Rail-Ability JCB 714 User manual

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

JCB 714 Super-Boss Road/Rail Conversion SB002 Operator’s Manual
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Contents
Introduction.....................................................................................5
Description and Intended Use.......................................................5
Limitations ......................................................................................5
Manuals...........................................................................................6
Specification - Principal Dimensions ...........................................7
Specifications.................................................................................9
General Safety Rules ...................................................................11
Electrocution Hazards ..............................................................................11
Collision Hazards .....................................................................................12
Crushing Hazards..................................................................................... 13
Component Damage Hazards.................................................................. 13
Explosion and Fire Hazards......................................................................13
Damaged Machine Hazards..................................................................... 13
Bodily Injury 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 for Fuel Leaks................................................................................ 22
Scheduled Maintenance...........................................................................23
Operational....................................................................................24
Safety Precautions ...................................................................................24
Control Layout.......................................................................................... 25
JCB 714 Operating Control Principles...................................................... 26
Rail Systems GUI Screen.......................................................................................... 26
Auxiliary Control Lever .............................................................................................. 26
Axle Select Change-Over.......................................................................................... 26
Steering Lock ............................................................................................................ 26

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Foot Switch................................................................................................................ 26
Gear Selector............................................................................................................ 26
Screen......................................................................................................27
Icons.......................................................................................................................... 27
System Boot.............................................................................................................. 29
Immobiliser................................................................................................................ 29
Main Screen.............................................................................................................. 30
Rail Axles .................................................................................................................. 31
Main Menu................................................................................................................. 32
I/O Status................................................................................................. 33
Machine Detail.......................................................................................... 34
Function Tests..............................................................................35
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 Lifting Instructions..............................................42
Loading Operation....................................................................................42
Securing to transport vehicle for transit ....................................................43

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Tables
Table 1 - Icon Descriptions............................................................................................... 27
Figures
Figure 1 –W6A Gauge Drawing......................................................................................... 7
Figure 2 –Module Fitment Dimensions.............................................................................. 7
Figure 3 - General Assembly.............................................................................................. 8
Figure 4 - Data Panel ....................................................................................................... 10
Figure 5 - Safe Distance (metres) from Power Lines in excess of 33kV on Steel Towers 12
Figure 6 - Safe Distance (metres) 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
Figure 17 - Input/Output Status ........................................................................................ 33
Figure 18 - Machine Detail Options.................................................................................. 34
Figure 19 - Screen Brightness Page................................................................................. 34
Figure 20 - Front Rail Axle Bonding Strap........................................................................ 41
Figure 21 - Rear Rail Axle Bonding Strap......................................................................... 41

JCB 714 Super-Boss Road/Rail Conversion SB002 Operator’s Manual
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INTRODUCTION
This Operator’s Manual has been compiled for the purposes of safe operation, maintenance and servicing of
Rail-Ability components and systems.
For other operating details (e.g. JCB vehicle, road rail operations, rail gear, etc.) please refer to the publications
listed in the Manuals section.
IMPORTANT
READ, UNDERSTAND AND OBEY THESE SAFETY RULES AND OPERATING INSTRUCTIONS BEFORE
OPERATING THIS MACHINE.
ONLY TRAINED AND AUTHORISED PERSONNEL SHALL BE PERMITTED TO OPERATE THIS
MACHINE.
THIS MANUAL SHOULD BE CONSIDERED A PERMANENT PART OF THIS MACHINE AND SHOULD
REMAIN WITH THE MACHINE AT ALL TIMES.
SHOULD YOU HAVE ANY QUESTIONS, CONTACT RAIL-ABILITY LTD.
Rail-Ability Ltd
Tollgate Drive
Tollgate Industrial Estate
Stafford
Staffordshire
ST16 3HS
Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]
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 module dependent on application and approvals.
The machine complies with the provisions of the following EC Council Directives:
See OEM Handbook
For further compliance information, please refer to the EC Declaration of Conformity supplied with this
machine.
LIMITATIONS
The use of this machine is limited to its intended use, as described above. If additional or special applications
or uses are required which are not covered by this Operator’s Manual, please contact Rail-Ability Ltd for further
instructions and advice.
Operational and environmental limitations of the equipment are described in the Specifications section of this
manual.

