Electric Rope Shovel Technical Training

Catalog
 Contents

Global Mining Solutions eLearning................................................................................................................ 5

General eLearning Lesson Descriptions ....................................................................................................... 6
Introduction and Product Overview ................................................................................................................ 6
Lesson 3.1 Shovel Introduction .................................................................................................................. 6
Lesson 3.2 Shovel Operation Basics .......................................................................................................... 6
Lesson 3.3 Shovel Electrical Basics ........................................................................................................... 7
Lesson 3.4 Shovel Mechanical Basics ....................................................................................................... 7
Operator eLearning Lesson Descriptions ..................................................................................................... 8
Shovel Operator ............................................................................................................................................ 8
Lesson 1.1 General Safety Procedures ...................................................................................................... 8
Lesson 1.2 Shovel Orientation ................................................................................................................... 9
Lesson 1.3 Operator Inspections and Procedures ...................................................................................... 9
Lesson 1.4 Shovel Operation ................................................................................................................... 10
Electrical eLearning Curriculums ................................................................................................................ 11
Centurion AC Package (ACS880) ................................................................................................................ 11
Centurion AC Package (ACS800) ................................................................................................................ 11
Centurion AC Package (2300XPC AC) ........................................................................................................ 11
Centurion DC Package ................................................................................................................................ 11
Electrical eLearning Lesson Descriptions................................................................................................... 12
Power Electronics ........................................................................................................................................ 12
Lesson 4.1 Power Distribution – DC Shovels ........................................................................................... 12
Lesson 4.2 Power Conversion – DC Shovels ........................................................................................... 13
Lesson 4.3 Protective Circuits – DC Shovels ........................................................................................... 13
Lesson 4.6 RPC Theory and Operation – Centurion................................................................................. 14
Lesson 4.7 Theory of DC Motor Operation ............................................................................................... 14
Lesson 4.8 DC Motor Maintenance .......................................................................................................... 15
Lesson 4.9 Power Distribution – AC Shovels ........................................................................................... 16
Lesson 4.10 Protection Circuits – AC Shovels.......................................................................................... 17
Lesson 4.13 AC Motor Theory and Operation .......................................................................................... 17
Control System ............................................................................................................................................ 18
Lesson 5.2 Remote IO ............................................................................................................................. 18
Lesson 5.3 Communication Devices ........................................................................................................ 18
Centurion Control System ........................................................................................................................ 19
Siemens Remote IO ................................................................................................................................. 19
Electric Rope Shovel Technical Training Catalog 2
 Drive System ............................................................................................................................................... 20
Lesson 6.3 DCS800 ................................................................................................................................. 20
ACS800.................................................................................................................................................... 20
ACS880.................................................................................................................................................... 20
Miscellaneous Electrical Equipment ............................................................................................................. 21
Lesson 8.1 UPS System .......................................................................................................................... 21
TripRite .................................................................................................................................................... 21
HMI Devices ................................................................................................................................................ 22
Lesson 9.5 Touch Screen System ............................................................................................................ 22
Mechanical eLearning Curriculums ............................................................................................................. 23
4800XPC AC Mechanical ............................................................................................................................ 23
4100XPC AC or DC Mechanical .................................................................................................................. 23
4100C BOSS AC or DC Mechanical ............................................................................................................ 24
4100C Mechanical ....................................................................................................................................... 24
2800XPC AC or DC Mechanical .................................................................................................................. 25
2300XPC Mechanical .................................................................................................................................. 25
Mechanical eLearning Lesson Descriptions ............................................................................................... 26
Disc Brakes ................................................................................................................................................. 26
Lesson 6.1 Introduction to Disc Brakes .................................................................................................... 26
Lesson 6.2 Brake System Operation ........................................................................................................ 27
Propel System ............................................................................................................................................. 28
Lesson 7.1 Propel System Description ..................................................................................................... 28
Lesson 7.2 Propel System Inspections ..................................................................................................... 28
Lesson 7.3 Crawler Adjustments .............................................................................................................. 28
House Filtration ........................................................................................................................................... 29
Lesson 9.1 AirScrubPro ........................................................................................................................... 29
Mine Air ....................................................................................................................................................... 29
Lesson 10.1 Mine Air................................................................................................................................ 29
Swing System .............................................................................................................................................. 30
Lesson 11.1 Swing System Description.................................................................................................... 30
Lesson 11.2 Swing Roller Circle ............................................................................................................... 30
Lesson 11.3 Center of Rotation ................................................................................................................ 31
Hoist System ............................................................................................................................................... 31
Lesson 12.1 Swing System Description.................................................................................................... 31
Lesson 12.2 Hoist Gear Case .................................................................................................................. 32

Electric Rope Shovel Technical Training Catalog 3

 Lesson 12.3 Hoist Drum ........................................................................................................................... 32
Lesson 12.4 Hoist Ancillary System ......................................................................................................... 32
Attachments................................................................................................................................................. 33
Lesson 14.1 Attachments ......................................................................................................................... 33
Crowd System ............................................................................................................................................. 33
Lesson 16.1 Crowd System Description ................................................................................................... 33
Lesson 16.2 Crowd Belt Assembly ........................................................................................................... 34
Lesson 16.3 Shipper Shaft and Saddle Block ........................................................................................... 34
Air Compressors .......................................................................................................................................... 35
Lesson 17.1 Sullair with Supervisor II Control .......................................................................................... 35
Lesson 17.2 Sullair with Q1 Control ......................................................................................................... 35
Rope Shovel Instructor-Led Training Outlines ........................................................................................... 36
Shovel Operator .......................................................................................................................................... 36
Shovel Operator Training ......................................................................................................................... 36
Electrical Systems ....................................................................................................................................... 38
Electrical Systems (AC) - Field ................................................................................................................. 38
Electrical Systems (AC) - Milwaukee ........................................................................................................ 40
Electrical Systems (DC) - Field ................................................................................................................. 42
Electrical Systems (DC) - Milwaukee ........................................................................................................ 44
Mechanical Systems .................................................................................................................................... 46
Mechanical Systems - Field...................................................................................................................... 46
Mechanical Systems - Milwaukee............................................................................................................. 48

Electric Rope Shovel Technical Training Catalog 4

 Global Mining Solutions eLearning
Product Training and Publications has identified eLearning as a delivery option for fundamental knowledge
and product specific training. eLearning provides several advantages over traditional training methods:
• eLearning content can be accessed through the Internet by any individual who has the appropriate
login and password credentials.
• Immediate availability of training content which provides a quicker, more productive workforce.
• Online training reduces the cost of training by eliminating travel, living, and other expenses associated
with Instructor-Led Training.
• eLearning provides students with the ability to learn at their own pace and in their own comfortable
environment.
• The training content can be delivered to a large contingent of people in varying locations and be
technically consistent across the board.
• When used as a prerequisite to Instructor-Led Training, eLearning can level the playing field between
novice and senior personnel. This makes the Instructor-Led Training more effective by allowing the
Instructor to spend more time developing skills rather than knowledge-based components.

This Course Catalog contains descriptions of the eLearning Lessons available to you through Product Training
and Publications.

Lesson duration:
Each eLearning Lesson is designed to be less than 60 minutes in duration. However, because eLearning is
self-paced training, actual duration may vary per student.

Target audience:
Shovel Operators, Technicians, and Engineers who will operate and/or perform maintenance on P&H Mining
Shovels.

Prerequisites:
Students should have a basic working knowledge of computers as well as a fundamental understanding of
electronics, mechanics, pneumatics, and hydraulics as it applies to the systems of P&H Mining Shovel.

Lesson location:
eLearning content can be accessed through the Internet by any individual who has the appropriate login and
password credentials.

Computer requirements:
It is recommended that all computers accessing eLearning content have the basic minimum requirements:
• Adobe Reader version 8 or better

Note:
Our eLearning content is periodically revised and updated.

Terms and Conditions:

Training materials and product information can represent confidential and proprietary information of Komatsu
Global Mining Solutions. This information is being made available to the individuals authorized to access or
participate in Komatsu training. These training materials and their contents may not be modified, copied,
reproduced, published, uploaded, posted, transmitted, or otherwise used for distribution to others.

