Permaquip Kubota RTV X900 RRV Installation and operation manual

MAN-M-O-220_01 24/01/2019 Page 1of 72
Operating & Maintenance Manual
Permaquip Kubota RTV X900 RRV
Permaquip Ltd
Brierley Industrial Park, Stanton Hill,
Sutton-In-Ashfield, Nottinghamshire, NG17 3JZ
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
www.permaquip.co.uk

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. Vibration...............................................................................................15
4.6. ROPS & FOPS.....................................................................................15
4.7. First of Type Brake Test Results...........................................................16
5. General Layout...........................................................................................17
5.1. Vehicle Cab Controls............................................................................18
5.2. Dimensions...........................................................................................19
5.3. Plant Gauge .........................................................................................20
5.4. Rear Seat/Load ....................................................................................21
5.5. Safety Chains.......................................................................................22
5.6. Position of Labels.................................................................................23
6. Operating Instructions.................................................................................26
6.1. Pre-Use Checks ...................................................................................26
6.2. CCTV....................................................................................................27
6.3. On-tracking Procedure..........................................................................28
6.4. On Tracking on Level Crossings / Access Points..................................28
6.5. Lifting Directly onto Track .....................................................................28
6.6. Lowering the Rail Gear.........................................................................29
6.7. Start-up.................................................................................................30
6.8. Off-tracking Procedure..........................................................................31
6.9. Off Tracking on Level Crossings / Access Points..................................31
6.10. Lifting Directly Off the Track ..............................................................32
6.11. Raising the Rail Gear.........................................................................32
7. Towing and Propelling................................................................................33
7.1. Connecting to the Vehicle (with hydraulic brakes) ................................33
7.2. Connecting to the Vehicle (with air brakes)...........................................34
7.3. Failsafe Break-away Warning System..................................................35
8. On Road.....................................................................................................35
9. Schematics.................................................................................................36
9.1. Vehicle Electrical Schematics...............................................................36
9.2. Relay / Fuse Box..................................................................................36
9.3. Air Brake Schematic.............................................................................37
9.4. Hydraulic Brake Schematic...................................................................37
9.5. Hydraulic Rail Gear Schematic.............................................................38
10. Emergency Recovery Procedure.............................................................39
10.1. Stowing of Equipment........................................................................39

MAN-M-O-220_01 24/01/2019 Page 3of 72
10.2. Rail Gear Failure ...............................................................................39
10.3. Recovery Times.................................................................................40
11. Vehicle Winterisation...............................................................................40
12. stabling....................................................................................................41
13. Training ...................................................................................................41
14. Defined Words.........................................................................................42
15. Document Review ...................................................................................43
16. Maintenance and Overhaul Programme ..................................................44
16.1. General..............................................................................................45
16.2. Maintenance Schedule......................................................................47
17. Record Sheets.........................................................................................52
18. Maintenance............................................................................................53
18.1. Tyres and Wheels..............................................................................53
18.2. Road Wheel Toe-in............................................................................54
18.3. Road wheel spacers..........................................................................54
18.4. Wheel Bolt Markers ...........................................................................54
18.5. Steering lock......................................................................................55
18.6. Brake test (COP0014 instructions) ....................................................55
18.7. Horn ..................................................................................................55
18.8. Rail Wheel Checks............................................................................55
18.9. Conductivity test................................................................................56
18.10. Rail Wheel Inspection for Wear ......................................................56
18.11. Wheel Bearing Checks...................................................................56
18.12. Engine and Gearbox Access ..........................................................56
18.13. General Lubrication........................................................................57
18.14. On Track Fault Finding...................................................................57
18.15. Trailer Air Brake System.................................................................57
18.16. Trailer Hydraulic Brake System ......................................................58
18.17. Gear Re-alignment.........................................................................58
18.18. Suspension Checks........................................................................58
18.19. Life Guard Checks..........................................................................58
18.20. Marker Lights and Connections......................................................59
18.21. Load lifting points / wire rope sling..................................................59
18.22. Track Test ......................................................................................59
19. Ordering ..................................................................................................61
20. Fastener Torques ....................................................................................65
21. ISO46 Oil Material Safety Data Sheet......................................................69

MAN-M-O-220_01 24/01/2019 Page 4of 72
Please note
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.
All information, illustrations and specifications in this operating & maintenance manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any time without notice.
Equipment operators and installers shall be responsible for ensuring that a safe working environment and safe
systems of work are in place and in certain circumstances advice and permission from the controlling authority
must be sought before any operation, installation or surveying work is carried out.
Permaquip™ is a trademark of Permaquip Ltd.
©2006 Permaquip Ltd.

