Rail-Ability SUPER BOSS User manual

ISSUE 1 LAST UPDATED 22/07/2005
(SB001)
RAIL OPERATIONS
&
EMERGENCY
RECOVERY
PROCEDURES
RAIL- ABILITY
JCB 714 SUPER BOSS
ROAD/RAIL VEHICLE

ISSUE 2 LAST UPDATED 22/07/2005 PAGE 1 OF 12
TABLE OF CONTENTS
TABLE OF CONTENTS .......................................................................... 1
CONTROL LAYOUT ............................................................................... 2
JCB 714 OPERATING CONTROLS ...................................................... 4
RAIL MASTER SWITCH......................................................................................4
AXLE CHANGE-OVER SWITCH........................................................................4
STEERING LOCK SWITCH.................................................................................4
AUXILIARY CONTROL LEVER.........................................................................4
GEAR SELECTOR ................................................................................................4
OPERATIONAL SAFETY PRECAUTIONS ........................................ 6
ON / OFF TRACKING THE JCB 714 .................................................... 7
GENERAL POINTS ..............................................................................................7
TRAVELLING ON THE RAIL ............................................................... 8
EMERGENCY OFF TRACKING ........................................................... 9
EMERGENCY RECOVERY ................................................................. 10
RECOVERY PUMP ................................................................................ 11
EARTH BONDING STRAPS................................................................. 12

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CONTROL LAYOUT
RAIL AXLE
CHANGE-OVER
SWITCH
RAIL MASTER
SWITCH
STEERING
LOCK
SWITCH
PARKBRAKE

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GEAR
SELECTOR
AUXILIARY
CONTROL
LEVER

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JCB 714 OPERATING CONTROLS
RAIL MASTER SWITCH
THIS SWITCH MUST BE OPERATED FOR ALL RAIL-MOUNTED OPERATIONS.
WHEN OPERATED THE SWITCH MAKES THE RAIL DRIVE AND RAIL AXLE
CONTROL SWITCHES AND STEERING LOCK SYSTEM ACTIVE. IT ALSO
ACTIVATES THE RAIL NAVIGATION LIGHTS AND GEAR RESTRICTION SYSTEM.
[WARNING] NEVER OPERATE THE MACHINE ON TRACK WITH OUT THE RAIL
MODE SWITCH ACTIVE. FAILURE TO ADHERE TO THIS REQUIREMENT WILL
RESULT IN THE RAIL SAFETY SYSTEMS ON THE MACHINE BEING INACTIVE AND
CAN RESULT IN EXCESSIVE SPEED BEING REACHED WHEN TRAVELLING ON
RAIL AND POTENTIAL DE-RAIL OCCURRING RESULTING IN SERIOUS INJURY OR
DEATH AND SEVERE DAMAGE TO THE RAIL INFRASTRUCTURE AND MACHINE.
AUXILIARY CONTROL LEVER
NORMALLY THIS OPERATES THE HYDRAULICS ON THE MODULE ATTACHED TO
THE CHASSIS, I.E. OPERATES THE TIPPING RAM ON THE 3-WAY TIPPER MODULE.
WHEN THE AXLE CHANGEOVER SWITCH IS OPERATED THIS RAISES AND
LOWERS THE SELECTED RAIL GEAR.
AXLE CHANGE-OVER SWITCH
THIS SWITCH CHANGES BETWEEN FORWARD AND REAR RAIL GEAR WHEN
RAISING AND LOWERING THE WHEELS. HOLDING THE LEFT SIDE OF THE
SWITCH DOWN GIVES POWER TO THE FRONT AXLE RAMS AND HOLDING THE
RIGHT SIDE SWITCHES FLOW TO THE REAR AXLE RAMS. WHEN THIS SWITCH IS
IM THE DEFAULT CENTRAL POSITION THE AUXILIARY HYDRAULIC CIRCUIT ITS
ACTIVE
STEERING LOCK SWITCH
ONCE THE STEERING LOCK SWITCH HAS BEEN OPERATED THE LOCK WILL
ONLY TAKE 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.
GEAR SELECTOR
WHEN TRAVELLING ON RAIL THE MACHINE MUST BE IN REVERSE GEAR TO
ACHIEVE FORWARD DRIVE AND CONVERSELY WHEN FORWARD IS
SELECTED THE MACHINE WILL TRAVEL BACKWARDS.
TO OPERATE THE GEAR SELECTOR THE BUTTON ON THE TOP NEEDS TO BE
PRESSED AND HELD IN BEFORE IT WILL SELECT A GEAR. PUSH THE LEVER
FORWARD INTO THE ‘V’ POSITION TO SELECT FORWARD TRAVEL OR PULL
BACK INTO THE ‘R’ POSITION FOR REVERSE TRAVEL.
IN NORMAL USE THE JCB 714 HAS 6 FORWARD GEARS AND 3 REVERSE. IF THE
GEAR LEVER IS JUST PUT IN FORWARDS POSITION IT WILL START IN
AUTOMATIC. TO CHANGE UP OR DOWN GEARS MANUALLY MOVE THE LEVER
TO THE SIDE AS INDICATED ON THE LABEL.
IN RAIL MODE THE VEHICLE IS REDUCED TO 3 FORWARD AND 2 REVERSE
GEARS. WHEN THE VEHICLE IS PUT INTO REVERSE IN RAIL MODE IT WILL

