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Dragline Operations Manitowoc 3000

Dragline Operations Manitowoc 3000
Pre-Op Set Up to Dig Abnormal Conditions Shut Down Procedures Operation
1. Pre-Op
work area examination
perform self assessment
check mental condition
check physical condition
use personal protection equipment
Approach Inspection
check crawlers
check wire ropes
Check Sheaves
Check Pendant Lines and boom
Check Ground Conditions
check for overhead & underground powerlines and utilities
Check for loose, missing or broken parts
check weather conditions
check for fresh fluid leaks (coolant, oil, etc)
check for signs of unknown activity
check for human or vehicle tracks
determine if maintenance work had been done or unauthorized activities
check glass
Daily Inspection
check crawlers
Cracked or welded pads
check keeper pins which are located at the end of the hinge pin between the pads.
check for kinks or loose travel chains
check the sprockets and rollers for wear, alignment, and/or missing teeth
check for safe access (clean crawler track if needed)
check car body
check for cracked or welded parts
check for fluid leaks
check for and clean off excess dirt and grease
check for cracks
open drains for oil sumps to drain water
check house rollers
check for wear, spider cracks, scaling, flat spots, and bearing pieces
check for the lack of lubrication
close air tank from the prior shift
check if wire rope is spooling straight on drums
check condition of wire rope
refer to rope retirement criteria
30 CFR Subpart R
check fairlead
check rollers, sheaves, alignment, lubrication fittings, mounting bolts, keepers
check condition of crane mats if used
check the condition of the sheet metal
check entire cab and the condition of door and track assembly
check grab iron
check for obstructions in the tail swing area
Pre Engine Start
Open the door
Check fire extinguisher
Check fluid levels
diesel fuel
engine oil
coolant
chain cases
sump oil
air compressor oil level
gasoline level
alcohol evaporator
Check belts for tension
engine
air compresser
sump pump (gear lube)
kuno filter needs a full turn every day
Check chain guard
Check fan shroud
Check air compressor belt guard
Check drum guards
boom hoist
hoist line
dragline
Check for lock out / tag out as applies
Check control levers are in neutral position
Hoist, Boom, Swing & Master Clutch
Check master clutch is disengaged
Adjust throttle
Make sure it is not full throttle
Start Engine
turn key and start engine
check for leaks
permit/allow air pressure to build up to full operating pressure
check oil pressure
check for operators manual and load charts
bring engine temperature up to a safe operating temperature
engage master clutch
maintain a low idle prior to slowly engaging
only after operating temperatures have been reached
check boom, hoist, and drag brakes and clutches
Check boom first
Boom up while holding brake on
Boom down while lightly applying brake to warm it up
Dry brake lining to prevent slippage
lower boom to the ground
swing to side of bucket placing boom on cribbing to reduce strain on boom pendant lines
set brakes and place levers in neutral position
never leave the seat with the master clutch engaged !!
disengage master clutch
inspect boom
bent, broken, or missing lacing, and damaged cords
bolts & pin connections
keepers
attachments
rollers and wire rope guides
sheaves (guards, chips, cracks, wear, damage, lubrication, bearings, alignment, & missing sheave)
boom angle indicator (free moving & correct calibration)
pendant lines (broken wires, pins and keepers are intact, rust, wear, lubrication, and defects)
equalizer (pins and keepers are intact & check sheaves)
boom hoist wire rope (broken wires & strands, rust, wear, lubrication, & other defects)
boom stops
gantry (pins, keepers, sheaves, lubrication, and other damage)
inspect bucket
teeth
hoist chains above and below the spreader bar
spreader bar
hoist clevis, pins, and keepers
dump (trip) sheave assembly
trunions
drag yokes (frog)
drag hitch clevises
all other components
raise the boom
set to desired boom angle
dry the hoist and drag brakes
run wire rope up and down with the brakes lightly applied to dry the brakes
raise bucket
swing machine side to side to dry the swing clutches
Pre Shift Meeting
listen to supervisor instructions
plan daily operations
traffic patterns
haul road maintenance
personal protective equipment
material blending
discuss any change in conditions
participate in daily safety meeting
2. Set Up to Dig
examine the site
mats and cribbing needed
travel route
soil conditions
any changes from previous shift
re-check swing radius
mount dragline
discuss mounting and dismounting safety
disengage travel dogs
If located on a hill, do not disengage travel dogs until ready to travel.
engage master clutch
place boom at a proper angle for travel
engage travel clutches
ensure the drive chains are located away from the digging end
travel onto the mats
center dragline on mats
make sure the idlers are not at the seam of two mats
chock/block the tracks in front of dragline
engage directional travel lock to prevent over travel toward excavation site
ensure dragline is level
3. Abnormal Conditions
weather
be aware of company policy
lightning
wind
precipitation
caved in bank
medical emergencies
basic first aid procedures
be aware of company communication system and policy
know where first aid kits are located
malfunction of machine
fire
catastrophic machine failure
4. Shut Down Procedures
remove bucket out of water
disengage travel locks
check boom angle
adjust boom angle for travel
swing to the direction of travel
move dragline into stable position
swing dragline to position for safe cab access
position bucket on ground or crib blocks
engage all brakes
disengage master clutch
never leave the seat without disengaging the master clutch!
allow engine to cool down at idle speed
shut off engine
dismount
engage travel locks
drain air tank
lubricate to manufacturer's specifications
re-examine site
5. Operation
re-examine conditions
determine the depth of the cut
How to:
lower bucket to the bottom
raise bucket slightly
gingerly sweep back and forth to determine depth and location of material
test various radius
start working the cut
dig within the front quadrant
DO NOT UNDERCUT!!
monitor ground conditions continuously while digging
monitor the dragline
engine gauges
listen for abnormal sounds
bucket conditions
wire rope condition
boom connections
wire rope alignment
sheaves
fairleads



build and monitor stockpile
slope for proper drainage
ensure proper placement
prepare for shutdown