STUDENT:……………………………………………………………………………………………………….

SHIFT:……………………………… CLUSTER:…………………….

INSTRUCTOR: J. Alberto Huamán Chipana

 EXCAVATOR OPERATION MANUAL JH MINING CENTER

DEFINITION

Excavators are machines that have been designed for excavation

and loading work. Excavators are equipped to work in any climate
and type of terrain, from the softest to rocky terrain, combining the
power of the engine with the hydraulic power of its accessories,
giving As a result, high production performance at the time of
operation and in this way move a greater amount of material. In the
shortest possible time, this is a rule that all heavy equipment
follows.
It is characterized by having a superstructure capable of rotating
360º.

BRANDS OF HYDRAULIC EXCAVATORS

• CAT
KOMATS
• U VOLVO CATERPILLAR
•• CASE HMLIIIDFII
FIAT
• ALLIS
• HYDROMEK
• DOOSAN 200SAN
• LIUHYUNDAI
GONG
• KOBELCO
• JHON
• DEERE JCB
•
TYPES OF Hr
HNDAI

EXCAVATOR:
ON TRACKS:
They are called that because they have a running gear or
move on caterpillars.

Floatation. HYUND
160 ic «
Traction. A
Maneuverability.
Difficult Terrains.
Quick location change.

ABOUT TIRES
These excavators are mounted on tires .

• Mobility and
speed.
•
the pavement.
Does not damage

• Better stability.
•
the blade.
Ability to work with

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

AMPHIBIOUS EXCAVATORS:
They are called this way because of their application in
mud, swampy areas, and work in rivers. The amphibious
excavator is characterized by excellent versatility, control,
high digging force, simple maintenance and comfortable
cabin to increase productivity and reduce operating costs.
Due to the large expanses that the swamps cover, the
amphibious excavator was designed to have maximum grip.

INTRODUCTION
The hydraulic excavator is a machine dedicated to
removing material and, in most cases, loading it onto
transport units, although it performs many other jobs such as ditching, load handling, etc. even
demolition work and forest breaking when a hydraulic hammer is incorporated.

HISTORY
The oldest documented hydraulic shovel appeared in 1882 and was produced by Sir WG
Armstrong & Co., a British company that previously built hull docks.Unrelated Armstrong
also built hydraulic water shovels. Another company that also attempted to produce them
was Kilgore Machina Co. of Minneapolis, Minnesota, who patented the shovel in 1897.

•el='dzeMn=eV2YAKNIWYellelMA=N2=NVVEVAYsle In 1948, a
wheeled prototype of the excavator was developed. They assigned the patents and
copyrights to a French company called SICAM in 1954, the same year that SICAM built the
Yumbo. The Yumbo, an S25 excavator, had a track mounted. Rollers and crawlers paved
their way in the industry so customers became interested in these products.

HYDRAULIC EXCAVATORS TODAY

Models like the Hitachi 570-ton EX5500 and the Caterpillar 360-ton Model 523OB are
among the most notable machines in the industry. However, these are not
equal in size to the Liebherr R996, which weighs 720 tons and has a

SMEqesys...n —C-gE
44 cubic yard (34 m 3 ) capacity; the Komatsu PCS8000, a 755 model
tons with a capacity of 46 cubic yards (35 m 3 ); or the Terex/O&K RH-400, a machine capable of
digging 57 cubic yards (44 m 3 ) and 1,000 tons.

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

EXCAVATOR APPLICATIONS.

• Excavation work. • Demolition.

• Consolidated and blasting cut. • Forest exploitation.
• Moderate mobility. • Mining jobs.
• Critical bench height for the production system. • I load in banks.
• Extremely effective in tight places. • Application with hydraulic hammer.
• Load hauling units.
OPTIONAL TOOLS

VIBRATORY VIBRATORY HAMMER

PLATE

METAL CUTTER
CLAMP WITHOUT
ROTATOR

CR28

CONCRETE CRUSHER ROCK RIPER

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

LOWER FRAME:
The bearing train and its components are housed in it and are made of a
rigid material.
Modified X-shaped box section chassis provides excellent resistance
against torsional bending.
The weight of the upper structure and the stresses have been evenly
distributed along the lower roller frame.
Robotic technology is used to provide consistent, high-quality welds
throughout the manufacturing process.

