ऑपरे शन पुस्तिका

डबल्यू – 2000 वॉककिंग ड्रैगऱाइन

सेन्ट्रऱ एक्सकॉवेशन रे ननिंग इन्ट््टीच्यूट (सी॰ई॰टी॰आई॰)

नॉर्द नद कोऱफील्ड्स लऱलिटे ड

लसिंगरौऱी (ि॰प्र॰)

OUR VISION
NEW HORIZONS IN LEARNING
CETI, NCL
Types of HEMMs deployed at NCL Mines
 FOREWORD

This manual describes procedures for operation, handling and safety. It will help the operator
or anyone realize peak performance through effective, economical and safe machine operation
and maintenance.

• Please read this manual carefully BEFORE operating the machine.

• Please continue studying this manual until proper operation is completely reinforced into
personal habit.

• This manual describes the basic techniques. Skill is acquired as the operator or anyone gets
the correct knowledge and performance of the machine.

• Operation and inspection should be carefully carried out and safety must be given the first
priority.

• The safety information contained in this manual is intended only to supplement safety codes,
insurance requirements, local laws rules and regulations.

• Some photographs and illustration pictures are different from your machine as technical
improvement is continuously reflected on it.

I express my gratitude to Shri Rajasekhar Kotturi, General Manager (HRD/ CETI) and Shri
Anand Wadnerkar, Chief Manager (Excavation/ CETI), NCL Singrauli for their encouragement
in publishing this manual. I sincerely thank Shri Inderjit Singh, Foreman (Excavation/ CETI) for
giving final shape to this book.

I believe this DRAGLINE Operation Manual will be very useful.

SHUBHAM SOURABH
Assistant Manager (Excavation/ CETI)
Central Excavation Training Institute
Northern Coalfields Limited
Singrauli (M.P.)
 A WORD WITH THE OPERATOR
Dear Operator,

This manual has been specially prepared for use, to ensure trouble-free service of your machine.

No machine, however well designed & manufactured, can be operated successfully without
proper operating procedure and scheduled maintenance. This manual explains in detail the
operating procedures which if carried out properly, will result in overall lower operational
costs and hence higher profits.

The successful operator should be proud of the results obtained by him.

Let the DRAGLINE be your PRIDE.

With best wishes.

(FOR INTERNAL CIRCULATION ONLY)
 Schematics
Side View

6.2 Side View

PRELIMINARY SAMPLE 03-25-2011

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 Schematics
Deck Plan

6.3 Deck Plan

PRELIMINARY SAMPLE 03-25-2011

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Safety
Safety Precautions
S.2.1 General Precautions
• The employment of qualified maintenance personnel, through a scheduled
maintenance program, is the best way to minimize machine downtime and maximize
productivity of equipment.
• Keep hands, feet and clothing away from rotating parts.
• Wear a hard hat, safety shoes and protective lenses at all times.
• Replace any and all safety and warning placards if they are defaced or removed from
the machine.
• Think before you act. Carelessness is one luxury the service person cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation.
In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material
and the suggested method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load
could slip off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don’t try to catch it.
• Keep your work area organized and clean. Wipe up oil or spills of any kind
immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall,
slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations
be sure all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
• Regularly inspect for any loose bolts or locking devices and properly secure them.
• Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless you are qualified.
• Check limit switches for proper operation.
• After servicing, be sure all tools, parts or servicing equipment are removed from the
machine and secured in an appropriate storage area.
• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion
(dynamic) brake in emergency situations only.
• Use proper interior and exterior lighting.
• Install and maintain proper grounding and ground fault protection systems.
• Perform functional tests of all safety circuits.
• Electrical inspection and maintenance should only be performed by a qualified
electrician.
• National, state and site safety systems must be read in conjunction with this manual.

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 Safety
Safety Precautions
S.2.3 Operating Precautions
• Wear hearing protection when exposed to the following noise levels in excess of the
period indicated:

8 hours at 90 dBa
4 hours at 95 dBa
2 hours at 100 dBa
1 hour at 105 dBa
30 minutes at 110 dBa
15 minutes at 115 dBa

• When in doubt about the noise level, wear approved hearing protection.
• Do not attempt to get on or off the machine while it is in operation. Notify the operator
prior to any attempt to board/exit the machine.
• Do not move or operate the machine without first knowing the location and purpose of
all personnel and test or support equipment on or near the machine.
• Do not allow unauthorized personnel on board the machine while in operation.
• Use audible signals to warn of machine movements. A signal horn button is provided
for this purpose.
• Do not propel until the travel route has been cleared of obstructions.
• Prevent trail cable from being dragged on the ground for long distances or at high
speeds.
• Limit the amount of cable being pulled by the machine. Pulling too much cable will
damage both the cable and the machine.
• Check to ensure all control panel cabinets are closed and secure.

