operation and maintenance instruction handbook

A T R 4 5 0Rail Mounted Trailer Operating and Maintenance Instruction

Aluminum Trailer 1800 X 1200 Maximum Load 450 kg

OPERATION AND MAINTENANCE INSTRUCTION HANDBOOK

OPERATION AND MAINTENANCE INSTRUCTION HANDBOOK ATR450 ALUMINIUM TRAILER PAGE 2

R A I L P R O D U C T S U K - AT R 4 5 0 - I S S U E 2 . 1 - 1 6 - 1 2 - 2 0 1 6

Mountcairn

22 Cairneymount Road

Carluke

South Lanarkshire - ML8 4EN

Phone: 0044 1555 773 027

Mobile: 0044 7788 924 848

[email protected]



Issue record

Issue Date Author Comments

1.0 01-05-2015 RVP Original document

1.1 22-06-2015 JV Lay out changed, review various articles

2.0 14-01-2016 RVP Added specifi cations, safety icons and illustrations

2.1 16-12-2016 JV New Issue, to comply with RIS 1530-PLT-Issue 6 changes

SIGNATURE:

DATE: 16-12-2016



Document review

The maintenance instruction shall be reviewed every year by a competent engineer.

The instruction shall include:

• A process for it to be regularly reviewed for potential to improve its effectiveness.

• For a record to be kept of decisions taken at each review.

• A process for the maintenance instruction to also be reviewed in the light of the following:

1. In process reviews of maintenance activities.

2. Performance of the machines and components covered by the instruction including relevant national

incident reports.

3. Changes in the pattern of use and operating environment.

4. Manufacturer’s advice.

5. Directives from Network Rail.

As part of the machine’s seven year review.

The frequency and content of each job description shall be reviewed and the records retained for audit purposes.

Each component failure should be assessed if there is a failure of maintenance that either caused or contributed to

the failure. The maintenance instruction should then be amended to refl ect the lessons learnt.

Regular reviews of the machines performance, reviews of maintenance activities, changes of use or frequency of

use of the machine, and external information could lead to changes in the instruction.

Each change of the instruction should be authorised by a nominated competent engineer. The amended instruc-

tion needs to be re-certifi cated by a CCB. It is recommended instruction the plan is kept as a live document, with

each change authorised by the competent engineer, who should decide if the amendment is serious (and requires

re- certifi cation immediately) or whether several changes can be bundled together and re-certifi cated at an annual

review.



Table of contents

1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1. Staff competency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2. Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3. Defi nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3. Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1. Data panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2. Identifi cation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3. CE Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4. Machine diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5. Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7. General operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.1. Daily checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.2. Layout and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.2.1. General features of trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.2.2. Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.3. Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.4. On / Off tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.5. Rail axle deployment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.5.1 Lowering rail axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.5.2. Raising rail axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.6. Rail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.7. Emergency recovery procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.8. Loading & unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26



8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1. Safe working practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1.1. Before maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1.2. Renewal policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1.3. Tightening of threaded fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.2. Maintenance frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.3. Summary of jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.3.1. Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.3.2. Rail axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.3.3. Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.4. Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.4.1. Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

8.4.2. Rail axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8.4.3. Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9. Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

9.1. Drawing no. 003: wheel profi le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

10. Rail Products UK Bolt, Screw & Nut Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11. Model Equipotentially Bonding Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

12. Spare Part ATR450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55



1. Foreword

It is the policy of Rail Products UK to promote safety in the operation and maintenance of its machines and to

create a general awareness of site safety and safe working practices.

This instruction has been written to provide the information necessary to keep the machine operating safely and

effi ciently throughout its service life.

This instruction is intended for both new and experienced personnel. It should remain with the machine at all

times. All 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.

This Manual details practices and operations that Rail Products UK recommend.

DO NOT operate this machine in ways other than those detailed within the manual of the ART 17 T(H) version 6.3

onwards.

Prior to commencing maintenance work you must:

Read and fully understand the enclosed working instructions. Ensure that any required safety precautions have

been taken. Adhere to safety notices contained within this manual.

Fully understand the risks involved and be competent to perform the work. Use only genuine spare parts as re-

placement items.

Ensure that prior to the machine being used, after maintenance work has been completed, all safety checks and

tests have been completed.

In accordance with their policy of continuous development Rail Products UK. reserve the right to amend the specifi -

cations of its machines without prior notice.

Rail Products UK does not accept liability for:

• Machines that have been altered or modifi ed without Rail Products UK’s prior written approval.

