Professional Documents
Culture Documents
IV. Lubricants
Table IV-I Lubricants
V. Capacities
Table V-I Engine Capacities
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Illustration I-I. Caterpillar Oil Drain Plug.
Remove filter (item 1) by unscrewing from filter head Remove the drain plug (item 1) to drain the transmission.
(item3). Remover the filter (item 4) from the filter head (item 8).
Discard old filter and O-ring (item 2). Fill the replacement filter with fresh transmission oil.
Clean filter head and remove any parts of the old O-ring Lubricate the seal (Item 5) with oil then install filter.
still left. Tighten 3/4 turns after seal contacts filter head.
Replace O-ring and new filter. Do not fill filter with fuel. Check the inside of the transmission through the drain
(hand tighten only) hole for accumulation of sludge. Any accumulation
To prime the fuel system cycle the keyswitch to On for should be removed by flushing with transmission oil.
thirty seconds then to Off. Repeat three more times to Remove the transmission breather filler cap (item 6) and
fully prime the system before attempting to start the engine. clean by agitating the filler cap in solvent until vent is
clear and dry with compressed air.
3 Reinstall the drain plug (item 1).
3
Fill transmission with 5 gallons of transmission fluid.
Start engine and run at idle speed to fill the transmission
2 2 cooler and lines with transmission fluid, and add
transmission fluid as necessary to keep the fluid level at
the Full mark (item 7).
Allow engine to run 10 to 15 minutes or until it reaches
normal operating temperature.
1
1 Once warm, shift the transmission through all speed
ranges, forward and reverse to ensure that all areas of
the transmission and clutchs are lubricated.
With the transmission in neutral N, recheck the oil level
Illustration I-V. Primary Fuel Filter Change. and add oil as necessary to bring oil level to Full mark
on dip stick.
Air Cleaner Reinstall breather filler cap (item 6).
Perform the following procedures to remove and replace the
air cleaner filter element. Refer to Illustration I-VI.
Clean around filter cap and loosen retaining bolts (item 1).
Remove filter cover (item 2) by pressing down and turn-
ing clockwise and aligning bolt heads with cutouts on lid
(item 3).
Illustration I-VIII. Transmission Oil Filter Change.
7 Remove spring (item 4) and Bypass Valve Assembly
(item 5).
Full Add
Remove old filter (item 6) and replace with new filter.
Illustration I-IX. Transmission Dip Stick. Replace Bypass Valve Assembly, spring, and filter cover.
Caution: Turn cover counter clockwise to lock against bolt heads
Do not overfill the transmission or and tighten bolts. (Do not overtighten bolts)
allow it to operate with insufficient fluid.
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Axle and Hub
The following section includes detailed instructions on the 2
lubrication and service of the axle and hub assemblies.
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Refer to Illustration I-X.
General Lubrication
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4 5
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Illustration I-XIII. Pressure Filter Replacement.
Remove old air filter and insert new air filter.
12 13 Reassemble filter and breather covers.
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2 1
7 4 5
Radiator Coolant
9 14 15 To replace engine coolant. Open the radiator drain cock and
remove the coolant surge tank cap and the coolant recovery
8 cap. Do this only when the engine and coolant are cool. The
surge tank cap is sealed and the surge tank will be pressur-
11 ized if the coolant is hot. Once the old coolant has drained
close the radiator drain cock and replace coolant through
the surge tank. Start and run the engine to pull coolant
11 10 thoughout the engine and add coolant as the level drops.
Once the coolant level in the surge tank remains level stop
the engine and fill the surge tank to about one inch from the
top and replace the surge tank cap. Add coolant to the
coolant recovery tank until level is half way in the sight
gauge and replace the cap. Coolant may be added to the
Non-Steer recovery tank to maintain coolant level.
Steer
16 17
10 Welding
Proper welding procedures are necessary in order to avoid
damage to the engines ECM, sensors, and associated
components. If at all possible, the component that is to be
18 welded should be removed from the machine for welding. If
removal of the component is not possible, the following pro-
cedure must be followed when welding on a machine that is
equipped with an electronic engine. This procedure is con-
sidered the safest and should provide minimum risk of elec-
tronic component damage.
Rail gauges on both front and rear rail units are 53-7/16
plus or minus 1/16mesured from the bottom of the rail
2 wheels in the full down position. To measure gauge, mea-
sure from inside flange on rail wheel to inside flange on
opposite rail wheel with the rail unit in the down position on
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the surface of the rail, or on floor if the unit is not on rail.
