Rail-Ability Komatsu D41 Series Operator's Manual

Track type tractor
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Issue 1
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Contents
Initial Issue 19 December 2017
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Engineering Manager

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Summary of Contents for Rail-Ability Komatsu D41 Series

  • Page 1 & & Contents Issue 1 Page 1 of 34 Initial Issue 19 December 2017 Engineering Manager...
  • Page 2: Table Of Contents

    Contents Introduction ......................4 Description and Intended Use ................6 General Dimensions .................... 6 Rail Specifications ....................6 Gauge Dimensions ....................7 Limitations ......................7 Operational Safety Precautions ................7 Safety Rules ......................9 General ........................9 Electrocution Hazards ..................... 9 Travel Hazards .....................
  • Page 3 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 ..................
  • Page 4: Introduction

    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.
  • Page 5 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 Tollgate Drive Tollgate industrial Estate Stafford...
  • Page 6: 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.
  • Page 7: Gauge Dimensions

    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.
  • Page 8 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.
  • Page 9: Safety Rules

    Safety Rules DANGER. FAILURE TO OBEY THE INSTRUCTIONS AND SAFETY RULES IN THIS MANUAL MAY RESULT IN DEATH OR SERIOUS INJURY. General  Read, understand and obey all applicable governmental regulations.  Read, understand and obey the employer’s safety rules and worksite regulations. ...
  • Page 10: 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. Issue 1 Page 10 of 34...
  • Page 11: Fall Hazards

    Fall Hazards  Always sit in the seat and fasten the seat-belt when operating the cab controls.  Always use the white steps and white handholds provided when accessing and exiting the vehicle tracks, or cab. Never climb into the cab by other means or jump from the cab onto the ground.
  • Page 12: Burn Hazards

     Do not contact the battery terminals or the cable clamps with tools that may cause sparks. Burn Hazards  As batteries contain acid, always wear protective clothing and eye wear when working with batteries.  Avoid spilling or contacting battery acid. ...
  • Page 13: Rail Safety

    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. General ...
  • Page 14: Control Layout

    Control Layout Forward/reverse travel & Rear rail gear raise/lower lever Horn Switch Work Rail Axle Low Speed Rail Mode Light Deploy / Rail Change Master Switch Switch Drive Switch Down Switch Figure 1 - Control Layout Note: The rail mode master switch changes the operation of the lever between rail gear raise/lower, when not in rail mode &...
  • Page 15: Operating Control Principles

    Operating Control Principles 11.1 Rail Systems This rail axle position automatically manages the rail functions for all rail-mounted operations. When operated, the blade controls are reassigned to operate the rail drive, rail brakes and rail axle deploy functions. It also activates the rail navigation lights and speed restriction system. The dozer blade shims and blade trolley lock system are all manually applied.
  • Page 16: Crawler Tracks Interlock

    11.7 Crawler Tracks Interlock The machine will only actuate the rear rail axle ram and travel on rail with the Crawler Track Cab exit lever down. This interlock prevents the machine spinning the tracks whilst operating rail functions. Crawler Tracks Crawler Tracks Interlock Lever...
  • Page 17: Rail Drive Acknowledge Interlock

    11.8 Rail Drive Acknowledge Interlock The machine will only travel on rail with the drive acknowledge switch pressed. This interlock prevents the machine from travelling should the operator become incapacitated. The light in the switch will illuminate when the switch is activated and the rail systems is correctly set for travel. 12V Aux Socket For Engine Revs Rail Drive...
  • Page 18: On / Off Tracking

    On / Off Tracking ON/OFF TRACK THE MACHINE ONLY AT AN APPROVED ACCESS POINT. NOTE – AN APPROVED ACCESS POINT IS ONE OF THE FOLLOWING:  Level crossing.  Yard where surface is level with the rail top.  Proprietary approved track access system with rail shields. ...
  • Page 19: Suggested On / Off Tracking Area Requirements

    Suggested On / Off Tracking Area Requirements Figure 4 - On / Off Tracking Area A Rail-Ability Universal Track Access System is recommended for on and off tracking a bull dozer. Drive forwards and align the machine parallel to the track.
  • Page 20: Installation Of Ram Strut For Travelling On Track

    Installation of Ram Strut for Travelling On Track [WARNING] The ram struts must always be installed when the dozer is on rail. These ensure the dozer blade does not settle and hence keeps the dozer within w6 gauge requirements. Failure to fit these may result in striking line side equipment and/or structures.
  • Page 21: Figure 6 - Retaining Pins

