Promax RR 14 EVO 2 400 Hybrid Installation and operation manual

PAMP020RR Revision Record
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December 2019 RR 14 EVO 2 400 Hybrid
Promax RR 14 EVO 2 400 Hybrid
RAIL MOUNTED MOBILE ELEVATING WORK PLATFORM
OPERATING & MAINTENANCE MANUAL
To be read in conjunction with:
 Platform Basket Use & Maintenance Manual, Logbook code: 4528576300.0,
Edition 11/2019
 Platform Basket Appendix of the Use & Maintenance Manual (Lithium Batteries
Version RR), Logbook code: 4528575300.0, Version 08/2019
PAMP020RR
ISSUED FOR: PB __________
Revision Two - 4th December 2019

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Revision
Date
Comments
1
12
/
11
/201
9
First Issue
–
reference RIS
-
1530
-
PLT
Issue 6
2
04/12/2019
Second issue
–
include notes/general guidance section to clarify details
that do not have a relevant section
Signed
Date
Author:
M.Caves
/ /
Technical Director
Approved by:
S.Day
/ /
Managing Director

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Document Review
The maintenance plan shall be reviewed every 12 months by a competent engineer.
The plan shall include:
A process for it to be regularly reviewed for potential to improve its effectiveness.
A process for a record to be kept of decisions taken at each review.
A process for the maintenance instruction to also be reviewed in the light of the following:
i) In process reviews of maintenance activities
ii) Performance of the machines and components covered by the instruction, including relevant
national incident reports
iii) Changes in the pattern of use and operating environment
iv) Manufacturer’s advice
v) Network Rail directives
vi) As part of the seven-year review of the machine
vii) Fault logs and GE/RT8250 NIRs
A key element in the development of a successful maintenance instruction is a commitment to review regularly
both the frequency and content of each job description. A nominated competent engineer identified by the
owner should review the maintenance instruction, as a minimum, every 12 months, and the records retained
for audit purposes.
Each component failure should be assessed to establish if there is a failure of maintenance that either caused
or contributed to the failure. The maintenance instruction should then be amended to reflect the lessons
learnt.
Regular reviews of the performance of the machine, reviews of maintenance activities, changes of use or
frequency of use of the machine, and external information, could all lead to changes in the instruction.
Each change of the instruction should be authorised by a nominated competent engineer and, where
reasonably practicable, the change should be agreed by the OEM. The amended instruction needs to be re-
certificated. It is recommended that the instruction is kept as a live document, with each change authorised by
the competent engineer, who should decide if the amendment is serious (and requires recertification
immediately), or whether several changes can be bundled together and re-certificated at an annual review.
The users of the maintenance instruction should be encouraged to contribute to the review process.

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Contents
Section 1 ........................................................................................................................................................................... 6
Foreword ...................................................................................................................................................................... 6
Staff Competency ......................................................................................................................................................... 7
Facilities ........................................................................................................................................................................ 7
Definitions .................................................................................................................................................................... 8
Section 2 ........................................................................................................................................................................... 9
Introduction.................................................................................................................................................................. 9
Section 3 .........................................................................................................................................................................10
Specifications..............................................................................................................................................................10
Section 4 .........................................................................................................................................................................10
General Safety and Operating Good practice ............................................................................................................10
Section 5 .........................................................................................................................................................................10
Controls, layout and locations ....................................................................................................................................10
Section 6 .........................................................................................................................................................................10
Devices, locations and descriptions ...........................................................................................................................10
Section 7 .........................................................................................................................................................................11
Electrical Circuit and Hydraulic Diagrams ..................................................................................................................11
Fuses / electrical trips.................................................................................................................................................11
Electric Circuit Diagrams ............................................................................................................................................12
Hydraulic Circuit Diagrams .........................................................................................................................................46
Section 8 .........................................................................................................................................................................47
ALO Working procedure .............................................................................................................................................47
Section 9 .........................................................................................................................................................................48
Emergency recovery procedure(s) and times ............................................................................................................48
Recovering aerial parts into gauge (travelling mode)............................................................................................48
Off tracking machine from rail using RRAP ............................................................................................................48
Section 10 .......................................................................................................................................................................49
Maintenance ..............................................................................................................................................................49
Safe Working Practice ............................................................................................................................................49
Warning – Fluids ....................................................................................................................................................49
Warning-Hydraulic Connections ............................................................................................................................49
Hydraulic Hoses .....................................................................................................................................................49
Warning - Batteries ................................................................................................................................................49
Warning - Welding .................................................................................................................................................50
Threaded Fasteners ...............................................................................................................................................50
Tightening of Threaded Fasteners .........................................................................................................................50

