Caterpillar Field Guide

FIELD GUIDE

A Reference Guide to Mining Machine Applications

Caterpillar Global Mining Equipment Management

www.CAT.com © 2004 Caterpillar Printed in U.S.A.

Scope

Contents

This document is primarily intended for use by Caterpillar and Cat dealer Project Managers as a ready reference for the assessment of machine application and haul road conditions on their project sites. It may also prove useful to other Caterpillar and Cat dealer personnel, in need of a concise reference tool.

Basic Application Benchmarks and Operating Techniques Loading Tools Trucks Wheel Dozers Motor Graders Track-type Tractors Tractor Scrapers Drill Rigs Basic Haul Road Design and Maintenance Design Maintenance Miscellaneous Management Strategies Hauling System Application Zones General Information Percentage Swell and Load Factors Approximate Loose Weight of Materials Typical Rolling Resistances Approximate Coefficient of Traction Factors Formulas and Rules of Thumb Weights and Measures Miscellaneous Technical Data Machine Specifications Track-type Tractors Wheel Loaders Wheel Dozers Trucks Wheel Loaders Motor Graders Tractor Scraper Underground Mining Equipment

It contains practical Benchmarking data that is achievable with correct and well-managed machine application. It is also intended to provide guidance on assessing haul road design and maintenance that supports sound industry practices.

2 8 14 18 22 25 26 34 42 51 53 59 60 62 63 64 66 70 73 75 77 79 75 83 85 87

LOADING TOOLS

L OA O A DI D I NG N G T OO O O LS LS

Watch for... for...

Basic Application Benchmarks and Operating Techniques First pass must be a good pass (operator has entire truck exchange to get it full). Ensure truck is correctly 'spotted' by loader (with first pass, or the horn).

Rope Shovels • 70 - 90 degree maximum swing • Efficient support machine activity to keep floor clean • Power cable maintenance • Never operate a bare edge Hydraulic Front Shovels • First two passes: Upper half of face • 3rd / 4th passes: Load out the center • Final passes: Clean up floor • Keep work area as tight as possible; as for backhoe • Avoid excessive prying or corner loading; don’t swing into pile * GET - Ground Engaging Tools ** ME - Mass Excavation

• Maximize GET tip contact and minimize bowl contact (i.e. boom up and curl bowl through material). Use boomup to minimize bucket heel contact. • Never operate a bare edge

Hydraulic Backhoes (ME**) • Maintain tight work zone; (ideally dig no more than 45 degrees either side of center line, i.e. work over idlers) and (swing no more than 60 degrees to truck) • Watch poorly blasted toe • Maximize GET tip contact & minimize bucket contact (i.e. enter face with tips at the correct angle, and curl bucket through material). Use boomup to minimize bucket heel contact • Never operate a bare edge

2 Wheel Loaders • Enter pile straight-on, with floor of bucket parallel to floor • Keep frame straight when digging • Lift bucket before crowding • Fill bucket by the time lift arms are horizontal • Minimize non-productive floor contact (clean up) • Maintain proper kick-out adjustment. • Keep time in face below 0.2 minutes (12 seconds) • Wheel turns only from face to truck • Never operate a bare edge

L OA O A DI D I NG N G T OO O O LS LS

Basic Application Benchmarks and Operating Techniques Rope Shovels

Hydraulic Front Shovels

Top of boom sheaves

Just above boom/ stick pivot

Cycle Times

28 - 40 seconds (avg. 35 seconds)

24 - 28seconds (avg. 27 seconds)

Bucket Fill Factor in Well-shot Rock

100 - 105%

90 - 100%

Most Efficient Pass Match

3 - 5 passes

4 - 6 passes

Favorable Site Conditions

• Working a single face of the

• Selective digging: can also efficiently mine

correct height • Stable/level floor • Wide benches (to facilitate truck maneuverability) • Well-shot material

multiple targets • Tight load area with tight material • Can work in poor floor conditions • Angle tracks slightly to face • Define dig pattern, L to R or R to L, and maintain mai ntain pattern

Adverse Site Conditions Avoid

• Poor underfoot

• Excessive tramming • Low benches

Optimum Bench Height

4

L OA DI NG T OO LS

Basic Application Benchmarks and Operating Techniques Hydraulic Backhoes (Mass Excavation) Length of stick, or between truck siderail and ducktail

Hydraulic Front Shovels

Cycle Times



Bucket Fill Factor in Well-shot Rock

80 - 110%

90 - 110%

Most Efficient Pass Match

4 - 6 passes

4 - 6 passes


• Correct bench height (worth 10-15%

• Level, dry, smooth, firm floors • Sufficient crossfall and drainage in high rainfall areas to minimize tire damage • Well fragmented materials that minimize crowding time, particularly in the toe-area of the cut • Lower face profile • Multi-face loading