• Machines not maintained in accordance with the conditions of operation and maintenance as specifi ed within

this manual.

• Neglect of local or national government regulations.

• Damage or injury (whether direct or consequential) resulting from ignorance or failure to comply with any of

the above items.

Please contact Rail Products UK if you have any queries.

It is the owners/users responsibility to know and comply with all applicable rules, regulations, laws, codes and any

other requirements applicable to the safe use of this equipment.



1.1. Staff competency

In order to comply with the requirements of Railway Group Standards, the following minimum level of compe-

tence required is:

• For all activities the person leading the task must be able to follow and carry out the instruction detailed in

this document.

In order to carry out this Maintenance Programme in a manner that achieves the required safety and quality, the

following minimum level of competence is required:

a) For all activities the person leading the task must be able to follow and carry out the instruction detailed in this

document. All Safety Critical Work must be carried out by persons competent in accordance with: Health and

Safety Executive publication “Railway safety principles and guidance” part 3 section A.ORR railway safety

publication 1 “Developing and maintaining staff competence” March 2007. The railway and other guided trans-

port systems “safety regulations 2006” and “Guidance on regulation, part 4 safety critical work.

b) All work relating to the maintenance and overhaul of axle bearings should be carried out by competent

persons.

All work relating to the maintenance and overhaul of axle bearings should be carried out by competent persons.

Requirements for axle bearings are set out in GMGN2646; these do not apply to possession-only rail machines but

may be used as a source of information.

Staff undertaking this work must have been trained and hold the following certifi cates of competency:

• SCWID (Safety Critical Work Identifi cation)

• Apprentice trained Craftsman/NVQ Level 3 in plant maintenance.

• Certifi cate issued by a CITB/CTA approved body – operation for maintenance purposes only.

• Re-assessment of competency in accordance with operator’s maintenance policy.

• All operators have to be Sentinal trained, using the NSARE scheme.

1.2. Facilities

In order to comply with the requirements of Railway Group Standards, all work described in section nine shall be

carried out using facilities (including those of sub contractors) which as a minimum have the following:

• Clean, dry, covered accommodation for dealing with wheelsets, bearings, mechanical, hydraulic, electrical

components and systems.

• Adequate illumination for inspection of components and underframes.

• Cleaning facilities that will not cause damage to the components.

• Handling facilities for removal and refi tting of components such as wheels.

• Protection from the weather of vulnerable areas of the machine and its components.

These maintenance activities may be carried out at any location, where the work area is correctly protected,

suffi cient clearance is available around the machine and movements will not present risks to other staff and the

machine is correctly secured against movement. Ensure all oil, grease and other fl uid containers or contaminated

materials are stored or disposed of as per the relevant procedures. Any specifi c requirements over and above those

listed will be identifi ed in the applicable job descriptions.

Record keeping

Auditable records of maintenance to this manual shall be kept in accordance with RIS-1530-PLT.

The trailer log book must be updated after each maintenance activity.



1.3. Defi nitions used in this manual

Term Defi nition

Adjust Correct to defi ned limits.

Change Remove the original, and fi t a new or overhauled part or assembly in its place.

Check Determine a particular nominal condition before, during or after repair, e.g. completeness, security

and position.

Clean Take off all dirt and deposits.

Defect Any fault or faults in a component or assembly that prevent it from Defective fulfi lling its designed

purpose.

Dismantle Take to pieces.

Examine Determine general condition before repair, e.g. wear, cracks, splits, leaks, scoring, corrosion, breaks,

distortion and looseness.

Gauge Determine a nominated dimension by using suitable measuring equipment, for example ruler,

micrometer, callipers, feeler gauges or Go/No-Go gauge.

Inspect Determine conformity to required standards during and after repair.

Overhaul Do what is necessary to make an assembly or sub-assembly reusable, that is dismantle, strip, clean,

examine, fi t new parts, repair, reassemble, test and inspect as required.

Paint Impart colour to a surface.

Reassemble Put together

Record Put down in writing the result of any specifi ed examination, test or inspection.

Rectify To set right (does not include renewal)

Refi t Put back together and reconnect.

Remove Disconnect and take off.

Renew Remove and scrap the original part, and provide a new specifi ed part in its place.

Repair Restore an original part to the required condition e.g. by hand tooling, machining, building up, weld-

ing, patching, bending and setting, heat treating, re-securing etc. (Does not include renewal).

Report Convey to the Supervisor the condition of the item examined.

Strip Remove covering, that is, paint, polish, fabric.