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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

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SPECIFICATION - PRINCIPAL DIMENSIONS
Figure 1 –W6A Gauge Drawing
Figure 2 –Module Fitment Dimensions

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Figure 3 - General Assembly
Refer to specifications table on the next page:

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SPECIFICATIONS
DIMENSIONS
MAXIMUM RATED
CAPACITY
14000 KG
OVERALL HEIGHT,
STOWED (ROAD)
3.500 M
OVERALL WIDTH,
STOWED
2.500 M
OVERALL LENGTH,
STOWED
8.493 M
ROAD WHEELBASE
4.055 M
RAIL WHEELBASE
4.956 M
FRONT OVERHANG
(ROAD)
2.174 M
REAR OVERHANG (ROAD)
APPROACH ANGLE
(ROAD)
12°
DEPARTURE ANGLE
(ROAD)
16°
TURNING RADIUS (ROAD)
4.175 M
ARTICULATION ANGLE
36°
MINIMUM TRACK CURVE
RADIUS
80 M
GROUND CLEARANCE
430 MM
VEHICLE DECK HEIGHT
(ROAD)
1.530 M
VEHICLE DECK HEIGHT
(RAIL)
1.810 M
ENVIRONMENTAL 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
MAXIMUM
HYDRAULIC
PRESSURE
(FUNCTIONS)
200 BAR
HYDRAULIC
SUPPLY AT REAR
CHASSIS
STANDARD
HYDRAULIC TANK
88 LITRES
FUEL TANK
210 LITRES
AIR SUPPLY
OPTIONAL
TYRE SIZE
16.00 R25 XGC
TYRE PRESSURE
(FRONT)
100 PSI
RAIL DRIVE
SPEEDS (APPROX)
1ST GEAR 6MPH
2ND GEAR 12MPH
3RD GEAR 18MPH
WEIGHTS
OVERALL WEIGHT
COMPRISING -
24,000 KG
FRONT AXLE MAX
(ROAD WHEELS)
14,750 KG
REAR AXLE MAX
(ROAD WHEELS)
15,250 KG

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99709
949***
-
*
Manufacturer/Converter
SN:
Owner
FN:
RSB0**
Rail-Ability Ltd
01785 214747
A P WEBB PLANT HIRE
01785 241335
Maximum Travelling Speed
20 mph
Maximum On/Off Track Gradient
01:25
Maximum Working Speed
6 mph
Maximum On/Off Track Cant
150mm
Maximum Travelling Speed Through Switches and
Crossings
5 mph
May Be Used Under LIVE Overhead
Lines in accordance with the E.C.C.
YES
Maximum Travelling 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 Curve Radius
80m
Max Machine Gross Weight with
loaded module fitted
24t
Maximum Non Service Braked Towed Load
N/A
REAR SOLID FILLED TYRES FITTED @ >750kg
Each Refer to Engineering Conformity Certificate
for module/attachment specific limitations.
Maximum Service Braked Towed Load
N/A
Figure 4 - Data Panel

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Operator’s Manual
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GENERAL SAFETY RULES
Danger
Failure to obey the instructions and safety rules in this manual will result in death or serious injury.
Do Not Operate Unless:
✓YOU LEARN AND PRACTICE THE PRINCIPLES OF SAFE MACHINE OPERATION
CONTAINED IN THIS OPERATOR’S MANUAL.
2. AVOID HAZARDOUS SITUATIONS.
KNOW AND UNDERSTAND THE SAFETY RULES BEFORE GOING ON TO THE NEXT SECTION.
3. ALWAYS PERFORM A PRE-OPERATION INSPECTION.
4. ALWAYS PERFORM FUNCTION TESTS PRIOR TO USE.
5. INSPECT THE WORKPLACE.
6. ONLY USE THE MACHINE AS IT WAS INTENDED.
✓YOU READ, UNDERSTAND AND OBEY THE MANUFACTURER’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
CONTACT WITH OR PROXIMITY TO ELECTRICAL CURRENT.
MAINTAIN SAFE DISTANCES FROM ELECTRICAL POWER LINES AND APPARATUS IN
ACCORDANCE WITH THE APPLICABLE GOVERNMENTAL REGULATIONS AND FIGURES 1 & 2
BELOW. WHEN IN OPERATION THE MACHINE MUST NOT BE WITHIN 15 METRES OF A POWER LINE
SUPPORTED BY METAL TOWERS OR WITHIN 9 METRES OF A LINE SUPPORTED BY WOODEN
POLES WHEN NOT ON RAIL.
OLE LINES ON RAIL ARE 25KV AND REQUIRE A MINIMUM SAFE APPROACH DISTANCE OF 2.75
METRES.

