Diesel Suspended Monorail Locomotive operating procedures

I. Job Requirements

 Monorail Locomotive drivers must undergo professional training, pass the exam, and obtain an operator qualification certificate before they can take up their duties.

Drivers must be fully familiar with the performance parameters, structural principles, and standard operating procedures of Monorail Locomotivess and possess basic emergency response capabilities.

Drivers must be in good physical condition and must not suffer from any medical conditions that could hinder underground operations (such as hypertension or epilepsy). This ensures accurate judgment and operation during operations.

II. Safety Regulations

Alcohol consumption is strictly prohibited before work. During work, drivers must not leave their posts, sleep, or engage in activities unrelated to their duties without permission. Shift handover and job responsibility systems must be strictly implemented, and the "Coal Mine Safety Regulations" and relevant regulations for underground operations must be fully complied with.

Operation must be conducted with valid certification. Unlicensed operation or unlicensed personnel are strictly prohibited.

During transportation, drivers must continuously monitor the track condition. If any problems, such as deformation, looseness, or obstructions, are detected, the driver must immediately stop the vehicle and address them. If the problem cannot be resolved on-site, the driver must promptly report it and wait until the hazard has been eliminated before continuing operations. Risky operation with potential hazards is strictly prohibited. .The driver needs to undergo a special physical examination every year. If the physical examination results do not meet the job requirements, he must be transferred to another position immediately to prevent safety accidents caused by physical reasons. .Monorail Locomotivess must undergo annual inspections in accordance with regulations. Equipment that fails the annual inspection is strictly prohibited from being put into use and must be rectified and qualified before it can be reactivated. .During operation, the driver must complete all operations in the cab. It is strictly prohibited to operate the locomotive outside the cab to prevent accidental falls or collisions with equipment. .

III. Operation preparation .

1. Static inspection .

(1) Check the integrity of the locomotive connection device, load wheels, guide wheels and drive wheels to ensure that there is no looseness, deformation or breakage.

(2) Focus on checking the wear of the drive wheel rubber. When the wear exceeds the specified limit, it must be replaced immediately to avoid affecting driving safety due to insufficient friction.

(3) Measure the thickness of the brake lining. If it is less than the design standard, it is necessary to replace the new lining in time to ensure reliable braking effect.

 (4) Check whether the brake pads are complete. If any are missing or damaged, they must be replaced on the spot. It is strictly forbidden to operate with defects.

 (5) Check the oil levels of diesel engine lubricating oil, hydraulic oil, cooling water, fuel oil and diesel oil, as well as the water level of the exhaust gas cooling box, to ensure that they are all within the specified scale range; if they are lower than the standard, the corresponding medium must be added to the qualified position. When replacing the cooling water, personnel should keep a distance of more than 1 meter from the water hole to prevent high-temperature waste water from spraying out and causing burns.

(6) Check whether there are any leaks in the hydraulic system pipes and joints. If any problems are found, notify the maintenance personnel immediately for processing. It is strictly forbidden to operate under pressure or disassemble by yourself.

 (7) Check the circuit lines and plug connection status to ensure that the cables are not damaged or exposed, eliminate explosion phenomena, and avoid the risk of gas explosion.

2. Dynamic inspection

 (1) After starting, observe the color of the diesel engine exhaust gas (normal is light gray), listen to whether the running sound is stable, and confirm that the data displayed on each instrument and the status of the indicator light are normal.​

(2) Test the locomotive lighting, horn and taillight functions to ensure that the lights are bright and the horn sounds clear, meeting the underground signal transmission requirements. ​

(3) Check the working status of the lifting motor and operating valve, lift and lower the hook several times without load, and confirm that the motor sprocket runs flexibly and the hook moves smoothly without jamming or abnormal noise. ​

(4) Test the working pressure of the brake to ensure that it meets the rated standard and can quickly lock the track during emergency braking without delay or failure. ​

