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Permaquip Kubota RTV X900 RRV Operating & Maintenance Manual

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Operating & Maintenance Manual
Permaquip Kubota RTV X900 RRV
Permaquip Ltd
Brierley Industrial Park, Stanton Hill,
Sutton-In-Ashfield, Nottinghamshire, NG17 3JZ
Tel: +44 (0) 1623 513349
Fax: +44 (0) 1623 517742
E-mail:
sales@permaquip.co.uk
www.permaquip.co.uk
MAN-M-O-220_01
24/01/2019
Page 1 of 72

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Summary of Contents for Permaquip Kubota RTV X900 RRV

  • Page 1 Operating & Maintenance Manual Permaquip Kubota RTV X900 RRV Permaquip Ltd Brierley Industrial Park, Stanton Hill, Sutton-In-Ashfield, Nottinghamshire, NG17 3JZ Tel: +44 (0) 1623 513349 Fax: +44 (0) 1623 517742 E-mail: sales@permaquip.co.uk www.permaquip.co.uk MAN-M-O-220_01 24/01/2019 Page 1 of 72...

  • Page 2: Table Of Contents

    CONTENTS 1. Issue and Revision Record ................5 2. Introduction ....................6 3. Safe and Correct Use ................... 8 4. Technical Specification ................11 4.1. Oil Specifications .................. 12 4.2. Battery Specifications ................13 4.3. Product Compliance ................13 4.4. Noise ....................15 4.5.
  • Page 3 10.2. Rail Gear Failure ................39 10.3. Recovery Times ................. 40 Vehicle Winterisation ................40 stabling ....................41 Training ....................41 Defined Words ..................42 Document Review ................... 43 Maintenance and Overhaul Programme ..........44 16.1. General ....................45 16.2. Maintenance Schedule ..............
  • Page 4 Whilst Permaquip Limited has taken every care in preparing this operating & maintenance manual it is intended as a technical guideline only. Save to the extent that there are statutory rights to the contrary, Permaquip accepts no liability in relation to any use or reliance made of any information in this operating & maintenance manual.

  • Page 5: Issue And Revision Record

    ISSUE AND REVISION RECORD This document will be updated when necessary by the re-issue of the complete document. Revised Revised Issue Description Date Page No. Initial document release. 04/05/2018 M.S. Draining residual moisture from air 24/01/2019 50 & 57 M.S. tank added to maintenance schedule.

  • Page 6: Introduction

    Trailer, Gas Bottle Trailer, Personnel Carrier, Drum Trailer, Railman and Long Rail Trailer. The Permaquip Kubota RRV is a 4 x 4 vehicle fitted with a diesel engine, which has the ability to carry two persons in the enclosed cab in addition to the payload located in the rear.
  • Page 7 Please see Permaquip’s T&Cs on our website for further details. Prior to using the Kubota RRV, Permaquip advise all operators and personnel to familiarise themselves with the vehicle. If required Permaquip offer a product familiarisation course. MAN-M-O-220_01 24/01/2019 Page 7 of 72...

  • Page 8: Safe And Correct Use

    SAFE AND CORRECT USE Please keep this operating & maintenance manual for future reference. To ensure safe and correct use of the Permaquip Kubota the following should be noted: Wear foot protection when using the Permaquip Kubota. Additional Personal Protective Equipment (PPE) should be worn according to local regulations.
  • Page 9 Do not operate in areas where the DC third and / or conductor rails are live. Do not use the Permaquip Kubota for any other purpose than as described in the introduction. Do not hold off the trailer brakes using mechanical means.
  • Page 10 Do not use the Kubota RRV for any other purpose than as described in the introduction. Do not reset any of the emergency stops until the vehicle has been brought to a controlled stop and the reason for the activation established. Do not use the Kubota RRV on light rail.

  • Page 11: Technical Specification

    • Minimum track curve radius 80 m Ensure that connections to the Permaquip Kubota are made using the Permaquip approved tow bars, the brakes fitted to the trailers are equipped with a compatible active failsafe hydraulic or air braking system and that the trailers can operate to the same speed limits.

