Permaquip Kubota RRV User manual

MAN-M-O-190_13 09/10/2014 Page 1of 56
User Guide
Permaquip Kubota 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...........................................................................4
2. Introduction...................................................................................................5
3. Safe and Correct Use...................................................................................6
4. Technical Specification.................................................................................8
4.1. Oil Specifications..................................................................................10
4.2. Battery Specifications...........................................................................10
4.3. Product Compliance .............................................................................11
4.4. Noise....................................................................................................12
4.5. Vibration...............................................................................................12
5. General Layout...........................................................................................13
5.1. Vehicle Cab Controls............................................................................13
5.2. W6a Gauge..........................................................................................14
5.3. Rear Seat/Load ....................................................................................15
5.4. Position of Labels.................................................................................17
6. Operating Instructions.................................................................................18
6.1. Pre-Use Checks ...................................................................................18
6.2. On and Off Tracking Area.....................................................................20
6.3. On-tracking Procedure..........................................................................21
6.4. Lowering the Rail Gear.........................................................................24
6.5. Start-up.................................................................................................25
6.6. Off-tracking Procedure..........................................................................26
6.7. Raising the Rail Gear............................................................................27
6.8. CCTV....................................................................................................27
6.9. Using the Lifting Beam..........................................................................28
7. Towing and Propelling................................................................................30
7.1. Connecting to the Vehicle (with hydraulic brakes) ................................30
7.2. Connecting to the Vehicle (with air brakes)...........................................31
7.3. Failsafe Break-away Warning System..................................................31
8. On Road (optional) .....................................................................................32
9. Routine Maintenance and Tests .................................................................33
9.1. Engine and Gearbox Access ................................................................34
9.2. On Track Fault Finding.........................................................................34
9.3. Trailer Hydraulic Brake System ............................................................35
9.4. Trailer Air Brake System.......................................................................36
9.5. Rail Wheel Inspection for Wear ............................................................36
9.6. Road Wheel Toe-in...............................................................................36
9.7. Gear Re-alignment...............................................................................37
9.8. Rail Wheel Checks ...............................................................................37
9.9. Suspension Checks..............................................................................37
9.10. Wheel Bearing Checks......................................................................37
9.11. Life Guard Checks.............................................................................38
9.12. Battery Management System.............................................................38
9.13. Rail Gear Gas Struts..........................................................................38
9.14. Track Test .........................................................................................38

MAN-M-O-190_13 09/10/2014 Page 3of 56
9.15. Resetting the CCTV Camera.............................................................39
9.16. Fastener Torques..............................................................................40
9.17. Vehicle Wiring (Additional Equipment)...............................................44
9.18. Control Module PCB..........................................................................45
9.19. Air Brake Schematic..........................................................................48
10. Training ...................................................................................................49
11. Ordering ..................................................................................................50
12. ISO46 Oil Material Safety Data Sheet......................................................52
Please note
Whilst Permaquip Limited has taken every care in preparing this User Guide 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 User Guide.
All information, illustrations and specifications in this User Guide 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-190_13 09/10/2014 Page 4of 56
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
02
This record sheet added.
24/11/2008
All
C.H.
Cleaning note added
24/11/2008
41
C.H.
03
Revised Electrical Schematic
01/12/2008
40/42
C.H.
04
Revised Electrical Schematic
08/12/2008
40
C.H.
05
Added battery charging note
16/02/2009
10
C.H.
06
Added section on lifting onto track
24/04/2009
21
C.H.
07
Added section on resetting camera
03/06/2009
35
C.H.
08
Changes for new MD
31/12/2009
All
C.H.
09
Updated for RIS-1530-PLT issue 2
31/01/2010
All
C.H.
10
Mass with options added
11/10/2010
8
C.H.
11
PC pin note added
05/11/2010
31
C.H.
12
Updated for RIS-1530-PLT issue 4
07/11/2013
All
M.S.
13
Updated for RIS-1530-PLT issue 5 +
air braking additions
09/10/2014
All
M.S.

MAN-M-O-190_13 09/10/2014 Page 5of 56
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™Rail Mover, Type
B Towing Trolley, Gas Bottle Trolley, Personnel Carrier, Drum Trolley and Railman.
The Permaquip Kubota RRV is a 4 x 4 vehicle fitted with a diesel engine, which has
the ability to carry two persons in addition to the payload located in the rear. This
payload area can also accommodate an additional four passengers when on rail.
The Kubota base vehicle has been equipped by Permaquip with the following
features:
Front and rear rail gear.
Ramps for on/off tracking across track (optional).
Control module.
Front and rear work lights.
Rear load/seating arrangement.
Towing/propelling couplings for use with the range of accessories.
Hydraulic & air brake couplings for use with the range of accessories.
The fail-safe brake system(s) causes the brakes to be applied when one of the
following occurs:
The Trolleys 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.

