the size of the haul trucks being used.

The grade is usually a maximum of 8% but can be up towill vary as regulations typically dictate that “all roadways must be 3.5times the width of the largest vehicle using it”.


Roadway to Access the Pit

to the bottom of the pit is gained via a pit ramp. The ramp isusually dug by an excavator when opening up the new pit area. Rampgrade and width is governed by the size of the haul trucks being used.

The grade is usually a maximum of 8% but can be up to 10%. The widthwill vary as regulations typically dictate that “all roadways must be 3.5times the width of the largest vehicle using it”.


Pitch Braces – Dipper Tooth Attack AngleAdjuster

A variable pitch brace connected between the handle and the dippoint spaced from the dipper axis changes the tooth attack angle of thedipper. Refer to Tooth Attack Angle and Dipper Heel Wear.

Pivot Point/Nip Point

These are areas where a person may be injured or become trapped due tomovement of the machine or implement

No person should enter this area unless the loading unit is locked out andtagged appropriately.


Dipper Tooth Attack Angle

A variable pitch brace connected between the handle and the dipper at apoint spaced from the dipper axis changes the tooth attack angle of thedipper. Refer to Tooth Attack Angle and Dipper Heel Wear.

– FEL

These are areas where a person may be injured or become trapped due tomachine or implement/bucket.

No person should enter this area unless the loading unit is locked out and


Plan and Prepare for Operationsconducting any work

Prior to conducting of any operational work, personnel should ensthey have planned and prepared themselves and their equipment to dothis safely and efficiently by:

Attending shift briefings, tool box talks and hand Obtain relevant data Clarify and analyse information and plan work Ensure the correct equipment and implements have been selected for

the required task Coordinate activities with other stakeholders on site Clarify unclear or incomplete information with your supervisor Conduct a site area inspection

PLC – Engine Saver

This shuts down a truck in case of

Low oil pressure High coolant temperature Low coolant level

It includes a visual alarm on a control box and an audible alarm, whichare activated for 30 seconds before the machine shuts down.

PLC Flash Code

Flash 1 Oil Pressure Flash 2 Coolant Temperature Flash 3 Coolant Flow Flash 4 Cab E/STOP Flash 5 Ground E/STOP Flash 6 Ansul


Plan and Prepare for Operations – Prior to

Prior to conducting of any operational work, personnel should ensure thatthey have planned and prepared themselves and their equipment to do

Attending shift briefings, tool box talks and hand-overs

Clarify and analyse information and plan workquipment and implements have been selected for

Coordinate activities with other stakeholders on siteClarify unclear or incomplete information with your supervisor

It includes a visual alarm on a control box and an audible alarm, whichare activated for 30 seconds before the machine shuts down.


PPE – Personnel Protective Equipment

Wear the appropriate Personal Protective Equipment also known as PPEfor your own safety and to prevent and/or reduc

Your employer is required to provide all staff and visitors with PPE. Theclothes and safety equipment should fit to your body size

Special tasks require special PPE.equipment and clothing for the job.

Pre-Shift Briefing /Tool Box MeetingsSafety

In a pre-shift briefing everything relevant to the upcoming shift will bediscussed. The briefing will normally be held in the shift change room,crib hut, deployment room before the commencement of each shift. Thesupervisor of the shift will explain any safety issues, hazards, previousshift information, working conditions and any updated plans. The preshift briefing also gives the operators an opportunity to discuss importantinformation and significant events whichIt is also used for information to be passed on by the supervisor aboutcurrent condition of the equipment be used during the shift. The OpenCut Examiner will report any changed road conditions and directions,work area conditions, etc. at most ofthese meetings.


Personnel Protective Equipment

Wear the appropriate Personal Protective Equipment also known as PPEfor your own safety and to prevent and/or reduce injuries.

Your employer is required to provide all staff and visitors with PPE. Theclothes and safety equipment should fit to your body size

Special tasks require special PPE. Be sure to wear the correctequipment and clothing for the job.

Briefing /Tool Box Meetings –

shift briefing everything relevant to the upcoming shift will bediscussed. The briefing will normally be held in the shift change room,crib hut, deployment room before the commencement of each shift. The

rvisor of the shift will explain any safety issues, hazards, previousshift information, working conditions and any updated plans. The pre-shift briefing also gives the operators an opportunity to discuss importantinformation and significant events which occurred during the last shift(s).It is also used for information to be passed on by the supervisor aboutcurrent condition of the equipment be used during the shift. The OpenCut Examiner will report any changed road conditions and directions,

conditions, etc. at most of


Pre-Split Drill Hole Barrelmarks on the excavation wall after blasting

drill hole


Split Drill Hole Barrel – Drill holemarks on the excavation wall after blasting


Pre-Start – During Shift and End of ShiftChecks/Inspections

All pre-start, during shift and end of shift checks andbe conducted in line with the mine’s Standards, Rules and Procedurespertaining to all checks needed to be conducted.

Refer to Walk around Inspection

Pre-Strip – Removal of wastematerial

Pre-strip is the process of removal of waste or overburden material bymeans of a Truck and loading unit operation, usually done above / beforea dragline operation.


During Shift and End of Shift

start, during shift and end of shift checks and inspections shouldbe conducted in line with the mine’s Standards, Rules and Procedurespertaining to all checks needed to be conducted.

Walk around Inspection in this Dictionary…

Removal of waste/overburden

process of removal of waste or overburden material byruck and loading unit operation, usually done above / before


Procurement of buckets

Choosing a New Bucket?

There are 4 ways to choose a new Bucket for your

Ask the Supplier to tell you what you need.

Guess what you need. X Use available historic data to determine capacity.

Do bucket modelling to ensure the optimal capacity for the specifictruck and loader

match!

What is wrong with loader capa

People who are deciding on capacities often don’t have knowledge ofall the variables which may impact the result.

Refer to Shovel Dipper Modelling in dictionary...


Procurement of buckets/dippers

There are 4 ways to choose a new Bucket for your loader:

Ask the Supplier to tell you what you need. X

Use available historic data to determine capacity. ?Do bucket modelling to ensure the optimal capacity for the specific

What is wrong with loader capacities?

People who are deciding on capacities often don’t have knowledge ofall the variables which may impact the result.

Refer to Shovel Dipper Modelling in dictionary...


Propelling Up and Down Haul RoadsOperation

The illustrations show the correct positioning of a loader’s attachmentswhen travelling up and down haul roads. Remember, when propellingover a long distance to be aware that propel gear will easily overheat.

When travelling downhill, depress the pedals fully to allow the retardervalve to function correctly.

The travel brakes are automatically released when drive is applied.the pedals have been released, the brakes apply in about fifteen seconds.When travelling on a haul road, ensure you remain well to the left.near the edge to allow other traffic to pass safely.


Propelling Up and Down Haul Roads –

positioning of a loader’s attachmentswhen travelling up and down haul roads. Remember, when propellingover a long distance to be aware that propel gear will easily overheat.

When travelling downhill, depress the pedals fully to allow the retarder

The travel brakes are automatically released when drive is applied. Afterthe pedals have been released, the brakes apply in about fifteen seconds.When travelling on a haul road, ensure you remain well to the left. Stay

dge to allow other traffic to pass safely.


Queuing – Waiting position

Operators need to ensure that they are in the correct waiting positionprior to reversing for being loaded. This will save valuable time in theprocess.

Trucks queuing should line up slightly to the left of the haul truck in frontand a minimum of two haul truck lengths back (check site procedure), thisallows for greater visibility.

Note: To ensure potential accidents are prevented during queuingoperations, the haul truck operator must be constantly aware of the extentof the restricted visibility available from the operator’s cabin.

The following safety points should be followed whenever haul truckoperators are queuing.

Park away from highwalls/low wall Park out of the shovel’s swing radius Always check the immediate area before moving off.

Correct Queuing

Correct


Waiting position

Operators need to ensure that they are in the correct waiting positionprior to reversing for being loaded. This will save valuable time in the

slightly to the left of the haul truck in frontand a minimum of two haul truck lengths back (check site procedure), this

To ensure potential accidents are prevented during queuings, the haul truck operator must be constantly aware of the extent

of the restricted visibility available from the operator’s cabin.

The following safety points should be followed whenever haul truck

low walls.Park out of the shovel’s swing radius/area.Always check the immediate area before moving off.


Radiator – Heat Exchanger

Cooling liquid passes through the engine block and absorbs excess heat.The heated coolant is lead away and passes through thecirculates through small tubes and finally transfers the heat into the air.The cooled liquid circulates back into the engine block and the processrepeats.


Heat Exchanger

Cooling liquid passes through the engine block and absorbs excess heat.The heated coolant is lead away and passes through the radiator where itcirculates through small tubes and finally transfers the heat into the air.The cooled liquid circulates back into the engine block and the process


Radiator Header – Storage for coolingliquid

Ramps

The ramps should be at a constant gradient, not level out in the middleBy designing all grades linear the following advantages can be achieved

Reduces number of truck transmission shifts Reduces fuel consumption Improves truck cycle times Reduces spillage

Keep all gradients at less than 1 in 10 or 10% better < 1 in 8 (8%)


Storage for cooling

constant gradient, not level out in the middle.By designing all grades linear the following advantages can be achieved:

Reduces number of truck transmission shifts

less than 1 in 10 or 10% better < 1 in 8 (8%)


Steep ramps are sub optimal for cycle time and overall efficiency. Rampgradients should be less than 10%.

Rated capacity – Designated capacity ofbuckets

The rated capacity is the name plate capacity whithe particular bucket. The general equation is struck volume (thatcontained inside the bucket) + volume on top.shovel assumes no volume heaped on top and therefore the rated capacityequals the struck capacity. The rated capacity for the excavator and theFEL assume a heaped volume on top.1:1 angle of repose for the backhoe and 2:1 angle of repose for the faceshovel and FEL.

Electric Rope Shovel - struck


Steep ramps are sub optimal for cycle time and overall efficiency. Ramp

Designated capacity of

The rated capacity is the name plate capacity which the supplier puts onThe general equation is struck volume (that

contained inside the bucket) + volume on top. A dipper/bucket on a ropeshovel assumes no volume heaped on top and therefore the rated capacity

The rated capacity for the excavator and theFEL assume a heaped volume on top. The SAE heaped capacity assumes a1:1 angle of repose for the backhoe and 2:1 angle of repose for the face

struck


Hydraulic Face Shovel - struck + heap at 2:1

Hydraulic Backhoe - struck + heap at 1:1

FEL - struck + heap at 2:1

Rehabilitation/Reclamationestablishing the Waste Spoil Heaps to aStable and Productive Landform

Reclamation is part of a mines Environmental Mlegal obligation.

The spoil heaps are shaped to create a stable landform on which torevegetate back to a natural shape. The reclaimed land will never be thesame as the original landform before mining, but when reshaped, topsoilreplaced and planted with vegetation, will be productive again.


struck + heap at 2:1

struck + heap at 1:1

Reclamation – Re-establishing the Waste Spoil Heaps to aStable and Productive Landform

Reclamation is part of a mines Environmental Management Plan and is a

The spoil heaps are shaped to create a stable landform on which torevegetate back to a natural shape. The reclaimed land will never be thesame as the original landform before mining, but when reshaped, topsoil

placed and planted with vegetation, will be productive again.


The state government holds a deposit on disturbed areas until it is signedoff.

Relative Density – RD

Refer to Specific Gravity in this Dictionary

Reliability – How long the Loaderkeeps Running

The reliability of the Loading unit or truck is a measure of its availabilityto operate. The formula for reliability of a system or individual componentis;

Reliability = MTTF/(MTTF + MTTR)

Where:

MTTF = Mean Time To Failure MTTR = Mean Time To Repair

Reclamation a few years old

Reclamation in Progress


The state government holds a deposit on disturbed areas until it is signed

RD

in this Dictionary

How long the Loader/Truck

The reliability of the Loading unit or truck is a measure of its availabilityThe formula for reliability of a system or individual component

(MTTF + MTTR)


Reject Bin gate openerbin remotely

Some trucks have a remote switch to activate a reject silo bin door frominside the truck for safety reasons.


Reject Bin gate opener – Opens Reject

Some trucks have a remote switch to activate a reject silo bin door from


Report – To give Information.

A report gives information to the recipient.either if the recipient cannot understand it. Reporting operator andoverall Truck and or Loader performance shows the recipient how theyare performing against a pre-set, achievable target. A report needs to be ina form that the recipient can understand and it should be explained sothey do.


To give Information.

A report gives information to the recipient. A report is not much helpeither if the recipient cannot understand it. Reporting operator andoverall Truck and or Loader performance shows the recipient how they

set, achievable target. A report needs to be inpient can understand and it should be explained so


Retarder – Braking lever

The retarder is used to slow the truck down prior to using the main brakeof the truck.


Braking lever

The retarder is used to slow the truck down prior to using the main brake


Retard Grid – Cooler

Dissipates heat from the Retarder.

Retarder – Non-friction Braking System

The actual grade capability for each gear will vary depending on outsidetemperatures, rolling resistance, load, the condition of the cooling systemand tire size. For additional braking and retarding information, seeOriginal Equipment Manufacturers operational manual Engine speedrelative to ground speed will vary due to tire size differences betweenbrands and types


friction Braking System

The actual grade capability for each gear will vary depending on outsidetemperatures, rolling resistance, load, the condition of the cooling systemand tire size. For additional braking and retarding information, see

uipment Manufacturers operational manual Engine speedrelative to ground speed will vary due to tire size differences between


Returning Phase – Operational

The steps of the returning phase involve returning the empty bucket to thedig position, lowering and crowding the bucket to commence the dig cycle.The return phase of the swing cycle, with the bucket empty, can beaccomplished at full rated speed. The operator must coordinate thelowering of the bucket to the digging position simultareturn swing.