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KEEP AWAY FROM THE MACHINE IF IT CONTACTS ENERGISED POWER LINES. PERSONNEL ON
THE GROUND OR IN THE CAB MUST NOT TOUCH OR OPERATE THE MACHINE UNTIL ENERGISED
POWER LINES ARE SHUT OFF.
DO NOT OPERATE THE MACHINE DURING LIGHTNING OR STORMS.
Figure 5 - Safe Distance (metres) from Power Lines in excess of 33kV on Steel Towers
Figure 6 - Safe Distance (metres) from Power Lines up to 33kV on Wooden Poles
Refer to Engineering 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 SITE AND GOVERNMENTAL RULES
REGARDING USE OF PERSONAL PROTECTIVE EQUIPMENT.
CHECK THE WORK AREA FOR OVERHEAD OBSTRUCTIONS OR OTHER POSSIBLE HAZARDS.
OBSERVE AND USE COLOUR-CODED DIRECTION ARROWS ON THE MACHINE DISPLAY FOR DRIVE
FUNCTIONS.
DO NOT ENGAGE IN STUNT DRIVING OR HORSEPLAY WHILST OPERATING THE MACHINE.

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DO NOT LOWER THE RAIL AXLES UNLESS THE AREA BELOW IS CLEAR OF PERSONNEL AND
OBSTRUCTIONS.
LIMIT TRAVEL SPEED ACCORDING TO CONDITIONS, SLOPE, LOCATION OF PERSONNEL, AND ANY
OTHER FACTORS, WHICH MAY CAUSE COLLISION.
DO NOT OPERATE THE MACHINE IN THE PATH OF ANY CRANE OR OTHER MOVING MACHINERY
UNLESS THE CONTROLS OF THAT MACHINERY HAVE BEEN LOCKED OUT AND/OR PRECAUTIONS
HAVE BEEN TAKEN TO PREVENT ANY POTENTIAL COLLISION. USE A ‘BANKSMAN’ OR MACHINE
CONTROLLER TO ALERT THE OPERATOR/DRIVER WHEN REQUIRED.
BEWARE OF SLIPPERY AND LIMITED TRACTION CONDITIONS ON RAIL. BRAKING DISTANCE CAN
INCREASE SIGNIFICANTLY IN WET OR ICY CONDITIONS.
ALWAYS OBEY NATIONAL/STATATORY AND INFRASTRUCTURE MANAGER REGULATIONS WHILST
DRIVING THE VEHICLE. BE AWARE OF THE VEHICLE’S OVERALL LENGTH, WIDTH AND HEIGHT.
Crushing Hazards
KEEP HANDS AND LIMBS AWAY FROM MOVING PARTS OF THE MACHINERY.
USE SITE SPECIFIC RISK ASSESMENTS, SAFE SYSTEM OF 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/REMOVED.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel or other explosive
substances.
Do not refuel the tank(s) when the engine is running.
Refuel the tank(s) and charge the battery only in an open, well-ventilated area away from sparks, flames and
lighted tobacco.
Do not operate the machine in hazardous locations or locations where potentially flammable or explosive
gases or particles may be present.
Do not spray ether into engines equipped with glow plugs.
KEEP SPARKS, FLAMES AND LIGHTED TOBACCO AWAY FROM THE BATTERIES. BATTERIES EMIT
AN EXPLOSIVE GAS. DO NOT SMOKE IN THE VEHICLE CAB.
DO NOT CONTACT THE BATTERY TERMINALS OR THE CABLE CLAMPS WITH TOOLS THAT MAY
CAUSE SPARKS.
Damaged Machine Hazards
DO NOT USE A DAMAGED OR MALFUNCTIONING MACHINE.

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CONDUCT A THOROUGH PRE-OPERATION INSPECTION OF THE MACHINE AND TEST ALL
FUNCTIONS BEFORE EACH WORK SHIFT. IMMEDIATELY TAG AND REMOVE FROM SERVICE A
DAMAGED OR MALFUNCTIONING MACHINE.
BE SURE ALL MAINTENANCE HAS BEEN PERFORMED AS SPECIFIED IN THIS MANUAL, THE
SERVICE MANUAL AND OTHER MANUALS.
BE SURE ALL DECALS ARE IN PLACE AND LEGIBLE. SEE THE DECALS SECTION OF THIS MANUAL.
BE SURE THE OPERATOR’S, SAFETY, AND RESPONSIBILITIES MANUALS ARE COMPLETE,
LEGIBLE AND LOCATED ON THE MACHINE.
IF IN DOUBT, CONTACT RAIL-ABILITY LTD.
Bodily Injury Hazards
BE AWARE OF CRUSHING HAZARDS WHEN GRASPING THE HAND RAIL.
DO NOT OPERATE A MACHINE WITH A HYDRAULIC OIL OR AIR LEAK. A HYDRAULIC LEAK CAN
PENETRATE AND/OR BURN SKIN.
IMPROPER CONTACT WITH COMPONENTS UNDER ANY COVER WILL CAUSE SERIOUS INJURY.
ONLY TRAINED MAINTENANCE PERSONNEL 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 CONTACTING BATTERY ACID. NEUTRALISE
BATTERY ACID SPILLS WITH BAKING SODA AND WATER.
DO NOT EXPOSE BATTERIES TO WATER OR RAIN.
Electrocution Hazards
INSPECT DAILY FOR DAMAGED CABLES AND WIRES. REPLACE DAMAGED ITEMS BEFORE
OPERATING.
Avoid contact with electrical terminals.
INSPECT THE EARTH BONDING STRAPS DAILY.
REPLACE DAMAGED STRAPS BEFORE OPERATING.
Earth bonding straps are fitted on the machine in the following positions:
✓Between front & rear rail axles and chassis.
✓Between the chassis and the sub-frame and from the sub-frame to the body.
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.

