Truck Loader Dictionary Dec13

Truck and
Loader
Dictionary
Second Edition
2013
Truck and Loader
Dictionary
Second Edition
2013
PwC Mining Intelligence and

Benchmarking
Truck & Loader Dictionary T: +61 7 3257 5000 Truck & Loader Dictionary T: +61 7 3257 5000
PwC – Mining Intelligence and Benchmarking Email: graham.lumley@au.pwc.com PwC – Mining Intelligence and Benchmarking Email: graham.lumley@au.pwc.com
Truck and Loader
Dictionary
Second Edition
2013
The First Edition of this Truck and Loader dictionary was started in 2010
and first released in 2012. Many hours were spent sourcing photos and
writing information. It has proved to be very popular and was universally
recognized as being a tremendous resource for anyone working in any
capacity in Truck and Loader operations. We were motivated by the
number of new people working in and around Truck and Loader
operations not being familiar with the terminology and jargon. This
includes operators, supervisors, maintenance personnel, engineers,
managers, contractors and consultants.
Special recognition is given for contribution of content to Jan Eike
Sapper, Trevor Trott, Graham m Lumley and Mark Lewis for making this
dictionary possible.
There will always be variations in terminology across sites and it would be
impossible to capture all of these. We do however continue to encourage
your input. If there is something not included in this dictionary please
Published by send us details and if possible photos. Send to
Graham.lumley@au.pwc.com. Wherever we use information and/or
PricewaterhouseCoopers, ABN 52 780 433 757
photos provided by people outside PwC we will acknowledge this if the
Riverside Centre,, 123 Eagle Street, BRISBANE QLD 4000, GPO Box 150,
entry is printed in future editions. Our aim is to produce the third Edition
BRISBANE QLD 4001
in 2015.
T: +61 7 3257 5000, F: +61 7 3257 5999, www.pwc.com.au
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business. This is core to PwC’s consulting business
b which
Copies available from publisher
provides mining clients with asset benchmarking, productivity
Advertising
g enquiries refer to the publisher
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are appended to the end of this publication.
This is an electronic copy of the publication. Like the Cat Handbook® we Contents
will continue to produce this as an electronic copy as an ongoing resource.
2 Way Radio – A Communication System .................................................................................
................................ 1
3D Dig – Mine Planning Software................................
..............................................................................................2
10/10/20 Rule................................................................
............................................................................................. 3
Access Ramp – Truck Entrance and Exit Road ......................................................................... 5
Access Stairs – Stairway for entry onto the equipment ............................................................6
Adverse Conditions – Dusty, Wet, Inclement or poor visibility ............................................... 7
Alternator – Converts Mechanical Energy to Electrical Energy...............................................
Energy 7
Ancillary Equipment – Equipment that is Associated with the Operation...............................8
Operation
ANSUL Automatic Fire Suppression – Extinguisher System....................................................9
System
ANSUL Automatic Fire Suppression Emergency Switch – Extinguisher System ....................9
Air Filter – Filters Air for the Engine .......................................................................................
................................ 10
Air Horns – Signal Horns .........................................................................................................
................................ 10
Backhoe ................................................................
......................................................................................................11
Bail less attachment – Connects the hoist ropes to the dipper(bucket) on a rope
shovel ................................................................
.....................................................................................................11
Bail-less Connection at Rear of Dipper .....................................................................................11
................................
Bail Arm (or just Bail) – Connects the hoist ropes to the dipper (bucket) ............................. 12
Batter – The Slope of the High or Low Wall ............................................................................ 13
Batter Cleaning – Cleaning of a highwall batter ...................................................................... 14
Battery – Electric Energy Storage ............................................................................................
................................ 14
BCM/BCY – Bank Cubic Metre/Yard................................
....................................................................................... 15
Bench – A Levelled Area where Mining Equipment Operates ............................................... 15
Bench Width................................................................
.............................................................................................. 16
The Bench Grade – Grade of bench ..........................................................................................17
................................
Example of working on a grade .................................................................................................17
................................
The Bench Height – Height of bench .......................................................................................
................................ 18
Benchmark Loading Unit – A Measure of Performance and Productivity ............................. 19
Benchmark for Truck Fleets – A measure of Performance P and Productivity .........................23
BER – Bucket Efficiency Ratio .................................................................................................28
................................
Berm – A Bund or mound of Material Placed near the Edges of an Excavat ion ....................29
BEST Practice – The Average of the Top 10% of Equipment in the PwC Mining
Production and Time Utilisation Database..........................................................................30
Database
The PwC database ................................................................
..................................................................................... 31
Blasting – Controlled Firing of Explosives to Break Rock......................................................32
Rock
Blast patterns – Designed to provide the correct broken rock size s or break up coal .............32
Blind Spot – Areas where operator’s or driver’s visibility is blocked ......................................33
Bogged equipment – Stuck................................
.......................................................................................................34
Boom point sheaves – The Pulleys that Guide the Hoist Ropes round the Top End
of the Boom ................................................................
...........................................................................................34
Bottom Loading – Truck Positioning .......................................................................................
................................ 35
Boom Jacking – Rope Shovel ...................................................................................................
................................ 35
Bottom Loading @90° - Truck Positioning................................
..............................................................................36 CAT (Unit Rig) MT4400 – Dump Truck ..................................................................................
................................ 73
Bottom Loading @45° – Over the Tail .....................................................................................36
................................ CAT (Unit Rig) MT5500 – Dump Truck ..................................................................................
................................ 74
Box Cut – The initial excavation that is dug when opening up a new pit ............................... 37 CAT (Unit Rig) MT6300 – Dump Truck ..................................................................................
................................ 75
Brakes................................................................
........................................................................................................38 CCTV – Machine cameras ........................................................................................................
................................ 76
Brake Oil reservoir & Level indicator – Indicates oil level ......................................................39 Circuit Control ................................................................
.......................................................................................... 76
Bucket – Loading/digging device .............................................................................................40
................................ Clean-up Outside Swing Radius – Spillage ..............................................................................
................................ 77
Bucket Spotting Time – Digging ..............................................................................................
................................ 41 Clean-up Inside Swing Radius – Spillage ................................................................................78
................................
Bucket Tooth – Cutting Tip that is pinned to the Adaptor ..................................................... 41 Climbing Up Work Benches – Procedure ................................................................................
................................ 79
Bund/Rill/Berm – See Windrow................................
..............................................................................................42 Controls – All Machines ..........................................................................................................
................................ 80
Cab - Operators Cabin ................................................................
..............................................................................42 CPP/ CHPP – Coal (handling) preparation plant .................................................................... 81
Refer to Operators Cab in the Dictionary................................
.................................................................................42 Coal - A Fossil Fuel consisting of Carbonised Vegetable Matter. ........................................... 81
Cable Access - Roadway for Cable ............................................................................................43
................................ Coal Edge – The Extent of the Exposed Coal on the Low Wall Side .......................................82
Cable Crossing – Portable Power Cable Protection Equipment .............................................44 Coal floor clean-up – Minimises coal contamination with unwanted spoil ...........................83
Cable Layout – Storing excess cable ........................................................................................
................................ 45 Coal Mining – Digging, Loading and Transporting the Coal ..................................................84
Cable Plug Stands – Keeps Cable Plugs off the Ground .........................................................46 Coal Recovery Measurement Trenches – Comparing geological predictions and
Cable – Power Lead that delivers Power to a Rope Shovel .................................................... 47 actual coal seam thickness................................
....................................................................................................85
Cable Reel Cable storage directly attached to some Electric Rope Shovels ............................48 Coal Reject Silo/ Bin – Storage area of unwanted wash plant material for removal
Cable Towers - Cable trees................................
........................................................................................................49 by dump truck................................................................
.......................................................................................85
Capital Cost ................................................................
...............................................................................................49 Collision Avoidance – Minimum distance to be maintained between equipment .................86
Carry Back – Material stuck in truck trays ..............................................................................50
................................ Collision Avoidance driving – Minimum distance between equipment .................................86
CAT 777 – Dump Truck ............................................................................................................
................................ 51 Compressed Air Tank – Holds the Supply of Compressed Air...............................................88
Air
CAT 785 – Dump Truck................................
............................................................................................................ 52 Cooling fan motor – Electric motor cooling ............................................................................89
CAT 789 – Dump Truck................................
............................................................................................................ 53 Counterweight – Balance................................
..........................................................................................................89
CAT 793 – Dump Truck................................
............................................................................................................ 54 Crowd – Force applied to load .................................................................................................90
................................
CAT 795 – Dump Truck ............................................................................................................
................................ 55 Cycle efficiency – Optimal cycle time efficiency ciency ......................................................................90
CAT 797 – Dump Truck ............................................................................................................56
................................ Cycle time (truck) – Time to complete a full cycle..................................................................
cycle 91
CAT 992 – Front End Loader ...................................................................................................
................................ 57 Cycle time (loading unit) – Load time from truck to truck ..................................................... 91
CAT 993K – Front End Loader ................................................................................................58
................................ Defect Reporting – Reporting of defects on machinery .........................................................92
CAT 994 – Front End Loader ...................................................................................................59
................................ Delay – Maintenance Delay Scheduled ....................................................................................93
................................
CAT5130B – Hydraulic Shovel/Excavator ...............................................................................60
................................ Delay – Maintenance Delay Unscheduled ...............................................................................93
................................
CAT5230B – Hydraulic Shovel/Excavator ..............................................................................
................................ 61 Delay – Standby................................................................
........................................................................................95
CAT6015 (RH40E) – Hydraulic Shovel/Excavator .................................................................62 Demag H285 – Hydraulic Shovel................................
.............................................................................................96
CAT6030 (RH120E) – Hydraulic Shovel/Excavator...............................................................63
Shovel/Excavator H285 Demag Hydraulic Shovel ................................................................................................96
................................
CAT6040 (RH170B) – Hydraulic Shovel/Excavator ...............................................................64 DER – Dipper Efficiency Ratio................................
.................................................................................................96
CAT6050 (RH200) – Hydraulic lic Shovel/Excavator ................................................................65 Dig Face – Digging area................................
............................................................................................................ 97
CAT6060 (RH340B) – Hydraulic Shovel/Excavator ..............................................................66 Dig Plan – How the pit will be dug................................
........................................................................................... 97
CAT6090 (RH400) – Hydraulic Shovel/Excavator ................................................................ 67 Dig Techniques (Sequence) – Common techniques ................................................................98
CAT (Unit Rig) MT3000 – Dump Truck................................
..................................................................................68 Diggability – Fragmentation analysis ......................................................................................99
................................
CAT (Unit Rig) MT3300 - Dump Truck ...................................................................................69
................................ Dip – Slope of the Coal Seam .................................................................................................100
................................
CAT (Unit Rig) MT3600 - Dump Truck ...................................................................................70
................................ Dilution – Contamination in a mineable seam. ......................................................................101
CAT (Unit Rig) MT3700 – Dump Truck ...................................................................................71
................................ Dipper – Rope Shovel Bucket .................................................................................................
................................ 102
CAT (Unit Rig) MT4000 – Dump Truck................................
.................................................................................. 72 Dipper Crowd – Electric rope shovel arm ..............................................................................
................................ 103
Dipper Door – Rope Shovel Bucket Door ..............................................................................
................................ 104 Face Width ................................................................
.............................................................................................. 133
Dipper Door Hinges – Dipper door pivots to open and close ............................................... 105 Failure – Unstable Wall or parts of it .....................................................................................
................................ 134
Dipper Door locking mechanism – Rope ope Shovel Bucket Door Lock.....................................
Lock 105 Fatigue................................................................
..................................................................................................... 135
Dipper Depth ................................................................
.......................................................................................... 106 Fatigue Incident ................................................................
...................................................................................... 136
Dipper Height/width ................................................................
.............................................................................. 106 Fault – A Fracture Zone in the Overburden .......................................................................... 137
Distance from face ................................................................
.................................................................................. 107 Fill................................................................................................
............................................................................ 138
Double benching – Loading technique ..................................................................................108
................................ Fitness for work ................................................................
...................................................................................... 138
Double Sided Loading – Loading with trucks either side ..................................................... 109 Fire suppression and emergency shut down..........................................................................
down 139
Downtime – Delay ................................................................
...................................................................................110 Fire Suppression Bottle – Storage container for fire suppressant ........................................ 139
Dozer – A Tracked or Rubber Tyred Machine ........................................................................ 111 Float – Lowbed/Flatbed/Transporter................................
.................................................................................... 140
Drill Rig – Device for drilling blast holes ................................................................................112
................................ Fragmentation – How well the material is shot .....................................................................141
Drill and Blast Areas – Area prepared for blasting................................................................113
blasting Free Dumping – Block Tipping ..............................................................................................
................................ 142
Drive-by Loading – Sequence .................................................................................................114
................................ Freeboard ................................................................
................................................................................................ 142
Drive-by observation on crest – Checking condition of tip head ...........................................115 Front End Loader – (FEL)................................
...................................................................................................... 143
Dump Area Maintenance – Keeping dumping area in good condition .................................115 Front End Loader – Controls .................................................................................................
................................ 144
Dump Area Sequence – Dump area strategy ..........................................................................116 Below is an example of the controls. ......................................................................................
................................ 144
Dump Site Maintenance ..........................................................................................................116
................................ Front End Loader – Filling cycle ............................................................................................
................................ 145
Dumping – Unloading material ..............................................................................................
................................ 117 Front End Loader – Loading from a stockpile.......................................................................
stockpile 146
Dumping Phase................................................................
........................................................................................ 117 Front End Loader – Loading technique .................................................................................
................................ 147
Dump – Placing of waste into spoil piles ................................................................................118
................................ Front End Loader – Schematic ..............................................................................................
................................ 148
Dust – Control of dust ................................................................
.............................................................................119 Fuel Burn Rate – Rate of fuel burn on the T&L Fleet ........................................................... 149
Electronic Monitoring System – EMS................................
.....................................................................................119 Fuel Filter – Filters fuel (Truck)................................
............................................................................................. 150
Elephant Skid – Highwall Power Cable Protection Equipment ............................................ 120 Fuel Tank – Diesel Storage................................
..................................................................................................... 150
Emergency Steering Switch – Activates emergency steering pump ..................................... 120 Fuel Tank Sediment Drain Valve – Drain valve .....................................................................151
Emergency Stop – Excavator/Shovel ......................................................................................121
................................ PwC – Worldwide Productivity and Reliability Database .................................................... 152
Emergency Stop – Truck .........................................................................................................121
................................ PwC – Productivity Philosophy ..............................................................................................
................................ 152
Engine Block – Engine ...........................................................................................................
................................ 122 Fill the bucket up & do it more often................................
...................................................................................... 152
Equivalent Annual Production ...............................................................................................
................................ 123 Gear leaver – Trucks................................................................
............................................................................... 153
Esco – Bucket and GET Manufacturer................................
................................................................................... 124 Geology – The structure of the earth................................
...................................................................................... 153
Excavator – Controls ................................................................
.............................................................................. 125 Geotechnical hazards................................................................
.............................................................................. 154
N (Neutral): The machine stops .............................................................................................
................................ 125 Geotechnical failure – Geotechnical interpretation, cracks or previous failure fail ................... 155
Excavator – Loading unit .......................................................................................................
................................ 125 Geotechnical failure – Crest Failure................................
....................................................................................... 156
Excavator – Schematic ...........................................................................................................
................................ 126 Geotechnical................................................................
............................................................................................ 156
Excavator Boom – Boom attachment ....................................................................................
................................ 126 Geotechnical failure – Foundation Failure ............................................................................
................................ 158
Excavator Bucket – Bucket attachment .................................................................................
................................ 127 G.E.T – Ground Engaging Tools ............................................................................................
................................ 160
Excavator – Lock Lever ..........................................................................................................
................................ 127 GPS Antenna – Global Positioning System................................
............................................................................ 160
Excavator Stick – Attachment ................................................................................................
................................ 128 Gravel – Surface Material for Roadways................................
.................................................................................161
Excavator Undercarriage – Walking mechanism .................................................................. 129 Grease lines – Carry hydraulic fluid................................
........................................................................................161
Exhaust Pipes – Exhaust outlet ..............................................................................................
................................ 130 Guide Post – Delineates Roadways ........................................................................................
................................ 162
Face Maintenance/Clean-up – Floor clean up.......................................................................
up 130 Gyratory Crusher – Rock breaker ..........................................................................................
................................ 162
Face Height – Optimal height .................................................................................................131
................................ Hang time – Wait vs. Queue time ..........................................................................................
................................ 163
Face Shovel................................................................
.............................................................................................. 132 Hard Dumping – Dumping technique ...................................................................................
................................ 164
Hauling................................................................
.................................................................................................... 165 Hydraulic Face Shovel – Machine ..........................................................................................203
................................
Haul road – Crossfall................................................................
.............................................................................. 166 Hydraulic Face Shovel – Bucket .............................................................................................204
................................
Haul road – Design................................................................
................................................................................. 167 Hydraulic Face Shovel – Schematic .......................................................................................205
................................
Haul Road Maintenance – Strategy .......................................................................................
................................ 169 Hydraulic Pump – Pressurises Hydraulic Fluid ....................................................................206
Haul road – Superelevation (Camber) ...................................................................................
................................ 170 Hydraulic Tank – Hydraulic Fluid Storage ............................................................................207
................................
Haul Road Undulation – Soft areas ........................................................................................
................................ 171 Idle Time – A stoppage when the operator fails to enter a delay into the monitor ..............207
Hazard – Something which may result in injury or harm ..................................................... 172 Idler – Undercarriage ................................................................
............................................................................ 208
Heel Wear (dipper) – Damage to the heel of a dipper caused by the tooth attack Inclinometer – Measures angles ...........................................................................................
................................ 208
angle ................................................................
.................................................................................................... 172 Isolation Station – A System to Positivelyy Remove Power....................................................209
Power
High wall – Wall left in undug overburden ........................................................................... 173 Joy Stick – Steering control................................
.................................................................................................... 210
High Wall failure – Unstable Wall or parts of it .................................................................... 174 Komatsu 630E 685E 730E – Dump Truck .............................................................................211
................................
Historical Data – Information from previous strips.............................................................
strips 174 Komatsu 830E-AC – Dump Truck .........................................................................................
................................ 212
Hitachi EH1600 – Dump Truck ..............................................................................................175
................................ Komatsu 860E – Dump Truck ...............................................................................................
................................ 213
Hitachi EH1700 – Dump Truck .............................................................................................
................................ 176 Komatsu 930E – Dump Truck ...............................................................................................
................................ 214
Hitachi EH3000 – Dump Truck .............................................................................................177
................................ Komatsu 960E – Dump Truck ...............................................................................................
................................ 215
Hitachi EH3500 – Dump Truck .............................................................................................
................................ 178 Komatsu (Demag) H285 – Hydraulic Shovel/Excavator ...................................................... 216
Hitachi EH4000 – Dump Truck ............................................................................................
................................ 179 Komatsu (Demag) H485 – Hydraulic Shovel/Excavator ...................................................... 217
Hitachi EH4500 – Dump Truck................................
.............................................................................................180 Komatsu (Demag) H655 – Hydraulic Shovel/Excavator ...................................................... 218
Hitachi EH5000 – Dump Truck .............................................................................................181
................................ Komatsu HD465 – Dump Truck ............................................................................................
................................ 219
Hitachi EX1800 – Hydraulic Shovel/Excavator .................................................................... 182 Komatsu HD785 – Dump Truck ............................................................................................220
................................
Hitachi EX1900 – Hydraulic Shovel/Excavator .................................................................... 183 Komatsu HD985 – Dump Truck ............................................................................................
................................ 221
Hitachi EX2500 – Hydraulic Shovel/Excavator ................................................................... 184 Komatsu HD1500 – Dump Truck ..........................................................................................222
................................
Hitachi EX3500 – Hydraulic Shovel/Excavator ................................................................... 185 Komatsu PC1800 – Hydraulic Shovel/Excavator..................................................................223
Shovel/Excavator
Hitachi EX3600 - Hydraulic Shovel/Excavator .................................................................... 186 Komatsu PC2000 – Hydraulic Shovel/Excavator .................................................................224
Hitachi EX5500 – Hydraulic Shovel/Excavator....................................................................
Shovel/Excavator 187 Komatsu PC3000 – Hydraulic Shovel/Excavator .................................................................225
Hitachi EX8000 – Hydraulic Shovel/Excavator ................................................................... 188 Komatsu PC4000 – Hydraulic Shovel/Excavator .................................................................226
Hitachi R90 – Dump Truck ....................................................................................................
................................ 189 Komatsu PC5500 – Hydraulic Shovel/Excavator ................................................................. 227
Hitachi R100 – Dump Truck ..................................................................................................
................................ 190 Komatsu PC8000 – Hydraulic Shovel/Excavator .................................................................228
Hitachi R120E – Dump Truck .................................................................................................191
................................ Komatsu WA800 – Front End Loader ...................................................................................229
................................
................................ 192 Komatsu WA900 – Front End Loader ...................................................................................230
................................
................................ 193 Komatsu WA1200 – Front End Loader .................................................................................
................................ 231
................................ 194 KPI – Key Performance Metrics .............................................................................................232
................................
................................ 195 Kress Coal Hauler – Unit body coal truck ..............................................................................233
................................
Hitachi R220 – Dump Truck................................
.................................................................................................. 196 Letourneau L 950 – Front End Loader (Now owned by Joy Global)....................................234
.................................................................................................. 197 Letourneau L 1100 – Front End Loader (Now owned by Joy Global) ..................................235
.................................................................................................. 198 Letourneau L 1150 – Front End Loader (Now owned by Joy Global)...................................236
Hoist Control Lever – Truck Tray Control .............................................................................
................................ 199 Letourneau L 1350 – Front End Loader (Now owned by Joy Global) .................................. 237
Hoist Cylinder/ram – Raises Tray to Dump Position .......................................................... 200 Letourneau L 1400 – Front End Loader (Now owned by Joy Global)..................................238
Hoist Ropes – Control rol Vertical Bucket Movements (Rope Shovel) ...................................... 201 Letourneau L 1800 – Front End Loader (Now owned by Joy Global) ..................................239
Host Rock – Waste ................................................................
................................................................................. 201 Letourneau L 1850 – Front End Loader (Now owned by Joy Global) ..................................240
Hydraulic Drive – Propels the Tracks ....................................................................................202
................................ Letourneau L 2350 – Front End Loader (Now owned by Joy Global) .................................. 241
Hydraulic Filters – Clean Hydraulic Fluids ...........................................................................202 Liebherr 994 – Hydraulic Shovel/Excavator .........................................................................242
Liebherr 995 – Hydraulic Shovel/Excavator .........................................................................243 P&H 4100 XPC – Rope Shovel ...............................................................................................
................................ 277
Liebherr 996 – Hydraulic Shovel/Excavator .........................................................................244 Park-up – Go – No Go lines ...................................................................................................278
................................
Liebherr 9250 – Hydraulic Shovel/Excavator .......................................................................245 Park Up Area Guide – Go – No Go line .................................................................................278
................................
Liebherr 9350 – Hydraulic Shovel/Excavator .......................................................................246 Parking – Waiting for water truck................................
.......................................................................................... 279
Liebherr 9400 – Hydraulic Shovel/Excavator el/Excavator ...................................................................... 247 Payload – The Amount of Material the tray carries to dump ................................................ 279
Liebherr 9800 – Hydraulic Shovel/Excavator ......................................................................248 Payload – Optimal load .........................................................................................................
................................ 280
Liebherr KL2420 KL2450 KL2680 – Dump Truck...............................................................249
Truck Payload – Sub-optimal load ...................................................................................................
................................ 281
Liebherr T252 & T262 – Dump Truck ...................................................................................250
................................ Payload Distribution – Truck Tray................................
.........................................................................................282
Liebherr T282 – Dump Truck ................................................................................................
................................ 251 Payload Indicator Lights – Payload lights .............................................................................283
................................
Liebherr TI 272 & TI274 – Dump Truck ................................................................................252
................................ Payload meter – Displays the weight of the loaded material in the t truck ............................284
Lighting Plant................................................................
..........................................................................................253 Payload weight display – Displays the weight of the loaded material ..................................285
Load Position on Trucks .........................................................................................................254
................................ Pit Design – Pit planning................................
........................................................................................................286
Loading – Precautions................................................................
............................................................................ 255 Pit Shape/Mine Planning Considerations ..............................................................................286
................................
Loading Techniques – Sequences ..........................................................................................256
................................ Pit Ramp – Roadway to Access the Pit................................
...................................................................................287
Lockout – Regulations................................................................
............................................................................ 257 Pitch Braces – Dipper Tooth Attack Angle Adjuster ............................................................ 288
Low-Wall Scavenging – Coal recovery ...................................................................................
................................ 257 Pivot Point/Nip Point – FEL .................................................................................................
................................ 288
Low Wall – Spoil Side Wall of the Excavation .......................................................................258 Plan and Prepare for Operations – Prior to conducting any an work........................................289
Lube System – Applies Lubricant ..........................................................................................259
................................ PLC – Engine Saver ................................................................
................................................................................289
Lubrication Chart – Machine specs .......................................................................................259
................................ PPE – Personnel Protective Equipment................................
.................................................................................290
Lubrication controller – Systems ...........................................................................................260
................................ Pre-Shift Briefing /Tool Box Meetings – Safety ....................................................................290
Matching – Truck matching to the shovel .............................................................................260
................................ Pre-Split Drill Hole Barrel – Drill hole marks on the excavation wall after blasting ........... 291
Mine strategy – Basic Strategies ............................................................................................
................................ 261 Pre-Start – During Shift and End of Shift Checks/Inspections ............................................292
Minerals – Excavation of a Resource .....................................................................................262
................................ Pre-Strip – Removal of waste/overburden material .............................................................292
Mining – Excavation of a Resource ........................................................................................262
................................ Procurement of buckets/dippers................................
............................................................................................293
Modified Drive-By Loading – Sequence ................................................................................263
................................ Propelling Up and Down Haul Roads – Operation ...............................................................294
Mounting and Dismounting – Getting on and off machinery...............................................264
machinery Queuing – Waiting position ...................................................................................................295
................................
Near Side Loading – Loading on Driver Side ........................................................................264 Radiator – Heat Exchanger ....................................................................................................296
................................
OEM – Original Equipment Manufacturer................................
............................................................................265 Radiator Header – Storage for cooling liquid ........................................................................ 297
Offside Loading – Loading on Blind Side ..............................................................................265
................................ Ramps................................................................
...................................................................................................... 297
Oil Sands – Tar Sands................................................................
.............................................................................266 Rated capacity – Designated capacity of buckets ..................................................................298
On-board fires – All equipment .............................................................................................
................................ 267 Rehabilitation/Reclamation – Re-establishing establishing the Waste Spoil Heaps to a Stable
Operator – Obligations and Roll ............................................................................................268
................................ and Productive Landform................................
...................................................................................................299
Operators Cabin – Control Centre of an Excavator ...............................................................269 Relative Density – RD................................................................
............................................................................ 300
Operating Cost ................................................................
........................................................................................269 Refer to Specific Gravity in this Dictionary................................
........................................................................... 300
Opportunity Cost ................................................................
....................................................................................270 Reliability – How long the Loader/Truck keeps Running ................................................... 300
Ore Body................................................................
.................................................................................................. 271 Reject Bin gate opener – Opens Reject bin remotely ........................................................... 301
Overextending crowd – Rope Shovel .....................................................................................
................................ 272 Report – To give Information.................................
................................................................................................302
Overloading – Trucks ................................................................
............................................................................. 273 Retarder – Braking lever ........................................................................................................303
................................
P&H 2800 XPA – Rope Shovel ..............................................................................................
................................ 274 Retard Grid – Cooler ................................................................
..............................................................................304
P&H 2800 XPA rope shovel ...................................................................................................
................................ 274 Retarder – Non-friction Braking System ...............................................................................304
................................
P&H 4100 A– Rope Shovel .....................................................................................................
................................ 275 Returning Phase – Operational ..............................................................................................305
................................
P&H 4100 XPB – Rope Shovel ...............................................................................................
................................ 276 Right Hand Operators Console – Cab ....................................................................................306
................................
Rill – Prevents truck from unwanted rolling .........................................................................306 Spoil – All ll Material removed from above a mineable seam ..................................................339
Rimpull – Force ................................................................
......................................................................................307 Spotting – Precautions ...........................................................................................................340
................................
An example of a Rimpull Chart ..............................................................................................307
................................ Spotting – Techniques ................................................................
............................................................................340
Rock Ejector – Removes rocks caught between tyres .......................................................... 308 Spotting for Top Loading @ 45° – Techniques......................................................................
Techniques 341
Roll – Material build up from the digging process ................................................................309 Spotting at 45˚ – Techniques .................................................................................................342
................................
Roll levelling – Levelling bench .............................................................................................309
................................ Reason same as loading 45 .....................................................................................................342
................................
Rolling Resistance – Resistance created by the interaction between the trucks tyres Spotting at 90˚ – Techniques .................................................................................................343
................................
and the haulroad................................................................
................................................................................. 310 Spotting at 90˚ – Incorrect Positioning .................................................................................344
................................
ROM Area – Run-of-Mine ......................................................................................................
................................ 312 Start-up Procedure ................................................................
.................................................................................344
ROM Stockpile – Run-of-Mine Buffer ...................................................................................
................................ 313 Steering system ................................................................
.......................................................................................345
Rope Shovel A-Frame – The anchor for the boom ................................................................ 314 Stockpile stacking/accumulation – Building manageable stockpile.....................................346
stockpile
Rope Shovel Boom – Attachment ..........................................................................................
................................ 315 Stoppages – Productivity ........................................................................................................
................................ 347
Rope Shovel Boom Suspension Ropes – The Wire Ropes that t Hold and Support the Strategy ................................................................
...................................................................................................348
Boom and Load.................................................................
.................................................................................. 316 Strike length................................................................
............................................................................................350
Rope Shovel – Fill Cycle .........................................................................................................
................................ 317 Stripping – Removing of overburden waste or spoil .............................................................350
Rope Shovel – Forces applied ................................................................................................
................................ 318 Stripping Ratio................................................................
........................................................................................ 351
Rope Shovel – Machine ..........................................................................................................
................................ 318 Struck capacity................................................................
........................................................................................ 351
Rope Shovel – Schematic .......................................................................................................
................................ 319 Stub Line –A Feeder Power Line................................
............................................................................................ 351
Rope Shovel Tracks – Travelling device................................
................................................................................. 319 Suspension – Shock Absorber (truck)................................
....................................................................................352
Roster – A Truck and Loader Crew’s Working Arrangement ...............................................320 Swell –The
The Enlargement of the Insitu Overburden after Blasting ........................................352
Safety Zone/Collision Avoidance – Safety .............................................................................
................................ 321 Swell Factor – The Percentage of Enlargement of the Insitu Overburden after
Scaling Batters – Removing loose material from a wall ........................................................322 Blasting ................................................................
...............................................................................................353
Scale Shovel – 1:7 th RB22 .......................................................................................................323
................................ Swing Arc Efficiency ................................................................
...............................................................................353
Selecting the “Right” Trucks for a Mine .................................................................................324
................................ Swing Clearance................................................................
......................................................................................354
What is the problem?................................................................
..............................................................................324 Swing Drive ................................................................
............................................................................................. 355
Variation in Truck and Loader Performance .........................................................................324 Swinging Phase ................................................................
.......................................................................................356
Service Roads – Light vehicle access................................
......................................................................................325 Swinging Rack and Roller Assembly – swing bearing and revolving frame ......................... 357
Service refill fittings rack – Lube ...........................................................................................326
................................ Switchbacks – Zigzag................................................................
.............................................................................. 357
SG – Specific Gravity ................................................................
..............................................................................326 Tags ................................................................
.........................................................................................................358
Shale – Fine grained material usually found as an intra-seam intra or on top of a coal Talpac – Truck & Loader Productivity Estimation Software................................................360
Software
seam. ................................................................
................................................................................................... 327 Tail gate – Stops spillage and increases body capacity..........................................................
capacity 361
Shift – A Crew Working a Roster ...........................................................................................
................................ 327 Terex (Dart) 3100 33100 – Dump Truck ...............................................................................362
................................
Shot ground – Blasted Overburden .......................................................................................328
................................ Terex (Dart) 3311 – Dump Truck ...........................................................................................363
................................
Shovel Dipper Modelling ........................................................................................................329
................................ Terex (Dart) 4150 4160 – Dump Truck................................
..................................................................................364
Simulator – A Test Device that Simulates Actual Conditions ...............................................330 Terex (Titan) 3315C 3315D – Dump Truck ............................................................................365
................................
Single Side Loading – Techniques .........................................................................................
................................ 331 Terex TR100/100DD – Dump Truck .....................................................................................366
................................
Single Bench – Loading technique .........................................................................................333
................................ Tip head edge/ Tip head stability ...........................................................................................
................................ 367
Soft Dumping Techniques – Techniques ...............................................................................334
................................ TKPH – Tonne Kilometre per Hour .......................................................................................368
................................
Specification Sheet – Machine ...............................................................................................335
................................ Toe – The Bottom of a Batter or Face ....................................................................................369
................................
Speed Limits – Safety ................................................................
.............................................................................336 Tooth Adaptor – Fitted to the Nose of the Bucket .................................................................370
Spillage ................................................................
.................................................................................................... 337 Tooth attack angle................................................................
................................................................................... 371
Split Benching – Loading technique ......................................................................................338
................................ Tooth Coverage – Percentage of the lip which is made up of teeth ...................................... 371
Top Loading ................................................................
............................................................................................ 372 Wire rope – Consists of several strands laid together like a helix .........................................407
Topsoil – The Dirt on the Surface that Grows Vegetation .................................................... 373 Witches Hats – Reflective Safety Cones for Demarcation ................................................... 408
Tracks (Continuous tracks or machine tracks) – Providing motion traction ....................... 374 Working Zones ................................................................
....................................................................................... 408
Trainee – Person Learning to Operate a Machine ................................................................. 375
Tramming – Moving the loader .............................................................................................
................................ 375
Truck & Loader Operations ....................................................................................................
................................ 376
Truck – Controls ................................................................
..................................................................................... 377
Truck Optimisation................................................................
.................................................................................378
Truck Payload ................................................................
......................................................................................... 379
Trucking – Truck matching to the shovel ..............................................................................
................................ 381
Truck Air Filter Indicators – Indicates the filter condition..................................................382
condition
Truck Forces – Forces on the Truck in operation .................................................................383
Truck parking bay ................................................................
...................................................................................383
Truck PLM (Payload Meter) – Measures the loaded Material .............................................383
Truck Positioning................................................................
....................................................................................384
Truck Spotting guide – A device to assist truck drivers ........................................................385
Truck Tow Pin ................................................................
.........................................................................................386
Truck Tray (Bed) – Carries Material on the chassis ..............................................................386
Truck Tray – Capacity................................................................
.............................................................................386
Truck tray cleaning – Reducing carry back................................
........................................................................... 388
Truck Tray Hoist Ram Pivot Point .........................................................................................389
................................
Tyres ................................................................
........................................................................................................389
Tyre Damage ................................................................
...........................................................................................390
Tyre management reports ......................................................................................................
................................ 391
Tyre Overheating ................................................................
....................................................................................392
Tyre Rim................................................................
..................................................................................................393
Tyre Safety................................................................
...............................................................................................394
Tyre Tread – Maintains traction with haulroad ....................................................................395
Ultra Class Trucks................................................................
...................................................................................396
Undercarriage – bottom deck................................
.................................................................................................396
Undercutting a Face above the bench ....................................................................................
................................ 397
Undercutting a Face below the bench ....................................................................................398
................................
Vienna Test System................................................................
.................................................................................399
Vital Information Management System (VIMS)...................................................................
(VIMS) 400
Volume – The Amount of waste in an area ...........................................................................
................................ 400
Void (dipper) – Volume in bucket which is not filled............................................................
filled 401
Wait On Truck (Hang Time) – Reporting ..............................................................................402
................................
Wait On Loader (reporting)................................
....................................................................................................403
Walk Around Inspection................................
........................................................................................................ 404
Wash bay – Machine................................................................
.............................................................................. 406
Wheel lock ring ................................................................
...................................................................................... 406
Windrow/Berm – Physical Barrier ........................................................................................407
................................
2 Way Radio – A Communication System 3D Dig – Mine Planning Software
Two way radios are used extensively on a mine site. Most Truck 3dDig is a software program for three dimensional planning of mining
min
operations have hand held 2 ways with a dedicated channel for the Truck operations. It has a unique rilling algorithm which allows Digital Terrain
personnel to use for local communication. Some of these 2 ways are UHF Models (DTM’s) to be dug (modified in the computer) and the spoil
and some VHF, both th either one with a dedicated channel are a very useful dumped. It is marketed by Earth Technology Pty Ltd.
and necessary means for the crew to keep in contact with each other
during operations. Safety issues was the main instigator to having hand
held radios available to the crew, as in large mines, the traffic
t on the
radios are exceptionally heavy, and with this means of communicating,
especially with crew downsizing, more positive contact is available.
Portable or
Hand-held 2
Way Radio
Fixed 2 Way
Radio
PwC – Mining Intelligence and Benchmarking Email: graham.lumley@au.pwc.com 1 PwC – Mining Intelligence and Benchmarking Email: graham.lumley@au.pwc.com 2
10/10/20 Rule The fact is that some suppliers are using the 10/10/20 policy in support of
warranty considerations and maintenance and repair contracts (MARC’s)
for Mining Trucks.
Some truck OEM’s will push the 10/10/20 rule.
r The 10/10/20 rule means
that the average payload won’t exceed the nominal OEM stated payload; A genuine attempt to conform to this rule will result in average payloads
no more than 10% of the loads will be more than 10% above average and not achieving the nominal payload. This is because the distribution of
none (0%) will be more than 20% over the nominal load. payload is inevitably flatter than what is required to meet this rule and
achieve average payload.
A genuine attempt to conform to this rule will result in average payloads
being well below the nominal payload. Consider the following real worldwide statistics for mining trucks
Technically, any overload could adversely affect component life, tyres,  22% of trucks exceed OEM nominated payload on average
chassis, and potentially affect steering & braking performance. The
question is, “What is the relationship
tionship between fatigue life and loading?”  63% of trucks fail the 10% overload rule (ie. they have more than
Fatigue life is a fixed amount and is continually used. The higher the 10% of payloads more than 10% over nominal payload)
loading, the quicker fatigue life is used (and micro cracks become macro  91% of trucks fail the 20% overload rule (ie. they have recorded
cracks which become life-limiting).
limiting). If the overloading is severe enough,
e payloads more than 20% over nominal payload)
the truck may be unsafe to operate.
 Only 7% pass 10% and 20% rules but these 7% achieve average
Some Cat research demonstrates that component life decreased
payloads 14% below OEM nominated payload.
significantly when overloaded 10% to 20%. The rate at which component
life decreased as a result of overloading is greater than the rate at which So what should a mine do? The options are;
componentnent life increased as a result of underloading. Cat provide a few
1. Make a genuine attempt to conform to 10/10/20 rule. The result
basic rules of thumb related to component life vs. payload. First, engine
will be that you will probably end up more than 10% below
life is directly related to fuel burn. If payload is increased, the truck gets
nominal payload on average. Now this is OK if you know and you
heavier creating a higher duty cyclee resulting in greater fuel burn and
can specify your equipment around this knowledge; but mines
shorter life. The torque converter and transmission life are related to
haven’t known
torque and again as payload is increased the truck gets heavier. More
torque is required to move a heavier truck resulting in shorter torque  Currently,
rrently, potential warranty and/or MARC issues for 93% of
converterter and transmission life. The lower powertrain life is related to trucks.
load and speed. A heavier truck puts more load on the lower powertrain
and again the results is a decrease in component life. 2. Ignore the 10/10/20 rule. The result of this approach is that you
will probably end up voiding warranty and MARC arrangements.
The unclear and unstated issue is the impact of factors such as haul road You also place yourself in some legal difficulty if a truck has
h an
characteristics, operator characteristics, load positioning, etc. Certainly, accident (and there are potential safety issues) and you can be
with draglines, where there is the most data and analysis, damage is shown to have not conformed to the 10/10/20 rule.
heavily impacted by what the operator is doing and not so much by the
load being carried. There appears
ppears to be a likelihood that the same will The industry needs a rethink on trucks and how they are designed and
apply with trucks. Consequently, there is some doubt that the impact of specified. Mines currently have the option of taking a hit on performance
pe
minor overloading is significant compared with what the truck is doing and costs or voiding warranties and MARC contracts and even ending up
and by extension the relevance of the 10/10/20 rule to damage and safety.
s in court.
However, it is part of some purchase contracts which means it is relevant Each mine purchasing trucks and loaders must consider this issue very
and you have to consider it. seriously.
Access Ramp – Truck Entrance and Exit Access Stairs – Stairway for entry onto
Road the equipment
This enables trucks, light vehicles and
an other machinery to access the There are a number of access stairs in and around mining equipment. The
loading and digging areas. stairs 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 every
employees responsibility to learn the mine’s procedures for getting on and
off and follow them at all times.
Access Stairs
Adverse Conditions – Dusty, Wet, Inclement Ancillary Equipment – Equipment that is
or poor visibility Associated with the Operation
There are times and circumstances when adverse driving conditions Ancillary equipment is any machine, vehicle or equipment that the Truck
require you to take extra care. and loading equipment requires to do its job. Example:
Adverse conditions including rain, snow, ice, and fog affect your visibility.  The dozer/ grader assists with the ground work for the operation.
In these conditions vehicles become difficult to control on curves or even  The cable handling tractor is a tool for pulling and positioning the
on
n straight stretches when the surface is slippery. Braking distances are cable for electric powered face shovels, when necessary.
also increased due to sub optimal road conditions. If conditions are  Transportation to and d from the excavator, rope or hydraulic shovel is
unsafe, follow your site procedures, park up in a safe way and wait for by light vehicle.
conditions to improve or wait for further instructions from your  The cable reeler is a machine for routing cable as required. The reel is
supervisor. usually mounted on an older front end loader.
Alternator – Converts Mechanical Energy to

