Rail-Ability Komatsu D41 Series User manual

Issue 1 Page 1 of 34 Initial Issue 19 December 2017 Engineering Manager
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Contents

Issue 1 Page 2 of 34 Initial Issue 19 December 2017 Engineering Manager
Contents
1Introduction..........................................................................................................4
2Description and Intended Use .............................................................................6
3General Dimensions............................................................................................6
4Rail Specifications ...............................................................................................6
5Gauge Dimensions..............................................................................................7
6Limitations ...........................................................................................................7
7Operational Safety Precautions...........................................................................7
8Safety Rules ........................................................................................................9
8.1 General...................................................................................................................9
8.2 Electrocution Hazards.............................................................................................9
8.3 Travel Hazards .....................................................................................................10
8.4 Tip-over Hazards ..................................................................................................10
8.5 Fall Hazards..........................................................................................................11
8.6 Collision Hazards..................................................................................................11
8.7 Crushing Hazards.................................................................................................11
8.8 Explosion and Fire Hazards..................................................................................11
8.9 Burn Hazards........................................................................................................12
8.10 Bodily Injury Hazards.........................................................................................12
8.11 Lifting Hazard....................................................................................................12
8.12 Damaged or Malfunctioning Machine Hazards ..................................................12
8.13 Component Damage Hazards...........................................................................12
9Rail Safety .........................................................................................................13
9.1 General.................................................................................................................13
9.2 On/Off Track.........................................................................................................13
10 Control Layout ...................................................................................................14
11 Operating Control Principles..............................................................................15
11.1 Rail Systems .....................................................................................................15
11.2 Blade UP-DOWN/Ripper Control Lever.............................................................15
11.3 Rail Axle Deploy/Rail Drive Change-Over..........................................................15
11.4 Rail Axle Deploy................................................................................................15
11.5 Bogie Axle Deploy.............................................................................................15
11.6 Blade Rams Lock..............................................................................................15
11.7 Crawler Tracks Interlock....................................................................................16
11.8 Rail Drive Acknowledge Interlock ......................................................................17
11.9 Rail Travel.........................................................................................................17
11.10 Low Speed Selector ..........................................................................................17
12 On / Off Tracking ...............................................................................................18
13 Suggested On / Off Tracking Area Requirements..............................................19

Issue 1 Page 3 of 34 Initial Issue 19 December 2017 Engineering Manager
14 Installation of Ram Strut for Travelling On Track...............................................20
15 Travelling on the Rail.........................................................................................22
16 Bogie Handling ..................................................................................................23
17 Front Bogie Connect/Disconnect.......................................................................24
18 Emergency Off Tracking....................................................................................27
19 Rail Lights..........................................................................................................27
20 Earth Bonding Straps.........................................................................................28
21 Emergency Recovery ........................................................................................28
22 Towing...............................................................................................................31
23 After Each Use...................................................................................................33
24 Transportation....................................................................................................33
24.1 General.............................................................................................................33
24.2 Loading .............................................................................................................33
24.3 Lashing Rings ...................................................................................................34
24.4 Transit...............................................................................................................34
25 Decals................................................................................................................34
Figures
Figure 1 - Control Layout..........................................................................................14
Figure 2 - Crawler Tracks Interlock ..........................................................................16
Figure 3 - Rail Drive Acknowledge Interlock.............................................................17
Figure 4 - On / Off Tracking Area.............................................................................19
Figure 5 - Ram Strut.................................................................................................20
Figure 6 - Retaining Pins..........................................................................................21
Figure 7 - Blade Angle and Tilt Ram Stops..............................................................21
Figure 8 - Travelling on the Rail...............................................................................22
Figure 9 - Front Bogie Connection...........................................................................24
Figure 10 - Hook Locks............................................................................................25
Figure 11 - Brake Connection Hose.........................................................................25
Figure 12 - Front Bogie Disconnection.....................................................................26
Figure 13 - Earth Bonding Straps.............................................................................28
Figure 14 - Emergency Recovery.............................................................................29
Figure 15 - Brake Adjuster .......................................................................................30
Figure 16 - Centre Plug Removal.............................................................................31
Figure 17 - Centre Shaft Removal...........................................................................31
Figure 18 - Centre Shaft Extraction..........................................................................32
Figure 19 - Plug Refit ...............................................................................................32

Issue 1 Page 4 of 34 Initial Issue 19 December 2017 Engineering Manager
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. Dozer vehicle, blade guidance systems, Road Rail Operations, Rail
Gear, etc.) refer to the publications listed below.
Left or right are to be with the reader sitting in the driver’s seat in the cab facing forwards, unless
otherwise stated.
Title
Part No
Rail-Ability
Operator’s Manual (this manual)
Original Instructions (English)
KOM002
Rail-Ability Rail-Reach
Parts Manual
1st Edition
GA****
Rail-Ability Service Manual
KOMDRMP001
EMI Safety Manual
27581
Manual of Responsibilities
ANSI A92.6-1990
44163
KOMATSU OPERATOR HAND BOOK
************
KOMATSU Service Manual
************
KOMATSU Parts Book
***********
Be sure the Operator’s, Safety, and Responsibilities manuals are complete, legible and located with
the machine.

