Excavator Simulation Training InstrumentLesson plan\ Operation Manual\ TroubleshootingJiangsu Hongchang Construction Machinery Co.,LtdContentsExcavator Simulation Training InstrumentLessonPlanJiangsu Hongchang ConstructionMachinery Co.,LtdTraining OutlineWe recommend that you operate the instrument and train students according to the following training outline in order to make full use of the simulation instrument, and you can also modify and add the contents for reaching the optimum training effect.1. Training items are total 22 lessons, they contains: training mode, test mode and entertainment mode.The training mode is the basic training lesson, it asks students to learn and operate the instrument firstly. Students can master the basic knowledge of excavator, such as, 8 movements of 2 control levers, the safety notes and skills through 11 lessons.The test mode designs 7 practical working items of excavator. Students must operate the first item qualifiedly then enter the next item, which ask students to be proficient in operation.The entertainment mode adopts some games to train students mastering the operation skills and contain education in amusement. In this mode, students finish some interesting items with various difficulties by controlling the boom, arm, bucket.2. The training items are arranged in the sequence from simple to complex, students should operate the first items, such as Free Movements and loading example, so that they can be proficient in the 8 movements of 2 control levers. Only building up a solid basis, students can finish the variously difficult items in the next stage because all kinds of excavator works ask operators must be skillful in the operation of 2 control levers.3. The aim of simulation instrument is to convert the first 5-10 hours training on the real excavator into the 30-50 hours training on the simulation instrument, which ensures students to master the 2 control levers, and saves the training cost for school, reduces the wear of real excavator and fuel consumption.4. In the process of training simulation instrument, the teacher should correct students’errors in time, and discipline students to operate the instrument in accordance with the practical operation rules and notes of excavator, this is to make students master the skills and safety notes of real excavator through the simulation instrument, students can standardize operation in the real excavator in the future.5. School should arrange students to read, write down and recite the safety notes and skills of excavator in the theory files.6. The teacher should be strict with students for they master the excavator operation, skills and notes, and laying the foundation for the future real excavator training, saving the training cost and improving the teaching quality.The First Stage: Teaching Section of Simulation InstrumentLessons ArrangementsClass Time: 5-8 ClassesTeaching Aim: Comprehend and master the preliminary functions of 2 control levers and excavator basic operations and skills.Class Arrangements: 1. Class Meeting；2. Item Arrangements;3. Summary;Detailed Teaching Plans：I. Class Meeting；(1)．Students register after entering classroom, the teacher tells students theclassroom disciplines and notes.(2)．Introduce each operational buttons.(3)．Introduce the teaching functions and aims of simulation instrument.①The simulation instrument is specially designed and manufactured for training the excavator driver. The operation of 2 control levers is the same with the real excavator (be able to switch the forehand or backhand). The instrument has the lifelike pictures, various sound and language hints. Students can be familiar with the excavator skills through simulation training, then go on the practical operation on the real excavator, which help students master the excavator skills and become a qualified driver.②During operating, not allow students to replace the items privately, they should strictly follow the appointed items and class time to operate, and keep the stable, correct, and light operation in stead of rude operation.(4). When operating the simulation instrument, students can watch the videos of real excavator according to the different items in order to know the operational contents and standard movements. The teacher introduces the excavator’s structures, components names and usages, working environments for students. Before operating, students should know the meanings of 2 labels sticking on the 2 control boxes and remember the 8 movements of 2 control levers. (tips: imagine excavator as people, ie. boom is the upper arm of people, arm is the lower arm, bucket is the hand, bucket teeth are the fingers, this is to be easily understand). Students can remember and answer the left/right control levers’ positions and functions, which is useful to operate smoothly and lay the foundation for the next items.(5). Requirements: Students should remember the movements of 2 control levers and their functions.(6). Watch and record the Power Point from the help files for masteringoperational skills and safety knowledge.II. Item ArrangementsItem Contents: Rudiment Learning – Free MovementsClass Time：3-5 classesClass Requirements: ask students to master the basic and compound operation of 2control levers.Teaching Plans:Free Movements1．Select the item through operating the simulation instrument.2．The teacher instructs the operational methods and functions of left/right levers.3．Firstly, arrange students to practice a single movement of left/right levers, for example, pulling the right control lever back is to raise the boom; pulling to the left is to close the bucket. Let students know and practice each single movement of 2 control levers, then go on the compound operation until they are really proficient in 8 movements.4. Operate the boom, arm and bucket to support one side of excavator for letting students know when the excavator need be support and the safety notes after supporting.5. Firstly, the teacher make the operational examples, (the teacher should instruct students while operating, so that students are easily to accept and understand). Students can operate the control levers up, down, left, right by themselves after watching teacher’s example. Don’t stamp on the pedals.Firstly, pull the right control lever back to raise boom and watch the pictures on computer, know each direction of control lever presents the movement name andfunction. During operating, don’t produce the sound when arm cylinder strikes bucket cylinder at the end of piston. When cylinder piston is near, the piston rod should keep 5-10 cm clearance. After mastering each movement of 2 control levers, park the machine properly.6. Use the 2 pedals to travel. Before traveling, students should know the meanings of front/rear travel devices. The teacher instructs the different controls and notes when front idler is in front or rear of travel device. Students master how to properly travel and know the safety knowledge of travel.7. Prepare for traveling. Firstly raise boom, fully roll out the arm cylinder and bucket cylinder, after that, lower boom, keep bucket 40-50cm above the ground. 