SWX â€B†Series Operator's Manual - Shuttlewagon mobile railcar ...
SWX â€B†Series Operator's Manual - Shuttlewagon mobile railcar ...
SWX â€B†Series Operator's Manual - Shuttlewagon mobile railcar ...
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MOBILE RAILCAR MOVERS<br />
<strong>SWX</strong> ”B” <strong>Series</strong><br />
Operator’s<br />
<strong>Manual</strong><br />
4116 Doctor Greaves Rd.<br />
Grandview, MO 64030<br />
Ph: (816) 767-0300 Fax: (816) 763-0705<br />
email: info@shuttlewagon.net
Table of Contents<br />
Table of Contents<br />
I. Introduction 1<br />
The <strong>Shuttlewagon</strong> ® in General 1<br />
The <strong>Shuttlewagon</strong> ® Off-Rail 1<br />
The <strong>Shuttlewagon</strong> ® On-Rail 2<br />
II. Safety 3<br />
Mechanical Safety 3<br />
General Operating Safety 4<br />
III. Controls and Indicators 5<br />
Illustration I. Cab Overview 5<br />
Illustration II. Controls and Indicators 1-4 6<br />
Illustration III. Controls and Indicators 5-12 7<br />
Illustration IV. Controls and Indicators 13-31 8<br />
Illustration V. Controls and Indicators 32-48 10<br />
Illustration VI. Controls and Indicators 49-55 13<br />
Illustration VII. Controls and Indicators 56-57 15<br />
Illustration VIII. Controls and Indicators 58-60 16<br />
Illustration VIII. Controls and Indicators 62-68 17<br />
Illustration VIII. Controls and Indicators 69-72 18<br />
Illustration IX. Controls and Indicators 73 18<br />
Illustration X. Controls and Indicators 74-75 19<br />
Illustration XI. Controls and Indicators 76 19<br />
IV. Pre-Start 20<br />
Pre-Start Walk Around 20<br />
Exterior Check 21<br />
Interior Check 21<br />
Recommended Monthly Inspections 23<br />
Recommended Semi-Annual Inspection 24<br />
V. Road Operation 25<br />
Operation (Road Mode) 25<br />
Oil Pressure 26<br />
Air Pressure 26
Table of Contents<br />
(cont.)<br />
Table of Contents<br />
VI. Rail Operation 28<br />
Mounting On Rail (400 <strong>Series</strong> and Single Steer Units) 28<br />
Mounting On Rail (500 <strong>Series</strong> and Dual Steer Units) 29<br />
Coupling 30<br />
Connecting Railcar Air Brakes 31<br />
Why Use the Train Brake System? 32<br />
Train Rail Brake Control 33<br />
Unhooking From Railcars 34<br />
Dismounting From Rail 34<br />
Towing 34<br />
VII. Railcar Movement 35<br />
Grade in Relation to Travel 35<br />
Railcar Brake Systems (Air and Mechanical) 37
Introduction<br />
I. Introduction<br />
Welcome to the <strong>Shuttlewagon</strong> ® Operators handbook. This handbook<br />
contains information, descriptions and illustrations for the various<br />
functions and operations of the <strong>Shuttlewagon</strong> ® , and is intended as a<br />
handy reference for operating the <strong>Shuttlewagon</strong> ® only. To obtain comprehensive<br />
<strong>Shuttlewagon</strong> ® training contact Central Manufacturing’s Training<br />
and Customer Support service at (816) 767-0300.<br />
The <strong>Shuttlewagon</strong> ® in General<br />
The <strong>Shuttlewagon</strong> ® is designed as a <strong>railcar</strong> mover to free up locomotives<br />
from switching yard duties. It’s unique design helps eliminate rail yard congestion<br />
by being able to move both on rail and off rail by means of<br />
hydraulically raised and lowered rail wheels.<br />
Under normal conditions the <strong>Shuttlewagon</strong> ® can move freely on asphalt,<br />
cement, gravel or dirt roads. Due to the narrow wheel base required for rail<br />
operation the <strong>Shuttlewagon</strong> ® should never be operated on an extreme<br />
grade or pitch.<br />
The <strong>Shuttlewagon</strong> ® utilizes a heavy duty power train and rubber tires to<br />
achieve tractive effort. The rubber tires achieve a greater tractive effort<br />
than <strong>railcar</strong> movers that use steel rail wheels for traction.<br />
Most components of the <strong>Shuttlewagon</strong> ® are comprised of brand name offthe-shelf<br />
parts (i.e. the power train is comprised of either a Caterpillar or<br />
Cummins engine, Funk transmission and Rockwell axles) in a factory built<br />
frame. Other systems use similar brand name parts with customized layouts.<br />
The <strong>Shuttlewagon</strong> ® Off-Rail<br />
When the <strong>Shuttlewagon</strong> ® is off-rail, it operates the same as a truck. It has<br />
hydrostatic steering, two wheel drive and disc brakes. All pedals, switches<br />
and controls conform to normal truck operation and application.<br />
The control panels are designed for the operator’s convenience. They are<br />
easy to read and within easy reach of the operator.<br />
Side view mirrors are located on both sides of the <strong>Shuttlewagon</strong> ® cab for<br />
all-round views from the driver’s seat. The driver’s seat is air suspension<br />
mounted on a swivel base and is fully adjustable with a lap seat belt.<br />
1<br />
Note:<br />
Do not attempt to operate the <strong>Shuttlewagon</strong> ® until you<br />
have been properly trained!
Introduction<br />
The <strong>Shuttlewagon</strong> ® On-Rail<br />
When the <strong>Shuttlewagon</strong> ® is ready to travel on rail, the rail units are positioned<br />
over the rails and lowered, the steering is locked and the rubber<br />
tires are used to provide traction for moving the <strong>Shuttlewagon</strong> ® and<br />
attached <strong>railcar</strong>s. The front axle is automatically engaged for four wheel<br />
drive during rail operation, providing increased traction.<br />
Note:<br />
The rail wheels do not provide any tractive effort.<br />
They are simply engaged to guide the <strong>Shuttlewagon</strong> ® along the track.<br />
The vehicle and rail unit suspensions are independent allowing for a<br />
smoother ride and increased stability for adverse track conditions. When<br />
ice and snow are present on the track, sanders located on both sides of<br />
each tire can be used to sand the track during forward or reverse operation.<br />
Mirrors at the front and back of the unit help you align the <strong>Shuttlewagon</strong> ®<br />
to the track and it’s coupler with rail car couplers. Hydraulic cylinders<br />
move the coupler and an air cylinder actuates the coupler opening<br />
mechanism.<br />
The <strong>Shuttlewagon</strong> ® is equipped with a train air brake valve to activate the<br />
air brake mechanisms of the rail cars to provide braking action for the rail<br />
cars and the <strong>Shuttlewagon</strong> ® when actively moving <strong>railcar</strong>s.<br />
Note:<br />
Do not attempt to stop the <strong>Shuttlewagon</strong> ® and <strong>railcar</strong> consist with the<br />
<strong>Shuttlewagon</strong> ® foot brake. Use the train air brake valve to brake both the<br />
consist and <strong>Shuttlewagon</strong> ® .<br />
The <strong>Shuttlewagon</strong> ® ’s foot brake is for use only in stopping the<br />
<strong>Shuttlewagon</strong> ® by itself, and may be used for that purpose either on or offrail.<br />
2
Safety<br />
II. Safety<br />
The operator of the <strong>Shuttlewagon</strong> ® is entirely responsible for the safe handling<br />
of the machine and must take every precaution to assure that the<br />
unit is maintained properly and that all systems are in good working order<br />
prior to start-up. Like any piece of heavy equipment, if poorly maintained<br />
or carelessly and improperly operated, the <strong>Shuttlewagon</strong> ® could cause<br />
injury to the user and/or others in the vicinity.<br />
Because the <strong>Shuttlewagon</strong> ® utilizes air and hydraulic systems for operation,<br />
a cracked hose or improperly tightened fitting can cause a loss of air or<br />
hydraulic pressure potentially resulting in loss of braking power or other<br />
related mechanical failure.<br />
It is imperative that checks of the mechanical systems, exterior features<br />
and interior functions be performed daily in order to operate in a safe and<br />
efficient manner.<br />
Under no circumstances should you, the operator, attempt to use or move<br />
the <strong>Shuttlewagon</strong> ® until you are satisfied that everything is in working order<br />
and safe to operate.<br />
Mechanical Safety<br />
As mentioned, the <strong>Shuttlewagon</strong> ® uses air and hydraulic systems for operation.<br />
The hydraulic system operates the:<br />
• rail gear<br />
• steering system<br />
• coupler positioner cylinders<br />
parking brake<br />
3<br />
•<br />
If hydraulic pressure does not build up, the rail wheels cannot be lowered<br />
and used to guide the <strong>Shuttlewagon</strong> ® along the rail.<br />
The air system operates the:<br />
• the <strong>Shuttlewagon</strong>® brakes<br />
• the <strong>railcar</strong> brakes<br />
• the air adjustable suspension seat<br />
the coupler opening mechanism<br />
•<br />
Inadequate air pressure will not allow either the vehicle brakes or the <strong>railcar</strong><br />
brakes to function properly.<br />
It is important that air and hydraulic pressures have built up to the correct<br />
pressure before moving the <strong>Shuttlewagon</strong> ® . There are many reasons pressure<br />
may not build. Under no circumstances should the <strong>Shuttlewagon</strong> be<br />
moved if pressures do not build to the correct minimum setting.