Test Prove correct operation by specifi ed trial.



2. Introduction

The ATR450 is designed to operate in a railway environment for the transportation of goods and equipment. This is

its “intended use”.

The ATR450 is not to be used on public roads. It is only suitable for in-possession rail working.

The ATR450 trailer must only be towed by the machine for which it is specifi cally designed, the Manitou ART 17 T(H).

At the front of the ATR450 is a coupling that is used to attach the ATR450 to the towing machine for on rail duties.

In use, it shall NOT be uncoupled from the towing RRV and left on track.

An assessment of the route over which the trailer is intended to be travelled should be undertaken prior to work,

and that any areas over which the trailer cannot be taken identifi ed (raised check rails) and briefed to staff.

Limitations as per ‘Engineering Conformance Certifi cate’ (ECC).

Before operating the ATR450 ensure that each operator has read and fully understood the operating manual.

Failure to do so may result in death or serious injury.



3. Specifi cations

Width 1.630 m.

Overall Length 2.70 m.

Weight 70.9 kg

Height on Transport Wheels 0.51 m.

Height on Rail Wheels 0.61 m.

Maximum Carrying Capacity 450 kg

Maximum Travel and Working Speed 4 km/h (2.5 mph)

Maximum Rail Cant - Travelling 180 mm.

Maximum Rail Cant - Working 200 mm. (8°)

Maximum Rail Gradient 1:25

Transport Wheel Diameter 250 mm. – 50 mm. tread

Rail Wheel diameter 160 mm.

Maximum Load 450 kg

Speed restriction for night time working is 4 km/h (2.5 mph)



3.1. Data panel

Example data panel ATR 450.

3.2. Identifi cation

This product carries a CE-mark. This means that the machine is build and delivered according the fundamental safe-

ty and healthy requirements on design, maintenance, operating and adjustment of the machine.

Example identifi cation ATR 450.



3.3. CE Declaration



4. Machine diagram



5. Electrical circuit diagram



6. Safety

• Do not carry passengers.

• Do not operate under energised overhead cables.

• In use, it shall NOT be uncoupled from the towing RRV and left on track.

• Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of

the ATR450.

• Do not alter, modify or disable in any way the controls or any other part of the machine.

• If an operator encounters any suspected malfunction on the ATR450 or any hazard or potentially unsafe

condition relating to capacity, intended use or safe operation, the operation shall cease, and request

further information as to safe operation from his management, or owner, or manufacturer before

further operation of the ATR450.

• The operator shall immediately report to their superior any problems or malfunctions, which becomes

evident during operation. Any problems or malfunctions that affect the safety of operation shall be

repaired prior to continued use and the machine log book must be updated accordingly.

• The operator shall implement means provided to protect against use by unauthorised persons.

• Should the trailer become detached from the host machine (Manitou ART 17 T(H)) it is prevented from

runaway by the trailer draw bar.

• Be careful with hands and feet when coupling, un-coupling, lifting and maintenance.

• Wear Safety-Gloves and Shoes when operating the trailer.

• Be careful with Electricity (Wiring – Lights – Battery).

• When trailer is not in use, it must be lifted off track (minimum 4 person lift) and placed on level ground.

The trailer design prevents a runaway situation.



• As a minimum, the following PPE must be worn at all times, whilst operating the trailer:

- Hi-vis trousers and jacket (current specifi cation)

- Safety boots (current specifi cation)

- Hard hat (current specifi cation)

- Some tasks may involve additional PPE requirements, as detailed within site specifi c risk assessment packs.

• Operators working on a PTS sight must have an valid PTS medical certifi cate and comply with site health

and safety regulations

• The trailer can travel under live OLE but it can not work under live OLE.

• The trailer is not intended for passenger or freight transport.

• The trailer may not circulate freely or work without restriction on switches, level crossings or other

installations. Possession only rail trailer.

• Do not operate under energised overhead cables.

ART 17 TH with ATR 450 in Plant gauge ART 17 TH with ATR 450 in Plant gauge

incl. exceedances



7. General operating instructions

7.1. Daily checklist

Before use each day, or at the beginning of each shift, the operator must check the safe condition of the machine

by visual inspection including, but not limited to the following:

• Operating and Safety Manuals are legible.

• Frame for damage.

• All instruction and warning labels are legible.

• All wheels for loose or missing fastenings.

• Lights, operational & undamaged.

• Check for loose, missing or damaged parts.

• Check the mounting of the railwheel is undamaged.

• Ensure routine maintenance is up to date; see section 8 of this manual.