Operational

The steps of the returning phase involve returning the empty bucket to thesition, lowering and crowding the bucket to commence the dig cycle.

The return phase of the swing cycle, with the bucket empty, can beThe operator must coordinate the

lowering of the bucket to the digging position simultaneously with the


Right Hand Operators Console

Rill – Prevents truck from unwanted rolling

At the Go – No Go area, a rill placed in the middle of the parking areaassists prevent unwanted movement and run away trucks.

Emergency stop

Windscreen wiperand washer

Park BrakeTrans. Direction Speed Control

RHS REV lightswitch

Reverse LightsAuto / Manual

PLC System


Right Hand Operators Console – Cab

truck from unwanted rolling

No Go area, a rill placed in the middle of the parking areaassists prevent unwanted movement and run away trucks.

Park retract switch Service /Hrmeter

Emergency stop

Windscreen wiperand washer

Reject bin gate opener

Ether start

Engine start switch

Automatic electronic traction aid

Break pressure gauge


Rimpull – Force

Most manufacturers of mining equipment supply rimpull vs. speedcurves.

Rimpull is the force (in kg, lb or KN).

Calculations:

Rimpull = [(weight of truck)*(grade of road)] + [(weight of truck) * rollingresistance)]

F(result uphill) = (coefficient of rollingresistance)(weight)+(weight(SIN(grade)))

An example of a Rimpull Chart


Most manufacturers of mining equipment supply rimpull vs. speed

Rimpull is the force (in kg, lb or KN).

Rimpull = [(weight of truck)*(grade of road)] + [(weight of truck) * rolling

of rollingresistance)(weight)+(weight(SIN(grade)))


Rock Ejector – Removes rocks caughtbetween tyres

Rock ejectors play a part in the removal of rocks that have been caughtbetween the tyres of a truck. Rock ejectors shouregular basis to ensure that they are not bent and can cause damage to thetyres.

Rock Ejector


Removes rocks caught

Rock ejectors play a part in the removal of rocks that have been caughtbetween the tyres of a truck. Rock ejectors should be inspected on aregular basis to ensure that they are not bent and can cause damage to the


Roll – Material build up from the diggingprocess

An incorrectly managed roll will cause a multitude of problems for theoperator. The most common causes for a big roll is that the trench hasbeen dug too shallow, or that too much material has been pulled downinto the trench.

Roll levelling – Levelling bench

Leveling of the roll correctly can assist the operator to be more productive.This minimises time lost on leveling of the roll, damage and the operatordoes not lose momentum.

Incorrect leveling of the roll can cause damage to the excavator’s bucket. Ifthe rear of the bucket is used to level the roll, the cylinders, rear bucketplate, grease lines, boom, stick etc. can be damaged.


Material build up from the digging

An incorrectly managed roll will cause a multitude of problems for theuses for a big roll is that the trench has

been dug too shallow, or that too much material has been pulled down

Levelling bench

Leveling of the roll correctly can assist the operator to be more productive.s time lost on leveling of the roll, damage and the operator

Incorrect leveling of the roll can cause damage to the excavator’s bucket. Ifthe rear of the bucket is used to level the roll, the cylinders, rear bucket

nes, boom, stick etc. can be damaged.


Rolling Resistance – Resistance created bythe interaction between the trucks tyres andthe haulroad

Rolling resistance is the deformation resistance/ friction between thesurfaces and the truck tyre

Road deformation under the tyre Tyre penetration into the road surface


Resistance created bythe interaction between the trucks tyres and

Rolling resistance is the deformation resistance/ friction between the

under the tyreTyre penetration into the road surface


Poor road maintenance practices result in an increase in rollingresistance. This results in:

Excessive fuel burn Reduced tire life

For off-highway trucks running radialrolling resistance of:

1.5% for a hard, well-maintained, permanent haul road 3% for a well-maintained road with little flexing 4% for a road with 25 mm (1 in) tire penetration 5% for a road with 50 mm (2 in) tire penetration 8% for a road with 100 mm (4 in) tire penetration 14% for a road with 200 mm (8 in) tire penetration

Tire Penetration In practice, a 5% increase in rolling resistance can resultin up to a 10% decrease in production and a 35% increase in productioncosts.

(CAT – Haul Road Design)

For ramps an increase in rolling resistance of 1% can reduce speed by 1013% while on flat roads a 1% increase in rolling resistance can reducespeed by 18-26%.


Poor road maintenance practices result in an increase in rolling

highway trucks running radial-ply tires, assume a minimum

maintained, permanent haul roadmaintained road with little flexing

4% for a road with 25 mm (1 in) tire penetration5% for a road with 50 mm (2 in) tire penetration

in) tire penetration14% for a road with 200 mm (8 in) tire penetration

Tire Penetration In practice, a 5% increase in rolling resistance can resultin up to a 10% decrease in production and a 35% increase in production

r ramps an increase in rolling resistance of 1% can reduce speed by 10-13% while on flat roads a 1% increase in rolling resistance can reduce


ROM Area – Run-of-Mine

Coal dumped by a truck into the coal preparation plant is called runmine, or ROM. This is the raw material for the CPP. The coal iscontaminated with rocks from the dig side. Contamination is usuallyintroduced during the excavation or from excavation equipment or thinlayers of rock in-between the coal seam.

ROM coal can have a large variability of moisture and maximum particlesize.


Mine

Coal dumped by a truck into the coal preparation plant is called run-of-mine, or ROM. This is the raw material for the CPP. The coal iscontaminated with rocks from the dig side. Contamination is usuallyintroduced during the excavation or from excavation equipment or thin

between the coal seam.

have a large variability of moisture and maximum particle


ROM Stockpile – Run-

A ROM stockpile is used to allow the wash plant to be fed coal atconstant rate.


-of-Mine Buffer

A ROM stockpile is used to allow the wash plant to be fed coal at a


Rope Shovel A-Frameboom

The A Frame is a critical component and is attached to the main chassis ofthe machine. It is a large structure as it takes the load from the loadeddipper as well as the weight of the other components and transfers it tothe main chassis.


Frame – The anchor for the

itical component and is attached to the main chassis ofthe machine. It is a large structure as it takes the load from the loadeddipper as well as the weight of the other components and transfers it to


Rope Shovel Boom – Attachment


Attachment


Rope Shovel Boom Suspension RopesWire Ropes that Hold and Support the Boomand Load.

Boom Suspension ropes are large wound wire ropes, usually galvanisedfor long term protection. Under normal operation, they last for manyhours. Most mines have non-destructive testing programs in place formonitoring the ropes’ condition. Because there are multiple ropes, it isimportant to have regularly maintained rope spreaders to prevent theropes rubbing against each other.


Rope Shovel Boom Suspension Ropes – TheWire Ropes that Hold and Support the Boom

Boom Suspension ropes are large wound wire ropes, usually galvanisedfor long term protection. Under normal operation, they last for many

destructive testing programs in place formonitoring the ropes’ condition. Because there are multiple ropes, it isimportant to have regularly maintained rope spreaders to prevent the


Rope Shovel – Fill Cycle

Enough space must be left between the tracks and the digging face toeliminate damage. Care should also be taken to avoid jacking the boom.Jacking the boom can cause severe damage to the suspension cables,boom assembly, and gantry assembly.

Do not overcrowd or jack the boom. Overcrowding is the use of excessivecrowd thrust while the dipper is engaged in the bank.


Fill Cycle

pace must be left between the tracks and the digging face toeliminate damage. Care should also be taken to avoid jacking the boom.Jacking the boom can cause severe damage to the suspension cables,boom assembly, and gantry assembly.

ack the boom. Overcrowding is the use of excessivecrowd thrust while the dipper is engaged in the bank.


Rope Shovel – Forces applied

During the operation of the electric rope shovel the following forcesare utilised.

Rope Shovel – Machine

A Rope Shovel is a loading unit as can be seen below. Please refer tospecific makes and models as illustrated in this dictionary.


Forces applied

During the operation of the electric rope shovel the following forces

Machine

Shovel is a loading unit as can be seen below. Please refer tospecific makes and models as illustrated in this dictionary.


Rope Shovel – Schematic

The nomenclature associated with electric rope shovels.

Rope Shovel Tracks –


Schematic

The nomenclature associated with electric rope shovels.

Travelling device


Roster – A Truck and LoaderWorking Arrangement

Most mines work 24/7 and have had to arrange a shift workingarrangement with their workforce. There are just about as many shiftrosters as there are mines in this industry, and most mines negotiate themost suitable roster with their workforce.

Examples of shift rosters are:

5 days on and 2 days off 10 days on and 4 days off 7 days on and 7 days off 5 days on, 3 days off, 4 days on and 5 days off Etc.


Truck and Loader Crew’sWorking Arrangement

Most mines work 24/7 and have had to arrange a shift workingarrangement with their workforce. There are just about as many shiftrosters as there are mines in this industry, and most mines negotiate the

st suitable roster with their workforce.

5 days on, 3 days off, 4 days on and 5 days off


Safety Zone/Collision Avoidance

Trucks must maintain at least 10 metres safety zone from the dump dozerand any other machine/truck/ancillary equipment on the dump site.Follow your Site rules and regulations.


Safety Zone/Collision Avoidance – Safety

t maintain at least 10 metres safety zone from the dump dozerancillary equipment on the dump site.

Follow your Site rules and regulations.


Scaling Batters – Removing loose materialfrom a wall

Ground conditions in the open pit operation can vary from competentsolid rock to incompetent, poor ground.clean face. Half barrels from the drill holes are a good sign the unfiredground has not been seriously damaged.result in shattered and loose rock sitting in the exposed face, especially atthe crest. While this rock sits in the face it is a hazard to personnel andequipment below.

Poor ground is usually associated with geological features such as faultsand shear zones. These can be planar in nature and depending on theirorientation may present a serious hazard where large amounts of materialmay be able to slide into the open pit.geological features in the wall with their supervisure they are fully aware of the hazards that may be present in the face.


Removing loose material

pit operation can vary from competentsolid rock to incompetent, poor ground. Competent ground will fire to a

Half barrels from the drill holes are a good sign the unfiredground has not been seriously damaged. Poor ground or poor firings mayesult in shattered and loose rock sitting in the exposed face, especially at

While this rock sits in the face it is a hazard to personnel and

Poor ground is usually associated with geological features such as faultsThese can be planar in nature and depending on their

orientation may present a serious hazard where large amounts of materialmay be able to slide into the open pit. You should discuss the controllinggeological features in the wall with their supervisor or a geologist to makesure they are fully aware of the hazards that may be present in the face.


Scale Shovel – 1:7th RB22

A shovels dipper or excavators bucket has arguable the largest influenceon overall productivity on a loading unit. Through amodelling project, one can make an informed decision on the correctmake, model and capacity of dipper/current conditions.


RB22

A shovels dipper or excavators bucket has arguable the largest influenceon overall productivity on a loading unit. Through a detailed practicalmodelling project, one can make an informed decision on the correct

/bucket designed specifically for your


Selecting the “Right” Trucks for a Mine

What is the problem?

For many mines the issue of matching truck capacity to loader capacity isproblematic and more often than not results in a majority of trucks beingeither under-loaded or over-loaded.in size the number of passes required to filldifficulty in attaining the match is becoming more difficult.getting the majority of trucks +/- 5% of the rated capacity just doesn’thappen. Under-loaded trucks result in reduced dig rates while overloaded trucks reduce speed and increase damage and the occurrence ofsudden failure. Clearly an innovative process is needed.innovative thinking is to benchmark what is currently being done.


Compounding the problem is the variation in truck and loaderperformance. It is a simple fact that different makes and models workbetter than others. In fact performance varies between makes and modelsof truck by up to 81%. This means that the average performance ofmodel moves 81% more than the average of another model.rock mine which is 400 metres deep is going to have lower truckproductivity than a coal mine where the trucks are being used in prestrip.However, it should be noted that the difffor excavator models is up to 66% and that is not dictated by the geometryof the pit where they are working.

The use of scale models is well established in the area of commercialdecision-making on shovel and backhoe capacitidone with truck trays. The correct application of testing techniques canaccount for nearly all previously defined impacts on payload.valid outcome the following must be accounted for in a scale modelingprogram.

Build the model dippers/buckets accurately Get spoil from the site or access similar spoil from nearby Set up the bank to be dug accurately Simulate the loading unit accurately Analyse the data in an appropriate manner


Selecting the “Right” Trucks for a Mine

ines the issue of matching truck capacity to loader capacity isproblematic and more often than not results in a majority of trucks being

As trucks and loading units increasein size the number of passes required to fill the truck is decreasing and thedifficulty in attaining the match is becoming more difficult. The goal of

5% of the rated capacity just doesn’tloaded trucks result in reduced dig rates while over-

ucks reduce speed and increase damage and the occurrence ofClearly an innovative process is needed. The first stage in

innovative thinking is to benchmark what is currently being done.


the problem is the variation in truck and loaderperformance. It is a simple fact that different makes and models workbetter than others. In fact performance varies between makes and models

This means that the average performance of onemodel moves 81% more than the average of another model. Clearly a hardrock mine which is 400 metres deep is going to have lower truckproductivity than a coal mine where the trucks are being used in prestrip.However, it should be noted that the difference in average performancefor excavator models is up to 66% and that is not dictated by the geometry

The use of scale models is well established in the area of commercialmaking on shovel and backhoe capacities. A little work has been

The correct application of testing techniques canaccount for nearly all previously defined impacts on payload. To ensure avalid outcome the following must be accounted for in a scale modeling

buckets accuratelyGet spoil from the site or access similar spoil from nearbySet up the bank to be dug accuratelySimulate the loading unit accuratelyAnalyse the data in an appropriate manner


Example of rope shovel pass per load (

Service Roads – Light vehicle access

It is important to have well designed and maintained service roads arounda mine site.