  • Page 12: Oil Specifications

    Off-road Driving (not on rail) • Maximum side slope angle 20° Note that the following points must be considered: • Wet, loose or muddy ground conditions will significantly reduce the angle and should not be used. • All loads must be removed from the vehicle. •...

  • Page 13: Battery Specifications

    The specification is: • Lead acid, AGM, 12V, 95Ah. (850amp Starting power “CCA”) 4.3. Product Compliance The Permaquip Kubota complies with the following: • RSSB standard RIS-1530-PLT. Note the following: • The vehicle may on/off track, travel, and work under live overhead lines when used in conjunction with a safe system of work determined and authorised in accordance with the requirements of GE/RT8024.
  • Page 14 MAN-M-O-220_01 24/01/2019 Page 14 of 72...

  • Page 15: Noise

    4.4. Noise The sound levels are as below: • Exterior sound level (stationary) 73 dB(A) • Exterior sound level (moving) 81 dB(A) • Driver-perceived sound level 76.6 dB(A) 4.5. Vibration The Hand Arm Vibration at the driver’s position has been measured as less than the action level of 2.5 m/s and therefore no additional measures needing to be considered.

  • Page 16: First Of Type Brake Test Results

    4.7. First of Type Brake Test Results Date /Location 02/11/17 EVR Wirksworth Type: Kubota RTV900 RRV Issue 6 Assessed Against Serial Number: Fleet Number: Network Rail ID: Vehicle Weight: 1470 kg Towing Weight: 0 kg High or Low Ride: Owner: Daniel Smail –...

  • Page 17: General Layout

    GENERAL LAYOUT The base vehicle general layout is defined in the Kubota Operator’s Manual. • OEM work lights have been fitted to the front and rear of the vehicle. • The original front driving head lights have been modified to also work in rail mode when driving forward.

  • Page 18: Vehicle Cab Controls

    5.1. Vehicle Cab Controls There is a Control Module mounted on the Permaquip Kubota dashboard, as shown below. These controls have the following function: • Air Pressure Gauge. • Warning Buzzer: Intermittent Sound: Low Air Pressure. Continuous Sound: Trailer Breakaway.

  • Page 19: Dimensions

    5.2. Dimensions MAN-M-O-220_01 24/01/2019 Page 19 of 72...

  • Page 20: Plant Gauge

    The road tyres infringe on the plant gauge and therefore the vehicle speed is restricted to 5mph in areas of raised check & guard rail. The following shows the Permaquip Kubota within the plant gauge when on track. MAN-M-O-220_01 24/01/2019...

  • Page 21: Rear Seat/Load

    If the triggered emergency stop is reset then the rail enhancements will be re-activated. The engine will not restart without the ignition key being turned to the start position. Permaquip recommend bringing the vehicle to a controlled stop prior to the resetting of any of the Emergency stops.

  • Page 22: Safety Chains

    Seats up Seats down 5.5. Safety Chains A safety chain has been fitted to the Kubota to prevent exiting the vehicle to the operating track without proposed intention, aid awareness and reduce the risk of falling from height. MAN-M-O-220_01 24/01/2019 Page 22 of 72...

  • Page 23: Position Of Labels

    5.6. Position of Labels There are a number of labels located on the Permaquip Kubota. It is important that these are always present, clean and clearly defined. The Data Panel compliant to RIS-1530-PLT is located to the side of the door. The following shows the label...
  • Page 24 Rear load/seat area SWL OHL warning on each ROPS post Park break & neutral Fuse identification label Hydraulic pump fuse label Air compressor fuse label MAN-M-O-220_01 24/01/2019 Page 24 of 72...
  • Page 25 Permaquip bonnet label Permaquip labels Hard hats must be worn labels Hard hats must be worn labels Data panel label, EAC expiry label Moving parts / pinch point labels & NWR vehicle number MAN-M-O-220_01 24/01/2019 Page 25 of 72...

  • Page 26: Operating Instructions

    Tow bar in position Fire Extinguisher in position All towing / propelled trailers that are to be coupled to the Permaquip Kubota later are secure. Ensure when coupling tow bars, the security lynch pin is correctly fitted. Tow bar pin correctly fitted...