Electrical Energy
ANSUL Automatic Fire Suppression – Air Filter – Filters Air for the Engine
Extinguisher System
This is a unit that filters air through a fine fibrous material. The filter
filt
omatic fire suppression system is designed to extinguish a fire in
The automatic removes most fine particles such as dust. It prevents abrasive particulate
the engine bay when activated by removal of the pin and depression of the matter from entering the engine's cylinders.
knob. This is normally situated both inside and outside of the machine for
easy access.
Air Horns – Signal Horns

ANSUL Automatic Fire Suppression
Sup Air horns are usually mounted on the front and rear of a machine. These
horns are used by the operator to indicate to others his intentions.
Emergency Switch – Extinguisher System
1. Short blast = Truck STOP.
The automatic Fire suppression system will extinguish an engine fire, 2. Short blasts = Truck GO/ forward
when activated by removal of the pin and depression of the knob. This is
normally situated in the Operators Cabin. 3. Short blasts = Reverse
Warning Panels
Most equipment
ipment is fitted with warning control modules containing LED
indicators and an audio alarm to provide a continuous update of system
status.
Backhoe Bail Arm (or just Bail) – Connects the hoist
ropes to the dipper (bucket
bucket)
A backhoe is one of two configurations which an hydraulic excavator may
be set up as. The backhoe arrangement is where the bucket
bucke digs down The location of the bail arm can impact payload significantly.
significan If it is
and to ward the machine to fill the bucket. connected part way along the dipper then it can impede material flow into
the dipper. When the bail is connected on the rear of the bucket or there is
no bail arm and the hoist ropes connect directly onto the bucket, average
payload is higher.
Bail less attachment – Connects the hoist

ropes to the dipper(bucket) on a rope shovel
The concept of bail vs. bail-less
less is more a function of where the connection
is made to the dipper. With a Bail less attachment, the connection is made
directly to the rear of the dipper.
Bail-less Connection at Rear of Dipper
Batter – The Slope of the High or Low Wall Batter Cleaning – Cleaning of a highwall
batter
The batter is the term given to the angle of a face of material measured as
the angle between the horizontal and the face. The angles on a high wall In some operations, excavators are utilised to clean and prepare the
(undug material) are normally steeper than on the low wallwal (dug highwall by removing loose or hanging
ging material on the highwall.
material), as high walls, being in virgin ground, are usually of more
competent material. The batter angle may vary from mine to mine,
however it is usually the competency of the overburden that dictates the
batter angles. Most mines in Australia use
us a 2:1 batter (approx. 63.4
degrees). In some mines around the world a vertical batter is used on
highwalls. This is not the predominant practice due to the potential for
failure of the highwall. The batter on low walls is generally equal to the
angle of repose although it is not unusual to “undercut” the lower part of
the batter to 1:1 or even steeper.
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 allow
electric devices to operate without the engine running.
Mostt batteries contain an electroyte which is an acid. It can cause injury if
comes in contact skin or eyes.
Always wear protective equipment when working with batteries.
BCM/BCY – Bank Cubic Metre/Yard Bench Width
The quantity off spoil that occupies 1 cubic metre/cubic yard of space The width of the bottom bench is imperative. The Excavator should be ±
before being disturbed by a blast. 2m from the edge of the bench. If the machine is too close to the edge, the
material can subside causing the machine to fall.
The quantity of spoil moved by loading units is usually defined in terms of
BCM (metric – Australia & Africa) or BCY (imperial – US).
BCM or BCY are calculated by takingking the weight of spoil moved and
dividing by the in-situ
situ specific gravity (or density).
Sample Metric Calculation (SG = 2.2 t/CuM).
Number of cycles in a Day 1,000
Average Payload 100 tonnes
Total Movement 1000 * 100/2.2 = 45,454 BCM
Sample Imperial Calculation (SG = 3,750 lbs/CuYd).

Number of cycles in a Day 1,000
Average Payload 220,000 lbs
Total Movement 1000 * 220000/3750
When the bottom bench is too wide, the Excavator operator cannot reach re
the floor to clean up spillage. Loading of the trucks correctly is also
58,667 BCY
affected.
Bench – A Levelled Area where Mining

Equipment Operates
A bench is a level area created as part of the mining
mini process. Mining
equipment requires stable flat ground from which to operate. Excavator,
hydraulic and rope shovel as well as FEL benches or floor conditions need
to be level (refer to OEM for specific working angle limitation).
Be mindful not to dig too much out in front of the excavator (and the dig
trench) as you can easily get caught in no-man’s
no land. (Hole too large and
machine cannot reach h the face in front to pull material down and you have
nothing to bridge out with)
The Bench Grade – Grade of bench The Bench Height – Height of bench
Most benches are not level but are normally planar and established with The height of the bench needs to be considered to optimise productivity:
p
fairly gently slopes of around 1 to 2% to facilitate drainage.
With a lower bench height.
In some coal mines, the grade of the bench is fixed by the slope of the
seam within the limits of operation of the type of equipment used. At  Lower Payload per Bucket.
times, digging at steeper grades is necessitated for ramp construction and  Higher frequency of Multi passes.
sump digging.  Longer face establishment times.
 Longer Cycle time for total operation.
Most operations utilise GPS systems to manage and conform to RL grade
specifications however some operations still use sighting rods or survey to Having the optimal bench height.
assist.
 Maximum Payload per dipper.
Example of working on a grade  Faster turnaround times of trucks due to a faster filling time on the
shovel.
 Less waiting on face preparation
Benchmark Loading Unit – A Measure of
Performance and Productivity
Benchmarking is a widely accepted business tool to identify your position
and performance against st yourself and the rest of the world. It is the
process of seeking out and studying the best internal practices that
produce superior performance to:
 Identify strengths and weaknesses;
 Support continuous improvement; and
 Measure and monitor the effectiveness
effectiv of change programs.
Every operation is different. Some dig deep and others are shallow. Some
dig ore and some dig prestrip. Some have hard digging and others soft
digging. Some have long hauls and some are short. Benchmarking won’t
answer all your questions. In fact it will raise quite a few questions which
the mine will need to answer.
The key to benchmarking trucks and loaders is to take the “glass half-full”
half
attitude. What can I learn about areas for improvement? What are others
achieving which I should be able to do? Many mines are shocked by first
time benchmark results and justify it through “But my operation is
different”. These mines are consigned to mediocrity. Those mines that say
“What can I do to improve?” inevitably do improve through the intangible
process of simply focussing on performance. Process improvements come
on top of attitude-based
based improvements.
The following pages outline how PwC performs benchmarking for loading
units and the key outputs and KPIs that we have found to be paramount
param in
identifying areas of improvement.
There are a number of different KPI’s and analysis that should be taken When benchmarking, PwC takes a standard approach and when defining
into account when benchmarking machines. We must take into account the Best Practice where all data is ranked by ‘total annual output’
specific digging conditions and this can be as simple as benchmarking (tonnes/BCMs moved). Best Practice is therefore made up of the average
against
st a specific geographical subset. of the top 10% of machines for a specified model.
Why not take the top machine? PwC believes that it is important to take
an average of the top machines as we can find that sometimes a machine
may perform exceptionally well for a single year but this is often not
sustainable.
There can also be specific idiosyncrasies for a single machines yearly
output and this can be misunderstood when not related back to the
original machine and its specific environment. By taking the top 10% of
machines we reduce the impact of these
th idiosyncrasies and help to provide
a 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 Best
Practice machines for the amount of time it was scheduled to work.
Depending on the specific time model of the mine this can identify
improvement areas such as industrial action, public holidays or simply
time in which the machine was parked up.
Availability: How does your machine
achine compare against Best Practice
machines for the amount of time it was available to work in the scheduled
time. This KPI identifies where breakdowns or preventative maintenance
may be hindering the machines productivity and gives a starting point
with which to look into this area of improvement in more detail.
Utilisation: Of the Available
able time how effective was your machine at
performing production related tasks? This KPI identifies if operational
delays are an area that needs more investigation. For example are your
operational delays being pushed up due to factors such as Wait on Truck
on Wait on Dozer?
Dig Rate: This KPI identifies the productivity of the machine for the
allocated production time. So using this information we can look further
into what is causing a lower than (or higher than) Best Practice result – is
it a lower payload or are the operators simply taking too long to fill the
bucket?
By identifying the major factors that are directly affecting the total output
of the machine it is possible to
o ‘drill down’ into more detailed analysis and
discussion amongst mine site personnel to identify how to improve each
machines performance.
Benchmark for Truck Fleets – A measure of machines we reduce the impact of these idiosyncrasies and help to provide
a general picture of what we calculate to be a ‘Best Practice’ machine.
Performance and Productivity
An important factor taken into account by PwC when performing Truck
Benchmarking is a widely accepted business tool
to to identify your position Benchmarks is the Haul Distance. It is not a fair comparison to compare a
and performance against yourself and the rest of the world. It is the truck fleet performing a 3km total haul to a truck fleet performing a 6km
process of seeking out and studying the best internal practices that haul. Based on this PwC is able to identify the total cycle time of the trucks
produce superior performance to: and split outt the specified travel portion. By adjusting this portion to
reflect a specific cycle distance we can then adjust the number of cycles
 Identify strengths and weaknesses; each fleet/truck can perform in the available total cycle time.
 Support continuous improvement; and
Using this process we can compare the trucks on a like for
f like basis and
 Measure and monitor the effectiveness of change programs. give a true indication of best practice based on a mines specific haul
Can you accurately benchmark mining trucks? distances without altering the other portions of the cycle (load time, queue
time etc.).
Every operation is different. Some dig deep and others are shallow. Some
dig ore and some dig prestrip. Some have hard digging and others
other soft
digging. Some have long hauls and some are short. Benchmarking won’t
answer all your questions. In fact it will raise quite a few questions which
the mine will need to answer.
The key to benchmarking trucks and loaders is to take the “glass half-full”
half
attitude. What can I learn about areas for improvement? What are others
achieving which I should be able to do? Many mines are shocked by first
time benchmark results and justify it through “But my operation is
different”. These mines are consigned to mediocrity.
m Those mines that say
“What can I do to improve?” inevitably do improve through the intangible
process of simply focussing on performance. Process improvements come
on top of attitude-based
based improvements.
The following pages outline how PwC performs benchmarking for loading
units and the key outputs and KPIs that we have found to be paramount in
identifying areas of improvement.
When benchmarking PwC takes a standard approach and when defining
the Best Practice where all data is ranked by ‘total annual
an output’
(tonnes/BCMs moved). Best Practice is therefore made up of the average
of the top 10% of machines for a specified model.
Why not take the top machine? PwC believes that it is important to take
an average of the top machines as we can find that
tha sometimes a machine
may perform exceptionally well for a single year but this is often not
sustainable. There can also be specific idiosyncrasies for a single machines
yearly output and this can be misunderstood when not related back to the
original machine
ine and its specific environment. By taking the top 10% of
When Benchmarking PwC compares a number of key factors:
Scheduled Time: How does your machine compare against Best
Practice machines for the amount of time it was scheduled to work.
Depending on the specific time model of the mine this can identify
improvement areas such as industrial action, public holidays or simply
time in which
h the machine was parked up.
Availability: How does your machine compare against Best Practice
machines for the amount of time it was available to work in the scheduled
time. This KPI identifies where breakdowns or preventative maintenance
may be hindering the machines productivity and gives a starting point
with which to look into this area of improvement in more detail.
Utilisation: Of thee Available time how effective was your machine at
performing production related tasks. This KPI identifies if operational
operatio
delays are an area that needs more investigation. For example are your
operational delays being pushed up due to factors such as Wait on Loader
or Wait
on Dozer?
Dig Rate: Thishis KPI identifies the productivity of the machine for the
allocated productionn time. So using this information we can look further
into what is causing a lower than (or higher than) Best Practice result – is
it a lower payload or are the operators simply taking too long to position
the truck?
By identifying the major factors that area directly affecting the total output
of the machine it is possible to ‘drill down’ into more detailed analysis and
discussion amongst mine site personnel to identify how to improve each
machines performance.
BER – Bucket Efficiency Ratio
Bucketet Efficiency Ratio is a measure of what weight of spoil a bucket of a
particular 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 the
rated
bucket capacity.
BER – Payload/Bucket Rated Capacity
While BER provides a measure of bucket performance irrespective of size, its
most useful function is in the calculation of optimum bucket capacity in selecting
select a
new bucket.
BER (t/m3) – Bucket Payload/Bucket

Bucket Rated Capacity
 Rope Shovel - 2.16 t/cu.m (Ave 1.87 t/cu.m)
t/
 Backhoe - 2.00 t/cu.m (Ave 1.74 t/cu.m
cu.m)
 Face Shovel & FEL – 2.07 t/ cu.m (Ave 1.82 t/ cu.m)
**Valid at time of going to press
Berm – A Bund or mound
ound of Material Placed BEST Practice – The Average of the Top 10%
near
ear the Edges of an Excavation of Equipment in the PwC Mining Production
A berm or bund should be placed around any excavation. The height and Time Utilisation Database
varies. The mining regulations state “the berm must be half the height of
the largest wheeled machine that uses the area” It is also used to identify
the pit edge during service days and allow safe access for vehicles. Best Practice means, for each individual production
prod or
time utilisation KPI, the average for that KPI calculated
from the top 10% of machine years for loading units in
an agreed benchmark population when ranked by total
annual output. That is, the machine years for loading
units in the agreed benchmark
ark population are ranked by
total annual output, the top 10% of machine years are
selected and separated out and the average of each
individual production KPI and time utilisation KPIs
calculated for the selected machine years only.
Important note: A particular

icular production or time utilisation KPI,
calculated as the average of that KPI recorded by the top 10% of machine
years for loading units in an agreed benchmark population when ranked
by total annual output, may be lower than what is achieved for the samesam
KPI when considered in isolation. There is no machine in the PwC
database which achieves the best result in each individual KPI. Further, a
number of KPIs in combination are counter-productive.
counter For example, best
practice filling times (lower is better) rarely
r provide best practice payloads
(larger is better).
The PwC database Blasting – Controlled Firing of Explosives to
The PwC mining equipment database has been gathering production data Break Rock
from trucks, electric rope shovels, front-end
front loaders, hydraulic excavators,
backhoes, draglines, drills and ancillary
ncillary equipment since 1992. The Overburden blasts are common on a mine site. Explosive products are put
database maintains more than 12,000 machine years of mining into the drill holes and fired to fracture the overburden. The quantity of
equipment data. The following table and pie chart provide a breakdown explosive or powder factor used in each hole depends on the hardness of
of the data in the PwC database. the overburden being blasted.
Blast patterns – Designed to provide the

correct broken rock size or break up coal
Square Pattern: The easiest type of drill pattern to layout and maintain
is the square pattern. This pattern is primarily used in shallow ground
where holes are spaced closely together.
Staggered Pattern: A staggered pattern provides better distribution of Bogged equipment – Stuck
the energy provided by the shot, but requires greater care by the drill
operator when laying out the holes.
Never attempt to remove a stuck or bogged piece of equipment without
Blind Spot – Areas where operator’s or the right responsible persons present. Follow your sites procedures.
driver’s visibility
y is blocked
The areas in blue mark are an example of the blind spot a truck. The
operator cannot see these areas from his position while driving.
Boom point sheaves – The Pulleys that Guide

the Hoist Ropes round the Top End of the
Boom
On a rope shovel, boom point sheaves guide the hoist ropes around the tip
of the boom and are made to swivel and oscillate so they always align with
the direction of the ropes. It is important that the operator is smooth so
that the ropes don’t jump the sheave grooves.
Bottom Loading – Truck Positioning
Bottom loading is defined as the excavator operating
operatin from the top of the
bench, and the truck being positioned on the floor below the excavator.
The excavator operator can position the truck at 45° or 90° depending on
ground conditions and pit configuration.
The bottom loading technique maximizes excavator efficiency by ensuring
faster cycle times, giving better productivity output than top loading. Bottom Loading @90° - Truck Positioning
The haul truck should be positioned with the end of the truck body below
the boom/stick hinge point.
The most common technique is loading at 90° over the side. The
excavator is placed on a bench above the truck and digs to the same level
as the truck’s driving surface. This technique
techn requires you to use more
hoist than other methods to clear the side of the truck body, and calls for
For efficient bottom loading, the bench height for general operations greater accuracy when unloading the bucket.
should be
Truck waiting/ queuing safety distances vary from mine site to mine site.
optimized as follows:
 For stable or consolidated materials, the optimum bench height
should be four metres or approximately equal to the stick length.
 For unstable materials, the bench height should be slightly less than
the stick length.
Boom Jacking – Rope Shovel

Boom jacking is the direct consequence of overcrowding by the operator
opera
(pushing out too much), during the dipper filling cycle. As a result of the
operator’s action, the boom is raised in reference to its normal working
position causing the suspension ropes to become slack and often rocking
the shovel.
Bottom Loading @45° – Over the Tail
The dipper loading cycle stops when the boom is displaced; causing lost
time and minimising production because the boom “falls “on recovery
Loading through the rear at 45° is similar to the 90° bottom side loading
after being raised, major structural stresses and loads are caused.
method, except that the truck is positioned at 45° to the excavator.
This technique allows smoother bucket unloading when coming in
through the rear of the truck body and requires
requ less hoisting than 90° over
the
side loading.
Brakes
Brakes are used to slow down
own or stop a truck as required. The main forms
of brakes in modern trucks are disc brakes. Disk brakes are actuated by
hydraulic oil.
Box Cut – The initial excavation that is dug

when opening up a new pit
The first excavation in a new pit in a coal mine is called a Box Cut, as there
are no open faces. Box cuts incur large volumes of rehandle in a dragline
operation. They tend to have bends in the pit as they follow the LOX (line
of oxidation) line of the coal seam.
A large number of box cuts are initially exposed by means of Truck and
Loader work.
Brake Oil reservoir & Level indicator – Bucket – Loading/digging
digging device
Indicates oil level
Refer to sections:
Allows operators to check oil level and if necessary refill
r oil to the  Hydraulic Shovel - Bucket
required level.  Excavator - Bucket
The sight glass allows operators to visually check rather than the old  Rope Shovel - Dipper
fashioned dip stick method.  Front End Loader- Bucket
Bucket Spotting Time – Digging Bund/Rill/Berm – See Windrow
Windr
This is the time taken to correctly engage the material being dug following The safety berms must be at least half the height of the tyre of the
the dumping into a truck. Operators should know where the next largest vehicle
bucketful is to be placed for optimal engage as part of the sequence
Berms and windrows are a safety feature which are designed for haul
vehicles and other mine vehicles to prevent them accidently running over
the edge of elevated sections
ons such as ramps or dumps.
Bucket Tooth – Cutting Tip that is pinned to
There are at least three principle berm/windrow designs that are common
the Adaptor within the mining industry.
The tooth on the bucket is the main cutting edge when digging. There are  Edge Berm/Windrow
various tooth styles and manufacturers in the market, so each mine has to  Central Berm/Windrow for lane separation
pick teeth that meet their requirements. The teeth are mounted on  Safety or Runaway Berm/Windrow
adaptors and are pinned to allow removal when they are worn out. Regular inspections must be planned.
planned
Some mines have the tips of the teeth hard surfaced to get longer wear out
of them and thus lower ground engaging tool (G.E.T.) costs.
Cab - Operators Cabin