(5) Verify the effectiveness of various locomotive protection devices (such as stall protection, explosion protection, etc.) to ensure that they can respond automatically when triggered. ​

(6) Check the integrity of lifting tools (including lifting chains, container clamps, etc.). The chain must not have cracks and the clamps must be closed firmly. If damaged, replace them immediately. ​

Note: If any problems are found during static or dynamic inspections, they must be notified to the maintenance personnel for processing or reporting. Operations can only be started after the hidden dangers are completely eliminated.​

IV. Normal Operation ​

1. Locomotive Start ​

(1) Open the accumulator ball valve and stop when the hydraulic accumulator pressure reaches 150 bar. ​

(2) Press the "manual start relief valve" with your left hand to activate the starting compensation valve and simultaneously open the stop valve and air valve cylinder; press the "start valve" with your right hand. ​

(3) Insert the ignition key into the switch and turn the operating handle to the left position. ​

(4) At this time, the brake exhaust valve is automatically activated and a functional test is performed. At the same time, the pressure is measured and the brake lock is turned on. Accompanied by a 3-second voice alarm prompt, the pre-start warning is completed. ​

(5) Observe the brake air pressure display in the cab (the green LED light is always on for normal operation). After confirming that it is correct, push the operating handle in the direction of operation (forward/backward) and start the locomotive. By adjusting the displacement of the operating handle to control the proportional valve, the diesel engine speed is increased or decreased, completing the acceleration and deceleration operation.

2. Material loading and reversing

 (1) When pushing a cart manually, only one cart is allowed at a time. The pusher must stand behind the vehicle in the forward direction. When pushing an ordinary vehicle, one hand should hold the vertical edge of the vehicle and the other hand should be placed on the back of the vehicle. When pushing a float or flatbed truck, both hands should be held tightly to the vertical frame. The pusher should observe the surrounding environment throughout the process to avoid collisions with roadway facilities or personnel.

(2) When pushing a cart in a double-track area of the parking lot, the vehicle parked on the other track must be secured with a car blocker. No part of the pusher's body should exceed 0.2 meters from the side of the vehicle being pushed. It is strictly forbidden to push the cart on both sides of the vehicle to prevent it from being squeezed by other vehicles.

(3) When pushing carts in the same direction, if the slope is less than 5‰, the distance between the two carts should be ≥10 meters; if the slope is 5‰-7‰, the distance should be ≥30 meters; if the slope is greater than 7‰, manual pushing is strictly prohibited and mechanical traction should be used instead.​

(4) After the vehicle is in place, a special car blocker must be used to support the material vehicle in both directions in front and behind. At the same time, a car blocker must be set up 5 meters in front of the transfer point in the yard to prevent other vehicles from entering the transfer area by mistake. ​

(5) It is strictly prohibited to push the vehicle manually on the line beyond the yard section to avoid accidents caused by narrow lanes or obstructed vision. ​

3. Transferring between Monorail Locomotives and rail-car or flatbed truck ​

(1) Before transferring, a dedicated person must be set up to monitor or turn on the red warning light 10 meters in front and behind the operation point. It is strictly prohibited for unrelated vehicles and personnel to enter the operation area. ​

(2) When transferring with a rail-car, the rail-car must be stopped and the start button turned off; when transferring with a flatbed, the flatbed must be firmly supported with a car blocker to prevent it from slipping. The transfer operation can only begin after the Monorail Locomotives moves to the top of the corresponding vehicle.

(3) Adjust the hook position according to the length of the material to be hoisted. When the lifting chain is strained, non-operating personnel must evacuate to the safe area of the platform outside the transfer station. It is strictly forbidden to stand inside the transfer station, on the flatbed truck, or directly under the material. Operators must ensure that they have enough space to avoid, and a dedicated person must monitor the lifting process throughout.