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Safety
Safety Precautions
S.2.4 Fire Prevention
• Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and
service the extinguisher as indicated on its instruction plate.
• DO NOT smoke while handling flammables or when near batteries.
• Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended
torque.
• Repair or replace loose or damaged lines, tubes and hoses as soon as possible.
• Make certain all clamps, guards and shields are replaced correctly so as to prevent vibration
and the chafing of parts during operation.
• DO NOT carry flammable fluids such as gasoline or solvents on board the machine.
• DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged
lines, tubes, or hoses. Replace them immediately.
• DO NOT start the machine or move any of the controls if a warning tag is attached to the
controls or the start panel.
• Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.
• Keep all structural frame compartments, walkways and work areas clean and free of lubricant
residue.
• NEVER weld, burn, or perform service on the machine alone.
• If a motor or other component is running hot, shutdown the machine until it has cooled and
the cause is determined and repaired.

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 Introduction
Machinery Details

1.2 Machinery Details

This section assists in understanding the construction of this machine and in identifying and
locating the main assemblies.

1.2.1 General Arrangement

The general arrangement of the dragline is shown in Figure 1-1.

Figure 1-1 General Arrangement

1.2.1.1 Base
The base comprises several sections, as shown in Figure 1-2, which are assembled together and
welded on site. Each section is made of steel plates forming boxed compartments. Manholes are
fitted to most compartments to allow assembly, internal inspection and maintenance of the base.
Certain compartments are not fitted with manholes because of obstruction by the roller rail and
rack gear top plates. In these cases access is gained through a side entrance from an adjacent
compartment.

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Introduction
Machinery Details
The center post is a steel forging welded into the base center section. The electrical high tension
supply cable passes through one of the outer sections and up to the middle of the center post to
the collector assembly.
The swing rack top plates are welded to the base to form the inner ring mounting for the rack
gears. The roller rail top plates are fixed to the base to form the outer ring mounting for the roller
rail. Each base outer section is fitted with a drain pipe to remove excess lubricant from the top of
the base.
The hook rail is fitted to the top outer rim of the base to provide a bearing surface for the hooks
when the machine is walking. Rear hooks are fitted on both sides of the rotate frame and raise
the rear of the base (leading edge) while the front of the base (trailing edge) slides along in
contact with the ground.

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 Introduction
Machinery Details
Wear plates are fitted to the bottom of the base to prevent damage to the main base structure
during the walking movement.

Figure 1-2 Base

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Introduction
Machinery Details
The live ring assembly, which supports the rotate frame on the base, comprises 120 flanged
machine tapered rollers revolving between two rails. The lower rail is attached to the Base top
plates, while the upper rail is secured to the rotate frame plates, as shown in Figure 1-3.

Figure 1-3 Live Ring Assembly

The rollers are mounted in a frame made up of inner and outer cages, both being rolled to
circular form. The cages are bolted together to form two concentric rings and separated by pins
on which the rollers are separated.

1.2.1.2 Rotate Frame

The rotate frame (Figure 1-4) is constructed of four full length girders into which are built
transverse girders and circular girders for carrying the rotate roller rail.

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 Introduction
Machinery Details
Three center transverse girders are built into the frame to carry the wing girders, which support
the walking legs and shoes.

Figure 1-4 Rotate Frame

Top and bottom plates and other auxiliary girders make up the complete frame. The ballast is
placed in the rear sections of the rotate frame during erection.
Mounting fixtures on the top deck plates support the machine superstructure. Fitted to the front of
the rotate frame is a hook, which serves to stabilize the machine if a sudden loss of load should
occur when dumping.

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Introduction
Machinery Details
1.2.1.3 Fairleads
Twin fairleads for the drag ropes are mounted on the front of the rotate frame (Figure 1-5). Each
unit has two horizontal pulleys running on fixed pins to provide a direct lead to the fairlead from
the drum without any tendency to swing the fairlead frame when the drag ropes leads to one side
of the drum.
The two vertical pulleys in each unit are mounted in a steel frame which is free to swing into line
with the drag rope, regardless of the position of the bucket. These frames are fitted with
renewable steel rollers at the front for leading the ropes on to the pulleys.