Refer to Operators Cab in the Dictionary
Cable Access - Roadway for Cable Cable Crossing – Portable Power Cable
Protection Equipment
Cable access needs to be prepared to allow safe entry of ancillary
equipment/trucks
trucks and light vehicles. The access is required to be wide Various means and methods are used to protect portable power cables
enough for the largest equipment to pass through safely. from damage and allow truck access in and around shovels and haul
roads. Reflectivee topped safety cones mark unprotected cables.
Cable Access beside roadway
Cable Layout – Storing excess cable Cable Plug Stands – Keeps Cable Plugs off
the Ground
“Cable loops” refers to the way excess cable is looped when it is stored on
the ground. Cable Plug Stands are used to keep cable plugs above the ground. Cable
 Cables must be laid out conducive to the type of loading plug halves are connected with a rubber seal in the middle to keep
sequence required. moisture out. However it is a requirement that they do not become
 Cable moves must be pre-planned
planned and laid out prior to shovel moves, immersed in water. Therefore stands are used to raise them off the
so as to minimize excessive down times. ground. There are as many different styles of stand as there are mines.
 Cables should be positioned in such a way out of the blasting area
if applicable.
 Cables should be hoisted up on cable towers to allow easier access for
trucks and ancillary equipment, for cleaning the face and double Cable Stand
sided loading.
 For deadheading to new a new area, cable layout should be done
before the walk begins to minimize delays.
Cable Plug
Cable – Power Lead that delivers Power to a Cable Reel - Cable storage directly attached
Rope Shovel to some Electric Rope Shovels
The cable is like an extension lead that brings the power from the
substation to the rope shovel. The new cable
cabl comes in lengths of 300
metres or 500 metres and can be ~8-10cm
~8 in diameter. It is very robust as
it has to endure the rigors of being moved around the rope shovel. The
core is made up of 3 cables and a continuity wire encased in heavy rubber.
Cable Towers- Cable trees  Physical modelling
 Engineering
Cable Towers/trees
trees are used for lifting cables above roadways to allow
vehicles to safely pass under. There are a number of designs and it
Carry Back – Material stuck in truck trays
important that they
hey are stable and when raising the cable with the lift
ropes. No personnel should be positioned below the cable in the event that Carry back occurs when material hangs up at the tail, front or side
it might fall. sections of a haul road truck with the consequence of the piece of
equipment carrying
rrying material back to the loading site and reducing the
actual load the truck dumps. This is dependent on type of material being
carried and the condition of it ie. Wet or dry. A further cause can be the
type of tray depending on material being used and design some try are
more 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,
roblem, and make its staff aware of the
Capital Cost costing and losses; however the simplest and cheapest method is to use
the excavator if available.
Capital is a one-time
time setup cost of plant (equipment) or a project, after
which there will only be recurring operational or running costs. The dump dozer operator and/or the loading unit operator can inform the
truck when there is carry back present.
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 expected
life.
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 6-9
6 months prior to the financial
year starting
Capital costs should include cost of engineering in the
th capital for example:
 Design work
CAT 777 – Dump Truck CAT 785 – Dump Truck
CAT CAT CAT CAT CAT CAT CAT CAT CAT
CAT 777 Series CAT 785
777 777B 777C 777D 777F 785 785B 785C 785D
Gross Power (kW) 648.8 686 745.7 758 Gross Power (kW) 1029 1029 1082 1082
Engine Engine
Net Power (kW) 649 649 699.5 700 Net Power (kW) 962 962 1005 1005
Transmission Max. Speed (kph) 58.3 60 60 60.4 64.5 Transmissio
Max. Speed (kph) 56 54.8 54.8 54.8
n
Empty (kg) 56428 60055 61800 70306.8 73976.4
Weight
Loaded (kg) 133540 146966 148000 161030 163293 106218-
Empty (kg) 96353 94922 95725
Weight 117597
Struck 36.3 36.4 42 41.9
Capacities Loaded (kg) 249433 249480 249480 249476
(m3) Heaped 51 51 52 61 60
Operating Struck 57 57 57
Specifications Capacities (m3)
Rated Payload (kg) 77,111 86,183 86,200 90,400 90,719 Heaped 78 78 78 78-85
Fuel Capacity (L) 947 946 1137 1136 Operating Rated Payload (tonnes) 136 118-136 136 131-143
Specification
Overall Length (m) 9.8 9.79 9.79 9.78 10.54 s Fuel Capacity (L) 1893 1893 1893 1893
Dimensions Overall Width (m) 3.51 5.46 5.13 6.1 6.49 Dump Height (mm) 11200 11207 11207 11809
Overall Height (m) 4.9 4.9 5.02 5 5.17 Raise Time (s) 15 15.2 15.2
Overall Length (mm) 11020 11022 11024 11548
Dimensions Overall Width (mm) 6630 6277 6274 7061
Overall Height (mm) 5770 5769 5769 5679
CAT CAT CAT CAT CAT CAT CAT
CAT 789 Series CAT 789D CAT 793 Series CAT 793F
789 789B 789C 793 793B 793C 793D
Gross Power (kW) 1342.3 1342 1417 1566 1715.
Gross Power (kW) 1801 1976
Engine 1
Net Power (kW) 1271.4 1272 1320 1468 Engine
1615.
Net Power (kW) 1534 1534 1743 1848
Transmission Max. Speed (kph) 54 54.4 52.6 57.2 2
Empty (kg) 121922 121922 135670 135012 Transmission Max. Speed (kph) 53.6 53.6 53.6 54.3 60
Weight 15799 15799 11351 15966 159207-
Loaded (kg) 317460 300000 317515 324319 Empty (kg)
2 2 0 2 163289
Weight
Capacities Struck 73 92 108 37499 37499 37649 38374 386007-
Loaded (kg)
(m3) SAE 2:1 2 2 0 9 390089
Operating Heaped 105 104.6 105
Specifications Struck 96 96 112-142
Rated Payload (kg) 176901 177000 176901 181000 Capacitie
s (m3) Heape 159-190
Fuel Capacity (L) 3222 3222 2082 Operating 129.2 129.2 129 129
d SAE 2:1
Specification
Overall Length (m) 12.18 12.18 12.18 12.7 s 21700 21700 22316 21772
Rated Payload (kg) 226800
0 0 8 4
Dimensions Overall Width (m) 7.34 7.34 7.67 6.5
Fuel Capacity (L) 3790 4354 2839/4922
Overall Height (m) 6.15 6.15 6.18 5.51
Overall Length (m) 12.87 12.87 12.87 12.86 13.7
Dimensions Overall Width (m) 7.41 7.41 7.41 7.68 8.3
Overall Height (m) 6.43 6.43 6.43 9.49 6.53
CAT 795 CAT 795F AC CAT 797 Series CAT 797 CAT 797B CAT 797F
Engine Gross Power (kW) 2536 Gross Power (kW) 2535.4 2648 2983
Engine
Transmission Max. Speed (kph) 64 Net Power (kW) 2406.4 2513 2828
Empty (kg) 202270 Transmission Max. Speed (kph) 64 67.6 67.6
Weight
Loaded (kg) 570678 Empty (kg) 231313 265000 260810
Weight
Struck 121.5-211 Loaded (kg) 557900 623690 623690
Capacities (m3)
SAE 2:1 181-252
Struck 173 188-213
Rated Payload (tonnes) 313 Capacities
Operating (m3) 240-267
Specifications Operating Heaped 220 220
Fuel Capacity (L) 3596 SAE 2:1
Specifications
Dump Height (mm) 15445 Rated Payload (kg) 326587 360000 363000
Raise Time (s) 26 Fuel Capacity (L) 6813 6813.7 3785
Overall Length (mm) 15146 Overall Length (m) 14.53 14.53 15.09
Dimensions Overall Width (mm) 9449 Dimensions Overall Width (m) 9.15 9.15 9.53
Overall Height (mm) 7800 Overall Height (m) 7.24 7.58 6.53
CAT 992 – Front End Loader CAT 993K – Front End Loader
Caterpillar 992C 992D 992G 992K Caterpillar 993K
Gross Power (kW) 548.1 548.1 656 674.1 Gross Power (kW) 782
Engine Engine
Flywheel Power (kW) 514.5 514.5 597 597.3 Flywheel Power (kW) 708
Operating Rated Payload (metric ton) 21.8 21.7 Rated Payload (metric ton) 22.7
Operating
Specification
Operating Weight (kg) 85180 89158 94927 97498.8 Specifications Operating
erating Weight (kg) 133637
s
Heaped (m3) 9.6 10.7 11.5 12.2 Heaped (m3) 13
Buckets Buckets Capacities
Capacities Struck (m3) 8.2 8.9 9.5 10.7 Struck (m3) 10
MAX Speed-Forward (kph) 21.1 21 21.8 20.6 MAX Speed-Forward

Forward (kph) 21.9
Transmissio Transmission
n MAX Speed-Reverse (kph) 23.3 22.9 24 22.4 MAX Speed-Reverse
Reverse (kph) 24.2
Raise Time (sec) 12 11.4 9.1 9.4 Raise Time (sec) 2.4
Hydraulic Hydraulic System Dump Time(sec) 9.4
Dump Time(sec) 2.5 3.4 3.2 1.8
System
Lower Time(sec) 4 3.7 3.5 3.7 Lower Time(sec) 2.1
MAX Overall Length(m) 12.72 13.15 15.59 15.74 Length with

th Bucket on Ground (m) 15.21
Height To Top Of Cab (m) 8.74 5.49 5.59 5.68 Dimensions Height To Top Of Cab (m) 6
Dimensions
Reach At Max Lift And Reach At Max Lift And Dump (m) 2.5
2.08 2.31 2.32 2.33
Dump (m)
777(Std)/
Pass Match with Trucks 777D/785 775/777/78 Others Match Trucks (CAT)
Others 785(High lift)
(CAT) C 5
CAT 994 – Front End Loader CAT5130B – Hydraulic Shovel/Excavator
Shovel
Caterpillar 994 994D 994F CAT 5130 5130B
Gross Power (kW) 996 1027 1176 Backho

Shovel Backhoe Shovel
Engine e
Bucket Bucket Bucket
Flywheel Power (kW) 932 933 1092 Bucket
34.5(Std.)/ 35(Std.)/ Gross power (kW) 600 600 641 641
Rated Payload (metric ton) 31 Engine
Operating 31(HL) 32(HL) Flywheel Power (kW) 555 555 597 597
Specifications 17703
Operating Weight (kg) 191200 195434 Max. Digging Depth (m) 8.4-9.7 3.2
7
Max. Cutting Height (m) 14.3-14.9 13.3
Buckets
Range (m3) 17.6 15-31 14-36 Working Max. Loading Height
Capacities 9.1-9.6 8.3-9.1
Range (m)
MAX Speed-Forward
Forward (kph) 24 24
Transmission Max Digging Reach (m) 14.9-16.2 12.4
MAX Speed-Reverse
Reverse (kph) 25.6 25.6
Operating Weight (kg) 175000 170000 182000 181000
Raise Time (sec) 12.5 11.3 Transmission Max. Speed (kph) 3.3 3.3
Hydraulic System Dump Time(sec) 3.4 3.1 Capacities (m3) 7.8 10.5 8.5-18.3 9.0-11.0
Lower Time(sec) 4 3.5 Buckets Boom Length (mm) 8560 6401
16.81(Std. 16.88(Std. Stick Length (mm) 5258 4928

Overall Length(m) )/ )/ Overall Height (To Cab) 6550 6550
17.59(HL) 17.52(HL)
Dimensions Dimensions Overall Length (No
Height To Top Of Cab (m) 6.71 6.74 8885 8885
(mm) Bucket)
Reach At Max Lift And Dump Overall Width 6620 6620
2.26 2.31
(m)
Others Match Trucks (CAT) 777D,775D,773D
785C, 789C(Std.)/
Others Pass Match with Trucks (CAT)
789C, 793C(HL)
CAT5230B – Hydraulic Shovel/Excavator
Shovel CAT6015 (RH40E) – Hydraulic
Shovel/Excavator
CAT 5230 5230B
Backhoe Shovel Backhoe Shovel CAT 6015 (RH40E) CAT6015 RH40E

Bucket Bucket Bucket Bucket
BB SB BB SB
Gross power (kW) 1096.2 1096.2 1232 1232
Engine Engine Net Power (kW) 522 522 453 453
Flywheel Power (kW) 1081 1081 1140 1140
Max. Digging Depth
Max. Digging Depth 7.3 2.2 7.3 2.1
9.4 9.5 3.8 (m)
(m)
Max. Cutting Height
Max. Cutting Height 11 10.9
15.1 15.2 (m)
(m)
Working Working Range Max. Dumping Height
Max. Loading Height 13 8.8 12.8 8.8
Range 9.8 9.8 10.3 (m)
(m)
Max Digging Reach
Max Digging Reach 13.5 10.5 13.5 10.5
17.2 17.8 14.9 (m)
(m)
Operating Weight (kg) 314793 328100 327000
Transmission Max. Speed (kph) 2.7 2.7 2.34 2.34
Transmissio
Max. Speed (kph) 2.5 2.5-3.4 2.5-3.4 SAE 1:1 6 8.1 6 8.1
n Capacitie
s (m3) SAE 2:1 5.2 7 5.2 7
Capacities (m3) 17 16 17 Buckets
Buckets Boom Length (mm) 9.5 6.9 Boom Length (m) 7.8 5.05 7.8 5.05
Stick Length (mm) 4.5 4.7 Stick Length (m) 3.3 3.55 3.3 3.55
Overall Height (To Overall Height 5250 5250 5250 5250

7455
Cab) Dimensions Overall Length
Dimensions 7355 7355 7355 7355
Overall Length (No (mm) (No Bucket)
(mm) 10000 10300 10300
Bucket) Overall Width 5340 5340 4740 4740
Overall Width 6296 Notes: BB = Backhoe Bucket; SB = Shovel Bucket
Others Match Trucks (CAT) 785, 789, 793
CAT6030 (RH120E) – Hydraulic CAT6040 (RH170B) – Hydraulic
Shovel/Excavator Shovel/Excavator
CAT 6030 (RH120E) CAT6030 RH120E CAT 6040 (RH170B and 170) CAT6040 RH170B RH170
BB SB BB SB BB SB BB SB BB SB
Engine Net Power (kW) 1140 1140 1044 1044 Engine Net Power (kW) 1516 1516 1516 1516 1516 1516
Max. Digging Depth (m) 6.1 2.5 6.1 2.5 Max. Digging Depth
7 2.6 7 2.6 7 2.6
(m)
Max. Cutting Height (m) 14.5 13.9 14.4 13.9
Working Max. Cutting Height
Max. Dumping Height (m) 10.7 10.7 16.8 14.4 17 14.4 17 14.4
Range (m)
Max Digging Reach (m) 15.1 13.7 15.3 13.7
Working Max. Dumping Height
10.9 10.9 10.9
Operating Weight (kg) 289700 287000 287100 284100 Range (m)
Transmission Max. Speed (kph) 1.4-2.7 1.4-2.7 1.4-2.7 1.4-2.7 Max Digging Reach
17.7 15.4 17.7 15.4 17.7 15.4
(m)
Capacities SAE 1:1 17 19 17 19
(m3) 3970 3974 3938 3944
SAE 2:1 15.3 16.5 15.3 16.5 Operating Weight (kg)
Buckets 00 00 00 00
Boom Length (m) 8.5 6.2 8.5 6.2
Transmissi 1.5-
1.5 1.5- 1.6- 1.6- 1.6- 1.6-
Max. Speed (kph)
Stick Length (m) 4 4.4 4 4.4 on 2.5 2.5 2.6 2.6 2.6 2.6
Overall Height 7600 7600 7600 7600 Capacitie SAE 1:1 22 25.3 20 25.3 20
Dimensions Overall Length s (m3) SAE 2:1 19.5 22 17.7 22 17.7 21
10270 10270 10270 10270 Buckets
(mm) (No Bucket) Boom Length (m) 9.5 7.3 7.3 9.5
Overall Width 6390 6390 6390 6390
Stick Length (m) 4.6 4.6 4.6 4.5
Others Match Trucks 136 tonnes truck
Overall Height 7870 7870 7870 7870 7870 7870
Notes: BB = Backhoe Bucket; SB = Shovel Bucket Dimension
Overall Length 1103 1103 1103 1103 1103 1103
s
(No Bucket) 5 5 5 5 5 5
(mm)
Overall Width 7200 7200 7200 7200 7200 7200
Others Match Trucks 172 tonnes truck
Notes: BB = Backhoe Bucket; SB = Shovel Bucket
CAT6050 (RH200) – Hydraulic CAT6060 (RH340B) – Hydraulic
shovel/Excavator Shovel/Excavator
CAT 6050 (RH200) CAT6050 RH200 CAT 6060 (RH340 and
CAT6060 CAT6060E RH340B RH340
340B)
BB SB BB SB
BB SB BB SB BB SB BB SB
Engine Net Power (kW) 1880 1880 1880 1880
Engine Net Power (kW) 2240 2240 1800 1800 2240 2240 1880 1880
Max. Digging Depth (m) 9.2 2.4 9.2 2.4
Max. Digging
Max. Cutting Height (m) 16.8 15.3 17 15.3 8.9 2.7 8.9 2.7 8.9 2.7 8.9 15.4
Depth (m)
Working
Max. Dumping Height (m) 11.8 11.8
Range Max. Cutting
15.9 15.5 15.9 15.5 15.9 15.5 15.9 15.4
Max Digging Reach (m) 19.5 16.2 19.4 16.2 Height (m)
Operating Weight (kg) 534000 525000 537000 525000 Working Max. Dumping
11.6 11.6 11.6 11.5
Range Height (m)
Transmissio
Max. Speed (kph) 1.6-2.3 1.6-2.3 1.6-2.3 1.6-2.3
n Max Digging
18.9 16.4 18.9 16.4 18.9 16.4 18.9 16.3
Reach (m)
SAE
28 30.5 28 30.5
1:1 Operating 56230 54550 54230 56750 56660 54700 55200
Capacities (m3) 564500
Weight (kg) 0 0 0 0 0 0 0
SAE
Buckets 24.6 26 24.6 26
2:1 Transmis Max. Speed
1.4-2.0 1.4-2.0 1.4-2.0 1.4-2.0 1.5-2.0 1.5-2.0 1.5-2.0 1.5-2.0
sion (kph)
Boom Length (m) 10.5 8 10.5 8
SAE
Stick Length (m) 5.5 5.1 5.5 5.1 34 39.5 34 39.5 34 39.5 34 39.5
Capacitie 1:1
Overall Height 8760 8760 8760 8760 s (m3) SAE
30.3 34 30.3 34 30.3 34 30.3 34
Dimensions Overall Length 2:1
11850 11850 11850 11850 Buckets
(mm) (No Bucket)
Boom Length
10.5 8 10.5 8 10.5 8 10.5 8
Overall Width 8730 8730 8100 8100 (m)
Others Match Trucks 218 tonnes truck Stick Length
5 5.1 5 5.1 5 5.1 5 5.1
(m)
Overall Height 8770 8770 8770 8770 8770 8770 8770 8770
Dimensio
Overall Length
ns 12570 12570 12195 12195 12570 12570 12195 12195
(No Bucket)
(mm)
Overall Width 8730 8730 8730 8730 8100 8100 8250 8250
Others Match Trucks 218 tonnes truck MT4400
CAT6090 (RH400) – Hydraulic CAT (Unit Rig) MT3000 – Dump Truck
Shovel/Excavator
CAT (Unit Rig) MT3000
Caterpillar (O&K) CAT 6090 RH400 Gross Power (kW) 895
Engine
Shovel Bucket Shovel Bucket Net Power (kW)
Engine Rate Power (kW) 3360 3360 Transmission Max. Speed (kph) 50
Max. Digging Depth (m) 2.3 2.3 Empty (kg) 97470
Weight
Max. Cutting Height (m) 20.2 20.2 Loaded (kg) 206470
Max. Dumping Height (m) 14.5 14.5 Struck
Working Range Capacities (m3)
Max Digging Reach (m) 19 19 Heaped 2:1 76
Operating Weight (kg) 980000 980000
Operating Rated Payload (kg) 109000
Payload (tonnes) 90
Specifications Fuel Capacity (L)
Transmission Max. Speed (kph) 1.6-2.2 1.7-2.2
SAE 1:1 59.8 (Std. rock) 52 (oil sand) Dump Height (mm)
Capacities
(m3) SAE 2:1 52 (Std. rock) 45 (oil sand) Raise Time (s) 25
Buckets
Boom Length (m) 9.5 9.5 Overall Length (mm) 12200
Stick Length (m) 5.8 5.6 Dimensions Overall Width
dth (mm) 6300
Overall Height (To Cab) 9990 10175 Overall Height (mm) 6300
Dimensions
Overall Length (No Bucket) 13545 13490
(mm)
Overall Width 9070 9780
CAT (Unit Rig) MT3300 - Dump Truck CAT (Unit Rig) MT3600 - Dump Truck
CAT (Unit Rig) MT3300 MT3300AC CAT (Unit Rig) MT3600 MT3600B
Engine Gross Power (kW) 1007 1286 Engine Gross Power (kW) 1343 1286.3
Net Power (kW) 1171 Net Power (kW) 1174.5
Transmission Max. Speed (kph) 53 64 Transmission Max. Speed (kph) 56 56.4
Weight Empty (kg) 104890 112880 Weight Empty (kg) 105053 116348
Loaded (kg) 240890 248934 Loaded (kg) 277053 270569
Operating Capacities (m3) Struck 59 Operating Capacities (m3) Struck 62
Specifications Specifications
Heaped 2:1 87 90 Heaped 2:1 98 98
Rated Payload (kg) 136000 136000 Rated Payload (kg) 172000 154221
Fuel Capacity (L) 2271 Fuel Capacity (L) 2877
Dump Height (mm) 10800- Dump Height (mm) 11800
11900
Raise Time (s) 29 20 Raise Time (s) 27 31
Dimensions Overall Length (mm) 12200 12300 Dimensions Overall Length (mm) 12700 13100
Overall Width (mm) 6300 7100 Overall Width (mm) 6700 7300
Overall Height (mm) 6100 6400 Overall Height (mm) 6800 6800
CAT (Unit Rig) MT3700 – Dump Truck CAT (Unit Rig) MT4000 – Dump Truck
CAT (Unit Rig) MT3700 MT3700B MT3700AC CAT (Unit Rig) MT4000
Gross Power (kW) 1492 1286.3 1510 Gross Power (kW)
kW) 1641
Engine Engine
Net Power (kW) 1174.5 1398 Net Power (kW)
Transmission Max. Speed (kph) 55 55 65 Transmission Max. Speed (kph) 50
Empty (kg) 120869 131065 149660 Empty (kg) 138034
Weight Weight
Loaded (kg) 306809 317037.9 335600 Loaded (kg) 357034
Struck 77 92 Struck
Capacities (m3) Heaped Capacities (m3)
105 111 123 Heaped 2:1 140
2:1
Operating Rated Payload (kg) 185940 185972.9 186000 Operating Rated Payload (kg) 219000
Fuel Capacity (L) 2877 2877 Fuel Capacity (L)
Dump Height (mm) 11900 12000 Dump Height (mm)

Raise Time (s) 27
Raise Time (s) 27 19 22
Overall Length (mm) 13160
Overall Length (mm) 12700 13100 13100
Dimensions Overall Width (mm) 7160
Dimensions Overall Width (mm) 6700 7300 7300
Overall Height (mm) 6500
Overall Height (mm) 6800 6900 6900
CAT (Unit Rig) MT4400 – Dump Truck CAT (Unit Rig) MT5500 – Dump Truck
CAT (Unit Rig) MT4400 MT4400AC CAT (Unit Rig) MT5500 MT5500AC
Engine Gross Power (kW) 1865 2014 Engine Gross Power (kW) 2014 2712
Net Power (kW) 1706 1855 Net Power (kW) 1847
Transmission Max. Speed (kph) 48 64 Transmission Max. Speed (kph) 65 65
Operating Capacities (m3) Struck 100 100 Operating Capacities (m3) Struck 158 158
Heaped 2:1 144 144 Heaped 2:1 218 218
Fuel Capacity (L) 3028 3028 Fuel Capacity (L) 3028 3028
Dump Height (mm) 12800 12700- Dump Height (mm) 13440 13440
13900
Raise Time (s) 22 22 Raise Time (s) 28 28
CAT (Unit Rig) MT6300 – Dump Truck CCTV – Machine cameras
CAT (Unit Rig) MT6300AC Cameras assist the operators to observe in the blind spot of the machine.
Gross Power (kW) 2796 These are a valuable safety feature installed on many types
typ of equipment.
Engine
Net Power (kW) 2610
Transmission Max. Speed (kph) 64
Empty (kg) 235828
Weight
Loaded (kg) 598640
Struck
Capacities (m3)
Heaped 2:1

Specifications Fuel Capacity (L)
Dump Height (mm) 13440
Raise Time (s)

Overall Length (mm) 15770
Dimensions Overall Width (mm) 9540
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 anything
an that will affect
the circuit flow.
 Help each other to keep the trucks cycling at equal intervals.
Clean-up
up Outside Swing Radius – Spillage Clean-up
up Inside Swing Radius – Spillage
The clean-up
up dozer pushes material up to maximum reach of the Cleaning inside the swing radius is when machines are required to clean
excavator without interfering with the excavator’s
excavato swing radius. up inside the bucket swing arc. Before entering the area, the cleanup
machine operator should obtain permission from the excavator operator.
Once the area outside the swing radius is clean, the dozer needs to wait for
permission from the excavator operator to enter the swing radius area. A safe practice is:
 The excavator operator stops digging, grounds the bucket and sets the
brakes 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.
Climbing
bing Up Work Benches – Procedure
Approach the bench at a 90° angle and use the bucket to pull the top
section down to lessen the angle of the climb. A maximum angle of 30%
must not be exceeded
Push the edge of the bench over and Walk the excavator to the edge and
place the bucket on the pit floor. start the decline from the bench,
keeping the tracks at a 90° angle to the
bench. A maximum angle of 30% must
not be exceeded.
Push the stick out and place the bucket Co-ordinate pulling the stick in and
on top of the bench. walking the excavator to climb the
bench.
Walk down the decline slowly, keeping

the weight on the boom and stick. When approaching the bottom of the
bench, commence lifting the bucket to
clear the surface. Continue walking off
the bench, raising the bucket to clear
the surface.
When nearing the top of the bench,
start lifting the boom to just clear of the
surface. Controls – All Machines
Refer to Excavator or Truck controls in the Dictionary of your
operator’s manual.
Once at the top of the bench, push the Select Low Speed and fully depress the
stick out to maintain balance. pedals to enable the travel retarder
valve to
operate properly.
CPP/ CHPP – Coal (handling)
handling) preparation Coal Edge – The Extent of the Exposed Coal
plant on the Low Wall Side
Coal Handling and Preparation Plant,
Plant another term for Coal Preparation oal edge is the low wall side of the exposed coal seam. Most
The coal
Plant (CPP). operations prefer to dig a bucket width down to the bottom of the coal
seam to allow cleaner extraction of the coal. This procedure comes at a
cost of extra rehandle as the low wall has to be moved
mov further out to
maintain the correct angle and for the toe to meet the trench floor.
Coal - A Fossil Fuel consisting of Carbonised

Vegetable Matter.
A fossil fuel consisting of carbonized vegetable matter deposited in the Coal Edge
Carboniferous period and altered through the actions of heat and
pressure.
The coal seam is compressed vegetable matter laid down in horizontal
layers. Some mines have multiple seams that they mine.
Coal Seams are varied and of different qualities.
Coal floor clean-up – Minimises coal Coal Mining – Digging, Loading
Loadi and
contamination with unwanted spoil Transporting the Coal
The easiest way to prevent/ reduce coal contamination is for loaders
loader to Coal mining consists of digging, loading and transporting the coal to the
leave a thin layer of coal in the digging area for the dozers to clean up wash plant. Most times the coal seam is blasted to break up the hard coal
more accurately than the loaders can. The aim is to prevent the mining seam to make it easier to dig.
equipment that is operating in the digging area from churning up the
Digging & Loading: There are many machines for digging
d and loading
boundary between the coal and the spoil
spo underneath. The dozers create a
the coal. Mines that have large coal seams mostly use Trucks and Shovel
stockpile of the “cleaned up” coal in the pit which is then loaded into
extraction.
trucks.
Mines with smaller seams tend to use excavators and/or
and front end
The result is greater volume of good quality coal with less or no wasted
loaders.
coal at the wash plant. This reduces the running cost of the coal washing
wa
plant and as well an increasing the efficiency of the operation. Truck fleets can include bottom (belly) dumpers and rear dumpers. Some
even use conveyor systems.
Caution: Clean up the floor and remove any over spillage after filling the
truck on a regular basis. Uneven Coal/ pit floors can damage the truck Some of the smaller mines use road trucks to haul the coal.
tyres.
Coal Recovery Measurement Trenches – Collision Avoidance – Minimum distance to
Comparing geological predictions and be maintained between equipment
actual coal seam thickness
Distances vary from mine site to mine site. Check regulations for your
y
A coal recovery measurement trench is dug across a strip to measure the mine. Most mines are investigating collision avoidance systems to assist
thickness of a coal seam. A measurement is then made from the top of in preventing incidents as well as minimising interaction between light
coal to the bottom of the seam and is compared with the predicted vehicles and heavy equipment.
geology. If the measurement varies from the predicted thickness of the
seam, a variance from the predicted amount of coal
coa will result.
Coal Reject Silo/ Bin – Storage area of

unwanted wash plant material for removal
by dump truck
Collision Avoidance driving – Minimum

distance between equipment
Distances vary from mine site to mine site. Check regulation for your
mine.
The minimum safety distance between two trucks was implemented to
allow the driver sufficient time to react and apply the brakes without
running the risk of not to having enough distance to stop.
Compressed Air Tank – Holds the Supply of
Compressed Air
The air tank is a large pressure vessel that holds the supply of compressed
air. Loaders and trucks are generally fitted with some kind of storage tank
for compressed air to assist in the breaking, starting and ancillary
systems. Air tanks are being constantly refilled during operation but, in
trucks, if brakes are constantly applied the air compressor might not be
able to refill the tank sufficiently to maintain working pressure. Loss of
braking power may occur.
Air tanks are subject to statutory testing periodically.
Compressed
Air Tank
Cooling fan motor – Electric motor cooling Crowd – Force applied to load
These are used to cool electric motors on some equipment. The crowd gear/motor
motor provides extra power and force
forc to enable a rope
shovel to push the dipper into the bank. This action in conjunction with
the hoist loads the bucket.
Counterweight – Balance
alance
Counterweights are designed to balance the weight of a fully laden
bucket/dipper
dipper including the weight of all attachments and spoil
contained. The reasoning for this is to control centre of gravity on the
machine. Cycle efficiency – Optimal cycle time
efficiency
The key to maximising efficiency is to minimise the work cycle. A saving of
one or two
wo seconds on each load cycle can increase efficiency over a
relatively short period.
Defect Reporting – Reporting of defects
on machinery
Defects or faults should be looked for and will from time to time be
observed during pre-shift
shift inspections, walk around checks, during
operation or
other 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 appropriate
position to ensure that either the faulty component or the whole
machine (as applicable) is not operated.
operate
Cycle time (truck) – Time to complete a  Report this to your supervisor immediately.
full cycle  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 it
Truck cycle time consists of travelling, waiting time, queuing, spotting, to the maintenance department through the appropriate channels.
dumping and loading. Measured from a specified
speci point in one cycle to the If a defect is observed that is not a Safety hazard and the machine can
same point in the next cycle. continue to work safely:
 The operator must attach an Information tag to the appropriate
position to ensure that other operators are aware of this issue.
Cycle time (loading unit) – Load time from  Report this to your supervisor during
uring or at the end of your shift.
truck to truck  Forwarding it to the maintenance department through the
appropriate channels.
Cycle time includes truck spotting time, digging, swinging and loading
time. It is again defined as the time from a specified point in one
o cycle to
the same point in the next cycle.
One Cycle New Cycle
Swing Swing Swing

Dig Spotting Dump Dig
Full Empty Full
Phase Delay Phase
Delay – Maintenance Delay Scheduled  Brake Pump  Hydraulic Valves
 Brake Test  Hydraulic Filters
 Air Systems  Suspension Repairs  Brakes System  Hydraulic Pump
 Axle Repairs  Tyre Inspection  Breakdown - Electrical  Hydraulic Cylinders
 Brake Repairs  Tyres Scheduled  Breakdown - FMS  Hydraulic General
 Cab Repairs  Tyres, Tracks or Frames  Breakdown - Mechanical  Lighting
 Cleaning for Maintenance  Fire Suppression  Bucket  Lube System
 Cleaning to Repair  Lube System Repair  Bucket General  Lube System Electrical
 Cooling System Repairs  Maintenance Inspection  Bucket Welding  Lube System Mechanical
 Daily Service  Maintenance Service  Cab/Walkways  Main Gear Boxes
 Engine Repairs  Planned Repairs  Cab Equipment  Maintenance Inspections
 Hydraulic Repairs  PM Air System  Cabin  Maintenance Delay
 Inspection  PM Brakes  Cabin Controls  Park Brake
 Light Vehicle Check  PM Cooling System  Cabin/Decks  Power Loss
 Maintenance Checks  PM Fire Sup Sys  Chassis/Body  Retarder
 Major Cab Clean  PM Steering  Control System  Rock Ejectors
 Major Service  PM Wash-down  Coolant System  Rock/Tyre Management
 Major Shutdown  Pre- Maintenance Inspect  Dispatch System  Starting System
 Service Break  Accidental Equipment Damage  Drive Brakes  Structural Damage
 Drive Cooling Sys. Radiator  Suspension
 Lights/Indicators  Suspension Cylinders
Delay – Maintenance Delay Unscheduled  Elec E Stop  Tray
 Elec Fail To Start  Truck Box Cleaning
 2-Way Radio  Fire Suppression  Elect General  Tyre Change
 Accident Damage  Frame/Structure Front Axle  Electrical Fault - 24 Volt  Tyres Unscheduled
 Accidental Damage  Front Strut  Engine System  Undercarriage
 Air Filters  Fuel Filters  Unplanned Electrical  Unscheduled Maintenance
 Air Intake System  Fuel Injectors  Unplanned Mechanical  Wait Electrician
 Awaiting Diagnosis  Fuel Pump  Filter System  Wait Fitter
 Awaiting Maintenance  Fuel Sys  Filters  Wash-down Equipment
 Backup Alarm  Fuel Tank
 Battery  Gear Shifting
 Bearings  General Electrical
 Blade/Bucket/Bowl/Ripper  Hydraulic Cylinders
 Blade/Cutting Edges  Hydraulic Oil Cooler
 Body/Frame Chassis  Hydraulic Oil Level Leaks
 Body/Tray  Hydraulic Pump - Main
Delay – Standby Demag H285 – Hydraulic Shovel
 Accident  No Operator H285 Demag Hydraulic Shovel
 Blast Misfire  No Operator - Other Duties
 Blasting  Off Shift Due To Roster Structure
 Blocked Access  Operational/Talk To Supervisor
 Crib  Operator Travel
 Dust/No Water Cart  Power Down
 Electrical Storm  Power Outage Site
 Env/Coal Fires  Public Holiday
 Environmental  Return From Maintenance
 Environmental Incident  Safety/Meetings
 Equipment Not Required  Safety Shutdown
 Floor Cleanup  Scheduled Down
 Fuel  Scheduled Off Shift
 Holidays(Shutdown)  Shift Change
 Idle  Site Emergency
 Idle -Safety  Smoke
 Illness  Snow
 Industrial Action  Standby
 Loader Delay  Stby No Production
 Long Term Standby  Stby Parked
 

