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

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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.

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Inspect daily for damaged cables and wires. Replace damaged items before operating.
Avoid contact with electrical terminals.
Earth bonding straps:
Straps must be in place at all times and securely fastened.
Inspect the straps daily.
Replace straps immediately if there are any signs of burning or damage.
Replace damaged straps before operating.
Check impedance levels after refitting any straps.
Earth bonding straps are fitted on the machine in the following positions:
Between front rail axle and chassis
Between machine upper structure and continuously along the boom
Between second stage boom and arm.
Avoid electrical shock from contact with battery terminals. Remove all rings, watches and other
jewellery.
Ensure a C Form has been obtained before on-tracking the machine in OLE areas.
6.3 Travel Hazards
Observe and use colour-coded direction arrows on the machine for drive functions.
Be aware of limited sight distance and blind spots when driving. Use a ‘banksman’ or machine
controller when required.
Limit travel speed according to conditions, slope, location of personnel, and any other factors
which may cause collision.
If a hook protrudes outside the edge of the machine, it must be removed before travelling.
Take care while travelling on rail, especially when the boom is elevated.
Beware of slippery and limited traction conditions on rail. Braking distance can increase
significantly in wet or icy conditions.
6.4 Tip-over Hazards
Do not alter or disable the safety switches (e.g. limit and proximity switches).
Do not alter or disable machine components that in any way affect safety and stability.
Do not replace items critical to machine stability with items of different weight or specification. If
in doubt, contact Rail-Ability Ltd.
Do not modify or alter this machine without prior written permission from Rail-Ability Ltd.
Ensure that all tracks are in good condition, track nuts (including rail wheels) are properly
tightened (see specifications section of this manual).
Do not drive the machine on temporary track, uneven or unstable track or other hazardous
conditions with the boom raised.
Do not use the machine while mounted on another moving surface of a machine.

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6.5 Fall Hazards
Always sit in the seat and fasten the seat-belt when operating the cab controls.
Always use the steps and handholds provided when accessing and exiting the machine bonnet
or cab. Never climb onto the rear by other means or jump from the cab onto the ground.
Machine deck:
Take care when on the deck (when performing inspection or maintenance), particularly in
wet or icy conditions.
Remove or secure any loose equipment or tools that could fall off during transit or present
a trip hazard.
Clean up any oil or other fluid spillages on the deck which could create a slippery surface.
Keep the deck clean and tidy.
6.6 Collision Hazards
Check the work area for overhead obstructions or other possible hazards.
Do not operate the machine in the path of any boom or other moving machinery unless the
controls of that machinery have been locked out and/or precautions have been taken to prevent
any potential collision. Use a ‘banksman’ or machine controller to alert the operator/driver when
required.
Boom:
Be aware of limited sight distance and blind spots when operating the boom. Use a
‘banksman’ or machine controller when required.
Be aware of boom position and tail-swing when slewing.
Do not lower the boom unless the area below is clear of personnel and obstructions.
6.7 Crushing Hazards
Keep hands and limbs away from moving parts of the machinery.
Maintain safe distances between the operator, the machine and fixed objects.
Use common sense and planning when operating the machine with a ‘banksman’ or controller
from the ground.
6.8 Explosion and Fire Hazards
Do not start the engine if you smell or detect diesel fuel or other explosive substances.
Do not refuel the tank(s) when the engine is running.
Refuel the tank(s) and charge the battery only in an open, well-ventilated area away from
sparks, flames and lighted tobacco.
Do not operate the machine in hazardous locations or locations where potentially flammable or
explosive gases or particles may be present.
Do not spray ether into engines equipped with glow plugs.
Keep sparks, flames and lighted tobacco away from the batteries as batteries emit an explosive
gas.
Do not contact the battery terminals or the cable clamps with tools that may cause sparks.