III. Controls and Indicators<br />
This section describes and illustrates each control/indicator found on the<br />
<strong>Shuttlewagon</strong> ® , and is useful as a quick reference only. A more thorough<br />
understanding of the controls/indicators can be obtained by contacting<br />
Central Manufacturing’s Training and Customer Support service at<br />
(816) 767-0300.<br />
The controls/indicators are numbered with an accompanying illustration<br />
to aid in identifying it and its location along with a brief description describing<br />
its purpose or function.<br />
A<br />
F<br />
Illustration I. Cab Overview<br />
G B<br />
A. Heater Assembly<br />
B. Dash Panels<br />
C. Driver’s Seat<br />
D. Passenger Seating<br />
E. Rear Throttle and Brake<br />
F. Steering Assembly<br />
G. Defroster Fan<br />
H. Floor Matting<br />
I. Map Lights<br />
J. Windshield Washer Fluid Container<br />
J<br />
H<br />
C<br />
Controls and Indicators<br />
I<br />
E<br />
D<br />
4
Controls and Indicators<br />
1. Turn signal lever<br />
Activates the signal lights located on each corner of the frame exterior.<br />
2. Emergency Flasher<br />
Pull the control out to activate the emergency flashers. Move the turn<br />
signal lever to deactivate the flashers<br />
3. Throttle Pedal (Forward)<br />
Regulates engine RPM. Depressing pedal increases engine RPM.<br />
4. Brake Pedal (Forward)<br />
Controls <strong>Shuttlewagon</strong> ® brakes. Depressing pedal increases braking<br />
action.<br />
5. Engine Oil Pressure Gauge<br />
Displays the oil pressure in the engine lubricating system in PSI.<br />
6. Engine Water (Coolant) Temperature Gauge<br />
Displays the temperature of the engine coolant in degrees Fahrenheit.<br />
5<br />
1<br />
Illustration II. Controls and Indicators 1-4<br />
2<br />
4<br />
3
Controls and Indicators<br />
7. Voltmeter<br />
Measures the voltage capacity being supplied by the alternator to<br />
recharge the battery.<br />
8. Fuel Gauge<br />
Indicates the amount of fuel (Diesel Oil) available in the fuel tank.<br />
9. Tachometer<br />
Displays engine speed in RPM (Revolutions Per Minute) times 100<br />
(RPM x 100).<br />
10. Hourmeter<br />
Records a total of engine running time in hours and tenths of hours.<br />
11. Low Oil Pressure Warning Light<br />
A warning light for low engine oil pressure. A red light will illuminate and<br />
a buzzer will sound if engine oil pressure drops below a predetermined<br />
pressure.<br />
12. High Water Temperature Warning Light<br />
A warning light for high coolant temperature. A red light will illuminate<br />
and a buzzer will sound if the engine coolant temperature exceeds<br />
normal limits.<br />
Caution:<br />
Do not attempt to operate the <strong>Shuttlewagon</strong> ® if either oil or<br />
water temperature indicator lamp is lit. Engine damage will occur!<br />
5<br />
11<br />
12<br />
7 8<br />
6<br />
10<br />
Illustration III. Controls and Indicators 5-12<br />
9<br />
6
Controls and Indicators<br />
13. Service Brake Air Pressure Gauge<br />
Indicates air pressure in service brake air system in PSI for the<br />
<strong>Shuttlewagon</strong> ® air system. Normal reading is approximately 115 PSI.<br />
14. Transmission Oil Temperature Gauge<br />
Indicates temperature of oil in the transmission torque converter in<br />
degrees Fahrenheit and Centigrade. Normal operating temperature is<br />
+180º to 220ºF.<br />
15. Hydraulic Oil Temperature Warning Light<br />
A red warning light that will illuminate if the hydraulic oil temperature<br />
exceeds normal limits.<br />
16. Hydraulic Oil Pressure Warning Light<br />
A red warning light that will illuminate and buzzer sound if the hydraulic<br />
oil pressure exceeds normal limits.<br />
17. Transmission Temperature Warning Light<br />
A red warning light that will illuminate if the transmission temperature<br />
exceeds normal limits.<br />
21 22 23 24 25 26<br />
Illustration IV. Controls and Indicators 13-31<br />
7<br />
14<br />
13<br />
15<br />
27<br />
16<br />
17<br />
18<br />
19<br />
20<br />
28<br />
29<br />
31<br />
30
Controls and Indicators<br />
18. Low Service Air Pressure Warning Light<br />
A red warning light that will illuminate if there is insufficient air pressure<br />
in the <strong>Shuttlewagon</strong> ® ’s service air reservoir. Below 65 PSI a buzzer will<br />
sound.<br />
19. Accumulator Light<br />
A red warning light that illuminates while the accumulator tank is<br />
charging, otherwise not lit when the accumulator tank is fully charged.<br />
20. Park Brake Light<br />
A red warning light that illuminates to indicate that the parking brake<br />
is engaged.<br />
21. Front Headlight Off/On and Dimmer Switch<br />
For front headlights, a three position rocker switch with Low,<br />
Off and High beam. A blue indicator light illuminates when the front<br />
headlights are switched to high beam.<br />
22. Rear Headlight Off/On and Dimmer Switch<br />
For rear headlights, a three position rocker switch with Low,<br />
Off and High beam. A blue indicator light illuminates when the rear<br />
headlights are switched to high beam.<br />
23. Strobe Light Switch<br />
A two position rocker switch with amber indicator light. Position the<br />
rocker switch to “On” to turn on the strobe light and “Off” to turn it off.<br />
24. Rail Wheel Lights Switch<br />
A two position rocker switch with orange indicator light. The Rail<br />
position turns on the rail wheel lights and illuminates the indicator light.<br />
25. Rear Window Wiper Switch<br />
A two position rocker switch. Position the rocker switch to “On” to turn<br />
on the rear wiper and “Off” to turn it off.<br />
26. Ignition Switch<br />
A four position key operated switch. The center(vertical) position is the<br />
off position and the key can be removed. Turning the key counterclockwise<br />
energizes the accessory circuit; turning the key clockwise<br />
from the off position turns the ignition on. The start position (full clockwise)<br />
energizes the starter. The switch is spring loaded and must be held<br />
in the start position; when released, it returns automatically to the<br />
on position.<br />
27. Front Defrost Fan Switch<br />
A two position rocker switch. Position the rocker switch to “Front” to turn<br />
on the fan and “Off” to turn it off.<br />
8
Controls and Indicators<br />
28. Rear Defrost Fan Switch<br />
A two position rocker switch. Position the rocker switch to “Rear” to turn<br />
on the fan and “Off” to turn it off.<br />
29. Parking Brake Switch<br />
A two position on/off rocker switch. When in the “On” position the park<br />
brake light (item 20) will be illuminated and brake set. In the “Off”<br />
position the brake will be released.<br />
30. Transmission Indicator/Diagnostic LED<br />
An LED display that indicates the gear range selected for the<br />
transmission. For information on its use in the diagnostic mode refer to<br />
the Funk Transmission manual.<br />
9<br />
32<br />
34<br />
33<br />
35<br />
45<br />
36 & 37<br />
38<br />
39<br />
43<br />
46<br />
Illustration V. Controls and Indicators 32-48<br />
40 41<br />
47<br />
48<br />
44<br />
42
Controls and Indicators<br />
31. Windshield Washer Switch<br />
A two position auto off return switch. Press to the “On” position to<br />
dispense windshield wiper solvent onto the front windshield. Releasing<br />
the switch will automatically return to the “Off” position.<br />
32. Front Rail Pressure Gauge<br />
A liquid filled pressure gauge. This gauge displays the hydraulic<br />
pressure being applied to the front rail unit in PSI.<br />
33. Rear Rail Pressure Gauge<br />
A liquid filled pressure gauge. This gauge displays the hydraulic<br />
pressure being applied to the rear rail unit in PSI.<br />
34. Low Front Rail Pressure Warning Light<br />
A red warning light that illuminates when the hydraulic pressure<br />
applied to the front rail unit drops below 200 PSI. A buzzer will also<br />
sound when the light is on.<br />
35. Low Rear Rail Pressure Warning Light<br />
A red warning light that illuminates when the hydraulic pressure<br />
applied to the rear rail unit drops below 200 PSI. A buzzer will also<br />
sound when the light is on.<br />
36. Rail Air Reservoir Gauge<br />
This gauge’s red needle measures the amount of air pressure available<br />
in the main air tank for pressurizing the train brake system.<br />
37. Rail Air Brake Gauge<br />
This gauge’s white needle measures the amount of air pressure being<br />
supplied to the train brakes during pressurization.<br />
38. Rail wheels up Switch (Front)<br />
A single position rocker switch with automatic off position return.<br />
Pressed to the up position will raise the front rail wheels.<br />
39. Rail Wheels Up Switch (Rear)<br />
A two position rocker switch with automatic off position return.<br />
Pressed to the up position will raise the rear rail wheels.<br />
40. Steering Mode Selector Switch (400 <strong>Series</strong> option)<br />
A two position rocker switch with “Front” for front axle steering only and<br />
“Dual” for dual axle steering.<br />
41. Steering Lock Switch<br />
A two position rocker switch with indicator light. Steering is unlocked in<br />
the “Unlock” position with indicator light off and locked in the “Lock”<br />
position with the green indicator light on.<br />
10
Controls and Indicators<br />
-<br />
42. Dive Mode Switch<br />
A two position rocker switch with road mode in the “Road” position<br />
and rail mode in the “Rail” position. A green indicator light will<br />
illuminate when in rail mode.<br />
43. Wheels Straight Ahead Indicator Front (All models)<br />
A green indicator light that remains on when front steer axle wheels are<br />
aimed straight ahead and wheels are straight with the vehicle.<br />
44. Wheels Straight Ahead Indicator Rear (400 <strong>Series</strong> option)<br />
A green indicator light that remains on when rear steer axle wheels are<br />
aimed straight ahead and wheels are straight with the vehicle.<br />
45. Coupler Positioner Switch (Front)<br />
A three position rocker switch with automatic off return position.<br />
Moves the front coupler from side to side.<br />
46. Coupler Positioner Switch (Rear)<br />
A three position rocker switch with automatic off return position.<br />
Moves the rear coupler from side to side.<br />
47. Coupler Release Switch<br />
A three position rocker switch with automatic off return position.<br />
Pressed to the “Front” position releases the front coupler and “Rear”<br />
releases the rear coupler.<br />
48. Rail Sanders Switch<br />
A three position rocker switch with automatic off return position.<br />
Pressing the switch to “Front” activates the front sanders until the switch<br />
is released. Pressing the switch to “Rear” activates the rear sanders.<br />
49. Front Rail Control Valve<br />
A two position hydraulic flow control valve. The valve must be in the<br />
down marked position to open the flow of hydraulic oil to the rail gear<br />
extension cylinders and remain in this position for rail operation. The<br />
“Closed” position will shut off the flow of hydraulic oil to the rail gear<br />
extension cylinders allowing them to be retracted for road operation.<br />
50. Rear Rail Control Valve<br />
A two position hydraulic flow control valve identical in function and<br />
operation to the Front Rail Control Valve above that operates the rear<br />
rail gear extension cylinders.<br />
11
49<br />
54<br />
50<br />
55<br />
Illustration VI. Controls and Indicators 49-55<br />
Controls and Indicators<br />
Caution:<br />
Always bring the vehicle to a full and complete stop before changing<br />
directions of travel. Power shifting the transmission with the vehicle<br />
under heavy load is not recommended and may shorten the life of the<br />
transmission. Never down shift the transmission for braking purposes.<br />
Note:<br />
A loud warning “beep” will sound repeatedly at short intervals<br />
whenever the transmission selector is positioned in reverse”R”.<br />
51. Transmission Selector Lever<br />
A three position selector valve consisting of forward, neutral and<br />
reverse. Four gear ranges in forward or reverse, with 1st and 2nd only in<br />
neutral. The selector must be in “Neutral” position for engine start up,<br />
selected gear range will be displayed in the Transmission Gear<br />
Indicator/Diagnostic LED (item 30).<br />
51<br />
53<br />
52<br />
12
Controls and Indicators<br />
52. Train Air Brake Control<br />
A variable air pressure valve. The “RELEASE”position enables<br />
compressed air flow to release the Train Railcar Brakes. The “APPLY”<br />
position releases air pressure from the Train Railcar Brakes causing the<br />
brakes to engage. This valve may be positioned anywhere between<br />
full release to full applied to provide braking power for the rail car<br />
consist when operating. The amount of braking action provided by the<br />
Train Air Brake Control may be measured by the white hand on the<br />
Rail Air Reservoir/Rail Air Brake Gauge (item 37).<br />
53. Train Brake Emergency Valve<br />
A red “push/Pull” knob. Pull the knob out to charge or open compressed<br />
air flow to the Train Air Brake Control (item 52). Push the knob<br />
in to release air pressure in the Train Railcar Brake system.<br />
Note:<br />
The Train Brake Emergency Valve (item 53) operates in conjunction<br />
with the Train Rail Brake Control (item 52) and must be in the up<br />
position in order to allow the Train Air Brake Control to charge the<br />
Train Railcar Brakes with air to release the brakes.<br />
Note:<br />
Railroads operate their cars at brake pressures of approximately 90 PSI.<br />
54. Front Rail Pressure Control<br />
A variable pressure rotary control knob with locking collar. To change<br />
the hydraulic pressure being applied to the rail wheels, loosen the locking<br />
collar and turn the control knob; clockwise to increase pressure or<br />
counterclockwise to decrease pressure. The pressure being applied to<br />
the rail unit will be displayed on Front Rail Pressure Gauge (item 32).<br />
54. Rear Rail Pressure Control<br />
Identical purpose and function to the Front Rail Pressure Control<br />
(item 54 above), but servicing the rear rail unit. It’s pressure is displayed<br />
on (item 33).<br />
13<br />
Caution:<br />
400 <strong>Series</strong>: Minimum rail pressure 300 PSI maximum 500 PSI<br />
500/600 <strong>Series</strong>: Minimum rail pressure 400 PSI maximum 600 PSI<br />
Failure to operate the <strong>Shuttlewagon</strong> ® within these rail pressures<br />
is not recommended.
