SHOVEL

This is the oldest excavation equipment of the world. This equipment can be classified  in the following way

 (a) Electric shovel

 (b) Hydraulic shovel.

The main useful component of the machine is the BUCKET, which digs in the soil or earth or mineral or ore body of any project. The component is attached to a member known as DIPPER STICK. This again moves forwarded and backward,which is regarded as CRWDING  with the help pinions  driven by pinion shaft. The bucket can be lifted up and down by hoist rope. This hoist rope is operated by hoist drum, which again driven by hoist shaft.

The bucket and the dipper stick along with the pinions are mounted on another member known as BOOM, which pinned to super structure at one end and held by rope pulley arrangement on the top. The whole of the unit as described   is mounted on platform through roller race.This makes the super structure capable of rotating about a vertical axis This rotation of the super structure about vertical axis is known as SWINGING .

The roller race  is placed on a big gear known as BULL GEAR, which is again mounted on an unit known as UNDER CARRIAGE unit. The under carriage unit  consists of two crawler mechanism, which are actually resting on the ground. The crawler unit is made of endless chain, which is driven by sprockets.  These   sprockets are driven by a shaft taking power from engine or motor. The endless chain consists of a No. of shoe members pin joined with each other and mounted over roller ring and driven wheel. These rings, the wheels  and the sprockets are held in a frame. Two frames of the two crawler mechanism are joined by other frame members. The assembly of the whole unit is regarded as under carriage unit.

ELECTRIC SHOVEL

INTRODUCTION:- The descriptions as stated remain the same for Diesel and Electric shovel. The only difference is that in Diesel shovel the various mechanisms such as crowd mechanism, swing mechanism, hoist mechanism and travel mechanism  are driven by Diesel engine through clutch, chain and sprocket, rope pulley and different liver mechanism While in Electric

shovel the same mechanism are driven by electric motor through clutch, gear box and related equipment. So different mechanisms are provided with  different motors, except that swing and propel mechanism are driven by the same motor with the restriction that both swing and travel activities  can’t be allowed to take place simultaneously. All these motors are D.C. motor, who draw power from D.C. generators, who in turn is driven an A.C synchronous motor. In fact all the D.C. generators and the synchronous motor are mounted on a common shaft joined by flexible coupling. This combination of motor and generator is called MOTOR GENERATOR (M.G.) set of Ward Leonard system.In the combine shaft one excitor  unit is mounted, which is mainly to control the electric current in the D.C. generator.

APPLICATION :- Power shovels are used at surface metal and nonmetal mines for overburden removal and for ore loading. Many different sizes of shovels may be used. depending on the type of operation and application.

Block Diagram

Accidents relating to shovel operation most often result from slips and falls, becoming caught in or struck by moving mechanisms, and standing or walking near the machine while it is in operation. Slips and falls occur most often during maintenance,' repair, or cleanup, and when mounting and dismounting the machine. Miners are most often struck by moving mechanisms during greasing or oiling, or when performing maintenance or repair. Injuries to persons standing or walking near the machine often occur when the person is in the area and the shovel operator is unaware of their location.

The basic job steps included in this module are:

1. Conduct walk-around inspection of shovel and  work area.

2. Mount and dismount.

3. Conduct on-board inspection.

4.  General operation.

5.  Shutdown procedure.

6.  Perform repairs and maintenance.

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HYDRAULIC SHOVEL

INTRODUCTION:- It will describe PC-650 But the mechanisms are driven by hydraulic motor  ,which in turn are driven by hydraulicpumps. These pumps are driven by either electric motor or Diesel engine.The operation of different mechanismsare done  by reciprocating piston-cylinder arrangement, while travel and swing activities are done by hydraulic traction motor. Now in this shovel no rope pulley arrangement is used. Hence this is also regarded as Non- Rope shovel. This  type of shovel is very compact and take less space in comparison with similar capacity of other variety shovels. General view of hydraulic shovel .

PC-650 MAINTENANCE IN DIFFERENT PREVENTIVE RESPECT:- Preventive maintenance is the activities to be followed at a particular interval period. They are nothing but certain check list to be followed as suggested by the manufacturer(s) in their literature during the supply of the equipment. Those need to be followed strictly.

250 hours maintenance :-radiator ,oil cooling fan , tension pully bearing ,  swing machinery case , final drive , fuel filter element.

500 hours maintenance:- fuel filter , swing machinery case, final drive case left/right .

1000 hours maintenance:- fuel filter , swing machinery case, final drive case left/right .

2000 hours maintenance :- hydraulic oil change , power take off (PTO) oil, swing pinion check.

ENGINE MAINTENANCE :- :- In open cast project engines are the main source of power for open cast machineries. High horse power diesel engines are used principally. Maintenance of these engines plays a very vital role for successful operation and achievement of an open cast project. It increases the availability, utilization of the machines as a whole. To understand the maintenance procedure for these engines, the constructional aspect of the engines need to discussed. The engine specifications of these machines are slightly different than those of other.

Lubrication System

The engine oil pump draws oil from the oil pan through a screen. The engine also has a scavenge pump at the rear of the engine to transfer oil from the rear of the oil pan to the main sump. Oil flows from the pump through an engine oil cooler bypass valve to the engine oil cooler. The bypass valve for the engine oil cooler permits oil flow to the system during cold starts when the oil is thick or if the cooler is plugged. Oil flows from the engine oil cooler to the oil filters. The

oil flows through the filters and enters the engine cylinder block to clean, cool, and lubricate the internal components and the turbochargers. Some trucks are equipped with an engine oil renewal system. Engine oil flows from the engine block to an engine oil renewal system manifold. A small amount of oil flows from the engine

oil renewal system manifold into the return side of the fuel pressure regulator. The engine oil returns to the fuel tank with the return fuel.

The following safe job procedures wil help minimize incidents which may cause injuries and adversely affect production:

Required and/or recommended personal protective equipment:

 Hard hat, safety shoes, safety glasses with side shields, gloves,

 clothing appropriate for weather conditions, hearing protection