  • Page 27: Cctv

    6.2. CCTV The CCTV system automatically comes on when the vehicle is started. The monitor is located within the Control Module and the camera is located on the rear number plate light mount. The CCTV system fitted is intended to aid reverse travel, particularly at dusk / dawn and at night when visibility is restricted.

  • Page 28: On-Tracking Procedure

    • Drive the vehicle onto the rails at a suitable level crossing (as directed by the supervisor), and ‘centre’ all four wheels thus ensuring that all of the Permaquip Kubota wheels are positioned over the rails and the front wheels are straight.

  • Page 29: Lowering The Rail Gear

    Kubota. Take up the slack. • Lift the Permaquip Kubota into position, aligned over the track. Continue to lower the vehicle slowly, allowing the front and rear rail wheels and tyres to make contact with the rail.

  • Page 30: Start-Up

    6.7. Start-up Observe the operating parameters defined in the Technical Specification. Observe the operating restrictions and safe working practices as defined by national and local regulations. In the event the vehicle needs to be restarted following an emergency or accidental stop utilising one of the emergency stop buttons, repeat the start-up procedures.

  • Page 31: Off-Tracking Procedure

    • Release the hand brake and move forward and fully apply the footbrake. Check that the trailer brakes are applied and that the consist stops smartly. • Release the hand brake and move forward and partly apply the footbrake. Check that the consist stops gently. •...

  • Page 32: Lifting Directly Off The Track

    Attach the four sling hooks to each of the lifting points ensuring the sling is not twisted or caught around any parts of the Kubota. Take up the slack. • Lift the Permaquip Kubota off track and slowly lower to the designated area. • Remove the wire rope sling.

  • Page 33: Towing And Propelling

    The Personnel carrier should only be propelled not towed by the Permaquip Kubota. The LRT should only be towed not propelled by the Permaquip Kubota. Wear eye and hand protection when coupling hydraulic connections. The following outlines the correct and safe procedures for operation of the Permaquip Kubota when used for towing / propelling appropriate equipment such as the Permaquip™...

  • Page 34: Connecting To The Vehicle (With Air Brakes)

    • Wait until the brakes can be seen to be released before engaging gear and moving off. When braking to a stop, apply the vehicle brakes gently in good time before the stopping point is reached. • Harder braking action will release the hydraulic pressure holding the trailer brakes off and they will apply fully in approximately 4-5 seconds.

  • Page 35: Failsafe Break-Away Warning System

    Note that the length of this Cable may vary depending on the consist configuration. A Dummy Plug is supplied to allow the Permaquip Kubota to be driven when it is not being used for towing / propelling.

  • Page 36: Schematics

    SCHEMATICS 9.1. Vehicle Electrical Schematics The rail conversion electrical schematics are documented on Permaquip drawings and are only available upon request: 41202 Control Box Schematic 41203 Relay / Fuse Box Schematic 41204 Loom A Schematic (Control box to Relay / Fuse box loom)

  • Page 37: Air Brake Schematic

    The Relay / Fuse Box is fixed to the bottom of the passenger seat to give easy access to the hydraulic fluid reservoir and base vehicle fuse box. 9.3. Air Brake Schematic 9.4. Hydraulic Brake Schematic MAN-M-O-220_01 24/01/2019 Page 37 of 72...

  • Page 38: Hydraulic Rail Gear Schematic

    9.5. Hydraulic Rail Gear Schematic MAN-M-O-220_01 24/01/2019 Page 38 of 72...

  • Page 39: Emergency Recovery Procedure

    All equipment must be stowed prior to recovery. The vehicle must not be propelled or towed at more than 5 mph. • The Permaquip Kubota has towing points on the front and rear which can be utilised to facilitate emergency recovery.

  • Page 40: Recovery Times

    10.3. Recovery Times • In the event of machine failure, the Kubota can be off-tracked and moved clear of the railway line within 2 hours. • For reasonably foreseeable failures of the electrical, hydraulic or pneumatic systems alone, the machine should be capable of returning to travelling mode gauge within 20 minutes.