56. Brake Pedal (Rear)<br />
Controls <strong>Shuttlewagon</strong> ® brakes. Depressing pedal increases braking<br />
action.<br />
57. Throttle Pedal (Rear)<br />
Regulates engine RPM. Depressing pedal increases engine RPM.<br />
57<br />
56<br />
Illustration VII. Controls and Indicators 56-57<br />
Controls and Indicators<br />
14
Controls and Indicators<br />
Illustration VIII. Controls and Indicators 58-60<br />
58. Front Windshield Wiper Control<br />
A variable position rotary knob with “off”/”on”. Rotating knob counterclockwise<br />
turns on wipers, further rotation increases wiper speed.<br />
59. Air Horn Pull Chain<br />
Pull down on cable to sound air horns.<br />
60. Front Dome Light Switch<br />
A two position “off”/”on” toggle switch. Push to right to turn on light, left<br />
to turn light off.<br />
61. Rear Dome Light Switch (not shown)<br />
Identical to Front Dome Light Switch (item 60). Also controlled by door<br />
jam switches and works off both doors when in the on position.<br />
62. Seat Back Control<br />
A knurled rotary knob. Rotating the knob clockwise will lean<br />
seat back, counterclockwise will lean seat forward.<br />
63. Seat Height Adjustment Lever<br />
Raise lever to adjust seat height<br />
15<br />
60<br />
59<br />
58
65<br />
68<br />
67<br />
66<br />
64. Seat Forward/Back Adjustment Lever<br />
Pull lever out and away from seat to slide seat forward or backward.<br />
65. Seat Air Ride Control<br />
Pull knob out to release air pressure and lower seat. Push knob in to<br />
raise seat height.<br />
66. Seat Safety Belt<br />
An adjustable lap-type seat belt with quick release buckle.<br />
67. Seat Rotation Control<br />
Pull handle out to disengage lock and rotate seat.<br />
63<br />
64<br />
Controls and Indicators<br />
68. Lumbar Adjustment Lever/Knob<br />
A five position lever. Move lever clockwise to increase lumbar pressure.<br />
63<br />
66<br />
62<br />
Illustration VIII. Controls and Indicators 62-68<br />
16
Controls and Indicators<br />
69. Front Railcar Air Supply Shutoff Valve<br />
A ball valve air supply for the <strong>railcar</strong> brakes. Position handle<br />
perpendicular to valve to shut off air supply, and parallel to valve to<br />
open air supply.<br />
70. Rear Railcar Air Supply Shutoff Valve<br />
Identical to Front Railcar Air Supply Shutoff Valve (item 69) on rear of unit.<br />
71. Gladhand Hose<br />
A rubber hose with special mating head for hooking to the train <strong>railcar</strong><br />
air brake system.<br />
17<br />
71<br />
69 & 70<br />
72. Coolant Level Sight Gauge<br />
A clear plastic (fluid level indicator)<br />
mounted on the Coolant Reservoir<br />
overflow tank. Normal fluid level is<br />
1/2 full when warm.<br />
73. Hydraulic Fluid Level Sight Gauge<br />
with Thermometer<br />
The sight gauge gives a visual indication<br />
of the level of hydraulic oil in<br />
the tank. The thermometer indicates<br />
the temperature of the oil in degrees<br />
Fahrenheit.<br />
72<br />
Illustration VIII. Controls and Indicators 69-72<br />
73<br />
Illustration IX.<br />
Controls and<br />
Indicators 73
74<br />
Controls and Indicators<br />
74. Transmission Fluid Level Dipstick<br />
To obtain an accurate check of the oil level in the transmission, the<br />
transmission oil should be warm, the transmission direction selector<br />
lever (item 51) placed in neutral “N” and the engine operating at idle.<br />
Failure to do so can result in an incorrect level reading.<br />
75. Transmission Oil Filler Tube<br />
Located next to the Transmission Fluid Dipstick (item 74) the Transmission<br />
Oil Fill Tube is used to add transmission oil.<br />
76. Engine Oil Dipstick (not shown)<br />
Located in different positions for various engines and types (ie.<br />
Cummins and Caterpillar) refer to the accompanying engine manuals<br />
for specific location.<br />
Pull the dipstick out and wipe it clean, reinsert the dipstick and check<br />
the oil level. The oil level should be between the full and add marks.<br />
Check the oil with the engine not running.<br />
Full Add<br />
75<br />
Illustration XI. Controls and Indicators 76<br />
Illustration X.<br />
Controls and Indicators 74-75<br />
18
Pre-Start<br />
IV. Pre-Start<br />
Pre-start inspections give you, the operator, a chance to catch safety<br />
hazards before you begin operation. Before you begin, you should be<br />
comfortable with the controls, indicators, features and the <strong>Shuttlewagon</strong> ®<br />
itself in general.<br />
This section will cover a recommended daily check list and pre-start tips. It<br />
is important to check everything.<br />
Pre-Start Walk Around<br />
The best way to learn about your Shuttlewaqgon ® is to check the systems<br />
daily.<br />
Checking the fluids daily is important to the life of the <strong>Shuttlewagon</strong> ® .<br />
Running it without hydraulic fluid, coolant, transmission fluid, etc. will cause<br />
it harm.<br />
Check the following items with unit not running.<br />
Exterior Check<br />
•When checking the fluid levels, start in the engine compartment<br />
with the engine oil dipstick. If needed, replenish with SAE 15/40<br />
motor oil.<br />
•Check the rear rail air compressor by the dipstick. If needed replenish<br />
with SAE 30 weight non-detergent oil.<br />
•While checking items in the engine compartment, be sure to check<br />
drive belts, radiator hoses, cables and linkages. Look for loose<br />
fittings or leaks that might have developed.<br />
•Check the following items with engine running, parking brake set,<br />
and transmission in neutral.<br />
•Start the unit and let run for three to five minutes. Check the transmission<br />
oil level in the engine comparment by the dipstick. The oil<br />
level should be at the “Full” mark. If low, replenish with Dextron 2 or<br />
Dextron 3 automatic transmission fluid.<br />
•Check the engine air cleaner indicator. Is the air filter indicator<br />
green? If the indicator is red, replace the air filter and reset the<br />
indicator.<br />
19
Pre-Start<br />
When checking the coolant level, to not check the radiator; always check<br />
the coolant recovery tank sight glass. The recommended level is half full<br />
when warm. If low replenish with 50/50 mixture of water and aintifreeze.<br />
Check the hydraulic oil level by the sight glass on the hydraulic tank. The<br />
rail units must be in the full up or raised position. The hydraulic level indicator<br />
should have fluid between the high and low marks. Before adding<br />
hydraulic fluid, wipe around the neck and the cpa to clean off any dirt<br />
that has accumulated. Only add fluid from a clean previously unopened<br />
container. Hydraulic fluid and dirt ;make an abrasive that can harm the<br />
internal components of the hydraulic system.<br />
•Check all eight - sander boxees if equipped. If low, replensih with<br />
number two chicken grit or a medium coarse sand. Which ever is<br />
used must be dry.<br />
•Check all four rail wheels for wear, including flanges, and ensure<br />
that bearings are not loose or seized.<br />
•Check both front and rear couplers for sagging, broken or missing<br />
parts.<br />
•Check both front and rear ball valves are closed and operational.<br />
•Check both rail air glad-hand hoses and the rubber gasket seals<br />
are intact.<br />
•Check all four tires for cuts, chips, bulges and correct air pressure.<br />
•Check all four wheels for loose or missing lug nuts.<br />
•Check for broken, missing parts, or leaks that may have developed.<br />
Interior Cab Check<br />
•Check that all gauges are working properly with correct readings.<br />
•Check service air pressure gauge to ensure proper air pressure has<br />
built up for vehicle brakes.<br />
•Check rail hydraulic pressures are reading zero. (calibration check)<br />
•Check straight ahead indicators are working correctly by steering<br />
the axle or axles if so equipped.<br />
20
Pre-Start<br />
•Check both low rail hydraulic pressure alarms by locking the steer<br />
mode switch to lock with the rail wheels in the up postion and<br />
down control valves in the closed position. Will have two red lights<br />
and two buzzers if working properly.<br />
•Check rail air brake reservoir air pressure, and rail air brake pipe<br />
pressure for correct operation. On gauge the red needle represents<br />
rail air reservoir, and the white needle represents the brake<br />
pipe pressure.<br />
•Check all lights, windshield wipers, air horn, and turn signals.<br />
•Check for correct readings of RPM at both an idle, and full engine<br />
RPM with no load.<br />
21<br />
•Check seat adjustments and seat belt for operation.<br />
•Check vehicle brakes for operation.<br />
•Check transmission selector forward and reverse. Parking brake<br />
must be released, and vehicle brakes engaged by foot valve. Also<br />
check gear ranges (first through fourth) in both directions by bumping<br />
shifter control left and right. Neutral will allow you to shift to first<br />
or second gear only. Check for Back Up Alarm while in reverse.<br />
•Check to ensure all headlights, windows, and mirrors are clean and<br />
adjusted properly.<br />
If any items were identified as a problem during your checkout, get<br />
it corrected before you start. Let a maintenance mechanic or supervisor<br />
know the problem, and they will determine the nature of the problem, and<br />
the actio needed to correct the problem.
Recommended Monthly Inspections<br />
The following lists are for your benefit when conducting monthly inspections.<br />
The checklists are for problems which occur less often but are still very<br />
important to watch for. Make sure to complete this check list each month.<br />
Engine Compartment Check List<br />
•Belt tension - tight, not slipping<br />
•Cables and linkage - tight, operational<br />
•Radiator Hoses - soft and clamps tight<br />
•Cleanliness Exterior Vehicle Check List<br />
•Batteries clean and cables tight<br />
•Visual check of all of the fittings and lines for leaks<br />
•Couplers in good condition and operating freely, not sagging<br />
•Rail wheels spin freely, not loose on spindles or seized<br />
•Torque lug nuts on wheels, 350 ft/lbs.<br />
•Check brake fluid level<br />
Tire pressure correct PSI<br />
•<br />
Interior Cab Check List<br />
•Seat operational with no broken parts<br />
•Seat belts operational, they must be in working condition<br />
•Brake and accelerator pedals working both front and rear<br />
•Emergency brake lever adjusted properly<br />
•Hydraulic gauges operational<br />
Doors operate properly<br />
•<br />
Pre-Start<br />
22
Pre-Start<br />
Recommended Semi-Annual Inspection<br />
The following list is for your benefit, when surveying, correcting and maintaining<br />
the <strong>Shuttlewagon</strong> ® . Perform the inspection semi-annually along<br />
with your daily and monthly inspections.<br />
•Clean unit thoroughly inside and out including engine compartment,<br />
radiator and transmission cooler.<br />
•Check hydraulic hose conditions, no leaks or cracks<br />
•Check belt condition - tight, no cracks and change belts annually<br />
•nspect engine and transmission mounts for cracks and bolt tightness<br />
•Visually inspect entire unit for fluid and air leaks<br />
•Inspect drive lines for bends or loose/missing bolts<br />
•Inspect all cylinders for a bent housing or bent rods<br />
•Inspect all cylinder rod pins for wear<br />
•Check hydraulic tank for holes<br />
•Check sander boxes for hardened sand<br />
•Inspect for loose or broken wiring<br />
•Check all operation systems including hydraulic, air, brake, etc.<br />
•Inspect latter and railing welds and repair all broken ones<br />
•Inspect engine air inlet and exhaust for leaks<br />
•Check rail gear hydraulic gauges for accuracy<br />
•Inspect train brake system for leaks or dirt in lines<br />
•Remove rail gear hub caps and inspect bearing lock and nut tightness<br />
•Check condition of brake master cylinder and brake lines<br />
•Ensure rail gear has free movement<br />
•Inspect steering axle for broken parts, worn pins, steering cylinders<br />
tight and tie rod ends good<br />
•Check axles and their nuts, bolts and mounts for unusual wear<br />
Inspect couplers by removing them from the unit<br />
23<br />
•<br />
Did everything check out okay? Are there any problems with the lights, signals,<br />
air pressure, etc? If so, fix it now!