These roads give vehicles and equipment access to the working areas ofthe mine. Service roads to the dragline, especially as the localenvironment to these machines can change regularly, needs to bemaintained in case of safety issues that may arise.

1 Passes2.3%

3 passes58.5%

4 passes2.0%

5 Passes0.2%

6 passes0.0% 7 passes

0.0%

A well designed and constructed service

road


Example of rope shovel pass per load (matched to 3 pass load)

Light vehicle access

It is important to have well designed and maintained service roads around

These roads give vehicles and equipment access to the working areas ofine, especially as the local

environment to these machines can change regularly, needs to bemaintained in case of safety issues that may arise.

1 Passes2.3%

2 passes37.1%

A well designed and constructed service


Service refill fittings rack

Most Trucks are equipped with a fast fill service system for adding fuel,hydraulic oil, gear oil, engine oil, and coolant.

SG – Specific Gravity

Relative density, or specific gravity, is theunit volume) of a substance to the density of a given reference material.Specific gravity usually means relative density with respect to water. Theterm "relative density" is often preferred in modern scientific usage.

Specific gravity is the term used for describing the density of theoverburden/waste, ore or coal.

The correct density entered into the production monitors, should give acloser correlation of the monitor production results to survey results.

An example of the typical material hauled in a Truck and Loaderoperation:

Material Density

Coal 0.9 – 1.05 t/m3

Coal Overburden,Limestone

1.5 – 1.90 t/m3

Iron Ore 2.1 – 2.80 t/m3


Service refill fittings rack – Lube

Most Trucks are equipped with a fast fill service system for adding fuel,hydraulic oil, gear oil, engine oil, and coolant.

Relative density, or specific gravity, is the ratio of the density (mass of aunit volume) of a substance to the density of a given reference material.Specific gravity usually means relative density with respect to water. Theterm "relative density" is often preferred in modern scientific usage.

vity is the term used for describing the density of the

The correct density entered into the production monitors, should give acloser correlation of the monitor production results to survey results.

material hauled in a Truck and Loader

Body Type

1.05 t/m3 Larger coal body

1.90 t/m3 Standard Rock body

2.80 t/m3 Smaller rock body


Shale – Fine grained material uas an intra-seam or on top of a coal seam

Shale in a coal mine is usually found in layers above and/or below the coalseam. Sometimes, especially during hours of darkness, it can be mistakenby the operators for the coal seam, as it sometimesmuch like coal, i.e. it is dark. In the accompanying picture the partings areshales.

Shift – A Crew Working a Roster

The shift is the time worked on the job.particular roster. Some rosters haveshifts have day and night shifts.


grained material usually foundseam or on top of a coal seam.

Shale in a coal mine is usually found in layers above and/or below the coalseam. Sometimes, especially during hours of darkness, it can be mistakenby the operators for the coal seam, as it sometimes has visual properties

In the accompanying picture the partings are

A Crew Working a Roster

The shift is the time worked on the job. A crew or a group of people work anight, day and afternoon shifts. 12 hr


Shot ground – Blasted Overburden

Overburden that has been blasted in preparation of the dragline digging itis described as shot or shot ground. As soon as the overburden is blastit should be levelled to seal it and stop a rain event affecting it by enteringthe fractured ground. The word shot can also apply to the act of blasting,as in “To let the shot off”.


Blasted Overburden

Overburden that has been blasted in preparation of the dragline digging itis described as shot or shot ground. As soon as the overburden is blasted,it should be levelled to seal it and stop a rain event affecting it by entering

The word shot can also apply to the act of blasting,


Shovel Dipper Modelling

A shovels dipper or excavators bucket haon overall productivity on a loading unit. Through a detailed practicalmodelling project, one can make an informed decision on the correctmake, model and capacity of dipper/current conditions.


Shovel Dipper Modelling

A shovels dipper or excavators bucket has arguable the largest influenceon overall productivity on a loading unit. Through a detailed practicalmodelling project, one can make an informed decision on the correct

/bucket designed specifically for your


Simulator – A Test Device that SimulatesActual Conditions

A simulator is a test machine that gives the learner operator a similar feelto the real machine.

There are a number of simulator providers in the market, including 5DT,Immersive Technologies, ThoroughTec, Caterpillar, CAE, etc.

The simulators are considered good tools for novices but may not be souseful with experienced operators if used incorrectly and without astructured training program.


A Test Device that Simulates

A simulator is a test machine that gives the learner operator a similar feel

There are a number of simulator providers in the market, including 5DT,Technologies, ThoroughTec, Caterpillar, CAE, etc.

The simulators are considered good tools for novices but may not be soif used incorrectly and without a


Single Side Loading –

Single side loading is where all truck loading is done with the trucks in thesame location.

Single-side loading with Rope shovels is not as efficient as double sideloading.

The shovel is positioned with the tracks parallel to the face and advancesparallel to the face as material is removed. The Single Digging Approach isused when:

Different levels are dug on one strip. Is best used when there is a limited space. When there is only a certain number of trucks

100% Used with difficult or poor fragmentation.


Techniques

Single side loading is where all truck loading is done with the trucks in the

side loading with Rope shovels is not as efficient as double side

The shovel is positioned with the tracks parallel to the face and advancesallel to the face as material is removed. The Single Digging Approach is

Different levels are dug on one strip.Is best used when there is a limited space.When there is only a certain number of trucks that does not match

t or poor fragmentation.


Used with longer haul routes with longer truck With smaller shovels, longer filling time of trucks.

When in close vicinity to other operations nearby.


Used with longer haul routes with longer truck turnaround time.With smaller shovels, longer filling time of trucks.

in close vicinity to other operations nearby.


Single Bench – Loading technique

Single Bench also known as Top loading is defined as when the excavatoris located on a higher level than the truck and sits on an elevated Bench.

The trucks can either be positioned at 450 or at 900 to the excavator.

Loading through the rear at 45° is similar to the 90° bottom sidemethod, except that the truck is positioned at 45° to the excavator. Thistechnique allows smoother bucket unloading when coming in through therear of the truck body and requires less hoisting than 90° over the sideloading.


Loading technique

op loading is defined as when the excavatoris located on a higher level than the truck and sits on an elevated Bench.

The trucks can either be positioned at 450 or at 900 to the excavator.

Loading through the rear at 45° is similar to the 90° bottom side loadingmethod, except that the truck is positioned at 45° to the excavator. Thistechnique allows smoother bucket unloading when coming in through therear of the truck body and requires less hoisting than 90° over the side


Soft Dumping Techniques

Soft dumping is referred to as reversing to a dump whilst loaded insoft/wet conditions. When doing this the front wheels will not provide thedesired turning force therefore causing the haul truck to slew from itsdesired course:

When soft dumping the procedure is as follows:

Always enter the dump in a clockwise direction Inspect the tip edge Locate the dump site Make a right hand turn to locate the truck at 90° to the dump edge Stop and place the transmission in reverse Reverse back and maintain the truck at 90° to the tip head Stop at or just before the bund wall

wall as a bump stop) Dump the load Move straight away from the dump once the tray is clear and fully

lowered to the truck


iques – Techniques

Soft dumping is referred to as reversing to a dump whilst loaded inWhen doing this the front wheels will not provide the

desired turning force therefore causing the haul truck to slew from its

oft dumping the procedure is as follows:

Always enter the dump in a clockwise direction

Make a right hand turn to locate the truck at 90° to the dump edgeStop and place the transmission in reverse

d maintain the truck at 90° to the tip headStop at or just before the bund wall/windrow (do not use the bund

Move straight away from the dump once the tray is clear and fully


Specification Sheet – Machine

Example of a specification sheet provided by all equipment suppliers andOEM’s:


Machine

Example of a specification sheet provided by all equipment suppliers and


Speed Limits – Safety

Operators of all mobile plant shall observe the site speed limits. Withinthe maximum speed limits imposed, mobile plant operators shall operatat speeds suited to the weather, visibility, condition of the roadway,clearances, passenger segregation from loads being carried, passengercomfort, traffic signs, safety and warning devices, such that they are in fullcontrol of the vehicle at all times and able to safely stop the vehicle in theevent of an emergency or other potentially hazardous incident.

Unless signposted otherwise the maximum speed limits for the site aremost operations:

Site access road - 80 kph Major haul roads – 60 kph Entry and exit roads of and within car parks Store delivery and unloading area All other areas - 30 kph

Check your local speed limits on your operation.


Operators of all mobile plant shall observe the site speed limits. Withinthe maximum speed limits imposed, mobile plant operators shall operateat speeds suited to the weather, visibility, condition of the roadway,clearances, passenger segregation from loads being carried, passengercomfort, traffic signs, safety and warning devices, such that they are in full

s and able to safely stop the vehicle in theevent of an emergency or other potentially hazardous incident.

Unless signposted otherwise the maximum speed limits for the site are on

and exit roads of and within car parks - 10 kphStore delivery and unloading area – 10 kph

Check your local speed limits on your operation.


Spillage

Spillage can cause serious damage to truck tyres and slow down the totalcycle. Truck operators should report all spillage to the Supervisor/graderoperator or the responsible person to ensure that this is cleaned up ASAP.

Spillage can be caused by overloading the trucks, sharp cornering, andincorrect load placement into the truckunit.


Spillage can cause serious damage to truck tyres and slow down the totalTruck operators should report all spillage to the Supervisor/grader

operator or the responsible person to ensure that this is cleaned up ASAP.

Spillage can be caused by overloading the trucks, sharp cornering, andincorrect load placement into the truck or at the dig face from the loading


Split Benching – Loading technique

Split Benching/double benching is definedmaterial to be loaded and sits on an elevated bench with the haul truck ona lower level.

This technique is generally used when the cut is too deep topass and when there is ample space.

Because of the decrease in swing and lift time as compared to othermethods, this is an efficient method and utilised by many contractors.

Some mines have difficulty with permission to do this as maintenancedon’t like it.


Loading technique

double benching is defined by the excavator splitting theand sits on an elevated bench with the haul truck on

ique is generally used when the cut is too deep to dig in one

Because of the decrease in swing and lift time as compared to othermethods, this is an efficient method and utilised by many contractors.

ficulty with permission to do this as maintenance


Spoil – All Material removed from above amineable seam

Spoil is the waste material above a mineable seam or between multipleseams.


l Material removed from above a

Spoil is the waste material above a mineable seam or between multiple

Insituspoil/waste


Spotting – Precautions

When spotting, the truck operator should consider the followingprecautions.

Proper communication with the loading unit to determine therequired position.

While spotting, avoid sharp turnsurface in soft underfoot conditions

Check the loading area for spillage and have it cleaned up to avoiddamage to tyres.

Always lookout for pedestrians, personnel, othervehicles that may have entered the area

Do not reverse into or up the loading

Spotting – Techniques

Spotting is:

The truck operator is waiting and remains facing the truck being loaded.After the truck has been loaded and moves away from the loading unit, thetruck operator moves the truck into the loading positionloading unit.

The operator should observe the following procedures for safe andefficient spotting.

The loading unit will indicate its readiness to load the truck by placingits full bucket in the air in the position where the loading unitoperator requires the truck to be positioned.

The truck operator is to move from the queue and carefully reverseinto the required position under the loading unit’s bucket.

When the truck is correctly positioned under the bucket, the loadingunit operator will sound one blast on the horn for the truck to stop.

Once under the loading units bucket/dipperthe park brake

If self-spotting, the operator should reverse into the loading positionusing the correct technique whilst always being


Precautions

operator should consider the following

with the loading unit to determine the

void sharp turning as this will damage the groundconditions and limit sidewall cuts to tyres.

Check the loading area for spillage and have it cleaned up to avoid

destrians, personnel, other equipment and lightvehicles that may have entered the area.

Do not reverse into or up the loading face or are on spillage.

Techniques

The truck operator is waiting and remains facing the truck being loaded.After the truck has been loaded and moves away from the loading unit, thetruck operator moves the truck into the loading position next to the

The operator should observe the following procedures for safe and

The loading unit will indicate its readiness to load the truck by placingits full bucket in the air in the position where the loading unit

ator requires the truck to be positioned.The truck operator is to move from the queue and carefully reverseinto the required position under the loading unit’s bucket.When the truck is correctly positioned under the bucket, the loading

sound one blast on the horn for the truck to stop.s bucket/dipper, apply neutral gear, apply

spotting, the operator should reverse into the loading positionusing the correct technique whilst always being vigilant for safety.


Spotting for Top Loading @ 45°

The truck operator must wait until the excavator operator has spotted thebucket in the correct position.

The truck driver must then line up the side of the tray to the bucket teethand reverse slowly until the excavator operator dumps the load into thetray or sounds the horn indicating the truck is in the right position.


Spotting for Top Loading @ 45° – Techniques

The truck operator must wait until the excavator operator has spotted the

The truck driver must then line up the side of the tray to the bucket teetheverse slowly until the excavator operator dumps the load into the

indicating the truck is in the right position.


Spotting at 45˚ – Techniques

Reason same as loading 45


Techniques


Spotting at 90˚ – Techniques

Line up with outside track.


Techniques


Spotting at 90˚ – Incorrect

Spotting incorrectly for the 900 loading can cause damage to the trucktray by contact with the excavator bucket.

Longer fill times will be experienced and the loading part of the cyclebecomes more difficult.

Start-up Procedure

The start-up procedure relates to turning a piece of equipment on, readyfor operation. Many pieces of equipment hamust be followed. An operator or a driver must be familiar with theprocedures as set down by their mine and must follow the proceduresas stated.


Incorrect Positioning

Spotting incorrectly for the 900 loading can cause damage to the truckthe excavator bucket.