Figure 1-5 Fairleads

1.2.1.4 Superstructure
The superstructure comprises the A-frame, the mast and the boom, as shown in Figure 1-6.
Platforms and catwalks are fitted to the machine to provide access to the entire superstructure.

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 Introduction
Machinery Details
The boom is a rectangular lattice construction in high tensile steel tubes comprising four main
cords and welded lacings. The boom can be supplied with boom lengths of 74.6m (245 ft), 85.1m
(279 ft), 95.6m (314.5 ft) or 100.85m (331 ft). Figure 1-6 shows an 85.1m (279 ft) boom.

Figure 1-6 Superstructure

The boom is anchored at the front of the rotate frame and supported from the mast by the upper
suspension ropes and the upper and lower intermediate suspension ropes. Both intermediate
suspension ropes are used when extensions are fitted. The lower intermediate suspension ropes
are only used on the shortest boom. Both intermediate suspension ropes are used on all other
boom lengths. The operating angle of the boom (300 or 380 degrees) is determined by the length
of the suspension ropes. See Section 5, Boom, for the procedure on changing the boom angle.
Front and rear fixing points secure the A-frame to the rotate frame. At the top of the A-frame and
mast are the jib tie pulley assemblies which are used to raise the boom and mast from ground
level during erection, or when changing the boom angle. Lower suspension ropes and anchor
plates are used to secure the boom and mast in their final operating position.

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Introduction
Machinery Details
On machines using the hoist unit to raise the boom and mast, the A-frame jib tie pulley assembly
consists of four pulleys and an equalizer. One end of the rope is secure to the hoist drum, the
other end to the equalizer. On machines with a boom hoist unit, the A-frame assembly consists of
five pulleys. One end of the rope is permanently fixed to the A-frame anchor plate; the other end
is fixed to the boom hoist drum. In both cases, the mast jib tie pulley assembly uses four pulleys.
The four main cords of the boom and the two rear legs of the A-frame are hollow and filled with
pressurized gas. Pressure gauges detect pressure drops due to gas leakage from cracks.
Pressure drops cause an annunciator panel light to flash and the warning buzzer to sound.

1.2.1.5 House and Cabs

The house is constructed from steel sheets on an angle framework supported by portal frames
with stairways, platforms and doors for easy access. Figure 1-7 is a cut-away illustration showing
the position of all major units inside the house.
An overhead travelling crane is fitted to facilitate the lifting of individual parts during major
overhauls. The crane girders extend beyond the rear of the machine, enabling leads to be
lowered to the ground or into trucks. The rear door travels with the crane when it is operating
outside the hose. Travelling of the crane full length of the house necessitates the “slackening off”
of the hoist ropes and boom hoist rope, if fitted. A one-ton capacity crane on the side of the
house is provided for handling stores.
An air conditioned cab is fitted on the right-hand side of the machine. The cab is separate from
the main machinery house and is positioned to provide clear, all-around vision. The cab is
constructed of a square tubular frame with an outer skin of sheet steel. Between the outer skin
and inner lining of teak-faced panelling is a layer of polystyrene insulation. The floor has a sound-
proof covering and all the windows are double-glazed to minimize noise. The front windshield is
fitted with twin wipers and washers. Inside each cab is the operator's console and an annunciator
panel. At the rear of each cab there is an insulated, sound-proof crew room that contains a table
and lockers.

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 Introduction
Machinery Details

Figure 1-7 House and Cab

1.2.2 Machinery
1.2.2.1 Hoist and Drag
The hoist and drag drive units (Figure 1-8) which are similar in design, except for drum grooving,
are mounted on the rotate frame inside the house. Each drum is powered by two electric motors
which drive a balanced double helical gear through flexible couplings. A pinion on the end of the
helical gear shaft meshes with a gear attached to the drum. All unit drive shafts are mounted on
anti-friction bearings.

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Introduction
Machinery Details
These two independent units are, therefore, directly connected to their respective motors without
the use of any operating clutches or brakes. This places the bucket under the operator’s control
of the operator. The motor brakes are normally used for parking and are controlled by the
operator. The brakes are also applied in the event of a power failure or emergency stop.
Limit switches are provided on the hoist and drag drums to prevent over-winding of the ropes and
damage to the boom head or fairleads. These are operated through a flexible coupling by the
driven end of the drum shaft. Controls are available to override these limit switches when using
the rope reeving winches to renew worn ropes. (For this procedure, see Section 3, Ropes.)
Provision is also made for the drum shaft to operate a drum position indicator.

