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Related Manuals for Rail-Ability RA400
Summary of Contents for Rail-Ability RA400
- Page 1 Operator’s Manual DRAFT Conversion RA400 Rail-Max Tracked Excavator ****DRAFT**** Operator’s Manual Part no. RAMAX400-001 Issue 1 November 2014 Original Instructions (English) © Copyright 2014 - Rail-Ability Limited Page 1 of 64...
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Page 2: Table Of Contents
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 © Copyright 2014 - Rail-Ability Limited Page 2 of 64... - Page 3 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 © Copyright 2014 - Rail-Ability Limited Page 3 of 64...
- Page 4 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 © Copyright 2014 - Rail-Ability Limited Page 4 of 64...
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Page 5: Introduction
Function Tests Workplace Assessment 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... -
Page 6: 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. -
Page 7: Manuals
Operator’s Manual DRAFT Conversion 4 Manuals Title Part No Rail-Ability RA400 Rail-Max Tracked Excavator Operator’s Manual (this manual) RAMAX400-001 Issue 1 - November 2014 - Original Instructions (English) Rail-Ability Rail Max RA400 Routine Maintenance Plan RARM400RMP001 Issue 1 - 1 July 2014... -
Page 8: Decal Legend
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. © Copyright 2014 - Rail-Ability Limited Page 8 of 64... -
Page 9: Safety Rules
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. © Copyright 2014 - Rail-Ability Limited Page 9 of 64... - Page 10 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. © Copyright 2014 - Rail-Ability Limited Page 10 of 64...
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Page 11: Travel Hazards
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). -
Page 12: Fall Hazards
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. © Copyright 2014 - Rail-Ability Limited Page 12 of 64... -
Page 13: Burn Hazards
Tag and remove from service a damaged or malfunctioning machine. 6.13 Component Damage Hazards Do not use any battery or charger greater than 24V to jump-start the host machine OEM engine detailed in section 4. © Copyright 2014 - Rail-Ability Limited Page 13 of 64... -
Page 14: Rail Safety
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. © Copyright 2014 - Rail-Ability Limited Page 14 of 64... - Page 15 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. © Copyright 2014 - Rail-Ability Limited Page 15 of 64...
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Page 16: Boom Safety
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. -
Page 17: Residual Risks
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 © Copyright 2014 - Rail-Ability Limited Page 17 of 64... -
Page 18: Before Operating
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. © Copyright 2014 - Rail-Ability Limited Page 18 of 64... -
Page 19: Safe Working Distances
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. © Copyright 2014 - Rail-Ability Limited Page 19 of 64... - Page 20 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. © Copyright 2014 - Rail-Ability Limited Page 20 of 64...
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Page 21: On/Off-Tracking The Machine
Yard where surface is level with the top of the rail Proprietary approved track access system with inbuilt rail shields Consolidated ballast to at least the underside of the railhead with rail shields. © Copyright 2014 - Rail-Ability Limited Page 21 of 64... -
Page 22: Emergency Operations
An additional buzzer will sound whenever an over-ride is active to indicate that the over-ride feature is being activated. Once the over-ride system is activated the data logger will monitor the system. © Copyright 2014 - Rail-Ability Limited Page 22 of 64... -
Page 23: Battery Driven Pump
Once the booms have been lowered to a stowed position, after the over-ride key has been activated, the blue LED strip will be off indicating that the machine is overridden. The machine must be inspected and reset by Rail-Ability Ltd prior to being put back into service. Figure 3 - Engine Bay Over-ride Button Location 10.2 Battery Driven Pump... -
Page 24: Electrical Power
Ensure the machine is configured to travel to avoid causing instability or a possible tip over situation occurring. THIS MANOEUVRE IS DANGEROUS AND MUST ONLY BE CARRIED OUT IN A REAL EMERGENCY. © Copyright 2014 - Rail-Ability Limited Page 24 of 64... - Page 25 ‘Grounding out’ the machine, while the machine is travelling off rail may result in severe damage to the machine and/or infrastructure. © Copyright 2014 - Rail-Ability Limited Page 25 of 64...