V. Road Operation<br />
Do not begin start up until you are convinced your pre-start was satisfactory<br />
and that the <strong>Shuttlewagon</strong> ® is in proper working order and that<br />
you are thoroughly acquainted with the precautions listed in this manual.<br />
Operation (Road Mode)<br />
To start:<br />
• Check your vehicle’s present movement mode<br />
• Is it in road mode (see item 42)<br />
• Are the rail wheels in the up and locked position<br />
(check items 38,39 and 49,50)<br />
• Is the steering properly engaged for road travel<br />
(see item 41)<br />
•<br />
•<br />
Road Operation<br />
Place the transmission selector lever (item 51)<br />
to the neutral position<br />
Set the parking brake (item 29)<br />
Ensure that rail units are up and locked<br />
Ensure that the steering wheel is unlocked and ready for road<br />
travel by turning the steering wheel from side to side. It should<br />
move freely, not bind or offer stiff resistance.<br />
To start, engage the starter (see item 26). The <strong>Shuttlewagon</strong> ® ’s ignition system<br />
is identical to an auto<strong>mobile</strong>’s. The diesel engine should start at once.<br />
If the engine fails to start after 30 seconds, let the starter cool for a couple<br />
of minutes, then try again. If the engine fails to start after three or four<br />
attempts a problem has occurred. Stop, identify and correct the problem<br />
before proceeding.<br />
24
Road Operation<br />
Oil Pressure<br />
Once the engine is started the oil pressure should begin to rise (see item 5).<br />
If it does not begin to rise after 15 seconds, shut down the engine and<br />
check for the cause. Once the oil pressure starts to build, increase the<br />
engine RPM slowly to be sure adequate lubrication is available to the<br />
bearings and allow the oil pressure to stabilize.<br />
Air Pressure<br />
Check the air pressure indicator gauges for service air (item 13) and rail air<br />
pressure (item 32). Normal air pressure should be 105 PSI to 120 PSI maximum<br />
for both gauges.<br />
After initial warm-up, operate the engine at 1500 to 1800 RPM until the air<br />
pressure indicator gauges (items 13 & 36) show that air pressure has built to<br />
operational norms.<br />
If both pressure gauges are below 65 PSI,the lower gauge will increase first<br />
until both gauges are equal. Both gauges will then increase together. As<br />
air pressure increases beyond 65 PSI (the minimum pressure required to<br />
activate the vehicle brakes), the audible buzzer will shut off.<br />
Once air pressure has built up to 65+ PSI, enough pressure is available to<br />
operate the <strong>Shuttlewagon</strong> ® ’s vehicle brakes (as indicated on item 13). Air<br />
pressure will continue to increase to approximately 105 PSI maximum.<br />
Air pressure required to operate the <strong>railcar</strong> brakes will need to continue to<br />
increase to a maximum of 120 PSI (as indicated by item 36).<br />
25<br />
Note:<br />
Idle the engine three to five minutes at 1000 RPM<br />
before operating under load.<br />
Note:<br />
If operating in temperatures below+32ºF, oil pressure<br />
indication will be higher than normal.<br />
Caution:<br />
If air pressure is below 65 PSI, an audible buzzer will sound.<br />
DO NOT attempt to move the <strong>Shuttlewagon</strong> ® if this condition persists.<br />
Not enough air pressure will be available to properly<br />
engage the vehicle brakes.
Check other gauges; fuel (item 8), battery charge (item 7), tachometer<br />
(item 9), etc. If everything is operating properly it is safe to move the<br />
<strong>Shuttlewagon</strong> ® .<br />
•<br />
•<br />
•<br />
Check to see no unauthorized passengers are aboard and the<br />
vehicle is clear and free to move.<br />
Make any final seat adjustments and fasten seat belt.<br />
Apply the vehicle service brakes.<br />
Release the parking brake.<br />
Select the desired transmission speed.<br />
• Release the vehicle service brakes to move the <strong>Shuttlewagon</strong>® .<br />
Once rolling test the vehicle service brakes by applying pressure<br />
to the brake pedal.<br />
If everything is okay, it is safe to continue.<br />
Road Operation<br />
Warning:<br />
If the vehicle service brakes fail to work, apply the emergency<br />
(Parking) brake to stop the <strong>Shuttlewagon</strong> ® and have the<br />
brake system checked to determine and correct the cause.<br />
26
Rail Operation<br />
VI. Rail Operation<br />
Before you start the <strong>Shuttlewagon</strong> ® and begin operation, check the<br />
grades, curvature and condition of the track you will be operating on. It is<br />
important to know the changes of track grade; even the slightest grade<br />
can have a significant effect on pulling power and stopping distance.<br />
Track curvature is equally important. Each <strong>railcar</strong> being pulled through a<br />
curve will require extra pulling effort. A combination of grade and curvature<br />
occurring together will have a cumulative effect requiring a reserve of<br />
extra pulling power to compensate for. If possible try to avoid stopping or<br />
starting where these conditions are present. In addition to grade and curvature,<br />
what is the condition of the track. Wet, muddy or icy track conditions<br />
will further reduce pulling power and stopping distance.<br />
Mounting On Rail<br />
•<br />
•<br />
•<br />
Select an improved crossing or area fairly flush with the track.<br />
• Line up rear of the <strong>Shuttlewagon</strong>® with the rail, using the rear mirror.<br />
Once the rear rail wheels are aligned with the track, cheange the<br />
Drive Mode Switch (item 42) to the rail position.<br />
Lower the rear rail wheels to the rail by turning the Rear Rail Control<br />
Valve (item 50) to the “Down” position.<br />
27<br />
For 500 <strong>Series</strong> and units with Dual Steer:<br />
•Align the front rail wheels over the track by backing up and steering<br />
the front axle while watching in the front rail mirror.<br />
Lower the front rail wheels to the rail by turning the Front Rail<br />
•<br />
•<br />
•<br />
•<br />
Straighten the rear steering axle by turning the steering<br />
wheel until the Rear Straight Ahead Light (item 44)<br />
illuminates.Note the position and continue turning the<br />
steering wheel in the same dirrection until it goes out. Note<br />
the position and turn the steering wheel back half the<br />
distance to center.<br />
Place the Steering Mode Selector Switch (item 40) from<br />
“Dual” to “Front”. This will disable the rear axle from the<br />
steering circuit, allowing the front axle only to steer.<br />
Control Valve (item 49) to the “Down” position.<br />
Straighten the front steering axle by turning the steering wheel until<br />
the Front Straight Ahead Light (item 43) illuminates. Note the<br />
position and continue turning the steering wheel in the same direction<br />
until it goes out. Note the position and turn the steering wheel
Rail Operation<br />
back half the distance to center.<br />
• Place the Steering Lock Switch from UNLOCK into the LOCK position.<br />
This will disable the front axle from the steering circuit.<br />
• Check both the Front and Rear RAil Pressure Gauges (items 32 & 33)<br />
for the correct rail pressure.<br />
NOTE: 400 <strong>Series</strong> 300 PSI Minimum - 500 PSI Maximum<br />
500 <strong>Series</strong> 400 PSI Minimum - 600 PSI Maximum<br />
• To adjust the rail pressure, loosen the locking collar on the Rail<br />
Pressure Control Knobs (items 54 & 55) and turn the knob clockwise<br />
to increase or counter clockwise to decrease. Adjust to the desired<br />
setting and relock with locking collar.<br />
• The <strong>Shuttlewagon</strong>® is installed on the rail. Check and see that you<br />
have four green lights on for four wheel steer units, or three green<br />
lights on for front wheel steer units.<br />
After the rail units have lowered to the rail, the accumulator light (item 19)<br />
should go out within two minutes. If it does not, there could be a problem<br />
with the hydraulic system.<br />
Note:<br />
It is very important to have the proper rail pressure for your unit.<br />
Operating without proper rail pressure will cause a probem.<br />
The correct pressure range is:<br />
400 <strong>Series</strong> 300 PSI to 500 PSI<br />
500 <strong>Series</strong> 400 PSI to 600 PSI<br />
Note:<br />
If accumulator light remains on after two minutes, stop the engine<br />
and notify maintenance.<br />
28
Rail Operation<br />
Coupling<br />
The next step in moving <strong>railcar</strong>s is coupling.<br />
To couple the <strong>Shuttlewagon</strong> ® with a <strong>railcar</strong> use the following procedure:<br />
• Move the <strong>Shuttlewagon</strong>® close to the selected <strong>railcar</strong> and align the<br />
coupler by viewing the coupler position in the mirror.<br />
29<br />
•<br />
To adjust the coupler position use the Coupler Positioning Switch<br />
(item 45 or 46) for the appropriate coupler, to swing the coupler<br />
from side to side to align with the <strong>railcar</strong> coupler.<br />
• Once the couplers are aligned, move the <strong>Shuttlewagon</strong>® slowly<br />
towards the <strong>railcar</strong> until the couplers join together. They should<br />
automatically lock together.<br />
• Test that the couplers have indeed locked by slowly backing away<br />
from the <strong>railcar</strong>. There should be some noticeable resistance that<br />
indicates that the couplers have locked.<br />
• Place the transmission in neutral “N” (item 51) and set the parking<br />
brake (item 29).
Connecting Railcar Air Brakes<br />
•Hook together the rail brake hoses. In a vertical position, mate the<br />
hoses together then lower them to lock in the horizontal position.<br />
The hoses must be in a vertical position to mate the gladhand hose<br />
ends.<br />
•<br />
Close the rear-most air valve of the rear-most car in the <strong>railcar</strong> consist,<br />
and open all other <strong>railcar</strong> air valves between the rear-most car and<br />
the <strong>Shuttlewagon</strong> ® .<br />
•Open the <strong>Shuttlewagon</strong>® Air Valve.<br />
•Make sure all handbrakes are released and all chocking devices are<br />
removed.<br />
•<br />
•<br />
Rail Operation<br />
In the cab, pull up the Train Brake Emergency Valve (item 53). This will<br />
allow air from the Rail Air Reservoir to flow through the Train Rail Brake<br />
Control (item 52) to the hoses and charge the <strong>railcar</strong> air brake system,<br />
releasing the <strong>railcar</strong> brakes.<br />
Move the Train Rail Brake Control (item 52) towards the dash to the<br />
release position.<br />
Note:<br />
The red hand on the Rail Air Reservoir Gauge must be above 90 PSI<br />
in order to pressurize the train brake system.<br />
It will take approximately three to five minutes to air charge the first <strong>railcar</strong><br />
and about one minute each for every additional attached <strong>railcar</strong>.<br />
Note:<br />
The Train Brake Emergency Valve (item 53)<br />
when pushed down will dump all air from the train brake system<br />
applying the train brakes.<br />
Normally this takes only a matter of seconds and is used<br />
emergency situations or to permanently exhaust service air<br />
from <strong>railcar</strong>s when parking.<br />
30
Railcar Movement<br />
Railcar Brake Systems (Air and Mechanical)<br />
The rail brakes are a very important safety factor in the movement of <strong>railcar</strong>s.<br />
For optimum safety, you should always hook up the air brake system<br />
before moving <strong>railcar</strong>s. This rule applies whether moving loaded or empty<br />
cars.<br />
The principle of all rail air brake systems is Air Pressure Reduction through a<br />
combination service and emergency valves. When the <strong>Shuttlewagon</strong>® is<br />
coupled to a rail car and the car brake system is “aired” or “charged”, the<br />
car brakes are held “released” by air pressure. As long as the required air<br />
pressure charges the car system, the car brakes remain “released”. If a<br />
pressure reduction occurs in the care brake system (as when the<br />
<strong>Shuttlewagon</strong> ® Train Air Brake Control (item 52) is moved), the car brakes<br />
are applied.<br />
The purpose of a Pressure Reduction system is to provide emergency braking<br />
to <strong>railcar</strong>s in the event a car becomes uncoupled or an air line ruptures.<br />
Should this occur, the car brakes will be applied automatically from<br />
the air reserve tank on each car. This system is of standard design on all<br />
AAR <strong>railcar</strong>s in the United States, Canada and Mexico. Specially built cars<br />
for intra-plant movement may be equipped with this same brake system,<br />
a differently designed brake system, or more commonly, no brakes at all.<br />
Railcars also have mechanically set hand brakes. The hand brake device<br />
is located at one end of the <strong>railcar</strong>. To apply this brake, turn brake wheel<br />
to tighten chain and set the brakes. To release this brake, release ratchet<br />
lock on hand brake body or turn the brake wheel to release the brakes.<br />
Before moving <strong>railcar</strong>s, make sure all hand brakes are released. Make sure<br />
all safety chocks, or other obstructions placed under the wheels are<br />
removed.<br />
31<br />
Note:<br />
Surplus, wrecked or damaged AAR cars, purchased for<br />
intra-plant movement, may still have the rail brake hoses and<br />
mechanism in place, but caution should be taken to determine<br />
whether or not they function properly before depending<br />
on them to stop a load.<br />
Note:<br />
Be sure the <strong>railcar</strong> brakes are fully “aired” or “charged”<br />
before moving, otherwise the system will not function properly.