Electric Rope Shovel Technical Training Catalog 5

 General eLearning Lesson Descriptions
Introduction and Product Overview
Lesson 3.1 Shovel Introduction
Lesson description:
This lesson provides the technician with an overview of the shovel sections, motions, systems, and internal and exterior
components.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Understand and identify the major sections, • Topic 2: Shovel Sections
motions, and systems associated with P&H
Mining Shovels • Topic 3: Shovel Motions

• Understand the purpose and function of the • Topic 4: Shovel Systems

exterior and interior components associated with • Topic 5: Exterior Component Overview
P&H Mining Shovels
• Topic 6: Interior Component Overview
• Understand the purpose and function of the
major components and controls associated with • Topic 7: Loading Control Center
the Operator Cab on a P&H Mining Shovel

Lesson 3.2 Shovel Operation Basics

Lesson description:
This lesson is intended to provide the technician with a general overview of the theory of operation for a P&H Mining
Shovel. Due to the wide variety of mining operations and conditions, this lesson cannot detail every application or task.
This lesson is intended to suggest general operating procedures and techniques only. Specific procedures will vary
from mine to mine.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Shovel Operation Introduction
• Understand the steps required to properly • Topic 2: Individual Motion Control Procedures
operation the shovel Hoist, Swing, Crowd, and
Propel motion • Topic 3: Setting Up for Productive Digging

• Understand how a shovel operator should setup • Topic 4: Pre-Start Inspection – Mechanical
the shovel for productive digging Systems

• Have a thorough understanding of the • Topic 5: Pre-Start Inspection – Electrical

Mechanical and Electrical System, the Ground Systems
Level, the On-Board, and Operation Station • Topic 6: Pre-Start Inspection – Ground Level
Inspections required prior to start the shovel
• Topic 7: Pre-Start Inspection – On-Board
• Have a thorough understanding of the 4 Phases
required to properly operate the shovel through • Topic 8: Pre-Start Inspection – Operator’s
a complete Dig Cycle Station
• Topic 9: Dig Cycle

Electric Rope Shovel Technical Training Catalog 6

 Lesson 3.3 Shovel Electrical Basics
Lesson description:
This lesson is intended to provide the learner with an introduction to electrostatic discharge, general electrical
guidelines, and troubleshooting steps.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Electrostatic Discharge (ESD)
• State the definition of ESD and explain how to • Topic 2: Schematic Diagram Guidelines
avoid damaging equipment through the transfer
of static energy • Topic 3: Troubleshooting Electrical Equipment

• Have a thorough understanding of how to • Topic 4: Maintenance Shutdown Procedures

navigate through an electrical schematic
• Be introduced to a Six Step Troubleshooting
technique
• Understand the steps recommended for shutting
the equipment down for maintenance
procedures

Lesson 3.4 Shovel Mechanical Basics

Lesson description:
This lesson covers basic procedures used in many of the mechanical maintenance tasks associated with P&H Mining
Shovels. The procedures covered in this lesson are general in nature and will apply to several tasks on the shovel.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Wire Rope Inspection
• Be aware of items to look for during a routine • Topic 2: Shims
daily inspection of wire rope
• Topic 3: Fasteners and Hardware
• Have a thorough understanding of how plastic
shims are used on P&H shaft and bearing • Topic 4: Motor Couplings
assemblies
• Become familiar with the types of fasteners used
on P&H equipment
• Understand the different grade of bolts and how
it influences the standard torque value specified
for a bolted joint
• Be able to explain the installation and lubrication
of P&H gear type motor couplings

Electric Rope Shovel Technical Training Catalog 7

 Operator eLearning Lesson Descriptions
Shovel Operator
Lesson 1.1 General Safety Procedures
Lesson description:
This lesson is provided as a guide to personnel involved in the operation of P&H Mining Shovels. We recommend that
operators review and become familiar with the general procedures and information contained within the lesson.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Safe Operating Practices
• Understand the basic qualifications, as • Topic 2: Safety Symbols
recommended for a Mining Shovel Operator
• Topic 3: Fire Extinguishers
• Have a basic understand of the Functional
Checks required of the Operator before starting • Topic 4: Emergency Evacuation
and operating a P&H Mining Shovel
• Have a basic understanding of the proper
conduct for an Operator of a P&H Mining Shovel
• Understand some basic guidelines and
suggestions, dos, and don’ts, for operating a
P&H Mining Shovel
• Have a basic understanding of the
responsibilities of crew members performing a
job on or near a Mining Shovel
• Have a basic understanding of the importance of
planning a job
• Be able to identify the different warning,
prohibition, and mandatory action safety
symbols used on the decals of a P&H Mining
Shovel
• Be able to identify the different types of fires and
ratings of fire extinguishers
• Explain how to use a cartridge operated and
stored pressure fire extinguishers provided on
P&H mining equipment
• Have a basic understanding of what an
Emergency Plan is and what, at minimum, it
should include
• Have a basic understanding of how to evacuate
a P&H Mining Shovel

Electric Rope Shovel Technical Training Catalog 8

 Lesson 1.2 Shovel Orientation
Lesson description:
This lesson provides the operator or maintenance technician with a complete overview of the shovel exterior, interior,
and cab components of current production model C Series P&H Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Exterior Component Overview
• Understand the purpose and function of the • Topic 2: Interior Component Overview
exterior and interior components associated with
P&H Mining Shovels • Topic 3: Loading Control Center

• Understand the purpose and function of the

major components and controls associated with
the Operator Cab on P&H Mining Shovels

Lesson 1.3 Operator Inspections and Procedures

Lesson description:
This lesson provides information for the operator to make Pre-Start, Startup, and Shutdown checks of the P&H Mining
Shovel.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Pre-Start Inspection – Mechanical
Systems
• Have a thorough understanding of the Ground
Level, On-Board, and Operator Station • Topic 2: Pre-Start Inspection – Electrical
inspections required prior to starting the shovel Systems
• Have a thorough understanding of the steps • Topic 3: Pre-Start Inspection – Ground Level
required to properly startup a shovel
• Topic 4: Pre-Start Inspection – On-Board
• Have a thorough understanding of the steps
required to properly shutdown a shovel under • Topic 5: Pre-Start Inspection – Operator’s
normal conditions and the extra steps required Station
for extended period shutdowns • Topic 6: Starting Up the Shovel
• Topic 7: Shutdown Procedures

Electric Rope Shovel Technical Training Catalog 9

 Lesson 1.4 Shovel Operation
Lesson description:
This lesson describes the operation of the individual motion controls and includes some recommended operation
procedures and practices that will aid the operator in the safe, smooth, and efficient operation of P&H Mining Shovels.

It is important to understand that this lesson is not complete without follow-up hands on skills-based training. This
lesson can provide the knowledge of the controls and functions of the P&H Mining Shovel. It is this knowledge portion,
combined with the skills training from a Factory Authorized Operator Trainer that will increase the competence of the
Shovel Operator Trainee.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Shovel Operation Introduction
• Have a thorough understanding of the steps • Topic 2: Individual Motion Control Procedures
required to properly operate the Shovel Hoist,
Swing, Crowd, and Propel motions • Topic 3: Dig Cycle

• Have a basic understanding of Dig Forces and • Topic 4: Propelling Guidelines

how it affects the shovel • Topic 5: Emergency Stops
• Have a basic understanding of Dipper Fill • Topic 6: Thirty-Second Delayed Shutdowns
Factors
• Have a thorough understanding of the four
phases required to properly operate the shovel
through a complete dig cycle
• Have a thorough understanding of the steps
required to reposition and relocate the shovel for
optimal digging
• Understand the purpose of the emergency stop
• Understand how to recognize a thirty-second
delayed shutdown alarm and what to do in case
it happens on the shovel during operations

Electric Rope Shovel Technical Training Catalog 10

 Electrical eLearning Curriculums
Below are pre-determined curriculums based on the different electrical systems available for P&H Shovels.

Centurion AC Package (ACS880) Centurion AC Package (ACS800)

Product Introduction Product Introduction
Lesson 3.1 Shovel Introduction Lesson 3.1 Shovel Introduction
Lesson 3.2 Orientation Basics Lesson 3.2 Orientation Basics
Lesson 3.3 Electrical Basics Lesson 3.3 Electrical Basics
Power Electronics Power Electronics
Lesson 4.9 Power Distribution – AC Shovels Lesson 4.9 Power Distribution – AC Shovels
Lesson 4.10 Protection Circuits – AC Shovels Lesson 4.10 Protection Circuits – AC Shovels
Lesson 4.13 AC Motor Theory and Operation Lesson 4.13 AC Motor Theory and Operation
Control System Control System
Lesson 5.6 Centurion Control System Lesson 5.6 Centurion Control System
Lesson 5.7 Siemens Remote IO Lesson 5.2 Remote IO
Lesson 5.3 Communication Devices Lesson 5.3 Communication Devices
Drive Control Drive Control
Lesson 6.8 ACS880 Lesson 6.7 ACS800
Miscellaneous Electrical Equipment & HMI Devices Miscellaneous Electrical Equipment & HMI Devices
Lesson 8.1 UPS System Lesson 8.1 UPS System
Lesson 8.5 TripRite Lesson 8.5 TripRite
Lesson 9.5 Touch Screen System Lesson 9.5 Touch Screen System

Centurion AC Package (2300XPC AC) Centurion DC Package

Product Introduction Product Introduction
Lesson 3.1 Shovel Introduction Lesson 3.1 Shovel Introduction
Lesson 3.2 Orientation Basics Lesson 3.2 Orientation Basics
Lesson 3.3 Electrical Basics Lesson 3.3 Electrical Basics
Power Electronics Power Electronics
2300XPC AC – Power Distribution Lesson 4.1 Power Distribution – DC Shovels
Lesson 4.13 AC Motor Theory and Operation Lesson 4.2 Power Conversion – DC Shovels
Control System Lesson 4.3 Protection Circuits – DC Shovels
2300XPC AC – Centurion Control System Lesson 4.6 Theory and Operation of the RPC – Centurion
2300XPC AC – Siemens Remote IO Lesson 4.7 Theory of DC Motor Operation
Lesson 5.3 Communication Devices Lesson 4.8 DC Motor Maintenance
Drive Control Control System
2300XPC AC – ACS880 Lesson 5.6 Centurion Control System
Miscellaneous Electrical Equipment & HMI Devices Lesson 5.2 Remote IO
Lesson 8.1 UPS System Lesson 5.3 Communication Devices
Lesson 8.5 TripRite Drive Control
Lesson 9.5 Touch Screen System Lesson 6.3 DCS800
Miscellaneous Electrical Equipment & HMI Devices
Lesson 8.1 UPS System
Lesson 8.5 TripRite
Lesson 9.5 Touch Screen System