Please take the latest Network Rail Infrastructure Plant Manual for further operational and industry for guidance

Do not operate until all occuring fails have been rectifi ed by a competent person!



7.2.2. Decals

1. Trailer Light System. 3. Trailer Light Operation OFF.

2. Battery. 4. Trailer Light Operation ON.

1

2

3

4

3

4

3

1

2

Key:

1. Road Wheel

2. Rail Wheel

3. Axle Locking Pin

4. Coupling Eye

7.2. Layout and locations

7.2.1. General features of trailer



7.3. Trailer coupling

Align the ATR450 coupling with the towing machine.

Align the towing eyes and connect the machine to the ATR450 securely using the machine towing pin, as shown in

the next fi gure.

Personnel must not stand in between the machine and trailer. Manual handling is required, minimum 2 person lift

(unless the entire trailer has to be lifted, in this case, minimum 4 person lift).

Connect the trailer brakeaway cable. See operators and instruction manual 6.4 AART 17 TH.

7.4. On / off tracking

The driver should inspect the designated rail access point to ascertain suitability for safe on tracking. The preferred

access is on a level crossing.

Points to consider are:

• Sleepered or ballasted track area.

• Road to trackside access: Suitable Gradient, Level Surface, Good Visibility.

• Rail on tracking point, Level Rail (maximum of 150 mm. cant), No Railside Obstructions (points, signalling

equipment, 3rd rail etc.).

• No steep embankments adjacent to access point.

• No personnel in the vicinity of on/off tracking area.

• Machine controller on site to guide driver and engage rail wheels with track.

Align the ATR450 rail wheels with the track. Fully lower the rail wheels (see Page 19, Rail Axle Deployment).

Off tracking is a reverse of the above procedure.

NOTE:

In use, it shall NOT be uncoupled from the towing RRV and left on track.

Ensure that all personnel are outside the operating range of the machine.

At all times great care must be taken to ensure that the machine remains stable. Re-start towing machine with

park brake applied.

Towing should be done in low gear at MAXIMUM speed of 4 km/h.

Total combined weight of ATR450 (70.9 kg) and max. load (450 kg) should not exceed the allowable maximum

trailing load specifi ed on the towing machine’s engineering acceptance certifi cate.



7.5. Rail axle deployment

7.5.1. Lowering rail axle (only to be carried out in unladen condition)

The rail axle is lowered onto rail line manually.

Release the Secure Clip and Axle Locking Pin beside each wheel. Lift the rear of the trailer. If the axle does not

slowly lower, push down on the axle until the locking holes correspond. Then secure the axle with the Locking pins

and clips.

Ensure latches on both wheels locate.

7.5.2. Raising rail axle (only to be carried out in unladen condition)

Release the latches on both axle ends and raise until the latch holes locate in the top position. Ensure latches on

both wheels locate. Insert the locking pin into the hole and secure with secure clip.

7.6. Rail lights

The lights should be switched

on whenever the ATR450 is

placed on the track. The con-

trol switch is located on the

front of the ATR450 on the

side of the rail light box.

When the ATR450 is station-

ary or moving forward, the

switch must be in the right

hand position, with red lights

showing. When reversing the

switch must be changed to

the left hand position, show-

ing white.

12

1. Axle Locking Pin

2. Secure clip



7.7. Emergency recovery procedure

Should it be necessary to move the trailer without a correctly confi gured towing machine being available, lift &

carry off track.

Max. estimated time for recovery is 5 min.

Trailer must only be lifted by a minimum of 4 personnel.

The emergency recovery procedure:

• Be careful for hazardous conditions.

• Uncouple the trailer by disconnecting the lead of the connector.

• Couple the lead into the contra-connector.

• Connect the coupling pin into the coupling of the ART 17 T(H).

• Switch the lights of the trailer into ‘‘ON’’.

• Lift the trailer into a safe working area.

• Switch the lights of the trailer into ‘‘OFF’’.

The trailer must only be removed in an unladen condition.



7.8. Loading & unloading

Loading and unloading can be dangerous. Machinery can seriously hurt people. Heavy loads, moving or overturn-

ing machines and working at height can all lead to injuries or death.

This guidance should be followed to help avoid problems.

Guidance

Loading and unloading areas should be:

- Clear of other traffi c, pedestrians and people not involved in loading or unloading.

- Clear of overhead electric cables so there is no chance touching them, or of electricity jumping to ‘earth’

through machinery, loads or people.