(4) Before the Monorail Locomotives enters the yard and transfers from the ground track, the yard electric locomotive and rail car must stop running. It is strictly forbidden to stay within 1.5 meters on both sides of the lifting beam. When crossing the electric locomotive or rail car, the minimum distance between the two cars (including the materials on the car) must be ≥200 meters to prevent collision.

 (5) During the transfer, if the material is lifted 200mm and has an unstable center of gravity and tends to overturn, the lifting must be stopped immediately and slowly lowered. A dedicated person must correct the center of gravity before re-lifting. It is strictly forbidden to maintain balance by dangerous methods such as "lifting the box".

 4. Lifting operation

 (1) Remove the ignition key and use a special lifting tool to fix the material. When pulling the lifting handle (chain), apply force slowly to avoid the material falling off due to impact.

(2) During the lifting process, the lifting chain and clamps must be straightened. Personnel must not stand within 1 meter on either side of the material to prevent chain breakage or clamp slippage and cause injury.

(3) The lifting load must comply with the lifting beam tonnage regulations. Overloading is strictly prohibited (the load can be confirmed to be within the limit through the instrument display).

(4) When lifting containers, special container clamps should be used first; if there are cracks in the clamps at both ends of the container, it must be directly lifted using the lifting chain. After lifting, if the container tilts too much (there is a risk of overturning), it must be lowered and readjusted. It is strictly prohibited for personnel to climb the container to balance.

 (5) The upper edge of the container or a single piece of material must be kept 10-20cm away from the lower plane of the lifting beam. The container clamp must be completely closed and locked to prevent it from falling off during transportation.​

(6) The load on the two hooks should be reasonably distributed according to the characteristics of the equipment to ensure that the lifting beam is evenly stressed. The distance between the material and the bottom plate should be ≥300mm to avoid scraping the bottom of the tunnel. ​

(7) When lifting equipment, it must be kept horizontal, stable and firm. The lifting point should avoid the protruding parts of the equipment and vulnerable parts (such as instruments, pipe interfaces, etc.) to prevent damage to the equipment. ​

(8) When transporting special large equipment, only one piece can be transported at a time. The bottom surface of the equipment must be kept parallel to the bottom plate of the tunnel, and the distance should be controlled within 100-200mm. ​

5. Locomotive operation ​

(1) Each locomotive must be equipped with two drivers, one in the front and one in the rear cab: the main driver is responsible for operating the locomotive, and the assistant driver (follower) monitors the track status, equipment operation and surrounding environment throughout the process. If any abnormality is found, the main driver will be notified to stop the vehicle immediately. ​

(2) After starting, run at low speed for a few minutes. After all systems (hydraulic, braking, etc.) enter a stable state, then slowly accelerate to the rated speed.​

(3) When passing through special sections such as bends, air gates, switches, intersections, and transfer stations, the train must slow down and stop 30 meters in advance, and the train attendant must get off the train to supervise: ​

· When passing through air gates, the train attendant must first open the air gate and hang the air gate hook, switch the switch to the correct position, perform "finger-to-mouth" confirmation, and then signal the driver to drive through; after the locomotive has completely passed, the train attendant must immediately close the air gate. It is strictly forbidden to open two air gates at the same time, and it is not allowed to stand between the two air gates. ​

· When passing through a switch, the train attendant must stand 0.5 meters outside the switch curve to prevent being scratched by the locomotive. ​

· When operating in the above sections, the speed of unloaded or hoisting general equipment is ≤1m/s, and the speed of hoisting large (heavy) equipment is ≤0.5m/s.

 (4) When the vehicle is parked in the tunnel for more than 20 minutes, the engine must be turned off; when the driver needs to leave the locomotive within 20 meters, the locomotive brake must be locked to prevent the vehicle from slipping.

(5) Before leaving the cab, the driver must remove the ignition key and keep it properly. It is strictly forbidden to leave the key in the vehicle.