2 feet lightly stamp the pedals, (reminding: know the systems of excavator, the front is front idler, the back is driving tumbler before traveling by pedals), 2 feet stamping forward is to travel forward, 2 feet stamping backward is to travel backward; Lifting left foot (when pedal is median), right foot stamps forward or backward, the excavator will travel forward and turn left or backward and turn left; Lifting right foot (when pedal is median), left foot stamps forward or backward, the excavator will travel forward and turn right or backward and turn right. If need turn where the excavator is, one foot stamps pedal forward, another stamps pedal backward.8. Pull the left control lever left or right, the excavator rotate 180°, then stop the control lever. Experience the pedals again. The cab facing the direction of front idler, stamp the pedal forward if need travel forward; the cab facing the direction of driving tumbler, stamp the pedal backward if need travel forward. Why? Please think over. Because the under carriage of excavator don’t change direction, but the upper structure has changed the direction, the control lever also has changed the direction with upper structure, students should ensure the direction before traveling. (Avoid dangers on the real excavator).Note: In the item of free movements, the excavator only travel in the green area. In all items, the pictures will appear the red flash, words and sound information if happen the wrong operation, for example, the bucket touches the track or any part of excavator. (If appear the above information, please check the cause and properly operate)After students are proficient in free movements, the teacher gives the commands according to the pictures for checking students the corresponding operations. After finish practicing, park the excavator properly.Requirements: When stamping the pedals, should be lightly stamp or lightly lift. Be familiar with the functions, notes and operations of control levers and pedals. Be clear about the front or back directions of excavator.9. The pictures are simple, but students can be proficient in operating 2 control levers through keeping practicing. Only mastering the 2 control levers, students can finish the future items successfully.Item Contents：Rudiment Learning— Loading ExampleClass Time：4-10 ClassesClass Requirements: Be proficient in the basic operation of loading and unloading Teaching Plans：Loading Example1．This item is a great help to operate the real excavator, so arrange students to practice more in order to master loading.2．This item contents：Following the green line to operate the left, right control levers, this is a single movement practice of digging soil and loading. Student should learn the whole process from the bucket opening to closing according to the standard movements. After mastering the basic loading movements, students can freely choose digging sand and loading.3. Details: Following the loading example to keep practicing for master the basic movements of digging and loading.4. The teacher should check students’operations for being standard. Students should pay attention to roll in the arm to the correct position and keep the bucket horizontal. Check the bucket for leaking soil or hitting other objects.Requirements: operate smoothly, correctly, lightly, but not too fast.5. The teacher should correct the problems: don’t lower the boom, don’t roll in arm, the bucket isn’t full. And instruct the safety notes of the real excavator operation. For example:①When unloading, the bucket is not beyond the truck and personnel.②Try to r otate excavator in a small angle for raising working efficiency.③ Be careful that dump soil from the suitable height for avoiding to damage trucks.④ Loading should start from the front of truck to the back, or start from the middle to 2 sides of truck, keep the loads uniform.6. In this item, the truck will automatically leave after taking the 10000Kg loads, the next truck will drive to the loading position for keeping operation.7. Note: if the picture flashes one time, 5 points will be deducted. The possible causes are hitting truck or leaking sand out of truck. If the loads were leaked out of truck, the truck wouldn’t drive, even damage, so the safety points on pictures don’t less than 80 points.III、Summary；1. The teacher makes the summary of occurred problems.①During digging sand, students haven’t rolled in the arm to the correct position, haven’t kept the bucket horizontal.②Operated so fast that the movement wasn’t standard.2. Students write a self-evaluation about the occurred problems, wrong operations and how to correct in the next training.Class Arrangements：1. Class Meeting；2. Item Arrangements；3. Summary；Detailed Teaching Plans：1、Class Meeting；1．The teacher reads students’self-evaluation for finding out and solving the common problems.Example 1: Students have not gained an adequate understanding of simulation instrument, or think it as a game.The teacher: The simulation instrument is specially designed for training excavator, not a simple game. It can help students have a perceptual knowledge about excavator through training before operating the real excavator, and help master the operational skills, so students must correct the attitude to perform a training exercises, only do this, students can master the excavator operation faster and better.Example 2: The movements of digging sand aren’t standard, the operations of arm and bucket aren’t proper.The teacher: Don’t operate too fast on simulation instrument, follow the examples to do standard, properly. Students should keep practicing until master movements.2. Ask students don’t replace the operational items privately.2、Item Arrangements；Item Contents：Rudiment Learning—90°digging and dumpingClass Time：5-8 classesRequirements：1．Master the skill and notes of digging and dumping.2. Be proficient in the match of 2 control levers and skills.3. Ask student dump through the simple, compound operations.Teaching Plans：90° Digging and DumpingTeaching Plans：Traveling and LoadingUp and Down Trailer。