MAN-M-O-220_01 24/01/2019 Page 5of 72
1. ISSUE AND REVISION RECORD
This document will be updated when necessary by the re-issue of the complete
document.
Issue
Description
Date
Revised
Page No.
Revised
By
00
Initial document release.
04/05/2018
All
M.S.
01
Draining residual moisture from air
tank added to maintenance schedule.
24/01/2019
50 & 57
M.S.
Authorised by:
Martin Sheppard
Engineering Manager

MAN-M-O-220_01 24/01/2019 Page 6of 72
2. INTRODUCTION
The Permaquip Kubota is an Off-Road Rail Vehicle (RRV) that has been designed to
facilitate the transportation of goods and personnel. These benefits can be
enhanced further when used in conjunction with the Permaquip™Type B Towing
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. This payload area can also accommodate an additional four passengers
when on rail when no load is carried.
The Kubota base vehicle has been equipped by Permaquip with the following
features:
•Front and rear hydraulic deployed/retracted rail gear.
•Drivers control module.
•Rear view CCTV system.
•Rail automatic switching driving lights, including rear headlights.
•Front and rear work lights.
•Hydraulic locking steering.
•Rear load/passenger tub.
•Towing propelling couplings for use with the range of accessories.
•Failsafe hydraulic & air braking systems for use with the range of accessories.
•Lifting points for on/off tracking via a crane or Hiab.
The fail-safe brake system(s) causes the brakes to be applied when one of the
following occurs:
•The Trailers or Personnel Carrier brakes away from the consist and causes the
hydraulic or air hose to rupture.
•A break in the Break-away Warning Circuit, in conjunction with the Marker
Light Board.
•The Engine Stops are operated.
•Operation of the handbrake at the driving position.
•Full application of the footbrake.
•Turning the brake system to the ‘Off’ position.
•Switching the vehicle into road mode.
•Powering the vehicle off.
Any modifications or enhancements made by the user or third party which have not
been approved by Permaquip are not recommended. Any modifications to systems
or whole vehicle will become the responsibility of the user or third party and the
warranty with Permaquip will become null and void.

MAN-M-O-220_01 24/01/2019 Page 7of 72
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 8of 72
3. 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.
Wear eye and hand protection when coupling hydraulic connections.
The Permaquip Kubota must not be used near live electrified lines.
The Permaquip Kubota must be repaired where applicable and retested
if any component becomes damaged, suspected to be damaged or the
vehicle has been derailed.
In addition to this operator and maintenance manual the users, operators
are obliged to take precautions given by the railway infrastructure
manager concerned.
For information and data on all aspects of the base vehicle, refer to the
Kubota Operator’s Manual supplied.
Store the Permaquip Kubota in a secure safe dry position when not
being used.
The connecting trailers must be equipped with a compatible active
failsafe braking system to operate in conjunction with the brake system
fitted to this vehicle. Ensure that the working pressures (when applicable)
of the connecting trailers are within the pressure defined in the Technical
Specification.
Only lift the Permaquip Kubota using the designated lifting points and
wire rope sling. Do not lift when loaded with goods or personnel. Hard
hats to be used when lifting.
Ensure that only Permaquip approved tow bars are used when
connecting trailers to the Permaquip Kubota for towing / propelling and
between connecting trailers within the consist. Ensure that the tow bar
pins are fully located lynch pins are correctly orientated and latched.

MAN-M-O-220_01 24/01/2019 Page 9of 72
Ensure that all Personnel are clear of the vehicle and consist before
moving.
Ensure that all personnel are to wear hard hats when accessing and
travelling in the rear passenger tub.
Ensure all staff using or around the Kubota have had periodical medical
checks to ensure normal hearing and sight.
Ensure the console is switched to road mode when not being used.
Leaving the vehicle in rail mode for long periods of time without being
used will lead to the battery running flat.
Stopping distances will greatly increase by icy or wet conditions;
gradients; an increase in load; an increase in speed.
Perform an additional risk assessment before using the vehicle in areas
where there are raised check rails and bridge guards.
Dispose of used oil and batteries responsibly and in accordance with
local regulations.
The Permaquip Kubota is not permitted to travel/work outside a
possession.
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.
Do not allow any load protrusions to face downwards such that they
could interfere with the trailer braking mechanism.
No passengers are allowed in the rear load area when on the highway.
Do not obstruct emergency stops within any accessible area.

MAN-M-O-220_01 24/01/2019 Page 10 of 72
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.