Longer fill times will be experienced and the loading part of the cycle

up procedure relates to turning a piece of equipment on, readyMany pieces of equipment have detailed procedures which

An operator or a driver must be familiar with theprocedures as set down by their mine and must follow the procedures


Steering system

This is the steering mechanism of all trucks and most Front eSome loading units and all rope shovels, excavators and hydraulic shovelsuse a Joy Stick to control the steering. (Refer to Joy Stick in thisDictionary)


This is the steering mechanism of all trucks and most Front end loaders.Some loading units and all rope shovels, excavators and hydraulic shovelsuse a Joy Stick to control the steering. (Refer to Joy Stick in this


Stockpile stacking/accumulationmanageable stockpile

From time to time, Front End Loaders or Excavators utilised on stockpilesneed to stack up spillage and smaller unloadable material to accumulate aloadable pile.

A larger/higher loading face/pile will increase efficiency, minimise truckdelays and may assist in reducing contam

On most stockpiles, space is limited and the stockpile shape needs to bemaintained for loading efficiently between loads or when loading activityhas been delayed.

Stockpile stacking is about the loader gathering this material and stackingthis together.


Stockpile stacking/accumulation – Building

t End Loaders or Excavators utilised on stockpilesneed to stack up spillage and smaller unloadable material to accumulate a

pile will increase efficiency, minimise truckdelays and may assist in reducing contamination.

On most stockpiles, space is limited and the stockpile shape needs to bemaintained for loading efficiently between loads or when loading activity

Stockpile stacking is about the loader gathering this material and stacking


Stoppages – Productivity

As well as keeping the T&L fleet going for as long as possible, it shouldalso be stopped as few times as possible

To achieve the positioning goals (swing angle) more than average numberof positioning's may be needed.

Average Operational and Maintenance Stoppages per day:

Excavators – 33 Rope Shovels – 32 Front End Loaders - 25

Max. Number of Operational and Maintenance Stoppages per day:

Excavators – 27 Rope Shovels – 31 Front End Loaders – 16


Productivity

As well as keeping the T&L fleet going for as long as possible, it shouldalso be stopped as few times as possible.

To achieve the positioning goals (swing angle) more than average number

Average Operational and Maintenance Stoppages per day:

Max. Number of Operational and Maintenance Stoppages per day:


Strategy

The two key strategies mines can follow are cost or quantity. You eitherproduce at the lowest unit cost or you produce the maximum quantity.There is no other option to maximise return. There is a lot which could bewritten about each of these strategies incstrategy should switch and how best to execute it.

It is extremely difficult to achieve performance levels equal to bestpractice for both loaders and trucks. Keep in mind that “best practice” isdefined as the average of the top decile by annual output (which equatesto close to the 95th percentile). A mine may only achieve high loaderperformance when over-trucked (usually typified by high queuing time fortrucks and low hang times for the loaders). You just have to keup to the loader to keep the loader loading. However, when a mine isover-trucked they don’t normally achieve high truck output (per truck).So you might have loader performance in say the 75th (or even 95th)percentile but the trucks might be only in the 45th or 50th or whateverpercentile.

The over-trucked scenario is a strategy which aims to maximise outputwith a potentially higher unit cost of mining. It is normally used whenmargins are high and production / volume is driving total returnover-trucked scenario there are two possible courses of action which amine may take.

1. Prioritise BI on the loaders. Trucks are queuing for the majorityof the time and the aim is to optimise how quickly the loaders canfill them and how much is put in them.

2. Reduce the number of trucks in the circuit. The high queuingtimes offer the potential to move the same amount of materialwith less trucks. Some mines have achieved success with thisthrough a “Theory of Constraints” approach. It is howeverimportant to realise in the overlooking for constraints on individual trucks as a priority.Constraints on individual trucks (different capacity, differentmake and model, etc) cause increased queuing and hang times.

The cost strategy requires minimising the number of trucks to move therequired volume of material. This is a case of returns driving production.Loaders will normally have higher hang times but truck queuing times willbe relatively low.


o key strategies mines can follow are cost or quantity. You eitherproduce at the lowest unit cost or you produce the maximum quantity.

here is no other option to maximise return. There is a lot which could bewritten about each of these strategies including how to recognise when thestrategy should switch and how best to execute it.

It is extremely difficult to achieve performance levels equal to bestpractice for both loaders and trucks. Keep in mind that “best practice” is

f the top decile by annual output (which equatesto close to the 95th percentile). A mine may only achieve high loader

trucked (usually typified by high queuing time fortrucks and low hang times for the loaders). You just have to keep trucksup to the loader to keep the loader loading. However, when a mine is

trucked they don’t normally achieve high truck output (per truck).So you might have loader performance in say the 75th (or even 95th)

only in the 45th or 50th or whatever

trucked scenario is a strategy which aims to maximise outputwith a potentially higher unit cost of mining. It is normally used whenmargins are high and production / volume is driving total return. In an

trucked scenario there are two possible courses of action which a

Prioritise BI on the loaders. Trucks are queuing for the majorityof the time and the aim is to optimise how quickly the loaders can

ut in them.

Reduce the number of trucks in the circuit. The high queuingtimes offer the potential to move the same amount of materialwith less trucks. Some mines have achieved success with thisthrough a “Theory of Constraints” approach. It is howeverimportant to realise in the over-trucked scenario that you arelooking for constraints on individual trucks as a priority.Constraints on individual trucks (different capacity, differentmake and model, etc) cause increased queuing and hang times.

st strategy requires minimising the number of trucks to move therequired volume of material. This is a case of returns driving production.Loaders will normally have higher hang times but truck queuing times will


In an under-trucked scenario there are again two possible courses ofaction which a mine may take.

1. Prioritise BI on the trucks. Trucks are running for the majority ofthe time and the aim is to optimise how quickly they can cycle andthe load they are carrying.

2. Reduce the number of loaders. The high hang times offer thepotential to move the same amount of material with less loadingcapacity. Maybe shut down smaller / higher cost loaders or cutseven day roster back to six or five. There are a range of optionsavailable.

In the case of under-trucking the mine needs to look at bottlenecks in thetruck circuits. That is, what are those things which are holding up thewhole process? Things like wet or poorly maintained roads; dumping orloading areas not set up well; etc.

A plot can be created to demonstrate oversample is shown below

The question is whether 67.7% over-period better or worse?

In an environment (in 2013) of low commodity prices a cost strateneeded by most mines. You can’t just thinkless it will cost.


scenario there are again two possible courses of

Prioritise BI on the trucks. Trucks are running for the majority ofthe time and the aim is to optimise how quickly they can cycle and

umber of loaders. The high hang times offer thepotential to move the same amount of material with less loadingcapacity. Maybe shut down smaller / higher cost loaders or cutseven day roster back to six or five. There are a range of options

trucking the mine needs to look at bottlenecks in thetruck circuits. That is, what are those things which are holding up thewhole process? Things like wet or poorly maintained roads; dumping or

demonstrate over-trucking vs under-trucking. A

-trucked is good. Is next month /

) of low commodity prices a cost strategy isYou can’t just think that the more you produce the


Strike length

Strike length is extremely important to the Split Benching sequence. Ashort strike length will have a negative effect on the productivityperformance of the Excavator, as there will be too many sequentialchanges in the sequence. A longer strike length will secure momentum forthe Excavator and assist in increasing efficiency.

Stripping – Removing of overburden wasteor spoil

Stripping is the generic term for diggingdigging the overburden to expose the coal.


Strike length is extremely important to the Split Benching sequence. Ashort strike length will have a negative effect on the productivityperformance of the Excavator, as there will be too many sequentialchanges in the sequence. A longer strike length will secure momentum forthe Excavator and assist in increasing efficiency.

Removing of overburden waste

the generic term for digging waste in coal mines. It refers todigging the overburden to expose the coal.


Stripping Ratio

Prime Cubic Metres per tonne of coal.

Need to always define what tonnes are being referred to as can be in situcoal, run of mine coal, or clean (washed) coal.

Stripping ratio is often used in planning and reconciliation (after surveypick-up.

Stripping Ratio = Prime Cubic Metres/tonnes of coal

Struck capacity

The struck capacity is the actual volumeor tray without any heaped material supported by the teeth or other partsof the bucket or tray.

See further explanation under Rated Capacity

Stub Line –A Feeder Power Line

The main power line to the shovel is usually placed outside the pitexcavation parameters. The power is then brought closer to the workingpit by a feeder line called a stub line. Stub lines are placed at around 1kmapart along the pit length so the equipment can access the power. Mostshovel with external substations will operate effof 2100m of cable from the substation.

As the pit advances, sections of the stub line can be removed as required.


Prime Cubic Metres per tonne of coal.

Need to always define what tonnes are being referred to as can be in situoal, or clean (washed) coal.

Stripping ratio is often used in planning and reconciliation (after survey

Cubic Metres/tonnes of coal

The struck capacity is the actual volume inside the structure of the bucketmaterial supported by the teeth or other parts

See further explanation under Rated Capacity.

A Feeder Power Line

The main power line to the shovel is usually placed outside the pitarameters. The power is then brought closer to the working

pit by a feeder line called a stub line. Stub lines are placed at around 1kmapart along the pit length so the equipment can access the power. Mostshovel with external substations will operate effectively with a maximumof 2100m of cable from the substation.

As the pit advances, sections of the stub line can be removed as required.


Suspension – Shock Absorber (truck)

These rear suspension cylinders minimise and absorb shock to the truckchassis.

Swell –The Enlargement of the InsituOverburden after Blasting

Overburden swell is the enlargement of the Insitu overburden afterblasting.

Blasting loosens up the overburden, creates air pockets within the burdenand therefore takes up more volume.

Swell of 25% is considered normal, although this can vary significantly.


Shock Absorber (truck)

These rear suspension cylinders minimise and absorb shock to the truck

The Enlargement of the InsituOverburden after Blasting

Overburden swell is the enlargement of the Insitu overburden after

Blasting loosens up the overburden, creates air pockets within the burdenand therefore takes up more volume.

ll of 25% is considered normal, although this can vary significantly.


Swell Factor – The Percentage ofEnlargement of the Insitu Overburden afterBlasting

The swell factor is the percentage of enlargement of the Insitu overburdenafter blasting. It is normally 15% - 30%.

Swing Arc Efficiency

The ideal truck positioning arc is shown above.tool swings the load over the back of the truck.for the truck is at 450. This ensures minimum swing time.

The secret to maximising loader efficiency is to minimise the work cycle.saving of one or two seconds on each load cycle builds up to manythousands of dollars over a relatively short period


The Percentage ofEnlargement of the Insitu Overburden after

The swell factor is the percentage of enlargement of the Insitu overburden30%.

The ideal truck positioning arc is shown above. On this arc the loadingtool swings the load over the back of the truck. The most efficient location

This ensures minimum swing time.

t to maximising loader efficiency is to minimise the work cycle. Asaving of one or two seconds on each load cycle builds up to manythousands of dollars over a relatively short period


Swing Clearance

Swing clearance is the amount of room required attool to ensure there is no contact between the loading tool and truck,material being dug or anything else.line of rotation or as a distance from the actual machine


Swing clearance is the amount of room required at the back of the loadingtool to ensure there is no contact between the loading tool and truck,

It may be measured from the centreline of rotation or as a distance from the actual machine


Swing Drive

The swing drive is the system which causes a shovel or excavator to rotatebetween disengage from the bank, dumping in the truck and returning tothe bank.


s the system which causes a shovel or excavator to rotatebetween disengage from the bank, dumping in the truck and returning to


Swinging Phase

Correct swing motion means smooth control and efficient swing control.The swing motion is commenced towards the haul truck when the bucketis full and is clear of the bench. The swing motion begins with smoothacceleration to an optimum point at which the excavator is plugged to astop over the haul truck.

Maximum efficiency and minimum swing machinerresults of mastering the swing motion.erratic control and an unsafe, inefficient swing cycle.with fast acceleration and maximum speed is maintained to the dumpspot, it will be necessary to stop the swing very suddenly.swing under these conditions results in jerky swing motion andunnecessary spillage onto the haul truck andpit floor.

Positioning of the haul truck also affects the swing time and it should bepositioned along the swing path with their centre lines approximatelyunder or slightly inside the swing path of the boom/stick pivot point.


Correct swing motion means smooth control and efficient swing control.towards the haul truck when the bucket

The swing motion begins with smoothacceleration to an optimum point at which the excavator is plugged to a

Maximum efficiency and minimum swing machinery wear are directresults of mastering the swing motion. Improper swing motion results inerratic control and an unsafe, inefficient swing cycle. If the cycle beginswith fast acceleration and maximum speed is maintained to the dump

ary to stop the swing very suddenly. Plugging theswing under these conditions results in jerky swing motion andunnecessary spillage onto the haul truck and

Positioning of the haul truck also affects the swing time and it should bealong the swing path with their centre lines approximately

under or slightly inside the swing path of the boom/stick pivot point.


Swinging Rack and Roller Assemblybearing and revolving frame

These are the system components which support the bodyor shovel and allow it to rotate between disengage from the bank,dumping in the truck and returning to the bank

Switchbacks – Zigzag

Switchbacks are often used if the haul road can’t be built straight due to asteep gradient in deep pits. The road is build with sharp turn and amoderate gardient to achieve a operable Haulroad. This way the haul roadcan be built in a confirmed space but still capable to go into deep pits.


Swinging Rack and Roller Assembly – swingbearing and revolving frame

These are the system components which support the body of the excavatoror shovel and allow it to rotate between disengage from the bank,dumping in the truck and returning to the bank.

Switchbacks are often used if the haul road can’t be built straight due to ats. The road is build with sharp turn and a

moderate gardient to achieve a operable Haulroad. This way the haul roadcan be built in a confirmed space but still capable to go into deep pits.