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AVOID ELECTRICAL SHOCK FROM CONTACT WITH BATTERY TERMINALS. REMOVE ALL RINGS,
WATCHES AND OTHER JEWELLERY.
ENSURE A ‘C FORM’ HAS BEEN OBTAINED BEFORE ON TRACKING THE MACHINE IN OLE AREAS
UNLESS THE MACHINE MODULE IS CONFIGURED TO WORK UNDER LIVE OLE.
Lifting Hazard
USE THE APPROPRIATE NUMBER OF PEOPLE AND PROPER LIFTING TECHNIQUES WHEN LIFTING
BATTERIES, DRAWBARS, TOOLS AND OTHER REMOVABLE ITEMS.
DECAL LEGEND
THE DECALS ON THIS MACHINE USE SYMBOLS, COLOUR CODING AND SIGNAL WORDS TO
IDENTIFY THE FOLLOWING:
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 RESULT IN DEATH OR SERIOUS
INJURY.
YELLOW WITH SAFETY ALERT SYSTEM - USED TO INDICATE THE PRESENCE OF
A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY CAUSE
MINOR OR MODERATE INJURY.
YELLOW WITHOUT SAFETY ALERT SYMBOL - USED TO INDICATE THE
PRESENCE OF A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, MAY RESULT IN PROPERTY DAMAGE.
GREEN - USED TO INDICATE OPERATION OR MAINTENANCE INFORMATION.

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RAIL SAFETY RULES
On / Off-Tracking the Machine - general points
On/Off-Track the vehicle only at an approved access point within possession limits only.
Note - an approved access point is one of the following:
•Level crossing
•Yard where surface is level with the top of the rail
•Proprietary approved track access system with rail shields.
•Consolidated ballast to at least the underside of the railhead with rail shields.
The following hazards should also be addressed:
•Cant - not to exceed 150mm
•Ballast shoulder –must be low
•Deep cess / soft cess must 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.
✓The module stowed in the fully lowered (transport) position.
✓Doors closed and latched.
✓Module system hydraulics de-activated.
To ensure the machine is complying with the W6 gauge requirement, before travelling on rail, it is essential
that the machine is configured as above to ensure overhead and line-side structures are not struck.
Failure to comply with these requirements may result in severe damage to the machine and/or the rail
infrastructure.

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Emergency Off-Tracking
EMERGENCY ON-TRACKING IS NOT COVERED IN THIS MANUAL AS THERE IS NO OCCASION WHEN
THIS PROCEDURE WOULD BE CONDONED.
Emergency Off-Tracking however may be necessary at in an emergency at the request of the Engineering
Supervisor / Machine Controller. It must be stressed that this is an Emergency Procedure Only and should
NOT be used for normal operation. If you are asked to Off-Track using this method (at an unprepared location)
without suitable justification you should report to your On- call Manager and ask his advice before attempting
this manoeuvre. If there is real cause to use this method there are still certain procedures that must be
followed:
•The Off-Tracking area must be inspected for its suitability as normal.
•An area where there are no obstructions should be selected. For example, there should be no
conductor rail present, no high ballast shoulders and no obvious hazards.
•Emergency 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.
•Slowly drive clear of the rail
•Move the machine at least 3 metres from the closest rail
When carrying out this operation always follow any hand signals given by a ‘banksman’ or machine controller
and carry out all movements smoothly and at a safe speed.
Ensure you are clear of all obstructions and that ground conditions are suitable.
Ensure the machine isconfigured to travel to avoid causing instability or a possible tip over situation occurring.
THIS MANOEUVRE IS DANGEROUS AND MUST ONLY BE CARRIED OUT IN A REAL EMERGENCY.
When Off-Tracking, care must be taken when the machine manoeuvres off the railhead. Make certain that the
rail bogies are raised up to the maximum height for travel.
‘Grounding out’ the machine, whilst the machine is travelling off rail may result in severe damage to the
machine and/or infrastructure.