Adverse Site Conditions Avoid

• High benches • Excessive tramming • Unstable benches • Low angle of repose material

Optimum Bench Height

more production than too high) • Truck below HEX (worth 15-20% over same-level loading) • Tight load area, with tight material • Short swing — 60° (worth 5% over 90° swing) • Well shot material • Remove farthest pass during truck exchange • Maintain key-cut

Bucket hinge pin height at maximum lift

• Poor/wet underfoot • Tight load areas • Tire damage due to poor clean-up

6

TRUCKS

TRUCKS

Exchange Time

Basic Application Benchmarks and Operating Techniques

Good (target)

0.7 minutes (42 seconds)

Acceptable 0.9 minutes (54 seconds) The elapsed time from when the loaded truck receives its last load until the next truck receives its first loading pass.

Load Placement

10

Center load above hoist cylinders or load arrow. Longitudinal Centered about centerline of body. General No substantial amount of material on headboard. Enough freeboard to minimize spillage from sides through corners and from the rear on grades. Target 66%/33% load split on front/ rear axles.

Correct Loading Incorrect Loading

Lateral

Payload Accuracy

VIMS/TPMS Payload system will read “heavy” if the load is placed rearward and “light” when the load is placed forward of the correct point. Payload accuracy can vary 3 – 5% for each 600 mm (2 feet) the load is out of position laterally.

Correct Loading Incorrect Loading

TRUCKS

Watch for...


• Truck Position - Spotted in correct position by loader operator, rather than where truck operator decides to stop. Can be spotted by horn, or by first pass.Positioned to help facilitate faster cycles: • At 45° for wheel loaders • Depending on loading technique for shovels and backhoes Not parked with rear tires up on toe of pile. No excessive queuing or waiting for loading tool. • Safety - Truck parked with Parking Brake ON, Trans. in ‘N’ (Retarder may be applied in addition to Parking Brake, but Parking Brake must be applied whenever truck is stopped more than momentarily). • Body - Watch for wear-through of liner plates: Dual Slope bodies typically wear the front 'triangle' of the rear slope, and rear corners. On Flat Floor bodies,

wear is typically even across the rear 1/3 of the floor. Also, ensure correct alignment of body pads. • Tires Tires offer a valuable insight into road and pit conditions. Look for sidewall cutting, impact and cutting in the tread face, erosion and cracking in the bead/flange area, etc. Check TKPH (TMPH)* for all chosen haul profiles.

12

Visit tire “graveyard” looking for scrapped tires with significant tread remaining. Identify causes and work to improve life and tread utilization.

WHEEL DOZERS

WHEEL DOZERS

Watch for...


• General Keep loads small and “roll”, don’t carry, the load. Avoid excessive downpressure that unloads front tires and leads to wheel spin... ballast of front tires is not recommended. Push load with machine as straight as possible Minimize heel-plate contact. Maintain full blade contact with the floor. • Blade Angle Keep heelplate parallel with floor and the back of the blade vertical. A blade rolled too far forward will wear end-bits and moldboard prematurely and decrease productivity.

• Truck / WD Match The following WTD model sizes are recommended for pushing dumped material from these truck models. 834 – 773 / 777 844 – 777 / 785 854 – 785 / 789 / 793

16

MOTOR GRADERS

MOTOR GRADERS

Watch for...

Basic Application Benchmarks and Operating Techniques General Grade in 2nd or 3rd gear (6–11 km/h / 4-7 mph). Grading in 4th gear greatly accelerates circle drive pinion and cutting edge wear. Speed is excessive if cutting edge shows signs of excessive heat (tempering back/bluing) and flaking. Maintain 1st gear for all ripping, manually operate throttle. Ensure cutting edges maintain protection for moldboard; change ahead of moldboard damage (recommend when 10 mm [1/2 inch] remaining). Keep edges sharp for improved penetration. Use scarifiers to break up hardpacked top surface for material redistribution if blade is unable to penetrate effectively. A number of passes may be required to achieve this effect.

Blade Position Tip Angle Top of moldboard should typically be ahead of the cutting edge by; 16 and 24 MG - 50mm - 100mm (2”- 4”), for optimal grading. Maintaining a constant tip angle in operation minimizes cutting edge wear. Blade Angle Use widest possible pass width, but increase angle if material flows around leading edge. When using the Graderbit system or a serrated edge, use a blade angle of 10 degrees maximum. Maintain full width cutting edge contact with road surface. Work Envelope If the motor grader cannot maintain full blade contact with the floor, with consequent high point loading on the cutting

20

edge, penetration will be poor. These situations are more likely better suited to a Track-type Tractor or Wheel Dozer.