Tags

Tags are used as a means of communicating important informother persons when not everyone is in the locale at any specific time.often contain important safety information and are coloured to attractattention. The following are examples.

Isolation/Lockout/Danger Tags

These tags are an instruction to all personnel that the equipment is not tobe started or operated. They are used to ensure that persons working onequipment can do so safely. Danger tags are in a bright red colure withblack and white

Out of Service Tags

Out of Service tags are placed on the isolation points of faulty equipmentthat could cause personal injury, equipment damage or impede theoperation. They are usually yellow coloured


Tags are used as a means of communicating important information toother persons when not everyone is in the locale at any specific time. Theyoften contain important safety information and are coloured to attract

The following are examples.

Danger Tags

o all personnel that the equipment is not tobe started or operated. They are used to ensure that persons working onequipment can do so safely. Danger tags are in a bright red colure with

d on the isolation points of faulty equipmentthat could cause personal injury, equipment damage or impede theoperation. They are usually yellow coloured


Information Tags

Information tags convey a message or instruction to personnel operatingor repairing an item of equipment.

Equipment with an attached Information tag may still be used oroperated. The tags are usually green.


Information tags convey a message or instruction to personnel operating

Equipment with an attached Information tag may still be used oroperated. The tags are usually green.


Talpac – Truck & Loader ProductivityEstimation Software

Simulates truck and loader mining systems enabling you to perform:

Travel Time Analysis

Fleet Production Analysis

Sensitivity Analysis

Optimum Fleet Sizing

Equipment Selection and Comparisons

Incremental Analysis

Haul Network Overview: 3D visualization and analysis of entire haulagenetwork. Allows users to determine shbetween source/destination. When integrated with XPAC/Xact or excel,scheduled truck requirements can be determined.


Truck & Loader Productivity

Simulates truck and loader mining systems enabling you to perform:

Equipment Selection and Comparisons

Haul Network Overview: 3D visualization and analysis of entire haulagenetwork. Allows users to determine shortest route and shortest timebetween source/destination. When integrated with XPAC/Xact or excel,scheduled truck requirements can be determined.


Tail gate – Stops spillage and increases bodycapacity

A tail gate on a truck may be used where in intmaterial to be carried is very low or the material being carried has verylow SG and additional payload capacity exists in the tray on the chassis.tail gate is often used with coal (low SG) or dry sand (low internal angle offriction).


Stops spillage and increases body

A tail gate on a truck may be used where in internal angle of friction ofmaterial to be carried is very low or the material being carried has verylow SG and additional payload capacity exists in the tray on the chassis. Atail gate is often used with coal (low SG) or dry sand (low internal angle of


Terex (Dart) 3100 33100

Terex(O&K, Dart)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Terex (Dart) 3100 33100 – Dump Truck

3100 33100

782 727

47.6

67302 68620

158002 159620

Struck

Heaped 2:1 57 57

90700 91000

15

10922 10820

5639 5030

5309 4850


Terex (Dart) 3311 – Dump Truck

Terex(O&K, Dart)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Dump Truck

3311C 3311D 3311E

626 626 727

60 60 64

53300 54800 63200

130300 131800 148200

Struck

Heaped 2:1 49.5 49.5 54

77000 77000 85000

16 16 16

10440 10440 10820

4720 4720 5080

4800 4770 4865


Terex (Dart) 4150 4160

Terex(O&K, Dart)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Terex (Dart) 4150 4160 – Dump Truck

4150 4160

783

96207 96660

232285 241809

Struck 138.4 138.4

Heaped 2:1 163 169

136078 145149

1514


Terex (Titan) 3315C 3315D

Terex(O&K, Dart)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)



Heaped 2:1

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


Terex (Titan) 3315C 3315D – Dump Truck

3315C 3315D

1343 1200-1500

56

104279

276279

Struck

Heaped 2:1 110

172000 156000

18

12600

6270

5900


Terex TR100/100DD –

Terex(O&K, Dart)


Net Power (kW)


Weight Empty (kg)

Loaded (kg)


Capacities (m3)

Rated Payload (kg)

Fuel Capacity (L)

Dump Height (mm)

Raise Time (s)


Overall Width (mm)

Overall Height (mm)


– Dump Truck

TR100 TR100DD

783 783

727 703

47.6 48.5

68260 67000

158980 157720

Struck 41.6 41.6

Heaped 2:1 57 57

91000 91000

1090 1275

8960 8960

16.3 16.3


5935 5935



Tip head edge/ Tip head stability

The tip head refers to the location where the truck is dumping its load.is a high risk area due to the fall in ground level behind the truck.the time when the truck is least stable with the tray up in dumpingarrangement.

There are a number of things that can be done to make tipheads as stableas possible:

Carry out dumping only when foundations have been properlyprepared;

Maintain a safety bund that is typically htruck tyre;

Reverse slowly and brake gently

Do not use the safety bund to stop the truck;

Move the tipping position regularly to give newly placed material timeto settle;

Always ensure that the approach grade is slightly uphicannot pond against the bund;

Avoid tiphead lifts greater than 30 metres wherever possible, and seekspecialist advice for lifts that are higher

Where there is poor visibility, dump short and push out with dozers.

Take particular care after heavy rain; check for cracking or bulging andwatch for water ponding near crest and toe areas.


Tip head edge/ Tip head stability

The tip head refers to the location where the truck is dumping its load. Itis a high risk area due to the fall in ground level behind the truck. It is also

k is least stable with the tray up in dumping

There are a number of things that can be done to make tipheads as stable

Carry out dumping only when foundations have been properly

Maintain a safety bund that is typically half the height of the largest

Do not use the safety bund to stop the truck;

Move the tipping position regularly to give newly placed material time

Always ensure that the approach grade is slightly uphill and water

Avoid tiphead lifts greater than 30 metres wherever possible, and seekspecialist advice for lifts that are higher

Where there is poor visibility, dump short and push out with dozers.

heavy rain; check for cracking or bulging andwatch for water ponding near crest and toe areas.


TKPH – Tonne Kilometre per Hour

TKPH = Average Load (tonnes) x Average Speed (kph)

TKPH is a rating based on the weight and speed that a tyre can toleratewithout overheating. Overheating causes tyres to deteriorate and fail.

PwC recommend operating trucks so that the tyres stay within 80the manufacturer’s TKPH rating.

To calculate the TKPH of the tyres when operating a three stage process isfollowed.

1. Calculate the average weight on the tyre (front + rear)

2. Calculate the average speed (Travel Distance

3. TKPH = Average Load (tonnes) * Average Speed (kph).

The calculation of TKPH for the tyres follows three stage calculations.

Tyre Load front and then rear tyre

Stage 2 – Average Speed.

The average speeds in km per hr are distance

Waste

Average Cycle Speed = x kph

Peak Cycle Speed = y kph

Stage 3 – Calculate TKPH

The calculation of TKPH for the front tyres is as follows;

Waste

Average TKPH = z

Peak TKPH = z

Compare with rated TKPH for all available tyres.


Tonne Kilometre per Hour

TKPH = Average Load (tonnes) x Average Speed (kph)

TKPH is a rating based on the weight and speed that a tyre can tolerateOverheating causes tyres to deteriorate and fail.

recommend operating trucks so that the tyres stay within 80-90% of

To calculate the TKPH of the tyres when operating a three stage process is

lculate the average weight on the tyre (front + rear)

Calculate the average speed (Travel Distance/Operating Time)

TKPH = Average Load (tonnes) * Average Speed (kph).

The calculation of TKPH for the tyres follows three stage calculations.

nd then rear tyre

The average speeds in km per hr are distance/time;

The calculation of TKPH for the front tyres is as follows;

Compare with rated TKPH for all available tyres.


Toe – The Bottom of a Batter or Face

The toe of an excavation is where the bottom of the batter meets the floor.The toe of the cut is an area that the operators need to concentrate onwhen digging near the floor as it is easy to leave a couple of metres ofmaterial outside the survey line. A prethe get and keep on line than a normal batter. The dozer has to clean thecoal, so if the toe has been dug properly and to the surveyed line, therewill be a minimum of burden left against the wall.

The spoil toe on the bench is another area that is tidied up by the dozer.


The Bottom of a Batter or Face

The toe of an excavation is where the bottom of the batter meets the floor.The toe of the cut is an area that the operators need to concentrate onwhen digging near the floor as it is easy to leave a couple of metres ofmaterial outside the survey line. A pre-split high wall batter is far easierthe get and keep on line than a normal batter. The dozer has to clean the

properly and to the surveyed line, therewill be a minimum of burden left against the wall.

The spoil toe on the bench is another area that is tidied up by the dozer.


Tooth Adaptor – Fitted to the Nose of theBucket

The Adaptor connects the tooth poinlip or directly to a plate lip. Whisler-points to a cast shovel dipper lip. The adaptor is used to ensure the toothpoint is correctly located relative to the bucket and to allow toothwear out and be replaced relatively cheaply.

Bucket

Adaptors


Fitted to the Nose of the

The Adaptor connects the tooth point to either the nose on a cast bucket-style Adaptors connect the tooth

The adaptor is used to ensure the toothpoint is correctly located relative to the bucket and to allow tooth points towear out and be replaced relatively cheaply.

Bucket

Adaptors

Toot


Tooth attack angle

Defined as the angle between a line from the top of the pivot point whichthe dipper arm rotates around to the front of the lip (A)line of the teeth (B). This is not favoured as the tooth attack angle will varyas the dipper arm is pushed out.

A better definition (and consistent regardless of how far extended thedipper arm is) is the angle between the centre line of the teeth (B) and thecentre line of the dipper arm (C).

Tooth Coverage – Percentage of the lipwhich is made up of teeth


a line from the top of the pivot point whichthe dipper arm rotates around to the front of the lip (A) and the centre

This is not favoured as the tooth attack angle will vary

A better definition (and consistent regardless of how far extended thedipper arm is) is the angle between the centre line of the teeth (B) and the

ercentage of the lipwhich is made up of teeth


Top Loading

Top loading is defined as when a backhoe sits at the same level as thetrucks and digs below itself.

The top loading technique is generally used when the cin one pass. Top loading may also be used when trucks are experiencingdifficulty pulling out from the face, or when the material is unsuitable forthe trucks to drive on. Because of the increase in swing and lift time ascompared to other methods, top loading is not an efficient method andshould only be carried out when necessary.

To improve efficiency, ensure that the bucket is positioned for optimumpenetration and material spillage is minimised by crowding the bucket tothe correct position.


Top loading is defined as when a backhoe sits at the same level as the

The top loading technique is generally used when the cut is too deep to digTop loading may also be used when trucks are experiencing

difficulty pulling out from the face, or when the material is unsuitable forBecause of the increase in swing and lift time as

other methods, top loading is not an efficient method andshould only be carried out when necessary.

To improve efficiency, ensure that the bucket is positioned for optimumpenetration and material spillage is minimised by crowding the bucket to


Topsoil – The Dirt on the Surface thatGrows Vegetation

Topsoil is the dirt on the top of the ground that grows the vegetation.

As is a scarce commodity mine sites are committed to saving all of it forfuture rehabilitation of the mining ar

Top soil is stripped and stockpiled ahead of mining operations for laterrecovery.


The Dirt on the Surface that

Topsoil is the dirt on the top of the ground that grows the vegetation.

As is a scarce commodity mine sites are committed to saving all of it forfuture rehabilitation of the mining areas.

Top soil is stripped and stockpiled ahead of mining operations for later


Tracks (Continuous tracks or machinetracks) – Providing moti

The tracks are what shovels and excavators use to move the machine.


Tracks (Continuous tracks or machineroviding motion traction

The tracks are what shovels and excavators use to move the machine.


Trainee – Person LearMachine

A trainee is a person who is learning to operate a machine. They are alsocalled a novice particularly when first starting. Training truck and loaderoperators is a long and involved process. There are a number of ways thata mine can train operators.

Most mines use a third party to initiate the training process by having theproposed trainees attending a novice trainee course that uses acombination of VTS technology, sand pit and classroom sessions. Theythen go back to site and continue with onsite trainers.

It has been shown and recorded that by using these tools, in a very shortperiod of time, the trainee then put onto a production machine tocontinue training has approximately 55% of his skills, so production doesnot suffer dramatically.

Tramming – Moving the loader

Tramming is the terminology used in some mines for moving andexcavator or a shovel. In the normal travel position the travel motors areat the rear of the excavator and the idlers are at the front of the machinBe aware of their position before you begin to travel. For forward travelpush the front of both pedals, for reverse push the back of both pedals.When pressure is released on the pedals they will return to their neutralposition.


Person Learning to Operate a

A trainee is a person who is learning to operate a machine. They are alsocalled a novice particularly when first starting. Training truck and loaderoperators is a long and involved process. There are a number of ways that

Most mines use a third party to initiate the training process by having thetrainees attending a novice trainee course that uses a

combination of VTS technology, sand pit and classroom sessions. Theycontinue with onsite trainers.

It has been shown and recorded that by using these tools, in a very shortperiod of time, the trainee then put onto a production machine tocontinue training has approximately 55% of his skills, so production does

Moving the loader

Tramming is the terminology used in some mines for moving andIn the normal travel position the travel motors are

at the rear of the excavator and the idlers are at the front of the machine.Be aware of their position before you begin to travel. For forward travelpush the front of both pedals, for reverse push the back of both pedals.When pressure is released on the pedals they will return to their neutral


Truck & Loader Operations

Truck and Shovel (T & S or T & L) operations are an alternative means toa dragline for moving overburden in the mining industry.