Train Air Brake Control<br />
Using the Train Air Brake Control will do three things for the <strong>Shuttlewagon</strong> ® .<br />
•<br />
It will increase tire life<br />
It will extend vehicle brake life<br />
•It will stop the <strong>Shuttlewagon</strong>® when pulling <strong>railcar</strong>s<br />
Rail Operation<br />
The operator will have to use his/her judgement on the amount of braking<br />
power for different situations. Down hill situations will call for more braking<br />
power and a slight dragging effect. Using more braking power allows the<br />
operator to keep better control of the <strong>railcar</strong>s.<br />
During upgrade situations, the operator is not likely to use any braking<br />
power and will have the Train Air Brake Control in the full “Release” position.<br />
This allows less drag and more power with less effort.<br />
During operation on level rail, the operator may run with a slight application<br />
of the Train Air Brake Control depending on travel distance. Even the<br />
slightest down grade can cause the <strong>railcar</strong>s to build up momentum and<br />
get out of control. Always be aware of the stopping distance and grade<br />
of track. You do not want to go past where you want to stop, but leave<br />
yourself plenty of room. You always want be in control of the <strong>railcar</strong>s.<br />
The Train Air Brake Control is a variable air flow control valve. In the full<br />
“Release” position the valve is completely open allowing compressed air<br />
from the Rail Air Reservoir to be applied to the train brakes keeping them<br />
open. In the full “Applied” position it vents air from the train brakes as well<br />
as stopping any air flow from the Railcar Air Reservoir allowing the brakes<br />
to fully close and apply maximum (50%) braking power.<br />
The red Train Brake Emergency Valve which must be pulled out in order to<br />
allow the Train Air Brake Control to operate is an emergency air bypass. If<br />
pushed in as in an emergency stop situation it will cut off air flow from the<br />
Rail Air Reservoir as well as vent air from the train brake system allowing the<br />
train brakes to apply (100%) braking. It reacts much faster than the Train Air<br />
Brake Control, and will cause the train brakes to fully apply in a matter of<br />
seconds if needed.<br />
32
Railcar Movement<br />
VII. Railcar Movement<br />
Grade in Relation to Travel<br />
Are you going to move up a grade, down a grade, or level? Don’t guess,<br />
rail grade is not always visible to the naked eye. As little as 1/2% grade can<br />
affect starting and stopping. As the <strong>Shuttlewagon</strong> ® operator, you should<br />
be aware of the grade throughout your facility.<br />
When starting a load, heavy loads may be eased in OPPOSITE DIRECTION<br />
of intended pull, to allow slack between the couplers. You can gain as<br />
much as 6 to 8 inches of Free travel for each coupled car. Using this technique,<br />
the <strong>Shuttlewagon</strong> ® starts pulling one car at a time and the momentum<br />
of the moving cars helps start the remaining cars. Maintain a steady<br />
increase of power so as not to lose the momentum gained.<br />
The <strong>Shuttlewagon</strong> ® power train is geared very low through the transmission,<br />
differential and planetaries. As a result tremendous torque develops quickly<br />
in first and second gears. A quickly applied throttle in the low gears could<br />
cause spin-out of the tires. Maximum drawbar pull is achieved in first gear<br />
and should be used when maximum drawbar pull is going to be required<br />
to start the load. When starting, apply the throttle steadily and smoothly to<br />
maintain maximum traction. The operator should learn to feel the difference<br />
between tire “creep” and tire “spin”. Maximum traction will be<br />
achieved at 1400 RPM in first gear just prior to tires creeping. and diminishes<br />
quickly once tires start spinning. Take full advantage of coupler slack<br />
when maximum pulls involve more than one car.<br />
The <strong>Shuttlewagon</strong> ® is equipped with a full powershift transmission, and the<br />
ratio variance between gear settings is substantial. Down shifting is not<br />
recommended. Should it be necessary to up-shift on the rail while under<br />
way, do so with a 50% RETARDED throttle then press gradually on the throttle<br />
after the shift is complete, to maintain desired speed.<br />
Move the cars at a safe speed, 5-7 mph. Plan stops in advance so the<br />
entire operation runs smoothly. Be sure you understand how both the<br />
<strong>Shuttlewagon</strong> ® and <strong>railcar</strong> air brakes operate. Know in advance what is<br />
expected of the <strong>Shuttlewagon</strong> ® . Know how many cars are to be switched<br />
and where they are to be switched. Know if additional cars are to be<br />
picked up and switched.<br />
Should a HEAVY (meaning maximum or near maximum load for the<br />
<strong>Shuttlewagon</strong> ® ) car or train be required to move through a tight curve<br />
(caution should start at 22º or more), PULL rather than push the car or consist,<br />
if possible.<br />
33
When pulling, the couplers continue to follow the center line of pull. When<br />
pushing maximum or near maximum loads around tight curves, the coupler<br />
in the <strong>Shuttlewagon</strong> ® and attached car will tend to pivot opposite to<br />
the direction of the curve until stopped by the coupler housing. At this<br />
point, the line of push is not following the center line of the vehicle. The<br />
<strong>Shuttlewagon</strong> ® weighing less than the load, is now pushing the load with<br />
couplers angled. This situation is more prevalent when a curve and<br />
upgrade occur together, rather than on level or downgrade curve where<br />
the car momentum might not require the <strong>Shuttlewagon</strong> ® to apply maximum<br />
push. An experienced operator will recognize this situation and be<br />
able to apply the right technique.<br />
PULLING<br />
Coupler reaction when pulling.<br />
COUPLER<br />
FORCE<br />
PUSHING<br />
Railcar Movement<br />
Coupler reaction when pushing heavy loads on tight curves.<br />
34
Rail Operation<br />
Unhooking From Railcars<br />
Before uncoupling the <strong>Shuttlewagon</strong> ® from the rail cars, be conscious of<br />
whether or not the cars are on a grade. If the rail cars are fully “aired” or<br />
“charged”, bring the cars to a full stop. Apply <strong>railcar</strong> brake using the Train<br />
Rail Brake Control (item 52). Use chocks and hand brakes to secure the <strong>railcar</strong>s.<br />
Release the couplers by using the coupler release switch. Pulling<br />
away slowly from the <strong>railcar</strong>s, the gladhands will automatically disconnect.<br />
Dismounting From Rail<br />
When you are ready to move off rail, select an improved crossing area or<br />
an area level to the track. Bring the vehicle to a complete stop.<br />
Place the Transmission Selector Lever (item 51) in the neutral “N” position<br />
and disengage the Steering Lock Switch (item 41). Move the Drive Mode<br />
Switch (item 47) from rail to road, this allows the accumulator to discharge.<br />
The Rail Pressure Gauges (items 32 and 33) will then show zero pressure;<br />
this does not mean the rail units are raised. Turn both Rail Control Valves<br />
(items 49 & 50) to the closed position. Use the Rail Unit control switches<br />
(items 38 & 39) to raise the rail units.<br />
You are now ready to move off the track.<br />
Towing<br />
If it is necessary to tow the <strong>Shuttlewagon</strong> ® , have the engine running to<br />
make sure the transmission clutches are lubricated. If unable to run engine,<br />
the maximum towing distance is one mile at 3 mph. If it is necessary to tow<br />
the <strong>Shuttlewagon</strong> ® further than one mile without the engine running, disconnect<br />
the drive lines. The <strong>Shuttlewagon</strong> ® should never be towed on rail<br />
without the engine running.<br />
35<br />
Warning:<br />
Never manually disconnect the hoses, trapped air pressure<br />
can be dangerous!<br />
Caution:<br />
For safety, ALWAYS apply <strong>railcar</strong> hand brake and<br />
place chocks under the <strong>railcar</strong> wheels before<br />
pulling away from the <strong>railcar</strong>.
<strong>SWX</strong> “B” <strong>Series</strong><br />
Lubrication and Service<br />
<strong>Manual</strong><br />
Central Manufacturing<br />
4116 Dr. Greaves Road<br />
Grandview, MO 64030<br />
Phone: (816) 767-0300<br />
Fax: (816) 763-0705
Introduction<br />
Table of Contents<br />
I. Lubrication and Servicing<br />
Lubrication<br />
Engine Oil and Filter Replacement<br />
Illustration I-I. Cummins Oil and Filter Change<br />
Illustration I-II. Caterpillar Oil and Filter Change<br />
Cummins Fuel Filter and Fuel-Water Separator (B <strong>Series</strong>)<br />
Illustration I-IV. B <strong>Series</strong> Cummins Fuel-Water Separator<br />
and Fuel Filter<br />
Cummins Fuel Filter and Fuel-Water Separator (C <strong>Series</strong>)<br />
Illustration I-V. C <strong>Series</strong> Cummins Fuel-Water Separator<br />
and Fuel Filter<br />
Caterpillar Fuel Filter and Fuel Water Separator<br />
Illustration I-VI. Caterpillar Fuel-Water Separator<br />
and Fuel Filter<br />
Air Filter<br />
Illustration I-VII. Air Filter Replacement<br />
Transmission Oil and Filter<br />
Illustration I-VIII. Transmission Filters<br />
Axle and Hub<br />
Illustration I-IX. Axle and Hub Lubrication<br />
Hydraulic Return Filter<br />
Illustration I-X. Hydraulic Return Filter<br />
Hydraulic Oil Change<br />
Illustration I-XI. Hydraulic Tank Drain System<br />
Hydraulic Pressure Filter<br />
Illustration I-XII. Hydraulic Pressure Filter<br />
Illustration I-XIII. Lubrication Points<br />
37CFM Compressor<br />
Illustration I-XIV. 37 CFM Compressor<br />
II. Operational Adjustment<br />
Hydraulic Pump Pressure<br />
Standby Pressure<br />
Illustrations II-I. and II-II.<br />
Main Relief Pressure Check<br />
Illustration II-III.<br />
Table of Contents
Table of Contents<br />
Table of Contents<br />
II. Operational Adjustment (cont.)<br />
Main Pump Pressure<br />
Train Rail Air Brake<br />
Illustration II-IV. Train Rail Air Brake Valve<br />
Rail Unit Rail Gauge Check<br />
Illustration II-V.<br />
Hydraulic Accumulator<br />
Checking Pre-Charge<br />
Illustration II-VI.<br />
III. Trouble Shooting<br />
Operation<br />
Service<br />
Rail Units<br />
Railcar Moving and Stopping<br />
IV. Lubricants<br />
Table IV-I Lubricants<br />
V. Capacities<br />
Table V-I Engine Capacities<br />
VI. Maintenance Schedule<br />
Table VI-I Maintenance Schedule
Introduction<br />
Introduction<br />
Welcome to the <strong>Shuttlewagon</strong> ® Service and Maintenance Handbook.<br />
Within, you will find information for servicing the different components<br />
of the <strong>Shuttlewagon</strong> ® , a chassis lubrication chart, a trouble shooting guide,<br />
a recommended maintenance chart, explanations on system adjustments<br />
and the accumulator system.
Lubrication and Servicing<br />
I. Lubrication and Servicing<br />
This section contains the maintenance and lubrication procedures. Also<br />
included are service specifications, adjustments, lubrication capacities<br />
and filter elements.<br />
Lubrication<br />
Lubrication of the various components of the <strong>Shuttlewagon</strong> should be<br />
done at regular intervals. Refer to the charts in the Service Illustrations section<br />
for service intervals, lubrication points and the type of lubricant to be<br />
used. Instructions for lubrication and servicing of the more complicated<br />
systems are contained in the paragraphs pertaining to those particular<br />
items.<br />
Engine Oil and Filter Replacement<br />
The following oil and filter replacement instructions are for both Cummins<br />
and Caterpillar engines. Refer to Illustrations I-I and I-II. Always change the<br />
engine oil when the oil is warm and do not over tighten filters and drain<br />
plugs. •Refer to the engine manual for more detailed specifications.<br />
Run the engine until the water temperature reaches +140ºF<br />
•<br />
(+60ºC) then shut down engine.<br />
•Remove the drain plug from the oil pan.<br />
•Visually check the condition of the used oil.<br />
Clean around the filter head (item 1), and remove the oil filter<br />
(item 2).<br />
Note:<br />
Thin, black oil indicates fuel dilution.<br />
Milky discoloration indicates coolant dilution.<br />
• •Clean the gasket surface on the bottom of the filter head.<br />
Fill the replacement filter with clean lubricating oil before installation.<br />
Note:<br />
The O-ring or fragments of the O-ring can stick to the filter head.<br />
Make sure all are removed.