MAN-M-O-190_13 09/10/2014 Page 6of 56
3. SAFE AND CORRECT USE
Please keep this User Guide for future reference.
To ensure safe and correct use of the Permaquip Kubota the following should be
noted:
Wear eye and feet protection when using the Permaquip Kubota.
Additional Personal Protective Equipment (PPE) should be worn
according to local regulations.
During transit the Permaquip Kubota must be kept away from all
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.
For information and data on all aspects of the base vehicle, refer to the
Kubota Operator’s Manual supplied.
The connecting trolleys must be equipped with a compatible active
failsafe braking system to operate in conjunction with the brake system
fitted to the vehicle. Ensure that the working pressures (when applicable)
of the connecting trolleys are within the pressure defined in the Technical
Specification.
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.

MAN-M-O-190_13 09/10/2014 Page 7of 56
Only lift the Permaquip Kubota using the designated lifting points and
with the Lifting Frame. Do not lift when loaded with goods or personnel.
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 Locking
Pins are located fully.
Ensure that all Personnel are clear of the vehicle and consist before
moving.
Stopping distances will greatly increase in wet or icy conditions.
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.

MAN-M-O-190_13 09/10/2014 Page 8of 56
4. TECHNICAL SPECIFICATION
Kubota 4 x 4
Width
1820 mm
Length
3400 mm (rail gear up)
Height
2100 mm
Mass (unladen)
1165 kg (standard)
1184 kg (standard + mounted lifting beam)
Centre of mass
Should only be lifted using the Permaquip Lifting Beam
Payload in rear load area of the Kubota, on rail only 400 kg
Payload in rear load area of the Kubota, on road 0 kg
Maximum seating capacity of the Kubota, front 2
Maximum seating capacity of the Kubota, rear, on rail only 4
Seating capacity of the Kubota, rear, on road 0
Maximum towing/propelling capacity16,500 kg
Maximum number of trolleys that can be connected24
SWL of Lifting Beam 1,200 kg
Maximum speed on Points and Crossings 5 mph
Maximum speed on plain line 20 mph
Hydraulic Pressure for Trailer Connections 80 - 140 bar
Air Pressure for Trailer Connections (where fitted) 5 - 6 bar
Maximum cant when on/off tracking 200 mm
Maximum gradient when on/off tracking 1:25 mm
Maximum cant 200 mm
Maximum gradient 1:25
Minimum curve radius 80 m
1Ensure that connections to the Permaquip Kubota are made using the Permaquip
approved tow bars, the brakes fitted to the trolleys are equipped with a compatible
active failsafe hydraulic or air braking system and that the trolleys can operate to the
same speed limits. These trolleys must have steel wheels.
2Ensure that the maximum towing / propelling capacity1is not exceeded.

MAN-M-O-190_13 09/10/2014 Page 9of 56
Off-road Driving (not on rail)
Maximum side slope angle 20°
Note that the following points must be taken into account:
Wet, loose or muddy ground conditions will significantly reduce the angle and
should not be used.
All loads must be removed from the vehicle.
Check that the wheels on the downhill side are not going to drop into any
depressions and that the uphill wheels will not run over any obstacles that will
increase this angle.
The front and rear rail gear will affect the approach, departure and ramp over
angles. Perform a risk assessment of all areas for suitability before use.
Please refer to the Kubota Operator’s Manual for additional information.

MAN-M-O-190_13 09/10/2014 Page 10 of 56
4.1. Oil Specifications
The recommended oil for the hydraulic failsafe braking system is:
Anti-wear hydraulic oil with an ISO viscosity grade 46.
Ensure that any alternatives used are to the same specification.
The specifications for the lubricants used within the Kubota itself can be found within
the Kubota Operator’s Manual. However a brief summary of these are shown below:
Grease
Multi-purpose grease NLGI-2 or NLGI-1 (GC-LB).
Transmission oil
Oil for the transmission case, front axle case, knuckle case, hydraulic pump and
power steering to be Kubota UDT or Super UDT fluid. Alternatives are not
recommended.
Brake fluid
Kubota DOT3. Alternatives are not recommended.
Engine oil
Oil that meets API Service Classification CD, CE or CF.
Use a SAE30, SAE10W-30 or 10W-40 above +25°C.
Use a SAE20, SAE10W-30 or 10W-40 between 0 and +25°C.
Use a SAE10W or SAE10W-30 below 0°C.
Engine Coolant
Fresh clean water with anti-freeze that is suitable for aluminium engines.
4.2. Battery Specifications
The vehicle has been fitted with an additional battery. The specification is:
Valve regulated lead acid, AGM, 12v, 42Ah
Replacement batteries must be to the same specification. If either of the batteries
are charged at any time, then ensure that a suitable 12v multi-stage charger, that
can accommodate wet lead acid and AGM batteries, is used.

