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JCB 714 Super-Boss Road/Rail Conversion

SB002

Operator’s Manual

Issue 1, R2

Last Updated 5 April 2017

Page 1 of 43

RAIL OPERATIONS

AND

EMERGENCY RECOVERY PROCEDURES

RAIL-ABILITY

JCB 714 SUPER BOSS ROAD/RAIL

VEHICLE

Summary of Contents for JCB 714

Page 1: ...4 Super Boss Road Rail Conversion SB002 Operator s Manual Issue 1 R2 Last Updated 5 April 2017 Page 1 of 43 RAIL OPERATIONS AND EMERGENCY RECOVERY PROCEDURES RAIL ABILITY JCB 714 SUPER BOSS ROAD RAIL VEHICLE ...

Page 2: ...ury Hazards 14 Burn Hazards 14 Electrocution Hazards 14 Lifting Hazard 15 Decal Legend 15 Rail Safety Rules 16 On Off Tracking the Machine general points 16 Travelling on the Rail 16 Emergency Off Tracking 17 Pre operation Inspection 18 Fundamentals 18 Checks 19 Maintenance 21 Check the Engine Oil Level 21 Check the Hydraulic Oil Level 21 Check the Batteries 21 Check the Tyre Pressures 22 Check fo...

Page 3: ...5 Fundamentals 35 Tests 35 From ground level 35 Pre Test Rail Drive Braking 35 From the vehicle cab 36 Test Emergency Stop 36 Test the Horn 36 Test Road Drive Braking 36 Test the Rail Gear Deployment 36 Test Rail Drive and Rail Braking 37 Suggested On Off Tracking Area Requirements 38 Emergency Recovery Off Tracking 39 Emergency Recovery 39 Recovery Pump 39 Earth Bonding Straps 41 Transport and Li...

Page 4: ...es from Power Lines up to 33kV on Wooden Poles 12 Figure 7 Ignition Park Gear and Controls 25 Figure 8 GUI Screen Diagram 28 Figure 9 Initial Boot Screen Page 29 Figure 10 Immobiliser Code Entry 29 Figure 11 Main Screen Page 30 Figure 12 Rail Axle Control Page 31 Figure 13 Axles Down Display 31 Figure 14 Selecting Front Rear Axles 32 Figure 15 Main Menu Page 32 Figure 16 Inputs Outputs Menus 33 Fi...

Page 5: ...tate Stafford Staffordshire ST16 3HS Tel 01785 214747 Fax 01785 214717 E Mail mail railability co uk www railability co uk DESCRIPTION AND INTENDED USE The Rail Ability machine consists of a road going JCB 714 718 4x4 articulated truck chassis modified for use on rail The chassis is fitted with rail gear front and rear to enable rail travel Mounted to the rear of the chassis is a demountable modul...

Page 6: ...ge 6 of 43 MANUALS Title Part No Rail Ability Operator s Manual Edition see cover See cover Rail Ability Service Manual Road Rail JCB Hybrid 714 Host machine RASBAMI001 JCB 714 Operator and Service Manual 9801 7160 JCB 714 Parts Book M830178 Module Operator and Service Manuals Consult Module Manufacturer ...

Page 7: ...714 Super Boss Road Rail Conversion SB002 Operator s Manual Issue 1 R2 Last Updated 5 April 2017 Page 7 of 43 SPECIFICATION PRINCIPAL DIMENSIONS Figure 1 W6A Gauge Drawing Figure 2 Module Fitment Dimensions ...

Page 8: ...JCB 714 Super Boss Road Rail Conversion SB002 Operator s Manual Issue 1 R2 Last Updated 5 April 2017 Page 8 of 43 Figure 3 General Assembly Refer to specifications table on the next page ...