Lubrication and Servicing<br />
•Apply a light film of lubricating oil to the O-ring (item 3).<br />
Caution:<br />
Mechanical over tightening may distort the threads<br />
or damage the O-ring.<br />
• •Install the oil filter (item 2) as specified by the filter manufacturer.<br />
•Clean around the oil pan drain hole and the drain plug as well.<br />
Install the drain plug then fill the crankcase with the required<br />
•<br />
amount of oil.<br />
•Operate the engine at idle and inspect for leaks.<br />
Shut off engine, wait 5 minutes then check oil level with dipstick.<br />
1<br />
1. Filter Head<br />
2. OIl Filter<br />
3. O-ring<br />
3<br />
2<br />
Illustration I-I. Cummins Oil<br />
and Filter Change.
Lubrication and Servicing<br />
1<br />
3<br />
2<br />
1. Filter Head<br />
2. OIl Filter<br />
3. O-ring<br />
Illustration I-II. Caterpillar Oil<br />
and Filter Change.
Lubrication and Servicing<br />
Cummins Fuel Filter and Fuel Water Separator (B <strong>Series</strong>)<br />
The following instructions are for Cummins B <strong>Series</strong> engines. Remember, do<br />
not over tighten filter and drain plugs. Refer to engine manual for more<br />
detailed specifications.<br />
To remove<br />
•<br />
water from fuel water separator:<br />
Open the drain valve (item 1) on the bottom of the fuel-water<br />
•<br />
separator (item 2) by turning the knob clockwise.<br />
When clean fuel is visible, close the valve (item 1) by turning the<br />
knob counterclockwise.<br />
To service<br />
•<br />
and replace filters:<br />
Unscrew the fuel-water separator (item 2) and fuel filter (item 3),<br />
•<br />
from the filter head (item 4).<br />
Clean the area around the filter head and clean the gasket<br />
•<br />
surfaces on the bottom of the filter head (item 4).<br />
Fill each of the new filters with clean fuel and lubricate the O-ring<br />
•<br />
seals (item 5) with clean lubricating oil.<br />
•Install the filters as specified by the filter manufacturer.<br />
•Remove worm clamps (item 6) on in-line filter (item 7).<br />
Remove old in-line filter, replace and reattach worm clamps.<br />
1. Drain Valve<br />
2. Fuel Water Separator<br />
3. Fuel Filter<br />
4. Filter Head<br />
5. O-ring Seal<br />
6. Worm Clamp<br />
7. In-line Fuel Filter<br />
5<br />
Illustration I-IV. B <strong>Series</strong> Cummins Fuel-Water Separator and Fuel Filter.<br />
1<br />
2<br />
4<br />
7<br />
6<br />
5<br />
3
Lubrication and Servicing<br />
Cummins Fuel Filter and Fuel Water Separator (C <strong>Series</strong>)<br />
The following instructions are for Cummins C <strong>Series</strong> engines. Remember, do<br />
not over tighten filter and drain plugs. Refer to engine manual for more<br />
detailed specifications.<br />
To remove<br />
•<br />
water from fuel water separator:<br />
Open the drain valve (item 1) on the bottom of the fuel-water<br />
•<br />
separator (item 2) by turning the knob clockwise.<br />
When clean fuel is visible, close the valve (item 1) by turning the<br />
knob counterclockwise.<br />
To service<br />
•<br />
and replace filters:<br />
Unscrew the fuel-water separator (item 2) from the filter head<br />
•<br />
(item 3).<br />
Clean the area around the filter head and clean the gasket<br />
•<br />
surfaces on the bottom of the filter head (item 3).<br />
Fill the new filter with clean fuel and lubricate the O-ring seal<br />
•<br />
(item 4) with clean lubricating oil.<br />
•Install the filter as specified by the filter manufacturer.<br />
•Remove worm clamps (item 5) on in-line filter (item 6).<br />
Remove old in-line filter, replace and reattach worm clamps.<br />
1. Drain Valve<br />
2. Fuel Water Separator<br />
3. Filter Head<br />
4. O-ring Seal<br />
5. Worm Clamp<br />
6. In-line Fuel Filter<br />
Illustration I-V. C <strong>Series</strong><br />
Cummins Fuel-Water<br />
Separator and Fuel Filter.<br />
4<br />
3<br />
2<br />
5<br />
6<br />
1
Lubrication and Servicing<br />
Caterpillar Fuel Filter and Fuel Water Separator<br />
The following instructions are for Caterpillar engines 3116T and 3116TA.<br />
Follow the instructions carefully and refer to Illustration I-IV. Remember, do<br />
not over tighten filters and drain plugs. Refer to engine manual for more<br />
detailed<br />
•<br />
specifications.<br />
Open the drain cock (item 1) to empty the fuel filter water<br />
•<br />
separator (item 2). Once drained, close drain cock.<br />
•Unscrew filter bowl (item 3) from filter (item 2).<br />
Unscrew filter from filter head (item 4) and discard old filter and<br />
•<br />
O-ring (item 5).<br />
•Clean filter head and remove any parts of the old O-ring still left.<br />
•Replace with new filter. (hand tighten only)<br />
Screw filter bowl back on. (hand tighten only)<br />
Illustration I-VI. Caterpillar Fuel-Water Separator and Fuel Filter.<br />
4<br />
5<br />
2<br />
3<br />
1
Air Filter<br />
Lubrication and Servicing<br />
Perform the following procedures to remove and replace the air filter<br />
element.<br />
•<br />
Refer to Illustration I-VI.<br />
•Remove filter cap (Item 1).<br />
•Loosen lower filter band clamp (item 2).<br />
•Release filter clamps (item 3).<br />
•Replace filter unit (item 4)).<br />
•Attach lower filter band clamp (item 2).<br />
•<br />
Position filter and clamp in place with filter clamps (item 3).<br />
•<br />
Replace filter cap (item 1).<br />
Press reset button on the air indicator (item 5) to reset.<br />
1<br />
Item 4<br />
Replacement Filter<br />
011-037736<br />
5<br />
Illustration I-VII. Air Filter<br />
Replacement.<br />
2<br />
4<br />
1. Filter cap<br />
2. Filter band clamp<br />
3. Filter clamps<br />
4. Filter cartridge<br />
5. Air flow indicator<br />
3
Lubrication and Servicing<br />
Transmission Oil and Filter<br />
The Lubricant and filter should be changed after the first 20 hours of<br />
transmission operation. After the initial lubricant and filter change, it is<br />
recommended the filter be changed every 200 hours of operation and the<br />
lubricant be changed every 600 hours of operation. Refer to Illustration I-VII.<br />
• •Remove the drain plug (item 1) to drain the transmission.<br />
Remove the oil strainer cover (item 2) and strainer (item 3) from the<br />
•<br />
transmission housing.<br />
Clean the strainer by agitating it in solvent and dry the strainer with<br />
•<br />
compressed air.<br />
•Remover the filter (item 4) from the filter head (item 8).<br />
Fill the replacement filter with fresh transmission oil. Lubricate seal<br />
(item 5) with oil then install filter. Tighten 3/4 turn after seal<br />
•<br />
contacts filter head.<br />
Check the inside of the transmission through the drain hole for<br />
accumulation of sludge. Any accumulation should be removed<br />
•<br />
by flushing with transmission oil.<br />
Remove the transmission breather filler cap (item 6) and clean by<br />
agitating the filler cap in solvent until vent is clear and dry with<br />
•<br />
compressed air.<br />
Reinstall the strainer (item 3), strainer cover (item 2), drain plug<br />
•<br />
(item 1).<br />
•Fill transmission with 5 gallons of transmission fluid.<br />
Start engine and run at idle speed to fill the transmission cooler<br />
and lines with transmission fluid, and add transmission fluid as<br />
•<br />
necessary to keep the fluid level at the “Full” mark (item 7).<br />
Allow engine to run 10 to 15 minutes or until it reaches normal<br />
•<br />
operating temperature.<br />
Once warm, shift the transmission through all speed ranges,<br />
forward and reverse to ensure that all areas of the transmission are<br />
•<br />
lubricated.<br />
With the transmission in neutral “N”, recheck the oil level and add<br />
•<br />
oil as necessary to bring oil level to “Full” mark on dip stick.<br />
Reinstall breather filler cap.<br />
Caution:<br />
Do not overfill the transmission or<br />
allow it to operate with insufficient fluid.
5<br />
4<br />
9<br />
Axle and Hub<br />
8<br />
1. Drain Plug<br />
2. Strainer Cover<br />
3. Strainer<br />
4. Filter<br />
5. Seal<br />
6. Filler Cap<br />
7. Dipstick<br />
8. Filter Head<br />
9. Transmission<br />
7<br />
Illustration I-VIII. Transmission Filters<br />
Lubrication and Servicing<br />
The following section includes detailed instructions on the lubrication and<br />
service •of the axle and hub assemblies. Refer to Illustration I-VIII .<br />
•Remove the drain plug (item 1).<br />
•When the oil has drained completely, reinstall the drain plug.<br />
•Remove the breather (item 2).<br />
•Clean the breather in solvent and dry with compressed air.<br />
•Reinstall the breather.<br />
•Remove the fill plug (item 3).<br />
•Fill the axle with oil until oil starts to flow from the fill plug hole.<br />
•Reinstall the fill plug.<br />
Maneuver the <strong>Shuttlewagon</strong> ® to position one of the hubs with the<br />
drain/fill plug (item 4) at the bottom of the hub (inset Drain).<br />
6<br />
Item 4<br />
Replacement<br />
Filter<br />
028-043700<br />
3<br />
1<br />
2
Lubrication and Servicing<br />
• •Remove the drain fill plug (item 4) and allow all hub oil to drain.<br />
Once drained, rotate the wheel 90º to bring the drain/fill port to<br />
•<br />
the fill position (inset Fill).<br />
Add the correct oil slowly until the oil starts to flow back out of the<br />
•<br />
drain/fill port then reinstall the drain plug.<br />
Repeat the above steps for the three remaining hubs.<br />
Caution;<br />
Do not overfill hubs. Seal damage may result.<br />
Note!<br />
Recheck rear differential after refilling hubs for correct oil level.<br />
(Rear-Floating Axles)<br />
Drain<br />
Position<br />
Fill<br />
Position<br />
1<br />
3<br />
2<br />
Illustration I-IX. Axle and Hub<br />
Lubrication<br />
4
Hydraulic Return Filter<br />
Lubrication and Servicing<br />
The following are instructions for servicing the hydraulic return filtration<br />
system •located in the top of the hydraulic tank.<br />
•Unscrew the filter cap (item 1).<br />
•Remove the filter (item 2).<br />
Remove the worm clamp (item 3) and extension hose (item 4),<br />
•<br />
and install onto new filter.<br />
Fill the replacement filter with fresh transmission oil, and insert into<br />
•<br />
hydraulic tank.<br />
Replace the filter cap and hand tighten.<br />
Item 2<br />
Use Element Kit P/N 265-042858<br />
3<br />
Illustration I-X. Hydraulic Return Filter<br />
1<br />
2<br />
4
Lubrication and Servicing<br />
Hydraulic Oil Change<br />
The following are instructions for changing the hydraulic oil. Refer to<br />
Illustration<br />
•<br />
I-X and I-XI.<br />
Remove the drain plug (item 1) located on the drain line (item 2)<br />
•<br />
in the rear coupler housing well.<br />
Open the ball valve (item 3) to drain oil.<br />
(Note: the hydraulic tank contains approximately 30 gallons of oil.<br />
It may be necessary shut off the oil flow several times while<br />
•<br />
draining the tank to empty the waste oil container.)<br />
When the hydraulic tank is empty close the ball valve (item 3) and<br />
•<br />
reinsert the hose end drain plug (item 1).<br />
Remove the hydraulic filler cap and clean all dirt and debris from<br />
•<br />
around the hole, and refill with 30 gallons of hydraulic oil.<br />
Start and idle engine till it reaches normal operating temperature<br />
to warm the oil, and check oil level in the temperature/sight<br />
•<br />
gauge(item 4).<br />
Oil level should be between the “high” and “low” marks when the<br />
•<br />
oil is warm.<br />
Always check oil level in road condition.<br />
Illustration I-XI. Hydraulic Tank<br />
Drain System<br />
1<br />
2<br />
3<br />
4
Hydraulic Pressure Filter<br />
Lubrication and Servicing<br />
The following instructions are for changing the hydraulic pressure filter.<br />
• Close the Pump Case Drain Valve (item 1) and the Pump Supply<br />
•<br />
valve (item 2).<br />
•Unscrew the Hydraulic Pressure Filter housing (item 3).<br />
•Remove and replace the filter element (item 4).<br />
•Reopen the Pump Case Drain Valve and Pump Supply valves.<br />
Recheck hydraulic oil level.<br />
Item 4<br />
Use Element Kit P/N 265-042857<br />
Illustration I-XII. Hydraulic Pressure<br />
Filter<br />
3<br />
4<br />
2<br />
1
Lubrication and Servicing<br />
Rail<br />
Wheels<br />
(1)<br />
Drain and<br />
Refill Oil<br />
Filled Hubs<br />
(4)<br />
Constant<br />
Velocity<br />
U-Joints<br />
(400 <strong>Series</strong><br />
Steer<br />
Axles)<br />
(5)<br />
Coupler<br />
Box Pivot<br />
Pin (2)<br />
Drain and<br />
Refill Axle<br />
Housings<br />
(4)<br />
Drive<br />
Shaft<br />
U-Joints<br />
(3)<br />
Rail<br />
Arms<br />
(8)<br />
Straight<br />
Ahead<br />
(7)<br />
Wear<br />
Plate<br />
(2)<br />
Drive<br />
Shaft<br />
U-Joints<br />
(3)<br />
Steer<br />
Cylinder<br />
Ends<br />
(7)<br />
Rail<br />
Unit<br />
Cylinders<br />
(6)<br />
Illustration I-XIII.<br />
Lubrication Points<br />
Refer to illustrations on<br />
next page for exact<br />
locations<br />
King<br />
Pins<br />
(top and<br />
bottom)<br />
(5)<br />
Grease under<br />
Coupler<br />
Housing Boxes<br />
(2)
1.<br />
3.<br />
6.<br />
7.<br />
4.<br />
Pin<br />
8.<br />
Lubrication and Servicing<br />
under<br />
plate<br />
CV<br />
U-Joint<br />
5.<br />
Pin<br />
Pin<br />
2.