No Avail Crushers
No Avail Dumps 
Stopped For Emergency
Stop-Work Meeting
DER – Dipper Efficiency Ratio
 No Avail Shovels(Auto)  Talk To Supervisor Dipper Efficiency Ratio is a measure of what weight of spoil a bucket of a
 No Avail Shvl Call Disp  Toilet Break particular capacity will carry. As such it is a measure of the digging
 No Available Dump  Tool Box/Safety Talk (getting the spoil into the bucket) and shape (holding spoil ini the bucket)
 No Available Employee  Total Operation Shutdown efficiency of the bucket. It is found by dividing the average payload by the
 No Available Face  Union Meeting rated
 No Available Hopper  Upub Special Public Holiday bucket capacity.
 No Available Shovel  Wait On Blast DER = payload/capacity in t/cu.m
 No Heavy Hauler  Wait On Dust
DER increases with tooth attack angle between 50˚ 50 and 70˚. This is expected to
 No Labour Available  Weather continue to a point where the interaction of the heel of the bucket and the spoil
 No Loading Unit  Wet Roads restricts tooth penetration and subsequent payload.
 No Oper - Hot Seating  Work Instructions Different dipper shapes achieve different payloads (for the same capacity). This is
a function of the shape of the dipper and the volume of the rear of the bucket
taken up with voids. This void is shown in the picture.
Dig Face – Digging area
Dig area where operator engages and fills the bucket/dipper.
bucket
Dig Techniques (Sequence) – Common

techniques
There are a number of different Dig methods or sequences a site could
use, 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).
Dig Plan – How the pit will be dug  Single Bench
The dig plan is the communication plan given to operators/supervisors
operators of  Loading with a Front-end
end Loader
what needs to be dug/removed
removed and according to specific design  Split Bench
parameters.
 Split Bench Face Heights
 Split Benching Method Ramping Down
Refer to individual pages on specific dig techniques in this dictionary.
Diggability – Fragmentation analysis Dip – Slope of the Coal Seam
Optimal Fragmentation is essential for truck
truc and loader productivity. The dip/slope
slope of a product i.e. coal or other specific body of ore
Diggability is a term used to describe how easy the material can be dug by for extraction.
the loading unit. The best measure of diggability is the Specific Dig
Energy.
SDE = Payload/Energy to Fill
As digging gets harder the payload goes down and
an the energy to fill goes
up. Hence the SDE goes down, and vice versa.
Example of optimal fragmentation.
Dilution – Contamination in a mineable Dipper – Rope Shovel Bucket
seam.
Dilution of the coal is the percentage of overburden or waste material

mixed with the coal. There is, at times, dilution within the coal seam itself.
The actions of the operators when removing the overburden from the top
of coal can have a major effect on dilution. Keeping the bucket off top of
coal is one way of reducing dilution. The dozer can clean the last half
metre down to the coal seam.
Dilution can also be caused by loading the coal into the spoil causing
contamination.
Dipper Crowd – Electric rope shovel arm Dipper Door – Rope Shovel Bucket Door
Crowd
Dipper Door Hinges – Dipper door pivots to Dipper Depth
open and close
Dipper depth is defined as the distance from top (teeth end) to bottom
(door end). These depths have been expressed as a percentage of the
width (distance across the mouth of the dipper). The following figure
demonstrates the depth.
Depth
Dipper Door locking mechanism – Rope
Shovel Bucket Door Lock 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 as
a percentage of the width (distance across the mouth of the dipper). The
following figure demonstrates
trates the definition of height and width.
Distance from face
Retract the dipper handle until the top end protrudes approximately 3m
beyond the shipper shaft. Bring the dipper up to about 20° and crowd
forward until the dipper teeth contact the bank. Allow
All enough clearance to
tuck the dipper in front of the crawlers to begin each digging cycle.
Retract the shovel dipper handle until

til the top end protrudes
approximately 3m beyond the shipper shaft. Bring the dipper up to about
20° and crowd forward until the dipper teeth contact the bank. Allow
Be mindful not to dig too much out in front of the excavator (and the dig enough clearance to tuck the dipper in front of the crawlers to begin each
trench) as you can easily get caught in no-man’s
no land. (Hole too large and digging cycle.
machine cannotot reach the face in front to pull material down and you have
nothing to bridge out with)
Double benching – Loading technique
Refer to Split Benching in this Dictionary.
When positioned correctly, the excavator operator can easily reach the top
bench face and dig in the downwards pulling motion.
Double Sided Loading – Loading with trucks Downtime – Delay
either side
Any time the machine (Truck or Loading unit) is not operational or
sided loading is used whenever possible, because it is considered
Double-sided available.
the most productive system of operation. Downtime can be classed as either Scheduled or Un-scheduled
Un
maintenance or operational delay.
Key Delay and Downtime Activities
160
135.3
Time Spent [h]

120
82.7
80
40
21 17.6 17
10.2 7.9 5.8 5.2
The shovel is positioned with the tracks at 90° to the face and advanced 0 24%
Percentage of Total Time [%]

directly into the face as material is removed. This operation is particularly
suited to high face heights and a large number of trucks, with little or no 16%
shovel relocation over the shift.
ift. With trucks positioned on each side of the
machine, the shovel can load with virtually no interruption and not exceed 8%
90° of swing for each truck. Clean-upsups are done only once the shovel has
parked with the bucket on the ground. 0%
SHIFT CHANGE
MINOR CLEALN/MOVE
GREASE LUBE SYSTEM

ROUTINE PM SERVICES -
LUBE - OILS - COOLANT
CRBI
WEATHER DELAYS
WAIT ON ACCESS
ENGINE
MOBILE
Trucks are normally required to spot without the aid of the shovel and are
usually positioned below the boom point swing path within 90° of shovel
swing. Inefficiency can affect the high productivity normally achieved with
this system if the haul trucks spot either inside or outside of the boom
point swing path.
Dozer – A Tracked or Rubber
Rub Tyred Machine Drill Rig – Device for drilling blast holes
A dozer is a necessary ancillary tool around a truck and shovel operation.
They are generally utilised for cleaning up of the loading area, spillage
around the loading area and on the haul route to minimise tyre damage to
the trucks.
Dozers
rs can also be used to push and establish benches as well as pushing
down high faces for loading. (Dozer Assist).
Drill and Blast Areas – Area prepared Drive-by Loading – Sequence
for blasting
Drive-byy loading is defined as the excavator operating from the top of the
bench, 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 the
excavator is in a tight spot and the bench
benc is very narrow. Most mining
operations avoid this type of loading due to the added exposure of the
truck tyres to the bench face causing extra damage on the drive by.
When spotting for this type of loading the truck operator must align
his/her left shoulder
der with the counterweight of the Excavator. The
excavator operator will indicate where to stop by sounding his beeper
once when the truck reaches the correct position.
Ensure that the bucket height is sufficient to clear the edge of the dump
body with thee 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
by observation on crest – Checking Dump Area Sequence – Dump area strategy
condition of tip head
As a truck enters the dump location it should always dump according to
This allows the driver to see the condition of the ground
groun and bund wall the strategy and according to where the previous truckload was dumped.
before reversing to dump. Minimum distances apply - check mine The operator on the dozer will normally
normal control the dump strategy and
regulations. communicate with the truck operators as to where to dump.
Drive by observation on crest
Dump Site Maintenance

Proper dump site maintenance is designed to:
 Prevent Tyre damage on Trucks
Dump Area Maintenance – Keeping  Prevent damage to Trucks by ground falling or running away
 Prevent loss of life
dumping area in good condition  Ensure quicker cycle times
 Take into consideration, berms, width, demarcation, sequence,
Correct dump area maintenance prevents unnecessary tyre damage and
ancillary equipment to be used to level and size (dozer, RTD/Wheel
RTD
wear and tear. Tip head must be maintained to the correct heights
Dozer, etc.)
Berm Height as a rule of thumb must be at least half the size of the Tyre
Ty
Correct Dump Site Maintenance
used by the largest Truck dumping.
Dumping – Unloading material Dump – Placing of waste into spoil piles
Material can be dumped from: The dump area should be kept as level as possible in all directions and
should provide a stable dumping platform.
platfor
 Truck Trays,
 Excavator and Loader Buckets, Dump sites with an uneven ground surface can produce instability and
 Shovel Dippers, even rollover risks when a full truckload is being hoisted to dumping
 Dragline Buckets. position. The shift in the centre of gravity brought about when the wheel
base is inclined from the horizontal, may
ma be sufficient to upset the balance
of the haul truck.
 Do not hoist the body to the dump position whilst the wheels are
positioned on uneven ground.
 Dumping uphill should be avoided as greater energy is required to lift
the load and high loads are imposed on the body trunnions and
machine frame.
Dumping Phase
The dumping phase of the digging cycle is part of the swing and return
phases. The dumping phase starts just before the loaded bucket passes
over the edge of the haul truck and finishes as the swing motion stops and
reverses. The dumping phase consists of swinging of the bucket, slowing,
stopping and reversing the swing
ng direction and, at the same time,
controlling the bucket to dump the load at the correct position.
Dust – Control of dust Elephant Skid – Highwall Power Cable
Protection Equipment
All haul routes should be managed to prevent dust. Dust can be controlled
by frequent watering with Water bowsers or by applying a chemical Elephant Skids are used to facilitate moving shovels back and forth the
compound mixed with water to bind fines causing
causin dust. length of a mining pit. The Elephant Skid is often used in conjunction with
Dust is a major problem at some mines with significant periods of standby in-pit cable
le trees and/or cable crossings to help prevent damage to the
caused by poor visibility caused by dust. electrical power cable as the shovel advances.
Electronic Monitoring System – EMS

The Electronic Monitoring System (EMS) consists of a fault alarm, a fault
light and a monitoringg panel with individual indicators for each truck
system listed on the panel.
The EMS is designed to alert the operator of an immediate or impending
problem in one of the truck systems covered. All equipment including
trucks, loading units and ancillary equipment
quipment has one form or another
EMS.
Emergency Steering Switch – Activates

emergency steering pump
This switch activates the emergency steering pump on a haul truck. The
emergency steering 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
seconds.
Emergency Stop – Excavator/Shovel
Excavator Engine Block – Engine
Emergency stop pull cables are located at various locations around the
loading
ng unit. Operators should familiarise themselves with the location of
these.
Engine Oil
Filter
Fuel Water
Separator
Additional
Extra Low Fuel
Spec Filter
Brake Oil
Emergency Stop – Truck Filter
If you are faced with an emergency situation, where the operation of a

truck has to be stopped immediately, the following procedure must be
followed.
 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 position
po and emergency details
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).
Equivalent Annual Production Esco – Bucket and GET Manufacturer
This is Annual production assuming full 7 day roster and no stoppages ESCO® is a manufacturer of a range of dragline/ hydraulic face shovel/
longer than 7 days. excavatorr and dipper buckets, GET components and other alloy steel wear
resistant products.
It is divided by in-situ SG to convert
ert tonnes (weight) to volume.
Equivalent Annual Production =
Annual Swings * 365_________** Ave. Payload
(365 – Stoppage days > 7 days)
Excavator – Controls Excavator – Schematic
Travel Levers with Pedals - These levers are used to change the direction
Boom
of travel between forward and reverse. Machinery
House
Forward: The lever is pushed forward,
rward, (The pedal is angled forward)
Reverse: The lever is pulled back (The pedal is angled back) Machinery
Deck
Dipper
N (Neutral): The machine stops

Hydraulic
Note: If the lever is shifted to the Forward or Reverse position from the Rams
Neutral position, the alarm sounds to warn that the machine

m is starting
to move.
Counter
Weight
Crawler
Belt/Track
Idler Bucket
Propel
Machinery/ Sprocket
Roller
Excavator Boom – Boom attachment

An excavators Boom is attached to the lower part of the machine deck and
holds all the other parts from the Arm plus the weight of the spoil. The
Boom is driven by the two hydraulic cylinders (Beam cylinders). They are
responsible for the vertical movements.
Excavator – Loading unit

An excavator is a loading unit as can be seen below. Please refer to specific
makes and models as illustrated in this dictionary. An excavator may be
set up as a backhoe (as shown) or face shovel.
Excavator Bucket – Bucket attachment Excavator Stick – Attachment
Excavator buckets are made of solid steel and generally present teeth The Stick is attached to the Boom and is driven by one or two hydraulic
protruding from the cutting edge, to disrupt hard material and avoid cylinders (Arm cylinders) which are attached on the upper part of the
wear-and-tear of the bucket. Boom. They are used for the horizontal movement.
Stick
Excavator – Lock Lever

When this lever is in the upwards position as illustrated, the excavator
cannot be operated as it applies the same principle as the park brake on a
truck or brakes on a shovel.
Once the operator is in the chair he can push the lever into the lower
position and continue work.
Excavator Undercarriage – Walking Exhaust Pipes – Exhaust outlet
mechanism
The undercarriage gives the excavator the mobility and flexibility to
ensure that it can cope with constantly changing
surroundings/conditions. The major undercarriage components consist c of
the crawler tracks; propel machinery and the track frame. The track frame
parts 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.
undercarr On most large
excavators, the track frame design is such that the tracks can be removed
for transportation.
Face Maintenance/Clean-up
Maintenance/Clean – Floor clean up
Face maintenance/clean-up
up is done to:
 To prevent tyre damage to Trucks
 To prevent an uneven loading surface for the trucks and the shovel
Item Description  To allow trucks to maneuver next to the loader as efficiently as
A Idler possible
 To prevent avoidable cable damage
B Track
 Increase production
C Top Roller
D Track Link assembly
E Track/Walking Frame
F Bottom Roller
G Sprocket
H Drive/Propel
Face Height – Optimal height Face Shovel
At any bench height greater than 30% of boom point height, a full payload A face shovel is one of two configurations which an hydraulic excavator
could be achieved. The issue at the lower bench heights may be the fact may be set up as. The face shovel arrangement is where the bucket digs
that the shovel has to be moved more often so that the dipper can reach up and away from the machine to fill the bucket.
the face.
Face Width Failure – Unstable Wall or parts of it
Face width depends on type of machine, the sequence utilised, the truck A high wall is said to have failed (deep seated failure) when part of it
type and by the available room. falls into a previously dug out pit. Can be a major hazard when equipment
is working in the vicinity.
It is also important for the face width to be constant over the length of the
dig to maintain
tain a consistent operation.
As a general rule the face width should be 3.3-3.5
3.3 times the boom point
radius distance for single sided loading and double this for double sided
loading.
The following illustration is for an electric rope shovel (4100XPC – boom
point radius = 24 metres.
Skin Slippage is a failure of parts of the wall where for example blasting
has weakened or cracked rocks in the high wall
Fatigue Fatigue Incident
This is a state of impaired mental and/or physical performance and This is an accident,
t, incident or error where fatigue is identified as a
lowered alertness arising as a result of hard physical and mental
me work, significant contributing factor.
health and psychological factors, inadequate restorative sleep or a
Reporting of Fatigue Incident Cases:
combination of these factors. Fatigue can either be work or non-work
non
related or a combination Personnel should be encouraged to report fatigue incidents and cases
of both. without fear of reprisal. Reported fatigue incidents and cases should be
followed up by supervision to identify the cause of the fatigue.
Operators are responsible for:
Reporting of Fatigue Cases and Fatigue incidents whilst driving on public
 Presenting themselves at work in a fit state
st to be able to conduct their
roads is also encouraged, particularly those events that may be associated
duties safely throughout their shift.
with commute travel to and from
 Use the opportunity for sleep provided to obtain adequate rest prior any site.
to commencing a rostered shift
 Report any instances of fatigue or fatigue related incidents to their Discussions with employees regarding fatigue incidents and cases should
supervisor. focus on prevention and the individual taking responsibility for fatigue
 Understanding
erstanding the effects of fatigue on safety and performance. related risks. If the fatigue appears to be more than a one-off
one incident, the
 Complying with the requirements of their site standards. employee can be referred ed for further assessment and further referral if
 Exercise particular care at critical times such as at shift change/and
change at required.
the end of shifts. Each operation should record and track reported fatigue cases and
 Actively participate if required to undergo a fatigue management incidents in the same way as the other Health & Safety incidents, however
individual plan. the fatigue related incidents will be broken into specific
specif categories for
improved Health & Safety fatigue monitoring.
(Life)
Engineers discovered that if you repeatedly applied and then removed a
nominal load to and from a metal part (known as a "cyclic load"), the part
would break after a certain number of load-unload
load cycles, even when the
maximum cyclic stress level applied was much lower than the strength of
the member. They discovered that as they reduced the magnitude of the
cyclic stress, the part would survive more cycles before breaking. This
behaviour became known as "FATIGUE" because it was originally thought
that the metal got "tired". When you bend a paper clip back and forth until
it breaks, you are demonstrating fatigue behaviour.
On a Loader, the cyclical action of dig, swing, dump and return creates
many fatigue situations
ons around the machine.
Fatigue life is a fixed quantity, and is always being used. The questions
are:
 How fast is the available fatigue life being used?
What are critical crack lengths compared to inspection strategies?
Fault – A Fracture Zone in the Overburden Fill
http://en.wikipedia.org/wiki/Geologic_fault Fill refers to the period of time between the bucket engaging the material
and disengaging the material with a load prior to swinging
s ready for
dump.
The following figures demonstrate a backhoe filling.
In geology a fault, or fault line, is a planar

plana fracture in rock in which the
rock on one side of the fracture has moved with respect to the rock on the
other side. Large faults within the Earth's crust are the result of
differential or shear motion and active fault zones are the causal locations
of most earthquakes.
Since faults do not usually consist of a single, clean fracture, the term fault
zone is used when referring to the zone of complex deformation that is Fitness for work
associated with the fault plane. The two sides of a non-vertical
non fault are
called the hanging
nging wall and footwall. By definition, the hanging wall Management of fatigue is just one part of an overall Fitness for Work
occurs above the fault and the footwall occurs below the fault. system. Each part of the system is interrelated and is likely to impact on
the other factors
rs if not managed effectively. The components of a holistic
Fitness 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 Impairment
Impairmen Management System
 A Health Management System;
 Medical Assessment (including assessment for potential sleep
disorders)
 Health Promotion & Health Programs
 Occupational hygiene
 Illness and Injury management
Fire suppression and emergency shut down Float – Lowbed/Flatbed
Flatbed/Transporter
A Float/Lowbed/Flatbed/Transporter
Transporter is a large trailer that is used to
transport large mining equipment.
Fire
e Suppression Bottle – Storage container
for fire suppressant
Fragmentation – How well
wel the material is Free Dumping – Block Tipping
shot
When the haul truck operator is required to carry out block dumping in
Fragmentation is how well the overburden is fractured or broken up. designated areas or roadwork the following procedures should be carried
Good fragmentation of the blasted overburden is when the dragline can out.
fill the bucket easily with a good heap of spoil on the top. Overburden can  The operator should observe the dumping site to ensure it is level,
at times be over fragmented
agmented and it will tend to flow out of the bucket clear of obstruction and able to support the weight of the loaded haul
without heaping. truck.
Good Fragmentation is when the particle rock sizes range from fines up to  Plan the approach and exit from the dump site.
around half the width of the bucket.  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 equipment
equi
required to spread or move the material.
An example of bad fragmentation is shown below.
Freeboard
Freeboard
board is the gap (usually deliberately) left between the material and
the 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
reduce output.
Front End Loader – (FEL) Front End Loader – Controls
A Front End Loader is a loading unit as can be seen below. Please refer to Below is an example of the controls.
specific makes and models as illustrated in this dictionary.
Front End Loader – Filling cycle Front End Loader – Loading from a
stockpile
Below is the illustrated filling technique of a front end loader.
When loading from a stockpile:
 The operator should position the bucket parallel to and just touching
the ground.
 Drive forward and engage the stockpile with the bucket in the
same position.
 Raise the bucket lift control lever to raise the bucket while continuing
to move forward into the material.
 Tilt the bucket back with the tilt control
con while moving up through
the material.
 Return the lift control to Hold/Float
Float position
posit to obtain additional
crowd.
 Adjust the wheel torque to prevent the wheels spinning.
 Once full, raise the bucket high enough to clear the material being
loaded.
 rse the loader away from the stockpile.
Reverse
 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.
Front End Loader – Loading technique Front End Loader – Schematic
To ensure efficiency and safety when loading the haul truck, the front end
loader should stand out from the face to enable the haul truck to reverse
into the correct position without obstructions. The loader operator will be
ready to dump the load by ensuring the bucket is fully raised to allow the
truck operator to reverse into position ensuring proper spotting.
The haul truck operator is to carefully reverse under the full bucket
ensuring that the haul truck is square to, and approximately two metres
from, the front wheels of the front end loader. Stop as the loader dumps
the first bucket of material and remain in that position during loading
until given the signal to pull away.
Side Loading with a Front-End

Correct loading position for Near-Side Front Loader
Fuel Burn Rate – Rate of fuel burn on the Fuel Filter – Filters fuel (Truck)
T&L Fleet
Fuel filters remove particles or other contamination from the fuel before it
This methodology employed, is PwC’s
PwC intellectual property and should not gets into the engine for combustion. This is an easy and cheap way to
be employed by others without the express written permission of PwC. It make sure that the fuel is clean enough for the engine. Filters should be
uses a series of graphs where each individual cycle has key dependent checked on a regular base as stated in OEM manuals.
variables plotted against independent variables.
The dependent variables are load time, spot time, dump time and queuing
time. The independent variables are haul distance loaded and return
distance; for the velocity an average velocity was taken over each cycle
performed by the unit over the period analysed. Fuel burn rate is analysed
by using fuel consumed over the time in relation
rel to distance and velocity.
The Main KPI used by PwC when assessing Fuel efficiency is
Litres/BCM/KM calculated as follows: ((Total Fuel/Cycle Count)/(Total
Count)
Full Haul Distance/Cycle Count))/Average Payload
Using this KPI we can take into account not only
on the productivity of the
truck but also the distance travelled to ensure that trucks can be
benchmarked fairly against one another. The lower the Litres/BCM/KM
value the more efficient the truck.
The following table shows the overall fuel efficiency for three models of
truck for the years
Fuel Tank – Diesel Storage
Fuel Tank Sediment Drain Valve – Drain PwC – Worldwide Productivity and
valve Reliability Database
This valve is used to drain the fuel line of any sediment on some makes PwC has been building this warehouse of data since 1992 and PwC has
and models of trucks and loading units. spent thousands of hours in its development:
Fuel Tank sediment

drain valve
**Valid at time of going to Press.
PwC – Productivity
ctivity Philosophy
Payload is critical. It is the most important metric and focus must be
provided to maintain payloads in loaders and trucks.
Fill the bucket up & do it more often
Gear leaver – Trucks Geotechnical hazards
The gear range can be selected with this lever to match
mat the travel Any issues related to the material being moved either pre or post digging
conditions. are geotechnical hazards. Cracks and Sinkholes, Settlement cracks are not
always serious but should be filled in. Avoid letting water drain into cracks
cr
D position: This is used for normal travel. If the lever is placed in this
position, the transmission is shifted automatically from 2nd to top gear to “Steps” formed across cracks may lead to failure. Tip short and doze to re-
re
match the travel speed of the machine. If the dump body is raised, the establish gradient and windrow. Sinkholes – risk of tyre/suspension
shift lever
ver is normally fixed at 1st. always lower the dump body when damage or rollover. They can appear well behind the tip head.
traveling.
Geology – The structure of the earth

Geology is a region or stratum distinguished by composition or content of
the overburden. The geology of the coal and overburden is very complex at
times.
Geotechnical failure – Geotechnical Geotechnical failure – Crest Failure
interpretation,
rpretation, cracks or previous failure
Geotechnical
Geotechnical failures are based on the results of geotechnical
interpretation, cracks or previous failure. Geotechnical instability hazards
can comprise of uncontrolled, un-retained
retained or poorly retained fill, slope
instability
ability (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
required.
 Trucks should be at least 4m from the edge of the dump. Geotechnical failure – Foundation Failure
 Define this distance using a windrow of sufficient height – i.e. a 1.5m
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.
G.E.T – Ground Engaging Tools
G.E.T are the replaceable/wearing
wearing parts that are on a bucket/dipper
bucket
which interact with the ground.
These parts wear out relatively quickly as they are constantly in contact
with the overburden
rburden as the bucket is dragged through it. GET includes;
teeth, adaptors, lip shrouds and cheek shrouds.
GPS Antenna – Global Positioning System

Satellite based positioning unit which allows an accurate positioning of
the truck/loading unit anywhere on n the mine.
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.
Gravel – Surface Material for Roadways Guide Post – Delineates Roadways
Gravel is a stony mix of material used to surface roadways and prevent Guide Posts are used on a mine site to delineate roadways.
excessive surface break up under use of heavy traffic. Crushed basalt or
Most guide posts used are various lengths of white PVC pipe with
similar hard igneous rocks are common roadway gravels used.
reflectors attached. 3 metre lengths of PVC are used on some haul roads to
make it easier for the large trucks to see the edges of the road.
Grease lines – Carry hydraulic fluid
Gyratory Crusher – Rock breaker

This is also known as a cone crusher /rock breaker. It is large crushing
machinery, using the gyratory sports in casing cone cavity of crushing
cone to produce extrusion, fracturing and bending role to materials for
crushing ore or rock of various hardness.
Hang time – Wait vs. Queue time Hard Dumping – Dumping technique
“Hang time” is the same as “Wait
Wait on truck”
truck time experienced by a loading Hard dumping refers to reversing to a dump whilst loaded in normal
unit versus the time lost by the trucks while queuing. operating conditions, this being on a firm, compacted dry dump area.
Mines should determine what the target is and set appropriate measures
in place to manage and achieve this.
Hauling Haul road – Crossfall
This is the transportation of resource or waste to another location by Crossfall is thee difference in elevation between the crest (crown) and the
truck. road edge. It is a widely used technique that effectively drains water from
road surfaces and is to be incorporated in all road designs.
During the hauling phase, the operator must observe the following to
ensure efficiency and safety are maintained
aintained at all times: Crossfall helps protect the road pavement from damage by water
w by
reducing pooling of water, mud and potholing. If water is allowed to
 Follow the planned haul route to your destination. accumulate on the running surface, deterioration of the sub-base
sub due to
 Always utilise your mirrors to ensure adequate visual awareness in water saturation may occur. If the sub-base
sub becomes exposed, tyre
your surrounding areas. damage may also occur.
 When exiting the pit, the truck will upshift automatically as the
ground speed increases. The rate of crossfall
all depends on a number of factors including the road
 Always select the appropriate gear to prevent unnecessary gearing gradient, the road surface and the expected weather conditions. From an
down while going up steep ramps for maximum efficiency. operator’s point of view, a level driving surface is most preferred because
 Maintain a minimum safety distance between trucks, other equipment this requires the least steering effort. However, to allow
a adequate
and light vehicles (follow site rules). drainage, crossfall must be applied and so the rate must accommodate
both a rapid removal of surface water and steerability.
 Keep on the correct side off 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 with wit all vehicles on the haul circuit
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 the
circuit.
Haul road – Design
To minimize or prevent damage to haul roads only suitable and dry
materials should be used in their construction. Make sure that there is no
wet material beneath the road; a minimum of 4 metres, or preferably 5-6
5
metres. A fully loaded truck generates vibrations which can penetrate up
to 4 metres into the ground (depending on material). These vibrations can
transform wet material into a very thick liquid-like
liquid state.
Design roads with a small slope to the side so that rain water can run off
quick and easily to the side away from the road. Remove any water puddle
on or beside road to avoid the water’s eventual penetration into the road
surface and substrates.
The radii of haul road corners are important issues to be taken into
consideration during the road planning stage.
To prevent overheating of truck tyres, the radius of a corner should be as
wide as 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 a
tyre especially when a truck is fully loaded.
Haul routes need to be well maintained and at an acceptable grade

gra of a
maximum of 10% (follow your sites regulations).
Haul Road Maintenance – Strategy Haul road – Superelevation (Camber)
If there is spillage (loose rock/material)
material) on the haul road due to Superelevation (camber) is a technique to assist vehicles in driving safely
overloading or aggressive cornering, the haul truck operator must contact around corners. It allows the vehicle taking the corner to counteract forces
the supervisor or thee road maintenance machine to come and clean-up
clean towards the outside of the curve, by directing the vehicle weight towards
and repair the haul road. the centre of radius of the curve. The amount of superelevation on a
corner is directly related to the radius of the corner and the desired
Damage to tyres (side wall cuts) is mainly due to spillage in the face and
vehicle speed through the corner.
on the haul roads. To enhance and speed up truck cycle time haul roads
should be regularly maintained. Superelevation is a particularly important design consideration for
switchbacks on pit ramps. On such corners, which typically have a small
 Pot-holes
holes and undulations etc. should be filled to minimize wear and turn radius, superelevation is extremely important. On switchbacks that
tear on the trucks. have the centre of the curve located on the up-side
up of the ramp, a well-
 To prevent excessive dust pollution, an allying compound should be chosen superelevation rate prevents material being spilled from loaded
used or water should be applied to the haul roads. trucks and also improves control.
 The width of the road should be wide enough for the biggest
b trucks
used on the site to pass each other with a suitable gap between them. The camber on some haul roads fall to the wrong side of the bend. This
 Also take into consideration the: grade, width, separation berms, causes an increase in tyre stress and damage as well as shifting the centre
corner camber, demarcation, weight of load & truck type, etc. of gravity on the trucks. Incorrect camber reduces truck stability (safety),
reduces tyre lifee (maintenance cost) and slows the trucks (production).
Incorrect superelevation.
Haul Road Undulation – Soft areas Hazard – Something which may result in
injury or harm
This is generally caused by an insufficient foundation or wet spots on the
road. These areas must be maintained and repaired to minimise damage Safety around an operation is paramount at all times. The identification of
to truck tyres and suspension. hazards is critical in incident prevention. It is the responsibility of all mine
employees to identify and control hazards in the work place.
Hazards cause….
Heel Wear (dipper) – Damage to the heel of

a dipper caused by the tooth attack angle
Heel wear in conjunction with wear under the teeth, is affected and
influenced by the tooth attack 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 High Wall failure – Unstable Wall or parts
of it
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. In aid to have failed when part of it falls into a previously dug
A high wall is said
competent material the angle is usually 70 degrees, but it time can be laid out pit. This can be a major hazard when equipment is working in the
back to 60 degrees. Some mines cut vertical high walls. This can create an vicinity.
issue with unstable material which creates a safety issue for people
working under it.
Some mines also presplit their high wall. When done correctly this
practice creates a very clean, stable wall.
Historical Data – Information from