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Preparing For Maintenance ...................................................................................................................................50
Information and Reference on how to perform maintenance tasks .....................................................................50
Section 11 .......................................................................................................................................................................51
Maintenance Schedules .............................................................................................................................................51
Job No. – EngCheck (Engine general condition) ....................................................................................................54
Job No. – EngDPFC (Engine DPF) ............................................................................................................................54
Job No. – HydCheck (Hydraulic fluid leak check) ...................................................................................................54
Job No. – ElecLC (Lighting check) ...........................................................................................................................55
Job No. – ElecHC (Horn check) ...............................................................................................................................55
Job No. – ElecHT (Horn test) ..................................................................................................................................55
Job No. – ElecEBT (Earth bond test) ......................................................................................................................56
Job No. – ChasRTC (Recovery towbar check) .........................................................................................................56
Job No. – ChasWTC (Wheels & Tyres check) .........................................................................................................56
Job No. – ChasRWC (Rail wheel check) ..................................................................................................................56
Job No. – ChasRWE (Rail wheel examine) .............................................................................................................57
Job No. – ChasRSC (Rail sweeper check)................................................................................................................58
Job No. – ChasBTBG (Back to back gauge) .............................................................................................................58
Job No. – ChasSBT (Service brake test) ..................................................................................................................58
Job No. – ChasPBT (Parking brake test) .................................................................................................................59
Job No. – OLET (OLE system test) ..........................................................................................................................60
Job No. – ALOT (ALO system test) .........................................................................................................................61
Section 12 .......................................................................................................................................................................62
Trailers ........................................................................................................................................................................62
Coupling/uncoupling ..................................................................................................................................................62
Section 13 .......................................................................................................................................................................63
Nominal wheel weights ..............................................................................................................................................63
Section 14 .......................................................................................................................................................................64
Dataloggers ................................................................................................................................................................64
Section 15 .......................................................................................................................................................................65
Records .......................................................................................................................................................................65
Brake test: ..............................................................................................................................................................65
Horn Test: ..............................................................................................................................................................67
Earth bond test: .....................................................................................................................................................69
Limitations ......................................................................................................................................................................70
ECC..............................................................................................................................................................................70

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Section 1
Foreword
As specialist equipment suppliers, Promax Access Ltd actively promote safety in the operation and
maintenance of its machines. We take great care to increase safety awareness and implement good working
practice.
This manual has been written to provide the information necessary to keep the RR 14 EVO 2-400 Hyrbid
operating safely and efficiently throughout its service life, and should be read and used in conjunction with
Platform Basket Use & Maintenance Manual, Logbook code: 4528576300.0, Edition 11/2019 and Platform
Basket Appendix of the Use & Maintenance Manual (Lithium Batteries Version RR), Logbook code:
4528575300.0, Version 08/2019.
This manual is intended for both new and experienced personnel. It should remain with the machine at all
times. All personnel should be aware of its location and contents.
It is important that all personnel are fully trained and familiar with the machine and that they have read and
understood the information contained within this manual before operating within the site conditions for which
the machine was designed and constructed.
This manual details practices and operations that Promax Access Ltd and IPAF (International Powered Access
Federation) recommend.
DO NOT operate or use this machine for any purpose other than lifting persons or as detailed within the
manual.
Prior to Commencing Maintenance Work You Must:
Read and fully understand the manufacturer's use and maintenance manual.
Ensure that any required safety precautions have been taken.
Adhere to safety notices contained within this manual and at the work site.
Fully understand the method statements and risk assessments and be competent to perform the work.
Use only genuine spare parts as replacement items.
Ensure that after maintenance work has been completed, and prior to machine being used, all safety checks
and tests have been completed.
In accordance with their policy of continuous development Promax Access Ltd. reserve
the right to amend the specifications of its machines without prior notice or consent.
Promax Access Ltd. does not accept liability for: -
1. Any machines, incidents or accidents arising from modifications, alterations or repairs carried out
without written approval and consent from Promax Access Ltd, or the manufacturer.
2. Machines not maintained in accordance with the conditions of operation and maintenance as specified
within this manual
3. Breach of any relevant guidelines or regulations.
4. Damage or injury (whether direct or consequential) resulting from ignorance or failure to comply with
any of the above items.
Please contact Promax Access Limited, Barnsley, S72 7BD on 01226 716657 or by email at
[email protected] if you have any queries regarding the operation and maintenance of the RR 14
EVO 2 400 Hybrid Mobile Elevation Work Platform (MEWP).