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3
53-7/16" + 1/16"
Road Mode.
5. Turn all other hydraulic components off. This places the
pump in Stand-by mode.
6. Remove the acorn head cap on the hydraulic pump (item 3).
The stand-by adjuster is an allen-head screw under the cap. Hydraulic Accumulator
7. Normal stand-by pressure is 500 PSI.
8. Turn adjuster to increase or decrease pressure as needed. The Shuttlewagon is equipped with a hydraulic accumula-
9. After adjusting, reconnect the wire to the air compressor tor, which is capable of producing high pressure and could
switch on the governor and allow the compressor to run cause injury if not released properly.
till it shuts off.
10. Once the correct pressure is achieved, reinstall acorn
head cap, and perform the main pressure check.
Warning:
NOTE:
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(5000-PSI accumulators do not have a valve core. The 3
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gas valve must be manually opened by turning its top 15 5
hex, counter clockwise). 13
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installed, place a small amount of fluid inside the unit for 2
lubrication.
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2. Remove the protective cap (gas valve guard) and the
valve cap (if there is one).
3. Attach the gland & nut portion (items 8, 11) of the charg- 9 10
ing assembly to a dry nitrogen gas bottle, tighten
securely. If this gland & nut do not fit, you are using the
wrong gas!
4. Attach the air chuck portion (item 2) of the charging 11 8
7 6
WARNING:
Initial pre-charging at a rate above 25 psi can cause
bladder to burst.
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assembly to the accumulator bladder gas valve by hand
tightening its swivel hex connection. Checking Pre-charge
5. Turn the air chuck T Handle clockwise until it stops.
This opens the valve core. 1. Release system pressure. Not gas pre-charge.
6. Set nitrogen bottle gas regulator (if attached) to 25 psig. 2. Remove gas valve guard (protective cap) and valve cap.
(The use of a nitrogen gas regulator is strongly 3. Install gauging device on gas valve stem.
recommended!) 4. Screw down air chuck T Handle, check pressure.
7. Open nitrogen bottle gas valve. (If you are not using 5. Add additional dry nitrogen gas, if necessary, using the
nitrogen gas regulator care should be taken to only above procedure.
6. To release excess nitrogen gas (if any) open up bleeder
WARNING: valve (Item 9), located at bottom of gauging device, until
Operation of accumulator without sufficient pre-charge desired pressure is achieved (maximum 600 PSI).
(minimum of 25% of maximum working pressure)
can cause bladder to pick-out. TYPE
1 AI-CG3-000SS 3000psi WP Max. 2200 psi, N2 3000 psi gauge
crack the valve open.) With a regulator, valve can be 2 AI-CG5-000SS 3000psi WP Max. 2200 psi, N2 5000 psi gauge
opened fully.
8. Pre-charge slowly (25 psig) using the dry nitrogen gas 1. Pressure gauge 9. Bleed Valve
until bladder is fully inflated. 2. Air Chuck 10. Copper Washer
9. Continue pre-charging to desired pressure (600 PSI) by 3. Adapter Block 11. Nut
4. Swivel Connector 12. Head Assembly
increasing gas flow slowly. 5. Tank Valve 13. Gauging & Head Assy.
10. Remove charging assembly. Check for gas leakage. 6. Coupling 14. Hose Assy.
(The use of gas leak detection fluid is recommended.) 7. Hose 15. Valve Core
11. Tighten hex jam nut and lock nut fully. 8. Nipple (Gland)
12. Replace the valve cap and valve guard. Tighten, hand
tight.
ENGINE PROTECT
ENGINE MALFUNCTION
An engine emissions fault has occurred. Check diagnostic Press F11 to access the diagnostics screen.
codes. Press F2 on the diagnostics screen to access the transmis-
sion screen.
ENGINE DIAGNOSTIC CODES
The transmission fault code is shown at the bottom of the
transmission screen.
Engine fault codes are shown at the top of the first engine LOW HYDRAULIC PRESSURE
screen.
Hydraulic pump pressure has dropped below 160 psi.
Engine fault codes consist of two numbers, an SPN and an
FMI. Hydraulic pump malfunctioning or set incorrectly
Hose failure
Switch malfunctioning Control lever malfunctioning
Broken electrical connection Computer settings incorrect (check factory settings)
Broken electrical connection
LOW AIR PRESSURE
FOOT THROTTLE FAULT
Compressor malfunctioning
Air system leak The foot throttle signal is outside of the normal operating
Switch malfunctioning range.