For further information, consult H-series Motor Grader Application Guide AEGQ0945.

TRACK-TYPE TRACTORS/ SCRAPERS

TRACK-TYPE TRACTORS Watch for...


General Operation Excessive tramming between jobs. (<5% of time). Loose or missing track hardware. Ripping General

Truck / Dozer Dump Match The following TTT model sizes are recommended for pushing dumped material from these truck models: D9 777 D10 777 / 785 / 789 D11 789 / 793 / 797 For further information, consult The Handbook of Ripping AEDK0752.

Ripper Position

Rip downhill wherever possible. When ripping for scrapers, rip in the same direction, as the scrapers will load. Generally, speeds of 1.52.5 km/hr (1-1.5 mph) at 2/3 throttle will give the most economical production, with reduced speeds in shock/impact conditions. Begin pass with ripper tip rearward, then pull tip forward/under the tractor after tip penetrates ground. Excessive track slippage and blunt tips are good indicators that ripper position is not correct.

Pin breakage in shank protectors or ripper tips is also a good indication of incorrect operation

Dozing General “Big loads slow” rather than “small loads fast”. Doze in 1st gear. Steer machine with Blade Tilt cylinders rather than steering clutches when blade is loaded; track slap in the middle of a cut is a good indication that steering clutches are being used. Use slot dozing wherever possible, as it can be worth up to 20% extra production and assure the tractor is pushing all it can push. Start to doze from the front of the cut. Work to the rear, moving back 1 to 2 machine lengths each additional pass. Keep slot depth to be a maximum of 2/3 blade height.

24

Minimize corner loading, prying and impact; maintain a steady dozing pressure.

Blade Position On Dual Tilt machines, begin cut with blade tilted forward for better penetration, then begin to lay blade back when about full. Continue to fill blade while lying back, until blade is full and racked fully back. GET Penetration ripper tip reinforcing ribs must face upward; they ship on the shank with the rib down. Ensure GET pins, retainers and bolts are installed correctly and are not missing. Never operate a bare shank.

SCRAPERS

Watch for...


Loading Time Average

Scraper/Tractor The following TTT model sizes are recommended for push loading the following scraper models. 621 – D8 631 – D9 / D10 651 – D10 / D11 For further information, consult Making the Most of Scraper Potential AEGQ2380 and Optimum Scraper Load Time AEGC0195.

23

Good: 0.4-0.5 minutes (24-30 seconds)* 0.6-0.7 minutes (36-43 seconds)* * Open bowl/push-loaded Wheel-Tractor Scraper (shorter time for tandem, longer time for singlepowered) Consult publications for self-loading (elevating/ auger) and push-pull machines.

DRILLS

DRILLS


Table notes:

* Penetration rates in coal can vary significantly depending upon rotation speed, drill bit used, pulldown pressure applied and intact rock strength. Penetration rates in coal are more affected by operator skill level than downhole conditions or rock type. + Penetration rates in hard rock are almost directly proportional to intact rock strength. Rule of thumb: the harder the rock, the lower the penetration rate. # Excessive vibration: the drill bit is bouncing off the bottom of the hole, which may knock out the carbide tips on the cones and cause excessive wear.

Drill “plunging” occurs when the pulldown hydraulics enter into an oscillation, and can be eliminated by better control of pulldown pressure. Excessive pulldown causes damage to the drill bit by overloading, and wears items such as pulldown chains/ropes/cylinders/motors, the mast structure, and rotation motors.

Excessive rotation speeds can cause premature wear of the drill bit from overheating. Bailing velocity is often incorrect; should be set at 1500–2500 m/min (5000-8250 ft/min). Low bailing velocity causes cuttings to fall back, blocking drill bits, and collapsing holes behind the drill bit. Chips don't eject far enough from the hole collar. High bailing velocity causes excessive wear of the drill bit, drill steels, and the under side of the drill deck, and wastes energy that is not required to adequately do the job. Chip/Cutting size gives the best indication of drilling function. Cuttings may vary from pea to golf ball size, depending on drill size and rock type. Fine powder indicates grinding rather than cutting.

28

A correctly leveled drill, and a flat floor are vital to ensure all holes are drilled parallel, and collar elevations are maintained. Every one degree of tilt/roll moves the toe of the hole by 1 m per 10 m (3 ft per 30 ft) drilled; over a 50 m (150 ft) hole, the toe can be out by up to 5 m (15 ft). This has a huge effect on fragmentation when blasted, particularly in the toe area, which can seriously affect ease of digging, GET wear and machine productivity.