Figure 1-8 Hoist and Drag Assembly

The twin hoist ropes are supported on the superstructure by pulleys on the A-frame, boom and
boom head. The boom head pulley swivels about the center line of the boom so that the hoist
ropes are always correctly seated in the pulley if the bucket swings from side to side.

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 Introduction
Machinery Details
1.2.2.2 Swing Gear
The swing drive rack consists of 16 cast steel segments which are bolted together and to the
base (rack gear) top plates.
Drive power for the swing motion comprises three motors and gearboxes (Figure 1-9) fitted on
the circular rotate framework at positions which give clearance for the drag ropes. Reduction
gears within the gearbox are single helical and all shafts are mounted on self aligning bearings.
The swing gearbox lubrication systems are built as an integral part of the rotate frame. Refer to
GSE 48371 W2000 Lubrications Systems Manual for details.
The motor flexible couplings can be split to allow the motor armature to be rotated on its' own, for
test purposes. Parking brakes are fitted to the swing motors and these must be applied when the
dragline is walking.

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Introduction
Machinery Details
The motor flexible couplings can be split to allow the motor armature to be rotated on its' own, for
test purposes. Parking brakes are fitted to the swing motors and these must be applied when the
dragline is walking.

Figure 1-9 Swing Drive Mechanism

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 Introduction
Machinery Details
1.2.2.3 Walk Gear
The walking gear (Figure 1-10) consists of a rectangular shoe on each side of the rotate frame,
lowered to the ground by the eccentric motion derived from the walk machinery. The shoes are of
fabricated construction with heavy angles attached to the underside to assist in gripping the
ground surface.

Figure 1-10 Walking gear

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Introduction
Machinery Details
Each shoe is connected by a spherical bearing to a fabricated walking leg containing an
eccentric driven by the walk shaft. Separate motor/gearbox units drive each walk shaft. The right-
hand and left-hand motors are electronically synchronized by optical encoders. Parking brakes
are fitted to each motor which are applied at the end of a walking motion, by the operator. The
machine is parked with the shoes raised off the ground, as shown in Figure 1-11; the swing and
hoist motions being inhibited unless the shoes are at the top dead center position.
The walking motion is carried out by rotating the walk shaft, which is fixed to the eccentric. One
complete revolution of the eccentric lowers the shoe to the ground, lifts and slides the machine
backwards and raises the shoe to the parked position. The optical encoders on each walk shaft
relay the position of the shoes during a walk step to an indicator unit on the operator's console.
The walk synchronizing system has preset points which automatically adjust the motor
characteristics. The points are operated as the optical encoders rotate.
The leg links are connected to the rotate frame in a manner which restricts the lower end of the
leg to a longitudinal motion.

Figure 1-11 Walk Assembly

Two sets of hooks on each side of the rotate frame lift the rear of the base as the machine lifts. A
shoe centralizing unit is connected between the rear of the shoe and the rotate frame to keep the
shoe parallel with the side of the machine in the parked position and when the shoe touches the
ground. The unit is a rubber suspension assembly which restricts the lateral movement but
allows free vertical movement around the spherical bearing. A twin roller assembly fixed to the
rotate frame wing girder levels the shoe in the parked position.

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 Introduction
Machinery Details
1.2.2.4 Ventilation
Two groups of air intake fans fitted on the side of the house deliver air into the machine through
filtration units. Of this, approximately one-half is extracted via fans in the house and rotate frame,
as shown in Figure 1-12. It is essential that the access doors in the rotate frame are closed for
correct operation of the ventilation system. Air extracted by the rear rotate frame fans is drawn
through the motor/generator sets and the rear hoist and drag motors. The front rotate frame
extract fans draw air through the walk motors and front hoist and drag motors. The extract fan at
the front of the house extracts hot air from the rotate motors.
The remaining air, not extracted by fans, sets up a small pressure in the machine and escapes
through various openings in the house - e.g., through the hoist and drag rope apertures. This
also ensures that dust cannot enter the machine when access doors are opened or the cranes
are being used.