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START IN 1ST GEAR AND TRAVEL IN THE FORWARD DIRECTION. WHEN MOVED
TO THE ‘+’ THE VEHICLE WILL CHANGE TO 2ND GEAR FOLLOWED BY
AUTOMATIC IF MOVED AGAIN. THIS IS ONLY AVAILABLE IN REVERSE FOR
FORWARD TRAVEL. GEAR SELECTION IS MANUAL IN THE REVERSE DIRECTION
IN THE FORWARD GEAR
WITH 3-WAY TIPPER MODULE:
• WHEN BODY IS TIPPED THE MACHINE IS RESTRICTED TO 1 FORWARD AND
1 REVERSE GEAR.
• AUXILIARY CONTROL LEVER OPERATES TIPPING RAM

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OPERATIONAL SAFETY PRECAUTIONS
• ALL WORK ON OR NEAR THE RAILWAY INFRASTRUCTURE MUST BE CARRIED
OUT STRICTLY IN ACCORDANCE WITH RAILWAY REGULATIONS.
• ATTENTION 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 CERTIFICATE FOR
ADDITIONAL, SPECIFIC MACHINE LIMITATIONS OF USE.

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ON / OFF TRACKING THE JCB 714
GENERAL POINTS
ON/OFF TRACK THE JCB 714 ONLY AT AN APPROVED ACCESS POINT
NOTE – AN APPROVED ACCESS POINT IS ONE OF THE FOLLOWING:
• LEVEL CROSSING
• YARD WHERE SURFACE IS LEVEL WITH THE RAIL TOP
• PROPRIETARY APPROVED TRACK ACCESS SYSTEM WITH RAIL SHIELDS.
• CONSOLIDATED BALLAST TO AT LEAST THE UNDERSIDE OF THE RAIL HEAD
WITH RAIL SHIELDS.
THE FOLLOWING HAZARDS SHOULD ALSO BE ADDRESSED:
• CANT – NOT TO EXCEED 150MM
• BALLAST SHOULDER – HIGH / LOW
• DEEP CESS / SOFT CESS
• DRAINAGE ROUTES, TROUGHING ROUTES AND OTHER SERVICES/CABLES
• OHLE, 3RD RAIL MUST BE WHERE GAP EXISTS ON BOTH SIDES, POWER
CABLES.