MAN-M-O-190_13 09/10/2014 Page 11 of 56
4.3. Product Compliance
The Permaquip Kubota complies with the following:
RSSB standard RIS-1530-PLT. Note the following:
1. The vehicle may on/off track, travel, and work under live overhead lines.
2. The vehicle will not operate spring loaded points.
3. The vehicle will not travel over raised check rails.
The latest issue of CoP0014.
Directive 2006/42/EC
Safety of Machinery.
Directive 93/68/EEC
CE Marking.
Directive 2004/108/EC
EMC.
For use in a commercial environment and not for use in a residential
environment.

MAN-M-O-190_13 09/10/2014 Page 12 of 56
4.4. Noise
The sound levels are as below:
Exterior sound level (stationary) 78.6 dB(A)
Exterior sound level (moving) 77.8 dB(A)
Driver-perceived sound level (stationary) 85.0 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/s2and therefore no additional measures need to be taken into
account.
The Whole Body Vibration for passengers located on the rear load bay seats has
been measured as less than the action level of 0.5 m/s2and therefore no additional
measures need to be taken into account.
Uncertainty is 50% of the values stated.

MAN-M-O-190_13 09/10/2014 Page 13 of 56
5. GENERAL LAYOUT
The base vehicle general layout is defined in the Kubota Operator’s Manual.
5.1. Vehicle Cab Controls
There is a Control Module mounted on the Permaquip Kubota front frame, as shown
below.
These controls have the following function:
Warning Buzzer (trailer breakaway).
Engine Stop Button.
Trailer Brakes - hydraulic, off and air (where fitted).
Work Lights (front, off and rear)
Vehicle Mode (road, rail and stationary).
CCTV Monitor.

MAN-M-O-190_13 09/10/2014 Page 14 of 56
5.2. W6a Gauge
The road tyres infringe on the W6a gauge and therefore the vehicle
should not be used in areas of raised check rail.
The following shows the Permaquip Kubota within the W6a track gauge when on
track.

MAN-M-O-190_13 09/10/2014 Page 15 of 56
5.3. Rear Seat/Load
When exiting from the rear seats, face towards the front of the vehicle to
step down as this is the safest method (in the same manner to climbing
down a ladder). Step on white areas only as these have a gritted non-slip
surface.
An Engine Stop and horn button have been fitted to allow passengers on the rear
seats (rail mode only), as shown below.
The Engine Stop will stop the engine, thereby bringing the vehicle to a stop in the
required distance (rail mode only).
The rear seats can be raised should loads be required to be carried. It is not
recommended that loads and personnel are transported at the same time.
Loads can be restrained by using the rear load bay fabrication tubes. Do not over
tighten any restraints, causing damage to the load or fabrication.
Each raised and lowered position should be locked in position with the Safety Pin, as
shown below.
Seats up

MAN-M-O-190_13 09/10/2014 Page 16 of 56
Seats down

MAN-M-O-190_13 09/10/2014 Page 17 of 56
5.4. 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 on each front wing. The following show their relative
positions:
Front and Rear Tyre pressure
No Access located on both
front wings
Working Pressure Limits
located near both Brake Couplings
Lifting Point SWL both sides
Towing capacity located at both ends
Operational Limits located
in the cab
Rear load/seat area SWL
OHL warning on each ROPS post

MAN-M-O-190_13 09/10/2014 Page 18 of 56
6. OPERATING INSTRUCTIONS
For information and data on all aspects of the base vehicle, refer to the
Kubota Owners Manual supplied.
The following outlines the correct and safe procedures for operation of the
Permaquip Kubota.
6.1. Pre-Use Checks
Before the Permaquip Kubota is used ensure that:
The Shift Maintenance Schedule checks are carried out.
The Front Rail Gear is raised and locked in position, with the Safety Pins
inserted, as shown below.
Front rail in raised position
Safety Pin in position
The Rear Rail Gear is raised and locked in position, with the Safety Pins
inserted, as shown below.

MAN-M-O-190_13 09/10/2014 Page 19 of 56
Rear rail in raised position
Safety Pin in position
All equipment within the vehicle loading area is secured. The Towbar and Fire
Extinguisher should be located as shown below.
Tow bar in position
Fire Extinguisher in position
All towing / propelled trolleys that are to be coupled to the Permaquip Kubota
later are secure.

MAN-M-O-190_13 09/10/2014 Page 20 of 56
6.2. On and Off Tracking Area
The diagram below outlines the minimum area required to on and off track the
Permaquip Kubota.