Rail-Ability RA400 User manual

DRAFT Operator’s Manual
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Part no. RAMAX400-001
Issue 1 November 2014
Original Instructions (English)
****DRAFT****
Operator’s Manual
RA400 Rail-Max
Tracked Excavator

DRAFT Operator’s Manual
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CONTENTS Page
1Introduction.....................................................................................................................5
2Description and Intended Use.........................................................................................6
3Limitations......................................................................................................................6
4Manuals..........................................................................................................................7
5Decal Legend.................................................................................................................8
6Safety Rules...................................................................................................................9
6.1 General...................................................................................................................9
6.2 Electrocution Hazards.............................................................................................9
6.3 Travel Hazards .....................................................................................................11
6.4 Tip-over Hazards ..................................................................................................11
6.5 Fall Hazards..........................................................................................................12
6.6 Collision Hazards..................................................................................................12
6.7 Crushing Hazards.................................................................................................12
6.8 Explosion and Fire Hazards..................................................................................12
6.9 Burn Hazards........................................................................................................13
6.10 Bodily Injury Hazards............................................................................................13
6.11 Lifting Hazard........................................................................................................13
6.12 Damaged or Malfunctioning Machine Hazards......................................................13
6.13 Component Damage Hazards...............................................................................13
7Rail Safety....................................................................................................................14
7.1 General.................................................................................................................14
7.2 On/Off Track.........................................................................................................14
7.3 Travelling on the Rail ............................................................................................14
8Boom Safety.................................................................................................................16
8.1 Requirements .......................................................................................................16
8.2 General.................................................................................................................16
8.3 Residual Risks......................................................................................................17
8.4 Before Operating...................................................................................................18
8.5 During Operation...................................................................................................18
8.5.1 Safe Working Distances....................................................................................19
8.5.2 Load Handling...................................................................................................19
9On/Off-Tracking the Machine........................................................................................21
9.1 General.................................................................................................................21
9.2 Access Points.......................................................................................................21
10 Emergency Operations.................................................................................................22
10.1 Recovery Options .................................................................................................22
10.1.1 Machine Engine ............................................................................................22
10.1.2 Battery Driven Pump.....................................................................................22
10.1.3 Manual Over-ride Latches.............................................................................22
10.2 Battery Driven Pump.............................................................................................23
10.3 On Rail Recovery..................................................................................................23
10.3.1 Towing ..........................................................................................................23
10.3.2 Electrical Power ............................................................................................24
10.4 Emergency Off Tracking .......................................................................................24
10.4.1 Preparation ...................................................................................................24
10.4.2 Procedure .....................................................................................................24
11 Machine Overview........................................................................................................26
12 Control Layout..............................................................................................................27
12.1 Cab Controls.........................................................................................................27
12.2 Emergency Stop ...................................................................................................27
12.3 Auxiliary Interface Controls ...................................................................................28
12.4 Rail Gear Controls Interface..................................................................................29
12.5 Display..................................................................................................................30
12.5.1 Screen Surround...........................................................................................30