previous strips
Significant knowledge is accumulated through experiences at a particular
operation. Historical data is information gathered by various means and
archived for future reference. Data is gathered by machine production
monitors, engineers and production personnel in hard or electronic copy,
and is a very useful meanss of verifying what may have happened during
the excavation of previous parts of the mine.
Sometimes historical data is lost due to the movement of key personnel
around site or to other sites and these needs to be planned for.
Hitachi EH1600 – Dump Truck
Truc Hitachi EH1700 – Dump Truck
Hitachi EH1600 Hitachi EH1700 EH1700-3
Engine Gross Power (kW) 783 Engine Gross Power (kW) 895 783
Net Power (kW) 732 Net Power (kW) 836 710
Transmission Max. Speed (kph) 58.6 Transmission Max. Speed (kph) 61.6 55.7
Weight Empty (kg) 70920 Weight Empty (kg) 71736 68137
Loaded (kg) 160664 Loaded (kg) 170100 163300
Operating Capacities (m3) Struck 35 Operating Capacities (m3) Struck 38.6 39.5
Heaped 2:1 57.1 Heaped 2:1 60.3 60.4
Rated Payload (kg) 89700 Rated Payload (kg) 98400 95200
Fuel Capacity (L) 1003 Fuel Capacity (L) 1003 1136
Dump Height (mm) 9780 Dump Height (mm) 9860 9820
Raise Time (s) 12.8 Raise Time (s) 12.8 12.8
Dimensions Overall Length (mm) 10110 Dimensions Overall Length (mm) 10290 10540
Overall Width (mm) 5890 Overall Width (mm) 6050 6250
Overall Height (mm) 5310 Overall Height (mm) 5310 5170
Hitachi EH3000 – Dump Truck Hitachi EH3500 – Dump Truck
Hitachi EH3000 Hitachi EH3500 EH3500ACII
Transmission Max. Speed (kph) 54.7 Transmission Max. Speed (kph) 55.7 56
Operating Capacities (m3) Struck 72.2 Operating Capacities (m3) Struck 79.9 74
Heaped 2:1 101.9 Heaped 2:1 115.1 111
Fuel Capacity (L) 2838 Fuel Capacity (L) 2838.8 2950
Raise Time (s) 17.9 Raise Time (s) 17.9 17.5
Hitachi EH4000 – Dump Truck Hitachi EH4500 – Dump Truck
Hitachi EH4000 EH4000ACII Hitachi EH4500 EH4500-2 EH4500 AOS
Engine Gross Power (kW) 1864 1864 Engine Gross Power (kW) 2013 2014 2013
Net Power (kW) 1790 1771 Net Power (kW) 1973 1939 1963
Transmission Max. Speed (kph) 48.4 56 Transmission Max. Speed (kph) 62 66.9 58.6
Weight Empty (kg) 157895 162000 Weight Empty (kg) 180014 198096 195625
Loaded (kg) 385923 384000 Loaded (kg) 435456 480362 469153
Operating Capacities (m3) Struck 92.9 106
Operating Capacities Struck 105.4 108 90.81
Specifications
Heaped 2:1 131.9 153 Specifications (m3)
Heaped 2:1 147.6 159 144.05
Rated Payload (kg) 228028 222000
Rated Payload (kg) 255442 282000 273528
Fuel Capacity (L) 3785 2680
Fuel Capacity (L) 3785 3785 3785
Dump Height (mm) 12520 13860
Dump Height (mm) 14250 14300 14400
Raise Time (s) 23 18
Raise Time (s) 22.2 22 22.2
Dimensions Overall Length (mm) 13510 14280
Dimensions Overall Length (mm) 14150 14300 14150
Overall Width (mm) 7870 9540
Overall Width (mm) 8150 9050 8760
Overall Height (mm) 6860 7360
Hitachi EH5000 – Dump Truck Hitachi EX1800 – Hydraulic
Shovel/Excavator
Hitachi EH5000 EH5000ACII
Engine Gross Power (kW) 2014 2014 Hitachi EX1800-2 EX1800-3
Net Power (kW) 1939 1896 Backhoe Shovel Backhoe Shovel
Transmission Max. Speed (kph) 66.9 60 Bucket Bucket Bucket Bucket
Weight Empty (kg) 213185 210000 Engine Gross Power (kW) 746 746 746 746
Loaded (kg) 528208 500000 Working Max. Digging Depth (m) 9.24 5.92 9.27 5.93
Range
Operating Capacities (m3) Struck 143.6 156 Max. Cutting Height (m) 14.45 14.55 14.44 14.54
Specifications Max. Dumping Height (m) 9.16 10.4 9.16 10.4
Heaped 2:1 196.1 206
Rated Payload (kg) 315000 290000 Max Digging Reach (m) 16.07 13.4 16.07 13.4
Fuel Capacity (L) 3785 4732 Operating Weight (kg) 177000 177000 180000 180000
Dump Height (mm) 14280 14460 Transmissio Max. Speed (kph) 2.1-2.8 2.1-2.8 2.1-2.8 2.1-2.8
n
Buckets Capacities (m3) PCSA 1:1 4.3-14 10.3- 4.4-14 10.5-
Dimensions Overall Length (mm) 14420 15220 14.5 14.5
Overall Width (mm) 9050 9280 PCSA 2:1 3.8-12.5 3.8-12.5
Overall Height (mm) 7170 8010 /CECE
Boom Length (m) 8.7 8.7
Stick Length (m) 4 4
Dimensions Overall Height 6115 6115 6910 6910
(mm)
Overall Length (No Bucket) 9750 9750 9760 9760
Overall Width 5770 5770 6200 6200
Others Match Trucks 46, 77, 120 tonnes truck
Hitachi EX1900 – Hydraulic Hitachi EX2500 – Hydraulic
Hitachi EX1900-5 EX1900-6 Hitachi EX2500 EX2500-5 EX2500-6
Backhoe Shovel Backhoe Shovel Backhoe Shovel Backhoe Shovel Backhoe Shovel
Bucket Bucket Bucket Bucket Bucket Bucket Bucket Bucket Bucket Bucket
Engine Gross Power (kW) 765 765 810 810 Engine Gross Power 970 970 1007 1007 1044 1044
(kW)
Net Power (kW) 775 775
Net Power (kW) 935 935 971 971 994 994
Working Max. Digging Depth (m) 8.18 5.92 8.18 5.92
Range Working Max. Digging 8.57 3.72 8.57 3.72 8.6 3.72
Range Depth (m)
Max. Dumping Height (m) 9.06 10.44 9.06 10.44
Max. Cutting 16.16 15.01 16.16 15.01 16.06 15.01
Max Digging Reach (m) 15.25 13.43 15.25 13.43 Height (m)
Operating Weight (kg) 186500 185900 192000 191000 Max. Dumping 10.36 10.35 10.36 10.35 10.33 10.35
Height (m)
Transmission Max. Speed (kph) 2.1-2.8 2.1-2.8 2.1-2.8 2.1-2.8
Max Digging 16.5 14.06 16.5 14.06 17.08 14.06
Buckets Capacities PCSA 1:1 4.4-12 4.4-12 Reach (m)
(m3)
PCSA 2:1 3.8-10.6 11.0- 11.0- Operating Weight 236000 238500 239000 242000 248000 249000
/CECE 15 15 (kg)
Boom Length (m) 8.3 8.3 Transmission Max. Speed (kph) 2.3 2.3 2.3 2.3 2.3 2.3
Stick Length (m) 3.6 3.6 Buckets Capacities PCSA 13.8 15 15
Dimensions Overall Height 6820 6820 6990 6990 (m3) 1:1
(mm) PCSA 14 15- 15-
2:1 16.5 16.5
Overall Width 6260 6260 6660 6660
Boom Length (m) 9 9 9
Others Match Trucks EH1700
Stick Length (m) 4.2 4.2 4.2
Dimensions Overall Height 7.04 7.04 7.04 7.04 7.25 7.25
(m)
Overall Length 10.225 10.225 10.225 10.225 10.225 10.225
(No Bucket)
Overall Width 6.35 6.35 6.2 6.2 7.56 7.56
Hitachi EX3500 – Hydraulic Hitachi EX3600 - Hydraulic
Hitachi EX3500-2 EX3500-3 Hitachi EX3600
EX3600-5 EX3600-6
Backhoe Shovel Backhoe Shovel Backhoe Shovel Backh Sho
Bucket Bucket Bucket Bucket Bucket Bucket oe vel
Bucke Buck
Engine Gross Power (kW) 1312 1312 1312 1312
t et
Net Power (kW)
Working Max. Digging Depth (m) 9.34 6.06 9.34 6.04
Net Power (kW) 1400 1400 1450 1450
Range
Woring Max. Digging Depth 8.58 3.91 8.58 4.16
Max. Dumping Height (m) 13.3 12.42 13.3 12.42 Range (m)
Max Digging Reach (m) 19.4 15.81 19.4 15.81 Max. Cutting Height 17.69 16.3 17.69 16.5
(m) 6
Max. Dumping Height 11.59 10.99 11.59 10.9
Transmission Max. Speed (kph) 1.8-2.4 1.8-2.4 1.8-2.4 1.8-2.4
(m) 9
Buckets Capacities PCSA 1:1 17-25 18-25 17-25 18-25
Max Digging Reach 18.19 15.22 18.19 15.4
(m3)
PCSA 2:1 15-22 15-22 (m) 7
/CECE Operating Weight (kg) 348000 35000 35900 3620
Boom Length (m) 10 10 0 0 00
Stick Length (m) 5 5 Transmissio Max. Speed (kph) 2.2 2.2 2.2 2.2
n
(mm) Buckets Capacitie PCSA 22 22
Overall Length (No 11130 11130 11130 11130 s (m3) 1:1
Bucket)
PCSA 21-23 21-
Overall Width 8240 8240 8240 8240 2:1 23
Others Match Trucks 154 tonnes truck Boom Length (m) 9.6 9.6
Stick Length (m) 4.5 4.5
Dimensions Overall Height 7.75 7.75 7.83 7.83
(m)
Overall Length (No 11.13 11.13 11.13 11.1
Bucket) 3
Overall Width 9.03 9.03 9.42 9.42
Hitachi EX5500 – Hydraulic Hitachi EX8000 – Hydraulic
Hitachi EX5500-1
1 EX5500-5 EX5500-6 Hitachi 8000 8000-6 8000 E-6
Backho Shovel Backho Shovel Backho Shovel Shovel Shovel Shovel
e Bucket e Bucket e Bucket Bucket Bucket Bucket
Engine Rate Power (kW) 2800 2900 2400
Engine Gross Power (kW) 1940 1940 2014 2014 2088 2088
Working Max. Digging Depth (m) 4.1 4.1 4.1
Net Power (kW) 1942 1942 1988 1988 Range
Max. Cutting Height (m) 20.5 20.5 20.5
Working Max. Digging 9 4.55 9 4.55 9 4.55
Max. Dumping Height (m) 13.8 13.8 13.8
Range Depth (m)
Max Digging Reach (m) 18.5 18.5 18.5
Max. Cutting 20.6 18.9 20.6 18.9 20.6 18.9
Height (m) Operating Weight (kg) 805000 811000 804000
Max. Dumping 13 13.1 13 13.1 13 13.1 Transmission Max. Speed (kph) 1.4-2.0 1.4-2.0 1.3-1.9
Height (m)
Buckets Capacities PCSA 40 40 40
Max Digging 20.9 16.6 20.9 16.6 20.9 16.6 (m3) heaped
Reach (m)
Dimensions Overall Height (To Cab) 9900 9900 9900
Operating Weight 515000 515000 518000 518000 522000 522000 (mm)
Overall Length (No Bucket) 13530 13530 13530
(kg)
Overall Width 10670 10670 10670
Transmission Max. Speed (kph) 2.3 2.3 2.3 2.3 2.3 2.3
Others Match Trucks (Hitachi) EH5000 EH5000ACII EH5000
Buckets Capacit PCSA 1:1 29 27 29 29
ies
PCSA 2:1 26 27/29/30. 27
(m3)
/CECE 6
Boom Length (m) 10.6 10.6 10.6
Stick Length (m) 5.3 5.3 5.3
Dimensions Overall Height 8.5 8.5 8.5 8.5 8.6 8.6
(m)
Overall Length 12.425 12.425 12.425 12.425 12.625 12.625
(No Bucket)
Overall Width 9.85 9.85 9.85 9.85 10.08 10.08
Hitachi R90 – Dump Truck Hitachi R100 – Dump Truck
Hitachi R90 R90C Hitachi R100
Engine Gross Power (kW) 690 690 Engine Gross Power (kW) 783
Net Power (kW) 650 650 Net Power (kW) 746
Transmission Max. Speed (kph) 57.55 54.8 Transmission Max. Speed (kph) 54.69
Weight Empty (kg) 63731 64410 Weight Empty (kg) 67541
Loaded (kg) 149687 155129 Loaded (kg) 158261
Operating Capacities (m3) Struck 35.7 35.7 Operating Capacities (m3) Struck 35.1
Heaped 2:1 52.7 52.7 Heaped 2:1 55
Rated Payload (kg) 85756 90718 Rated Payload (kg) 90720
Fuel Capacity (L) 1003 1003 Fuel Capacity (L) 1230.1
Dump Height (mm) 9730 9730 Dump Height (mm) 10240
Raise Time (s) 12 12 Raise Time (s) 20
Dimensions Overall Length (mm) 10260 10260 Dimensions Overall Length (mm) 10640
Overall Width (mm) 5440 5890 Overall Width (mm) 5540
Overall Height (mm) 5180 5180 Overall Height (mm) 5640
Hitachi R120E – Dump Truck Hitachi R130 – Dump Truck
Hitachi R120E Hitachi R130 R130B R130M
Engine Gross Power (kW) 895 Engine Gross Power (kW) 1007 1007 1007
Transmission Max. Speed (kph) 50.2 Transmission Max. Speed (kph) 38.5 49 59.8
Weight Empty (kg) 81460 Weight Empty (kg) 79357 94761 79350
Loaded (kg) 190320 Loaded (kg) 217700 226761 197286
Operating Capacities (m3) Struck 42.5 Operating Capacities Struck 50.3 50.3 50.3
Specifications Specifications (m3)
Heaped 2:1 65.4 Heaped 2:1 71.9 71.9 71.9
Rated Payload (kg) 108860 Rated Payload (kg) 138371 132000 117936
Fuel Capacity
ty (L) 1930.4 Fuel Capacity (L) 1930.4 1930.4
Raise Time (s) 18 Raise Time (s) 20 12.8 20
Dimensions Overall Length (mm) 11380 Dimensions Overall Length (mm) 11250 11230 11250
Overall Width (mm) 5800 Overall Width (mm) 5840 6070 5840
Overall Height (mm) 5610 Overall Height (mm) 5840 5770 5760
Hitachi R150 – Dump
p Truck Hitachi R170 – Dump Truck
Hitachi R150 Hitachi R170 R170C
Transmission Max. Speed (kph) 55.4 Transmission Max. Speed (kph) 55.4 54.7
Operating Capacities (m3) Struck 59.3 Operating Capacities (m3) Struck 68.4
Heaped 2:1 84.1 Heaped 2:1 97
Fuel Capacity (L) 1930.4 Fuel Capacity (L) 1930.4 2838.8
Raise Time (s) 25 Raise Time (s) 25 17.9
Hitachi R190 R190C Hitachi R220
Engine Gross Power (kW) 1342 1342 Engine Gross Power (kW) 1491
Net Power (kW) 1230 Net Power
wer (kW)
Transmission Max. Speed (kph) 52.6 55.4 Transmission Max. Speed (kph) 56
Weight Empty (kg) 114416 127252 Weight Empty (kg) 133800
Loaded (kg) 286784 310652 Loaded (kg) 324310
Operating Capacities (m3) Struck 77.7 Operating Capacities (m3) Struck 78.7
Heaped 2:1 106.8 106.8 Heaped 2:1 108.3
Rated Payload (kg) 172368 183400 Rated Payload (kg) 190510
Fuel Capacity (L) 2854 Fuel Capacity (L)
Dump Height (mm) 11160 Dump Height (mm)
Raise Time (s) 26 26 Raise Time (s)
Dimensions Overall Length (mm) 11790 11980 Dimensions Overall Length (mm)
Overall Width (mm) 6680 7160 Overall Width (mm)
Overall Height (mm) 5920 6370 Overall Height (mm)
Hitachi R260 Hitachi R280 R280AC
Net Power (kW) 1780 Net Power (kW) 1973
Transmission Max. Speed (kph) 48.8 Transmission Max. Speed (kph) 62 62
Operating Capacities Struck 92.9 Operating Capacities (m3) Struck
Specifications (m3) Specifications
Heaped 2:1 131.9 Heaped 2:1
Raise Time (s) 23 Raise Time (s) 22
Hoist Control Lever – Truck Tray Control Hoist Cylinder/ram – Raises Tray to Dump
Position
This is the control used to raise, lower or float the truck tray.
These cylinders raise the truck tray up for dumping or maintenance.
Lever Hold Raise
Power Down Float Travelling Position
Hydraulic Drive – Propels the Tracks
Hoist Ropes – Control
ontrol Vertical Bucket These are the hydraulic motors that propel some machines.
Movements (Rope Shovel)
Hydraulic Filters – Clean Hydraulic Fluids
Host Rock – Waste

Host rock or waste is rock which serves as a host for or the surrounding
material of an ore body or mineral deposits. Material above and around
an ore body may need to be removed in the mining process of an open cut
mine.
Hydraulic Face Shovel – Machine Hydraulic Face Shovel – Bucket
A Hydraulic Face Shovel is a loading unit as can be seen below. As
opposed to the backhoe which digs towards itself, the face shovel digs
away from itself. Please refer to specific makes and models as illustrated
in this dictionary.
Hydraulic Face Shovel – Schematic Hydraulic Pump – Pressurises Hydraulic
Fluid
Hydraulic Tank – Hydraulic Fluid Storage Idler – Undercarriage
Inclinometer – Measures angles

Inclinometers are used to determine the angle of operation on many
loading machines. Most loading units have designed cross fall and slope
angle limitations and must not be operated past
p these. Operating a
loading unit on an angle increases damage to the machine.
Idle Time – A stoppage when the operator

fails to enter a delay into the monitor
Idle time is usually a failure on the part of the operator to enter a delay
into the production monitor. Not all monitors call it idle; some may call it
stand-by
by or some form of unknown delay. There should never be idle time
for trucks and loaders as there is always a reason for a delay, and the
operator should ensure there is a delay entered.
Isolation Station – A System to Positively Joy Stick – Steering control
Remove Power
An example of a Joy Stick steering control used on a Front End Loader is
The rules regarding the application and locks and or tags to equipment illustrated below.
are there to protect you and your fellow workers
worke from a potentially serious
or life-threatening incident. The general rules for tags and locks are:
 No person shall attempt to start or operate any plant or equipment
that has a personal locks, Danger tags (if required) or Out of Service
tags attached
 nce tags have been used they must be destroyed
Once
Komatsu 630E 685E 730E – Dump Truck Komatsu 830E-AC – Dump Truck
Komatsu 630E 685E 730E 630E 685E 730E 730 E-7 Komatsu 830E Series 830E 830E-AC
Net Power (kW) 1271 1383 1388 1388 Net Power (kW) 1761 1761
Transmission Max. Speed (kph) 51 67 55.7 55.7 Transmission Max. Speed (kph) 48.8 64
Weight Empty (kg) 113559 128369 140592 140592 Weight Empty (kg) 162505 164200
Loaded (kg) 285559 309369 324322 324319 Loaded (kg) 385852 385848
Operating Capacities Struck 77 77 Operating Capacities (m3) Struck 117 117
Heaped 103 111 111 111 Heaped 2:1 147 147
2:1
Rated Payload (kg) 172000 181000 183730 185949
Dimensions Overall Length (m) 14.2 14.4
Dump Height (m) 12.51 12.51
Overall Width (m) 7.32 7.32
Overall Height (m) 6.88 6.88
Dimensions Overall Length (m) 11.89 11.94 12.83 12.83
Overall Width (m) 7.01 7.21 7.54 7.54
Overall Height (m) 6.38 6.55 6.25 6.25
Komatsu 860E – Dump Truck Komatsu 930E – Dump Truck
Komatsu 860E 860E-1K Komatsu 930E Series 930E 930E-2 930E-3 930E-4 930E-
4SE
Engine Gross Power (kW) 2014
Net Power (kW) 1902
Net Power (kW) 1865 1902 1902 1902 2558
Transmission Max. Speed (kph) 64.5
Transmission Max. Speed (kph) 64.5 64.5 64.5 64.5 64.5
Weight Empty (kg) 200351
Weight Empty (kg) 180440 20223 21168 21018 215307
Loaded (kg) 454363
- 2 1 7
Operating Capacities (m3) Struck 122 190268
Specifications
Heaped 2:1 169 Loaded (kg) 462440 49895 50197 50197 505755
- 2 4 4
Rated Payload (kg) 254012
480567
Fuel Capacity (L) 4542
Operating Capacitie Struck 171 171 171 171
Dump Height (m) 14.04 Specification s (m3)
Heape 161-
161 211 211 211 211
s
Raise Time (s) 22 d 2:1 184
Dimensions Overall Length (m) 14.93 Rated Payload (kg) 282000 29000 29029 29179 290448
- 0 3 0
Overall Width (m) 9.39 290299
Overall Height (m) 7.3 Fuel Capacity (L) 4542 4542 4542 5300
Dimensions Overall Length (m) 15.2 15.32 15.6 15.6 15.6
Overall Width (m) 8.43 8.69 8.69 8.69 8.69
Overall Height (m) 7.26 7.32 7.37 7.37 7.37
Komatsu 960E – Dump Truck Komatsu (Demag) H285 – Hydraulic
Shovel/Excavator
Komatsu 960E 960E_1 960E_1K 960E_2 960E_2K
Engine Gross Power (kW) 2610 2610 2610 2610 Komatsu (Demag) Demag H285 Demag H285S Komatsu PC4000
Net Power (kW) 2495 2495 2495 2495 Backho Shovel Backho Shovel Backho Shovel
e Bucket e Bucket e Bucket
Weight Empty (kg) 249475 249475 249475 249475
Engine Gross Power (kW) 1400 1400 1300 1300 1400 1400
Loaded (kg) 576072 576072 576072 576072 Net Power (kW) 1350 1350 1178.2 1178.2 1350 1350
Operating Capacitie Struck 149 149 149 149 Working Max. Digging Depth 8 2.8 3.15 8 2.8
Specification s (m3) (m)
Heaped 214 214 214 214 Range
s
2:1 Max. Cutting Height 17.5 15
Rated Payload (kg) 326585 326585 326585 326585 (m)
Fuel Capacity (L) 5300 5300 5300 5300 Max. Dumping Height 12 12.7 12
(m)
Dump Height (m) 14.1 15.51 14.1 15.51
Max Digging Reach 14.7 17.5
Raise Time (s) 24 23 24 24 (m)
Dimensions Overall Length (m) 15.6 15.34 15.6 15.34 Operating Weight (kg) 301000 303000 33500 392000/ 385000
0 397000 /
Overall Width (m) 9.6 10 9.6 10
390000
Overall Height (m) 7.37 7.67 7.37 7.67 Transmissio Max. Speed (kph) 2.1 2.1 1.9 1.9 2.1 2.1
n
Buckets Capacities (m3) 21 16(Std) 17.3 29 (2:1)/ 29
/24 32.7(1:1
)
Boom Length (m) 9.65 7.15 6.3 9.75 7.15
Stick Length (m) 5 4.9 4.3 4.5 4.9
Dimensions Height To Top of Cab 8.26 8.26 7.81 7.81 8.3 8.3
(m) (m)
Overall Length 10.69 10.69 14.2 10.92 10.92
(No Bucket) (W/B)
Overall Width 7.65 7.65 6.45 6.45 8.33 8.33
Komatsu (Demag) H485 – Hydraulic Komatsu (Demag) H655 – Hydraulic
Komatsu (Demag) H485S H485SP H485/H655 Komatsu H485/H655/H685S H655S
/H685SP P
BB SB BB SB BB SB BB SB BB SB
Engine Net Power (kW) 2240- 2240- 2780 1592 1592 Engine Net Power (kW) 1592 1592 2769.5
3000 3000
Working Max. Digging Depth (m) 2.7
Working Max. Cutting Height (m) 18-20.4 20.4 18 Range
Max. Cutting Height (m) 18 20.5
Range
Max. Dumping Height (m) 13-15 14 15
Max. Dumping Height (m) 15 14
Max Digging Reach (m) 16-18 16-18 17
Max Digging Reach (m) 17 16.8
Operating Weight 600- 600- 680- 680- 500- 500-
Operating Weight 500-575 500- 685
(metric ton) 650 650 685 685 575 575
(metric ton) 575
Transmission Max. Speed (kph) 2.1/2.24 2.1/2.2 2.25 2.25 2.1 2.1
Transmissio Max. Speed (kph) 2.1 2.1 2.1 2.1
Buckets Capacities (m3) Std. 33 33 35 35 20 38 n
Long 38 44 Buckets Capacities (m3) Std. 20 38 33-35 33-35
Boom Length (m) 11.5 8.15 Long 38 44
Stick Length (m) 6.3 5.75 Boom Length (m) 11.5 8.15
Dimensions Overall Height (To CAB) 8.21 9.21 9.21 9.21 8.82 8.82 Stick Length (m) 6.3 5.75
(m)
Overall Length (No Bucket) 12.7-13.4 12.7- 13.38 13.38 12.79 12.79 Dimensions Overall Height (To CAB) 8.82 8.82 9.61 9.61
13.4 (m)
Overall Width (Over tracks) 7.8/8.0 7.8/8.1 8.1 8.1 7.8 7.8 Bucket)
Notes: BB = Backhoe Bucket; SB = Shovel Bucket Overall Width (Over 7.8 7.8 7.8 7.8
tracks)
Others Match Trucks CAT793F/EH4000/830
E
Komatsu HD465 – Dump Truck Komatsu HD785 – Dump Truck
Komatsu HD465 Series HD465-
HD465 HD465- HD465- HD46 HD465- Komatsu 785 Series HD785--1 HD785-2 HD785-3 HD785-5 HD785-7
2 3 5 5- 7/7R/7E
5QPA O
K Net Power (kW) 654 654 753 753 879
Engine Gross Power (kW) 551 551 Transmission Max. Speed (kph) 70 65 68 64.7 65
Net Power (kW) 506.3 524 533 533 533 Weight Empty (kg) 55500 56000 60400 70490 72000
Transmissio Max. Speed (kph) 65 65 70 70 70 Loaded (kg) 129555 134000 147400 166468 166000
n
Operating Capacities Struck 40
Weight Empty (kg) 36500 37770 42500 46700 43100 Specifications (m3)
Heaped 52 52 53 60 60
Loaded (kg) 82555 83000 96100 10000 99680 2:1
0
Rated Payload (kg) 78000 78000 87000 91000 91000
Operating Capaciti Struck 25 25
Fuel Capacity (L) 1240 1250 1308
Specificatio es (m3)
Heape 34.2 34.2 34.2 40 34.2
ns Dimensions Overall Length (m) 10.13 10.13 10.1 10.49 10.29
d 2:1
Overall Width (m) 5.7 5.7 5.5 5.66 6.89
Rated Payload (kg) 46000 46000 55000 60000 55338
Overall Height (m) 4.99 4.92 4.92 5.05 5.05
Fuel Capacity (L) 780 780 780 780
Dimensions Overall Length (m) 9 9 9.12/9.4 9.12 9.36
Overall Width (m) 4.05 4.05 4.17/5.1 5.1 5.4
Overall Height (m) 4.25 4.25 4.35/4.4 4.43 4.55
Komatsu HD985 – Dump Truck Komatsu HD1500 – Dump Truck
Komatsu 985 HD985-3 HD985-5 Komatsu HD1500 HD1500-5 HD1500-7
Net Power (kW) 753 753 Net Power (kW) 1048 1048
Transmission Max. Speed (kph) 70 70 Transmission Max. Speed (kph) 58 58
Operating Capacities Struck 45 Operating Capacities Struck 54 54
Specifications (m3) Specifications (m3)
Heaped 2:1 64 Heaped 2:1 78 78
Dump Height (mm) 10135 Dump Height (mm) 11440
Komatsu PC1800 – Hydraulic Komatsu PC2000 – Hydraulic
Hydra
Komats Backhoe Shovel omatsu PC2000-8
u Bucket Bucket
Backhoe Shovel
PC1800
Engine Flywheel
lywheel Power (kW) 676 676 Bucket Bucket
Max. Digging Depth (m) 9.265 3.22 Engine Gross Power (kW) 728 728
Max. Cutting Height (m) 13.38 14.42 Net Power (kW) 713 713
Max. Dumping Height (m) 8.62 9.635 Working Range Max. Digging Depth (m) 9.23 3.19
Max Digging Reach (m) 15.78 13.17 Max. Cutting Height (m) 13.41 14.45
Operating Weight (kg) 180000- 180000- Max. Dumping Height (m) 8.65 9.665
184120 184120
Max Digging Reach (m) 15.78 13.17
Transmissio Max. Speed
d (kph) 2.7 2.7
n
Transmission Max. Speed (kph) 2.7 2.7
Buckets Capacities (m3) 5.6-12 11
Buckets Capacities PCSA 1:1 12 11
(m3)
PCSA 2:1/CECE 11
Dimensions Overall Height 6.745 8.18
(m) Stick Length (m) 3.9 4.45
Overall Length (with Bucket) 17.185 13.23
Dimensions (mm) Overall Height 7030 7030
Overall Width 6.015 6.015
Komatsu PC3000 PC3000-6 Komatsu PC4000 PC4000-6
Backho Shovel Backho Shovel Backhoe Shovel Backhoe Shovel

e Bucket e Bucket Bucket Bucket Bucket Bucket
Bucket Bucket Engine Gross Power (kW) 1400 1400 1400 1400
Engine Gross Power (kW) 940 940 940 940 Net Power (kW) 1350 1350 1350 1350
Net Power (kW) 900 900 900 900 Working Max. Digging Depth (m) 8 2.8 8 2.8
Range
Working Max. Digging Depth 7.8 3.2 7.9 3.3 Max. Cutting Height (m) 14.6 16 15 16
Range (m) Max. Dumping Height (m) 9.6 12 9.6 12
Max. Cutting Height 14.1 14 14.1 15.1 Max Digging Reach (m) 17.5 15.2 17.5 15.2
(m) Operating Weight (kg) 390000 380000 392000 385000
Max. Dumping Height 9 10.2 9 10.2 Transmission Max. Speed (kph) 2.1 2.1 2.1 2.1
(m)
Buckets Capacities PCSA 1:1 22 25 22 25
Max Digging Reach 16.2 13.4 16.2 13.3 (m3)
PCSA 2:1 22 22
(m) /CECE
Operating Weight (kg) 253000 250000 256000 252000 Boom Length (m) 9.75 7.15 9.75 7.15
Transmissio Max. Speed (kph) 2.4 2.4 2.4 2.4 Stick Length (m) 4.5 4.9 4.5 4.9
n
Buckets Capacitie PCSA 15 17.2 15-Jan (mm)
s (m3) 1:1
Overall Width 7650 7650 7975 7975
PCSA 15 15
Others Match Trucks 150-231 tonnes 136-218 tonnes
2:1
/CECE
Boom Length (m) 8.6 6 8.6 6
Stick Length (m) 4 4.3 4 4.3
(mm)
Overall Length (No 10435 10435 10365 10365
Bucket)
Overall Width 6800 6800 6800 6800
Others Match Trucks 77-150 tonnes truck
Komatsu PC5500 PC5500-6 Komatsu PC8000 PC8000-6
Backhoe Shovel Backhoe Shovel Backhoe Shovel Backhoe Shovel
Bucket Bucket Bucket Bucket Bucket Bucket Bucket Bucket
Engine Gross Power (kW) 1880 1880 1880 1880 Engine Power (Diesel Drive)(kW) 3000 3000 3000 3000
Net Power (kW) 1800 1800 1800 1800 Power (Electric Drive)(kW) 2900 2900 2900 2900
Working Max. Digging Depth (m) 8.3 2.7 8.3 2.7 Working Max. Digging Depth (m) 8.09 8.4 3
Range Range
Max. Cutting Height (m) 15.5 19.5 15.5 19.5 Max. Cutting Height (m) 18.3-19.5
Max. Dumping Height (m) 10.1 13.4 10.1 13.3 Max. Dumping Height (m) 14 13.9
Max Digging Reach (m) 19.8 16.5 19.8 16.5 Max Digging Reach (m) 19.73 15.8-17.2 19.9 16.1
Operating Weight (kg) 535000- 535000- 535239- 530703- Operating Weight (kg) 700 700 710-720 700-
549000 549000 548847 544311 710
Transmission Max. Speed (kph) 2.1 2.1 2.1 2.1 Transmission Max. Speed (kph) 2.2 2.2 2.4 2.4
Buckets Capacities (m3) PCSA 28 32 29 Buckets Capacities (m3) PCSA 1:1 38-42 44 38-42 48
1:1 PCSA 2:1 38 42
PCSA 28 29 /CECE
2:1 Boom Length (m) 11.5 8.15 11.5 8.15
/CECE
Stick Length (m) 5.5 5.75 5.5 5.75
Boom Length (m) 11 7.6 11 7.6
Dimensions Overall Height 9.5 9.5
Stick Length (m) 5.1 5.6 5.1 5.6 (m)
Dimensions Overall Height 8.61 8.61 8.61 8.61
(m) Overall Width 9.07 9.07 10 10
Bucket) Others Match Trucks CAT793F/EH4000AC/ 60E-1K
830E
Overall Width 8.6 8.6 8.62 8.62
Others Match Trucks (Komatsu) 830E 860E-1K
Komatsu WA800 – Front End Loader Komatsu WA900 – Front End Loader
Komatsu WA800-3 WA800-3EO Komatsu WA900-3 WA900-3EO
Engine Gross Power (kW) 636 636 Engine Gross Power (kW) 672 672
Flywheel Power (kW) 603 603 Flywheel Power (kW) 637 638
Operating Operating Weight (kg) 98300 101900 Operating Operating Weight (kg) 101550 107200
Buckets Std. Capacities (m3) 11 11 Buckets Std. Capacities (m3) 13 13
Transmission MAX Speed (kph) 28.3 28.3 Transmission MAX Speed (kph) 28.3 28.3
Hydraulic Raise Time (sec) 11.2 11.2 Hydraulic Raise Time (sec) 11.2 11.2
System System
Dump Time(sec) 2 2 Dump Time(sec) 2.8 2
Lower Time(sec) 4.8 4.8 Lower Time(sec) 4.8 4.8
Dimensions MAX Overall Length(mm) 13730 13960 Dimensions MAX Overall Length(mm)
(mm) 14270 14490
Height To Top Of Cab
ab (mm) 5275 5275 Height To Top Of Cab (mm) 5275 5275
Hinge-Pin Height (mm) 6785 6785 Hinge-Pin Height (mm) 6950 6960
Width Outside Tires (mm) 4585 4585 Width Outside Tires (mm) 4585 4585
Others Fuel Tank (L) 1425 1555 Others Fuel Tank (L) 1430 1555
Komatsu WA1200 – Front End Loader KPI – Key Performance Metrics
Komatsu WA1200-3 WA1200-6 KPI’s are used to measure
ure the performance of a truck/loader
truck operation or
Engine Gross Power (kW) 1280 1411 an operator.
Flywheel Power (kW) 1165 1316 These KPI’s give the operator or the mine a measure of how they are
Operating Operating Weight (kg) 205200 216400 tracking against pre-set targets.
Specifications
KPI’s need to be recorded and managed on an Hourly, Shift or Day basis:
Buckets Std. Capacities (m3) 20 20
Transmission MAX Speed (kph) 22.6 19.3
 Fill Time.
 Total Loads.
Hydraulic Raise Time (sec) 13.5 14.8
System  Truck Loading Time.
Dump Time(sec) 3 3.2
 Truck Travelling Time.
Lower Time(sec) 5 5.3  Truck Idle Time.
Dimensions MAX Overall Length(mm) 18200 18310  Shovel Idle Time (waiting on trucks).
Height To Top Of Cab (mm) 6970 6970  Shovel Utilization, (Other Delays blasting etc.)
Hinge-Pin Height (mm) 8830 8850  Truck Availability.
Width Outside Tires (mm) 5820 5820  Shovel Availability.
Others Fuel Tank (L) 5100 5100 KPI variation against Previous Period.
For [785 Trucks, 789 Trucks]
40
30
AP: 18.0
20 LT: 14.9
10
Variation [%]
0
TP: -0.9 LP: -2.6 PR: -3.5
-10
-20
TT: -19.1
-30
-40
This Month
KPI variation against Previous Period.