(6) When transporting equipment in the chute, strictly implement the "vehicles are driving, not pedestrians" rule: when passing through intersections, bends, or encountering pedestrians, sound the horn 30 meters in advance, control the speed to less than 0.5m/s and pass slowly to ensure that pedestrians are in place.

 (7) The locomotive must maintain "front lighting and rear red tail lights". The brightness of the lights must be clearly visible within 50 meters to ensure that vehicles and personnel in front and behind can be identified in time.

 (8) During transportation, except for sudden dangers (such as track breakage, personnel intrusion, etc.), it is strictly forbidden to use the emergency stop function to avoid material falling or equipment damage due to emergency stops.​

(9) The driver must carry a portable gas detector with him to monitor the gas concentration in real time: when the concentration is ≥0.4%, he must stop the vehicle immediately, shut down the diesel engine, lock the locomotive, and all personnel must retreat to the main air intake tunnel and report to the dispatch room. ​

(10) The driver must operate in the forward direction from the cab. It is strictly forbidden to drive in the reverse direction or look out of the vehicle to observe. When two vehicles are running on the same track and in the same direction, the distance between them must be ≥100 meters to prevent rear-end collisions. ​

(11) During operation, close attention must be paid to the cables, communication lines, air ducts, fans, and air and water pipes hanging in the tunnel to ensure that they are kept at a safe distance from the locomotive and the materials they carry to avoid scratches and damage. ​

(12) When transporting across the equipment below, the distance between the bottom of the material and the equipment below must be greater than 200mm. Otherwise, the route must be adjusted or the equipment below must be removed before passing. ​

6. Locomotive Braking ​

(1) When parking normally, slowly retract the operating handle to gradually slow down the locomotive. After the handle returns to its original position, the braking system automatically takes effect and the vehicle is parked.​

(2) In case of emergency, immediately press the "Emergency Stop" button on the right side of the cab or operate the hydraulic mechanical brake lever to achieve forced locking. ​

7. Shutdown operation ​

Slowly retract the operating handle to slow the locomotive to a stop. After the handle returns to its original position, remove the ignition key, turn off the hydraulic accumulator, and finally press the "Stop button" to complete the shutdown of the entire machine. ​

V. Special operations ​

1. Measures for handling Monorail Locomotives locomotive derailment ​

(1) After derailment, immediately stop the locomotive and drop the loaded materials to the ground smoothly to prevent the center of gravity from shifting and expanding the scope of the accident. ​

(2) Check for injuries: If there are any injuries, immediately report to the on-duty team leader and the dispatch room, give priority to organizing rescue of the injured, and protect the scene at the same time. ​

(3) Investigate the cause of the derailment and the extent of damage to the equipment and locomotive, report in detail to the on-duty team leader and the accompanying team leader, and identify the fault point.​

(4) The team leader and the team leader shall organize and prepare the equipment for the track operation (such as fall chains, lifting chains, jacks, etc.) according to the on-site conditions, and ensure that the tool specifications match. ​

(5) The track operation must be directed on-site by the team leader or team leader, and the safety officer shall supervise the whole process: ​

· If the roadway beam is found to be damaged, immediately notify the on-duty team leader to contact the relevant team to repair and reinforce it. ​

· Set up a warning 40 meters before and after the accident point, and strictly prohibit non-operating personnel from entering the closed area. ​

(6) The track operation must be carried out using a fall chain. The fall chain suitable for the tonnage should be selected according to the weight of the equipment. The rope loop must not be replaced with lead wire. A special lifting chain must be used. If the lifting device is damaged or loose, it must be re-secured; if the track is severely deformed, it must be replaced before the track is put on. ​

(7) During the track operation, all operators must pay close attention to the stability of the roadway support and strictly abide by the standing regulations: Do not stand on the side where the locomotive may fall or overturn to prevent secondary accidents. (8) Operators must obey unified command and are strictly prohibited from operating without authorization or blindly. Ensure coordinated actions.