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12.5.2 Screen Icons.................................................................................................30
12.5.3 Initial Screen Pages ......................................................................................31
12.5.4 Travel Control................................................................................................32
12.5.5 A-Lock...........................................................................................................32
12.5.6 PBrake..........................................................................................................33
12.5.7 Rail Axle Control ...........................................................................................33
12.5.8 Axle Selection ...............................................................................................34
12.5.9 Axle Control...................................................................................................34
12.5.10 Main Menu ....................................................................................................35
12.5.11 Run Recovery ...............................................................................................36
12.5.12 Emergency Recovery....................................................................................36
12.5.13 I/O Status......................................................................................................37
12.5.14 Display Settings ............................................................................................39
12.5.15 System Information .......................................................................................41
13 Pre-Operation Actions ..................................................................................................43
13.1 Requirements .......................................................................................................43
13.2 General.................................................................................................................43
13.3 Inspection .............................................................................................................43
13.4 Completion............................................................................................................44
14 Routine Maintenance....................................................................................................45
14.1 Requirements .......................................................................................................45
14.2 General.................................................................................................................45
14.3 Engine Oil Level....................................................................................................45
14.4 Hydraulic Oil Level................................................................................................45
14.5 Batteries ...............................................................................................................45
14.6 Rail Wheels and Profiles.......................................................................................46
14.7 Fuel Leaks............................................................................................................46
14.8 Completion............................................................................................................46
15 Function Tests..............................................................................................................47
15.1 Requirements .......................................................................................................47
15.2 General.................................................................................................................47
15.3 From the Machine Cab..........................................................................................47
15.3.1 Emergency Stop............................................................................................47
15.3.2 Horn..............................................................................................................47
15.3.3 Crawler Drive Braking ...................................................................................47
15.3.4 Rail Gear Deployment...................................................................................48
15.3.5 Rail Drive and Rail Braking............................................................................48
15.4 Completion............................................................................................................49
16 Workplace Assessment................................................................................................50
16.1 Requirements .......................................................................................................50
16.2 General.................................................................................................................50
16.3 Assessment..........................................................................................................50
16.4 Completion............................................................................................................51
17 Operating Instructions...................................................................................................52
17.1 Requirements .......................................................................................................52
17.2 General.................................................................................................................52
17.3 Emergency Stop ...................................................................................................52
17.4 Deploying the Rail Gear........................................................................................52
17.5 Drive on Rail.........................................................................................................53
17.6 Road Mode...........................................................................................................53
17.7 Work Lights...........................................................................................................53
17.8 Restricting the Operating Envelopes.....................................................................53
17.8.1 General.........................................................................................................53
17.8.2 Boom.............................................................................................................54
17.9 Load Handling.......................................................................................................54
17.9.1 General.........................................................................................................54

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17.9.2 Lifting Moment Limiting Device......................................................................54
17.9.3 Manoeuvres of the boom...............................................................................54
17.9.4 Stow..............................................................................................................54
17.10 After Each Use......................................................................................................54
17.11 On and Off Tracking..............................................................................................55
18 Transportation ..............................................................................................................57
18.1 General.................................................................................................................57
18.2 Loading.................................................................................................................57
18.3 Machine................................................................................................................57
18.4 Transit...................................................................................................................58
19 Attachment Handling ....................................................................................................59
19.1 General.................................................................................................................59
19.2 Detaching..............................................................................................................59
19.3 Lifting....................................................................................................................59
20 Decals ..........................................................................................................................60
21 Specifications ...............................................................................................................64
FIGURES Page
Figure 1 - Safe Distance (metres) from Power Lines in excess of 33kV on Steel Towers.....10
Figure 2 - Safe Distance (metres) from Power Lines up to 33kV on Wooden Poles..............10
Figure 3 - Engine Bay Over-ride Button Location..................................................................23
Figure 4 - Location of Machine Components........................................................................26
Figure 5 - In-Cab Controls....................................................................................................27
Figure 6 - In-Cab Dashboard Emergency Stop Button..........................................................27
Figure 7 - In-Cab Auxiliary Controls......................................................................................28
Figure 8 - Left hand lever .....................................................................................................29
Figure 9 - Right hand lever...................................................................................................29
Figure 10 - Screen Surround................................................................................................30
Figure 11 - Boot Screen Page..............................................................................................31
Figure 12 - Main Screen Page..............................................................................................32
Figure 13 - Speedometer......................................................................................................32
Figure 14 - Rail Axle Selection Page....................................................................................33
Figure 15 - Front/Rear Axle Selection Page .........................................................................34
Figure 16 - Front/Rear Axle Control Page ............................................................................34
Figure 17 - Axles Down Display............................................................................................35
Figure 18 - Main Menu Page................................................................................................35
Figure 19 - Run Recovery Page...........................................................................................36
Figure 20 - I/O Status Selection Page ..................................................................................37
Figure 21 - Inputs/Outputs Status Page................................................................................37
Figure 22 - Force Values Password Page ............................................................................38
Figure 23 - Force Values Page.............................................................................................38
Figure 24 - Display Settings Page ........................................................................................39
Figure 25 - Brightness Page.................................................................................................39
Figure 26 - Software Version Page.......................................................................................40
Figure 27 - Hardware Info Page ...........................................................................................40
Figure 28 - System Information Page...................................................................................41
Figure 29 - Runtimes Page...................................................................................................41
Figure 30 - Total Distances Page.........................................................................................42
Figure 31 - Base Machine - Front Nearside Isometric View..................................................61
Figure 32 - Base Machine - Rear Offside Isometric View......................................................62
Figure 33 - Base Machine - Front View ................................................................................63