Figure 1-12 Ventilation System

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 Operation
Motion Controls, Instruments, and Indicators
Operation

2.1 Motion Controls, Instruments, and Indicators

2.1.1 Motion Controls
An operators console, situated at the front of the cab, gives the operator a clear, unobstructed,
view through the full length front window of the cab.
The seat is located between the two control consoles. Each console has a fully instrumented
control panel.
The main motion controls comprise two hand operated levers and two pedals. The controls are
positioned in front of the operator and project from the two control consoles.

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Operation
Motion Controls, Instruments, and Indicators
2.1.2 Operator’s Seat
The operator’s seat is positioned at the front of the operator’s cab to provide the best location to
view the machine’s work area. Two joystick assemblies are provided to control the machine
positioning functions.

Figure 2-1 Motion Controls

2.1.2.1 Hoist Control Joystick

The HOIST CONTROL joystick, located to the right of the operator, provides an infinitely variable
signal for the precise control of the hoist drum. The joystick has a notched central (neutral)
position. Pushing the joystick forward, from the central position, lowers the bucket. Pull the
joystick back, from the central position, to raise the bucket.

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 Operation
Motion Controls, Instruments, and Indicators
The joystick is only operative when the walk shoes are parked.
A tensioning pushbutton is incorporated on top of the hoist control joystick. The tensioning
pushbutton is used to control the tension of the hoist rope while dragging.

2.1.2.2 Drag/Propel Joystick

The DRAG/Propel joystick is located to the operator’s left. It projects from the left-hand console.
The joystick is a dual-function control. It controls either the drag ropes on the bucket or the propel
motion of the machine. The joystick’s mode of operation is selected by the propel transfer switch
on the right-hand console panel. The selected mode is indicated by signal lamps.
The joystick gives precise, infinitely variable control either side of a notched central (neutral)
position.
In “propel” mode, the joystick is pushed to commence a walk step.
In “drag” mode, the joystick is pulled back to drag the bucket. It is pushed forward (from the
central position) to payout the drag rope. When the bucket is raised and the drag lever is pushed
forward, the bucket will tip, releasing the load.

2.1.2.3 Swing Control Pedals

The SWING CONTROL pedals provide foot control of the swing motors that rotate the boom and
house about the machine base.
• Right swing: Push down on the right-hand pedal
• Left swing: Push down on the left-hand pedal
The pedals are mechanically linked and spring loaded, to give a push-pull action, giving a
positive feel to the swing motion. With both feet off the pedals, the mechanism returns them to
the neutral position.

2.1.3 Operator Control Panels

The main control panels are located on the two consoles situated on either side of the operator’s
seat.
The facilities provided on the two control panels, together with the main motion controls, enable
the operator to have complete control of the machine with minimum physical effort. The control
panels also feature the HMI panel which gives an immediate indication of any problem arising in
the electrical or lubrication system

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Operation
Motion Controls, Instruments, and Indicators
2.1.3.1 Controls on the Left Panel

Figure 2-2 Left Control Panel

2.1.3.1.1 Earth Continuity Lockout

A 2-position, lockable, pushbutton used for safety lockout and ground test.

2.1.3.1.2 Window Washer Pushbutton

A pushbutton to operate the windshield washer pump.

2.1.3.1.3 Windshield Wiper Selector Switch

A 3-position switch to control the operator’s cab wiper and speed (Off, Low, High).

2.1.3.1.4 Fault Reset

Pushbutton used to clear all faults after the problem has been solved.

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 Operation
Motion Controls, Instruments, and Indicators
2.1.3.1.5 Grease Spray Fault Light
The GREASE SPRAY FAULT LIGHT is amber. It lights when the automatic grease sprays are
not operating.

2.1.3.1.6 Auto-Park Pushbutton

A green illuminated pushbutton used to initiate the automatic parking function. When lit it
indicates that the walking shoes are in their parked position. When flashing it indicates the shoe
park is operating.

2.1.3.1.7 Propel Excess Error Override Pushbutton

The PROPEL EXCESS ERROR OVERRIDE pushbutton is colored black. Pressing the
pushbutton allows the machine to continue any step interrupted by the excess error signal and
brings the machine safely to rest.

2.1.3.1.8 Rope Limit Bypass Pushbutton

A pushbutton used to back out of a final hoist, drag or tightline limit. A light will flash in a first
stage limit and light steadily on a shutdown.

2.1.3.1.9 Boom Lights Selector Switch

The BOOM LIGHTS switch is an on/off switch to control the site floodlight units mounted at the
boom head and on the boom structure.