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6.9 Burn Hazards
As batteries contain acid, always wear protective clothing and eye wear when working with
batteries.
Avoid spilling or contacting battery acid.
Neutralise battery acid spills with baking soda and water.
Do not expose batteries to water or rain.
6.10Bodily Injury Hazards
Be aware of Crushing Hazards when grasping any part of the boom or track frame.
Do not operate a machine with a hydraulic oil or air leak as a hydraulic leak can penetrate
and/or burn skin and air which enters the body can cause death or serious injury.
Improper contact with components under any cover will cause serious injury. Only trained
maintenance personnel should access compartments. Access by the operator is only advised
when performing a pre-operation inspection.
All compartments must remain closed and secured during operation.
Always operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.
6.11Lifting Hazard
Use the appropriate number of people and proper lifting techniques when lifting:
batteries
drawbars
tools
other removable items.
6.12Damaged or Malfunctioning Machine Hazards
Do not use a damaged or malfunctioning machine.
Tag and remove from service a damaged or malfunctioning machine.
6.13Component Damage Hazards
Do not use any battery or charger greater than 24V to jump-start the host machine OEM engine
detailed in section 4.

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7 Rail Safety
DANGER. FAILURE TO OBEY THE INSTRUCTIONS AND SAFETY RULES
IN THIS MANUAL MAY RESULT IN DEATH OR SERIOUS INJURY.
Failure to comply with these requirements may result in severe damage to the
machine and/or the rail infrastructure.
7.1 General
All work on or near the railway infrastructure must be carried out strictly in accordance with
railway regulations.
Always observe Network Rail codes of practice.
Work must be carried out in accordance to rulebook GE/RT 8000 and all safety precautions
must be followed at all times.
Attention must be paid to Railway Group Standards and all safety precautions must be followed
at all times.
All staff must be fully trained and certified as competent to use this piece of equipment on
railway infrastructure by the owner/operator.
When working on electrically operated routes, be sure to observe official regulations. Always
observe minimum clearance from overhead wires.
Ensure a relevant C Form is obtained.
Never use in 3rd and 4th rail areas.
Never use on track without a possession.
Never use on track under live OLE.
Never use on track when trains are running.
Never On/Off-Track in areas with close proximity hazards such as in station platforms under/on
bridges, in tunnels or in areas with low overhead structures or line side structures.
See the Network Rail V.A.B. Engineering Acceptance Certificate and EC Type Examination
Certificate for additional, specific machine limitations of use.
7.2 On/Off Track
Always utilise an approved On/Off-Tracking method.
Never On/Off-Track in areas with any cable connections to the rail.
Never On/Off-Track in areas with ATP loop cables either in the rail web or in the “four foot”.
Never On/Off-Track in areas with any cables cleated to the top surfaces of sleepers.
Never On/Off -rack in areas with any signalling equipment fitted in the “four foot”.
7.3 Travelling on the Rail
Before travel commences, ensure the following:
Crowd ram fully extended so that bucket is fully crowded round.
Dipper ram fully extended so that the dipper is fully in.

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Tab second stage arm rams fully retracted so that second stage is fully out.
Main lift ram set so that the bucket is approximately 300mm above the rail head so that the arm
is positioned below the highest point of the cab.
Rail Gear deployed fully.
WARNINGS: (1) TO ENSURE THE MACHINE IS COMPLYING WITH THE W6A GAUGE
REQUIREMENT, BEFORE TRAVELLING ON RAIL, IT IS ESSENTIAL THAT THE
MACHINE IS SLEWED SO THAT THE UPPER STRUCTURE IS PARALLEL TO
THE LOWER STRUCTURE AND THAT THE CAB DOOR IS SHUT TO ENSURE
THIS IS MAINTAINED. IT IS ALSO ESSENTIAL THAT THE ARM IS POSITIONED
LOWER OR EQUAL TO THE HEIGHT OF THE CAB. THIS IS TO ENSURE
OVERHEAD STRUCTURES ARE NOT STRUCK. THE PROLEC HEIGHT LIMITER
FITTED TO THE MACHINE CAN THEN BE SET AND ACTIVATED TO MAINTAIN
THIS POSITION.
(2) EXTRA CARE AND OBSERVATION OF LINE SIDE AND OVERHEAD
STRUCTURES IS REQUIRED WHEN THE MACHINE IS FITTED WITH AN
ATTACHMENT THAT IS OUTSIDE THE W6A TRAVEL GAUGE IN ANY WAY.
(3) FAILURE TO COMPLY WITH THESE REQUIREMENTS MAY RESULT IN
SEVERE DAMAGE TO THE MACHINE AND/OR THE RAIL INFRASTRUCTURE.