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Operator’s Manual
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PRE-OPERATION INSPECTION
DO NOT OPERATE UNLESS:
✓YOU LEARN AND PRACTICE THE PRINCIPLES OF SAFE MACHINE OPERATION CONTAINED IN
THIS OPERATOR’S MANUAL.
1. AVOID HAZARDOUS SITUATIONS.
2. ALWAYS PERFORM A PRE-OPERATION INSPECTION.
KNOW AND UNDERSTAND THE PRE-OPERATION INSPECTION BEFORE GOING ON TO THE
NEXT SECTION.
3. ALWAYS PERFORM FUNCTION TESTS PRIOR TO USE.
4. INSPECT THE WORKPLACE.
5. ONLY USE THE MACHINE AS IT WAS INTENDED.
Fundamentals
IT IS THE RESPONSIBILITY OF THE OPERATOR TO PERFORM A PRE-OPERATION INSPECTION AND
ROUTINE MAINTENANCE.
THE PRE-OPERATION INSPECTION IS A VISUAL 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 LIST ON THE NEXT PAGE AND CHECK EACH OF THE ITEMS IN TURN.
IF DAMAGE OR ANY UNAUTHORISED VARIATION FROM FACTORY DELIVERED CONDITION IS
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 AGAIN BEFORE GOING ON TO THE
FUNCTION TESTS.
IF IN DOUBT, CONTACT RAIL-ABILITY LTD.

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SCHEDULED MAINTENANCE INSPECTIONS SHALL BE PERFORMED BY QUALIFIED SERVICE
TECHNICIANS, ACCORDING TO THE MANUFACTURER’S SPECIFICATIONS, GOVERNMENTAL
REGULATIONS AND THE REQUIREMENTS LISTED IN THE SERVICE MANUAL.
Checks
❑ENSURE THAT THE OPERATOR’S AND SERVICE MANUALS ARE COMPLETE, LEGIBLE & IN
THE STORAGE CONTAINER LOCATED IN THE JCB CHASSIS CAB.
❑ENSURE THAT ALL DECALS ARE LEGIBLE & IN PLACE. SEE DECALS SECTION.
❑ENSURE GEAR SHIFT LEVER IS IN NEUTRAL.
❑CHECK ENGINE & RELATED COMPONENTS (E.G. RADIATOR, ALTERNATOR, BELTS, ETC.).
SEE JCB MANUAL.
❑CHECK FOR ENGINE OIL LEAKS & PROPER OIL LEVEL. ADD OIL IF NEEDED. SEE JCB
MANUAL.
❑CHECK FOR HYDRAULIC OIL LEAKS & PROPER OIL LEVELS. 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 BATTERY FLUID LEAKS. SEE JCB MANUAL.
❑CHECK CAB WINDSCREEN & WIPERS.
❑CHECK ALL ELECTRICAL PLUGS ARE CONNECTED & HYDRAULIC CONNECTIONS ARE
COUPLED.
❑CHECK ALL BODY-LOCKS ARE ENGAGED AND LOCKED.
CHECK THE FOLLOWING COMPONENTS OR AREAS FOR DAMAGE, IMPROPERLY INSTALLED,
LOOSE OR MISSING PARTS AND UNAUTHORISED MODIFICATIONS:
❑ELECTRICAL COMPONENTS, WIRING, ELECTRICAL CABLES & EARTH STRAPS.
❑HYDRAULIC POWER UNIT, TANK, HOSES, PIPES, FITTINGS, CYLINDERS & MANIFOLDS
❑BATTERIES & CONNECTIONS
❑FUEL & HYDRAULIC TANKS
❑MODULE TURNTABLE DRIVE MOTORS
❑MODULE WEAR PADS
❑PROXIMITY SWITCHES, ALARMS & HORNS

JCB 714 Super-Boss Conversion SB002
Operator’s Manual
Issue 1, R2 Last Updated 5 April 2017 Page 20 of 43
❑NUTS, BOLTS, PINS & OTHER FASTENERS
❑LUBRICATION POINTS
❑ALL CONTROL PANELS & DISPLAYS
❑TOW BAR
❑FIRE EXTINGUISHER
❑RAIL WHEEL HUBS, TREADS, FLANGES & 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 COMPARTMENT COVERS
ARE IN PLACE AND LATCHED.