For [830E Trucks, 4400 Terex Trucks]
40
30
PR: 19.8
20 TP: 14.6
TT: 10.0 LT: 7.8
10
Variation [%]
AP: 5.4 LP: 2.3
0
-10
-20
-30
-40
This Month
Kress Coal Hauler – Unit body coal truck Letourneau L 950 – Front End Loader (Now
owned by Joy Global)
Originally built by the independent Kress Corporation,
Corporation these bottom
dump trucks come in various sizes and have been built in 145 to 290
Letourneau L950
tonne capacities. They have a high PER.
Engine Gross Power
ower (kW) 783
Flywheel Power (kW)
Specifications
Operating Weight (kg) 107275
Buckets Std. Capacities (m3) 13.76
Transmission MAX Speed (kph) 19.31
Hydraulic System Raise Time (sec) 11
Dump Time(sec) 2
Lowerr Time(sec) 5
Dimensions MAX Overall Length(m) 15.66
Height To Top Of Cab (m) 5.64
Hinge-Pin
Pin Height (m) 6.91
Width Outside Tires (m) 4.98
Others Fuel Tank (L) 2384
Pass Match with Trucks (tonnes) 68-109
Letourneau L 1100 – Front End Loader (Now Letourneau L 1150 – Front End Loader (Now
owned by Joy Global) owned by Joy Global)
Letourneau L1100 Letourneau L1150
Engine Gross Power (kW) 895 Engine Gross Power (kW) 899
Flywheel Power (kW) Flywheel Power (kW)
Operating Rated Payload (kg) 29938 Operating Rated Payload (kg) 34473
Operating Weight (kg) 136085 Operating Weight (kg) 140614
Buckets Std. Capacities (m3) 16.82 Buckets Std. Capacities (m3)
(m 19.11
Transmission MAX Speed (kph) 18.5 Transmission MAX Speed (kph) 19.31
Hydraulic System Raise Time (sec) 13 Hydraulic System Raise Time (sec) 13
Dump Time(sec) 3 Dump Time(sec) 3
Lower Time(sec) 6.5 Lower Time(sec) 5
Dimensions MAX Overall Length(m) 15.34 Dimensions MAX Overall Length(m) 16.28
Height To Top Of Cab (m) 5.41 Height To Top Of Cab (m) 5.82
Hinge-Pin
Pin Height (m) 7.67 Hinge-Pin
Pin Height (m) 7.82
Width Outside Tires (m) 5.18 Width Outside Tires (m) 5.11
Others Fuel Tank (L) 1741 Others Fuel Tank (L) 2384
Pass Match with Trucks (tonnes)
(t Pass Match with Trucks (tonnes) 136-181
Letourneau L 1350 – Front End Loader (Now Letourneau L 1400 – Front End Loader (Now
owned by Joy Global) owned by Joy Global)
Flywheel Power (kW) Flywheel Power (kW)
( 1342
Operating Rated Payload (kg) 40823 Operating Rated Payload (kg)
Buckets Std. Capacities (m3) 22.94 Buckets Std. Capacities (m3) 21.4
Transmission MAX Speed (kph) 19.31 Transmission MAX Speed (kph) 15.29
Hydraulic System Raise Time (sec) 15 Hydraulic System Raise Time (sec) 14
Dump Time(sec) 3 Dump Time(sec) 4
Lower Time(sec) 5 Lower Time(sec) 6
Dimensions MAX Overall Length(m) 17.06 Dimensions MAX Overall
all Length(m) 17.22
Height To Top Of Cab (m) 6.05 Height To Top Of Cab (m) 6.32
Hinge-Pin
Pin Height (m) 8.71 Hinge-Pin
Pin Height (m) 8.89
Width Outside Tires (m) 5.77 Width Outside Tires (m) 5.84
Others Fuel Tank (L) 3501 Others Fuel Tank (L) 3974
Pass Match with Trucks (tonnes) 181-236 Pass Match with Trucks (tonnes)
Letourneau L 1800 – Front End Loader Letourneau L 1850 – Front End Loader (Now
(Now owned by Joy Global) owned by Joy Global)
Flywheel Power (kW) 1343 Flywheel Power (kW)
Operating Rated Payload (metric ton) 45 Operating Rated Payload (kg) 54431
Buckets Capacities Range (m3) 21.4-42.1 Buckets Std. Capacities (m3) 30.58
Heaped (m3) 25.2 Transmission MAX Speed (kph) 19.31
Combo (m3) 34.4 Hydraulic System Raise Time (sec) 16
Hydraulic System Raise Time (sec)
c) 14 Dump Time(sec) 4
Dump Time(sec) 4 Lower
ower Time(sec) 6
Lower Time(sec) 6 Dimensions MAX Overall Length(m) 18.9
Dimensions Length with Bucket on Ground (m) 17.8 Height To Top Of Cab (m) 6.37
Overall Height (Bucket Raised) (m) 11.9 Hinge-Pin
Pin Height (m) 9.4
Overall Width (m) 6 Width Outside Tires (m) 6.04
Others Fuel Tank (L) 3975
Pass Match with Trucks (tonnes) 236-327
Letourneau L 2350 – Front End Loader Liebherr 994 – Hydraulic Shovel/Excavator
Shovel
(Now owned by Joy Global)
Liebherr 994 994B
Letourneau L2350 Backhoe Shovel Backhoe Shovel
Bucket Bucket Bucket Bucket
Engine Rate Power (kW) 937 937 1120 1120
Flywheel Power (kW)
Working Max. Digging Depth 8.7 3.7 9.5 3.7
Operating Rated Payload (kg) 72574 Range (m)
Specifications
Operating Weight (kg) 266622 Max. Cutting Height 15.6 14.8 15.4 16.2
Buckets Std. Capacities (m3) 40.52 (m)
Transmission MAX Speed (kph) 19.31 Max. Dumping Height 10.3 10.9 10.2 11.2
(m)
Hydraulic System Raise Time (sec) 17
Max Digging Reach 16 12.9 17 14.6
Dump Time(sec) 3 (m)
Lower Time(sec) 6 Operating Weight (kg) 229000 226400 296800 306500
Dimensions MAX Overall Length(m) 20.3 Transmission Max. Speed (kph) 2.6 2.6 2.3-3.0 2.3-3.0
Height To Top Of Cab (m) 6.71 Buckets Capacities Std. 13 13.5 18 18
Hinge-Pin
Pin Height (m) 9.91 (m3)
Other 4.5-20 10.5-18 15.3-18 15.3-18
Width Outside Tires (m) 6.76 Boom Length (m) 9 9.3
Others Fuel Tank (L) 4940 Stick Length (m) 4.2
Pass Match with Trucks (tonnes)
( 290-363 Dimensions Overall Height (To 7100 7100 7570 7570
(m) Cab)
Overall Length (No 9780 9780 10625 10625
Bucket)
Overall Width 6440 6440 7190 7190
Liebherr 995 – Hydraulic Shovel/Excavator
Shovel Liebherr 996 – Hydraulic Shovel/Excavator
Shovel
Liebherr 995 Liebherr 996 996B
Backhoe Shovel Bucket Backhoe Shovel Backhoe Shovel
Bucket Bucket Bucket Bucket Bucket
Engine Rate Power (kW) 1600 1600 Engine Rate Power (kW) 2240 2240 2240 2240
Working Range Max. Digging Depth (m) 8.6 4.4 Working Max. Digging Depth (m) 8.8 3.8 8.11 3.3
Range
Max. Cutting Height (m) 16.3 18.3 Max. Cutting Height (m) 16.6 16.56
Max. Dumping Height (m) 10.5 12.8 Max. Dumping Height 10.5 14.3 10.67 12.9
(m)
Max Digging Reach (m) 20 17 20.2 16.5
Buckets Capacities (m3) Std. 26.5 26.5
Buckets Capacities Std. 30(Std)/ 34 36 34
Other 24 24
(m3) 33(Arctic)
Boom Length (m) 10
Other 25/30/33/ 25/29/ 32/34 31/32/36
Dimensions (m) Overall Height (To Cab) 8820 8820 36(Arctic) 36(Arctic)
Overall Length (No Bucket) 11310 11310 Boom Length (m) 12.5 8.65 12 8.65
Overall Width 8230 8230 Stick Length (m) 7.5 5.62 7.5 5.62
Dimensions Overall Height (To Cab) 9.07 9.07 9.26 9.26
(m)
Bucket)
Overall Width 8.25 8.25 8.08 8.08
Others Match Trucks
(Komatsu)
Liebherr 9250 – Hydraulic Liebherr 9350 – Hydraulic
Liebherr 9250/ 9250Arctic Liebherr 9350/9530Arctic 9350E
Backhoe Shovel Backhoe Shovel Backhoe Shovel
Bucket Bucket Bucket Bucket Bucket Bucket
Engine Rate Power (kW) 960 960 Engine Rate Power (kW) 1120 1120 1200 1200
Working Range Max. Digging Depth (m) 8.7 3.8 Working Max. Digging Depth (m) 9.5 3.8 9.5 3.8
Range
Max. Cutting Height (m) 15.2 15.6 Max. Cutting Height (m) 15.4 16 15.4 16
Max. Dumping Height (m) 10.3 11 Max. Dumping Height (m) 10.2 11.2 10.2 11.2
Max Digging Reach (m) 16.1 13.8 Max Digging Reach (m) 17 14.6 17 14.6
Operating Weight (kg) 250000 253500 Operating Weight (kg) 302000 310000 314600 322500
Transmission Max. Speed (kph) 2.1-2.7 2.1-2.7 Transmission Max. Speed (kph) 2.5-3.3 2.5-3.3 2.2 2.2
Buckets Capacities (m3) Std. 15 15 Buckets Capacities (m3) Std. 18 18 18 18
O
Other 13-17 11.0-17 Other 15.3-20 15.3- 15.3-18 15.3-18
11- Arctic 20.5
Boom Length (m) 9 6.37 Boom Length (m) 9.3 6.75 9.3 6.75
Stick Length (m) 4 4.2 Stick Length (m) 4.2 4.2 4.2 4.2
Dimensions (mm) Overall Height (To Cab) 7250 7250 Dimensions Overall Height (To Cab) 7800 7800 7800 7800
(mm)
Overall Length (No Bucket) 10280 10280 Overall Length 10470 10470 10470 10470
(No Bucket)
Overall Width 7400 7400 7400 7400
Liebherr 9400 – Hydraulic Liebherr 9800 – Hydraulic
Liebherr 9400 Liebherr 9800
Backhoe Shovel Bucket Backhoe Bucket Shovel Bucket
Bucket
Engine Rate Power (kW) 2984 2984
Engine Rate Power (kW) 1250 1250
Working Max. Digging Depth (m) 9 3.3
Working Range Max. Digging Depth (m) 9.5 3.9 Range
Max. Cutting Height (m) 16.2 18.3
Max. Cutting Height (m) 15.5 16
Max Digging Reach (m) 17 14.8
Transmission Max. Speed (kph) 2.0-2.5 2.0-2.5
Buckets Capacities Std. 38-42 38-42
Buckets Capacities (m3) Std. 22 22 (m3)
Other
Other 18-24 18-24
Stick Length (m) 5 5.1
Dimensions Overall Height (To Cab) 10338 10338
Dimensions (m) Overall Height (To Cab) 8343 8343 (m)
Others Match Trucks 220, 290, 360 tonnes trucks
Liebherr KL2420 KL2450 KL2680 – Dump Liebherr T252 & T262 – Dump Truck
Truck
Liebherr T252 T262
Liebherr KL2420 KL2450 KL2680 Engine Gross Power (kW) 1286- 1510-
1510 1864
Engine Gross Power (kW) 1492 1865 2238
Net Power (kW)
Net Power (kW)
Transmission Max. Speed (kph) 51 51
Transmission Max. Speed (kph) 55 62 65
Weight Empty (kg) 148320 156940
Weight Empty (kg) 129500 152000 190562
Loaded (kg) 331120 390090
Loaded (kg) 324500 370000 500000
Operating Capacities (m3) Struck 76.5 84
Operating Capacities Struck 95 134 Specifications
Specifications (m3) Hea
Heaped 2:1 107.8 119
Heaped 2:1 108 147 207
Rated Payload (kg) 195000 218000 309438
Fuel Capacity (L)
Dump Height (mm)
Dump Height (mm)
Liebherr T282 – Dump Truck Liebherr TI 272 & TI274 – Dump Truck
Liebherr T282 T282B T282C Liebherr TI272 TI274
Engine Gross Power (kW) 1864- 2725 2800 Engine Gross Power (kW) 2014 2238
2050
Net Power (kW) Net Power (kW)
Transmission Max. Speed (kph) 64 64.4 54 Transmission Max. Speed (kph) 68 64
Weight Empty (kg) 203300 187000 237000 Weight Empty (kg) 151500 170000
Loaded (kg) 566300 592000 600000 Loaded (kg) 441900 460000
Operating Capacities Struck 122 Operating Capacities (m3) Struck
Heaped 2:1 183.5 212 Heaped 2:1 175
Rated Payload (kg) 364000 363000 363000 Rated Payload (kg) 290000 290000
Fuel Capacity (L) 4730 4730 6813 Fuel Capacity (L) 4540
Dump Height (mm) 13900 13300 15050 Dump Height (mm) 12300
Dimensions Overall Length (mm) 14500 14500 15690 Dimensions Overall Length (mm) 13100
Overall Width (mm) 8700 8400 9679 Overall Width (mm) 8500 8290
Overall Height (mm) 7400 7400 8294 Overall Height (mm) 6900 8320
Lighting Plant Load Position on Trucks
Lighting plants are used during night shifts or in low visibility to It is important that the load is positioned
positio in the centre of the truck tray. If
illuminate the work/dump
dump area or hazardous areas. it is off 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 and
spillage on the haul road. It also causes a lot of safety issues.
issues The primary
safety problem is that when the load is to one side,
side especially where there
are large rocks in the load it can cause problems at the dump when tipping
the load off.
Load incorrectly positioned
Also when the truck is cornering a lot of spillage will occur which requires
requ
a grader to clean. It reduces also the lifetime of the tyres when the trucks
are cornering while driving down hill. The tyres are starting to overheat
and in the worst case they can ignite. The truck location can have a
negative effect on correct load placement.
Load incorrectly positioned
Loading – Precautions Loading Techniques – Sequences
When loading, truck and loading unit operators should observe the There are many different loading techniques associated with each type of
following precautions: loading unit:
 Always remain inside the cab during loading operations, unless Hydraulic Excavator
otherwise instructed, e.g. when loading very large rocks. This will
w
 Top Loading
prevent material falling onto the operator and causing a potential
injury.  Top Loading @ 45°
 Use the payload indicator to gain an understanding of the current  Top Loading @ 90°
payload and ensure you obtain targeted payload every cycle.  Bottom Loading @ 45°
 Do not overload, follow the 10/10/20 rule (or site specific operating  Bottom Loading @ 90°
instructions).  Drive-by Loading
 Do not drive off until instructed to by the loader operator. Hydraulic/Electric Shovel
 Always look for rocks, spillage and poor/sub-standard
poor road conditions
that can damage tyres and the truck.  Near Side Loading
 Utilise reverse cameras on trucks where available and fitted.  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…
Lockout – Regulations risk is clearly understood. No untrained operator should perform these
techniques due to the risk of low wall or highwall failure and the potential
for great
The rules regarding
egarding the application and locks and or tags to equipment
coal losses.
are there to protect you and your fellow workers from a potentially serious
or life-threatening incident. The general rules for tags and locks are:
 No person shall attempt to start or operate any plant or equipment
that has a personal locks, Danger tags (if required) or Out of Service
tags attached
 Once tags have been used they must be destroyed
Without using your personal lock at the isolation point and an additional
signing at the Isolation pointt you are not allowed to access a machine
during maintenance days or during a shut down. This ensures that no one
can start any part of the machine or the machine itself before all
maintenance personnel are off the machine.
Low Wall – Spoil Side Wall of the

Excavation
The low wall is the side of the pit where the dug spoil has been placed.
Spoil
Piles
Low wall
Low-Wall
Wall Scavenging – Coal recovery
Scavenging coal from the low wall or highwall by different methods is
widely practiced. Before such activities, the operator must ensure that the
Lube System – Applies Lubricant Lubrication controller – Systems
The lube system delivers automatically
cally a controlled amount of lubricant to Lubrication controllers provide control and feedback to the operator.
attached parts while the machine is running. This allows the parts to be
lubricated at a set interval without down time.
Applying lubricant is often most effective when it is dispensed in small,
measured amounts over er short, frequent time intervals.
Lubrication Chart – Machine specs
Matching – Truck matching to the shovel

Refer to Trucking – Truck matching to
t the shovel in this Dictionary.
Mine strategy – Basic Strategies Minerals – Excavation of a Resource
1. Sell as much as possible A mineral is a naturally occurring solid chemical substance formed
2. Sell as little as possible through biogeochemical processes, having characteristic chemical
3. Try to optimise output composition, highly ordered
rdered atomic structure, and specific physical
4. Sell as much as possible (>30%) properties.
– Use when prices are high By comparison, a rock is an aggregate of minerals and/or mineraloids and
– Can usually get more coal exposure capacity does not have a specific chemical composition. Minerals range in
composition from pure elements and simple salts to very complex
co silicates
o Increased truck
uck and loader with thousands of known forms.
o Increased contractors
o Lower dragline horizon Reference: http://en.wikipedia.org
– 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 Mining – Excavation of a Resource
5. Sell as little as possible (>60%) Mining is the extraction of valuable minerals from the earth, from an ore
– When price is low you want to lose as little money as possible body, vein or (coal) seam.
– Just do enough to still be in business when price improves Materials recovered by mining include base metals, precious metals, iron,
– There is a fixed cost just to have the mine operating uranium, coal, etc.
– Just long term contracts
– Can reduce coal uncovery capacity
o Send contractors away
o Dragline pullback
o Reduce hours
o Optimise Sales (<10%)
6. Often this will be the same as 1. or 2.
– When price is average and you are making average profits the
equation of optimising mine strategy is difficult
– If you increase sales you might
ght need higher cost (lower margin)
methods of uncovering the coal
– If you reduce sales then the fixed costs become a greater
percentage of total costs and unit cost increases
– Luckily?? the coal industry is not often in this position. We work
in a boom and bust industry and often mines only have to choose
between 1. or 2.
Modified Drive-By
By Loading – Sequence Mounting and Dismounting – Getting on
and off machinery
The modified drive by loading system or parallel approach is a good
loading option without affecting production, if double
doub sided loading is not Injuries can result from incorrect mounting and or dismounting mobile
achievable. The advantage of this technique is being highly productive equipment. Injuries
njuries also occur where operators slip due to dirt and
with a low number of trucks with a low dozer clean up delay. Some material build up on steps. When mounting or dismounting the machine,
conditions must be given to avoid damage to the trucks and a low make sure of the following:
production.
 Mount and or dismount the machine
mach only where ladders, steps and
The Shovel removess material at less than the maximum digging radius by
handrails are provided.
traversing the face. The trucks approach parallel to the bench and spot at
 Face the machine when mounting or dismounting.
dismounting
45˚ to the shovel.
 Always maintain a three-point
point contact with the steps and handrails.
handrails
Due to the fact that shovel and the trucks operate in the opposite direction  Never get on or off a moving machine.
reduces the manoeuvring time of the trucks. During the fill of a truck the  Never jump off the machine.
waiting truck can move into position. As soon as the loaded truck drives  chine controls as hand-holds
Do not use machine hand when entering or exiting
on the waiting truck can start position for the next loading cycle. 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 dipper
arms along the side of the truck body, ensure to stay parallel
paral with the lay
flat, while reversing into position. Place the transmission in neutral and
apply the park brake. Once in the correct position the shovel operator will
load the first dipper of material into the truck.
OEM – Original Equipment Manufacturer
Manufactur Oil Sands – Tar Sands
Examples of OEM’s are: Oil sands/tar
tar sands are a type of petroleum ore deposit.
Oil sands are loose sand or partially consolidated
consolid sandstone containing
naturally occurring mixtures of sand, clay, and water, saturated with a
dense and extremely viscous form of petroleum technically referred to as
bitumen.
ETC…
Offside Loading – Loading on Blind Side

During offside or right side loading, the shovel is positioned on the right
hand side of the haul truck. Align the teeth of the shovel dipper with the
side of the truck body, (using your right hand mirror) while
whil reversing into
position. Place the transmission in neutral and apply the park brake. Once
in the correct position the shovel operator will load the first dipper of
material into the truck.
Be extra careful when reversing the haul truck in on the off side,
sid ensuring
all blind spots are clear. Maintain a three metre gap between the truck and
the counter weight of the shovel.
On-board fires – All equipment Operator – Obligations and Roll
A fire on any loading unit or haul truck has the potential to create a Obligations
serious situation; therefore, the following procedure must be adhered to
and initiated quickly (refer to your specific mine site procedures).  Do not endanger your or any persons health and safety
 Report all unsafe conditions, activities,
activities near misses, hazards or
 Bring the machine operation to a stop as quickly as possible. injuries to your supervisor.
 Position the implementss on the ground if fitted (loading units).  Do not tamper with or deactivate any health and safety devices or
 Reduce engine to low idle. procedures.
 Apply the park brake.  Use the appropriate PPE.
 Turn ignition to off position.  Report all damage and or defects.s.
 Notify your position and emergency details using the two way radio if  Do not attempt a task unless qualified, authorised, competent
safe to do so. (refer to your site emergency procedures). and confident.
 Activate
ate the in cab Automatic Fire Suppression System by removing
Roll
the pin and striking the actuation nob (if fitted).
fitted)
 Leave the operators cabin and dismount at the safest exit point.  Attend all shift briefings,, tool box talks and shift handovers.
 Use the hand-held
held extinguisher to control fire, ensuring not to place  Ensure you understand and have all relevant data available on your
yourself in a position where personal injury may result. planned activities.
 Once the hand-held
held extinguisher is discharged, move away from the  Understand/analyse all information/instructions
information given and plan
machine to a safe location. your task.
 Use the correct equipment for the job.job
Note:: Always follow your sites rules and regulations regarding emergency
procedures  Do the required walk around and pre-start/shift
pre inspections.
 Understand and apply the relevant tagging procedures.
 Practice a high standard of housekeeping.
housekeeping
 Operate the machine safely and in accordance with the
manufacturer’s instructions.
 Assess and apply all site safety, environmental rules and regulations.
regulations
 Operate as efficiently and cost effectively as possible.
Operators Cabin – Control Centre of an Opportunity Cost
Excavator
In any economic analysis this is the really important cost
Cab houses the major and minor controls that an
An operators Cabin/Cab  What you really need to understand is what the value in moving more
operators needs to utilise to enable the functioning of the excavator. dirt or the opportunity cost of moving less is.
Besides all the controls, this will also house the operator’s seat platform
plat  If you know this then you can make informed decisions on certain
and most of the warning systems. This is basically the control room of the actions.
truck, or loading unit.
In any simple economic analysis follow
ollow the 3 step approach:
approach
 Where draglines are involved convert
onvert all dragline material moved to
prime
 Calculate additional material that will be moved.
 Calculate the cost/value
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 pit
layout, etc.
– No other prestrip or ancillary equipment to shut down first
– Is usually used when considering moving fleets faster and/or
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
Operating Cost – Need to know what incremental profit is
This is broken down into fixed costs and variable costs.

Fixed costs are the same regardless of what the T&L fleet does and
include access to electricity grid, lease payments, labour, etc.
Variable costs depend on hours operating and/or
and number of cycles
done.
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 to
move spoil compared to a dragline operation and the T&L cost is between
$3.00 and $4.00/PBCM
PBCM (This is the cost in operating the machine).
Ore Body Overextending crowd – Rope Shovel
An ore is a type of rock (spoil)
spoil) that contains a valuable mineral with Do not over-extend the dipper handle to load the dipper. The equipment
important elements including metals (copper, iron etc.). Ore is extracted should be propelled closer to the loading face.
through a mining process. Ore is then processed to extract the valuable
Overextending affects the hoist ropes, and causes overheating of the
element.
crowd motor.
Ore bodies are formed by a variety of geological processes.
process The process of
Over extending the dipper handle results in overheating of the motors and
ore formation is called ore genesis.
hoist rope damage/stresses. Consequence
onsequences are premature motor failure,
low availability and loss of production.
Overloading – Trucks P&H 2800 XPA – Rope Shovel
Excessive
ive overloading or badly loaded trucks put an immense pressure on P&H 2800 XPA rope shovel
tyres which are designed to hold only a specific weight. Any pressure over
the manufacture recommended load will have an impact on the tyre life
span
The tyre stress will be even more, if the
th driver operates the haul road truck
at high speeds over rough surfaces and through corners.
As well the spillage caused will subsequently damage tyres to following
trucks, if not removed from the haul road.
Solution:
 Adjust loading to account for material
materi
 Adjust speed to haul road condition
 Report bad road and mine conditions
P&H 4100 A– Rope Shovel
Shove P&H 4100 XPB – Rope Shovel
P&H 4100A 4100A/LR 4100T P&H 4100XPB
S
Max. Power DC (kW)
Max. Power DC (kW) 3400 3176 3773
AC (kVA)
AC (kVA)
Working Range Max. Digging Depth (m) 1.93
Working Range Max. Digging Depth (m)
Max. Cutting Height (m) 18.06
Max. Cutting Height (m)
Max. Dumping Height (m) 10.44
Max. Dumping Height (m) 9.19 15.42 9.7
Max Digging Reach (m) 23.8
Max Digging Reach (m) 20.85 25.04 20.85
Operating Weight (tonne) 1455
Operating Weight (tonne) 1238.9 1223.5 1350.1
Nominal Payload (tonne) 104
Nominal Payload (tonne) 88 65.5 82.4
Rated Suspended Load (tonne)
Rated Suspended Load (tonne)
(tonne
Transmission Max. Speed (kph)
Buckets Capacities (m3) SAE Struck 55.8
Buckets Capacities (m3) SAE Struck 47.4 35.2 44.3
SAE 2:1
SAE 2:1
Dimensions (m) Overall Height (Over Gantry) 14.35
Dimensions (m) Overall Height (Over Gantry) 12.62 12.62 12.62
Overall Length (No Bucket) 14.33
Overall Length (No Bucket) 15.24 15.24 15.24
Overall Width
th (Over tracks) 14.35
Overall Width (Over tracks) 13.16 13.16 13.16
Others Match Trucks size (tonne) 172-363
P&H 4100 XPC – Rope Shovel Park-up – Go – No Go lines
P&H 4100XPC-DC 4100XPC-AC The go, no-go
go line is where the trucks commence their shift from and
Max. Power DC (kW) 2*1860 return for crib breaks and shift changes. Operators should be cautious of
water tankers watering/dust
dust allying the area.
AC (kVA) 4640
Working Range Max. Digging Depth (m) 1.6 1.6 Trucks should enter and exit the designated parking area in a one-way
one
flow. This is to minimise interaction between the trucks and other traffic.
Max. Cutting Height (m) 16.8 16.8
Max.. Dumping Height (m) 9.5 9.5  Other traffic (light vehicles etc.) should not enter this area.
Max Digging Reach (m) 23.9 23.9  Speed should be minimised in this area.
Operating Weight (tonne) 1489 1535
 Trucks should be Fundamentally Parked over the hump/berm/ridge
hump
to minimise the possibility of involuntary movement/run
movement away.
Nominal Payload (tonne) 99.8-108.9 99.8-108.9
Rated Suspended Load (tonne) 195 195 Hard Park / Truck Stand Correct Flow

Buckets Capacities (m3) SAE Struck 53.5-62.7 53.5-62.7
SAE 2:1 67.6 67.6
Dimensions (m) Overall Height (Over Gantry) 14.7 14.7
Overall Width (Over tracks) 14.4 14.4
Others Match Trucks size (tonne) 172-363 172-363
Park Up Area Guide – Go – No Go line

Some areas have indicative lines for trucks to park in. This is to assist
operators park safely and in such a manner that they minimise interaction
with other machiness and trucks in the area.
Parking – Waiting for water truck Payload – Optimal load
If areas are deemed to be too dusty and unsafe to operate, truck operators
must stop and wait for the dust to be controlled, usually through watering.
Payload – The Amount of Material the tray

tra
carries to dump
Payload is one of the most important factors in Truck and Loader
productivity. All operators of loaders should understand what is
required/targeted
targeted and ensure that they load this consistently.
Payload – Sub-optimal
optimal load Payload Distribution – Truck Tray
Incorrect distribution in the truck tray increases wear and tear/damage
tear to
the truck and reduces tyre life.
Incorrect placement and payload distribution.
Correct distribution of payload.
Payload Indicator Lights – Payload lights Payload meter – Displays the weight of the
loaded material in the truck
Some Truck types are fitted with Payload indicator lights.
The payload lights are an indicator to the loader operator as to the current In some trucks, the payload meter is incorporated into the speedometer
status of the payload. While loading, the Red indicator light will be dial or on the dash.
illuminated untill the payload has been reached (when the Green indicator The Payload meter records Payload weight along with other operating
light become illuminated). information.
Payload weight display – Displays the Pit Design – Pit planning
weight of the loaded material
Pit Shape/Mine
Mine Planning Considerations
Some Truck types are fitted with Payload indicator displays.  Location of pit limits
The payload display is an indicator to the
t loader operator as to the current  Final pit outline
status of the payload. While loading, the display will indicate the payload.  Pit Shape Optimisation
 Destinations/dump
dump designs and locations for in-pit
in materials
 In-pit Bench/strip geometry
 Ore/coal access
 The pit progress process/sequencing
sequencing
 Pit slope/highwalls/lowalls
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 Ramp – Roadway to Access the Pit Pitch Braces – Dipper Tooth Attack Angle
Adjuster
Access to the bottom of the pit is gained via a pit ramp. The ramp is
usually dug by an excavator when opening up the new pit area. Ramp A variable pitch brace connected between the handle and the dipper
dip at a
grade and width is governed by the size of the haul trucks being used. point spaced from the dipper axis changes the tooth attack angle of the
The grade is usually a maximum of 8% but can be up to 10%. The width dipper. Refer to Tooth Attack Angle and Dipper Heel Wear.
will vary as regulations typically dictate that “all roadways must be 3.5
times the width of the largest vehicle using it”.
Pivot Point/Nip Point – FEL