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Operation
Motion Controls, Instruments, and Indicators
2.1.3.2 Controls on the Right Panel

Figure 2-3 Right Control Panel

2.1.3.2.1 Machine Shutdown

A red, flush-mounted pushbutton used to initiate machine shutdown.

2.1.3.2.2 Excitation Stop Switch

Pressing this pushbutton de-energizes the control system; the green light on the excitation
pushbutton will go out.
NOTE: When leaving the cab, press this pushbutton.

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 Operation
Motion Controls, Instruments, and Indicators
2.1.3.2.3 Excitation Start Pushbutton
The EXCITATION START pushbutton energizes the machine’s control system (which is the final
stage of any start-up procedure). When the system is energized, the pushbutton illuminates
green, indicating the machine is ready for operation.
NOTE: This switch is ineffective unless the motion controls are in the central (neutral) position.

2.1.3.2.4 Propel Transfer Switch

The PROPEL TRANSFER switch has two positions: “drag” and “walk.” Either the green “drag
selected” signal lamp or the red “walk selected” signal lamp will be illuminated, showing the
selected mode.

2.1.3.2.5 Air Compressor Switch

A 4-position selector switch to turn the air compressors on or off (Off, 1 On, 1 & 2 On, 2 On).

2.1.3.2.6 Swing Brake Selector Switch

The SWING BRAKE selector switch is a two-position switch used to set or release the swing
motor brakes. The swing brake signal lamp will light when the “set” position is selected.

2.1.3.2.7 Drag/Propel Brake Selector Switch

The DRAG/WALK BRAKE switch is a two-position switch used to set or release the drag or walk
motor brakes, depending on which mode has been selected by the power transfer switch.

2.1.3.2.8 Hoist Brake Selector Switch

The HOIST BRAKE selector switch is a two-position switch used to set or release the hoist motor
brakes. The hoist brake signal lamp illuminates when the “set” position is selected.

2.1.3.2.9 Propel Mode Light

A yellow light that indicates the machine is in PROPEL mode.

2.1.3.2.10 Drag Mode Light

A red light that indicates the machine is in DRAG mode.

2.1.3.2.11 Propel Brake Light

The PROPEL BRAKE light is red. It lights when the propel motor brake is set.

2.1.3.2.12 Swing Brake Light

The SWING BRAKE light is red. It indicates that the swing motor brakes are set, as selected by
the swing brake selector switch.

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Operation
Motion Controls, Instruments, and Indicators
2.1.3.2.13 Drag Brake Light
The DRAG BRAKE light is red. It lights when the drag motor brake is set.

2.1.3.2.14 Hoist Brake Light

The HOIST BRAKE light is red. It indicates that the hoist motor brake is set, as selected by the
hoist brake selector switch.

2.1.3.2.15 Emergency Stop Pushbutton

The EMERGENCY STOP pushbutton is a large mushroom-head button, colored red. Pressing
this button shuts down the electrical control system and applies the motion brakes.

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 Operation
Operating the Machine

2.5 Operating the Machine

2.5.1 Walking
The walk operation is carried out by the jacking action of the eccentric legs raising the machine
and sliding it backwards on the trailing edge of the base. Direction of walking is determined by
rotating the machine about the base when the shoes are in their “parked” position.

2.5.2 Preparation for Walking

The machine is designed to walk up or down gradients of not more than 1 in 10 (10%). When
preparing to walk on level ground, or on gradients, the path should at all times be level at right
angles to the line of walking. Ensure that both shoes simultaneously contact the ground.
On well-prepared level ground, carry the bucket at one-third radius.
When travelling up a gradient, bring in the bucket close to the fairlead. However, do not bring the
bucket so close that it operates the “drag-in” limit switch, as this prevents “walk” mode from being
selected.
If the ground is very soft, it might be advantageous to park the bucket on the ground, with the
drag ropes left slack enough to allow several steps before movement of the bucket becomes
necessary. Doing so reduces drag force on the base and increases the load on the shoes.