DRILLS


Typical Size Classes

(25000-40000 lb) 110 – 180 kN Pulldown

(40000–60000 lb) 180 – 270 kN Pulldown

Typical Machines in this Class

Driltech DK55, DK40 Ingersol IR60, IR45 Reedrill SK50, SK45

Driltech DK55 Ingersol IR60 Reedrill SK50

Depths

Up to 40 m (130 feet) multi-pass 10-12m (30-40 feet) single pass

Up to 60 m (200 feet) multi-pass 12-20m (40-66 feet) single pass

Hole Sizes (Generic)

100 – 200 mm (4–8 inches)

150 – 250 mm (6–10 inches)

Rotation Speeds: Coal

120 – 150 rpm

100 – 130 rpm

100 – 120 rpm (up to 40 rpm hammer)

80 – 110 rpm

40 – 60 m/hr (130–200 ft/hr)

40 – 80 m/hr (130–260 ft/hr)

10 – 30 m/hr (30–100 ft/hr)

10 – 40 m/hr (30–130 ft/hr)

Rotation Speeds: Hard Rock Penetration: Coal* Penetration: Hard Rock + Watch for... #

Drill “plunging” Bailing velocity Chip/cutting size

Correctly leveled machine, and level floors Excessive pulldown pressures Excessive rotation speeds Excessive vibration (except for hammer drills)


Level floor Regular pattern spacing Limited tramming

Adequate maneuvering space Minimal water ingress Minimal fracturation of ground

30

DRILLS


Typical Size Classes

(60000–125000 lb) 270 – 570 kN Pulldown

Typical Machines in this Class

Driltech DK75, DK90 Ingersol DM-P, DM-M3, DM-H Pit Viper 351 P&H 100XP, 250XP, 120A Up to 100 m (330 feet) multi-pass 14-20 m (15-22 yd) single pass

Driltech Gator Ingersol LNEAC 500, 600

Hole sizes (Generic)

200 – 350 mm (8–14 inches)

Up to 150 mm (Up to 6 inches)

Rotation Speeds: Coal

80 – 110 rpm

80 – 120 rpm

Rotation Speeds: Hard Rock

70 – 90 rpm

Up to 40 rpm hammer

Penetration: Coal*

40 – 100 m/hr (130–330 ft/hr)

30 – 50 m/hr (100–165 ft/hr)

Penetration: Hard Rock +

10 – 50 m/hr (30–165 ft/hr)

10 – 30 m/hr (30–100 ft/hr)

Depths

32

Track Drills

Tamrock (most models)

Up to 50 m (165 feet) multi-pass 8-10 m (26-35 feet) single pass

Watch for... #

Drill “plunging” Bailing velocity Chip/cutting size

Correctly leveled machine, and level floors Excessive pulldown pressures Excessive rotation speeds Excessive vibration (except for hammer drills)


Level floor Regular pattern spacing Limited tramming

Adequate maneuvering space Minimal water ingress Minimal fracturation of ground

BASIC HAUL ROAD DESIGN AND MAINTENANCE

Basic Haul Road Design and Maintenance

Horizontal and General Vertical Alignment

Cross-slopes

36

To maximize safe working, corners and crests must be designed such that machine operators are capable of seeing and avoiding hazards when travelling at normal operating speeds. These calculations must be completed using worst case scenarios (i.e. smallest obstacle, longest stopping distance, highest expected speeds, wet roads, etc).

On Flats Apply the minimum slope to maintain drainage for expected rainfall conditions on site. If conditions permit, consider a 2% constant crossfall, with loaded trucks running on the 'uphill' side of the road. This can help optimize tire load sharing across the rear of the truck. Otherwise, a crown with minimum slope angle.

1 10

On Grades Minimal cross-slope required unless rainfall is very heavy, as drainage is provided by downgrade.

2° constant crossfall

Basic Haul Road Design and Maintenance

Grade

General Smooth, and of constant grade to minimize transmission shifts, and maintain higher average grade speed. This also allows more constant braking effort on return journey.

Corners

Radius Use maximum practical radius. Keep as constant and smooth as possible. Super-elevation Employ if speeds exceed 15 km/h (10 mph) per Performance Handbook (PHB) recommendations (Tables section). Super-elevation greater than 10% should be used with caution due to the danger of sideways slippage in wet conditions.

Road Width

1 way Straights/Corners A minimum 2 - 2.5 widths is recommended. 2 way - In Straights A minimum of 3 - 3.5 truck widths. - In Corners A minimum of 3.5 - 4 truck widths.

38

Correct

Incorrect

One-way (Straights/Corners) Two-way (In Straights)

Caterpillar Field Guide

Recommend Documents