Broken electrical connection
Foot pedal malfunctioning
Computer settings incorrect (check factory settings)
FRONT WHEELS NOT STRAIGHT Broken electrical connection
REAR WHEELS NOT STRAIGHT
TRAIN BRAKE FAULT
Alarm may be activated intermittently traveling on rough rail
or through switches and crossings. The train brake signal is outside of the normal operating
range.
Wheels are held in place with hydraulic cylinders. Some
small movement will occur during normal operation. While Control lever malfunctioning
stopped, unlock steering, center wheels, and re-lock steer- Computer settings incorrect (check factory settings)
ing.
Broken electrical connection
Loose steering bushings.
LOW FUEL LEVEL
Hydraulic steering lock valves malfunctioning.
Cylinder seal or hose leak Unexpected activation of the low fuel alarm may indicate
Switch malfunctioning other fuel system problems.
Broken electrical connection
Switch assembly out of adjustment Fuel leak
Fuel level sender malfunctioning
LOW ACCUMULATOR PSI Computer settings incorrect (check factory settings)
Broken electrical connection
The accumulator is an important safety back up, which
maintains rail gear pressure if the hydraulic pump fails. TRACTION CONTROL ACTIVE
It requires up to 2 minutes for the accumulator to charge Continuous or unexpected activation of the traction control
during start up. active alarm may indicate a system fault.
The hand throttle signal is outside of the normal operating Transmission oil temperature is above 250F.
range.
High ambient temperature
Wrong gear for vehicle speed/load Use the P1 knob to enter the password. Press F8 to verify
Blockage in oil filter, strainer, or hoses the correct password. If the password is correct, the display
will automatically change to the factory settings screen. If
Transmission oil low, deteriorated, or wrong grade
the password is incorrect, the screen will not change. Press
Brakes not released F4 to return to the set screen.
Transmission cooler damaged or blocked
Fan malfunctioning FACTORY SETTINGS SCREEN
Electronic Settings
SET SCREEN
Press F12 to access the set screen.
Pressing the F2 button toggles between foot and hand throt- SETTINGS SCREEN
tle modes when the unit is in rail mode. This setting is
stored into memory until changed. The foot throttle is re-
engaged when in road mode.
PASSWORD SCREEN
From the Set Screen press F8 to accesss the Password From the Factory Setting Screen Press the F3 button to
Screen. access the Settings Screen.
The F1 button toggles between the 500/600 series and the
400 Series.
The F2 Button toggles the ABS/ATC to on or off.
The P1 knob adjusts the Standard Deadband setting.
(Deadband is the allowable slippage of the tires measured
in ft. per minute). Fatory setting is 50 ft. per min. This set-
ting can be adjusted from 0 to 99.
The P2 knob adjusts the Alternate Deadband setting.
The F8 button stores the adjusted settings into memory.
Once stored these settings can be toggled between through
the set screen F4 traction assist button.
Caution:
Increasing deadband settings can contribute to reduced
tire life.
CHANGE PASSWORD MAX CTS Highest possible signal from input device, set
From the Factory Setting Screen Press the F4 button to using P1 knob on maximum settings screen
access the Change Password Screen.
MIN EU Lowest desired output related to input device, set
using P2 knob on minimum settings screen
MAX EU Highest desired output related to input device, set
using P2 knob on maximum settings screen
SAVE Press F7 to store new values in memory
Example:
Use F5 and F6 to set the input to TBP.
Move the train brake control lever from release to apply and
watch the ACTUAL CTS (counts) reading. Record the high-
est and lowest ACTUAL CTS readings. The train brake con-
trol lever normally produces a signal from about 48 CTS in
the apply position to 480 CTS in the release position.
Use the MIN (F15) and MAX (F16) keys to toggle between
Use P1 knob to enter a new password. Press F8 to store the minimum and maximum settings.
the new password into memory. Press F4 to return to the On the MIN screen, use the P1 adjustment knob to set MIN
factory settings screen. CTS to the lowest ACTUAL CTS reading, and press the
SAVE key (F7).
CALIBRATION SCREEN
From the Factory Setting Screen Press the C button to On the MAX screen, use the P1 adjustment knob to set
access the Calibration Screen. MAX CTS to the highest ACTUAL CTS reading, and press
the SAVE key (F7).
CTS settings calibrate the computer to properly read the
train brake control lever. Engineering unit (EU) settings cali-
brate the computer to produce the desired train brake pres-
sure.