- Level. To maintain stability, trailers should be parked on fi rm level ground,

- Loads should be spread as evenly as possible, during both loading and unloading. Uneven loads can make the

machine or trailer unstable.

- Loads should be secured, or arranged so that they do not slide around. Use of lashing down points may help

stability.

- Safety equipment must be considered. There may be other mechanical dangers and safety procedures to be

considered.

- Ensure the machine or trailer is as stable as possible.

- No-one should be in the loading/unloading area if they are not needed.

- Trailers must never be overloaded. Overloaded trailers can become unstable, diffi cult to steer or be less able to

brake.

- Always check the fl oor or deck of the loading area before loading to make sure it is safe. Look out for debris,

broken parts, cracks, etc.

- Loading should allow for safe unloading.

- Loads must be suitably packaged. When pallets are used, the driver needs to check that:

- They are in good condition

- Loads are properly secured to them.

- Loads are safe on the machine. They may need to be securely attached to make sure they cannot fall off.

- If over-hang cannot be avoided, it must be kept to a minimum. The over-hanging part of the load must be

clearly marked.

- If more than one company is involved, they should agree in advance how loading and unloading will happen.

For example, if visiting drivers unload their machines themselves, they must receive the necessary instructions,

equipment and co-operation for safe unloading. Arrangements will need to be agreed in advance between the

machine controller and the workers.

- Checks must be made before unloading to make sure loads have not shifted during transit, and are not likely to

move or fall when restraints are removed.This does happen, and is extremely dangerous. Measures could

include:

- The person in charge of loading or unloading could keep hold of the machine keys or paperwork until it is

safe for the machine to be moved.



8. Maintenance

Auditable records of maintenance to this manual shall be kept in accordance with RIS-1530-PLT.

8.1. Safe working practice

8.1.1. Before maintenance tasks

Machine must be on fi rm level ground.

Chock wheels.

Warning - welding

When welding do NOT use the ATR450 as a ground.

Threaded fasteners

8.1.2. Renewal policy

All split cotter pins, star washers, locking tabs, spring washers and prevailing torque nuts removed during main-

tenance and repairs MUST BE RENEWED. All other fasteners removed during maintenance and repairs shall be

renewed if any part of them is worn or distorted.

8.1.3. Tightening of threaded fasteners

Where torque loading is specifi ed nuts must only be tightened by means of a calibrated torque wrench.

Threads are not to be lubricated but a thin fi lm of corrosion inhibitor can remain on the threads, unless otherwise

stated.

The torque fi gures quoted in this instruction apply only to self-coloured (i.e. unplated) nuts. Where plated nuts are

used the manufactures torque fi gures must be used.

Unless otherwise specifi ed, slotted nuts shall be over tightened if necessary to align the next slot to allow for the

insertion of split cotter pins. Under no circumstances shall nuts be eased back.

When prevailing torque nuts are used, whether of the nylon insert type or bent beam type, at least 2 complete

threads of the bolt must protrude through the nut.

8.2. Maintenance frequencies

The trailer is to be examined at frequencies no greater than the limits set out below:

Type Of Exam Working Hours Calendar Time

A 10 Daily or pre use

B 50 Weekly

C 250 Monthly

D 1500 6 Monthly

E - Yearly

F - 2 Yearly



8.3. Summary of jobs

8.3.1. Wheels

Scheduled work

Exam Code:Job Title Intent Job No.

A B C D E F

Wheel Nuts Check 8.4.1.1 • • • • •

Rail Wheels Check 8.4.1.2 • • •

Rail Wheels Examine 8.4.1.3 • • •

Rail wheel back to back Check 8.4.1.4 • • •

Transport Wheels Examine 8.4.1.5 • • • • •

8.3.2. Rail axles

Scheduled work


A B C D E F

Rail axles Check 8.4.2.1 • •

Rail axles pivots Examine 8.4.2.2 • • • • •

Rail axles Examine 8.4.2.3 • • •

Rail head scrapers Examine 8.4.2.4 • • • • • •

8.3.3. Superstructure

Scheduled work


A B C D E F

Safety Labels Check 8.4.3.1 • • • • • •

Tow Connection Examine 8.4.3.2 • • • • • •

Underframe & Superstructure Check 8.4.3.3 • • •

Underframe & Superstructure Examine 8.4.3.4 • • •

Lights Examine 8.4.3.5 • • •

Visibility of Paintwork Check 8.4.3.6 • • • • •

Battery Check & Test 8.4.3.7 • • •

Wiring Examine 8.4.3.8 • •

Trailer Breakaway Cable Examine 8.4.3.9 • • • • •



8.4. Maintenance instructions

Scheduled Work: is that mandatory work which should be undertaken at the prescribed examinations.