Lubrication and Servicing<br />
37 CFM Compressor<br />
The following instructions are for servicing the 37CFM air compressor air<br />
and •oil filters.<br />
To check lubricant in the compressor use the compressor dipstick<br />
•<br />
(item 1) to check the oil level in the case.<br />
To replace lubricant, unscrew the case plug (item 2) and drain<br />
crank case.<br />
2<br />
1<br />
Illustration I-XIV. 37 CFM Compressor<br />
• •Replace case plug and fill crank case with 30 W non-detergent oil.<br />
Remove breather wing nut (item 3), and remove breather cover<br />
•<br />
(item 4).<br />
•Remove old air filter and insert replacement (item 5).<br />
•Reassemble breather cover and wing nut.<br />
Repeat above steps to replace second air filter.<br />
Welding<br />
Observe the following precaution when performing welding operations on<br />
the <strong>Shuttlewagon</strong> ® .<br />
Attach welding ground cable to a structural steel member of<br />
the frame. Do not attach ground cable to rail wheels or any other<br />
component that is supported by bearings. Failure to comply could<br />
result in damage to bearings and premature bearing failure.<br />
5<br />
4<br />
3
Operational Adjustment<br />
This section contains the procedures for adjusting hydraulic pressure, rail<br />
air brake pressure, hydraulic oil flow for the 37cfm compressor and rail<br />
unit gauge. If you have questions, contact your local dealer or the<br />
manufacturer. (816) 767-0300<br />
Hydraulic Pump Pressure<br />
The following directions are for adjusting the standby and main pressure for<br />
the hydraulic pump.<br />
Standby Pressure<br />
Operational Adjustment<br />
Note:<br />
Standby pressure should be checked and set first.<br />
1. Connect a 0-3000 PSI test gauge to the quick disconnect fitting<br />
(item 1) on the PTP port on the main hydraulic block.<br />
2. Start engine and warm hydraulic oil to normal operating<br />
temperature.<br />
3. Disconnect a wire from the pressure switch on the rail air tank<br />
to disable the compressor.<br />
4. Position all rail switches to the “up“ and switch to “Road Mode”.<br />
5. Turn all other hydraulic components off. This places the pump in<br />
“standby “ mode.<br />
Illustration II-I. Illustration II-II.<br />
1<br />
PTP 2<br />
3
Operational Adjustment<br />
6. Remove the upper acorn head cap on the hydraulic pump (item 2).<br />
The standby adjuster is an allen head screw under the cap.<br />
7. Normal standby pressure is between 260-600 PSI.<br />
8. Turn adjuster to increase or decrease pressure as needed.<br />
9. After adjusting, reconnect the wire to the switch and allow the<br />
compressor to run till it shuts off.<br />
10. Repeat steps 5 through 8 until desired setting is achieved.<br />
11. The optimum standby pressure will be achieved when the<br />
compressor functions smoothly until shut-off without bogging down.<br />
12. Once the correct pressure is achieved, reinstall allen head cap,<br />
and perform the main pressure check.<br />
Main Relief Pressure Check<br />
• •Hold the “Rail Gear” switch in the up position.<br />
Check the relief valve pressure by unscrewing the lower acorn<br />
cap (ITEM 3 Illustration II-II) and adjusting the allen head screw in<br />
until the gauge stop moving. This indicates the setting for the<br />
•<br />
pressure relief valve.<br />
If the gauge indicates a pressure other than 2850, the main pressure<br />
relief valve will need to be adjusted up.<br />
Caution:<br />
Do not exceed 3000 PSI before adjusting the pressure relief valve down.<br />
• To<br />
• Once<br />
adjust the main pressure<br />
relief, loosen the locking nut on<br />
the pressure main relief valve<br />
marked RDFA 2850 (item 5),<br />
and adjust the pressure by<br />
turning the allen headed shaft,<br />
until the gauge stabilizes at<br />
2850 PSI.<br />
the pressure is set,<br />
retighten the locking nut.<br />
5<br />
Illustration II-III.
Main Pump Pressure<br />
•With the Rail Wheels “up” switches still activated, adjust lower allen<br />
set screw (item 3 Illustration II-II) till pressure indicates 2600 PSI, and<br />
replace acorn cap.<br />
Train Rail Air Brake<br />
The Train Rail Air Brake Valve is preset at the factory at 90 PSI. If the pressure<br />
needs to be reset do the following:<br />
•Close the air supply valves at both ends of the <strong>Shuttlewagon</strong> ® •<br />
.<br />
Loosen the acorn cap nut (item 1) and move the handle towards<br />
the release position until the white hand on the Rail Brake Air<br />
•<br />
Gauge indicates 90 PSI.<br />
•Tighten the acorn cap nut.<br />
The opposing acorn cap nut (item 2) may be loosened to adjust<br />
the throw of the brake lever. It is usually adjusted to allow the<br />
brake lever to return to the lowest position.<br />
Rail Unit Rail Gauge Check<br />
1<br />
Illustration II-IV. Train Rail Air Brake Valve<br />
Operational Adjustment<br />
Rail gauges on both front and rear rail units are 53-7/16” plus or minus<br />
1/16”. To measure gauge, measure from inside flange on rail wheel to<br />
inside flange on opposite rail wheel with the rail unit in the down position<br />
on the surface of the rail, or on floor if the unit is not on rail.<br />
53-7/16” + 1/16”<br />
Illustration II-V.<br />
2
Operational Adjustment<br />
Hydraulic Accumulator<br />
The <strong>Shuttlewagon</strong> ® is equipped with a hydraulic accumulator, which is<br />
capable of producing high pressure and could cause injury if not<br />
released properly.<br />
Warning:<br />
Never use oxygen or shop air!<br />
This will void all warranties and can be dangerous.<br />
• •Pre-charge with DRY NITROGEN GAS ONLY!<br />
•Never operate accumulator without proper nitrogen gas pre-charge.<br />
Release all system hydraulic pressure before attempting any main-<br />
•<br />
tenance or service.<br />
Use only approved charging and gauging equipment for<br />
•<br />
precharging and pressure check.<br />
Follow all instructions below:<br />
1. a) If accumulator is installed, turn off all power to system (all dash<br />
panel switches set to “off”), remove all hydraulic pressure from<br />
accumulator.<br />
b.) If accumulator is not yet installed, place a small amount of fluid<br />
inside the unit for lubrication.<br />
2. Remove the protective cap (gas valve guard) and the valve cap<br />
(if there is one).<br />
3. Attach the gland & nut portion (items 8, 11) of the charging<br />
assembly to a dry nitrogen gas bottle, tighten securely. If this gland<br />
& nut do not fit, you are using the wrong gas!<br />
4. Attach the air chuck portion (item 2) of the charging assembly to<br />
the accumulator bladder gas valve by hand tightening its swivel<br />
hex connection.<br />
5. Turn the air chuck “T” handle clockwise until it stops. This opens the<br />
valve core. NOTE: (5000 PSI accumulators do not have a valve<br />
core. The gas valve must be manually opened by turning its top<br />
hex, counter clockwise).<br />
6. Set nitrogen bottle gas regulator (if attached) to 25 psig. (The use<br />
of a nitrogen gas regulator is strongly recommended!)<br />
7. Open nitrogen bottle gas valve. (If you are not using a nitrogen<br />
gas regulator care should be taken to only “crack” the valve<br />
open.) With a regulator, valve can be opened fully.<br />
8. Pre-charge slowly (25 psig) using the dry nitrogen gas until bladder<br />
is fully inflated.
Warning:<br />
Initial pre-charging at a rate above 25 psig can cause bladder to burst.<br />
9. Continue pre-charging to desired pressure (Maximum 600 psi) by<br />
increasing gas flow slowly.<br />
10. Remove charging assembly. Check for gas leakage. (The use of<br />
gas leak detection fluid is recommended.)<br />
11. TIghten hex jam nut and lock nut fully.<br />
12. Replace the valve cap and valve guard. Tighten, hand tight.<br />
13. Install accumulator on system. CHECK FOR LEAKAGE.<br />
14. Pressurize system.<br />
Warning:<br />
Operation of accumulator without sufficient pre-charge<br />
(minimum of 25% of maximum working pressure) can cause<br />
bladder “pick-out”.<br />
Checking Pre-charge<br />
Operational Adjustment<br />
1. Release system pressure. Not gas pre-charge.<br />
2. Remove gas valve guard (protective cap) and valve cap.<br />
3. Install gauging device on gas valve stem.<br />
4. Screw down air chuck “T” handle, check pressure.<br />
5. Add additional dry nitrogen gas, if necessary, using the above<br />
procedure.<br />
6. To release excess nitrogen gas (if any) open up bleeder valve<br />
(item 9), located at bottom of gauging device, until desired<br />
pressure is achieved (maximum 600 psi).<br />
Gas Safety Cap<br />
The plastic safety cap, located at the top of the valve guard<br />
(protective cap), is designed to “blow-off” if there is a valve stem<br />
gas leak. If cap is missing, check pre-charge immediately!