On the MIN screen, use the P2 adjustment knob to set the
MIN EU to 1950, and press the SAVE key (F7).
On the MAX screen, use the P2 adjustment knob to set the
MAX EU to 3900, and press the SAVE key (F7).
These settings will normally produce a minimum train brake
pressure of about 45 psi and a maximum train brake pres-
sure of about 90 psi.
If the actual pressures shown on the gauge are unsuitable,
the MIN EU and MAX EU values can be adjusted.
INPUT Use F5 and F6 to select a device:
As the MIN EU and MAX EU values are adjusted and
saved, the train brake pressure will change accordingly.
FRPT Front Rail Pressure Transducer
RRPT Rear Rail Pressure Transducer Note:
HTP Hand Throttle Potentiometer The red emergency stop valve will automatically reset if the
FTP Foot Throttle Potentiometer pressure drops too low. Be sure to set MIN EU high
FLS Fuel Level Sender enough that the emergency stop button holds with the train
TBP Train Brake Potentiometer brake lever in the apply position.
MIN/MAX Use F13 and F14 to move between minimum and RESTORING FACTORY SETTINGS
maximum setting screens.
If settings are lost or corrupted, return to the factory settings
COUNTS (CTS) Signal from input device, voltage and cur- screen and press F1 to restore all settings to the factory
rent are typical inputs defaults.
Engineering Units (EU) Output parameter related to input RESETTING FAULTS
device
Press ESC on any screen to reset non-critical fault condi-
ACTUAL CTS Actual signal from the input device tions. If the fault condition persists, the alarm or fault mes-
sage will return. Faults originating from the engine and
MIN CTS Lowest possible signal from input device, set
transmission cannot be reset with this function.
using P1 knob on minimum settings screen
III. TROUBLE SHOOTING Rail Guide Wheels Flanging To One Side
If you develop a problem with the Shuttlewagon during
Steering tires not locked straight with vehicle
operation, refer to the problems and possible causes listed Low tire pressure
below. If a problem should occur check for the simplest Vehicle brakes partially applied
cause first. You may wish to contact the nearest Track leaning to one side
Shuttlewagon dealer for assistance or contact Central Front suspension urethane pads worn out
Manufacturing service department. Hydraulic cylinder internal leak
Rail gear out of alignment
Problem/Possible Cause:
Operator Panel is ON, but display is malfunctioning
PROBLEMS DURING OPERATION
Symptoms:
Premature Tire Wear
Rear axle not engaged Red block on screen
Excessive tire spin Unexpected reset during operation
Load too heavy Readouts show no data or appear faint
Railcar hand brakes not released
Contaminates on rail Causes:
Rail pressure set incorrectly
Railcar air brakes not fully charged CAN Bus network has broken electrical connection
Incorrect tire pressure
Vehicle controller malfunctioning
Foot valve malfunction
ABS/Traction control disabled Vehicle controller has lost power, check fuses and
electrical connections
Shuttlewagon Brakes Will Not Apply Operator Panel malfunctioning
Low air pressure Operator Panel CAN Bus speed is set incorrectly
Air leaks Low electrical system voltage, vehicle controller or
Air in brake fluid operator panel has reset
Low brake fluid level in master cylinder
Axle seals leaking oil on brake pads Operator Panel does not turn ON
Foot valve malfunction
No power, check fuses and electrical connections
Shuttlewagon Will Not Steer
Steering locked in rail mode Operator Panel malfunctioning
Low hydraulic oil level Low electrical system voltage
Steering cylinders internal leak
Dual steer axles in crab position Traction Control malfunction Tires slipping
Low hydraulic pump pressure settings The traction control system normally allows tire slip up to
Hydraulic pump failure 1/2 mph to maximize tractive effort.
Steering relief valve not set properly
Steering control unit malfunction Excessive tire wear or wrong tire size
Wheel speed sensor malfunctioning
Shuttlewagon Will Not Move
Transmission speed sensor malfunctioning
Parking brake switch not released
Low hydraulic brake release pressure Broken electrical connection
Transmission shift control malfunction Traction Control is disabled in computer factory settings
Transmission malfunction, check fault codes Wrong model size selected in computer factory settings
Transmission oil low
Transmission solenoid malfunction ABS malfunction Tires locking
NOTE:
Install the second bearing retainer nut with the bevel
Make sure you relieve all hydraulic down pressure on
the rail wheels before attempting to disassemble rail toward the bearing retainer lock washer, and tighten to
wheel components. hold bearing retainer lock washer against inner bearing
retainer nut.