Page 9: ...TAL DATA LIMITS SOUND POWER LEVEL ENGINE LWA 107DB VIBRATION 2 5 M S2 OPERATING TEMPERATURE 5 C TO 30 C MAXIMUM GRADIENT RAIL 1 IN 25 MAXIMUM CANT RAIL 150 MM MAXIMUM SLOPE RATING STOWED POSITION ON TYRES 3 0 MAXIMUM SIDE SLOPE RATING STOWED POSITION ON TYRES 3 0 POWER SUPPLY POWER SOURCE 24 VOLT D C BATTERIES 2 X 115 AH CONTROLS PROPORTIONAL 110 VOLT AC OUTLET OPTIONAL 24 VOLT DC OUTLET STANDARD ...

Page 10: ...ng Speed Through Raised Checkrails 2 mph May Be Used On LIVE 3 Or 4 Rail Lines NO Maximum Working Cant See E C C For Module limitations 200mm May Be Used On ISOLATED 3 Or 4 Rail Lines YES Maximum Travelling Cant 200mm May Be Used Adjacent To Running Line in accordance with the E C C YES Maximum Working Gradient 01 25 Minimum 1300mm Height Clearance On Out Of Gauge Tail Swing N A Minimum Track Curv...

Page 11: ...UFACTURER S INSTRUCTIONS AND SAFETY RULES SAFETY AND OPERATOR S MANUALS AND MACHINE DECALS YOU READ UNDERSTAND AND OBEY THE EMPLOYER S SAFETY RULES AND WORKSITE REGULATIONS YOU READ UNDERSTAND AND OBEY ALL APPLICABLE GOVERNMENTAL REGULATIONS YOU ARE PROPERLY TRAINED TO SAFELY OPERATE THE MACHINE Electrocution Hazards THIS MACHINE IS NOT ELECTRICALLY INSULATED AND WILL NOT PROVIDE PROTECTION FROM C...

Page 12: ...gineering Acceptance Certificate for live OLE limitations Collision Hazards BE AWARE OF LIMITED SIGHT DISTANCE AND BLIND SPOTS WHEN DRIVING OR OPERATING THE MACHINE USE A BANKSMAN OR MACHINE CONTROLLER ON THE GROUND WHEN REQUIRED AND DRIVE AT AN APPROPRIATE WALKING SPEED TAKE CARE WHILST MOVING ON RAIL ESPECIALLY WHEN THE BODY IS ELEVATED OUT OF GAUGE OPERATORS MUST COMPLY WITH THE EMPLOYER S JOB ...

Page 13: ...WORK AND WORK PACKAGE PLANNING WHEN OPERATING THE MACHINE WITH A BANKSMAN OR MACHINE CONTROLLER FROM THE GROUND MAINTAIN SAFE DISTANCES BETWEEN THE GROUND STAFF THE MACHINES AND FIXED OBJECTS Component Damage Hazards Do not use any battery or charger greater than 24V to jump start the engine Do not use the machine as a ground for welding DO NOT OPERATE THE MACHINE WITH THE COVERS OR GUARDS OPEN RE...

Page 14: ...EL SHOULD ACCESS COMPARTMENTS ACCESS BY THE OPERATOR IS ONLY ADVISED WHEN PERFORMING A PRE OPERATION INSPECTION Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning ALL COMPARTMENTS MUST REMAIN CLOSED AND SECURED DURING OPERATION Burn Hazards BATTERIES CONTAIN ACID ALWAYS WEAR PROTECTIVE CLOTHING AND EYE WEAR WHEN WORKING WITH BATTERIES AVOID SPILLING OR CONTACTI...

Page 15: ...WING 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 RED USED TO INDICATE THE PRESENCE OF AN IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY ORANGE USED TO INDICATE THE PRESENCE OF A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD...

Page 16: ...st not be travelled across Drainage routes troughing routes and other services cables must not be approached OHLE power cable heights energised isolated and machine earth bonding integrity Confirm isolated no conductor rails or where a sufficient gap exists both sides of the track Adjacent lines closed to traffic Travelling on the Rail Machine travel position as follows Rail Gear deployed fully Th...