These are areas where a person may be injured or become trapped due to
movement of the machine or implement/bucket.
implement
No person should enter this area unless the loading unit is locked out and
tagged appropriately.
Plan and Prepare for Operations – Prior to PPE – Personnel Protective Equipment
conducting any work
Wear the appropriate Personal Protective Equipment also known as PPE
Prior to conducting of any operational work, personnel should ensure
ens that for your own safety and to prevent and/or reduce
reduc injuries.
they have planned and prepared themselves and their equipment to do Your employer is required to provide all staff and visitors with PPE. The
this safely and efficiently by: clothes and safety equipment should fit to your body size
 Attending shift briefings, tool box talks and hand-overs
hand Special tasks require special PPE. Be sure to wear the correct
 Obtain relevant data equipment and clothing for the job.
 Clarify and analyse information and plan work
 Ensure the correct equipment
quipment 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, which
are activated for 30 seconds before the machine shuts down.
Pre-Shift Briefing /Tool Box Meetings –
PLC Flash Code Safety
 Flash 1 Oil Pressure
 Flash 2 Coolant Temperature In a pre-shift
shift briefing everything relevant to the upcoming shift will be
 Flash 3 Coolant Flow discussed. The briefing will normally be held in the shift change room,
 Flash 4 Cab E/STOP crib hut, deployment room before the commencement of each shift. The
 Flash 5 Ground E/STOP supervisor
rvisor of the shift will explain any safety issues, hazards, previous
shift information, working conditions and any updated plans. The pre -
 Flash 6 Ansul
shift briefing also gives the operators an opportunity to discuss important
information and significant events which occurred during the last shift(s).
It is also used for information to be passed on by the supervisor about
current condition of the equipment be used during the shift. The Open
Cut Examiner will report any changed road conditions and directions,
work area conditions, etc. at most of
these meetings.
Pre-Split
Split Drill Hole Barrel – Drill hole Pre-Start – During Shift and End of Shift
marks on the excavation wall after blasting Checks/Inspections
start, during shift and end of shift checks and inspections should
All pre-start,
be conducted in line with the mine’s Standards, Rules and Procedures
pertaining to all checks needed to be conducted.
drill hole
Refer to Walk around Inspection in this Dictionary…
Pre-Strip – Removal of waste/overburden

waste
material
Pre-strip is the process of removal of waste or overburden material by
means of a Truck
ruck and loading unit operation, usually done above / before
a dragline operation.
Procurement of buckets/dippers
buckets Propelling Up and Down Haul Roads –
Operation
Choosing a New Bucket?
There are 4 ways to choose a new Bucket for your loader: The illustrations show the correct positioning of a loader’s attachments
when travelling up and down haul roads. Remember, when propelling
 Ask the Supplier to tell you what you need. X over a long distance to be aware that propel gear will easily overheat.
 Guess what you need. X
When travelling downhill, depress the pedals fully to allow the retarder
 Use available historic data to determine capacity. ? valve to function correctly.
 Do bucket modelling to ensure the optimal capacity for the specific
truck and loader The travel brakes are automatically released when drive is applied. After
the pedals have been released, the brakes apply in about fifteen seconds.
match! When travelling on a haul road, ensure you remain well to the left. Stay
What is wrong with loader capacities?
capa near the edge
dge to allow other traffic to pass safely.
 People who are deciding on capacities often don’t have knowledge of

all the variables which may impact the result.
Refer to Shovel Dipper Modelling in dictionary...
Queuing – Waiting position Radiator – Heat Exchanger
Operators need to ensure that they are in the correct waiting position Cooling liquid passes through the engine block and absorbs excess heat.
prior to reversing for being loaded. This will save valuable time in the The heated coolant is lead away and passes through the radiator where it
process. circulates through small tubes and finally transfers the heat into the air.
The cooled liquid circulates back into the engine block and the process
Trucks queuing should line up slightly to the left of the haul truck in front
repeats.
and a minimum of two haul truck lengths back (check site procedure), this
allows for greater visibility.
Correct Queuing
Correct
Note: To ensure potential accidents are prevented during queuing

operations,s, 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
operators are queuing.
 Park away from highwalls/lowlow walls.
wall
 Park out of the shovel’s swing radius/area.
radius
 Always check the immediate area before moving off.
Radiator Header – Storage for cooling
liquid
Steep ramps are sub optimal for cycle time and overall efficiency. Ramp
gradients should be less than 10%.
Ramps
The ramps should be at a constant gradient, not level out in the middle.
middle Rated capacity – Designated capacity of
By designing all grades linear the following advantages can be achieved:
achieved
buckets
 Reduces number of truck transmission shifts
 Reduces fuel consumption The rated capacity is the name plate capacity which
whi the supplier puts on
 Improves truck cycle times the particular bucket. The general equation is struck volume (that
 Reduces spillage contained inside the bucket) + volume on top. A dipper/bucket on a rope
shovel assumes no volume heaped on top and therefore the rated capacity
Keep all gradients at less than 1 in 10 or 10% better < 1 in 8 (8%)
equals the struck capacity. The rated capacity for the excavator and the
FEL assume a heaped volume on top. The SAE heaped capacity assumes a
1:1 angle of repose for the backhoe and 2:1 angle of repose for the face
shovel and FEL.
Electric Rope Shovel - struck
The state government holds a deposit on disturbed areas until it is signed
off.
Reclamation in Progress
Hydraulic Face Shovel - struck + heap at 2:1
Reclamation a few years old
Hydraulic Backhoe - struck + heap at 1:1
FEL - struck + heap at 2:1
Relative Density – RD
Refer to Specific Gravity in this Dictionary
Reliability – How long the Loader/Truck

Loader
keeps Running
Reclamation – Re-
Rehabilitation/Reclamation The reliability of the Loading unit or truck is a measure of its availability
to operate. The formula for reliability of a system or individual component
establishing the Waste Spoil Heaps to a is;
Stable and Productive Landform
Reliability = MTTF/(MTTF
(MTTF + MTTR)
Reclamation is part of a mines Environmental Management
M Plan and is a Where:
legal obligation.
 MTTF = Mean Time To Failure
The spoil heaps are shaped to create a stable landform on which to  MTTR = Mean Time To Repair
revegetate back to a natural shape. The reclaimed land will never be the
same as the original landform before mining, but when reshaped, topsoil
replaced
placed and planted with vegetation, will be productive again.
Reject Bin gate opener – Opens Reject Report – To give Information.
bin remotely
A report gives information to the recipient. A report is not much help
Some trucks have a remote switch to activate a reject silo bin door from either if the recipient cannot understand it. Reporting operator and
inside the truck for safety reasons. overall Truck and or Loader performance shows the recipient how they
are performing against a pre-set,
set, achievable target. A report needs to be in
a form that the recipient
pient can understand and it should be explained so
they do.
Retarder – Braking lever Retard Grid – Cooler
The retarder is used to slow the truck down prior to using the main brake Dissipates heat from the Retarder.
of the truck.
friction Braking System

Retarder – Non-friction
The actual grade capability for each gear will vary depending on outside
temperatures, rolling resistance, load, the condition of the cooling system
and tire size. For additional braking and retarding information, see
Original Equipment
uipment Manufacturers operational manual Engine speed
relative to ground speed will vary due to tire size differences between
brands and types
Returning Phase – Operational Right Hand Operators Console – Cab
The steps of the returning phase involve returning the empty bucket to the Emergency stop Automatic electronic traction aid
PLC System Engine start switch
dig position,
sition, lowering and crowding the bucket to commence the dig cycle. Ether start Break pressure gauge
The return phase of the swing cycle, with the bucket empty, can be
accomplished at full rated speed. The operator must coordinate the
lowering of the bucket to the digging position simultaneously
simulta with the
return swing. Reverse Lights
Auto / Manual
Trans. Direction Speed Control Park Brake

Windscreen wiper
Park retract switch Service /Hr
and washer
meter
RHS REV light Reject bin gate opener
switch
Rill – Prevents truck from unwanted rolling

At the Go – No Go area, a rill placed in the middle of the parking area
assists prevent unwanted movement and run away trucks.
Rimpull – Force Rock Ejector – Removes rocks caught
between tyres
Most manufacturers of mining equipment supply rimpull vs. speed
curves. Rock ejectors play a part in the removal of rocks that have been caught
Rimpull is the force (in kg, lb or KN). between the tyres of a truck. Rock ejectors should
shou be inspected on a
regular basis to ensure that they are not bent and can cause damage to the
Calculations: tyres.
Rimpull = [(weight of truck)*(grade of road)] + [(weight of truck) * rolling
resistance)]
F(result uphill) = (coefficient of rolling
resistance)(weight)+(weight(SIN(grade)))
An example of a Rimpull Chart
Rock Ejector
Roll – Material build up from the digging Rolling Resistance – Resistance created by
process the interaction between the trucks tyres and
the haulroad
An incorrectly managed roll will cause a multitude of problems for the
operator. The most common causesuses for a big roll is that the trench has Rolling resistance is the deformation resistance/ friction between the
been dug too shallow, or that too much material has been pulled down surfaces and the truck tyre
into the trench.
 Road deformation under the tyre
 Tyre penetration into the road surface
Roll levelling – Levelling bench

Leveling of the roll correctly can assist the operator to be more productive.
This minimisess time lost on leveling of the roll, damage and the operator
does not lose momentum.
Incorrect leveling of the roll can cause damage to the excavator’s bucket. If
the rear of the bucket is used to level the roll, the cylinders, rear bucket
plate, grease lines,
nes, boom, stick etc. can be damaged.
Poor road maintenance practices result in an increase in rolling ROM Area – Run-of-Mine
Mine
resistance. This results in:
 Excessive fuel burn Coal dumped by a truck into the coal preparation plant is called run-of-
run
 Reduced tire life mine, or ROM. This is the raw material for the CPP. The coal is
contaminated with rocks from the dig side. Contamination is usually
For off-highway
highway trucks running radial-ply
radial tires, assume a minimum introduced during the excavation or from excavation equipment or thin
rolling resistance of: layers of rock in-between
between the coal seam.
 1.5% for a hard, well-maintained,
maintained, permanent haul road ROM coal can have a large variability of moisture and maximum particle
 3% for a well-maintained
maintained road with little flexing size.
 4% for a road with 25 mm (1 in) tire penetration
Tire Penetration In practice, a 5% increase in rolling resistance can result
in up to a 10% decrease in production and a 35% increase in production
costs.
(CAT – Haul Road Design)
Forr ramps an increase in rolling resistance of 1% can reduce speed by 10-
10
13% while on flat roads a 1% increase in rolling resistance can reduce
speed by 18-26%.
ROM Stockpile – Run--of-Mine Buffer Rope Shovel A-Frame
Frame – The anchor for the
boom
A ROM stockpile is used to allow the wash plant to be fed coal at a
constant rate. itical component and is attached to the main chassis of
The A Frame is a critical
the machine. It is a large structure as it takes the load from the loaded
dipper as well as the weight of the other components and transfers it to
the main chassis.
Rope Shovel Boom – Attachment Rope Shovel Boom Suspension Ropes – The
Wire Ropes that Hold and Support the Boom
and Load.
Boom Suspension ropes are large wound wire ropes, usually galvanised
for long term protection. Under normal operation, they last for many
hours. Most mines have non-destructive
destructive testing programs in place for
monitoring the ropes’ condition. Because there are multiple ropes, it is
important to have regularly maintained rope spreaders to prevent the
ropes rubbing against each other.
Rope Shovel – Fill Cycle Rope Shovel – Forces applied
Enough space
pace must be left between the tracks and the digging face to During the operation of the electric rope shovel the following forces
eliminate damage. Care should also be taken to avoid jacking the boom. are utilised.
Jacking the boom can cause severe damage to the suspension cables,
boom assembly, and gantry assembly.
Do not overcrowd or jack
ack the boom. Overcrowding is the use of excessive
crowd thrust while the dipper is engaged in the bank.
Rope Shovel – Machine

A Rope Shovel is a loading unit as can be seen below. Please refer to
specific makes and models as illustrated in this dictionary.
Rope Shovel – Schematic Roster – A Truck and Loader Crew’s
Working Arrangement
The nomenclature associated with electric rope shovels.
Most mines work 24/7 and have had to arrange a shift working
arrangement with their workforce. There are just about as many shift
rosters as there are mines in this industry, and most mines negotiate the
most
st suitable roster with their workforce.
Examples of shift rosters are:
 5 days on and 2 days off
 5 days on, 3 days off, 4 days on and 5 days off
 Etc.
Rope Shovel Tracks – Travelling device
Safety Zone/Collision Avoidance – Safety Scaling Batters – Removing loose material
from a wall
Trucks mustt maintain at least 10 metres safety zone from the dump dozer
and any other machine/truck/ancillary
ancillary equipment on the dump site. Ground conditions in the open pit operation can vary from competent
Follow your Site rules and regulations. solid rock to incompetent, poor ground. Competent ground will fire to a
clean face. Half barrels from the drill holes are a good sign the unfired
ground has not been seriously damaged. Poor ground or poor firings may
result
esult in shattered and loose rock sitting in the exposed face, especially at
the crest. While this rock sits in the face it is a hazard to personnel and
equipment below.
Poor ground is usually associated with geological features such as faults
and shear zones. These can be planar in nature and depending on their
orientation may present a serious hazard where large amounts of material
may be able to slide into the open pit. You should discuss the controlling
geological features in the wall with their supervisor
supervi or a geologist to make
sure they are fully aware of the hazards that may be present in the face.
Scale Shovel – 1:7th RB22 Selecting the “Right” Trucks for a Mine
A shovels dipper or excavators bucket has arguable the largest influence What is the problem?
on overall productivity on a loading unit. Through a detailed practical
For many minesines the issue of matching truck capacity to loader capacity is
modelling project, one can make an informed decision on the correct
problematic and more often than not results in a majority of trucks being
make, model and capacity of dipper//bucket designed specifically for your
either under-loaded or over-loaded. As trucks and loading units increase
current conditions.
in size the number of passes required to fill the truck is decreasing and the
difficulty in attaining the match is becoming more difficult. The goal of
getting the majority of trucks +/- 5% of the rated capacity just doesn’t
happen. Under-loaded
loaded trucks result in reduced dig rates while over-
over
loaded trucks
ucks reduce speed and increase damage and the occurrence of
sudden failure. Clearly an innovative process is needed. The first stage in
innovative thinking is to benchmark what is currently being done.
Variation in Truck and Loader Performance
Compounding the problem is the variation in truck and loader
performance. It is a simple fact that different makes and models work
better than others. In fact performance varies between makes and models
of truck by up to 81%. This means that the average performance of one
model moves 81% more than the average of another model. Clearly a hard
rock mine which is 400 metres deep is going to have lower truck
productivity than a coal mine where the trucks are being used in prestrip.
However, it should be noted that the difference
diff in average performance
for excavator models is up to 66% and that is not dictated by the geometry
of the pit where they are working.
The use of scale models is well established in the area of commercial
decision-making
making on shovel and backhoe capacities.
capaciti A little work has been
done with truck trays. The correct application of testing techniques can
account for nearly all previously defined impacts on payload. To ensure a
valid outcome the following must be accounted for in a scale modeling
program.
 Build the model dippers/buckets
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
4 passes
5 Passes
0.2%
6 passes
0.0% 7 passes
0.0%
1 Passes
2.3%
Service refill fittings rack – Lube
2.0%
Most Trucks are equipped with a fast fill service system for adding fuel,
hydraulic oil, gear oil, engine oil, and coolant.
2 passes
37.1%
3 passes
58.5%
Example of rope shovel pass per load (matched

( to 3 pass load)
Service Roads – Light vehicle access

It is important to have well designed and maintained service roads around
a mine site.
These roads give vehicles and equipment access to the working areas of SG – Specific Gravity
the mine. Service roads to the dragline,
ine, especially as the local
environment to these machines can change regularly, needs to be Relative density, or specific gravity, is the ratio of the density (mass of a
maintained in case of safety issues that may arise. unit volume) of a substance to the density of a given reference material.
Specific gravity usually means relative density with respect to water. The
term "relative density" is often preferred in modern scientific usage.
Specific gravity
vity is the term used for describing the density of the
overburden/waste, ore or coal.
The correct density entered into the production monitors, should give a
closer correlation of the monitor production results to survey results.
An example of the typical material hauled in a Truck and Loader
operation:
Material Density Body Type
Coal 0.9 – 1.05 t/m3 Larger coal body
Coal Overburden, 1.5 – 1.90 t/m3 Standard Rock body
Limestone
A well designed and constructed service Iron Ore 2.1 – 2.80 t/m3 Smaller rock body
road
Shale – Fine grained material usually
u found Shot ground – Blasted Overburden
as an intra-seam
seam or on top of a coal seam.
seam
Overburden that has been blasted in preparation of the dragline digging it
Shale in a coal mine is usually found in layers above and/or below the coal is described as shot or shot ground. As soon as the overburden is blast ed,
seam. Sometimes, especially during hours of darkness, it can be mistaken it should be levelled to seal it and stop a rain event affecting it by entering
by the operators for the coal seam, as it sometimes has visual properties the fractured ground. The word shot can also apply to the act of blasting,
much like coal, i.e. it is dark. In the accompanying picture the partings are as in “To let the shot off”.
shales.
Shift – A Crew Working a Roster

The shift is the time worked on the job. A crew or a group of people work a
particular roster. Some rosters have night, day and afternoon shifts. 12 hr
shifts have day and night shifts.
Shovel Dipper Modelling
A shovels dipper or excavators bucket has
ha arguable the largest influence
on overall productivity on a loading unit. Through a detailed practical
modelling project, one can make an informed decision on the correct
make, model and capacity of dipper//bucket designed specifically for your
current conditions.
Simulator – A Test Device that Simulates

Actual Conditions
A simulator is a test machine that gives the learner operator a similar feel
to 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 so
useful with experienced operators if used incorrectly and without a
structured training program.
 Used with longer haul routes with longer truck turnaround time.
 With smaller shovels, longer filling time of trucks.
When in close vicinity to other operations nearby.
Single Side Loading – Techniques
Single side loading is where all truck loading is done with the trucks in the
same location.
Single-side
side loading with Rope shovels is not as efficient as double side
loading.
The shovel is positioned with the tracks parallel to the face and advances
parallel
allel to the face as material is removed. The Single Digging Approach is
used 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 that does not match
100%
 Used with difficultt or poor fragmentation.
Single Bench – Loading technique Soft Dumping Techniques
iques – Techniques
Single Bench also known as Top op loading is defined as when the excavator Soft dumping is referred to as reversing to a dump whilst loaded in
is located on a higher level than the truck and sits on an elevated Bench. soft/wet conditions. When doing this the front wheels will not provide the
desired turning force therefore causing the haul truck to slew from its
The trucks can either be positioned at 450 or at 900 to the excavator.
desired course:
Loading through the rear at 45° is similar to the 90° bottom side loading
When soft
oft dumping the procedure is as follows:
method, except that the truck is positioned at 45° to the excavator. This
technique allows smoother bucket unloading when coming in through the  Always enter the dump in a clockwise direction
rear of the truck body and requires less hoisting than 90° over the side  Inspect the tip edge
loading.  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 d maintain the truck at 90° to the tip head
 Stop at or just before the bund wall/windrow
wall (do not use the bund
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
Specification Sheet – Machine Speed Limits – Safety
Example of a specification sheet provided by all equipment suppliers and Operators of all mobile plant shall observe the site speed limits. Within
OEM’s: the maximum speed limits imposed, mobile plant operators shall operat e
at speeds suited to the weather, visibility, condition of the roadway,
clearances, passenger segregation from loads being carried, passenger
comfort, traffic signs, safety and warning devices, such that they are in full
control of the vehicle at all timess and able to safely stop the vehicle in the
event of an emergency or other potentially hazardous incident.
Unless signposted otherwise the maximum speed limits for the site are on
most operations:
 Site access road - 80 kph
 Major haul roads – 60 kph
 Entry and exit roads of and within car parks - 10 kph
 Store delivery and unloading area – 10 kph
 All other areas - 30 kph
Check your local speed limits on your operation.
Spillage Split Benching – Loading technique
Spillage can cause serious damage to truck tyres and slow down the total Split Benching/double
double benching is defined by the excavator splitting the
cycle. Truck operators should report all spillage to the Supervisor/grader material to be loaded and sits on an elevated bench with the haul truck on
operator or the responsible person to ensure that this is cleaned up ASAP. a lower level.
Spillage can be caused by overloading the trucks, sharp cornering, and This technique
ique is generally used when the cut is too deep to dig in one
incorrect load placement into the truck or at the dig face from the loading pass and when there is ample space.
unit.
Because of the decrease in swing and lift time as compared to other
methods, this is an efficient method and utilised by many contractors.
Some mines have difficulty
ficulty with permission to do this as maintenance
don’t like it.
Spoil – Alll Material removed from above a Spotting – Precautions
mineable seam
When spotting, the truck operator should consider the following
Spoil is the waste material above a mineable seam or between multiple precautions.
seams.  Proper communication with the loading unit to determine the
required position.
 While spotting, avoid
void sharp turning
turn as this will damage the ground
surface in soft underfoot conditions and limit sidewall cuts to tyres.
 Check the loading area for spillage and have it cleaned up to avoid
damage to tyres.
Insitu  Always lookout for pedestrians,
destrians, personnel, other equipment and light
spoil/waste vehicles that may have entered the area.
area
Do not reverse into or up the loading face or are on spillage.
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, the
truck operator moves the truck into the loading position next to the
loading unit.
The operator should observe the following procedures for safe and
efficient spotting.
 The loading unit will indicate its readiness to load the truck by placing
its full bucket in the air in the position where the loading unit
operator
ator requires the truck to be positioned.
 The truck operator is to move from the queue and carefully reverse
into the required position under the loading unit’s bucket.
 When the truck is correctly positioned under the bucket, the loading
unit operator will sound one blast on the horn for the truck to stop.
 Once under the loading unitss bucket/dipper,
bucket/dipper apply neutral gear, apply
the park brake
 If self-spotting,
spotting, the operator should reverse into the loading position
using the correct technique whilst always being vigilant for safety.
Spotting for Top Loading @ 45° – Techniques Spotting at 45˚ – Techniques
The truck operator must wait until the excavator operator has spotted the Reason same as loading 45
bucket in the correct position.
The truck driver must then line up the side of the tray to the bucket teeth
and reverse
everse slowly until the excavator operator dumps the load into the
tray or sounds the horn indicating the truck is in the right position.
Spotting at 90˚ – Techniques Spotting at 90˚ – Incorrect Positioning
Line up with outside track. Spotting incorrectly for the 900 loading can cause damage to the truck
tray by contact with the excavator bucket.
Longer fill times will be experienced and the loading part of the cycle
becomes more difficult.
Start-up Procedure
up procedure relates to turning a piece of equipment on, ready
The start-up
for operation. Many pieces of equipment have
ha detailed procedures which
must be followed. An operator or a driver must be familiar with the
procedures as set down by their mine and must follow the procedures
as stated.
Steering system Stockpile stacking/accumulation – Building
manageable stockpile
This is the steering mechanism of all trucks and most Front end e loaders.
Some loading units and all rope shovels, excavators and hydraulic shovels From time to time, Frontt End Loaders or Excavators utilised on stockpiles
use a Joy Stick to control the steering. (Refer to Joy Stick in this need to stack up spillage and smaller unloadable material to accumulate a
Dictionary) loadable pile.
A larger/higher loading face/pile
pile will increase efficiency, minimise truck
delays and may assist in reducing contamination.
contam
On most stockpiles, space is limited and the stockpile shape needs to be
maintained for loading efficiently between loads or when loading activity
has been delayed.
Stockpile stacking is about the loader gathering this material and stacking
this together.
Stoppages – Productivity Strategy
As well as keeping the T&L fleet going for as long as possible, it should The two o key strategies mines can follow are cost or quantity. You either
also be stopped as few times as possible.
possible produce at the lowest unit cost or you produce the maximum quantity.
There
here is no other option to maximise return. There is a lot which could be
To achieve the positioning goals (swing angle) more than average number
written about each of these strategies including
inc how to recognise when the
of positioning's may be needed.
strategy should switch and how best to execute it.
Average Operational and Maintenance Stoppages per day:
It is extremely difficult to achieve performance levels equal to best
 Excavators – 33 practice for both loaders and trucks. Keep in mind that “best practice” is
 Rope Shovels – 32 defined as the average off the top decile by annual output (which equates
 Front End Loaders - 25 to close to the 95th percentile). A mine may only achieve high loader
performance when over-trucked
trucked (usually typified by high queuing time for
Max. Number of Operational and Maintenance Stoppages per day: trucks and low hang times for the loaders). You just have to keep
ke trucks
 Excavators – 27 up to the loader to keep the loader loading. However, when a mine is
over-trucked
trucked they don’t normally achieve high truck output (per truck).
 Rope Shovels – 31
So you might have loader performance in say the 75th (or even 95th)
 Front End Loaders – 16 percentile but the trucks might be only in the 45th or 50th or whatever
percentile.
The over-trucked
trucked scenario is a strategy which aims to maximise output
with a potentially higher unit cost of mining. It is normally used when
margins are high and production / volume is driving total return.
return In an
over-trucked
trucked scenario there are two possible courses of action which a
mine may take.
1. Prioritise BI on the loaders. Trucks are queuing for the majority
of the time and the aim is to optimise how quickly the loaders can
fill them and how much is putut in them.
2. Reduce the number of trucks in the circuit. The high queuing
times offer the potential to move the same amount of material
with less trucks. Some mines have achieved success with this
through a “Theory of Constraints” approach. It is however
important to realise in the over-trucked
over scenario that you are
looking for constraints on individual trucks as a priority.
Constraints on individual trucks (different capacity, different
make and model, etc) cause increased queuing and hang times.
The cost
st strategy requires minimising the number of trucks to move the
required volume of material. This is a case of returns driving production.
Loaders will normally have higher hang times but truck queuing times will
be relatively low.
In an under-trucked scenario there are again two possible courses of Strike length
action which a mine may take.
1. Prioritise BI on the trucks. Trucks are running for the majority of Strike length is extremely important to the Split Benching sequence. A
the time and the aim is to optimise how quickly they can cycle and short strike length will have a negative effect on the productivity
the load they are carrying. performance of the Excavator, as there will be too many sequential
changes in the sequence. A longer strike length will secure momentum for
2. Reduce the number
umber of loaders. The high hang times offer the the Excavator and assist in increasing efficiency.
potential to move the same amount of material with less loading
capacity. Maybe shut down smaller / higher cost loaders or cut
seven day roster back to six or five. There are a range of options
available.
In the case of under-trucking
trucking the mine needs to look at bottlenecks in the
truck circuits. That is, what are those things which are holding up the
whole process? Things like wet or poorly maintained roads; dumping or
loading areas not set up well; etc.
A plot can be created to demonstrate over-trucking
over vs under-trucking. A
sample is shown below
Stripping – Removing of overburden waste

or spoil
Stripping is the generic term for digging waste in coal mines. It refers to
digging the overburden to expose the coal.
The question is whether 67.7% over--trucked is good. Is next month /

period better or worse?
In an environment (in 2013)) of low commodity prices a cost strategy
strate is
needed by most mines. You can’t just think that the more you produce the
less it will cost.
Stripping Ratio Suspension – Shock Absorber (truck)
Prime Cubic Metres per tonne of coal. These rear suspension cylinders minimise and absorb shock to the truck
chassis.
Need to always define what tonnes are being referred to as can be in situ
coal, run of mine coal,
oal, or clean (washed) coal.
Stripping ratio is often used in planning and reconciliation (after survey
pick-up.
Stripping Ratio = Prime Cubic Metres/tonnes of coal
Struck capacity
The struck capacity is the actual volume inside the structure of the bucket
or tray without any heaped material supported by the teeth or other parts
of the bucket or tray.
See further explanation under Rated Capacity.
Capacity
Stub Line –A
A Feeder Power Line
The main power line to the shovel is usually placed outside the pit
excavation parameters.
arameters. The power is then brought closer to the working
pit by a feeder line called a stub line. Stub lines are placed at around 1km
apart along the pit length so the equipment can access the power. Most
shovel with external substations will operate effectively
eff with a maximum
of 2100m of cable from the substation.
Swell –The
The Enlargement of the Insitu
As the pit advances, sections of the stub line can be removed as required.
Overburden after Blasting
Overburden swell is the enlargement of the Insitu overburden after
blasting.
Blasting loosens up the overburden, creates air pockets within the burden
and therefore takes up more volume.
Swell
ll of 25% is considered normal, although this can vary significantly.
Swell Factor – The Percentage of Swing Clearance
Enlargement of the Insitu Overburden after
Blasting
The swell factor is the percentage of enlargement of the Insitu overburden
after blasting. It is normally 15% - 30%.
Swing Arc Efficiency
The ideal truck positioning arc is shown above. On this arc the loading
tool swings the load over the back of the truck. The most efficient location
for the truck is at 450. This ensures minimum swing time.
Swing clearance is the amount of room required at the back of the loading
The secrett to maximising loader efficiency is to minimise the work cycle. A tool to ensure there is no contact between the loading tool and truck,
saving of one or two seconds on each load cycle builds up to many material being dug or anything else. It may be measured from the centre
thousands of dollars over a relatively short period line of rotation or as a distance from the actual machine
Swing Drive Swinging Phase
Correct swing motion means smooth control and efficient swing control.
The swing motion is commenced towards the haul truck when the bucket
is full and is clear of the bench. The swing motion begins with smooth
acceleration to an optimum point at which the excavator is plugged to a
stop over the haul truck.
The swing drive iss the system which causes a shovel or excavator to rotate
between disengage from the bank, dumping in the truck and returning to
Maximum efficiency and minimum swing machinery
machiner wear are direct
the bank.
results of mastering the swing motion. Improper swing motion results in
erratic control and an unsafe, inefficient swing cycle. If the cycle begins
with fast acceleration and maximum speed is maintained to the dump
spot, it will be necessary
ary to stop the swing very suddenly. Plugging the
swing under these conditions results in jerky swing motion and
unnecessary spillage onto the haul truck and
pit floor.
Positioning of the haul truck also affects the swing time and it should be
positioned along 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 Assembly – swing Tags
bearing and revolving frame
Tags are used as a means of communicating important information
inform to
other persons when not everyone is in the locale at any specific time. They
often contain important safety information and are coloured to attract
attention. The following are examples.
Isolation/Lockout/Danger
Danger Tags
These tags are an instruction to
o all personnel that the equipment is not to
be started or operated. They are used to ensure that persons working on
equipment can do so safely. Danger tags are in a bright red colure with
black and white
These are the system components which support the body of the excavator
or shovel and allow it to rotate between disengage from the bank,
dumping in the truck and returning to the bank.
bank
Switchbacks – Zigzag
Switchbacks are often used if the haul road can’t be built straight due to a Out of Service Tags
steep gradient in deep pits.
ts. The road is build with sharp turn and a
moderate gardient to achieve a operable Haulroad. This way the haul road Out of Service tags are placed
d on the isolation points of faulty equipment
can be built in a confirmed space but still capable to go into deep pits. that could cause personal injury, equipment damage or impede the
operation. They are usually yellow coloured
Information Tags Talpac – Truck & Loader Productivity
Information tags convey a message or instruction to personnel operating Estimation Software
or repairing an item of equipment.
Equipment with an attached Information tag may still be used or Simulates truck and loader mining systems enabling you to perform:
operated. The tags are usually green.  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 haulage
network. Allows users to determine shortest
sh route and shortest time
between source/destination. When integrated with XPAC/Xact or excel,
scheduled truck requirements can be determined.
Tail gate – Stops spillage and increases body Terex (Dart) 3100 33100 – Dump Truck
capacity
Terex(O&K, Dart) 3100 33100
Engine Gross Power (kW) 782 727
Net Power (kW)

Loaded (kg) 158002 159620
Operating Capacities (m3) Struck
Specifications
Heaped 2:1 57 57
Fuel Capacity (L)
Dump Height (mm)
Raise Time (s) 15
A tail gate on a truck may be used where in internal
int angle of friction of
material to be carried is very low or the material being carried has very
low SG and additional payload capacity exists in the tray on the chassis. A
tail gate is often used with coal (low SG) or dry sand (low internal angle of
friction).
Terex (Dart) 3311 – Dump Truck Terex (Dart) 4150 4160 – Dump Truck
Terex(O&K, Dart) 3311C 3311D 3311E Terex(O&K, Dart) 4150 4160
Engine Gross Power (kW) 626 626 727 Engine Gross Power (kW) 783
Net Power (kW)

Net Power (kW)
Transmission Max. Speed (kph) 60 60 64
Weight Empty (kg) 53300 54800 63200
Loaded (kg) 130300 131800 148200
Loaded (kg) 232285 241809
Specifications Operating Capacities (m3) Struck 138.4 138.4
Heaped 2:1 49.5 49.5 54 Specifications
Heaped 2:1 163 169
Rated Payload (kg) 77000 77000 85000
Fuel Capacity (L)
Fuel Capacity (L) 1514
Dump Height (mm)
Dump Height (mm)
Raise Time (s)
Dimensions Overall Length (mm)
Overall Width (mm)
Overall Height (mm)
Terex (Titan) 3315C 3315D – Dump Truck Terex TR100/100DD – Dump Truck
Terex(O&K, Dart) 3315C 3315D Terex(O&K, Dart) TR100 TR100DD
Engine Gross Power (kW) 1343 1200-1500 Engine Gross Power (kW) 783 783
Net Power (kW)
Net Power (kW) 727 703
Transmission Max. Speed (kph) 56
Weight Empty (kg) 104279
Loaded (kg) 276279
Loaded (kg) 158980 157720
Specifications Operating Capacities (m3) Struck 41.6 41.6
Heaped 2:1 110
Specifications
Heaped 2:1 57 57
Fuel Capacity (L)
Dump Height (mm)
Dump Height (mm) 8960 8960
Raise Time (s) 18
Raise Time (s) 16.3 16.3
Dimensions Overall Length (mm) 12600
Overall Width (mm) 6270
Tip head edge/ Tip head stability TKPH – Tonne Kilometre per Hour
The tip head refers to the location where the truck is dumping its load. It TKPH = Average Load (tonnes) x Average Speed (kph)
is a high risk area due to the fall in ground level behind the truck. It is also
TKPH is a rating based on the weight and speed that a tyre can tolerate
the time when the truck k is least stable with the tray up in dumping
without overheating. Overheating causes tyres to deteriorate and fail.
arrangement.
PwC recommend operating trucks so that the tyres stay within 80-90%
80 of
There are a number of things that can be done to make tipheads as stable
the manufacturer’s TKPH rating.
as possible:
To calculate the TKPH of the tyres when operating a three stage process is
 Carry out dumping only when foundations have been properly
followed.
prepared;
1. Calculate
lculate the average weight on the tyre (front + rear)
 Maintain a safety bund that is typically half
h the height of the largest
truck tyre; 2. Calculate the average speed (Travel Distance/Operating
Distance Time)
 Reverse slowly and brake gently 3. TKPH = Average Load (tonnes) * Average Speed (kph).
 Do not use the safety bund to stop the truck; The calculation of TKPH for the tyres follows three stage calculations.
 Move the tipping position regularly to give newly placed material time Tyre Load front and
nd then rear tyre
to settle;
 Always ensure that the approach grade is slightly uphill
uphi and water
cannot pond against the bund;
 Avoid tiphead lifts greater than 30 metres wherever possible, and seek
specialist advice for lifts that are higher
Stage 2 – Average Speed.