Arising Work: is that work that is to be done to rectify the defects found in the course of carrying out Scheduled

Work.

The item numbers of the two parts correspond. I.e. the work to be done to rectify a defect in item 2 of scheduled

work will be found in item 2 of arising work.

Torque data for all bolts, screws and nuts is in section 10. This must be adhered to unless otherwise stated.



8.4.1. Wheels

8.4.1.1. Wheel location bolts - CHECK

Scheduled work

1 Check the rail wheel bolt (in the front centre of the wheel) is tight by grasping the wheel and testing for

any side-to-side play. This is factory tightened and locked with Loctite.

2 Check the axle bolt at the inside of the wheel. The wheel axle should not have any play. This is factory

tightened and locked with Loctite.

Arising work

1 Should the wheel show any signs of side to side play, the fi xing bolt should be totally removed, cleaned and

retightened with new Loctite (heavy duty). Tighten until the spill is gone and the wheel is still running

smoothly. Be sure new heavy duty Loctite is used.

2 Should the wheel axle be loose, the fi xing bolt should be totally removed, cleaned and retightened with

new Loctite (heavy duty). Tighten this M10 RVS 10.9 bolt with 65 Nm. Be sure new heavy duty Loctite is

used.

2

1

1 Axle bolt

2 Wheel bolt



8.4.1.2. Rail wheels - CHECK

Scheduled work

1 Visually check the wheels for any signs of pitting, scoring, fl at spots or other damage.

Arising work

1 Carry out Job No. 8.4.1.3 Rail wheels – Examine.



8.4.1.3. Rail wheels - EXAMINE

Scheduled work

1 With the trailer standing on its transport wheels, ensure that the rail wheels are in the locked position.

2 Clean the entire wheel fl ange and tread, removing any grease, corrosion and debris.

3 Rotate the wheel slowly by hand, and examine all surfaces of the wheel, checking for cracks, cavities, metal

migration and fl ats. The limits for each will be found on Table 1. A description of the types of defects will

be found in clauses A, B & C. Record fi ndings on Table 1.

4 Use a P1 profi le gauge (fi gure 1) and feeler gauges to check the following.

4.1 The hollow-wear on the tread is less than 1.5 mm.

4.2 Flange wear is less than 4 mm. See Clause 6 if doubt exists.

4.3 There are no steps in the fl ange profi le greater than 1.5 mm.

4.4 The tread to the outside of the wheel is not more than 2 mm. above the running tread surface (a false

fl ange). See fi gure 2.

This dimension is not

to exceed 2.0 mm

Figure 1

Figure 2



Vehicle no:

Location: Examiner:

Record fi ndings here:Type of defect Allowable Limit

Tick if none found: Record details if found:

Cracks

See section 3 None allowed

Cavities

See section 4 15 mm. length

Migration 5 mm. tread roll over,

See section 5 otherwise no limit

Flats 20 mm

Tick if wear is less than limits, or record if amount is over limit

Wear / Limit Axle: Axle:

Defect (mm) LEFT*: RIGHT*:

Tread Hollow 1.5

Flange 4

Steps 1.5

False Flange 2

Rail/road wheel

diam. 250 mm. 10

Table 1

* Left and Right is defi ned as standing with ones back to the vehicle in the normal direction of travel.

If required, a more accurate method of gauging fl ange thickness is to use gauge to Drg. B-A2-1710 (BR Cat No

39/29839) as follows:

With face A squarely on the fl ange back, hold the gauge radially to the wheel and draw it into profi le, see

next fi gure.

Acceptable profi les are indicated by the gauge contacting the profi le only at the fl ange.

Pass Fail

Gap Gauge touching

Use of GO/NO GO fl ange thickness and height gauge to Drg. No B-A2-1710 to measure fl ange thickness

Flange height as new 30.0 mm - Max. Worn 36.5 mm.Flange thickness as new 28.0 mm - Max. Worn 24.0 mm.



Arising work

3 Re-Profi le Wheel to Drg No 003. (see section 8)

4 Re-Profi le Wheel to Drg No 003. (see section 8)

Change the wheels in matched pairs if re-profi ling is not possible, or if rail wheels diameter will be reduced

below the following: 150 mm.

Report fi ndings to supervisor.