(9) Before going on the track, the electromechanical worker must fully check the vehicle's braking, driving and other major systems. Only after confirming that there are no faults can the vehicle be put on the track for operation.

(10) After the locomotive is on the track, it must be driven to a safe area and the locomotive's operating status and hidden dangers of the track and hoisting components must be checked again. Operation can only be resumed after the problems are solved.

(11) The site must be cleaned up in a timely manner, and tools, damaged parts, etc. must be moved to the designated location. No debris should be left behind that affects track traffic.

(12) After the accident is handled, it must be reported step by step in the order of "on-duty team leader → on-duty team leader → safety, transportation, and dispatching departments", and the handling process must be recorded simultaneously. (13) After get off work, the person responsible for the accident must go to the team headquarters or relevant departments to cooperate in the accident investigation. After clarifying the cause, targeted preventive measures must be formulated and all staff must be organized to study.

2. Measures for handling large equipment falling down the track

(1) After the equipment falls down the track, first place the equipment on the ground steadily and use lifting chains and wire ropes to tie it up in multiple directions to prevent parts from falling.

 (2) Use a fall chain of appropriate tonnage to fix the equipment to the tunnel support or stable structure to prevent the equipment from tipping over or falling and injuring people.

 (3) Use tools such as fall chains and jacks to place the equipment steadily on the bottom plate and use wooden wedges or car blockers to support and stabilize it to prevent secondary sliding.

(4) Repair the Monorail Locomotives and track according to the "Measures for Handling Locomotive Falling Down the Track". After inspecting the locomotive and confirming that there is no fault, lift the equipment again and transport it away from the accident site.

 (5) The entire process must be under the on-site command of the team leader and the team leader, and the safety officer must supervise. Illegal operation or simplified procedures are strictly prohibited.

3. Measures for Handling Locomotive Slipping Accidents

(1) If the locomotive is found to be slipping when going up or down a slope, the driver must immediately press the "Emergency Stop" button to trigger the emergency brake to lock the track.

(2) After braking, it is strictly forbidden to restart the locomotive. The accompanying electromechanical technician must be notified to conduct a comprehensive inspection of the brake block wear, the clamping force of the drive unit, the brake state, etc., and the locomotive can only be restarted after the hidden faults are eliminated. ​

(3) If the locomotive slips due to slippery tracks (such as wet weather or purification spray), the track must be treated with anti-skid measures (such as temporarily turning off the purification spray, laying dry sand, etc.), and the track friction must be restored before driving. ​

(4) If the locomotive or large equipment derails due to slipping, follow the "Measures for Handling Locomotive Derailment" and "Measures for Handling Large Equipment Derailment" step by step. ​

4. Towing a Faulty Monorail Locomotives ​

(1) If the faulty locomotive can be lifted, the loaded materials must be unloaded first to reduce the towing load. ​

(2) Turn off the diesel engine of the faulty locomotive and cut off the power output.

(3) Connecting the train: Use a special connecting rod to rigidly connect the faulty locomotive and the towing locomotive, ensuring that the connection is firm and not loose.

(4) Operate the faulty locomotive: Close the hydraulic accumulator and open the "clamping pressure ball valve", "manual pump conversion valve" and "brake exhaust valve" in sequence.

(5) Switch the short-circuit ball valve of the faulty locomotive's piston pump to the "short-circuit" position to avoid damage to the hydraulic system.

(6) The towing operation must be supervised on-site by the team leader, and 3 dedicated personnel are required to divide the work:

1 person is responsible for monitoring the status of the track and turnouts, and timely prompting obstacle avoidance;

1 person is responsible for monitoring the connection between the two vehicles to prevent uncoupling;

1 person is responsible for driving the towing locomotive. No one is allowed to stay in the cab of the faulty locomotive.

(7) After confirming that the materials have been unloaded, start the towing locomotive, control the speed within 1m/s, and tow the faulty locomotive smoothly to the maintenance chamber.