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8 Boom Safety
8.1 Requirements
The machine operator shall be held directly responsible for the correct operation of the boom
including any requirements of the site conditions.
8.2 General
Adhere to the following items in order to avoid possible accidents while operating the boom.
Do not interfere with the safety and protection devices. Note that interference with the
check valves and removal of the lead seal removes and invalidates the Manufacturer’s
warranty.
Only authorized persons are allowed to operate the boom.
The machine must be used on firm ground.
Check that the machine brake is on and that the tracks are locked.
Before every operation make sure that:
no-one is within the working area of the boom
the safety devices are in place and operative
the minimum safe working distances from power lines are observed
the load is correctly slung and hooked.
Stabilize the machine by making sure that the rail wheels are properly positioned on the track.
Use the boom in accordance with the use and maintenance manual, making sure that:
the load and radius are within the maximum limits shown on the load chart
the boom is used progressively, avoiding sudden load movements
swinging or dragging of the load is avoided
the load is lifted before rotating.
When using implements, set up an exclusion zone.
The machine is not left unless the load is on the ground.
Before driving the machine make sure that the boom is in the folded position.
The use of the boom is reserved for authorized personnel, instructed in advance, who must
conform to the safety norms and instructions contained in the manual supplied with the boom
(see norms ISO 9926-1).
It is prohibited to walk or stop under a suspended load.
It is prohibited for unauthorized persons to be within the working area.
Warning, instruction and operation plates must be replaced when no longer readable or
missing. Contact Rail-Ability to replace any missing plates.
When transporting the machine, to avoid hitting bridges or tunnels know the overall height of the
boom in the folded position or in laid position in the body. Always respect and pay proper
attention to road signs placed in proximity of such obstacles.

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8.3 Residual Risks
It is forbidden to use the boom without having read and understood the manual for use and
maintenance and without having being previously instructed by experienced personnel on all
aspects of safe boom operation.
Risk evaluation shall be followed by adequate provisions in order to avoid risks and damage to
people and objects.
Overturn: the boom can overturn, thus hurting people and damaging objects especially in the
following conditions:
not correctly railised
moment limiting device disabled
ground conditions at the site not stable enough
excessive speed.
Moment limiting device: never try to bypass or tamper with the moment limiting device and the
various safety systems installed on the boom. Understand the alarm messages generated by
the "moment limiting device" and act accordingly.
Control position: before operating the controls the operator shall make sure that they are safe
from hazards.
From the control position the operator shall be able to visually inspect the whole working area at
all times. If it is not possible, they shall team up with a co-worker able to control the whole area
and who can see all potential hazards clearly at all times.
Load rigging: carefully inspect the load rigging. The operator shall make sure that the load is
properly attached and balanced and that all unexpected movements are not allowed. Be careful
not to hit any potential impediments during the boom movements.
Overload and/or fatigue: the boom can break down due to fatigue or overload:
if it is misused (with cycles, loads or pump oil flow not pertinent to the boom class)
if it is used for improper tasks (side, oblique or reversal pull)
if it is used in poor sites (corrosive environment, too high or too low temperature, foundry
- see Workplace Assessment)
if the load exceeds the rated capacity indicated on the relevant plates.
Wrong manoeuvring: the boom can fall, break or overturn if the operator performs a wrong
manoeuvre due to the lack of familiarity with the operation procedures or due to inadequate
psychophysical conditions. There are directives and rail regulations in force that impose suitable
training of the personnel before using these types of machines and they require an adequate
psychophysical condition to operate safely a lifting device that implies an inherent danger when
lifting a load.
Weather conditions: too high or too low temperatures may damage the components of the
hydraulic and electric circuits. Do not operate the machine during a storm with lightning
hazards, and if these condition occur it is recommended that the boom is folded down and put
to rest.
Shearing, entrapment: the boom has a lot of parts in movement that it is impossible to protect,
therefore the operator shall always be aware of this residual risk and keep clear from the parts
in movement, particularly from the load. The operator is held responsible not only for themself
but also for those working in proximity of the boom including any that are not authorized.
Electrocution: the boom is not eclectically insulated and therefore it is not equipped to work
with conductors, including if a contact is accidental. Be compliant with the minimum clearance
prescribed by the national directives in force. Generally speaking the clearance from electric
lines of 33kV should be at least 9 metres. Above 33kV, the distance should be at least 15m and