2.5.3 Walk Procedure

When ready to move, the bucket should be parked in the appropriate position, as described
above, for the prevailing site conditions.
1. Ensure that all controls are in neutral.
2. Ensure that hoist and swing brake switches are “set.”
3. Ensure that the grease-pump and gear-spray are operational.
4. Select “walk” mode using the POWER TRANSFER switch on the right hand side console.
5. Release WALK/DRAG brake; ensure the “walk brake set” signal light is extinguished.
6. Push the WALK CONTROL LEVER to begin the walk step.
NOTES:
• The action of the shoes is automatic throughout the walk cycle.
• The positions of the shoes during the walk cycle are indicated by the shoe position
indicator on the right-hand console panel.
• The shoes do not move at a constant speed during the cycle. They move rapidly from the
parked position, at top dead center, to a position above the surface of the ground. At this
point the shoes slow, allowing controlled and soft contact with the ground. Full power is
then available for lifting the machine. Regenerative braking effect gently lowers it to its
new position. Next, the shoes’ action speeds up to return them to their maximum ground
clearance position (top dead center), or through to the ground for succeeding steps.

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Operation
Operating the Machine
7. If a further step is required, continue to push on the control lever.
8. The step can be completed and the shoes automatically parked as follows:
a. Observe the shoe position indicator.
b. When the dial indicates that the shoes are in the last quadrant of the walk cycle, i.e.,
between approximately 270 and 360 degrees; press the auto-park pushbutton.
c. When the shoes reach top dead center they automatically “park” and the SHOES
PARKED signal light illuminates.
d. Return the WALK CONTROL LEVER to neutral.
NOTE: The walk machinery is designed to synchronize the movement of the two shoes.
However, a slight variation in the angular rotation of the walk shafts may be noticed
during the walk cycle. This may be caused by uneven terrain or differences in load
bearing conditions beneath the shoes. Should the angle between the two shafts
become excessive, the walk machinery automatically stops. Press the WALK EXCESS
ERROR OVERRIDE pushbutton to complete the step and bring the machine safely to
rest.

2.5.4 Direction of Walking

Walking direction is controlled by rotating the machinery house and boom about the base. This
can only be done when the shoes are in the “parked” position (top dead center).
1. Ensure the SHOES PARKED signal light is illuminated.
2. Select the “brake release” position on the SWING BRAKE selector switch. Ensure the
SWING BRAKE signal light is extinguished.
3. Operate the SWING MOTION PEDALS to rotate the machine in the desired direction.
4. Re-set the SWING BRAKE selector switch. Ensure the signal light illuminates.
5. Begin walking in the new direction.

2.5.4.1 Hoist
The hoist drum is rotated by operating the right-hand control lever. The lever has a notched
central (neutral) position. Pull the lever to raise the bucket and push the lever to lower the bucket.
The rate of rotation of the hoist drum is determined by the amount of movement of the control
lever from neutral.
A thumb operated pushbutton on the top of the lever is used to control the hoist rope tension. The
hoist rope is automatically kept under tension when the button is pressed, keeping the rigging
clear of the bucket while dragging.
The HOIST CONTROL LEVER is only operational when the shoes are parked. Before operating
the lever, make sure the HOIST BRAKE selector switch is in the “released” position and the
HOIST BRAKE signal light is extinguished.

2.5.4.2 Drag
Rotate the drag drum by operating the left-hand control lever. The lever has a notched central
(neutral) position.

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 Operation
Operating the Machine
• Pull the lever to drag the bucket
• Push the lever to pay out the drag rope
The drag drum’s rate of rotation is determined by the amount of movement of the control lever
from neutral.
To select drag motion (at the end of a walk cycle):
1. Ensure the shoes are in “parked” position, as indicated by SHOES PARKED signal light.
2. Ensure the GREASE PUMP STOPPED signal light is illuminated.
3. Ensure the GEAR SPRAY STOPPED signal light is illuminated.
4. Select “drag” mode using POWER TRANSFER switch; ensure the “drag” mode signal light
is illuminated.

Make sure the “grease pump stopped” and “gear spray stopped” lights are on before
operating the power transfer switch.

5. Ensure the DRAG/WALK BRAKE selector switch is in the “released” position.

The DRAG CONTROL LEVER is now operative.

2.5.4.3 Swing Motion

Swing motion is controlled by two pedals. They are mechanically coupled: when one pedal is
pushed down, the other lifts by an equal amount. Therefore, with both feet on the pedals, a push-
pull action is achieved, giving a positive feel to the swing motion. When both feet are removed
from the pedals, the pedals return to the neutral position.

2.5.4.3.1 Swing Procedure

1. Ensure the shoes are in the “parked” position (indicated by SHOES PARKED signal light).
2. Select “release” position with SWING BRAKE selector switch.
NOTE: The swing brake cannot be released unless the shoes are at top dead center.
3. Ensure the SWING BRAKE signal light is extinguished.
4. Operate the pedals to swing the machine:
• To swing right: push down the right pedal
• To swing left: push down the left pedal
• To stop swing: If swinging right, press the left pedal; if swinging left, press the right pedal.