The average speeds in km per hr are distance/time;
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
Where there is poor visibility, dump short and push out with dozers. Average TKPH = z
Take particular care after heavy rain; check for cracking or bulging and Peak TKPH = z
watch for water ponding near crest and toe areas.
Compare with rated TKPH for all available tyres.
Toe – The Bottom of a Batter or Face Tooth Adaptor – Fitted to the Nose of the
Bucket
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 on The Adaptor connects the tooth point
poin to either the nose on a cast bucket
when digging near the floor as it is easy to leave a couple of metres of lip or directly to a plate lip. Whisler--style Adaptors connect the tooth
material outside the survey line. A pre-split
pre high wall batter is far easier points to a cast shovel dipper lip. The adaptor is used to ensure the tooth
the get and keep on line than a normal batter. The dozer has to clean the point is correctly located relative to the bucket and to allow tooth points to
coal, so if the toe has been dug properly and to the surveyed line, there wear out and be replaced relatively cheaply.
will 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.
Bucket
Adaptors
Toot
Tooth attack angle Top Loading
Top loading is defined as when a backhoe sits at the same level as the
trucks and digs below itself.
Defined as the angle between a line from the top of the pivot point which
the dipper arm rotates around to the front of the lip (A) and the centre
line of the teeth (B). This is not favoured as the tooth attack angle will vary
as the dipper arm is pushed out.
A better definition (and consistent regardless of how far extended the
dipper arm is) is the angle between the centre line of the teeth (B) and the The top loading technique is generally used when the cut
c is too deep to dig
centre line of the dipper arm (C). in one pass. Top loading may also be used when trucks are experiencing
difficulty pulling out from the face, or when the material is unsuitable for
the trucks to drive on. Because of the increase in swing and lift time as
compared to other methods, top loading is not an efficient method and
Tooth Coverage – Percentage
ercentage of the lip should only be carried out when necessary.
which is made up of teeth
To improve efficiency, ensure that the bucket is positioned for optimum

penetration and material spillage is minimised by crowding the bucket to
the correct position.
Topsoil – The Dirt on the Surface that Tracks (Continuous tracks or machine
Grows Vegetation tracks) – Providing
roviding motion
moti traction
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 for
future rehabilitation of the mining areas.
ar
Top soil is stripped and stockpiled ahead of mining operations for later
recovery.
The tracks are what shovels and excavators use to move the machine.
Trainee – Person Learning
Lear to Operate a Truck & Loader Operations
ations
Machine
Truck and Shovel (T & S or T & L) operations are an alternative means to
A trainee is a person who is learning to operate a machine. They are also a dragline for moving overburden in the mining industry.
called a novice particularly when first starting. Training truck and loader T&S is a more costly process per cubic metre and is around 3-5
3 times
operators is a long and involved process. There are a number of ways that dearer per cubic metre than a dragline operation. In the smaller mining
a mine can train operators. operations, Truck and Shovel/Excavator
Excavator is used extensively as the cost
Most mines use a third party to initiate the training process by having the outlay of a dragline cannot be justified.
proposed trainees attending a novice trainee course that uses a
combination of VTS technology, sand pit and classroom sessions. They
then go back to site and continue with onsite trainers.
It has been shown and recorded that by using these tools, in a very short
period of time, the trainee then put onto a production machine to
continue training has approximately 55% of his skills, so production does
not suffer dramatically.
Tramming – Moving the loader

Tramming is the terminology used in some mines for moving and
excavator or a shovel. In the normal travel position the travel motors are
at the rear of the excavator and the idlers are at the front of the machin e.
Be aware of their position before you begin to travel. For forward travel
push 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
position.
Truck – Controls Truck Optimisation
Core considerations of a Truck and Shovel operation. Like every other
material
aterial carrying tool in the mining industry the key to optimizing the
truck performance is in optimising payload.
Haul Road Construction Material
Haul Road Design Bench Width
Haul Elevation (Height) Bench Strike Length (EXC)
Haul Dist (VERT) Bench Height (EXC)
Rope Shovel (Type, Make, CAP) Best practices
HYD, Shovel (Type, Size, CAP) Drilling Patterns
HYD EXC (Type, Size, CAP) Blast Volumes & Frag
Truck & Shovel

FEL (Type, Size, CAP) Core Consideration DIG Sequences & Methods
• Through Planning
& Design
Truck (Type, Size, CAP) • Regular Review & Cable Plans & Layout
Emergency Emergency Accelerator Monitoring
Brake Brake pedal Support Equipment
• Change Process
Shovel Assist Methods
Tech & Other Support Double Side Loading
Face Height Single Side Loading
Bump Plans Starta Team Competencies Other Consideration

• Location • DRE Planning
• Construction • Rehab
• Number of Dumps Environment Volumes (BSM) • Bridges (DRE)
Weather Polices & Procedures
Truck Payload Weight to be carried 251 tonnes
It is the split between payload weight and non-payload
non weight as part of
Like every other material carrying tool in the mining industry the key to the 251 tonnes which must be optimised. The weight of the trays will limit
optimizing the truck performance
rmance is in optimising payload. The industry, the target payload and thiss needs to be quantified by every site, however
however, has a problem with truck payload being 5-15%
5 below nameplate the value in carrying more payload may far outweigh maintenance costs
capacity. The average payload carried around the world by a 218 t (240 T) so mines need to consider how to optimise payload carried while
truck is 201 tonnes. The following plot shows the distributions
distribution of maintaining acceptable life.
payloads achieved by this class of truck.
If the split between steel and payload reflects standard trays the following
is the result.
Total Operating Weight 386 tonnes
Chassis Weight 135 tonnes
Weight to be carried 251 tonnes
Tray Weight (average) 38 tonnes
Nominal payload 213 tonnes
If a mine is to respect the specification of the trucks then no more than
213 tonnes (235T)) 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 of
suppliers. These range in weight from 25 tonnes to 38 tonnes (including
liners). If the calculation is repeated using a tray weight of 28 tonnes then
Given the fact that there are multiple passes to each single truck there is a the target payload may increase as follows.
small capacity to vary loader payloads to ensure the truck is filled. This Total Operating Weight 386 tonnes
means one or more “overfull” loads by the loader can be offset by a final
“smaller” load. The situations which must be avoided are excessive Chassis Weight 135 tonnes
numbers of passes to fill the trucks and half loads to fill an individual Weight to be carried 251 tonnes
truck. It is easy to see why it is an exercise where the skill and experience
of the loader operator becomes critical. This small amount of flexibility in Lightweight Tray 28 tonnes
the loader payload means that the key parameter in optimising the loader Nominal payload 223 tonnes (maximum 226 tonnes)
and truck match is the payload which can be placed on the truck tray.
Consequently, the first consideration is maximising
maximis the load which the
truck tray can consistently and safely carry.
Following on with the example of 240T (218 t) trucks the
t following is a
typical OEM produced weight distribution for 240 T trucks (CAT793,
Komatsu 830E, Terex 4400, etc).
Total Operating Weight 386 tonnes
Chassis Weight 135 tonnes
Trucking – Truck matching to the shovel Truck Air Filter Indicators – Indicates the
filter condition
What is Matching/Trucking?
Matching is basically ensuring the right amount of Trucks to a shovel to ndicates when filters needs to be cleaned/replaced
Indicates cleaned
Optimize Productivity and minimise delay on waiting for trucks or
overcrowding trucks (Over Trucking).
Matching can be worked out taking all elements into consideration, Size of
Truck and Shovel, cycle time, delays etc.
Truck Forces – Forces on the Truck Truck Positioning
in operation
The truck positioning for loading is important for production as the swing
angles of the dig unit need to be minimised to speed up loading times
without compromising safety. When an excavator is loading on a bench
thee most productive position to place a truck is 45° to the bench where the
operator has just to raise the bucket up over the back end not up and over
the side of the truck. The disadvantage of that position is that the truck
drivers have difficulty self spotting
tting to the excavator.
The most common way excavator operators load trucks is 90°to the bench
but the disadvantage of that method is that the bucket has to be lifted up
and over the side of the truck. The advantage of that method is that the
truck drivers can easily self spot to the excavator.
Truck parking bay
Designated area for trucks to be parked. This is also commonly known as

the Go – No Go area.
Truck PLM (Payload Meter) – Measures the

loaded Material
Truck Spotting guide – A device to assist Truck Tow Pin
truck drivers
A cable or other structure is hung from specific points under the boom for
the truck driver to use when spotting the truck ready for loading. It allows
the truck
ruck driver to correctly spot and reverse under the dipper
Truck Tray (Bed) – Carries Material on the

chassis
The tray or bed is the generic term given to the (usually) steel structure
which sits on the chassis and is used to contain
contai the material being carried.
Truck Tray – Capacity

SAE standard J1363 has been traditionally used to define truck tray
capacity. In this standard struck
truck capacity provides for the load to go to
the top of the sides of the truck tray, and if the tray is open
op at the back, Truck tray cleaning – Reducing carry back
this material is assumed to be sloping at 1:1.
The 2:1 heaped capacity is the total of the trucks capacity, plus the Some mines with clayey material have problems with material not being
material above the tray sides with an assumed angle of repose of 2:1 slope. dumped efficiently. This causes material to build up in the tray. This
For most mining applications, the 2:1 heaped volume
vo is an optimistic reduces the effective capacity of the tray and the productivity of the truck.
estimate of the quantity which can be carried on average in A number of methods can be used to clean carryback out of the truck.
the tray.
The first one is to use a backhoe. This
his should only be done by experienced
More recently truck tray manufacturers have been using their own operators. The tray can be easily penetrated with the bucket teeth. Lift the
computer models in an effort to gain a more accurate indication of the truck tray up, the excavator and truck should be in one line, gently start
true volumetric capacity. This still leaves the issue of the conversion from removing the material out of the tray.
the capacity being calculated as a volume to the capacity being stated in
Another, safer way is to remove it with a water cannon. This is potentially
tonnes or tons.
less efficient at removing the carryback.
Truck Tray Hoist Ram Pivot Point Tyre Damage
Tyres
Major offroad tyre brands are Bridgestone - 40% market share, Michelin -
40% market share and Goodyear - 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
have distributor networks. Each truck manufacturer will approve certain
makes 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
used. This makes it difficult for the smaller suppliers to gain market share.
Tyres are rated according to TKPH (see previous) and it is important that
the actual TKPH on site be kept to 80-90%
80 of the rated TKPH.
Tyre management reports Tyre Overheating
Tyre reports are an integral part of tyre management on mine sites. Care must be taken when dealing with tyres
t that are suspected of being
overheated.
Key issues to be included are;
 Tyre cost A good guide as to whether a tyre is operating at too high a temperature or
not, is to touch it with the palm of your hand. Temperature wise, it should
 Dates fitted and removed
feel comfortable to touch.
 Reasons for removal, (eg. Worn out, case separation, rock damage,
irregular wear, spare) An overheated tyre may eventually
lly cause a fire which can destroy the
truck.
 Tyre specification, (brand, type, ply rating, TKPH rating, rubber
compound, tread depth and pattern)
ttern)
 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 Tyre TKPH
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 fire.
Tyre Tread – Maintains traction with Ultra Class Trucks
haulroad
The largest, highest payload capacity haul trucks are referred to as "ultra
class" trucks.
The ultra class includes all haul trucks with a payload capacity of 300
short tons (272 tonnes) or greater.
Undercarriage – bottom
om deck
Walking gear, travel motors, etc.
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 optimum
o tread
Undercutting a Face above the bench Undercutting a Face below the bench
The dangers of undercutting a high face include: In order to retreat from the edge of an excavation should the footing
collapse, always position the undercarriage square to the
t edge of the
 The face can collapse excavation with the travel motors at the rear.
 Single rocks can fall onto the machine
This can cause damage to the excavator and serious injury or death
dea to the
operator and
other people.
When the overhang collapses, the material can fall onto the bucket and
damage the hydraulic cylinders or the hoses. In the worst case the
machine could become unstable and tip over due to the heavy/ large
amount of material in the bucket.
When the face collapses the material can fall onto the bucket and damage
hydraulic cylinders, hoses and grease lines. Dipper arm and or structural
boom damage could occur. In the worst case the machine could become
unstable
nstable and tip over due to the heavy/ large amount of material in/on the
dipper arm/bucket.
Vienna Test System Vital Information Management System
(VIMS)
The Vienna Test System (VTS) is a computer based testing program that
assesses the perception and co-ordination
ordination abilities required for safe and The Vital Information Management System (VIMS) consists of a message
productive performance for operators of machinery
mach and vehicles. VTS centre module and a VIMS keypad module.
mo The message centre module
consists of powerful basic software and over 82 individual tests. Its use is for the VIMS is used to display information to the operator. The operator
easy and intuitive. can use the VIMS keypad module to input information. There is an action
More than 5000 Vienna Test Systems are in use around the world. alarm. There is an alert indicator. There is an action lamp. The VIMS is
designed
ned to alert the operator of an abnormal condition in one or more of
Two-hand
hand coordination test and time movement anticipation test are the the machine systems. These abnormal conditions are called events. The
best predictors of operator productivity. These two tests plus age explain VIMS will store data.
64% of the variation in operator performance. The reliability of Two-hand
Two
Coordination test and Time Movement Anticipation test is excellent.
Pearson correlation of 0.964 for the two
tw hand coordination test and 0.970
for time movement anticipation test have been recorded for operators.
Volume – The Amount of waste in an area

Volume is amount of bank cubic metres, B.C.M. in a given
g area. Before
digging, mining engineers usually will work out the volume of
overburden/waste
waste bcm’s to be removed from the pit. The production
monitors record the volumes of overburden/waste
overburden removed and on a
regular basis, reports are printed to keep track
tr of how productive the
truck and loading units are. Survey will, on a regular basis; reconcile the
volumes of material removed against the production monitors
Void (dipper) – Volume in bucket which is Wait On Truck (Hang Time) – Reporting
not filled
This information will help the supervisors assess whether there is the
correct amountt 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 up
and will be waiting for a short time before it is their turn to go in for its
load. If the loader has no trucks available to be loaded, this is called wait
on trucks. Mines which have relatively high wait on trucks are said to be
under trucked.
Up to 25% of a bucket/dipper
dipper might not
n be filled when the bucket is
regarded as loaded. This is a function of the shape of the bucket and the
action of the loading tool.
Wait On Loader (reporting) Walk Around Inspection
This information will help the supervisors assess whether there is the The main aim of a walk around inspection is to identify problems before
correct amount of trucks in the spread.
pread. When the truck is almost loaded they reach the stage where equipment fails or breaks down.
with one more bucket to go on it another truck should be just turning up
The sooner problems are found, the greater the lead time that the
and will be waiting for a very short time before it is his turn to go in for its
maintenance department has for planning, gathering materials,
load. If the trucks are waiting for two or more buckets to be put
p on the
coordinating the shutdown, and estimating and scheduling the manpower
truck being loaded the waiting time is beginning to be too long and they
for the maintenance work.
would be almost at a queuing stage. If the trucks are queued, waiting to
load, this is called wait on loader. Mines which have relatively high wait A walk around inspection needs to be carried out at the beginning of each
on loader are said to be over trucked. shift, 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 manner
prescribed
ed by the mine or the manufacturer.
http://www.flickr.com/photos/tom_oconnor2/5579445038/
Always complete a through pre-start

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 with machine
 Check coolant level Wash bay – Machine
 Check engine oil level
 Check Hydraulic oil This is an area to clean trucks, loaders and other mining equipment prior
to servicing and or transport off site.
 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
Dipper on loading units
 Ladders, hand rails
 Monitor, brake and steering operation
 Drain sediment from fuel tank
 Check monitor panel
 Check wiring
 batteries,
Always refer to the OEM
 starter motor, (Original Equipment Wheel lock ring
 alternator Manufacturers)
 Check parking brake operational manual and All lock rings are split. In three-piece
piece assemblies, the lock ring is designed
your site specific to hold the continuous side ring on the rim.
 Check emergency steering regulations to carry out a
 Check brake pedal operation thorough pre-shift
 Check tyre pressure & wheel nuts
 Adjust seat & seat belt
 Adjust mirrors
 Park brake is on
 Transmission neutralized
Windrow/Berm – Physical Barrier Witches Hats – Reflective Safety Cones
for Demarcation
Is a line of heaped waste, which acts as a physical barrier. It is used to
separate
parate people or equipment from hazardous situations Witches hats are used extensively around a mine site. Around a dragline,
they mark
ark the cable, parking areas, and anywhere that demarcation is
required.
Wire rope – Consists

onsists of several strands laid
together like a helix
Wire rope consists of several strands laid (or 'twisted') together like a
helix. Each strand is likewise made of metal wires laid together
toge like a
helix. Initially wrought iron wires were used, but today steel is the main
material used for wire ropes.
Working Zones
The exclusion area while excavator or shovel is loading. For maximum
output, the excavator working zone should be limited to 15° either side of
the centerline, or approximately
oximately equal to the undercarriage width.
The publishers of the Truck and Loader Dictionary have exercised the utmost care in the composition of
this publication; however, PwC cannot be held responsible for errors, inaccuracies, or omissions resulting
from the nature of the information provided or previously published, or through typographical compilation.
© 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.
This content is for general information purposes only,

only and should not be used as a substitute for
consultation with professional advisors.
PwC’s Mining Intelligence and
Benchmarking
Service Overview
November 2013
pwc.com.au
Driving value through productivity and reliability data
PwC maintains the leading database of open cut mining equipment performance in the world. PwC Mining
Intelligence and Benchmarking (MIB) enables mining organisations to unleash the value of the data. Data
is your most valuable strategic resource.
Whether the goal is to optimise When choosing new or

operational throughput, reduce replacement equipment, MIB’s
operating costs or optimise total data can provide insight on how
value, MIB can identify areas of different equipment performs,
real improvement potential that Improve enabling better equipment
can be achieved independently or purchasing decisions to maximise
Operating
with the aid of PwC’s productivity productivity during the mine’s life
Performance
improvement capabilities.
Equipment
Performance Instead of planning based on
Rather than rely on equipment
name-plate capacities, out-of- Database averages and forecasting future
date rules of thumb or sub-par performance using qualitative
levels of past performance, “industry experience”, MIB uses real
De-risk data to provide a quantitative
MIB enables you to target the Set real mine picture of performance. It provides
real productivity & reliability targets planning
potential of your equipment ranges of current performance
which allows risk to be understood.
PwC's Mining Intelligence and Benchmarking is a PwC service offering.
In September 2013 PwC acquired the GBI Mining Intelligence business. This is core to PwC’s consulting
PwC 2
business which provides mining clients with asset benchmarking, productivity and analytics services.
Our database
The experience contained in our open cut mining equipment database:
5 136 308 4,670 12,000+ 47M+ 700M+

Continents Mines Makes and Individual Years of data Hours of Cycles
Models machines operations
Which commodities does it include?

Africa - Non-
• Coal • Copper Coal
13% North America
• Iron Ore • Silver, Lead, Zinc - Coal
Africa - Coal 18%
4%
• Gold • Platinum
Asia - Non- North America
Coal - Non-Coal
2% 2%
Asia - Coal South America
Where has the data come from? 4% - Coal
6%
The data comes directly from equipment monitors and Australia - South America
reporting systems Non-Coal - Non-Coal
10% 2%
• Jigsaw • Modular
• Wenco • Tritronics
• Minestar • Pegasys
Australia - Coal
39%
PwC 3
Our database
The breadth and depth of PwC MIB database is unparalleled
The breath – Extensive equipment information

Electric Rope Hydraulic Front End Ancillary (Dozers,
Characteristic/Class Dragline Mining Trucks Drills
Shovel Excavator Loader Graders etc)
Number of Models 18 32 51 22 87 60 38
Number of Machines 174 171 432 298 2,596 286 713
Number of Mines 74 38 70 58 66 41 22
Equivalent Years of Data 1,171 496 869 704 6,510 552 1,850
No of Cycles 321M 93M 136M 65M 64M
The depth – Key performance indicators include (but are not limited to)
Time based metrics Production based metrics Other Metrics
• Operating Time Generic Dragline and truck specific Dragline Specific Other
• Downtime • Payload • Swing Time (Dragline) • Fill Energy (Dragline) • Fuel Usage
(Mechanical/Electrical) • Cycle count • Swing Angle (Dragline) • Fill Distance (Dragline) • Bucket Capacity
• Delays • Loading/Fill Time • Return Time (Dragline) • Engage x & y (Dragline) • Truck Size
• Standby • Hang time • Queue Time (Trucks) • Disengage x & y (Dragline)
• Unscheduled • Dig Rate • Spot Time (Trucks) • Dig mode (Dragline)
• Weather • Annual Output
• Availability
• Utilisation
• Reliability
Data as at 16 September 2013

PwC 4
Our experience
You can have complete confidence in the PwC Mining Intelligence and Benchmarking team, with our
extensive experience in open cut mining across the world.
Australia (58 Mines) Global (136 mines)
We have worked with Australia’s leading mining

companies to benchmark their assets across
over 50 mine sites
PwC 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 for
our clients
Comparison of multiple site loaders
of a specific make and model with
Comparison of annual output of all
summarised industry performance
site loaders with all loaders in the
for the agreed population
PwC database showing median and
90th percentile performance
Machines that are in the

top priority list for
improvement
Gaps in performance between a

particular machine and best
practice .
Group of machines
performing under the
median of the
KPI’s that are in the top priority
industry
list for improvement
PwC 6
Our service offering
PwC Mining intelligence and benchmarking supports mining organisations all the way from setting
targets to minimising operating costs
Benchmarking and Best Practice

Data Provision
Analysis
Worldwide or geographically focussed analysis against Provision of insights from the database presented by
Best practice and against yourself. geographic region, class of equipment, make and model
or commodity.
We know Best Practice and average performance of all
major earth moving machines in our database to assist Ranked by annual output, dig rate, availability, etc.
with identifying a machines true potential.
Equipment Selection Training and Development
Using the data in our database we can assist you in Training suites from novice to advanced operators and
choosing the correct machine for your application. management in dragline, truck and loader Productivity.
Bucket, rigging, tray analysis and comparison to enable Best Practice standards courses leveraging the PwC
the correct targeted outcome. database best practice data to contribute to a strategic
advantage in cost and productivity performance.
PwC 7
PwC MIB in the broader mining productivity offering
The acquisition of GBI Mining Intelligence in September 2013 by PwC adds a world leading benchmarking
and mining analytics capability to PwC’s broader productivity proposition.
There is a strong opportunity for mining
companies to improve productivity
Optimise Mineral Optimise Asset Optimise Unit through equipment management
Inventory Base Cost
Mining Equipment Productivity Index
Solutions for 115
Mineral Flow Optimisation Operational Performance Improvement
Mine Assets in
Operation Mine Plan Optimisation OEE and Throughput Cost Reduction 110
Improvement
105
Cut-off Grade Optimisation Process Improvement Sourcing and Procurement
Index(#)
Redesign
100
Improve Asset Management
and Capital Employed 95
Mining Intelligence and Benchmarking 90
85
Business Improvement Capability *2003 Result set at 100
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Turn-Key Set Up of the Internal Business Improvement Function and Up-Skilling
Skilling Existing Teams
Performance Tracking and Systems Design

+12,000
Organisation Design, Structure and Workforce Optimisation
equivalent years of equipment data
Capability Development and Behaviour Change:
Lean, Six Sigma, 5S, etc.
Nobody else in the world has this
amount of data
Solutions for Capital Productivity Improvement
Development By acquiring GBI, PwC adds to it’s
Projects
Project Execution Support
mining productivity proposition a
tangible source of real
Risk Management and Execution Support competitive advantage for our
clients
PwC 8
MIB - Use by other PwC businesses
PwC Mining Intelligence and Benchmarking is part of the PwC Consulting business. The MIB database
and IP can be used to enhance what other PwC businesses deliver and to provide strategic advantage in
the market.
Assurance
The appropriateness of the

value of the mine / reserves /
resources on the balance sheet. Deals
Due diligence by
benchmarking actual
performance or planning
assumptions used. Tax
Support for and enhancement

of client R&D activities
Enterprises & Private Clients
Any work in mining may

benefit from the MIB data
and the IP
PwC 9
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 were
treated as 3 separate truck fleets), based on same commodity, same country and same make and model. Populations
were 17 - 89 machine years for loaders and 118 – 515 machine years for the truck fleets.
We undertook an analysis of the performance of the mine’s loaders and trucks in 2012-2013
2012 compared with the average
of the top 10% by annual output of equipment in the population selected from the PwC productivity and reliability
database (external comparison); and their performance in 2012-2013
2012 compared with their 2011-2012 performance
(internal comparison). Production metrics were compared as well as gaps in production and reliability metrics
quantified.
Outcomes:
We identified that both loaders and trucks had significant improvement potential. Trucks and loaders could add up to
134 Mt pa which was almost exactly twice what they moved in 2012-13.
2012
We also concluded that the mine’s volume strategy (over-truck
(over so that the loaders just keep loading) was not executed
effectively.
Further data analysis revealed that both
oth loaders and trucks had gaps in operational standby time especially under “No
work available” and “No operator”, indicating inefficiency in utilisation. The analysis also disclosed gaps in hang time
and 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. The study identified the
PwC
performance gaps and will allow 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 to fit to the chassis. The
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.
• 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 tray
added $6 million of value per year to the mine compared with selecting the standard tray used by the make
and model truck..
• We recommended the loader bucket capacity to give an optimised number of passes to fill the
recommended tray.
PwC
Case study 3 – The importance of Truck Make and Model
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 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
the operation. As material movement carries a value it is really important to select the appropriate equipment
to maximise this value.
High level summary:
80,000
Ultra-class trucks
Utilising the PwC Productivity and 75,000
tkm/Tonne of Nominal Capacity

Reliability Database our team provided a 70,000
detailed performance analysis of actual

65,000
operating performance of different truck
makes and models and how each of the 60,000
ultra class trucks would be matched with 55,000
the loader. 50,000

1 1 1 1 1 2 3 3 4 4 4 4 4 5 5 6 6 6 7 7 7
Make and Model
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
PwC capacity appropriate loaders and loaders capacity.
Appendix B – Thought Leadership
PwC
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 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:
The 93% of trucks which fail this rule (placing them potentially in breach of contract) may face consequences
including 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
10% below nominal payload on average.
If a mine ignores the 10/10/20 rule, they may void the warranty and MARC arrangements. They may also
place the mine in some legal difficulty if a truck has an accident.
PwC
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
mine performance and is not indicative of equipment
efficient performance. Equipment performance / output analysis is exclusive to PwC through the Productivity
and Reliability Database. This analysis demonstrates the true industry productivity.
High level summary:

The PwC Mining Productivity Index has been developed
as a combination of dragline, rope shovel, hydraulic
excavator, front end loader and truck performance
referenced to a value of 100 for 2003 performance. The
relative weighting is based on the amount of material
moved by each class of equipment worldwide. The
weighting of each has been applied to the performance of
each class to give a relative value for each year.
Outcomes:
Mining equipment productivity has decreased 18% since 2007. This trend is observed across all mining
jurisdictions. In 2013 equipment productivity dropped 5% compared with 2012. Most mining jurisdictions are
facing challenges in this area.
The breakdown of this analysis provides insight into key areas for mining equipment productivity
PwC improvement. The most important is payload followed by operating time.
Contacts
Stephen Loadsman
Partner
T: +61 (7) 3257 8304
E: stephen.loadsman@au.pwc.com
Graham Lumley
Director
T: +61 (7) 3257 5135
E: graham.lumley@au.pwc.com
Laura Seviour
Senior Manager
T: +61 (7) 3257 5128

E: laura.seviour@au.pwc.com
Agnes Fan
Senior Analyst
T: +61 (7) 3257 5130

E: agnes.fan@au.pwc.com
PwC 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)

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Truck and

PwC Mining Intelligence and

Alternator – Converts Mechanical Energy to

Air Horns – Signal Horns

Bail less attachment – Connects the hoist

Bail-less Connection at Rear of Dipper

Battery – Electric Energy Storage

Sample Imperial Calculation (SG = 3,750 lbs/CuYd).

Bench – A Levelled Area where Mining

When Benchmarking PwC compares a number of key factors:

BER (t/m3) – Bucket Payload/Bucket

Important note: A particular

Blast patterns – Designed to provide the

Boom point sheaves – The Pulleys that Guide

Boom Jacking – Rope Shovel

Box Cut – The initial excavation that is dug

Cab - Operators Cabin

Cable Access beside roadway

MAX Speed-Forward (kph) 21.1 21 21.8 20.6 MAX Speed-Forward

MAX Overall Length(m) 12.72 13.15 15.59 15.74 Length with

Gross Power (kW) 996 1027 1176 Backho

16.81(Std. 16.88(Std. Stick Length (mm) 5258 4928

Backhoe Shovel Backhoe Shovel CAT 6015 (RH40E) CAT6015 RH40E

Overall Height (To Overall Height 5250 5250 5250 5250

Dump Height (mm) 11900 12000 Dump Height (mm)

Operating Rated Payload (kg) 363000

Dump Height (mm) 13440

Raise Time (s)

Walk down the decline slowly, keeping

Coal - A Fossil Fuel consisting of Carbonised

Coal Reject Silo/ Bin – Storage area of

Collision Avoidance driving – Minimum

Swing Swing Swing

Phase Delay Phase

Dig Techniques (Sequence) – Common

Example of optimal fragmentation.

Dilution of the coal is the percentage of overburden or waste material

Retract the shovel dipper handle until

Time Spent [h]

Percentage of Total Time [%]

GREASE LUBE SYSTEM

Drive by observation on crest

Dump Site Maintenance

Electronic Monitoring System – EMS

Emergency Steering Switch – Activates

If you are faced with an emergency situation, where the operation of a

N (Neutral): The machine stops

Neutral position, the alarm sounds to warn that the machine

Excavator Boom – Boom attachment

Excavator – Loading unit

Excavator – Lock Lever

In geology a fault, or fault line, is a planar

An example of bad fragmentation is shown below.

Side Loading with a Front-End

Fuel Tank – Diesel Storage

Fuel Tank sediment

**Valid at time of going to Press.

Fill the bucket up & do it more often

Geology – The structure of the earth

GPS Antenna – Global Positioning System

Grease lines – Carry hydraulic fluid

Gyratory Crusher – Rock breaker

Haul routes need to be well maintained and at an acceptable grade