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Staff Competency
In order to comply with the requirements of RIS-1530-PLT, the following minimum level of competence
required is:
For all activities the person leading the task must be able to follow and carry out the instruction detailed in this
document.
All safety critical work must be carried out by persons competent in accordance with:
ORR Railway Safety Publication 1 "Developing and Maintaining Staff Competence" March 2007.
All work relating to the maintenance and overhaul of axle bearings should be carried out by competent
persons.
Staff undertaking this work must have been trained and hold the following certificates of competency:
SCWID (Safety Critical Work Identification).
Apprentice trained Craftsman/NVQ Level 3 in plant maintenance.
Certificate issued by a CITB/CTA approved body – operation for maintenance purposes only.
Re-assessment of competency in accordance with operator’s maintenance policy.
Facilities
In order to comply with the requirements of RIS-1530-PLT, all work described in section nine shall be carried
out using facilities (including those of sub contractors) which as a minimum have the following:
Clean, dry, covered accommodation for dealing with wheelsets, bearings, mechanical, hydraulic, electrical
components and systems. Adequate illumination for inspection of components, rail axles and underframes.
Cleaning facilities that will not cause damage to the components.
Handling facilities for removal and refitting of components such as rail axles and engines.
All weather of vulnerable areas of the vehicle and its components.
A suitable length of straight level rail track for carrying out brake tests.
These maintenance activities may be carried out at any location, where the work area is correctly protected,
sufficient clearance is available around the machine and movements will not present risks to other staff and
the machine is correctly secured against movement. Ensure all oil, grease and other fluid containers or
contaminated materials are stored or disposed of as per the relevant procedures. Any specific requirements
over and above those listed will be identified in the applicable job descriptions or section nine.
Auditable records of maintenance to this manual shall be kept in accordance with RIS-1530-PLT Issue 6.

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Definitions
Term
Action required
Adjust
Correct to defined limits
Change
Remove the original and fit a new or overhauled part or assembly in its place
Check
Determine a particular nominated condition before, during, or after repair, for example
completeness, security, position
Clean
Remove all dirt and deposits
Defective
Any fault or faults in a component or assembly, for example structural fractures or
weld
fractures, which may prevent the component or assembly from fulfilling its designed
purpose
Dismantle
Take to pieces
Examine
Determine general condition before repair, for example wear, cracks, splits, leaks, scoring,
erosion, breaks, distortion, looseness
Gauge
Determine a nominated dimension by using suitable measuring equipment, for example
ruler, micrometer, callipers, feeler gauges or Go / No-Go gauge
Inspect
Determine general condition after repair and attention, that is to say, conformity to
required standards
Lubricate
Apply lubricant
Overhaul
Do what is necessary to make an assembly or sub
-
assembly reusable, that is to say,
dismantle, strip, clean, examine, fit new parts, repair, reassemble, test and inspect, as
required
Paint
To impart colour to a surface
Re
-
assemble
Put together
Record
Put down in writing a finding from examination, test, inspection or special checks
Rectify
To set right
Refit
Put back and reconnect
Remove
Disconnect and take off
Renew
Remove, scrap the original part and put a new part in its place
Repair
Restore an original part to the required condition by hand tooling, machining, build
-
up,
welding, patching, bending, setting, heat-treating, re-securing etc
Strip
Remove covering, that is to say, paint, polish, fabric
Test
Prove correct operation by
trial