T&S is a more costly process per cubic metre and is around 3dearer per cubic metre than a dragline operation.operations, Truck and Shovel/Excavator is used extensively as the costoutlay of a dragline cannot be justified.


ations

Truck and Shovel (T & S or T & L) operations are an alternative means toa dragline for moving overburden in the mining industry.

T&S is a more costly process per cubic metre and is around 3-5 timesdearer per cubic metre than a dragline operation. In the smaller mining

Excavator is used extensively as the costoutlay of a dragline cannot be justified.


Truck – Controls

EmergencyBrake


EmergencyBrake

Acceleratorpedal


Truck Optimisation

Core considerations of a Truck and Shovel operation.material carrying tool in the mining industry the key to optimizing thetruck performance is in optimising payload.

Truck & ShovelCore Consideration• Through Planning

& Design• Regular Review &

Monitoring• Change Process

Haul Road Construction Material

Haul Elevation (Height)

Haul Road Design

Haul Dist (VERT)

Rope Shovel (Type, Make, CAP)

HYD, Shovel (Type, Size, CAP)

HYD EXC (Type, Size, CAP)

FEL (Type, Size, CAP)

Truck (Type, Size, CAP)

Support Equipment

Tech & Other Support

Face Height

Bump Plans• Location• Construction• Number of Dumps

Starta

Environment

Weather


Core considerations of a Truck and Shovel operation. Like every otheraterial carrying tool in the mining industry the key to optimizing the

truck performance is in optimising payload.

Truck & ShovelCore Consideration

Through Planning& Design

Regular Review &Monitoring

Change Process

Haul Road Construction Material

Bench Width

Bench Strike Length (EXC)

Bench Height (EXC)

Best practices

Drilling Patterns

Blast Volumes & Frag

DIG Sequences & Methods

Cable Plans & Layout

Shovel Assist Methods

Double Side Loading

Single Side Loading

Team Competencies

Volumes (BSM)

Polices & Procedures

Other Consideration• DRE Planning• Rehab• Bridges (DRE)


Truck Payload

Like every other material carrying tool in the mining industry the key tooptimizing the truck performance is in optimising payload. The industry,however, has a problem with truck payload being 5capacity. The average payload carried around the world by a 218 t (240 T)truck is 201 tonnes. The following plot shows the distributionpayloads achieved by this class of truck.

Given the fact that there are multiple passes to each single truck there is asmall capacity to vary loader payloads to ensure the truck is filled. Thismeans one or more “overfull” loads by the loader can“smaller” load. The situations which must be avoided are excessivenumbers of passes to fill the trucks and half loads to fill an individualtruck. It is easy to see why it is an exercise where the skill and experienceof the loader operator becomes critical. This small amount of flexibility inthe loader payload means that the key parameter in optimising the loaderand truck match is the payload which can be placed on the truck tray.Consequently, the first consideration is maximistruck tray can consistently and safely carry.

Following on with the example of 240T (218 t) trucks ttypical OEM produced weight distribution for 240Komatsu 830E, Terex 4400, etc).

Total Operating Weight 386 tonnes

Chassis Weight 135 tonnes


Like every other material carrying tool in the mining industry the key tormance is in optimising payload. The industry,

however, has a problem with truck payload being 5-15% below nameplatecapacity. The average payload carried around the world by a 218 t (240 T)truck is 201 tonnes. The following plot shows the distributions ofpayloads achieved by this class of truck.

Given the fact that there are multiple passes to each single truck there is asmall capacity to vary loader payloads to ensure the truck is filled. Thismeans one or more “overfull” loads by the loader can be offset by a final“smaller” load. The situations which must be avoided are excessivenumbers of passes to fill the trucks and half loads to fill an individualtruck. It is easy to see why it is an exercise where the skill and experience

operator becomes critical. This small amount of flexibility inthe loader payload means that the key parameter in optimising the loaderand truck match is the payload which can be placed on the truck tray.Consequently, the first consideration is maximising the load which thetruck tray can consistently and safely carry.

Following on with the example of 240T (218 t) trucks the following is atypical OEM produced weight distribution for 240 T trucks (CAT793,

135 tonnes


Weight to be carried 251 tonnes

It is the split between payload weight and nonthe 251 tonnes which must be optimised. The weight of the trays will limitthe target payload and this needs to be quantified by every site, howeverthe value in carrying more payload may far outweigh maintenance costsso mines need to consider how to optimise payload carried whilemaintaining acceptable life.

If the split between steel and payloadis the result.




Tray Weight (average) 38 tonnes

Nominal payload 213 tonnes

If a mine is to respect the specification of213 tonnes (235T) can be targeted on average. This obviously variesdepending on the actual weight of the tray.

Lighter trays suitable for the 240st trucks are available from a number ofsuppliers. These range in weight fromliners). If the calculation is repeated using a tray weight of 28 tonnes thenthe target payload may increase as follows.




Lightweight Tray 28 tonnes

Nominal payload 223 tonnes (maximum 226 tonnes)


251 tonnes

It is the split between payload weight and non-payload weight as part ofthe 251 tonnes which must be optimised. The weight of the trays will limit

s needs to be quantified by every site, howeverthe value in carrying more payload may far outweigh maintenance costsso mines need to consider how to optimise payload carried while

split between steel and payload reflects standard trays the following

386 tonnes

135 tonnes

251 tonnes

38 tonnes

213 tonnes

If a mine is to respect the specification of the trucks then no more than) can be targeted on average. This obviously varies

depending on the actual weight of the tray.

Lighter trays suitable for the 240st trucks are available from a number ofsuppliers. These range in weight from 25 tonnes to 38 tonnes (includingliners). If the calculation is repeated using a tray weight of 28 tonnes thenthe target payload may increase as follows.

386 tonnes

135 tonnes

251 tonnes

28 tonnes

223 tonnes (maximum 226 tonnes)


Trucking – Truck matching to the shovel

What is Matching/Trucking?

Matching is basically ensuring the right amount of Trucks to a shovel toOptimize Productivity and minimiseovercrowding trucks (Over Trucking).

Matching can be worked out taking all elements into consideration, Size ofTruck and Shovel, cycle time, delays etc.


Truck matching to the shovel

Matching is basically ensuring the right amount of Trucks to a shovel toOptimize Productivity and minimise delay on waiting for trucks orovercrowding trucks (Over Trucking).

Matching can be worked out taking all elements into consideration, Size ofTruck and Shovel, cycle time, delays etc.


Truck Air Filter Indicatorsfilter condition

Indicates when filters needs to be cleaned


Truck Air Filter Indicators – Indicates the

ndicates when filters needs to be cleaned/replaced


Truck Forces – Forces on the Truckin operation

Truck parking bay

Designated area for trucks to be parked. This is also commonly known asthe Go – No Go area.

Truck PLM (Payload Meter)loaded Material


Forces on the Truck

Designated area for trucks to be parked. This is also commonly known as

Truck PLM (Payload Meter) – Measures the


Truck Positioning

The truck positioning for loading is important for production as the swingangles of the dig unit need to be minimised to speed up loading timeswithout compromising safety. When an excavator is loading on a benchthe most productive position to place a truck is 45° to the bench where theoperator has just to raise the bucket up over the back end not up and overthe side of the truck. The disadvantage of that position is that the truckdrivers have difficulty self spotting to the excavator.

The most common way excavator operators load trucks is 90°to the benchbut the disadvantage of that method is that the bucket has to be lifted upand over the side of the truck. The advantage of that method is that thetruck drivers can easily self spot to the excavator.


The truck positioning for loading is important for production as the swingangles of the dig unit need to be minimised to speed up loading timeswithout compromising safety. When an excavator is loading on a bench

e most productive position to place a truck is 45° to the bench where theoperator has just to raise the bucket up over the back end not up and overthe side of the truck. The disadvantage of that position is that the truck

tting to the excavator.

The most common way excavator operators load trucks is 90°to the benchbut the disadvantage of that method is that the bucket has to be lifted upand over the side of the truck. The advantage of that method is that the

can easily self spot to the excavator.


Truck Spotting guide –truck drivers

A cable or other structure is hung from specific points under the boom forthe truck driver to use when spotting the truck ready for loading.the truck driver to correctly spot and reverse under the dipper


– A device to assist

A cable or other structure is hung from specific points under the boom forthe truck driver to use when spotting the truck ready for loading. It allows

ruck driver to correctly spot and reverse under the dipper


Truck Tow Pin

Truck Tray (Bed) – Carries Material on thechassis

The tray or bed is the generic term given to the (usually) steel structurewhich sits on the chassis and is used to contai

Truck Tray – Capacity

SAE standard J1363 has been traditionally used to define truck traycapacity. In this standard struck capacity provides for the load to go to


Carries Material on the

is the generic term given to the (usually) steel structurewhich sits on the chassis and is used to contain the material being carried.

Capacity

SAE standard J1363 has been traditionally used to define truck traytruck capacity provides for the load to go to


the top of the sides of the truck tray, and if the tray is opthis material is assumed to be sloping at 1:1.

The 2:1 heaped capacity is the total of the trucks capacity, plus thematerial above the tray sides with an assumed angle of repose of 2:1 slope.For most mining applications, the 2:1 heaped voestimate of the quantity which can be carried on average inthe tray.

More recently truck tray manufacturers have been using their owncomputer models in an effort to gain a more accurate indication of thetrue volumetric capacity. This still leaves the issue of the conversion fromthe capacity being calculated as a volume to the capacity being stated intonnes or tons.


the top of the sides of the truck tray, and if the tray is open at the back,this material is assumed to be sloping at 1:1.

The 2:1 heaped capacity is the total of the trucks capacity, plus thematerial above the tray sides with an assumed angle of repose of 2:1 slope.For most mining applications, the 2:1 heaped volume is an optimisticestimate of the quantity which can be carried on average in

More recently truck tray manufacturers have been using their owncomputer models in an effort to gain a more accurate indication of the

This still leaves the issue of the conversion fromthe capacity being calculated as a volume to the capacity being stated in


Truck tray cleaning –

Some mines with clayey material have problems with material not beingdumped efficiently. This causes material to build up in the tray.reduces the effective capacity of the tray and the productivity of the truck.A number of methods can be used to clean carryback out of the truck.

The first one is to use a backhoe. This should only be done by experiencedoperators. The tray can be easily penetrated with the bucket teeth. Lift thetruck tray up, the excavator and truck should be in one line, gently startremoving the material out of the tray.

Another, safer way is to remove it with a water cannon.less efficient at removing the carryback.


Reducing carry back

Some mines with clayey material have problems with material not beingThis causes material to build up in the tray. This

reduces the effective capacity of the tray and the productivity of the truck.A number of methods can be used to clean carryback out of the truck.

his should only be done by experiencedoperators. The tray can be easily penetrated with the bucket teeth. Lift thetruck tray up, the excavator and truck should be in one line, gently startremoving the material out of the tray.

remove it with a water cannon. This is potentiallyless efficient at removing the carryback.


Truck Tray Hoist Ram Pivot Point

Tyres

Major offroad tyre brands are Bridgestone40% market share and Goodyear - 15%Yokahama, Toyo, Belshina, Titan, Guilin / Torch, Triangle, Shifeng,Haian/Luan, Taishan, Shandong BotoMost of the mining companies buy the "Big 3" direct. The smaller playershave distributor networks. Each truck manufacturer will approve certainmakes and models of tyres which can be safely used with the truck model.This means that they will maintain any warranty when these tyres areused. This makes it difficult for the smaller suppliers to gainTyres are rated according to TKPH (see previous) and it is important thatthe actual TKPH on site be kept to 80


Truck Tray Hoist Ram Pivot Point

Bridgestone - 40% market share, Michelin -15% market share. Others include

Yokahama, Toyo, Belshina, Titan, Guilin / Torch, Triangle, Shifeng,Haian/Luan, Taishan, Shandong Boto and have around 5% market share.Most of the mining companies buy the "Big 3" direct. The smaller players

Each truck manufacturer will approve certainmakes and models of tyres which can be safely used with the truck model.This means that they will maintain any warranty when these tyres are

This makes it difficult for the smaller suppliers to gain market share.Tyres are rated according to TKPH (see previous) and it is important thatthe actual TKPH on site be kept to 80-90% of the rated TKPH.


Tyre Damage



Tyre management reports

Tyre reports are an integral part of tyre management on mine

Key issues to be included are;

Tyre cost

Dates fitted and removed

Reasons for removal, (eg. Worn out, case separation, rock damage,irregular wear, spare)

Tyre specification, (brand, type, ply rating, TKPH rating, rubbercompound, tread depth and pattern)

Tyre ID

Vehicle ID

Tyre position on vehicle

Hours operated (or distance travelled)

Remaining tread (mm, % worn)

Max TKPH (24 hrs), average TKPH

Report Analysis

Key performance indicators which should be calculated are;

Hours (or distance)

Cost/hour (by brand, type, etc)

Percentage tread worn

Percentage tyres separated

Percentage tyres injured

Percentage TKPH (average & maximum)

Hours/mm tread worn

Detailed Report Analysis

Specific reports for factors such as separated tyres include the following;

Percentage of total

Percentage by brand

Cost of damage (tread remaining)

Percentage by tyre position

Percentage by tyre type, original tread depth

Percentage vs TKPH rating

Percentage site TKPH/Tyre TKPH


Tyre management reports

Tyre reports are an integral part of tyre management on mine sites.

Reasons for removal, (eg. Worn out, case separation, rock damage,

Tyre specification, (brand, type, ply rating, TKPH rating, rubberttern)

Hours operated (or distance travelled)

Max TKPH (24 hrs), average TKPH

Key performance indicators which should be calculated are;

Percentage TKPH (average & maximum)

Specific reports for factors such as separated tyres include the following;

Cost of damage (tread remaining)

Percentage by tyre type, original tread depth

Tyre TKPH


Tyre Overheating

Care must be taken when dealing with toverheated.