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1 Introduction
This Operator’s Manual has been compiled for the purposes of safe operation, maintenance and
servicing of Rail-Ability components and systems.
For other operating details (e.g. machine, Boom, Road Rail Operations, Rail Gear, etc.) refer to the
publications listed in section 4.
Left or right are to be with the reader sitting in the driver’s seat in the cab facing forwards, looking over
the front floating axle unless otherwise stated.
IMPORTANT
READ, UNDERSTAND AND OBEY THE CONTENTS OF THIS OPERATOR’S MANUAL BEFORE
THE OPERATION OF THIS MACHINE.
ONLY TRAINED AND AUTHORISED PERSONNEL SHALL BE PERMITTED TO OPERATE THIS
MACHINE.
THIS MACHINE IS VERY COMPLEX AND POTENTIALLY DANGEROUS. IT IS IMPORTANT THAT
BEFORE ANY USE OF THE MACHINE OCCURS, EXCEPT TRANSPORTATION AND
ATTACHMENT HANDLING, THE FOLLOWING ACTIVITIES HAVE ALL BEEN PERFORMED AND
CARRIED OUT IN THE ORDER STATED:
1. Pre-Operation Actions
2. Routine Maintenance as determined by the Pre-Operation Actions
3. Function Tests
4. Workplace Assessment
5. Operating Instructions.
THIS MANUAL SHOULD BE CONSIDERED A PERMANENT PART OF THIS MACHINE AND
SHOULD REMAIN WITH THE MACHINE AT ALL TIMES.
Should you have any questions, contact Rail-Ability Ltd:
Rail-Ability Ltd
Tilcon Avenue
Stafford
ST18 0YJ
Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]
The Rail-Ability web site is www.railability.co.uk.

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2 Description and Intended Use
The Rail-Ability Rail-Max machine consists of a road-going tracked excavator ridged chassis, modified
for use on rail by Rail-Ability Ltd as detailed in section 4. The chassis is fitted with rail gear front and
rear to enable rail work. Various attachments can be mounted onto the boom and these are delta with
collectively. For further information concerning attachments, see the manuals detailed in section 4.
The Rail-Max is intended for use on and off-track and/or rail wheels to enable operators and personnel
to undertake maintenance work underneath overhead lines and structures forming part of the rail
infrastructure.
The Rail-Max complies with the provisions of the following EC Council Directives:
Electromagnetic Compatibility (EMC) 2004/108/EC
Noise Emission in the Environment by Equipment for use Outdoors 2000/14/EC.
3 Limitations
The use of this machine is limited to its intended use, as described above. If additional or special
applications or uses are required which are not covered by this Operator’s Manual, carefully analyse
the situation and refer to Rail-Ability Ltd for advice before proceeding.
Operational and environmental limitations of the equipment are described in the Specifications section
of this manual.