Electric Rope Shovel Technical Training Catalog 11

 Electrical eLearning Lesson Descriptions
Power Electronics
Lesson 4.1 Power Distribution – DC Shovels
Lesson description:
This lesson provides maintenance personnel with the knowledge of High Voltage Distribution on P&H Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Introduction
• Identify all safety issues and conduct a risk • Topic 1: Tail Cable
analysis
• Topic 2: Air Disconnect Switch with Earthing
• Identify and explain the purpose of all the major
components utilized • Topic 3: Collector Ring Assemblies

• Demonstration proficiency in loading, • Topic 4: High Voltage Cabinet

configuring, usage and application of test • Topic 5: Key Interlock System
equipment and remote programming panels as
required • Topic 6: Main Transformer

• Remove and replace faulty components • Topic 7: Bus Bars

including a failure analysis • Topic 8: Suppression
• Explain the relationship to the rest of the shovel • Topic 9: Auxiliary/Field Transformer
systems
• Analyze schematics, control diagrams, and
relevant documentation utilized for
troubleshooting and repair
• Describe the purpose of the High Voltage
Systems in relation to overall Mining Shovel
operation
• Identify critical personal safety procedures when
working on High Voltage Systems
• Assess risk to humans and machine related to
maintaining and servicing the High Voltage
Systems
• Describe the purpose of all major assemblies of
the High Voltage System

Electric Rope Shovel Technical Training Catalog 12

 Lesson 4.2 Power Conversion – DC Shovels
Lesson description:
This lesson provides maintenance personnel with the basic knowledge of Power Conversion used on P&H Mining
Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Introduction
• Identify all safety issues and conduct a risk • Topic 1: Power Conversion – Theory of
analysis Operation
• Identify and explain the purpose of all the major • Topic 2: SCR Testing
components utilized
• Topic 3: Converter Cabinet Layout
• Demonstration proficiency in loading,
configuring, usage and application of test
equipment and remote programming panels as
required
• Remove and replace faulty components
including a failure analysis
• Explain the relationship to the rest of the shovel
systems
• Analyze schematics, control diagrams, and
relevant documentation utilized for
troubleshooting and repair

Lesson 4.3 Protective Circuits – DC Shovels

Lesson description:
This lesson provides maintenance personnel with the knowledge of Protective Circuits located on P&H Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Introduction
• Identify all safety issues and conduct a risk • Topic 1: Instantaneous Overload Relay
analysis
• Topic 2: Main Transformer Thermal Overloads
• Identify and explain the purpose of all the major
components utilized • Topic 3: Ground Fault Relays

• Demonstration proficiency in loading, • Topic 4: Suppression Circuits

configuring, usage and application of test • Topic 5: Phase Monitor Relay
equipment and remote programming panels as
required • Topic 6: Diverter Circuits

• Remove and replace faulty components • Topic 7: Main Phase Sensing Relay
including a failure analysis
• Explain the relationship to the rest of the shovel
systems
• Analyze schematics, control diagrams, and
relevant documentation utilized for
troubleshooting and repair

Electric Rope Shovel Technical Training Catalog 13

 Lesson 4.6 RPC Theory and Operation – Centurion
Lesson description:
In this lesson you will learn about Reactive Power Compensation (RPC) theory and the components used for RPC –
Centurion on a P&H Mining Shovel.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: RPC Component Overview - Centurion
• Identify all safety issues and conduct a risk • Topic 2: RPC Power Circuit Operation
analysis
• Topic 3: RPC Control Circuit Operation
• Identify and explain the purpose of all the major
components utilized • Topic 4: RPC Cabinet Layout

• Demonstration proficiency in loading, • Topic 5: RPC Troubleshooting

configuring, usage and application of test
equipment and remote programming panels as
required
• Remove and replace faulty components
including a failure analysis
• Explain the relationship to the rest of the shovel
systems
• Analyze schematics, control diagrams, and
relevant documentation utilized for
troubleshooting and repair

Lesson 4.7 Theory of DC Motor Operation

Lesson description:
This lesson discusses the theory of DC Motors on P&H Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: P&H Mining DC Motors
• Be able to identify and understand the • Topic 2: Types of DC Motors
components used in the construction of a DC
Motor • Topic 3: DC Motor Construction

• Be able to state the function of torque in a DC • Topic 4: Principles of Operation

Motor and how torque is developed • Topic 5: Generator Action in a DC Motor
• Be able to describe how Counter Electromotive • Topic 6: Armature Reaction
Force (CEMF) is developed in a DC Motor
• Topic 7: DC Motor Speed Control
• Be able to describe the relationship between
field current and magnetic field size in a DC
Motor
• Be able to state the function of the CEMF that is
developed in a DC Motor
• Be able to describe how the speed of a DC
Motor is adjusted

Electric Rope Shovel Technical Training Catalog 14

 Lesson 4.8 DC Motor Maintenance
Lesson description:
This lesson discusses the inspection and maintenance practices associated with the performance of P&H DC Motors.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Understand the elements associated with Motor • Topic 2: Commutator Maintenance
Peak Electrical Performance
• Topic 3: Brush Maintenance
• Be able to describe and identify Satisfactory and
Unsatisfactory Commutator surface conditions • Topic 4: Lubrication Practices

• Understand the steps necessary to maintain the • Topic 5: Insultation System

proper Commutator surface conditions • Topic 6: Insulation Resistance Inspection
• Understand the importance and steps required • Topic 7: Detrimental Conditions
for inspection and maintain the Brushes and
Brush Holders on P&H DC Electric Motors • Topic 8: Motor Inspection

• Understand the steps required for replacing the

Brushes on P&H DC Electric Motors
• Describe grease lubrication practice for P&H DC
Electric Motors
• Identify the locations of lube points associated
with P&H Electrical Motors
• Understand the lubrication requirements for
replacement of P&H DC Electric Motors
• Understand the lubrication procedures for P&H
DC Electric Motors during and after extended
storage as well as for remanufactured motors
• Understand and describe the conditions
associated with Insulation Failure
• Understand and be able to describe the steps
required for performing Insulation Resistance
Inspection for P&H DC Electric Motors
• Understand the conditions that cause
detrimental conditions for P&H DC Electric
Motors
• Be able to describe the inspection process for
P&H DC Electric Motors first time use and after
Start-Up

Electric Rope Shovel Technical Training Catalog 15

 Lesson 4.9 Power Distribution – AC Shovels
Lesson description:
This lesson provides maintenance personnel with the knowledge of High Voltage Distribution on P&H AC Mining
Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Introduction
• Have a thorough understanding of the high • Topic 1: Tail Cable
voltage distribution of P&H AC Shovels
• Topic 2: Air Disconnect Switch with Earthing
• Understand the purpose and function of the Tail
Cable as well as identify the basic components • Topic 3: Collector Ring Assembly

• Understand some basic safety principles • Topic 4: High Voltage Cabinet

associated with the handling of the Tail Cable • Topic 5: Key Interlock System
• Understand the purpose, function, and operation • Topic 6: Main Transformer
of the Air Disconnect Switch with Earthing, the
Collector Ring Assembly, the Upper High • Topic 7: Auxiliary Transformer
Voltage Cabinet, the Main Transformer • Topic 8: Lighting Transformer
Contactor, the Key Interlock System, the Main
Transformer, the Auxiliary Transformer, and the
Lighting Transformer
• Identify the location and components of the
Lower High Voltage Cabinet, the Collector Ring
Assembly, the Upper High Voltage Cabinet, the
Main Transformer, the Auxiliary Transformer,
and the Lighting Transformer

Electric Rope Shovel Technical Training Catalog 16

 Lesson 4.10 Protection Circuits – AC Shovels
Lesson description:
This lesson provides maintenance personnel with the knowledge of Protection Circuits on P&H AC Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Introduction
• Have a thorough understanding of the purpose, • Topic 1: Main Transformer Thermal Overloads
location, and operation of the Main Transformer
Thermal Overloads, or TTMT • Topic 2: Instantaneous Overload Relay

• Have a thorough understanding of the purpose, • Topic 3: Ground Fault Relays

location, and operation of the Instantaneous • Topic 4: Main Phase Sensing Relay
Overload Relay, or OTTM
• Topic 5: Undervoltage Monitor
• Have a thorough understanding of the purpose,
location, and operation of the Ground Fault • Topic 6: E-Stop Safety Relay
Relays, GFRM and GFRA
• Have a thorough understanding of the purpose,
location, and operation of the Main Phase
Sensing Relay, or PSR
• Have a thorough understanding of the purpose,
location, and operation of the Undervoltage
Monitor, or UVM
• Have a thorough understanding of the purpose,
location, and operation of the E-Stop Safety
Relay, or ESSR

Lesson 4.13 AC Motor Theory and Operation

Lesson description:
This lesson provides information on the theory of operation and maintenance practices associated with P&H AC
Motors.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: AC Motor Theory
• Have a thorough understand of AC Motor theory • Topic 2: Types of Motors
as it related to Induction Motors
• Topic 3: AC Motor Maintenance
• Have a working vocabulary of the components
associated with the AC Motors on P&H
equipment
• Understand the proper maintenance practiced
required to keep P&H AC Motors operation at
optimal performance.