Operational Adjustment<br />
4<br />
1<br />
15<br />
7<br />
5<br />
9<br />
TYPE<br />
1 AI-CG3-000SS 3000psi WP Max. 2200 psi, N 2 3000 psi gauge<br />
2 AI-CG5-000SS 3000psi WP Max. 2200 psi, N 2 5000 psi gauge<br />
1. Pressure gauge 9. Bleed Valve<br />
2. Air Chuck 10. Copper Washer<br />
3. Adapter Block 11. Nut<br />
4. Swivel Connector 12. Head Assembly<br />
5. Tank Valve 13. Gauging & Head Assy.<br />
6. Coupling 14. Hose Assy.<br />
7. Hose 15. Valve Core<br />
8. Nipple (Gland)<br />
3<br />
14<br />
10<br />
2<br />
Illustration II-VI.<br />
12<br />
6<br />
13<br />
11<br />
8
Trouble Shooting<br />
If you develop a problem with the <strong>Shuttlewagon</strong> ® during operation, refer<br />
to the problems and possible causes listed below. If a problem should<br />
occur check for the simplest cause first. You may wish to contact the<br />
nearest <strong>Shuttlewagon</strong> dealer for assistance or contact the manufacturer’s<br />
service department.<br />
Problem/Possible Cause:<br />
Problems During Operation<br />
Premature Tire Wear<br />
Excessive tire spin<br />
Load too heavy<br />
Railcar hand brakes not released<br />
Contaminates on rail<br />
Rail pressure controls pressure incorrect<br />
Railcar air brakes not fully charged<br />
Incorrect tire pressure<br />
Foot valve sticking<br />
<strong>Shuttlewagon</strong> ® Brakes Will Not Apply<br />
Low air pressure<br />
Air leaks<br />
Air in brake lines<br />
Low brake fluid level in master cylinder<br />
Axle seals leaking oil on brake pads<br />
Moisture in air tanks<br />
Foot valve bypassing<br />
<strong>Shuttlewagon</strong> ® Will Not Steer<br />
Steering lockout in rail position<br />
Low hydraulic oil level<br />
Straight ahead assembly not lubricated<br />
Steering cylinders bypassing<br />
Low hydraulic pump pressure settings<br />
Hydraulic pump failure<br />
<strong>Shuttlewagon</strong> ® Will Not Move<br />
Parking brake switch not released<br />
Low hydraulic brake release pressure<br />
Transmission shift control malfunction<br />
Transmission ECU malfunction<br />
Transmission oil low<br />
Trouble Shooting
Trouble Shooting<br />
<strong>Shuttlewagon</strong> ® Will Not Move (cont.)<br />
Transmission solenoid malfunction<br />
Derailing (general)<br />
Steering tires not locked straight with vehicle<br />
Excessive vehicle speed<br />
Rail pressure gauges out of calibration<br />
Hydraulic pump pressure too low<br />
Moving more than vehicle rated capacity<br />
Bad track and or conditions<br />
Rail wheel flanges too thin<br />
Rail wheel gauge improperly set<br />
Rail wheels loose on spindles<br />
Rail arm bushings seized/frozen<br />
Rail Guide Wheels Flanging To One Side<br />
Steering tires not locked straight with vehicle<br />
Low tire pressure<br />
Vehicle brakes partially applied<br />
Track leaning to one side<br />
Oscillating brackets out of adjustment<br />
Hydraulic cylinder bypassing<br />
Rail gear out of alignment<br />
Service Problems<br />
Front Axle Will Not Engage<br />
Fuse blown<br />
Wire disconnected<br />
Solenoid malfunction<br />
Switch defective<br />
Transmission Overheating<br />
Low transmission oil<br />
Speed range too high<br />
Cooler hoses blocked<br />
Oil filter clogged<br />
Oil strainer clogged<br />
Wrong transmission oil<br />
Transmission oil burned<br />
Moving more than rated vehicle capacity<br />
Railcar hand brakes not released<br />
Railcar air brakes not released
Hydraulic Pump Noise<br />
Hydraulic oil cold<br />
Hydraulic oil contaminated<br />
Hydraulic oil strainer clogged<br />
Hydraulic return filter clogged<br />
Tank shutoff valve closed<br />
Hydraulic oil level low<br />
Hydraulic oil too hot<br />
Hydraulic pump malfunction<br />
Rail Unit Problems<br />
Rail Cylinder Will Not Hold Pressure<br />
Drive mode switch not in rail position<br />
Rail control valve not in down position<br />
Regulating valves adjusted too low<br />
Rail cylinder leaking internally<br />
Hydraulic pump pressure setting out of adjustment<br />
Rail Cylinders Won’t Raise or Lower Smoothly or Evenly<br />
Hydraulic oil level low<br />
Air in hydraulic system<br />
Cylinder leaking internally<br />
Hydraulic pressure settings low<br />
Regulating valve malfunction<br />
Rail arm bushings not lubricated<br />
Rail arm bushings binding<br />
Slow Rail Cylinder Movement<br />
Cylinder leaking internally<br />
Oil level too low<br />
Pump not delivering sufficient oil<br />
Rail arm bushings not lubricated<br />
Rail arm bushings binding<br />
Railcar Moving and Stopping<br />
Will Not Pull Cars<br />
Front axle not engaged<br />
Railcar hand brakes not released<br />
Railcar air brakes not fully charged<br />
Rail pressure regulating valves adjusted too high<br />
Railcar brake shoes frozen to wheels<br />
Trouble Shooting
Trouble Shooting<br />
Will Not Pull Cars (cont.)<br />
Moving more than rated vehicle capacity<br />
Track conditions slippery<br />
Railcar Brakes Will Not Release<br />
Railcar air brakes not fully charged<br />
Railcar air shutoff valve closed<br />
Rail air reservoir air pressure too low<br />
Railcar hand brakes not released<br />
Rear rail air compressor switch out of adjustment<br />
Train brake air regulating valve set too low<br />
Train brake control handle out of adjustment<br />
Moisture in air reservoirs<br />
Insufficient time to release <strong>railcar</strong> air brake system<br />
Railcar Brakes Will Not Apply<br />
Rail air brake system not fully charged<br />
Air hoses and valves not connected correctly<br />
Train brake control handle adjusted too high<br />
Moisture in air reservoirs<br />
Shutoff valves not open between cars<br />
Railcar brakes defective<br />
Railcar Braking and Release Time Too Long<br />
Incorrect use of train brake control handle<br />
Air leak in system or <strong>railcar</strong>s<br />
Rail air reservoir air supply too low<br />
Note:<br />
Normal time to release <strong>railcar</strong> air brakes is three to five minutes<br />
for the first <strong>railcar</strong> and one minute for each additional <strong>railcar</strong><br />
in the consist.<br />
Note:<br />
For engine and transmission trouble shooting, refer to<br />
manufacturer’s service manuals supplied with the <strong>Shuttlewagon</strong>.
Lubricants<br />
Lubricants<br />
Component<br />
Cummins B <strong>Series</strong><br />
Cummins C <strong>Series</strong><br />
Caterpillar 3116<br />
Caterpillar 3126<br />
Transmission<br />
DF 150/250<br />
Hydraulic System<br />
Axle Gear Oil<br />
Rockwell Axles<br />
Grease Fittings<br />
Wheel Bearings<br />
Master Cylinder<br />
37 CFM Compressor<br />
Radiator / Cooling<br />
System<br />
Table IV-I. Lubricants<br />
Lubricant<br />
API CG-4 & CH4<br />
API CG-4 & CH4<br />
API CG-4 & CH4<br />
API CG-4 & CH4<br />
Dextron III<br />
ISO No. 32<br />
API Class GL-5<br />
Multi-purpose<br />
Lithium<br />
Dot 3 Brake Fluid<br />
Compressor Oil<br />
50% Water<br />
50% Anti-freeze<br />
Viscosity<br />
SAE 15/40W<br />
SAE 15/40W<br />
SAE 15/40W<br />
SAE 15/40W<br />
SAE10W<br />
SAE30W<br />
10W<br />
30W<br />
75/140W<br />
85/140W<br />
No. 1<br />
SAE J1703<br />
SAE30W<br />
Temperature<br />
Year Round<br />
Year Round<br />
Year Round<br />
Year Round<br />
Below 32ºF<br />
Above 32ºF<br />
Below 32ºF<br />
Above 32ºF<br />
Below 32ºF<br />
Above 32ºF<br />
Year Round<br />
Year Round<br />
Year Round<br />
Year Round<br />
Note:<br />
The above specifications are subject to change without notification by<br />
the manufacturer. Refer to accompanying manufacturer’s literature for<br />
more complete information.
Component<br />
Cummins<br />
4BTA3.9C 130HP <strong>SWX</strong>405B<br />
6BT5.9 152HP <strong>SWX</strong>415B<br />
6BTA5.9 174HP <strong>SWX</strong>435B<br />
6BTA5.9 200HP <strong>SWX</strong>455B<br />
6CT8.3 215HP <strong>SWX</strong>525B<br />
6CTA8.3 230HP <strong>SWX</strong>545B<br />
6CTA8.3 250HP <strong>SWX</strong>565B<br />
6CTA8.3 260HP <strong>SWX</strong>605B<br />
CATERPILLAR<br />
3116DIT 155HP <strong>SWX</strong>415B<br />
3116DIT 170HP <strong>SWX</strong>435B<br />
3116DITA 190HP <strong>SWX</strong>455B<br />
3116DITA 210HP <strong>SWX</strong>525B<br />
3126DITA 240HP <strong>SWX</strong>545B<br />
3126DITA 260HP <strong>SWX</strong>565B<br />
3126ATAAC 300HP <strong>SWX</strong>605B<br />
Transmission DF150<br />
Transmission DF250<br />
Rockwell Axles 400 <strong>Series</strong><br />
Rockwell Axles 500/600 <strong>Series</strong><br />
Table IV-II. Engine Capacities<br />
Oil & Filter<br />
11.6 Qts<br />
17.3 Qts<br />
17.3 Qts<br />
17.3 Qts<br />
24 Qts<br />
24 Qts<br />
24 Qts<br />
24 Qts<br />
21 Qts<br />
21 Qts<br />
21 Qts<br />
21 Qts<br />
33.8 Qts<br />
33.8 Qts<br />
33.8 Qts<br />
Capacities<br />
Engine<br />
10 Qts<br />
15 Qts<br />
15 Qts<br />
15 Qts<br />
20 Qts<br />
20 Qts<br />
20 Qts<br />
20 Qts<br />
19.6 Qts<br />
19.6 Qts<br />
19.6 Qts<br />
19.6 Qts<br />
N/A<br />
N/A<br />
N/A<br />
Capacities<br />
Refer to accompanying<br />
manufacturer’s literature<br />
Radiator<br />
9.7 Qts<br />
10.5 Qts<br />
14.5 Qts<br />
14.5 Qts<br />
10.6 Qts<br />
13 Qts<br />
13 Qts<br />
13 Qts<br />
14 Qts<br />
14 Qts<br />
14 Qts<br />
14 Qts<br />
17.6 Qts<br />
17.6 Qts<br />
17.6 Qts<br />
Note:<br />
The above specifications are subject to change without notification by<br />
the manufacturer. Refer to accompanying manufacturer’s literature for<br />
more complete information.
Maintenance Schedule<br />
Air/Oil<br />
Sep.<br />
Filter<br />
Air<br />
Comp.<br />
Air Filter<br />
Air<br />
Comp.<br />
Oil Filter<br />
Air<br />
Comp.<br />
Oil<br />
Air<br />
Filter<br />
Element<br />
Hyd.<br />
Filters<br />
Axles Hyd.<br />
Oil<br />
Trans.<br />
Filter<br />
Coolant Trans.<br />
Oil<br />
Coolant<br />
Filter<br />
Fuel<br />
Filter<br />
Oil<br />
Filter<br />
Engine<br />
Oil<br />
HOURS<br />
*<br />
200<br />
250<br />
300<br />
400<br />
500<br />
600<br />
750<br />
800<br />
900<br />
1000<br />
1200<br />
1250<br />
1400<br />
1500<br />
1600<br />
1750<br />
1800<br />
2000<br />
2100<br />
2200<br />
2250<br />
2400<br />
2500<br />
2600<br />
2700<br />
2750<br />
2800<br />
3000<br />
3200<br />
3250<br />
3300<br />
* First Transmission Oil change at 50 hours and every 1000 hours thereafter.<br />
Table VI-I. Maintenance Schedule