    [WARNING] Do not over extend the blade rams. If the blade is lowered excessively so that the front of the dozer is too high, extensive damage to the bogie may result. Figure 6 - Retaining Pins Fit the blade angle and tilt ram stops in the same way (see Figure 7). Figure 7 - Blade Angle and Tilt Ram Stops Issue 1...
  • Page 22: Travelling On The Rail

    Travelling on the Rail Figure 8 - Travelling on the Rail Machine travel position as shown above and as follows:  All 4X ram shims installed. (if the rams shims do not fit over the ram rods, the machine is not compliant with W6a gauge.
  • Page 23: Bogie Handling

    Bogie Handling  Never lift the entire machine with a crane.  The machine must be parked on a level surface.  The machine must be secured to prevent rolling while the bogie is being demounted.  If the bogie being lifted, be sure the crane vehicle capacity, and lifting chains or straps are sufficient to withstand the bogie weight.
  • Page 24: Front Bogie Connect/Disconnect

    Front Bogie Connect/Disconnect The blade trolley locates between the cutting edge on the blade and the blade retaining profiles on the trolley. The hook locks on the trolley must be aligned with the bar plates on the back of the blade. This ensures correct blade to trolley alignment is maintained.
  • Page 25: Figure 10 - Hook Locks

    Engage the hook locks by rotating the hook profiles over the blade bars, then lock them with the secondary pins. Figure 10 - Hook Locks Connect the trolley brake connection hose to the machine bonnet hydraulic quick release coupling. Figure 11 - Brake Connection Hose Issue 1 Page 25 of 34...
  • Page 26: Figure 12 - Front Bogie Disconnection

    The blade can now be raised fully to lift of the bogie clear of the ground and the machine can be moved. To disconnect the bogie from the machine follow this procedure in reverse order. To remove the trolley from the blade lower the blade until the trolley contacts level ground. Disconnect the trolley brake connection hose.
  • Page 27: Emergency Off Tracking

    Emergency Off Tracking Emergency off tracking may be necessary during the working lifespan of the machine. It must be stressed that this is an emergency procedure only and should not be used in the normal cause of events. If you are asked to off track using this method, at an unprepared location, without suitable justification you should report to your on call manager and ask his advice before attempting this manoeuvre.
  • Page 28: Earth Bonding Straps

    Earth Bonding Straps Earth bonding straps are fitted on the machine between the chassis and rear rail axle and the chassis to blade. Earth bonding straps must be in place at all times and securely fastened. Replace immediately if any signs have burning or damage. Check impedance levels after refitting any straps.
  • Page 29: Figure 14 - Emergency Recovery

    RECOVERY OF THE MACHINE IN THE EVENT OF A BREAKDOWN WHILST ON THE TRACK Recovery Pump Handle Stowage Hand Recovery Pump Figure 14 - Emergency Recovery The rear rail axle can be raised to enable the machine to be removed from the rail track by using the hand pump shown above.
  • Page 30: Figure 15 - Brake Adjuster

    To recover the machine when mounted on the front bogie, back off the brake adjuster as shown in photograph below (13mm spanner required). Figure 15 - Brake Adjuster Issue 1 Page 30 of 34 Initial Issue 19 December 2017 Engineering Manager...
  • Page 31: Towing

    Towing Towing on rail wheels [WARNING] The dozer should be coupled to the towing machine before this procedure is followed. The dozer brakes are disabled when in free – wheel mode. Failure to couple the dozer initially may result in it rolling away. Remove centre plug using 22mm allen key (see Figure 16).
  • Page 32: Figure 18 - Centre Shaft Extraction

    Removal (keep shaft in a safe, clean place, see Figure 18). Figure 18 - Centre Shaft Extraction Refit centre plug (to prevent contamination of gear box, see Figure 19). Figure 19 - Plug Refit Repeat on each gear box. Gearboxes are in free-wheel to allow the dozer to be towed towing. Issue 1 Page 32 of 34 Initial Issue 19 December 2017...
  • Page 33: After Each Use

    [WARNING] The towing jaw on the rear rail gear is for means of towing the dozer for recovery on rail only. Overloading this towing jaw may result in severe damage to the rail gear. This jaw is not to be used to tow the dozer when working on its tracks.
  • Page 34: Lashing Rings

    Ensure that the machine parking brake is applied. Never leave the machine in gear as this can damage the transmission. Ensure that the bogie is secure if fitted. 24.3 Lashing Rings The lashing rings can be used to chain the machine down when it is carried as a load on a lorry. Note: They are not suitable for lifting the machine from.

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