Page 17: ... Off Tracking must not be carried out on a cant In the event of a real emergency the procedure for Emergency Off Tracking is as follows Ensure the machine is configured for travel module fully stowed Approach the Off Tracking area at a safe speed Sound the horn to alert personnel at the Off Tracking area as you approach Raise the rear and front rail gear fully Deselect rail mode and steering lock ...

Page 18: ... INSPECTION PERFORMED BY THE OPERATOR PRIOR TO EACH WORK SHIFT THE INSPECTION IS DESIGNED TO DISCOVER IF ANYTHING IS APPARENTLY WRONG WITH A MACHINE BEFORE THE OPERATOR PERFORMS THE FUNCTION TESTS THE PRE OPERATION INSPECTION ALSO SERVES TO DETERMINE IF ROUTINE MAINTENANCE PROCEDURES ARE REQUIRED ONLY ROUTINE MAINTENANCE ITEMS SPECIFIED IN THIS MANUAL MAY BE PERFORMED BY THE OPERATOR REFER TO THE ...

Page 19: ... ADD OIL IF NEEDED SEE MAINTENANCE SECTION CHECK TIGHTNESS OF WHEEL NUTS CHECK CONDITION OF TYRES WHEELS CHECK FOR PROPER TIRE PRESSURE ADD AIR TO THE FRONT TYRES IF NEEDED SEE MAINTENANCE SPECIFICATIONS SECTIONS CHECK CONDITION OF AXLES TRANSMISSION ARTICULATION LOCK CHECK OPERATION OF SERVICE PARKING BRAKE SEE JCB MANUAL CHECK OPERATION OF THE ROAD RAIL LIGHTS AND WARNING BEACONS CHECK FOR BATTE...

Page 20: ...ANGES RAIL SWEEPERS LADDERS STEPS HAND RAILS GUARDS COVERS CHECK THE ENTIRE MACHINE FOR CRACKS IN WELDS OR STRUCTURAL COMPONENTS DENTS OR DAMAGE TO MACHINE EXCESSIVE WEAR RUST CORROSION OR OXIDATION ENSURE THAT ALL STRUCTURAL AND OTHER CRITICAL COMPONENTS ARE PRESENT AND ALL ASSOCIATED FASTENERS AND PINS ARE IN PLACE AND PROPERLY TIGHTENED AFTER YOU COMPLETE YOUR INSPECTION BE SURE THAT ALL COMPAR...

Page 21: ...l MAINTAINING THE HYDRAULIC OIL AT THE PROPER LEVEL IS ESSENTIAL TO MACHINE OPERATION IMPROPER HYDRAULIC OIL LEVELS CAN DAMAGE HYDRAULIC COMPONENTS DAILY CHECKS ALLOW THE INSPECTOR TO IDENTIFY CHANGES IN OIL LEVEL THAT MIGHT INDICATE THE PRESENCE OF HYDRAULIC SYSTEM PROBLEMS PERFORM THIS PROCEDURE WITH THE MODULE IN THE STOWED POSITION 1 VISUALLY INSPECT THE OIL LEVEL IN THE HYDRAULIC TANK THE SIG...

Page 22: ...the rail wheels in good condition is essential to safe operation and good performance Excessive flange and or tread wear could result in machine derailment and tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Bodily injury hazard Excessively worn rail wheels can develop sharp burrs due to material migration Tip over hazard Do not attempt to ...

Page 23: ...epair the leak immediately Scheduled Maintenance MAINTENANCE PERFORMED WEEKLY MONTHLY QUARTERLY SIX MONTHLY ANNUALLY AND 2 YEARLY MUST BE COMPLETED BY A PERSON TRAINED AND QUALIFIED TO PERFORM MAINTENANCE ON THIS MACHINE ACCORDING TO THE PROCEDURES FOUND IN THE SERVICE MANUAL MACHINES THAT HAVE BEEN OUT OF SERVICE FOR MORE THAT THREE MONTHS MUST RECEIVE AT LEAST THE QUARTERLY INSPECTION BEFORE THE...