Electric Rope Shovel Technical Training Catalog 17

Control System
Lesson 5.2 Remote IO
Lesson description:
This lesson provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills to maintain the Remote I/O System used on the Centurion Control System.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Theory of Operation
• Describe the purpose of the Remote I/O System • Topic 2: Components
• Locate and identify the main components of the • Topic 3: Module Diagnostics
Remote I/O System
• Topic 4: Install and Remove
• Identify the function of each main component of
the Remote I/O system
• Remove and replace the I/O devices
• Perform diagnostics of the Remote I/O System

Lesson 5.3 Communication Devices

Lesson description:
This lesson provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills to maintain the Communication Devices used in the Centurion Control System.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Ethernet Electrical Lean Switch
• Know the purpose of the Communication • Topic 2: Profibus Optical Bus Terminal
Devices
• Topic 3: Profibus Resolver Interface Module
• Locate and identify each Communication Device
• Topic 4: Power Rain Booster
• Identify/explain the function of each
Communication Device • Topic 5: DDCS Branching Unit

Electric Rope Shovel Technical Training Catalog 18

 Centurion Control System
Lesson description:
This lesson describes the purpose, component location, and operation of the Centurion Control System used on P&H
AC Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Control System Overview
• Be able to locate the Control Cabinet on a • Topic 2: Communication Protocols
typical Shovel Deck Plan
• Topic 3: AC800
• Be able to locate the Drive Control Units within
the Control Cabinet • Topic 4: Centurion Electrical Equipment

• Be able to identify the connectors associated

with the Drive Control Unit
• Understand the purpose, function, and operation
of the Drive Control Unit
• Understand the Communication Protocols
• Be able to identify the Centurion Electrical
Equipment

Siemens Remote IO
Lesson description:
This lesson provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills of the Siemens Remote IO System used in the Centurion Control System.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Siemens Remote IO Hardware
• Describe the purpose of the Siemens Remote IO
System
• Locate and identify the main components of the
Siemens Remote IO System
• Identify the function of each main component of
the Siemens Remote IO System

Electric Rope Shovel Technical Training Catalog 19

Drive System
Lesson 6.3 DCS800
Lesson description:
This lesson provides the maintenance technician or end-user with the necessary knowledge of the theory of operation
of the DCS800 Digital Drive.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Theory of Operation
• Explain the purpose of the DCS800 • Topic 2: Hardware Overview
• Locate and identify the hardware components • Topic 3: Troubleshooting
associated with the DCS800
• Identify and explain the function of each
hardware component associated with the
DCS800
• Identify and explain the DCS800 troubleshooting
procedures and corrective actions

ACS800
Lesson description:
This lesson provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills to maintain the ACS800 used on Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Understand and identify the major sections of • Topic 2: ACS800 RDCU
the ACS800 BCU
• Topic 3: IGBT Supply Unit (ISU)
• Understand and identify the major sections of
the IGBT Supply Unit (ISU) • Topic 4: Inverter (INV)

• Understand and identify the major sections of

the Inverter (INV)

ACS880
Lesson description:
This lesson provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills to maintain the ACS880 used on Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: System Introduction
• Understand and identify the major section of the • Topic 2: ACS880 BCU
ACS880 BCU
• Topic 3: IGBT Supply Unit (ISU)
• Understand and identity the major sections of
the IGBT Supply Unit (ISU) • Topic 4: Inverter (INV)

• Understand and identify the major sections of

the Inverter (INV)

Electric Rope Shovel Technical Training Catalog 20

Miscellaneous Electrical Equipment
Lesson 8.1 UPS System
Lesson description:
This tutorial provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills to understand the UPS System.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: General Information
• Describe the purpose of the UPS system • Topic 2: Settings and Procedures
• Locate and identify the hardware components of • Topic 3: Troubleshooting
the UPS system
• Identify and explain the function of each
hardware component of the UPS system
• Identify and explain the procedures of the UPS
system
• Distinguish/recognize the alarm signals and
troubleshooting procedures of the UPS system

TripRite
Lesson description:
This lesson provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills to understand the TripRite System.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Location
• Describe the basic Theory of Operation of the • Topic 2: System Overview
TripRite
• Locate and identify the hardware components of
the TripRite
• Identify and explain the function of each
hardware component of the TripRite
• Identify and explain the function of each
software used on the TripRite

Electric Rope Shovel Technical Training Catalog 21

HMI Devices
Lesson 9.5 Touch Screen System
Lesson description:
This lesson provides the electrical maintenance technician or end-user with the necessary knowledge and working
skills to understand the Touch Screen System.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Theory of Operation
• Identify and explain the purpose of the Touch • Topic 2: Hardware Overview
Screen System
• Topic 3: Procedures Overview
• Locate and identify the hardware components of
the Touch Screen System • Topic 4: Operation Screen Procedures

• Identify and explain the function of each • Topic 5: Diagnostic Screen Procedures
hardware component of the Touch Screen • Topic 6: Setup Screen Procedures
System
• Topic 7: Activity Screen Procedures
• Identify and explain the Touch Screen
troubleshooting procedures and corrective • Topic 8: Help Screen Procedures
actions. • Topic 9: Troubleshooting

Electric Rope Shovel Technical Training Catalog 22

 Mechanical eLearning Curriculums
Below are pre-determined curriculums based on the different C-Series P&H Shovel models.
**denotes machine class specific lessons

4800XPC AC Mechanical 4100XPC AC or DC Mechanical

Product Introduction Product Introduction
Lesson 3.1 Shovel Introduction Lesson 3.1 Shovel Introduction
Disc Brakes Disc Brakes
Lesson 6.1 Introduction to Disc Brakes Lesson 6.1 Introduction to Disc Brakes
Lesson 6.2 Brake System Operation Lesson 6.2 Brake System Operation
Propel System Propel System
Lesson 7.1 Propel System Description Lesson 7.1 Propel System Description
Lesson 7.2 Propel System Inspections Lesson 7.2 Propel System Inspections
Lesson 7.3 Crawler Adjustments** Lesson 7.3 Crawler Adjustments**
Air Filtration Air Filtration
Lesson 9.1 AirScrubPro** Lesson 9.1 AirScrubPro**
Mine Air Mine Air
Lesson 10.1 Mine Air Lesson 10.1 Mine Air
Swing System Swing System
Lesson 11.1 Swing System Description Lesson 11.1 Swing System Description
Lesson 11.2 Swing Roller Circle** Lesson 11.2 Swing Roller Circle**
Lesson 11.3 Center of Rotation** Lesson 11.3 Center of Rotation**
Hoist System Hoist System
Lesson 12.1 Hoist System Description** Lesson 12.1 Hoist System Description**
Lesson 12.2 Hoist Gearcase** Lesson 12.2 Hoist Gearcase**
Lesson 12.3 Hoist Drum** Lesson 12.3 Hoist Drum**
Lesson 12.4 Hoist Ancillary Systems Lesson 12.4 Hoist Ancillary Systems
Attachments Attachments
Lesson 14.1 Attachments** Lesson 14.1 Attachments**
Crowd System Crowd System
Lesson 16.1 Crowd System Description** Lesson 16.1 Crowd System Description**
Lesson 16.3 Shipper Shaft and Saddle Blocks** Lesson 16.2 Crowd Belt Assembly**
Lesson 16.3 Shipper Shaft and Saddle Blocks**
Air Compressors Air Compressors
Lesson 17.1 Sullair with Supervisor II Control Lesson 17.1 Sullair with Supervisor II Control
Lesson 17.2 Sullair with Q1 Controller Lesson 17.2 Sullair with Q1 Controller