MACHINE STRUCTURE:
UPPER FRAME:
The robust main frame is designed for long life and efficient
use of materials.
Robotic technology is used to provide consistent, high-quality
welds.
The outer frame has pressure-formed curved side rails to
provide uniformity and great strength along its entire length.
Channels in the box section improve the rigidity of the upper
frame under the cab.

Feather

Arm
Cabin

Turning
linkage engine hood

Ladle

Superstructure

lifting eye

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

EXCAVATOR IMPLEMENTS AND ACCESSORIES

1 . ARM
1.1. Anchor for the eyebolt bucket cylinder.
1.2. Anchor for the eyebolt cylinder rod
hydraulic arm.
1.3. Eyebolt for the anchoring of the pen.
1.4. Eyebolt for the anchoring of ladle.
1.5. Eyebolt for the mechanical tie rod.

2 BOOM OR GAUILON
2.1. Anchor for arm eyebolt
2.2. Anchor for the eyebolt of the hydraulic cylinder of
the arm
2.3. Boom Hydraulic Cylinder Stem Eyebolt
2.4. Eyebolt for anchoring the platform

ARM TYPES
• ARM R3.9B. The R3.9B arm offers the largest working reach limit with the smallest buckets.
• ARM R2.5B. The R2.5B arm offers a good limit of digging reach with larger buckets and stability for hammer work.
• R1.9C ARM. The R1.9C arm allows the use of the largest C family buckets.
• M2.4C ARM. M2.4C arm offers limited reach limit but allows use of larger buckets with high forces
of excavation.

1
TYPES OF PEN ' - - -—W .
• REACH BOOM. The reach boom has an optimal design that takes full advantage of digging reach limits with three arm choices.
“ II ■
• REACH BOOM FOR SPECIAL APPLICATIONS (SA). Special application reach arms and boom are designed for severe
applications.
• BOOM FOR LARGE VOLUME EXCAVATION. The high-volume excavation boom maximizes productivity. The M version offers
considerably higher digging forces and allows the use of larger buckets.

LADLE
""eq
The so-called buckets are the tools with which excavators normally work.
Optionally, instead of the bucket, other accessories can be used, for example. vibrating plate, ditch
cleaning bucket, stone crushers, etc.

GENERAL PURPOSE BUCKETS

Designed to dig in moderately abrasive and low-impact materials such as soil, mud, gravel, clays.

HEAVY DUTY BUCKET

Designed for use in abrasive applications such as mixing soil, clay and rock.

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

HEAVY DUTY ROCK BUCKET

Designed for aggressive bucket loading in highly abrasive terrain such as blasted rock
and granite.

SPECIAL HEAVY DUTY BUCKET

Designed for use in abrasive applications where
that peel forces and cycle times are the most important factors and for use on materials such as very
hard, mixed soil and rock

TRENCH CLEANING BUCKET

Designed for trench cleaning, slope formation, grading and other finishing work. It is provided
with blades and holes on the sides that allow the liquid to escape to facilitate the discharge of
the material.

SPECIAL BUCKETS
Caterpillar has designed buckets tailored to your needs, specialty buckets are
designed for a range of applications.

COUPLERS
Couplers exchange tools quickly and easily to improve production and increase speed:

HYDRAULIC COUPLING:
Through a lever or switch it is operated to remove the pins and place another tool, this is done by the operator without leaving the seat. The
objective of quick couplings is to allow tool changes with ease and in the shortest time.
MECHANICAL COUPLING
It is done manually.
COUPLER WITH WEDGE CROSS
COUPLER WITH PIN HOLDER

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

OPERATOR CONTROLS
Note: Your machine may not be equipped with all of the controls described in this section.

(1) Hydraulic lock control

(2) Scroll controls
(3) hourometer
(4) Screen
(5) Joystick controls
(6) Engine speed control
(7) Engine start switch
(8) Right side control panel
(9) Operator seat
(10) Radio
(11) Auxiliary controls
(12) Travel speed control
(13) Automatic Engine Speed Control (AEC)
(14) Displacement alarm switch
(15) Tool Control
(16) Heavy lifting control
(17) Windshield washer
(18) Wiper washer
(19) Light switch
(20) Quick coupler control
(21) Seat heater
(22) leveling switch
(23) Precise rotation control
-,,
(24) Overload warning device ■
(25) Smart pen control
(26) Control of the air conditioning and heating system.