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Operation
Operating Precautions

2.6 Operating Precautions

Best digging results are achieved by operating the machine on near level ground. However, it is
advisable to maintain an one-degree slope away from the cut to guard the machine against
hazardous ground conditions following heavy rain.
The arresting of any motion is accomplished by reversing the appropriate control lever or pedal.
It is important that under normal working conditions the motions are brought to rest in this
manner before applying the brakes.
“Hoist” and “drag” motions are fitted with limit switches to prevent over-winding in either direction.
While these switches are operative at all times, they are not intended for use as part of the
normal arresting procedure. Operators should therefore avoid using them as such, particular
attention being given to the “drag-in” limit switch. Unnecessary use of the limit switches causes
excessive brake wear and extends the cycle time.
Do not drop the bucket from a great height. Doing so might damage the bucket, dump sheave,
spreader bar and/or chains.
Do not drop the bucket flat on the ground. Doing so will damage the bottom of the bucket and
impair the digging angle of the lip and teeth.

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 Operation
Digging Cycle

2.7 Digging Cycle

For the purpose of these instructions, assume that the cycle starts with the bucket suspended
over the digging area (Figure 2-40, item A) and that all the motion procedures have been carried
out and the motion controls are now operative.
Lowering the bucket refer to Figure 2-40, item A.

Figure 2-40 Digging Cycle

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Operation
Digging Cycle
1. High speed lowering of the bucket is obtained by pushing the HOIST CONTROL LEVER
forward. However, the lever must be pulled back, through neutral, into the hoist position to
hinder the bucket motion sufficiently to prevent the bucket from striking the ground.
2. Use the DRAG CONTROL LEVER to ensure that the bucket is in a digging attitude when it
reaches the ground.
Filling the bucket refer to Figure 2-40, item B.
3. As soon as the bucket reaches the ground, in a digging attitude, return the HOIST
CONTROL LEVER to neutral; at the same time pull the DRAG CONTROL LEVER to drag
the bucket in. While the bucket is filling it is important to keep the spreader bar clear of the
bucket by maintaining a slight tension in the hoist rope. This can be achieved by using the
ROPE TENSION lever.
Lifting the loaded bucket and swinging to dump refer to Figure 2-40, item C.
4. Pull the HOIST CONTROL LEVER back from the neutral position to raise the bucket. At the
same time, keep the DRAG CONTROL LEVER marginally in the drag-in position (to prevent
the loaded bucket pulling the drag rope from the drum, which would result in spilling).
Use the HOIST and DRAG CONTROL LEVERS simultaneously, to ensure that the load is
carried to the dump position without undue spillage. Carefully balance the tension in the
drag rope against the lift of the hoist rope. Too much slack will cause the bucket to dump
prematurely; too much tension will increase the load on the hoist rope and bring the bucket
too close to the underside of the boom.
5. While the bucket is being hoisted, swing the machine, as necessary, to reposition the
bucket for discharging.
Discharging the load refer to Figure 2-40, item D.
6. Discharge the load by gradually pushing forward the DRAG CONTROL LEVER to release
the drag rope tension and lower the front of the bucket. This operation should be started as
the bucket approaches the dump site.
Returning to the digging site
7. Swing the machine back over the digging site and lower the bucket, as previously
described, to start the next cycle.

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 Operation
Operating Techniques

2.8 Operating Techniques

Dragline operating calls for a good sense of timing and much practice to become efficient.
To cut the cycle time, and so increase efficiency, some of the stages of the cycle may be
combined. It may be practicable to dump the load while still swinging and similarly to lower the
bucket during the return swing movement.
Carry the bucket in the lowest possible path between digging and dumping positions.
When digging, lift the bucket clear of the face as soon as it is filled. Time and effort is wasted by
allowing the material to “boil” over the back of the bucket.

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CETI CAMPUS
BASIC DUMPER TRAINING PROGRAM, CETI
79 BATCH (13.05.2019 – 25.05.2019)
TH

In the centre pic,

SHRI RAJASEKHAR KOTTURI, GM (HRD), NCL (middle)
SHRI ABHAY PAL, MANAGER (MINING), CETI (right)

CENTRAL EXCAVATION TRAINING INSTITUTE (C.E.T.I)

NORTHERN COALFIELDS LIMITED
SINGRAULI (M.P.)