Electric Rope Shovel Technical Training Catalog 23

4100C BOSS AC or DC Mechanical 4100C Mechanical
Product Introduction Product Introduction
Lesson 3.1 Shovel Introduction Lesson 3.1 Shovel Introduction
Disc Brakes Disc Brakes
Lesson 6.1 Introduction to Disc Brakes Lesson 6.1 Introduction to Disc Brakes
Lesson 6.2 Brake System Operation Lesson 6.2 Brake System Operation
Propel System Propel System
Lesson 7.1 Propel System Description Lesson 7.1 Propel System Description
Lesson 7.2 Propel System Inspections Lesson 7.2 Propel System Inspections
Lesson 7.3 Crawler Adjustments** Lesson 7.3 Crawler Adjustments**
Air Filtration Air Filtration
Lesson 9.1 AirScrubPro** Lesson 9.1 AirScrubPro**
Mine Air Mine Air
Lesson 10.1 Mine Air Lesson 10.1 Mine Air
Swing System Swing System
Lesson 11.1 Swing System Description Lesson 11.1 Swing System Description
Lesson 11.2 Swing Roller Circle** Lesson 11.2 Swing Roller Circle**
Lesson 11.3 Center of Rotation** Lesson 11.3 Center of Rotation**
Hoist System Hoist System
Lesson 12.1 Hoist System Description** Lesson 12.1 Hoist System Description**
Lesson 12.2 Hoist Gearcase** Lesson 12.2 Hoist Gearcase**
Lesson 12.3 Hoist Drum** Lesson 12.3 Hoist Drum**
Lesson 12.4 Hoist Ancillary Systems Lesson 12.4 Hoist Ancillary Systems
Attachments Attachments
Lesson 14.1 Attachments** Lesson 14.1 Attachments**
Crowd System Crowd System
Lesson 16.1 Crowd System Description** Lesson 16.1 Crowd System Description**
Lesson 16.2 Crowd Belt Assembly** Lesson 16.2 Crowd Belt Assembly**
Lesson 16.3 Shipper Shaft and Saddle Blocks** Lesson 16.3 Shipper Shaft and Saddle Blocks**
Air Compressors Air Compressors
Lesson 17.1 Sullair with Supervisor II Control Lesson 17.1 Sullair with Supervisor II Control
Lesson 17.2 Sullair with Q1 Controller Lesson 17.2 Sullair with Q1 Controller

Electric Rope Shovel Technical Training Catalog 24

2800XPC AC or DC Mechanical 2300XPC Mechanical
Product Introduction Product Introduction
Lesson 3.1 Shovel Introduction Lesson 3.1 Shovel Introduction
Disc Brakes Disc Brakes
Lesson 6.1 Introduction to Disc Brakes Lesson 6.1 Introduction to Disc Brakes
Lesson 6.2 Brake System Operation Lesson 6.2 Brake System Operation
Propel System Propel System
Lesson 7.1 Propel System Description Lesson 7.1 Propel System Description
Lesson 7.2 Propel System Inspections Lesson 7.2 Propel System Inspections
Lesson 7.3 Crawler Adjustments** Lesson 7.3 Crawler Adjustments**
Air Filtration Air Filtration
Lesson 9.1 AirScrubPro** Lesson 9.1 AirScrubPro**
Mine Air Mine Air
Lesson 10.1 Mine Air Lesson 10.1 Mine Air
Swing System Swing System
Lesson 11.1 Swing System Description Lesson 11.1 Swing System Description
Lesson 11.2 Swing Roller Circle** Hoist System
Lesson 11.3 Center of Rotation** Lesson 12.4 Hoist Ancillary Systems
Hoist System Attachments
Lesson 12.1 Hoist System Description** Lesson 14.1 Attachments
Lesson 12.2 Hoist Gearcase** Crowd System
Lesson 12.3 Hoist Drum** Lesson 16.3 Shipper Shaft and Saddle Blocks**
Lesson 12.4 Hoist Ancillary Systems Air Compressors
Attachments Lesson 17.1 Sullair with Supervisor II Control
Lesson 14.1 Attachments** Lesson 17.2 Sullair with Q1 Controller
Crowd System
Lesson 16.1 Crowd System Description**
Lesson 16.2 Crowd Belt Assembly**
Lesson 16.3 Shipper Shaft and Saddle Blocks**
Air Compressors
Lesson 17.1 Sullair with Supervisor II Control
Lesson 17.2 Sullair with Q1 Controller

Electric Rope Shovel Technical Training Catalog 25

 Mechanical eLearning Lesson Descriptions
Disc Brakes
Lesson 6.1 Introduction to Disc Brakes
Lesson description:
This lesson describes the component functions and system operation of the disc brakes on P&H Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Disc Brake Overview
• Understand the terms set and release, and how • Topic 2: Disc Brake Components
they apply to disc brakes
• Topic 3: Brake Orientation
• Identify the location of the disc brakes on the
mining shovel • Topic 4: Stored Energy in Brake Safety

• Understand the difference between static and • Topic 5: Identification of Brakes

dynamic braking
• Identify brake components that must be correctly
oriented when the disc brake is assemble
• Recognize how disc brake assemblies must be
rotated correctly for orientation when installed
• Identify and locate the various components of
the disc brake system
• Have a working knowledge of how disc brake
components fit together to create a disc brake
assembly
• Identify correct reference sources to find brake
assembly part numbers and become familiar
with how P&H brake assembly part numbers are
found
• Describe the concept of stored mechanical
energy and some of the hazards caused by it
• Describe how to remove stored mechanical
energy from a mechanical drive train before
maintenance will be performed on it

Electric Rope Shovel Technical Training Catalog 26

 Lesson 6.2 Brake System Operation
Lesson description:
This lesson provides information on the brake systems associated with the P&H Mining Shovel and how they operate.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Operator Controls
• Identify the operator’s controls and displays • Topic 2: Brake Hold Mode
used for the brake system
• Topic 3: Brake System Transducers
• Describe how the operator’s controls are used to
release and set the brakes and what the • Topic 4: Brake Limit Switches
indicators display • Topic 5: Brake System Alarms
• Describe how the operator’s controls are used to • Topic 6: How Disc Brakes Work
transfer between dig mode and propel mode and
what the indicators display
• Identify the situations that cause a brake hold
mode
• Identify the effects of each situation that causes
a brake hold mode
• Identify the action that must be taken to bring
the shovel out of each brake hold mode
• Identify the number and location of the brake
system transducers
• Describe the function of the transducers in the
brake system
• Identify the programmed set points for the air
pressure for brakes in the shovel’s logical
control system
• Identify and understand the function of the limit
switches
• Describe the sequence of events that occurs as
the brake releases and sets
• Identify the brake system alarms
• Recognize the logic that is generating the
alarms
• Identify the input devices, transducers, and limit
switches that provide the signals that generate
the alarms

Electric Rope Shovel Technical Training Catalog 27

Propel System
Lesson 7.1 Propel System Description
Lesson description:
This lesson provides a brief overview of the propel system components associated with P&H Mining Shovels.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Propel System Components
• Be able to identify the major assemblies and • Topic 2: Propel System Component Details
components of the Propel System
• Be able to describe the function of the major
assemblies and components of the Propel
System
• Explain the basic theory of operation of the
Propel System on P&H Mining Shovels
• Describe the differences between older Propel
Drive System and the newer Delta Drive System

Lesson 7.2 Propel System Inspections

Lesson description:
This lesson provides the information required to inspect the Propel and Crawler Systems of a Mining Shovel.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify the major assemblies and • Topic 2: Propel System Components
components of the Propel and Crawler Systems
• Topic 3: Crawler System Components
• Be able to describe the function of the major
assemblies and components for the Propel and
Crawler Systems
• Have a thorough understand of the inspection
requires for the components of the Propel and
Crawler Systems

Lesson 7.3 Crawler Adjustments

Lesson description:
This lesson provides the technician information on adjusting and maintaining the components of the crawler tracks.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Understand the importance of crawler track • Topic 2: Adjusting Crawler Track Tension
tension and how to determine if track tension is
ideal, too tight, or too loose • Topic 3: Adjusting Front Idler Shaft Retainer
Collars
• Have a thorough understanding of how to adjust
the crawler track tension
• Have a thorough understanding of how to adjust
the front idler shaft retainer collars

Electric Rope Shovel Technical Training Catalog 28

House Filtration
Lesson 9.1 AirScrubPro
Lesson description:
This lesson provides the technician with information they need to understand the components of the AirScrubPro
System, how they operate, and how they should be maintained.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify the components of the • Topic 2: Theory of Operation
AirScrubPro system and describe their
function/purpose • Topic 3: System Inspections

• Have a thorough understanding of the theory of • Topic 4: System Adjustments

operation as it relates to the AirScrubPro
System
• Have a thorough understanding of how to
inspect the components of the AirScrubPro
System
• Understand the steps required to adjust the air
pressure regulator, replace the cartridge filters,
and clearing objects within the screw conveyor

Mine Air
Lesson 10.1 Mine Air
Lesson description:
This lesson provides a general overview of the Mine Air System, its controllers, and maintenance required to keep the
system operating efficiently.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify the major components of the • Topic 2: Mine Air Controllers
Mine Air System
• Topic 3: Maintenance
• Have a basic understanding of the operation of
the Mine Air System
• Be able to identify the SEC and MLC controllers,
and their functions, associated with the Mine Air
System
• Have a general understanding of the
maintenance required to keep the Mine Air
System operating efficiently

Electric Rope Shovel Technical Training Catalog 29

Swing System
Lesson 11.1 Swing System Description
Lesson description:
This lesson provides technicians with an introduction to the Swing System components.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify and locate all major • Topic 2: Component Identification
components of the Swing System
• Have a thorough understanding of the purpose
of the components used in the Swing System