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

Hourmeter (3)
This screen indicates the total number of operating hours (engine running). Refer to the screen to determine maintenance intervals by
service hours.

Joystick Controls (5)

The joystick control is used to control the functions of the machine's attachments.

Engine speed control (6)

Turn the speed dial to control the engine speed (engine rpm). Dial RPM- Hydraulic
Select the desired position from the ten available positions. Position. Engine. Power
The selected position of the engine speed selector appears
on the electronic display. 1 800 20%

2 1020 35%

3 45%
4 69%
Decrease - Turn the engine speed selector counterclockwise to decrease the engine speed (engine rpm).
5 1470 78%

6 1590 84%
ON (CONNECTED)
7 1700 84%
m1
P Increase - Turn the speed selector clockwise to 8 1800 84%
increase engine speed.
9 1900 92%
10 100 %

To activate the electrical system, insert the main switch key and turn it to the right. The
main switch must be in the ON position before starting the engine.

OFF (OFF)
To deactivate the electrical system, turn the main switch counterclockwise to the OFF position.

The main switch works differently from the engine start switch.
When the main switch is in the OFF position, the electrical system is deactivated. By placing the starter switch in the OFF position and the main switch
in the ON position, the battery remains connected to the entire electrical system.

Machine Safety System (MSS)

Machines equipped with a Security System
Caterpillar Machine (MSS) can be identified by a label located in the operator's station. The MSS system is designed to prevent
unauthorized operation of the machine.

Fuel level
This gauge indicates the amount of fuel left in the tank.
When the fuel gauge indicates that the fuel level is in the red range, add fuel immediately.

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

Low battery charge

Hydraulic oil temperature
-+ The electric charging system
This gauge is working
indicates incorrectly. of the hydraulic oil. The normal operating
the temperature
E/ Immediately check the electrical components of the charging circuit.
range is the green range. If the meter reaches the red range, reduce the system
Make any necessary repairs. Yo OR
load. If the meter remains in the red range, stop the machine and investigate the
cause of the problem.

Hydraulic filter clogging

The hydraulic oil return filter is clogged. This causes the hydraulic components
to not function properly. Turn the engine start switch to the OFF position and
then turn it to the ON position. If the warning disappears, the filter is good.
Operate the machine on a horizontal surface for at least ten minutes. If the
warning reappears, replace the return filter cartridge.

Low hydraulic oil level

Hydraulic oil level is too low. Stop the machine immediately. Stop
the engine and investigate the cause of the failure.

Engine coolant temperature

This gauge indicates the engine coolant temperature. The normal operating range is the green range. If the meter reaches the
red range, stop the machine and investigate the cause of the problem.

Engine air filter clogging

The air filter works in a reduced capacity. Reduces engine power.
Immediately inspect the air filter. Clean the air filter.
Inspect its condition. Replace if necessary. Make any necessary repairs.

— Full water separator

F.H. The water separator is full.
Drain water from the water separator as soon as possible.

Engine Overspeed Warning

Engine speed is too high. Change the operation technique.

Low engine oil pressure

Engine oil pressure is too low. Stop the machine immediately. Stop the engine and investigate the cause of the problem. Do not
operate the machine until the cause of the problem has been corrected.

Low engine oil level

Engine oil level is too low. Stop the machine immediately. Stop the engine and investigate the cause of the failure.

LOW COOLANT LEVEL

Coolant level is too low.
Stop the machine immediately. Stop the engine and investigate the cause of the
failure.

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

UNDERCARRIAGE

The running gear is the assembly that allows the movement of the tracked machine and is made up of:
Final drives plus their sprocket, guide wheel, lower and upper rollers, track or chain assembly, and the frame on which these components are
mounted.