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Page 26: Machine Overview
Top Deck Access Steps Rear Tow Coupling Tracks Hydraulic Oil Filler Rear Rail Gear Track Sweepers Top Deck Handrails Batteries Front Rail Gear Fuel Filler Draw Bar Front Tow Coupling © Copyright 2014 - Rail-Ability Limited Page 26 of 64... -
Page 27: Control Layout
Figure 5 - In-Cab Controls 12.2 Emergency Stop Disables all rail control functions and stops machine movements, see Fig.6. Figure 6 - In-Cab Dashboard Emergency Stop Button © Copyright 2014 - Rail-Ability Limited Page 27 of 64... -
Page 28: Auxiliary Interface Controls
(see Figures 8 and 9). For other auxiliary functions, refer to the steel wrist operator hand book. The Prolec RCI instructions are given in the Prolec lift watch rail operator hand book. © Copyright 2014 - Rail-Ability Limited Page 28 of 64... -
Page 29: Rail Gear Controls Interface
2. Spare (Front Roller) 3. Low flow auxiliary 4. Low flow auxiliary 5. Auto idle 6. Bucket / Grab divert Toggle (Front Green Button) Figure 9 - Right hand lever © Copyright 2014 - Rail-Ability Limited Page 29 of 64... -
Page 30: Display
The green axle lock icon is activated by the Axle Lock On physical lock system being currently on. The red axle lock icon is activated by the Axle Lock Off physical lock system being currently off. © Copyright 2014 - Rail-Ability Limited Page 30 of 64... -
Page 31: Initial Screen
Figure 11 - Boot Screen Page While the system initialises, the image shown above will be displayed. This will remain as the only displayed screen page for approximately 5 seconds. © Copyright 2014 - Rail-Ability Limited Page 31 of 64... -
Page 32: Travel Control
All travel on rail track must be carried out with the axle unlocked. By operating the A-Lock (axle lock) button the axle can be locked; this will provide greater stability whilst carrying out stationary rail-mounted operations. © Copyright 2014 - Rail-Ability Limited Page 32 of 64... -
Page 33: Pbrake
The axles will be shown as UP when they are no longer sensed by the system as down, and will be coloured yellow. The axles will be shown as DOWN and coloured green when the system’s sensors have indicated they are down. © Copyright 2014 - Rail-Ability Limited Page 33 of 64... -
Page 34: Axle Selection
MUST HAVE 'DIG MODE' ENABLED AND CAN NOT BE IN LIFTING MODE. THE PROLEC LIFT WATCH RAIL RCI IS AN INHERENT AND INTEGRAL SYSTEM WITHIN THE RAIL-ABILITY SAFETY SYSTEMS ON THE MACHINE. COMPLETE FAMILIARITY WITH THE PROLEC OPERATION MANUAL IS VITAL IN COMBINATION WITH THIS MANUAL TO HAVE A COMPLETE UNDERSTANDING OF THE MACHINES SAFETY FEATURES AND OPERATIONAL INTERLOCKS. -
Page 35: Main Menu
There are 4 possible selections to make at this screen, and it is possible to scroll through the selections using the up and down arrow keys. The selected option will be highlighted orange. To access the item of the menu, press “ok” when the item is highlighted. © Copyright 2014 - Rail-Ability Limited Page 35 of 64... -
Page 36: Run Recovery
Raise front rail gear/blade trolley; Raise the rear rail gear. Operate the machine controls in the usual way to bring the machine into travel gauge to prepare for towing. © Copyright 2014 - Rail-Ability Limited Page 36 of 64... -
Page 37: I/O Status
Use the F4 key for “ESC” to return to the I/O Status menu page. © Copyright 2014 - Rail-Ability Limited Page 37 of 64... - Page 38 “ok” button input. These pages must only be used for vehicle component testing and initialisation; there should be no need to access these pages under normal operation of the system. © Copyright 2014 - Rail-Ability Limited Page 38 of 64...
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Page 39: Display Settings
Using the left and right arrow keys it is possible to decrease and increase the screen brightness respectively. Similarly, using the F1 and F2 keys will change the brightness to 100% or 50%. © Copyright 2014 - Rail-Ability Limited Page 39 of 64... - Page 40 Accessing the “Hardware Info” option of the main menu will show the page above on the screen; this is simply for reference to give hardware information. Using the “ok” button will also return the screen to the main menu as with the “ESC” key. © Copyright 2014 - Rail-Ability Limited Page 40 of 64...
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Page 41: System Information
The “RCI Active” values are in reference to the Prolec system components, the “Recovery Active” values are increased only with the operation of the recovery pumps, and “Rail Mode” time is incremented only when both rail axles are considered fully deployed by the system. © Copyright 2014 - Rail-Ability Limited Page 41 of 64... - Page 42 Smaller distances such as the recorded trip distance, distances from ignition, 24 hour average, and the “Freewheel” travel will be recorded and displayed up to 6 significant figures (potentially 9999.99) with up to 2 decimal places. © Copyright 2014 - Rail-Ability Limited Page 42 of 64...