Descriptive clauses:

A. Cracks

Cracks normally have a jagged saw tooth-type of surface profi le with sharp edges. Cracks will normally form at

the tread chamfer in an axial direction (across the thread) see Figure Wheel with crack.

Figure Wheel with crack

No cracks are permitted. Renew wheels unless the cracks can be completely removed by re-profi ling.

Crack

TreadFlange



B. Cavities

Rolling contact fatigue causes microscopic subsurface cracks which develop into a localised network.

(See Figure Microscopic cracks).

Figure Microscopic cracks Figure Cavities

Over a long period small sections or spalls break away leaving cavities (see Figure Cavities). Record the number

and length of the cavities. Take action if the length of any cavity exceeds 15 mm, or if two cavities are with-

in 50mm. of each other and their combined length exceeds 15 mm. Re-profi le wheels to remove cavities and

cracks, otherwise renew the wheels.

C. Migration

Material migration results from a rolling action that forces the surface material sideways. This can occur in two

places:

C1. Tread Rollover: This forms on the tread chamfer (see Figure Rollover limit). The maximum allowable is 5

mm. Associated with this are circumferential cracks (see Figure Circumferential cracking) which do not affect

the integrity of the wheel.

Figure Circumferential cracking Figure Rollover limit ass. with rollover

5 mm. max

Tread

rollover



C2. Migration down the fl ange, is shown in the next fi gure, where the extreme edges have fl aked off.

Figure Migration down the fl ange

This does not affect the integrity of the wheel. These defects are removed when re-profi ling becomes neces-

sary to restore the wheel profi le.



8.4.1.4. Rail wheel back to back - CHECK

Scheduled work

1 Check Wheel back-to back measurement is within tolerance of 1358mm – 1362mm (manufactured/-

re-profi led) and 1358mm – 1363mm (in service). using a wheel spacing gauge, Part No. 7540, at three

locations around the wheels.

Arising work

1 If out of tolerance at any of the three locations the trailer should be returned to Rail Products UK for

adjustment.



8.4.1.5. Transport wheels - EXAMINE

Scheduled work

1 Examine the transport wheels (part no. 84017142). The following are unacceptable:

1.1 Distortion of more than 10 mm.

1.2 Cracks.

1.3 Look for missing bolts and washers, replace if required.

Arising work

1.1 Renew defective wheels.

1.2 Renew defective wheels.

1.3 Renew missing components and seal with Loctite, see Figure 2.

Figure 1 Figure 2

Remark

Matching transport wheels must be fi tted.

Detail transport wheel

Seal with loctite



8.4.2. Rail axles

8.4.2.1. Rail axles - CHECK

Scheduled work

1 Visually check the Axles for any signs of deformation, cracks or damage.

Arising work

1 Carry out Job No. 8.4.2.3 Rail Axles – Examine.



8.4.2.2. Rail axle pivots - EXAMINE

Scheduled work

1. Examine pivot for any signs of distortion, cracks, broken welds and damage.

2. Test rail axle fi xations. Ensure fi xation pins and security clips on both wheels locate.

3. Check pivot bolts are tight and the axle will raise and lower with a little effort.

Arising work

1. Renew defective components or repair.

2. Renew defective components.

3. Examine threads for damage. Renew defective components.

Figure 1: Rail axle pivot



8.4.2.3. Rail axles - EXAMINE

Scheduled work

1. Examine axle for any signs of distortion, cracks or surface damage.

2. Ensure bearing securing bolts are tight. Check for any signs of movement between bolted faces.

3. Rotate wheels and check they run true.

Arising work

1. Renew axle.

2. If any nut/bolt moves more than half a turn renew them all.

3. Renew axle.



8.4.2.4. Rail Head Scrapers - EXAMINE

Location

• Both rail wheels.

Scheduled work

1. Examine the integrity & security of the rail head scrapers.

2. Ensure that they do not exceed the maximum distance from the rail head of 30mm.

Arising work

1. Straighten & adjust the scrapers or replace the rubber sweeper as required.

2. Straighten & adjust the scrapers or replace the rubber sweeper as required.



8.4.3. Superstructure - Safety Labels – CHECK

8.4.3.1. Safety labels - CHECK

Scheduled work

1 Check labels are in place and are legible (see Section 7.2.2. for position of labels).

Arising work

1 Renew labels.



8.4.3.2. Tow connection - EXAMINE

Scheduled work

1 Examine condition of tow connection eye.

2 Examine the condition of the swan neck draw bar for any signs of cracks, damage, wear or deformation.

Arising work

1 Renew or repair, competent staff required.

2 Renew or repair, contact Rail Products UK as it is an integral part of the trailer.



8.4.3.3. Underframe - CHECK

Scheduled work

1. Check the structure for any signs of defects, such as; cracks and deformation.

2. Check the trailer decking and 6 lashing down points for presence and security.

3. Check the side of the trailer for any signs of wear or damage.

Arising work

1 Repair defective welds in accordance with procedure prepared by competent body or seek advice from Rail

Products Europe.