  • Page 41: Stabling

    • Product familiarisation. • Component location and function. • Product preparation. • Safe and Correct Use. • Maintenance. • Testing. • Practical experience. Permaquip Ltd offer a training service – please contact us for further details. MAN-M-O-220_01 24/01/2019 Page 41 of 72...

  • Page 42: Defined Words

    14. DEFINED WORDS The following outlines the defined words used within this Maintenance Programme. Term Action required Adjust Correct to defined limits Change Remove the original and fit a new or overhauled part or assembly in its place. Check Determine a particular nominated condition before, during or after repair, for example completeness, security, position Clean Remove all dirt and deposits...

  • Page 43: Document Review

    • Directives from Network Rail. • The vehicle’s seven-year review. • Fault logs and GE/RT8250 NIRs 2. A record of any decisions taken at this review are retained. 3. The process of review follows the Permaquip Engineering Change Control procedure. MAN-M-O-220_01 24/01/2019...

  • Page 44: Maintenance And Overhaul Programme

    Standards etc. e) All staff to have undergone the training course for the appropriate Permaquip equipment, to the extent of the responsibilities and the tasks they are asked to be perform by the machine and equipment owners and their agents.

  • Page 45: General

    A suitable length of straight level track for carrying out brake tests. Maintenance action is intended to ensure the continued safe operation of the Permaquip Kubota RTV X900 4x4 RRV towing / propelling vehicle and associated trailers. The maintenance programme has been derived from reliability and safety apportionment’s and failure by the owner to follow these activities would invalidate...
  • Page 46 Product folder. Do not record information directly onto this document. For spare parts please contact your nearest Permaquip service centre. It is recommended that parts are purchased from Permaquip to ensure machine reliability and safety.

  • Page 47: Maintenance Schedule

    Toe-in (see See Kubota OEM Manual (pg. 66) & ⓪ Permaquip Adjust Workshop Permaquip Manual. Toe set to 0. manual) ⓪ Check See Kubota OEM Manual (pg. 63) Workshop Fuel filter element See Kubota OEM Manual (pg. 76).
  • Page 48 Front axle case ⓪ Change See Kubota OEM Manual (pg. 76) Workshop Front knuckle ⓪ Change See Kubota OEM Manual (pg. 74) Workshop case oil See Kubota OEM Manual (pg. 76). Engine valve ⓪ Adjust Consult your local KUBOTA Dealer for Workshop clearance this service.
  • Page 49 Documentation vehicle is suitable for required tasks. Marker, head Check / Correct operation and are clean. See ⓪ ⓿ On Site and work lights Clean Permaquip manual. Visual ⓪ Visual only On Site Check Rail wheels bolts ⓿ ⓪ Record...
  • Page 50 Record On Site stopping distance 60m ⓪ ⓿ Track operation Check No vibration, noise or steering problems On Site Clean and Present. See Permaquip ⓪ ⓿ Labels Check On Site Manual. Present and damage free, if signs of any ⓪...
  • Page 51 Present and secure. Workshop fasteners Rail wheel life ⓪ guard/rail head Record Rubber height <30mm On Site sweep See Kubota OEM Manual & Permaquip ⓪ Check On Site manual. Horn Record sound level on 4 quadrants. See ⓪ Record On Site Permaquip manual.

  • Page 52: Record Sheets

    • Kubota RTV X900 RRV After First Week Maintenance Schedule • Kubota RTV X900 RRV After First Month Maintenance Schedule • Kubota RTV X900 RRV Shift & Safety Exam Maintenance Schedule • Kubota RTV X900 RRV Weekly Maintenance Schedule • Kubota RTV X900 RRV Monthly Maintenance Schedule •...

  • Page 53: Maintenance

    Contact Permaquip for all non-standard additional equipment adjustment and repairs. Refer to Permaquip or an authorised Kubota agent for all base vehicle adjustment and repairs. The following list outlines the additional equipment fitted by Permaquip to the Kubota base vehicle: • Hydraulic front and rear rail gear •...