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Page 43: Pre-Operation Actions
Repairs to the machine may only be made by a qualified service technician, according to the manufacturer’s specifications. After repairs are completed, the operator must perform a pre-operation inspection again before going on to the function tests. If in doubt, contact Rail-Ability Ltd. 13.2 General ... -
Page 44: Completion
If any routine maintenance has been identified in these pre-operation actions, carry it out as specified in the Routine Maintenance section of this manual. If no routine maintenance is required, carry out the Function Tests detailed in this manual. © Copyright 2014 - Rail-Ability Limited Page 44 of 64... -
Page 45: Routine Maintenance
Only routine maintenance items specified in this manual shall be performed by the operator. Use only manufacturer’s original replacement parts. Contact Rail-Ability Ltd if in doubt. Machines that have been out of service for more than three months must receive at least the Quarterly Inspection before they are put back into service (see Service Manual in section 4). -
Page 46: Rail Wheels And Profiles
If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 14.8 Completion Carry out the Function Tests detailed in this manual. © Copyright 2014 - Rail-Ability Limited Page 46 of 64... -
Page 47: Function Tests
After repairs are completed, the operator must perform a Pre-operation Inspection and carry out the Function Tests again before putting the machine into service. If in doubt, contact Rail-Ability Ltd. Refer to the sections below and carry out each of the items in turn. -
Page 48: Rail Gear Deployment
Result: The machine should stop promptly and firmly. Press the park brake button. THE BRAKES MUST BE ABLE TO HOLD THE MACHINE ON ANY SLOPE IT IS ABLE TO CLIMB. Always close the cab door. © Copyright 2014 - Rail-Ability Limited Page 48 of 64... -
Page 49: Completion
Operator’s Manual DRAFT Conversion 15.4 Completion If the machine is to be used, carry out the Workplace Assessment detailed in this manual. © Copyright 2014 - Rail-Ability Limited Page 49 of 64... -
Page 50: Workplace Assessment
Make sure that there is no risk of elements falling on the operator or on the boom and take the right precautions to prevent it. Ensure any items assessed as hazardous above are addressed before the machine can be used. © Copyright 2014 - Rail-Ability Limited Page 50 of 64... -
Page 51: Completion
Operator’s Manual DRAFT Conversion 16.4 Completion If the machine is to be used, carry out the Operating Instructions detailed in this manual. © Copyright 2014 - Rail-Ability Limited Page 51 of 64... -
Page 52: Operating Instructions
17.4 Deploying the Rail Gear The rail gear can only be deployed using the controls located in the machine cab as detailed in the Rail Axle Control section of this manual. © Copyright 2014 - Rail-Ability Limited Page 52 of 64... -
Page 53: Drive On Rail
The machine is now in road mode and can be driven using the cab controls. Follow the Off-Tracking procedure described in this manual and the relevant Rail-Ability manual. 17.7 Work Lights The work lights on the booms can be switched on and off by using the pushbutton in the cab. -
Page 54: Boom
Ensure the boom is fully stowed. Off-Track the machine. Park the machine on a firm level surface, clear of obstruction and traffic at least 3 metres away from the nearest railway lines. © Copyright 2014 - Rail-Ability Limited Page 54 of 64... -
Page 55: On And Off Tracking
RAIL BEFORE THE WEIGHT OF THE MACHINE IS EXERTED ONTO THE TRACK. IF THE MACHINE IS NOT PERPENDICULAR TO THE RAIL WITHIN THE RAIL WHEEL FLANGE TOLERANCE OF THE RAIL AXLES OR SEVERE DAMAGE TO THE TRACK MAY RESULT. © Copyright 2014 - Rail-Ability Limited Page 55 of 64... - Page 56 CLEAR INFRASTRUCTURE (DO NOT OVER TIGHTEN THE TRACKS) Note: The rail lights will automatically illuminate, the drive travel Joystick will become active and the speedometer will recalibrate for rail mode. © Copyright 2014 - Rail-Ability Limited Page 56 of 64...
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Page 57: Transportation
If an accessory is mounted, it must be tied down at all times during transport. Make sure that the rams are within the overall width of the machine and locked by the safety devices. © Copyright 2014 - Rail-Ability Limited Page 57 of 64... -
Page 58: Transit
Adjust the position to prevent damage to the chains and machine. Never chain over the boom, cab or dipper. Only chain to the dedicated identified chaining-down eyes. © Copyright 2014 - Rail-Ability Limited Page 58 of 64... -
Page 59: Attachment Handling
After the machine has been stabilised on flat level ground: Disengage the hydraulic, air and electrical connections to the host machine. Disengage the quick hitch. 19.3 Lifting Never lift the machine. © Copyright 2014 - Rail-Ability Limited Page 59 of 64... -
Page 60: Decals
For other decals fitted which are marked ‘817/…..’ refer to the OEM Manuals referred to in section 4. Use the illustrations on the following pages to verify that all decals are legible and in place. © Copyright 2014 - Rail-Ability Limited Page 60 of 64... - Page 61 A0617 A0617 A0617 SWL Plate SWL Plate 28171 (Inside) 28161 A4281 POV Number (Inside) A2380 A3973 28164 (Inside) A4281 28161 Figure 31 - Base Machine - Front Nearside Isometric View © Copyright 2014 - Rail-Ability Limited Page 61 of 64...
- Page 62 Conversion A0617 SWL Plate A0617 A0617 A0617 28161 Tail Swing Marker A3973 POV Number A2380 A0617 Tail Swing Marker 28161 Figure 32 - Base Machine - Rear Offside Isometric View © Copyright 2014 - Rail-Ability Limited Page 62 of 64...
- Page 63 Operator’s Manual DRAFT Conversion A2236 A0623 A4281 A0617 Figure 33 - Base Machine - Front View © Copyright 2014 - Rail-Ability Limited Page 63 of 64...
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Page 64: Specifications
2 x 115 Ah rating, stowed Controls Proportional position, on tracks 24 Volt DC outlet at dipper Standard Maximum hydraulic 405 bar pressure Hydraulic tank 120 litres Fuel tank 290 litres © Copyright 2014 - Rail-Ability Limited Page 64 of 64...
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