Issue 1 Page 5 of 34 Initial Issue 19 December 2017 Engineering Manager
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 MODULE
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
Tollgate Drive
Tollgate industrial Estate
Stafford
ST163HS
Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]
The Rail-Ability web site is www.railability.co.uk.

Issue 1 Page 6 of 34 Initial Issue 19 December 2017 Engineering Manager
2 Description and Intended Use
The Rail-Ability Bull Dozer machine consists of a construction bulldozer, with rail axle attachments for
use on rail by Rail-Ability Ltd. The chassis is fitted with rail gear at the rear and a detachable rail
bogie under the blade at the front to enable rail travel.
The Rail Equipment complies with the provisions of the following EC Council Directives:
Machinery 2006/42/EC
Electromagnetic Compatibility (EMC)2004/108/EC
Noise Emission in the Environment by Equipment for use Outdoors 2000/14/EC.
Guidance has also been taken from European standard EN 15746:20.
For further compliance information, refer to the EC Declaration of Conformity supplied with the OEM
machine.
3 General Dimensions
4 Rail Specifications
The machine with the rail equipment fitted has a gross weight of 14 tonnes and the front bogie has a
Tare weight of 750kg when detached from the Dozer.

Issue 1 Page 7 of 34 Initial Issue 19 December 2017 Engineering Manager
5 Gauge Dimensions
6 Limitations
For limitations of use, refer to the Engineering Compliance Certificate issued for the machine.
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 Operational Safety
Precautions section of this manual.
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.
7 Operational Safety Precautions
All work on or near the Railway infrastructure must be carried out strictly in accordance with
Railway regulations.
Attention must be paid to Railway Group Standards and all safety precautions must be followed
at all times.
When working on electrically operated routes, be sure to observe official regulations. Always
observe minimum clearance from overhead wires.
All staff must be fully trained and assessed as competent to use this piece of equipment on
Railway Infrastructure.

Issue 1 Page 8 of 34 Initial Issue 19 December 2017 Engineering Manager
See the network rail VAB engineering acceptance certificate for additional, specific machine
limitations of use.
This manual should be used in conjunction with the operators Safe System of Work and OEM
manuals.
Modifications to the vehicle must be authorised by rail-ability and a plant acceptance body that
will issue an amended engineering conformance certificate. Failure to get approval will
invalidate the existing engineering conformance certificate.
This manual should remain with the machine at all times. All OPERATING 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 in the
site conditions for which the machine was designed.
Only authorised staff may start, operate or interface with the vehicle.
The user of the vehicle shall only operate the machine IN ACCORDANCE TO THIS MANUAL
and avoid overloading.
All personnel are obliged to take precautions given by the railway infrastructure manager.
Personnel are NOT permitted between moving vehicles.
The vehicle may only operate with the access adjacent to access or a line closed to all train
movements or the documented safe system of work must take account of adequate safe
clearances to adjacent lines.
The vehicle is not suitable for operation of spring loaded points.
The vehicle is not for use on live third/forth rail areas.
The vehicle is not designed to tow or propel other machines.
The machine is not designed to tow or propel rail trailers.
The machine is not designed to carry or lift loads.
The machine does not have a working mode on track. It has a travel mode only.
The machine brakes should be checked prior to each use.
Each machine function and interlock should be tested before the machine is put on track and /
or used for work.
For working in dusty environments the machine should be equipped with the optional
pressurised cab system.
Shearing, entrapment: the machine has a lot of moving parts that are impossible to protect,
therefore the operator shall always be aware of this residual risk and keep clear from the
moving parts in, particularly from the blade assembly and tracks. The operator is held
responsible not only for them self but also for those working in proximity of the machine
including any that are not authorized.

Issue 1 Page 9 of 34 Initial Issue 19 December 2017 Engineering Manager
8 Safety Rules
DANGER. FAILURE TO OBEY THE INSTRUCTIONS AND SAFETY RULES IN THIS MANUAL
MAY RESULT IN DEATH OR SERIOUS INJURY.
8.1 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 vehicle on roads. Be aware of the
vehicle’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:
Using the work platform for anything other than lifting personnel, along with their
tools and materials, to an aerial work site is unsafe and dangerous.
Do not engage in stunt driving or misbehave while operating the machine.
8.2 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 conductor rails and
apparatus in accordance with the applicable regulations .

Issue 1 Page 10 of 34 Initial Issue 19 December 2017 Engineering Manager
Keep away from the machine if it contacts energised power cables / rails. Personnel on
the ground or in the cab 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 truck cabin, stay inside without touching the vehicle 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.
Refer to Engineering Acceptance Certificate for live OLE limitations.
Do not use the machine as a ground for welding unless the machine is equipped with the weld
line to platform option and it is properly connected.
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.
Avoid electrical shock from contact with battery terminals. Remove all rings, watches and other
jewellery.
8.3 Travel Hazards
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.
Take care while travelling on rail, especially when the work mast is fitted.
Beware of slippery and limited traction conditions on rail. Braking distance can increase
significantly in wet or icy conditions.
8.4 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.