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Rail-Ability Komatsu D41 Series, Operator'S Manual, Page: 5 / 34

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Rail-Ability Komatsu D41 Series Operator'S Manual Download Page 5

 

 

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: (01785) 214747 
Fax: (01785) 214717 
E-Mail: [email protected] 
 
The Rail-Ability web site is www.railability.co.uk. 
 

Summary of Contents for Komatsu D41 Series

Page 1: ...O OM M 0 00 02 2 R RA AI IL L O OP PE ER RA AT TI IO ON NS S E EM ME ER RG GE EN NC CY Y R RE EC CO OV VE ER RY Y P PR RO OC CE ED DU UR RE ES S R RA AI IL L A AB BI IL LI IT TY Y K KO OM MA AT TS SU...

Page 2: ...rds 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 9 Rail Safety 13 9 1 General 13 9 2 O...

Page 3: ...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...

Page 4: ...d 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 Instru...

Page 5: ...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...

Page 6: ...pment 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 Outd...

Page 7: ...ribed 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...

Page 8: ...e 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 docu...

Page 9: ...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 Kno...

Page 10: ...void 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 bur...

Page 11: ...on Use a banksman or machine controller to alert the operator driver when required Cab Be aware of limited sight distance and blind spots when operating the machine Use a banksman or machine controlle...

Page 12: ...hould 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...

Page 13: ...or When working on electrically operated routes be sure to observe official regulations Always observe minimum clearance from overhead wires Never use in 3rd and 4th rail areas Never use on track with...

Page 14: ...ail mode master switch changes the operation of the lever between rail gear raise lower when not in rail mode travel forward reverse when in rail mode Rail Mode Master Switch Rail Axle Deploy Rail Dri...

Page 15: ...tion will only operate if the track drive lever cab exit lock is down to isolate the crawler travel controls 11 3 Rail Axle Deploy Rail Drive Change Over This changes between rear rail gear for raisin...

Page 16: ...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 ra...

Page 17: ...rail select the rail drive switch and the Drive Acknowledge switch then has to be pressed and held down Simultaneously push and hold the travel lever into the forward position to initiate forward tra...

Page 18: ...r cables Care should be taken when on off tracking with tracked excavators not to damage the railhead suitable rail shields should be used When on tracking the rear rail wheels should be aligned to th...

Page 19: ...track with the Crawlers and align the front bogie and rear rail axle with the track UTAS 5 Deploy the rear rail axle to only just lift the rear of the machine slightly clear of the Track UTAS 6 Utilis...

Page 20: ...its maximum extent and that an equal amount of blade over hang is achieved over the sides of the trolley This ensures the dozer remains within w6 gauge requirements Failure to ensure that this is done...

Page 21: ...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...

Page 22: ...nstalled if the rams shims do not fit over the ram rods the machine is not compliant with W6a gauge WARNING extra care and observation of line side and overhead structures is required when the machine...

Page 23: ...e crane vehicle capacity and lifting chains or straps are sufficient to withstand the bogie weight See the serial plate on the bogie for the bogie weight Do not demount removable bogie when on a slope...

Page 24: ...ning 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 To install the tro...

Page 25: ...nager 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 bonne...

Page 26: ...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 trolle...

Page 27: ...on the railhead until the machine is perpendicular to the rail Track the machine clear of the running rail When carrying out this operation always follow any hand signals and carry out all movements...

Page 28: ...this reason the Komatsu track type tractor has been fitted with an auxiliary power system and a tow bar by which another machine can tow it to safety Instructions on how the auxiliary system works are...

Page 29: ...rail axle can be raised to enable the machine to be removed from the rail track by using the hand pump shown above Note the pump is hosed up ready for recovery no other action is necessary RECOVERY O...

Page 30: ...of 34 Initial Issue 19 December 2017 Engineering Manager 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...

Page 31: ...wing 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 1 Remove centre plug using 22mm...

Page 32: ...Removal keep shaft in a safe clean place see Figure 18 Figure 18 Centre Shaft Extraction 4 Refit centre plug to prevent contamination of gear box see Figure 19 Figure 19 Plug Refit 5 Repeat on each ge...

Page 33: ...cab doors to secure from unauthorised use 24 Transportation 24 1 General Never lift the machine with a crane The transport vehicle must be parked on a level surface The transport vehicle must be secu...

Page 34: ...ifting point on the bogie for lifting the bogie only when it is detached from the machine 24 4 Transit Turn the machine ignition key switch to the off position remove the key and lock the cab doors be...

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