A good guide as to whether a tyre is operating at too high a temperature ornot, is to touch it with the palm of your hand. Temperature wise, it shouldfeel comfortable to touch.

An overheated tyre may eventually cause a fire which can destroy thetruck.


Care must be taken when dealing with tyres that are suspected of being

A good guide as to whether a tyre is operating at too high a temperature ornot, is to touch it with the palm of your hand. Temperature wise, it should

lly cause a fire which can destroy the


Tyre Rim



Tyre Safety

In the event of tyre damage, stop the truck as soon as possible,considering:

Haul road surface

Weather conditions

Travelling up or down inclines

Loaded or empty

Speed

Other vehicles/machines.

In the event of a tyre failure or tyre fire:

Bring the truck to an immediate stop

Apply correct park procedure

Switch on hazard lights

Switch of engine

Advise supervisor, other operators and dispatch

Evacuate the truck and area if the tyre is on


In the event of tyre damage, stop the truck as soon as possible,

In the event of a tyre failure or tyre fire:

Bring the truck to an immediate stop

Advise supervisor, other operators and dispatch

Evacuate the truck and area if the tyre is on fire.


Tyre Tread – Maintains traction withhaulroad

If a tyre with too much tread is used then this will:

Decrease the TKPH rating

Reduce the Casing Life

Maybe lose the tyre prematurely from casing failure.

Tread can be cut off or added to obtain the o


Maintains traction with

If a tyre with too much tread is used then this will:

Maybe lose the tyre prematurely from casing failure.

Tread can be cut off or added to obtain the optimum tread


Ultra Class Trucks

The largest, highest payload capacity haul trucks are referred to as "ultraclass" trucks.

The ultra class includes all haul trucks with a payload capacity of 300short tons (272 tonnes) or greater.

Undercarriage – bottom deck

Walking gear, travel motors, etc.


The largest, highest payload capacity haul trucks are referred to as "ultra

The ultra class includes all haul trucks with a payload capacity of 300

om deck


Undercutting a Face above the bench

The dangers of undercutting a high face include:

The face can collapse

Single rocks can fall onto the machine

This can cause damage to the excavator and serious injury or deaoperator andother people.

When the face collapses the material can fall onto the bucket and damagehydraulic cylinders, hoses and grease lines. Dipper arm and or structuralboom damage could occur. In the worst case the machine could becomeunstable and tip over due to the heavy/ large amount of material in/on thedipper arm/bucket.


Undercutting a Face above the bench

The dangers of undercutting a high face include:

rocks can fall onto the machine

This can cause damage to the excavator and serious injury or death to the

When the face collapses the material can fall onto the bucket and damagehydraulic cylinders, hoses and grease lines. Dipper arm and or structuralboom damage could occur. In the worst case the machine could become

nstable and tip over due to the heavy/ large amount of material in/on the


Undercutting a Face below the bench

In order to retreat from the edge of an excavation should the footingcollapse, always position the undercarriage square to texcavation with the travel motors at the rear.

When the overhang collapses, the material can fall onto the bucket anddamage the hydraulic cylinders or the hoses. In the worst case themachine could become unstable and tip over due to theamount of material in the bucket.


Undercutting a Face below the bench

In order to retreat from the edge of an excavation should the footingcollapse, always position the undercarriage square to the edge of theexcavation with the travel motors at the rear.

When the overhang collapses, the material can fall onto the bucket anddamage the hydraulic cylinders or the hoses. In the worst case themachine could become unstable and tip over due to the heavy/ large


Vienna Test System

The Vienna Test System (VTS) is a computer based testing program thatassesses the perception and co-ordination abilities required for safe andproductive performance for operators of machconsists of powerful basic software and over 82 individual tests.easy and intuitive.

More than 5000 Vienna Test Systems are in use around the world.

Two-hand coordination test and time movement anticipation test are thebest predictors of operator productivity. These two tests plus age explain64% of the variation in operator performance. The reliability of TwoCoordination test and Time Movement Anticipation test is excellent.Pearson correlation of 0.964 for the twfor time movement anticipation test have been recorded for operators.


The Vienna Test System (VTS) is a computer based testing program thatordination abilities required for safe and

productive performance for operators of machinery and vehicles. VTSconsists of powerful basic software and over 82 individual tests. Its use is

More than 5000 Vienna Test Systems are in use around the world.

hand coordination test and time movement anticipation test are thebest predictors of operator productivity. These two tests plus age explain64% of the variation in operator performance. The reliability of Two-handCoordination test and Time Movement Anticipation test is excellent.Pearson correlation of 0.964 for the two hand coordination test and 0.970for time movement anticipation test have been recorded for operators.


Vital Information Management System(VIMS)

The Vital Information Management System (VIMS) consists of a messagecentre module and a VIMS keypad mofor the VIMS is used to display information to the operator. The operatorcan use the VIMS keypad module to input information. There is an actionalarm. There is an alert indicator. There is an action lamp. The VIMS isdesigned to alert the operator of an abnormal condition in one or more ofthe machine systems. These abnormal conditions are called events. TheVIMS will store data.

Volume – The Amount of

Volume is amount of bank cubic metres, B.C.M. in a gdigging, mining engineers usually will work out the volume ofoverburden/waste bcm’s to be removed from the pit. The productionmonitors record the volumes of overburdenregular basis, reports are printed to keep trtruck and loading units are. Survey will, on a regular basis; reconcile thevolumes of material removed against the production monitors


Vital Information Management System

The Vital Information Management System (VIMS) consists of a messagecentre module and a VIMS keypad module. The message centre modulefor the VIMS is used to display information to the operator. The operatorcan use the VIMS keypad module to input information. There is an actionalarm. There is an alert indicator. There is an action lamp. The VIMS is

ned to alert the operator of an abnormal condition in one or more ofthe machine systems. These abnormal conditions are called events. The

The Amount of waste in an area

Volume is amount of bank cubic metres, B.C.M. in a given area. Beforedigging, mining engineers usually will work out the volume of

waste bcm’s to be removed from the pit. The productionmonitors record the volumes of overburden/waste removed and on aregular basis, reports are printed to keep track of how productive thetruck and loading units are. Survey will, on a regular basis; reconcile thevolumes of material removed against the production monitors


Void (dipper) – Volume in bucket which isnot filled

Up to 25% of a bucket/dipper might nregarded as loaded. This is a function of the shape of the bucket and theaction of the loading tool.


Volume in bucket which is

dipper might not be filled when the bucket isThis is a function of the shape of the bucket and the


Wait On Truck (Hang Time)

This information will help the supervisors assess whether there is thecorrect amount of trucks in the spread. When the truck is almost loadedwith one more bucket to go on it another truck should be just turning upand will be waiting for a short time before it is their turn to go in for itsload. If the loader has no trucks available toon trucks. Mines which have relatively high wait on trucks are said to beunder trucked.


(Hang Time) – Reporting

This information will help the supervisors assess whether there is thet of trucks in the spread. When the truck is almost loaded

with one more bucket to go on it another truck should be just turning upand will be waiting for a short time before it is their turn to go in for itsload. If the loader has no trucks available to be loaded, this is called wait

Mines which have relatively high wait on trucks are said to be


Wait On Loader (reporting)

This information will help the supervisors assess whether there is thecorrect amount of trucks in the spread. When the truck is almost loadedwith one more bucket to go on it another truck should be just turning upand will be waiting for a very short time before it is his turn to go in for itsload. If the trucks are waiting for two or more buckets to be ptruck being loaded the waiting time is beginning to be too long and theywould be almost at a queuing stage. If the trucks are queued, waiting toload, this is called wait on loader. Mines which have relatively high waiton loader are said to be over trucked.

http://www.flickr.com/photos/tom_oconnor2/5579445038/


Wait On Loader (reporting)

This information will help the supervisors assess whether there is thepread. When the truck is almost loaded

with one more bucket to go on it another truck should be just turning upand will be waiting for a very short time before it is his turn to go in for itsload. If the trucks are waiting for two or more buckets to be put on thetruck being loaded the waiting time is beginning to be too long and theywould be almost at a queuing stage. If the trucks are queued, waiting to

Mines which have relatively high waitover trucked.

http://www.flickr.com/photos/tom_oconnor2/5579445038/


Walk Around Inspection

The main aim of a walk around inspection is to identify problems beforethey reach the stage where equipment fails or breaks down.

The sooner problems are found, the greater the lead time that themaintenance department has for planning, gathering materials,coordinating the shutdown, and estimating and scheduling the manpowerfor the maintenance work.

A walk around inspection needs to be carried out at the beginning of eachshift, even if the truck or shovel has recently been utilised or a “hot seat”changeover occurs.

Inspections must be done as per the mine’s schedule and in a mannerprescribed by the mine or the manufacturer.

Always complete a through pre-start inspection:

Walk-around

Check for evidence of greasing

Check attachment security

Check underneath machine and hoses for leaks and damage

Check for general abnormalities and/or damage


Walk Around Inspection

The main aim of a walk around inspection is to identify problems beforewhere equipment fails or breaks down.

The sooner problems are found, the greater the lead time that themaintenance department has for planning, gathering materials,coordinating the shutdown, and estimating and scheduling the manpower

A walk around inspection needs to be carried out at the beginning of eachshift, even if the truck or shovel has recently been utilised or a “hot seat”

Inspections must be done as per the mine’s schedule and in a mannered by the mine or the manufacturer.

start inspection:

Check underneath machine and hoses for leaks and damage

Check for general abnormalities and/or damage with machine


Check coolant level

Check engine oil level

Check Hydraulic oil

Check transmission level.

Check fuel level

Looking for machine security, wear, fuel, oil and water leaks

Tyre inspection, cuts, inflation and rims

Condition of tracks

GET on the bucket/Dipper on loading units

Ladders, hand rails

Monitor, brake and steering operation

Drain sediment from fuel tank

Check monitor panel

Check wiring

batteries,

starter motor,

alternator

Check parking brake

Check emergency steering

Check brake pedal operation

Check tyre pressure & wheel nuts

Adjust seat & seat belt

Adjust mirrors

Park brake is on

Transmission neutralized


Looking for machine security, wear, fuel, oil and water leaks

Tyre inspection, cuts, inflation and rims

Dipper on loading units

Monitor, brake and steering operation

Check tyre pressure & wheel nuts

Always refer to the OEM(Original EquipmentManufacturers)operational manual andyour site specificregulations to carry out athorough pre-shift


Wash bay – Machine

This is an area to clean trucks, loaders and other mining equipment priorto servicing and or transport off site.

Wheel lock ring

All lock rings are split. In three-piece assemblies, the lock ring is designedto hold the continuous side ring on the rim.


This is an area to clean trucks, loaders and other mining equipment priorto servicing and or transport off site.

piece assemblies, the lock ring is designedto hold the continuous side ring on the rim.


Windrow/Berm – Physical Barrier

Is a line of heaped waste, which acts as a physical barrier. It is used toseparate people or equipment from hazardous situations

Wire rope – Consists of several strands laidtogether like a helix

Wire rope consists of several strands laid (or 'twisted') together like ahelix. Each strand is likewise made of metal wires laid togehelix. Initially wrought iron wires were used, but today steel is the mainmaterial used for wire ropes.


Physical Barrier

Is a line of heaped waste, which acts as a physical barrier. It is used toparate people or equipment from hazardous situations

onsists of several strands laid

Wire rope consists of several strands laid (or 'twisted') together like ahelix. Each strand is likewise made of metal wires laid together like ahelix. Initially wrought iron wires were used, but today steel is the main


Witches Hats – Reflective Safety Conesfor Demarcation

Witches hats are used extensively around a mine site. Around a dragline,they mark the cable, parking areas, and anywhere that demarcation isrequired.

Working Zones

The exclusion area while excavator or shovel is loading.output, the excavator working zone should be limited to 15° either side ofthe centerline, or approximately equal to the undercarriage width.


Reflective Safety Cones

Witches hats are used extensively around a mine site. Around a dragline,ark the cable, parking areas, and anywhere that demarcation is

The exclusion area while excavator or shovel is loading. For maximumoutput, the excavator working zone should be limited to 15° either side of

oximately equal to the undercarriage width.

The publishers of the Truck and Loader Dictionarythis publication; however, PwC cannot be held responsible for errors, inaccuracies, or omissions resultingfrom the nature of the information provided or previously published, or through typographical compilation.

© 2013 PricewaterhouseCoopers. All rights reserved. PwC refers to thesometimes refer to the PwC network. Each member firm is a separate legal entity. Please seewww.pwc.com/structure for further details.

This content is for general information purposes onlyconsultation with professional advisors.

Truck and Loader Dictionary have exercised the utmost care in the composition ofcannot be held responsible for errors, inaccuracies, or omissions resulting

from the nature of the information provided or previously published, or through typographical compilation.

rights reserved. PwC refers to the Australian member firm, and maysometimes refer to the PwC network. Each member firm is a separate legal entity. Please see

This content is for general information purposes only, and should not be used as a substitute for

PwC’s Mining Intelligence andBenchmarking

Service Overview

November 2013

pwc.com.au

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PwC's Mining Intelligence and Benchmarking is a PwC service offering.