THE CATERPILLAR OR CHAIN IS MADE UP

OF:
1. Shoes (with 3 claws or ribs.)
2. Links
3. Pin or pin
4. Bushing or horn
TYPES OF SHOES:
Single grouser shoes
Two grouser shoes
Three grouser shoes

PRECAUTIONS DURING STARTING:

MAINTAIN THREE POINTS OF CONTACT WHEN GETTING ON AND OFF

THE MACHINE:
Do not jump to enter or exit the machine.
Never try to get on or off a moving machine.
When getting in and out of the cab, first fully open the door to the locked position and check
that doesn't move. (For machines with cabin).

• Always face the access system and maintain three points of contact
with the support points while getting on and off the machine.
• Keep support points and platform clean.
• Never use the locking lever or control levers as support points.

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

CLEAR THE SPECTATOR AREA BEFORE STARTING

THE MACHINE:

Do not start the engine until you are sure. Before

starting, check or perform the following:
• Walk around the machine and notify all personnel who may
be working on the machine or in the path of the machine. Do
not start until all personnel are clear of the machine.
• Check for a “DO NOT USE” label or similar lock card on the
cab door, controls or start switch.
• Sound the horn to alert all bystanders in the work area.

AFTER STARTING THE ENGINE:

After starting the engine, carry out the following operations and
checks in a safe place, without people or obstacles in the area. If any fault is detected, follow the power cut procedure and report the fault.
• Warm up the engine oil and hydraulic fluid.
• Observe all warning indicators or instruments to check if they are working correctly.
• Look for unusual noises.
• Check engine speed control.
• Operate all controls to ensure proper operation. XEVAe]U)lNVAN2NVAN2=3ANDYAVD
DISPLACEMENT CONTROLS

Normal displacement position v II mI•mmam _

(A) Back of machine GVs
(B) Final drive I vl 1 NANEEEK.Em (C) Guide wheel

DISPLACEMENT
While traveling, make sure the final drive drive wheels (B) are under the rear of the
machine.
STOP - Release the travel pedals/levers to stop the machine. When you release the
pedals/shift levers from any position, they will return to the CENTER position. This action
engages the travel brakes.

DIFFERENT UNDERCARRIAGE FUNCTIONS

Move both travel levers or pedals at the same time and in the same direction so that the machine travels in a straight line.
FORWARD MOVEMENT

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

REVERSE SCROLL

LEFT SHIFT FORWARD (PIVOT TURN)

LEFT PIVOT TURN (BACKWARD)

FORWARD COUNTER-ROTATION TURN (LEFT)

FORWARD PIVOT TURN (RIGHT)

PIVOT TURN TO THE RIGHT (BACKWARD)

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

TURN AGAINST ROTATION IN FORWARD

(RIGHT)

SAE PATTERN (EXCAVATOR

PATTERN) Arm Out

Lower Pen

Standard System
of backhoe

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

ELECTRONIC MONITOR BOARD

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CATERPILLAR

TRAINING AND SPECIALIZATION CENTER IN HEAVY MACHINERY

INDICATORS ON THE MONITOR
DASHBOARD

………………………………………………………………..

"AT THE VANGUARD OF EDUCATION"

CATERPILLAR

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

WORK MODALITIES

4 {t}HM

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•
•
CATERPILLAR

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

PEN PRIORITY MODE

•
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•
•
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AR

ROTATION PRIORITY MODE

………………………………………………………………………………

CATERPILL
AR

Nine
PRECISE CONTROL MODE
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CATERPILLAR

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

USER MODE
•
•
•

tamping mode (U1) • .

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………………………………………………………………………………………….

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HOW TO ESTABLISH THE USER MODE CATERPILLAR

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HAMMER MODE
CATERPILLAR “AT THE VANGUARD OF EDUCATION”
*

CUSTOMER MODALITY (U3)

•....................................................................................................................

POWER MODE

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10
 EXCAVATOR OPERATION MANUAL JH MINING CENTER

AUTOMATIC ENGINE CONTROL

4 12:00 I0

n/
mm

ALARM CANCEL SWITCH

. 12:00 ill

CATERPILLAR

J. ALBERTO HUAMAN CH. HEAVY MACHINERY INSTRUCTOR

“AT THE VANGUARD OF EDUCATION” 10