Page 24: ... 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 SEE THE NETWORK RAIL VAB ENGINEERING ACCEPTANCE C...

Page 25: ...tor s Manual Issue 1 R2 Last Updated 5 April 2017 Page 25 of 43 Control Layout Figure 7 Ignition Park Gear and Controls FOR OTHER CAB CONTROLS PLEASE REFER TO THE JCB MANUAL Gear Selector Auxiliary Control Lever Ignition Key Switch Park Brake ...

Page 26: ...e affect once the chassis is straight This may require the steering to be moved from side to side to find the linear position until the lock engages The steering wheel will no longer turn until the steering lock is turned off again Foot Switch The machine will only travel on rail with the foot switch pressed This interlock prevents the machine from travelling should the operator become incapacitat...

Page 27: ...lated to release the park brake as requested Parking Brake ERROR Off Pressure has not dissipated to release the park brake as requested Steering locked and centred Steering is locked and centred rail drive available Steering locked with ERROR and centred Steering locked and centred but an error is present with one of the locks Steering unlocked and centred Steering is unlocked but centred Steering...

Page 28: ... 5 April 2017 Page 28 of 43 Icon Name Function Return Return to previous page Confirm Accept user input Cancel Clear user input Figure 8 GUI Screen Diagram ok Button F1 Function Key F2 Function Key F4 Function Key F3 Function Key Down Key Left Key Right Key Up Key Screen Display ...

Page 29: ...iate 6 digit passcode must be entered The up down left and right keys on the screen dial will navigate the numbers Once the required number is selected press the ok button to enter it as a passcode digit The DEL button will remove the previously entered passcode digit The F1 key will confirm the entry for comparison to the required passcode if it is correct the user is prompted to confirm and move...

Page 30: ...and the road park brake by the icon in the top right corner When in rail mode the foot SWITCH must be pressed to allow drive via the in cab joystick If drive is requested in rail mode without the foot SWITCH pressed the icon will flash blue to indicate this The PTO text above the F2 button will show white by default indicating the PTO is inactive Pressing the F2 button will request activation of t...

Page 31: ...he display to the main screen page when utilised To allow the machine to travel in rail or road mode the rail axles must be fully deployed or retracted respectively Each axle can only be operated uniquely To select the front or rear axle use the Left key and Right keys respectively The axles are coloured yellow red and green as they move through being up midway and down deployed for rail mode resp...

Page 32: ...s shown above The key machine information such as steering positioning and drive requests will remain displayed Main Menu Figure 15 Main Menu Page Having pressed the ok key at the main screen the main menu will be displayed 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 highligh...

Page 33: ... to select the required categories for their respective status lists Figure 17 Input Output Status On the Inputs Outputs status pages the important system variables will be listed The system component s current status noted in states such as ON and OFF updated in real time Additionally the states of the safe input connections are displayed and change is noted since the system has been powered on U...

Page 34: ...main menu will then display the menu shown above It is possible from this menu to access the control of the brightness of the display s screen and key backlights Figure 19 Screen Brightness Page Using the up and down arrow keys it is possible to increase and decrease the screen brightness respectively Similarly using the F1 and F2 keys will change the brightness to 100 or 50 instantaneously ...

Page 35: ...EST ALL MACHINE FUNCTIONS A MALFUNCTIONING MACHINE MUST NEVER BE USED IF MALFUNCTIONS ARE DISCOVERED THE MACHINE MUST BE TAGGED AND REMOVED FROM SERVICE 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 AND FUNCTION TESTS AGAIN BEFORE PUTTING THE M...