Lesson 11.2 Swing Roller Circle

Lesson description:
This lesson provides the technician information on inspecting and maintaining the components of the Swing Roller
Circle.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Have a thorough understanding of how to • Topic 2: Inspecting the Roller Paths
inspect the components and assemblies of the
Swing Roller Circle • Topic 3: Inspecting the Ring Gear

• Have a thorough understanding of the • Topic 4: Inspecting all other Roller Circle
procedures required to repair the upper and Components
lower roller paths • Topic 5: Repairing the Upper Roller Path
• Have a thorough understanding of the • Topic 6: Repairing the Lower Roller Path
procedures required to repair gaps between the
swing ring gear and carbody • Topic 7: Repair Caps between the Ring Gear
and Carbody

Electric Rope Shovel Technical Training Catalog 30

 Lesson 11.3 Center of Rotation
Lesson description:
This lesson provides the technician information on inspecting and maintaining the components of the center gudgeon.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Have a thorough understanding of how to • Topic 2: Inspecting the Center Gudgeon
inspect the components associated with the
center gudgeon and be instructed on when the • Topic 3: Adjusting the Center Gudgeon
center gudgeon adjusting nut needs to be Adjusting Nut
adjusted • Topic 4: Spherical and the Thrust Washer
• Have a thorough understanding of the Replacement
procedures required to adjust the center
gudgeon adjusting nut
• Understand when the spherical washer and
thrust washer on the center gudgeon needs to
be replaced
• Have a thorough understanding of the steps
required to replace the spherical washer and
thrust washer on the center gudgeon

Hoist System
Lesson 12.1 Swing System Description
Lesson description:
This lesson provides technicians with an introduction to the Hoist System components.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify and locate all major • Topic 2: Component Identification
components of the Hoist System
• Have a thorough understanding of the purpose
of the components used in the Hoist System

Electric Rope Shovel Technical Training Catalog 31

 Lesson 12.2 Hoist Gear Case
Lesson description:
This lesson provides the technician information on inspecting and maintaining the components of the Hoist Gear Case.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify all the components of the • Topic 2: Hoist Gear Case Inspection
Hoist Hear Case and describe their
function/purpose in the system • Topic 3: Adjusting the Hoist Gear Case Support

• Have a thorough understanding of how to

inspect the components and assemblies of the
Hoist Gear Case
• Have a thorough understanding of the procedure
required to adjust the Hoist Gear Case supports

Lesson 12.3 Hoist Drum

Lesson description:
This lesson provides the technician information on inspecting and maintaining the components of the Hoist Drum.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify all the components of the • Topic 2: Inspecting the Hoist Drum
hoist drum and describe their function/purpose
in the system • Topic 3: Hoist Drum Locking System

• Have a thorough understanding of how to • Topic 4: Hoist Slack Rope Detector

inspect the components and assemblies of the
Hoist Drum
• Have a thorough understanding of the procedure
required to engage/disengage the hoist drum
locking bar
• Have a basic understanding of the components
of the hoist slack rope detector and their
purpose in the hoist system

Lesson 12.4 Hoist Ancillary System

Lesson description:
This lesson provides the information a technician requires to utilize and maintain the remote hoist controller and cable
tuggers.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Have a thorough understanding of how to utilize • Topic 2: Remote Hoist Controller
and maintain the remote hoist controller and the
cable tuggers • Topic 3: Cable Tugger Operation

Electric Rope Shovel Technical Training Catalog 32

Attachments
Lesson 14.1 Attachments
Lesson description:
This lesson provides maintenance personnel the information their require inspecting and maintain the attachments
associated with the boom assembly.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify and describe the attachment • Topic 2: Boom Assembly
components associated with the boom assembly
• Topic 3: Gantry
• Have a thorough understanding of the inspection
process required for the boom and gantry • Topic 4: Boom Point Assembly

• Have a thorough understanding of the inspection • Topic 5: Boom Limit Resolver

process required for the boom point assembly • Topic 6: Hoist Rope Guides
and boom limit resolver
• Have a thorough understanding of the inspection
process required for the hoist rope guides

Crowd System
Lesson 16.1 Crowd System Description
Lesson description:
This lesson provides technicians with an introduction to the Crowd System components.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify and locate all major • Topic 2: Component Identification
components of the Crowd System
• Have a thorough understanding of the purpose
of the components used in the Crowd System

Electric Rope Shovel Technical Training Catalog 33

 Lesson 16.2 Crowd Belt Assembly
Lesson description:
This lesson provides the technician information on inspecting and maintaining the components of the crowd belt
assembly.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify all the components of the • Topic 2: Inspecting the Crowd Belt Assembly
crowd belt assembly and describe their
function/purpose in the system • Topic 3: Hydraulic Hand Pump

• Have a thorough understanding of how to • Topic 4: Re-tensioning the Crowd Belt

inspect the components of the crowd belt
assembly
• Have a thorough understanding of the procedure
required to adjust the crowd belt assembly

Lesson 16.3 Shipper Shaft and Saddle Block

Lesson description:
This lesson will teach you how to perform the shipper shaft axial clearance and saddle block upper and lower wear
plate adjustments.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify all the components of the • Topic 2: Shipper Shaft and Saddle Block
shipper shaft assembly and saddle block Inspection
assembly
• Topic 3: Shipper Shaft Axial Clearance
• Understand what inspection criteria is required Adjustment
when performing the prescribe inspections
• Topic 4: Saddle Block Upper Wear Plate
• Understand the steps required to adjust the Adjustment
shipper shaft axial clearance to within specified
parameters • Topic 5 Saddle Block Lower Wear Plate
Adjustment
• Understand the steps required to adjust the
saddle block upper plate to within specified
parameters
• Understand the steps required to adjust the
saddle block lower wear plate to within specified
parameters

Electric Rope Shovel Technical Training Catalog 34

Air Compressors
Lesson 17.1 Sullair with Supervisor II Control
Lesson description:
This lesson provides the technician information on using and maintaining the Sullair Air Compressor with Supervisor II
Controller.

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify the components of the Sullair • Topic 2: Theory of Operation
Air Compressor
• Topic 3: Supervisor II Controller
• Have a thorough understanding of the operation
of the Sullair Air Compressor • Topic 4: Maintenance

• Understand the buttons, lamps, and display

features of the Supervisor II Controller
associated with the Sullair Air Compressor
• Understand the procedures required for the fluid
filter replacement, the air/fluid separator
replacement, and inlet control valve
maintenance.

Lesson 17.2 Sullair with Q1 Control

Lesson description:
This lesson provides the technician information on using and maintaining the Sullair Air Compressor with Q1 Controller

Objectives: Lesson outline:

Upon completion of this lesson the student will: • Topic 1: Introduction
• Be able to identify all the components of the • Topic 2: Theory of Operation
Sullair Air Compressor
• Topic 3: Q1 Controller
• Have a thorough understanding of the operator
of the Sullair Air Compressor • Topic 4: Maintenance

• Understand the buttons, lamps, and display

features of Q1 Controller associated with the
Sullair Air Compressor
• Understand the procedures required for the fluid
filter replacement, the air/fluid separator
replacement, and inlet control valve
maintenance.

Electric Rope Shovel Technical Training Catalog 35

 Rope Shovel Instructor-Led Training Outlines
Shovel Operator
Shovel Operator Training
Course Description:
Operators will gain insight into the overall machine operation and learn required user maintenance areas. Initially a
classroom presentation is conducted which is followed by hands-on training with the shovel in a production
environment. Students will be given the opportunity to operate the shovel and practice the techniques covered in the
classroom.

Course Duration:
40 Hours

Target Audience:
This training is targeted for personnel who operate P&H Mining Shovels for production.

Prerequisites:
Operators should have a basic knowledge of Mining Shovels.

Course Location:
Field

Objectives: Main Concepts:

Upon completion of this lesson the student will: • Shovel Mechanical Overview
• Make walk around safety inspections • Production Techniques
• Identify the location of the controls and warning • Various Digging Techniques
systems
• User Maintenance Areas
• Understand the function of the controls and
warning systems • Identifying Machine Problems

• Perform minor mechanical repairs and • Drives Windows Overview

adjustments
• Operate the shovel in a productive and safe
manner to avoid damage to equipment and
reduce overall operating cost

Electric Rope Shovel Technical Training Catalog 36

 Course Outline:
Safety Feeding a Crusher
• Safety equipment • Communications
• Communications • Traffic patterns
• Pre-operational checks • Inspection of working area
• Inspection of operational area • Material selection
• Job conditions
• Weather conditions Truck Operation
• Operation at night • Communications
• Inspection of working area
Operation • Condition of the digging area
• Communications • Blasting residue in the digging area
• Shovel swing radius • Type of material being loaded
• Traffic patterns • Traffic patterns
• Clean up at the shovel • Truck positioning
• Positioning of power cables • Uniform load
• Maintaining bench grades • Loading set-up

Course Evaluation and Wrap Up

• Q&A
• Course evaluation

Electric Rope Shovel Technical Training Catalog 37

Electrical Systems
Electrical Systems (AC) - Field
Course Description:
The student is introduced to the operation and maintenance of the P&H Mining Shovel. Furthermore, the course
focuses on critical knowledge and skills required in supporting present day P&H Mining Shovels. Topics included are
the Centurion AC Shovel Control System.