  • Page 54: Road Wheel Toe-In

    It is recommended that a functional brake test is carried out immediately before further use and a brake stopping distance test at the earliest opportunity. 18.2. Road Wheel Toe-in The front road wheel toe-in geometry has been altered. It is essential that the toe-in is adjusted to 0°...

  • Page 55: Steering Lock

    18.5. Steering lock When in rail mode there will always be either the Red or Green Steering Lock LED illuminated. When the Red LED is illuminated the steering will function as per standard. When the Green LED is illuminated the steering will be locked. The steering lock is isolated from the emergency stop system.

  • Page 56: Conductivity Test

    be worn, or the tread and flange of the wheel may be worn or damaged causing a wobbling sensation. Track test the vehicle to verify whether the vibrations were caused by loose Rail Wheels or flanges etc…. 18.9. Conductivity test The Kubota should also be tested to the following specification.

  • Page 57: General Lubrication

    18.13. General Lubrication General multi-purpose grease should be applied to all grease nipples, hinge points, axles and bearing surfaces as per the Maintenance Schedule. 18.14. On Track Fault Finding Problem Probable Cause Possible Remedy Vehicle loaded heavy on one Move load to centre of vehicle. side.

  • Page 58: Trailer Hydraulic Brake System

    18.16. Trailer Hydraulic Brake System Some vehicles have been fitted with a hydraulic braking system to accommodate the trailer brakes. The pressure must be set to that shown in the Technical Specification. The oil tank, mounted on the pump, is located under the front bonnet, as shown below.

  • Page 59: Marker Lights And Connections

    18.20. Marker Lights and Connections While the vehicle is in rail mode check that the base vehicle lights have been isolated. When in forward the front white lights and rear red lights should be illuminated. When in reverse the front red lights and rear white lights should be illuminated. When in neutral the front red lights and rear red lights should be illuminated.
  • Page 60 If the paint did not wear evenly, note which Rail Wheels, flange and/or tread the paint is worn on and: • Repaint the flanges and treads on all Rail Wheels. • Operate the vehicle in reverse for a short distance at a normal operating speed. •...

  • Page 61: Ordering

    19. ORDERING DESCRIPTION PART NO Permaquip Kubota RTV 41000 X900 RRV Type B Towing Trailer 33284 (Hydraulic Brakes) Type B Towing Trailer 38239 (Air Brakes) Type B Personnel Carrier 33375 (Hydraulic Brakes) Type B Personnel Carrier 38374 (Air Brakes) MAN-M-O-220_01...
  • Page 62 Type B Gas Bottle Trailer 33827 (Hydraulic Brakes) Type B Gas Bottle Trailer 38650 (Air Brakes) Wire Rope Sling c/w Bag 41223 Marker Light Board 33801 Trailer to Trailer Tow Bar 30723 RRV to Trailer Tow Bar 32920 MAN-M-O-220_01 24/01/2019 Page 62 of 72...
  • Page 63 RRV to PC Tow Bar 41200 10" Brake Test Tool 34712 Red Light 040820218 Wheel Profile Gauge Kit 34597 Lead Assembly (25m) 34379 Lead Assembly (18m) 34378 Lead Assembly (10m) 33812 MAN-M-O-220_01 24/01/2019 Page 63 of 72...
  • Page 64 Lead Assembly (7.5m) 33869 Lead Assembly (4.5m) 33870 Permaquip Ltd offer a maintenance and testing service – please contact us for further details. Our contact details are shown on the front of this manual. MAN-M-O-220_01 24/01/2019 Page 64 of 72...

  • Page 65: Fastener Torques

    20. FASTENER TORQUES MAN-M-O-220_01 24/01/2019 Page 65 of 72...
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  • Page 69: Iso46 Oil Material Safety Data Sheet

    21. ISO46 OIL MATERIAL SAFETY DATA SHEET The following outlines the oil supplied within the fail-safe rail braking system of the Permaquip Kubota. MAN-M-O-220_01 24/01/2019 Page 69 of 72...
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