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be verified in each case by competent technicians and with respect to the environment
conditions.
Attachment overload: attachments are controlled by the moment limiting device only under the
conditions described in this manual.
Accessories: be careful when attaching/detaching any accessories (buckets, grabs, etc). First
verify the weight, the quick hitch and the instructions. Then appraise their centres of gravity and
avoid sudden movements.
Breakdown of some sensors: the moment limiting device is always monitored during
operation. The system, after having activated the various circuits, checks the presence of all the
inputs and then continuously monitors the operation and the efficiency of the limiting device.
8.4 Before Operating
WARNING: Before boom use check that safety and protection devices shown above and
detailed below are fitted and active:
Check valve for boom rams
Check valve for dipper ram
Check valve for cab ram
Rotation limiting device
Check valves for rotation control (flow regulators)
Lifting moment limiting device.
Keep the steps and the work areas clean.
Check that the working area is adequate and properly illuminated.
Carefully inspect the condition of ropes or chains if present.
8.5 During Operation
Do not run the engine in an indoor area without first making sure there is adequate ventilation.
If there is inadequate ventilation, take the machine fumes away from the working area by fitting
an extension tube of a suitable diameter and of sufficient length to the exhaust system.

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Make sure that no one is within the working area of the boom.
8.5.1 Safe Working Distances
Avoid swinging the load above working and transit areas, any hidden danger situation must be
audibly alarmed.
Avoid all those situations which may result in crushing during machine stabilization, boom
movement and load handling.
Avoid crushing parts of the body by following the minimum safe working distances below (see EN 349
standard for further guidance). The table below indicates the minimum safety working distances
concerning the various parts of the body and each figure illustrate circumstances which may turn out
to be dangerous if you fail to respect the minimum safe distances.
Part
of
body
Minimum safe
working
distance (mm)
Figure
Part of body
Minimum safe
working
distance (mm)
Figure
Whole
body
500
Foot
120
Head
300
Hand/wrist/fist
100
Leg
180
Toe
50
Arm
120
Finger
25
8.5.2 Load Handling
Examples of good and poor practices:
Carefully inspect the load rigging. Ensure you follow good
practice, such as that shown on the right.
This item on the right shows poor practice and must not
be used.
Do not utilize the boom for push/pull, lateral or
sideways operations.
Crushing or push manoeuvres are not permitted.

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Hook up the load, checking that it does not exceed the capacity indicated on the lifting diagram
specific to each load configuration.
Make sure that the lifted load is balanced.
Avoid swinging the load above the control station. In cases where the load is too close, the
boom must be operated from the opposite side.
Do not operate with sudden movements. Activate the controls with slow and progressive
movements and rotate slowly and with care paying attention to the stability of the machine.
With vertical lift, rotate slowly in order to avoid side-skidding.
Only move the machine when the boom is in transport position.
The machine must not be left unless the load is on the ground and the booms are folded
and laid on a solid base.