Course Duration:
Two Days

Target Audience:
Electricians, Technicians, and Engineers who service and maintain P&H Mining Shovels.

Prerequisites:
Students should have knowledge of power electronics and computers. It is suggested that students complete Power,
Drive, and Control System eLearning training modules.

Course Location:
Field

Objectives: Main Concepts:

Upon completion of this lesson the student will: • AC Drive Overview
• Identify and explain the purpose of all the major • Drive PC Tool Overview
components utilized
• AC800M (Advant Controller 800) Hardware
• Use application software and programs as Overview
required
• Control Builder Overview
• Remove and replace faulty components
including a failure analysis • Auxiliary Systems Operation

• Explain the inter-relationship of the shovel • System Maintenance and Troubleshooting

systems
• Analyze schematics and control diagrams
utilized for troubleshooting and repair

Electric Rope Shovel Technical Training Catalog 38

 Course Outline:
Day 1 Day 2

Course Introduction Advant Controller 800 and Remote I/O

• Pre-assessment • Advant Controller Components
• General safety • Remote I/O Components
• ESD • Control builder overview
• Monitoring I/O Status
Electrical System Diagrams • Student worksheets
• Systems diagram overview
• Shovel schematics Air System
• Use of the index • Theory of operation
• Use of location codes • Hardware overview
• Reading P&H Schematics • Troubleshooting
• Schematic Exercises
Brake System
Touch Panel & GUI Systems • Theory of operation
• Touch panel navigation • Hardware overview
• Touch panel software tools and calibration • Troubleshooting
• Touch Panel Navigation Lab
Automatic Lubrication System
AC Power Systems • Theory of operation
IGBT Devices (101) • Hardware overview
• Basic theory of operation • Troubleshooting
• Basic troubleshooting techniques • Student worksheets
IGBT Supply Unit (ISU)
• Theory of operation Hoist Lube Pump System
• Hardware overview • Theory of operation
• Reduced run feature • Hardware overview
• Fault tracing
Inverter Unit (INV) Rear House Blower System
• Theory of operation • Theory of operation
Auxiliary Control Unit (ACU) • Hardware overview
• Theory of operation
• Hardware overview Auto Crowd Belt Tensioning System (4100XPC)
• Theory of operation
Drive Control Unit (RDCU)
• Theory of operation Course Evaluation and Wrap Up
• Hardware overview • Post-assessment
• Software chains • Course evaluation
• Group 19 data transfer
• Student worksheets

Electric Rope Shovel Technical Training Catalog 39

 Electrical Systems (AC) - Milwaukee
Course Description:
The student is introduced to the operation and maintenance of the P&H Mining Shovel. Furthermore, the course
focuses on critical knowledge and skills required in supporting present day P&H Mining Shovels. Topics included are
the Centurion AC Shovel Control System. The concepts that are covered in the classroom are reinforced in a
laboratory environment that allows the students to load, install, and configure application software.

Course Duration:
Three Days

Target Audience:
Electricians, Technicians, and Engineers who service and maintain P&H Mining Shovels.

Prerequisites:
Students should have knowledge of power electronics and computers. Students will be assigned Power and Control
System eLearning training modules as part of course registration.

Course Location:
Milwaukee Training Facility

Objectives: Main Concepts:

Upon completion of this lesson the student will: • AC Drive Overview
• Identify and explain the purpose of all the major • Drive PC Tool Overview
components utilized
• AC800M (Advant Controller 800) Hardware
• Use application software and programs as overview
required
• Control Builder Overview
• Remove and replace faulty components
including a failure analysis • Auxiliary Systems Operation

• Explain the inter-relationship of the shovel • System Maintenance and Troubleshooting

systems
• Analyze schematics and control diagrams
utilized for troubleshooting and repair

Electric Rope Shovel Technical Training Catalog 40

 Course Outline:
Day 1 Day 2 Day 3

Course Introduction Drive Control Unit (RDCU) Rear House Blower System
• Pre-assessment • Theory of operation • Theory of operation
• General safety • Hardware overview • Hardware overview
• ESD
Drive PC Tool Software Auto Crowd Belt Tensioning System
Electrical System Diagrams • Drives Windows overview (4100XPC)
• Systems diagram overview • ID RUN overview • Theory of operation
• Shovel schematics • Student lab activities • Hardware overview
• Use of the index • Troubleshooting
• Use of location codes Advant Controller 800 and Remote
• Reading P&H Schematics I/O Student Lab Activities
• Schematic Exercises • Advant Controller • AC800 Procedures
Components • Drive Procedures
Touch Panel & GUI Systems • Remote I/O Components • Install I/O stations
• Touch panel navigation • Control builder overview • Verify connectivity
• Touch panel software tools • Monitoring I/O Status • Test Inputs
and calibration • Student lab activities • Test Outputs
• Touch Panel Navigation Lab • I/O system troubleshooting
Air System
AC Power Systems • Theory of operation Shop Tour
IGBT Devices (101) • Hardware overview
• Basic theory of operation • Troubleshooting Course Evaluation and Wrap Up
• Basic troubleshooting • Student lab activities • Post-assessment
techniques • Course evaluation
IGBT Supply Unit (ISU) Brake System
• Theory of operation • Theory of operation
• Hardware overview • Hardware overview
• Reduced run feature • Troubleshooting
• Fault tracing
Inverter Unit (INV) Automatic Lubrication System
• Theory of operation • Theory of operation
Auxiliary Control Unit (ACU) • Hardware overview
• Theory of operation • Troubleshooting
• Hardware overview • Student lab activities

Hoist Lube Pump System

• Theory of operation
• Hardware overview

Electric Rope Shovel Technical Training Catalog 41

 Electrical Systems (DC) - Field
Course Description:
The student is introduced to the operation and maintenance of the P&H Mining Shovel. Furthermore, the course
focuses on critical knowledge and skills required in supporting present day P&H Mining Shovels. Topics included are
the Centurion DC Shovel Control System.

Course Duration:
Two days

Target Audience:
Electricians, Technicians, and Engineers who service and maintain P&H Mining Shovels.

Prerequisites:
Students should have knowledge of power electronics and computers. It is suggested that students complete Power,
Drive, and Control System eLearning training modules.

Course Location:
Field

Objectives: Main Concepts:

Upon completion of this lesson the student will: • DC Drive Overview
• Identify and explain the purpose of all the major • Drive PC Tool Overview
components utilized
• AC800M (Advant Controller 800) Hardware
• Use application software and programs as overview
required
• Control Builder Overview
• Remove and replace faulty components
including a failure analysis • Auxiliary Systems Operation

• Explain the inter-relationship of the shovel • System Maintenance and Troubleshooting

systems
• Analyze schematics and control diagrams
utilized for troubleshooting and repair

Electric Rope Shovel Technical Training Catalog 42

 Course Outline:
Day 1 Day 2

Course Introduction Drive System (DCS800 or DCS600)

• Pre-assessment • Theory of operation
• General safety • Hardware overview
• ESD • Student worksheets
• Drive Windows procedure
Electrical System Diagrams
• Systems diagram overview Advant Controller 800 and Remote I/O
• Shovel schematics • Advant Controller Components
• Use of the index • Remote I/O Components
• Use of location codes • Control builder overview
• Reading P&H Schematics • Monitoring I/O Status
• Schematic Exercises • Student Lab Activities
• Controller loading procedures
DC Motors • I/O System troubleshooting
• Theory of operation
• P&H Motor Types Air System
• Maintenance inspections/procedures • Theory of operation
• Hardware overview
DC Power Systems • Troubleshooting
SCR (101) • Student worksheets
• Basic theory of operation
• Basic troubleshooting techniques Brake System
P&H Converter Configuration • Theory of operation
• Theory of operation • Hardware overview
• Hardware overview • Troubleshooting
• SCR Troubleshooting 101
Diverter Circuit Automatic Lubrication System
• Theory of operation • Theory of operation
• Hardware Overview • Hardware overview
• Basic troubleshooting • Troubleshooting
• Student worksheets • Student worksheets
RPC
• Theory of operation Touch Panel & GUI Systems
• Hardware overview • Touch panel navigation
• Student worksheets • Touch panel software tools and calibration
• Touch Panel Navigation Lab

Course Evaluation and Wrap Up

• Post-assessment
• Course evaluation

Electric Rope Shovel Technical Training Catalog 43

 Electrical Systems (DC) - Milwaukee
Course Description:
The student is introduced to the operation and maintenance of the P&H Mining Shovel. Furthermore, the course
focuses on critical knowledge and skills required in supporting present day P&H Mining Shovels. Topics included are
the Centurion DC Shovel Control System. The concepts that are covered in the classroom are reinforced in a
laboratory environment that allows the students to load, install, and configure application software.

Course Duration:
Three days

Target Audience:
Electricians, Technicians, and Engineers who service and maintain P&H Mining Shovels.

Prerequisites:
Students should have knowledge of power electronics and computers. Students will be assigned Power and Control
System eLearning training modules as part of course registration.