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Section 2
Introduction
The Promax RR 14 EVO 2-400 Hybrid is designed to operate in a railway or construction environment to
facilitate the lifting of persons and associated tools - A maximum of three personnel plus tools and equipment
(400kgs combined) may be carried in the platform on rail to maximum 200 mm cant and at maximum 1:16
gradient.
See page 30, sect '3' Technical Specification of Platform Basket Use & Maintenance Manual, Logbook code:
4528576300.0, Edition 11/2019 for height and reach etc and/or working diagrams attached to machine.
The machine is designed and built to be able to on and off track at any designated RRAP.
This machine is suitable for use under the live OLE when used in conjunction with a safe system of work
determined and authorised in accordance with the requirements of GE/RT8024
With the Platform fully stowed (telescope fully retracted, main boom down and turret inline /in-gauge the RR
14 EVO will travel at maximum allowable rail speed for this class of RRV.
MEWPs are not intended for use as cranes and must not be used for lifting or suspending loads other than
persons and small tools, wire pulling etc.
The RR 14 EVO is able to travel in working mode while elevated or slewed out of the stowed position
(telescopic boom fully retracted) while maintaining floating / oscillating axle -whilst the MEWP is travelling with
the boom in an un-stowed configuration, the machine is to proceed at walking speed and ground staff control
the movement in reverse until the superstructure can be slewed to face direction of travel.
Emergency stopping devices shall not be used for stopping normally and should only be used in emergency
situations. Activation of an emergency stop button will turn off all electrical power to the machine (including all
machine lighting), de-energise the engine fuel valve (which should shut down the engine) and disable all
controls of the machine.
This RRV has electrical / electronic equipment sited at various locations around the vehicle including chassis
and railgear. Electrical equipment such as sockets and modules cannot be totally sealed against against
water ingress during immersion or high pressure washing.
Do Not operate the RRV with the wheels in water above the hub/axle level.
Do Not direct high pressure water onto switches, sensors, slip rings, plugs, sockets, panels or electronic
modules.
Limitations as per engineering conformance certificate.
This manual should be read in conjunction with the following documents:
Platform Basket Use & Maintenance Manual, Logbook code: 4528576300.0, Edition 11/2019.
Platform Basket Appendix of the Use & Maintenance Manual (Lithium Batteries Version RR), Logbook code:
4528575300.0, Version 08/2019.
BEFORE OPERATING, MAINTAINING or LOADING / UNLOADING ENSURE YOU ARE FULLY FAMILIAR WITH ITS
CORRECT OPERATION AND FULLY UNDERSTOOD THE OPERATING MANUAL. FAILURE TO DO SO MAY RESULT IN
DEATH OR SERIOUS INJURY.

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Section 3
Specifications
Please refer to Section '3' pages 30-40, Technical specification in the Platform Basket Use & Maintenance
Manual, Logbook code: 4528576300.0, Edition 11/2019 for lengths, weights, reach etc
Section 4
General Safety and Operating Good practice
Refer to section '4', pages 41-52 of Platform Basket Use & Maintenance Manual, Logbook code: 4528576300.0,
Edition 11/2019.
Section 5
Controls, layout and locations
Refer to section '5', pages 53-62 of Platform Basket Use & Maintenance Manual, Logbook code: 4528576300.0,
Edition 11/2019.
Exhaust outlet position is not identified in the manual mentioned above. For safety purposes, the exhaust
outlet position is identified in the image below:
Section 6
Devices, locations and descriptions
Section '6' pages 63-75. Platform Basket Use & Maintenance Manual, Logbook code: 4528576300.0, Edition
11/2019 gives detailed description of limit switches, pins and indicators etc. their location, designation and use.