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Characteristic/Class DraglineElectric Rope

ShovelHydraulicExcavator

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Our databaseThe breadth and depth of PwC MIB database is unparalleled

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Time based metrics Production based metrics

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Number of Machines 174 171 432

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• Downtime(Mechanical/Electrical)

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Data as at 16 September 2013

HydraulicExcavator

Front EndLoader

Mining Trucks DrillsAncillary (Dozers,

Graders etc)

51 22 87 60 38

The breadth and depth of PwC MIB database is unparalleled

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Dragline and truck specific

Swing Time (Dragline)

Dragline Specific

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Other

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51 22 87 60 38

432 298 2,596 286 713

70 58 66 41 22

869 704 6,510 552 1,850

136M 65M 64M

Key performance indicators include (but are not limited to)

Swing Time (Dragline)

Swing Angle (Dragline)

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Our experienceYou can have complete confidence in the PwC Mining Intelligence and Benchmarking team, with our

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5

However, the data is just a resource.PwC owns the data and has a strong analytics capability that will turn data into meaningful information forour clients

Comparison of annual output of allsite loaders with all loaders in the

PwC database showing median and90th percentile performance

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Group of machinesperforming under themedian of theindustry

However, the data is just a resource.PwC owns the data and has a strong analytics capability that will turn data into meaningful information for

Comparison of multiple site loadersof a specific make and model with

summarised industry performancefor the agreed population

Gaps in performance between aparticular machine and best

practice .

Machines that are in thetop priority list forimprovement

6

KPI’s that are in the top prioritylist for improvement

Our service offering

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7

Training suites from novice to advanced operators andmanagement in dragline, truck and loader Productivity.

Best Practice standards courses leveraging the PwCdatabase best practice data to contribute to a strategicadvantage in cost and productivity performance.

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Skilling Existing Teams


*2003 Result set at 10085

90

95

100

105

110

115

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

Ind

ex(#

)88

By acquiring GBI, PwC adds to it’smining productivity proposition atangible source of realcompetitive advantage for ourclients

Nobody else in the world has thisamount of data

equivalent years of equipment dataOrganisation Design, Structure and Workforce Optimisation

Capability Development and Behaviour Change:Lean, Six Sigma, 5S, etc.

MIB - Use by other PwC businessesPwC Mining Intelligence and Benchmarking is part of the PwC Consulting business. The MIB databaseand IP can be used to enhance what other PwC businesses deliver and to provide strategic advantage inthe market.

Assurance

Deals

The appropriateness of thevalue of the mine / reserves /resources on the balance sheet.

Due diligence bybenchmarking actualperformance or planningassumptions used.

PwC

Use by other PwC businessesPwC Mining Intelligence and Benchmarking is part of the PwC Consulting business. The MIB databaseand IP can be used to enhance what other PwC businesses deliver and to provide strategic advantage in

Enterprises & Private Clients

Tax

Any work in mining maybenefit from the MIB data

Support for and enhancementof client R&D activities

9

benefit from the MIB dataand the IP

Appendix A – Case Studies

PwC

Case study 1 – Benchmarking

Benchmarking 18 Loaders and 118 Trucks

Challenge:

To determine how well a mine’s loaders and trucks were performing relative to what they are capable of.

High Level Approach:

Our team selected a relevant population of similar machines for each of the 18 loaders and 118 trucks (which wereOur team selected a relevant population of similar machines for each of the 18 loaders and 118 trucks (which weretreated as 3 separate truck fleets), based on same commodity, same country and same make and model. Populationswere 17 - 89 machine years for loaders and 118 – 515 machine years for the

We undertook an analysis of the performance of the mine’s loaders and trucks in 2012of the top 10% by annual output of equipment in the population selected from the PwC productivity and reliabilitydatabase (external comparison); and their performance in 2012(internal comparison). Production metrics were compared as well as gaps in production and reliability metricsquantified.

Outcomes:

We identified that both loaders and trucks had significant improvement potential. Trucks and loaders could add up to134 Mt pa which was almost exactly twice what they moved in 2012

PwC

134 Mt pa which was almost exactly twice what they moved in 2012

We also concluded that the mine’s volume strategy (overeffectively.

Further data analysis revealed that both loaders and trucks had gaps in operational standby time especially under “Nowork available” and “No operator”, indicating inefficiency in utilisation. The analysis also disclosed gaps inand queue time indicating inefficiency in cycling.

The analysis revealed opportunities for improvement . Capitalising on these opportunities would allow the mine to

better utilise their equipment and to execute their operating strategy more effectively.

performance gaps and will allow targeted changes to be initiated to improve performance

To determine how well a mine’s loaders and trucks were performing relative to what they are capable of.

team selected a relevant population of similar machines for each of the 18 loaders and 118 trucks (which wereteam selected a relevant population of similar machines for each of the 18 loaders and 118 trucks (which weretreated as 3 separate truck fleets), based on same commodity, same country and same make and model. Populations

515 machine years for the truck fleets.

We undertook an analysis of the performance of the mine’s loaders and trucks in 2012-2013 compared with the averageof the top 10% by annual output of equipment in the population selected from the PwC productivity and reliabilitydatabase (external comparison); and their performance in 2012-2013 compared with their 2011-2012 performance(internal comparison). Production metrics were compared as well as gaps in production and reliability metrics

significant improvement potential. Trucks and loaders could add up topa which was almost exactly twice what they moved in 2012-13.pa which was almost exactly twice what they moved in 2012-13.

We also concluded that the mine’s volume strategy (over-truck so that the loaders just keep loading) was not executed

oth loaders and trucks had gaps in operational standby time especially under “Noindicating inefficiency in utilisation. The analysis also disclosed gaps in hang time

for improvement . Capitalising on these opportunities would allow the mine to

better utilise their equipment and to execute their operating strategy more effectively. The study identified the

targeted changes to be initiated to improve performance

Case study 2 – Optimising Truck and Loader Match

Optimisation of truck trays and loader buckets

Challenge:

The mine was purchasing a new fleet of trucks and wanted to choose an optimised

tray market has multiple offerings. The performance of different trays has not been well understood.tray market has multiple offerings. The performance of different trays has not been well understood.

In addition the capacity of the loader bucket which matched the truck trays was to be recommended.

High level summary:

Utilising the PwC Productivity and Reliability Database we were able to identify the potential output for the

trucks and loaders. We combined industry performance metrics from the PwC database with the information

collected from tray and bucket manufacturers along with site characteristics to analyse every possible option of

truck trays.

Outcomes:

• We provided a recommendation that the current number of trucks was 6 too many for the operation.

PwC

• We provided a recommendation that the current number of trucks was 6 too many for the operation.

• We were able to rank eight trays by value added. The most14,000 times per year * 23 trucks more than the truck supplier’s tray. Theadded $6 million of value per year to the mine compared with selecting the standard tray used by the makeand model truck..

• We recommended the loader bucket capacity to give an optimised number of passes to fill therecommended tray.

Optimising Truck and Loader Match

The mine was purchasing a new fleet of trucks and wanted to choose an optimised tray to fit to the chassis. The

tray market has multiple offerings. The performance of different trays has not been well understood.tray market has multiple offerings. The performance of different trays has not been well understood.

In addition the capacity of the loader bucket which matched the truck trays was to be recommended.

Utilising the PwC Productivity and Reliability Database we were able to identify the potential output for the

trucks and loaders. We combined industry performance metrics from the PwC database with the information

collected from tray and bucket manufacturers along with site characteristics to analyse every possible option of

current number of trucks was 6 too many for the operation.current number of trucks was 6 too many for the operation.

We were able to rank eight trays by value added. The most productive tray moved 14 tonnes per load *14,000 times per year * 23 trucks more than the truck supplier’s tray. The selection of the optimum trayadded $6 million of value per year to the mine compared with selecting the standard tray used by the make

We recommended the loader bucket capacity to give an optimised number of passes to fill the

Case study 3 – The importance of Truck

Ultra-class trucks selection analysis

Challenge:

A mine was looking to upgrade their trucks from 218 tonne class to ultra class (>290t payload). Different

makes and models perform differently. Some mines have acquired too few trucks when upgradingmakes and models perform differently. Some mines have acquired too few trucks when upgrading

output. The aim was to assist the mine make the decision on ultra class trucks which would add most value to

the operation. As material movement carries a value it is really important to select the appropriate equipment

to maximise this value.

High level summary:

Utilising the PwC Productivity and

Reliability Database our team provided a

detailed performance analysis of actual

operating performance of different truck

makes and models and how each of the 60,000

65,000

70,000

75,000

80,000

tkm

/To

nn

eo

fN

om

ina

lC

ap

aci

ty

PwC

makes and models and how each of the

ultra class trucks would be matched with

the loader.

Outcomes:

The analysis allowed the mine to insert actual production rates for different makes and models into their

economic analysis improving the equipment selection process, including truck model, fleet number, tray

capacity appropriate loaders and loaders capacity.

50,000

55,000

1

tkm

/To

nn

eo

fN

om

ina

lC

ap

aci

ty

The importance of Truck Make and Model

A mine was looking to upgrade their trucks from 218 tonne class to ultra class (>290t payload). Different

makes and models perform differently. Some mines have acquired too few trucks when upgrading and had lostmakes and models perform differently. Some mines have acquired too few trucks when upgrading and had lost

output. The aim was to assist the mine make the decision on ultra class trucks which would add most value to

As material movement carries a value it is really important to select the appropriate equipment

Ultra-class trucks

The analysis allowed the mine to insert actual production rates for different makes and models into their

economic analysis improving the equipment selection process, including truck model, fleet number, tray

1 1 1 1 1 2 3 3 4 4 4 4 4 5 5 6 6 6 7 7 7

Make and Model

Appendix B – Thought Leadership

PwC

Thought Leadership

Thought Leadership - 10/10/20 rule

The impact of 10/10/20 rule on truck operations

Challenge:

The 10/10/20 rule says that average payload won’t exceed the nominal OEM stated payload; no more than 10%

of truck loads will be more than 10% over the nominal truck capacity; and none are more than 20% over theof truck loads will be more than 10% over the nominal truck capacity; and none are more than 20% over the

nominal truck capacity. A number of suppliers insist mines agree to this rule as part of the purchase contract

and / or maintenance and repair contracts (MARC).

High level summary:

An analysis of data from the PwC Productivity and Reliability Database demonstrated that 93% of trucks

worldwide fail the rule.

The 7% which pass the rule achieve average payloads 14% below OEM nominated payload

Outcomes:

PwC

Outcomes:

The 93% of trucks which fail this rule (placing them potentially in breach of contract) may face consequencesincluding warranty issues, MARC, health and safety, legal and maintenance.

If a mine makes a genuine attempt to conform to 10/10/20 rule, their trucks will probably end up more than10% below nominal payload on average.

If a mine ignores the 10/10/20 rule, they may void the warranty and MARC arrangements. They may alsoplace the mine in some legal difficulty if a truck has an accident.

10/10/20 rule

The 10/10/20 rule says that average payload won’t exceed the nominal OEM stated payload; no more than 10%

of truck loads will be more than 10% over the nominal truck capacity; and none are more than 20% over theof truck loads will be more than 10% over the nominal truck capacity; and none are more than 20% over the

nominal truck capacity. A number of suppliers insist mines agree to this rule as part of the purchase contract

An analysis of data from the PwC Productivity and Reliability Database demonstrated that 93% of trucks

The 7% which pass the rule achieve average payloads 14% below OEM nominated payload

The 93% of trucks which fail this rule (placing them potentially in breach of contract) may face consequencesincluding warranty issues, MARC, health and safety, legal and maintenance.

If a mine makes a genuine attempt to conform to 10/10/20 rule, their trucks will probably end up more than

If a mine ignores the 10/10/20 rule, they may void the warranty and MARC arrangements. They may alsoplace the mine in some legal difficulty if a truck has an accident.

Thought leadership – The true productivity of our mines

Industry

Challenge:

Most people rely on the publicly available government statistics to determine mine productivity trends.However, this is a narrow representation of whole-of-mine performance and is not indicative of equipmentHowever, this is a narrow representation of whole-of-mine performance and is not indicative of equipmentefficient performance. Equipment performance / output analysis is exclusive to PwC through the Productivityand Reliability Database. This analysis demonstrates the true industry productivity.

High level summary:

The PwC Mining Productivity Index has been developedas a combination of dragline, rope shovel, hydraulicexcavator, front end loader and truck performancereferenced to a value of 100 for 2003 performance. Therelative weighting is based on the amount of materialmoved by each class of equipment worldwide. Theweighting of each has been applied to the performance of

PwC

weighting of each has been applied to the performance ofeach class to give a relative value for each year.

Outcomes:

Mining equipment productivity has decreased 18% since 2007. This trend is observed across all miningjurisdictions. In 2013 equipment productivity dropped 5% compared with 2012. Most mining jurisdictions arefacing challenges in this area.

The breakdown of this analysis provides insight into key areas for mining equipment productivityimprovement. The most important is payload followed by operating time.

productivity of our mines

Most people rely on the publicly available government statistics to determine mine productivity trends.mine performance and is not indicative of equipmentmine performance and is not indicative of equipment

Equipment performance / output analysis is exclusive to PwC through the Productivitydemonstrates the true industry productivity.

The PwC Mining Productivity Index has been developed

referenced to a value of 100 for 2003 performance. The

weighting of each has been applied to the performance ofweighting of each has been applied to the performance of

since 2007. This trend is observed across all miningequipment productivity dropped 5% compared with 2012. Most mining jurisdictions are

The breakdown of this analysis provides insight into key areas for mining equipment productivityimprovement. The most important is payload followed by operating time.

Contacts

Stephen LoadsmanPartner

T: +61 (7) 3257 8304E: [email protected]

Graham LumleyDirector


Laura SeviourSenior Manager


PwC

Agnes FanSenior Analyst


17

www.pwc.com.au

© 2013 PricewaterhouseCoopers. All rights reserved.PwC refers to the Australian member firm, and may sometimes refer to the PwC network.Each member firm is a separate legal entity. Please see www.pwc.com/structure for further details.

Liability is limited by the Accountant's Scheme under the Professional Standards Act 1994 (NSW)

for further details.

Liability is limited by the Accountant's Scheme under the Professional Standards Act 1994 (NSW)

truck and loader dictionary

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