Course Location:
Milwaukee Training Facility

Objectives: Main Concepts:

Upon completion of this lesson the student will: • DC Drive Overview
• Identify and explain the purpose of all the major • Drive PC Tool Overview
components utilized
• AC800M (Advant Controller 800) Hardware
• Use application software and programs as overview
required
• Control Builder Overview
• Remove and replace faulty components
including a failure analysis • Auxiliary Systems Operation

• Explain the inter-relationship of the shovel • System Maintenance and Troubleshooting

systems
• Analyze schematics and control diagrams
utilized for troubleshooting and repair

Electric Rope Shovel Technical Training Catalog 44

 Course Outline:
Day 1 Day 2 Day 3

Course Introduction Drive System Hardware Overview Auto Crowd Belt Tensioning System
• Pre-assessment • DCS600 Circuit board (4100XPC)
• General safety operation • Theory of operation
• ESD OR • Hardware overview
• DCS800 Circuit board • Troubleshooting
Electrical System Diagrams Operation
• Systems diagram overview Student Lab Activities
• Shovel schematics Drive PC Tool Software • AC800 Procedures
• Use of the index • Drives Windows Overview • Drive Procedures
• Use of location codes • Student lab activities • Install I/O stations
• Reading P&H Schematics • Verify connectivity
Advant Controller 800 and Remote
• Schematic Exercises • Test Inputs
I/O
• Test Outputs
• Advant Controller
Touch Panel & GUI Systems • I/O system troubleshooting
Components
• Touch panel navigation
• Remote I/O Components
• Touch panel software tools Shop Tour
• Control builder overview
and calibration
• Monitoring I/O Status
• Touch Panel Navigation Lab Course Evaluation and Wrap Up
• Student lab activities
• Post-assessment
DC Power Systems • Course evaluation
Air System
SCR (101)
• Theory of operation
• Basic theory of operation
• Hardware overview
• Basic troubleshooting
• Troubleshooting
techniques
• Student lab activities
Converter Operation
• Theory of operation
Brake System
• Shovel Configuration
• Theory of operation
• Troubleshooting
• Hardware overview
• Student lab activities
• Troubleshooting
Diverter Operation
• Theory of operation
Automatic Lubrication System
• Shovel Configuration
• Theory of operation
• Troubleshooting
• Hardware overview
• Student lab activities
• Troubleshooting
RPC Operation
• Student lab activities
• Theory of operation
• Program Configuration
• Troubleshooting
• Student lab activities

Electric Rope Shovel Technical Training Catalog 45

Mechanical Systems
Mechanical Systems - Field
Course Description:
The course introduces the student to the operation and maintenance of P&H Mining Shovels. The course focuses on
critical knowledge and skills required in supporting P&H Mining Shovels. All mechanical systems and adjustments are
discussed. Recommended preventive and corrective maintenance procedures and practices are also discussed.

Course Duration:
Two days

Target Audience:
This training is targeted for Mechanical Maintenance and Supervisory personnel responsible for preventive and
corrective maintenance and servicing of P&H Mining Shovels.

Prerequisites:
Students should have a basic knowledge of mechanical terminology and practical experience with maintenance
equipment.

It is also suggested that students complete the following eLearning training modules: Product Overview, Disc Brakes,
Theory of Operation of the Propel, Swing, Hoist, and Crowd Systems, and Compressed Air.

Course Location:
Field

Objectives: Main Concepts:

Upon completion of this lesson the student will: • Review of relevant reference material
• Locate and identify major mechanical systems, • Shovel motions and major components
subsystems, and components
• Lower machine structure and Propel System
• Identify and use available reference material to
operate or maintain the shovel • Revolving Frame and Swing System

• Understand the design and function of various • Hoist System

Shovel Mechanical Systems • Boom Assembly and Crowd System
• Conduct preventive maintenance inspections • Machinery House and Ventilation System
• Perform maintenance adjustments and repairs • Compressed Air System
• Recognize safety hazards associated with • Brake System
inspection, repair, and maintenance of shovel
mechanical systems • Automatic Lubrication System
• Inspections, tests, and adjustments of major
Mechanical Systems
• Preventive and corrective maintenance
procedures

Electric Rope Shovel Technical Training Catalog 46

 Course Outline:
Day 1 Day 2

Source Information Shovel System: Hoist

• Mechanical Maintenance Manual • Hoist System Overview
• LinkOne Parts Book
• Service Bulletins and Service Notices Shovel Structures: Attachment
• Booms, Handles and ABSS
Shovel Orientation and Introduction
• Shovel Orientation Shovel System: Dippers
• Mechanical and Structural Overview • Dipper Wear Components
• Dipper Trip Mechanism
Safety Overview • “SnubRite” Snubbers
• Electrical and Mechanical Hazards • Pitch Braces
• Stored Mechanical Energy
Shovel System: Crowd
General Assembly Procedures • Crowd System Overview
• Bolt Torqueing Principles and Practices • Crowd Belt Replacement and Tensioning
• Bolt Tensioning • Shipper Shaft and Saddle Block Adjustments
• “SuperNuts”
• Bearing Types and Adjustment Shovel System: Compressed Air System
• Air System Overview
Shovel System: Propel • Air Compressor
• Lower Structure and Lower Works • Air System Control
• Propel System Overview • Brake Air System
• DELTA Drive System • Lube Air System
• Crawler Track Tension Adjustment
Shovel System: Disc Brakes
Shovel System: Machinery House • Operation and Components Overview
• House Ventilation and Pressurization • Disc Brake Safety
• AirScrubPro • Disc Brake Maintenance

Shovel System: Swing Shovel System: Lubrication System

• Swing System Overview • Types of Lubricants
• Center Gudgeon Nut Adjustment • Motor and Gearcase Lubrication
• Automatic Lubrication System Overview

Course Evaluation and Wrap Up

• Q&A
• Course evaluation

Electric Rope Shovel Technical Training Catalog 47

 Mechanical Systems - Milwaukee
Course Description:
The course introduces the student to the operation and maintenance of P&H Mining Shovels. The course focuses on
critical knowledge and skills required in supporting P&H Mining Shovels. All mechanical systems and adjustments are
discussed. Recommended preventive and corrective maintenance procedures and practices are also discussed.

Course Duration:
Three Days

Target Audience:
This training is targeted for Mechanical Maintenance and Supervisory personnel responsible for preventive and
corrective maintenance and servicing of P&H Mining Shovels.

Prerequisites:
Students should have a basic knowledge of mechanical terminology and practical experience with maintenance
equipment.

It is also suggested that students complete the following eLearning training modules: Product Overview, Disc Brakes,
Theory of Operation of the Propel, Swing, Hoist, and Crowd Systems, and Compressed Air.

Course Location:
Milwaukee Training Facility

Objectives: Main Concepts:

Upon completion of this lesson the student will: • Review of relevant reference material
• Locate and identify major mechanical systems, • Shovel motions and major components
subsystems, and components
• Lower machine structure and Propel System
• Identify and use available reference material to
operate or maintain the shovel • Revolving Frame and Swing System

• Understand the design and function of various • Hoist System

Shovel Mechanical Systems • Boom Assembly and Crowd System
• Conduct preventive maintenance inspections • Machinery House and Ventilation System
• Perform maintenance adjustments and repairs • Compressed Air System
• Recognize safety hazards associated with • Brake System
inspection, repair, and maintenance of shovel
mechanical systems • Automatic Lubrication System
• Inspections, tests, and adjustments of major
Mechanical Systems
• Preventive and corrective maintenance
procedures

Electric Rope Shovel Technical Training Catalog 48

 Course Outline:
Source Information Shovel System: Hoist
• Mechanical Maintenance Manual • Hoist System Overview
• LinkOne Parts Book
• Service Bulletins and Service Notices Shovel Structures: Attachment
• Booms, Handles and ABSS
Shovel Orientation and Introduction
• Shovel Orientation Shovel System: Dippers
• Mechanical and Structural Overview • Dipper Wear Components
• Dipper Trip Mechanism
Safety Overview • “SnubRite” Snubbers
• Electrical and Mechanical Hazards • Pitch Braces
• Stored Mechanical Energy
Shovel System: Crowd
General Assembly Procedures • Crowd System Overview
• Bolt Torqueing Principles and Practices • Crowd Belt Replacement and Tensioning
• Bolt Tensioning • Shipper Shaft and Saddle Block Adjustments
• “SuperNuts”
• Bearing Types and Adjustment Shovel System: Compressed Air System
• Air System Overview
Shovel System: Propel • Air Compressor
• Lower Structure and Lower Works • Air System Control
• Propel System Overview • Brake Air System
• DELTA Drive System • Lube Air System
• Crawler Track Tension Adjustment
Shovel System: Disc Brakes
Shovel System: Machinery House • Operation and Components Overview
• House Ventilation and Pressurization • Disc Brake Safety
• AirScrubPro • Disc Brake Maintenance

Shovel System: Swing Shovel System: Lubrication System

• Swing System Overview • Types of Lubricants
• Center Gudgeon Nut Adjustment • Motor and Gearcase Lubrication
• Automatic Lubrication System Overview

Course Evaluation and Wrap Up

• Q&A
• Course evaluation

Electric Rope Shovel Technical Training Catalog 49