Page 36: ...NCY STOP BY PULLING OUT THE BUTTON Test the Horn 9 PUSH THE HORN BUTTON ON THE STEERING WHEEL O RESULT THE VEHICLE HORN SHOULD SOUND Test Road Drive Braking THE BRAKES MUST BE ABLE TO HOLD THE MACHINE ON ANY SLOPE IT IS ABLE TO CLIMB 10 SELECT FIRST GEAR AND DRIVE FORWARDS SLOWLY 11 BRAKE FIRMLY USING THE BRAKE PEDAL O RESULT THE MACHINE SHOULD STOP PROMPTLY AND FIRMLY 12 SELECT NEUTRAL ON THE TRA...

Page 37: ...ULT THE REAR RAIL GEAR WILL LOWER ONTO THE RAILS AND LIFT THE MACHINE OFF THE GROUND O RESULT THE GREEN INDICATOR LIGHT TO THE LEFT OF THE LEVER WILL ILLUMINATE WHEN THE REAR RAIL GEAR IS FULLY DEPLOYED Test Rail Drive and Rail Braking PRIOR TO DRIVING ON RAIL ENSURE THAT THE CENTRAL ARTICULATING JOINT STEERING LOCK BAR ON THE JCB VEHICLE HAS BEEN LOCKED USING THE PINS PROVIDED ON THE CHASSIS 22 S...

Page 38: ...ddle the track with all road wheels and align the front and rear rail axle with the track 5 Deploy the rear rail axle to only just lift the rear road wheels slightly clear of the sleeper ends 6 Steer the machine to fine align the front rail axle with the track 7 Deploy the rear rail axle fully then deploy the front rail axle fully 8 Straighten the steering with the steering lock active 9 When the ...

Page 39: ...mportant that the machine is placed in a safe position as soon as possible For this reason the JCB 714 has been fitted with a manual recovery pump and tow bar by which another machine can tow it to safety Instructions on how the recovery pump works are described below you must make a point of reading and understanding the procedures so that in the event of a machine failure you are able to put the...

Page 40: ... Page 40 of 43 Raise the rail gear until the drive hubs are no longer in contact with the road wheels The wheels can now roll freely The machine can now be towed to the access point where the rail gear can be lifted fully with the hand pump and the machine can then be towed clear of the line ...

Page 41: ...il axle and chassis see Figure 20 Between rear rail axle and chassis see Figure 21 Between the module and the rear chassis Earth bonding straps must be in place at all times and securely fastened Replace immediately if there are any signs of burning or damage Check impedance levels after refitting any straps Impedance must be below 0 15 Figure 20 Front Rail Axle Bonding Strap Figure 21 Rear Rail A...

Page 42: ...OT DRIVE THE MACHINE ON A SLOPE THAT EXCEEDS THE SLOPE RATING SEE DRIVING ON A SLOPE IN THE OPERATING INSTRUCTIONS SECTION IF THE SLOPE OF THE TRANSPORT VEHICLE BED EXCEEDS THE MAXIMUM SLOPE RATING THE MACHINE MUST NOT BE LOADED AND A SUITABLE TRANSPORT VEHICLE MUST BE OBTAINED Loading Operation AFTER THE MACHINE IS LOADED 1 ENSURE THAT THE RAIL GEAR REMAINS RAISED AFTER LOADING ONLY THE ROAD WHEE...

Page 43: ...CH TO THE OFF POSITION REMOVE THE KEY AND LOCK THE CAB DOORS BEFORE TRANSPORTING INSPECT THE ENTIRE MACHINE FOR LOOSE OR UNSECURED ITEMS USE CHAINS OF AMPLE LOAD CAPACITY USE A MINIMUM OF 2 CHAINS ADJUST THE RIGGING TO PREVENT DAMAGE TO THE CHAINS AND MACHINE NEVER CHAIN OVER THE MODULE OR RAIL GEAR ONLY CHAIN TO THE DEDICATED CHAINING DOWN EYES SEE JCB MANUAL FOR INFORMATION ...

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