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TRAVELLING ON THE RAIL
MACHINE TRAVEL POSITION AS SHOWN ABOVE AND AS FOLLOWS:
− STEERING LOCK IS ENGAGED
[WARNING] EXTRA CARE AND OBSERVATION OF LINE SIDE AND OVERHEAD
STRUCTURES IS REQUIRED WHEN THE MACHINE IS FITTED WITH AN
ATTACHMENT THAT IS OUTSIDE THE W6 TRAVEL GAUGE IN ANY WAY.
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 OFF TRACKING MAY BE NECESSARY DURING THE WORKING
LIFESPAN OF THE MACHINE. IT MUST BE STRESSED THAT THIS IS AN EMERGENCY
PROCEDURE ONLY AND SHOULD NOT BE USED IN THE NORMAL CAUSE OF EVENTS.
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
CERTAIN PROCEDURES THAT SHOULD 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 CANTS.
IN THE EVENT OF A REAL EMERGENCY THE PROCEDURE FOR OFF TRACKING IS
AS FOLLOWS:
• APPROACH THE OFF TRACKING AT A SAFE SPEED.
• SOUND THE HORN TO ALERT PERSONNEL AT THE OFF TRACKING AREA
AS YOU APPROACH.
• RAISE ALL OF THE RAIL WHEELS.
• DRIVE THE MACHINE CLEAR OF THE RUNNING RAIL.
WHEN CARRYING OUT THIS OPERATION ALWAYS FOLLOW ANY HAND SIGNALS
AND CARRY OUT ALL MOVEMENTS SMOOTHLY AT A SAFE SPEED.

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EMERGENCY RECOVERY
IF YOUR MACHINE BREAKS DOWN IN SUCH A POSITION THAT IT IS LIKELY TO
OBSTRUCT AN ADJACENT LINE OR CAUSE AN ACCIDENT OR DAMAGE TO THE
RAILWAY INFRASTRUCTURE OR ANY OTHER VEHICLE, IT IS IMPORTANT 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
MACHINE IN A SAFE POSITION.
THE MAIN POINTS ARE:
CONNECT YOUR MACHINE AND RECOVERY VEHICLE TOGETHER WITH THE
APPROVED TOW BAR.
SELECT THE REQUIRED RAIL GEAR WITH THE TAP ON THE HAND PUMP, MAKING
SURE THAT THE SCREW TAP ON THE SIDE OF THE PUMP IS SCREWED IN. DOING
THIS RAISE THE RAIL GEAR SO THERE IS APPROXIMATELY 10mm BETWEEN THE
ROAD WHEEL AND THE DRIVE TRUMPET.
WHEN USING THE HAND PUMP THE RAIL GEAR WILL MOVE SLOWLY.
ONLY RELEASE RAISE THE RAIL GEAR OF THE FAILED MACHINE ONCE THE TOW
BAR HAS BEEN CONNECTED TO THE RECOVERY VEHICLE OTHERWISE THE
MACHINE MIGHT RUN AWAY.
ENSURE THAT TOWING IS CARRIED OUT AT A SLOW SPEED APPROXIMATELY 2 MPH
AS THE RECOVERY VEHICLE HAS TO BRAKE FOR BOTH VEHICLES, AT A HIGHER
SPEED BRAKING DISTANCE WOULD BE GREATLY INCREASED.

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RECOVERY PUMP
[WARNING] THE MACHINE SHOULD BE COUPLED TO THE TOWING VEHICLE BEFORE
THIS PROCEDURE IS FOLLOWED. THE MACHINE’S BRAKES ARE DISABLED WHEN IT
IS IN FREE–WHEEL MODE. FAILURE TO COUPLE THE MACHINE INITIALLY MAY
RESULT IN IT ROLLING AWAY.
THERE IS A TAP ON THE RECOVERY PUMP TO DIRECT THE FLOW TO THE FRONT OR
REAR RAIL GEAR. ONCE THE CORRECT AXLE HAS BEEN SELECTED USE THE HAND
PUMP TO LIFT THE RAIL GEAR. MAKE SURE SCREW TAP IS TIGHTENED.
RAISE THE RAIL GEAR UNTIL THE DRIVE TRUMPET IS 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.

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EARTH BONDING STRAPS
EARTH BONDING STRAPS ARE FITTED ON THE MACHINE IN THE FOLLOWING
POSITIONS:
FIGURE A. BETWEEN FRONT RAIL AXLE AND CHASSIS.
FIGURE B. BETWEEN REAR RAIL AXLE AND 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 0.15Ω
FIGURE A

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FIGURE B