8.4.3.4. Underframe - EXAMINE

Scheduled work

1 Examine the structural members of the underframe for any defects such as cracks and distortion.

2 Examine the trailer decking and lashing point.

3 Examine the frame and mesh forming the body sides for distortion, broken welds and damage.

Arising work

1 Repair defective welds in accordance with procedure prepared by competent body or seek advice from Rail

Products Europe.





8.4.3.5. Lights - CHECK

Scheduled work

1 Examine lenses.

2 Check switch and lights operate correctly.

3 Examine wiring, looms and plugs.

Arising work

1 Renew or clean lenses as required.

2 Renew switch / fuse / lights.

3 Renew faulty wiring, re-secure loose connections and replace plugs as required.



8.4.3.6. Visibility of paintwork - CHECK

Scheduled work

1 Check the paintwork around the trailer is visible and yellow i.e. not discoloured.

Arising work

1 Clean trailer.

1 Repaint machine or affected areas.



8.4.3.7. Battery - CHECK & TEST

Scheduled work

1 Plug voltmeter capable of reading at least 20 volts into charging socket and turn lights on.

2 Check the voltage is at least 12 volts.

Arising work

1 Charge battery.

2 Renew battery

2.1 Remove bolts holding battery box lid and take off lid.

2.2 Remove screws and strap.

2.3 Remove battery connections.

2.4 Remove battery.

2.5 Reassemble in reverse order with new battery.

NOTE: When replacing the battery care must be taken not to crush the wires.

Dispose of battery in a careful and considerate manner, be mindful of hazardous waste. There are no other

potential chemical hazards to consider on the trailer.



8.4.3.8. Wiring - CHECK

Scheduled work

1 Examine condition of wiring, looms and plugs.

Arising work

1 Renew faulty wiring, re-secure loose connections.



8.4.3.9. Trailer Breakaway Cable - EXAMINE

Scheduled work

1. Examine the trailer breakaway cable for any signs of wear or damage.

Arising work

1 Replace the cable.

NOTE: Trailer breakaway alarm is tested using the host machine (ART 17T (H).



9. Drawings

9.1. Drawing no. 3 - Wheel profi le



10. Rail Products UK bolt, screw & nut torque data

Grade

8.8 10.9 12.9

Size Torque Torque Torque

Nm lbf ft Nm lbf ft Nm lbf ft

M2 0.34 0.25 0.48 0.35 0.58 0.43

M2.5 0.7 0.5 1.0 0.7 1.2 0.9

M3 1.2 0.9 1.7 1.3 2.1 1.5

M3.5 1.9 1.4 2.6 1.9 3.1 2.3

M4 2.8 2.1 3.9 2.9 4.7 3.5

M5 5.5 4.1 7.7 5.7 9.3 6.9

M6 9.4 6.9 13 10 16 12

M7 16 12 22 16 26 19

M8 22 16 32 24 38 28

M10 45 33 65 48 75 55

M12 75 55 110 81 130 96

M14 120 90 170 125 205 151

M16 190 140 270 199 320 236

M18 265 195 365 269 440 325

M20 370 275 530 391 631 465

M22 510 380 720 531 860 634

M24 650 480 910 671 1090 804

M27 950 700 1300 959 1560 1150

M30 1290 950 1810 1335 2170 1600

M33 1750 1290 2450 1808 2950 2176

M36 2250 1660 3160 2330 3790 2795

M39 2910 2150 4100 3025 4920 3628

M42 3610 2660 5070 3740 6090 4491

M45 4530 3340 6360 4690 7640 5634

M48 5430 4010 7630 5630 9150 6748

M52 7000 5170 9340 6890 11810 8709

M56 8660 6390 12180 8990 14620 10782

M60 10990 8110 13460 9930 20080 14808

M64 12980 9580 18250 13470 21900 16150

Bolts, screws and nuts under M20 are grade 8.8

Bolts, screws and nuts over M20 are grade 10.9

Cap heads are grade 12.9



11. Model Equipotentially Bonding Form



12. Spare Parts ATR450

operation and maintenance instruction handbook

Documents