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4 Manuals
Title
Part No
Rail-Ability RA400 Rail-Max Tracked Excavator
Operator’s Manual (this manual)
Issue 1 - November 2014 - Original Instructions
(English)
RAMAX400-001
Rail-Ability Rail Max RA400
Routine Maintenance Plan
Issue 1 - 1 July 2014
RARM400RMP001
Rail-Ability RA400 Rail-Max Tracked Excavator
Parts Manual
1st Edition
XXXXX
HOST MACHINE: MAINTENANCE INFORMATION:
Excavator
Publication No. 9803/6580-5,
JX235/JZ255, for machines with serial
numbers in the range 1234500 to
1235499
Engine Manuals
Isuzu 4HK1X - Tier III Engine Service
Manual, part number - 0297 9912, 3rd
edition, 03/03 and the Engine Parts
Manual, part number- 0312 0836, 1st
edition, 01/03
Prolec RCI
Prolec Liftwatch Rail Rated Capacity
Indicator Operators Manual, 560386-000
Issue 1.2, dated Feb 2011
Steel wrist Operator Hand Book
Steel wrist Operator Hand Book
Be sure the Operator’s and Safety manuals are complete, legible and located with the machine.

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5 Decal Legend
The decals on this machine use symbols, colour coding and signal words to identify the following:
Red with safety alert symbol –used to indicate the presence of an
imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Safety alert symbol –used to alert personnel to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
Orange with safety alert symbol –used to indicate the presence of a
potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Yellow with safety alert symbol –used to indicate the presence of a
potentially hazardous situation which, if not avoided, may cause minor or
moderate injury.
Yellow without safety alert symbol –used to indicate the presence of a
potentially hazardous situation which, if not avoided, may result in property
damage.
Green –used to indicate operation or maintenance information.
These symbols are also used in this manual as an appropriate visual indication and their meaning is
as detailed above.
Be sure all decals, including those shown in the Decals Section of this manual, are in place and
legible.

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6 Safety Rules
DANGER. FAILURE TO OBEY THE INSTRUCTIONS AND SAFETY RULES
IN THIS MANUAL MAY RESULT IN DEATH OR SERIOUS INJURY.
6.1 General
Read, understand and obey all applicable governmental regulations.
Read, understand and obey the employer’s safety rules and worksite regulations.
Comply with the employer’s, job site and governmental rules regarding use of personal
protective equipment.
Read, understand and obey the manufacturer’s instructions and safety rules, safety and
operator’s manuals and machine decals.
Learn and practice the principles of safe machine operation contained in this operator’s manual.
Be properly trained to safely operate the machine.
Always obey national traffic regulations while driving the machine on roads. Be aware of the
machine’s overall length, width and height.
Avoid hazardous situations.
The lack of maintenance may cause damage or hurt people.
Know and understand the safety rules before going on to the next items:
Prior to use:
Always perform Pre-Operation Actions
Always perform Function Tests
Always perform a Workplace Inspection.
Only use the machine as it was intended:
Do not engage in stunt driving or misbehave while operating the machine.
6.2 Electrocution Hazards
This machine is NOT electrically insulated and will NOT provide protection from contact with or
proximity to electrical current.
When in operation maintain the minimum safe distances from electrical power lines and
apparatus in accordance with the applicable governmental regulations and Figures 1 and 2
below.

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Figure 1 - Safe Distance (metres) from Power Lines in excess of 33kV on Steel Towers
Figure 2 - Safe Distance (metres) from Power Lines up to 33kV on Wooden Poles
Personnel must carefully evaluate the danger of electrocution before moving. If closer than 10
metres from the boom, the machine, the load or the electric line, move at least 10 metres away,
by shuffling away with small steps, in order to minimize the chance of getting a high voltage
difference between the feet.
OLE lines on rail are 25kV and require a minimum safe approach distance of 2.75 metres.
Allow for platform movement, electrical line sway or sag.
Keep away from the machine if it contacts energised power lines. Personnel on the
ground or in the platform must NOT touch or operate the machine until energised power
lines are shut off.
Do not attempt to assist someone in direct or indirect contact with the power line before
the power has been disabled as you run the risk of being electrocuted yourself.
Warn others to stay away.
Call for help.
Contact the power company to de-energize the line.
If you are in the machine cabin, stay inside without touching the machine body because
it's extremely hazardous to go out before the line is de-energised.
Help the electrocuted person if you know the first-aid procedures, otherwise wait for the
paramedics to arrive.
Do not operate the machine during lightning or storms.
Refer to Engineering Acceptance Certificate for live OLE limitations.