Lock the bearing retainer lock washer lock tang that is
Remove rail wheel hubcap retaining bolts.
aligned correctly with one of the slots in the inner bearing
Remove hubcap and rubber gasket seal assembly. retainer nut.
Release tang on bearing retainer lock washer from
bearing retainer nut slot. NOTE:
Remove bearing outer retainer nut with the tool supplied. Be sure lock tang is engaged completely into slot and
seated correctly.
Remove bearing retainer lock washer.
Remove bearing inner retainer nut with the tool supplied. Tighten outer bearing retainer nut until bearing retainer
Remove bearing retainer flat washer. lock washer lock tang is aligned with the slot.
Remove outer bearing from rail wheel assembly. Torque the outer bearing retainer nut to 35-45 ft. lbs. with
Next slide rail wheel off of the spindle carefully, as not to the grove in the outer bearing retainer nut aligned for
damage the spindle seal if you plan to reuse the same one of the lock tangs to engage.
seal.
NOTE:
NOTE: The torque of the outer bearing retainer nut should not
Rail wheel is heavy and weighs approximately 350 exceed 50 ft. lbs. of torque when installed.
pounds each, and can be awkward to handle due to the
rail wheel flange on the rail wheel. Lock the bearing retainer lock washer tang that is aligned
into the slot on the outer bearing nut.
Remove spindle seal from rail wheel.
NOTE:
Remove inner bearing from rail wheel assembly.
Be sure lock tang is engaged completely into slot and
Clean and inspect rail wheel bearings (replace bearings seated correctly.
if scored or damaged).
Clean and inspect bearing cups (replace bearing cup if Grease rail wheel bearings cups and bearings by
scored or damaged). pumping grease into grease zerk on rail wheel, until
Repack inner rail wheel bearing, or pack new bearing. grease projects through outer bearing cone.
Install hubcap gasket.
Reassembly of Rail Wheels Install hubcap and install bolts and tighten.
NOTE:
The left front rail spindle (part number 046532) is
machined for the rail wheel traction encoder in the rail
wheel spindle, and must be mounted in the left front rail
arm assembly. The right rear rail spindle (part number
045770) must be located on the right rear. Two spindles
located on the left rear and right front rail arm assemblies
are the same (part number 045792). Be sure to look in
the parts book for proper mounting locations.
Axles
400 Series Hours
Oil 2000
Grease 250
500 - 600 Series Hours
Oil 2000
Grease 250
Hydraulic
All Series Hours
Oil * 2000
Breather * 2000
Pressure Filter 500
Return Filter 500
* or Annually
Air Compressor
All Series Hours
Oil 2000
Oil Level Weekly
Air Filter 600
Chassis Lubrication
All Series Hours
Rail Wheels 250
Drive Shafts 250
Rail Cylinders 250
Steering Cylinders 250
Tie Rods 250
V. CAPACITIES King Pins 250
Rail Arms 250
Oil & Coupler Box Pivot 250
Filter Hydraulic Transmission Radiator Coupler Wear Plate 250
Cummins
Coupler Slide In Box 250
QSB 400 Series 20.5 Qts. 42 Gal. 8 Gal. 9 Gal.
C. V. U-Joints 250
QSC 500/600 24 Qts. 42 Gal. 8 Gal. 9 Gal.
Items to Inspect
All Series Hours
VI. MAINTENANCE SCHEDULE
Steering Pins 250
Steering Bushings 250
Engine
Tie Rods 250
Cummins QSB QSC
Coupler Pins 250
Oil 500 500
Master Cylinder Monthly
Oil Filter 500 500
Rail Wheels Monthly
Fuel Water Separator 500 500
Hydraulic Pressure 6 Months
Fuel Filter 500 500
Coolant 2000 2000 Transmission
Coolant Filter 500 DF 150/250 Hours
Air Cleaner indicator indicator Initial Clean Out 50
Oil 1000
Filter 500
Note:
Recommended maintenance intervals listed are
considered Maximum for ideal operating conditions.
Unusual temperature or operating conditions may require
other recommendations. A regular lubrications schedule
can be determined by analysis of lube samples taken
from the assembly at specified intervals.
Note:
Tire air pressure for non-original or replaced tires should
follow the tire manufacturers specifications.
Sanders
Use a medium to coarse sandblasting sand or No, 2 chick-
en grit, which may be purchased from a local feed and grain
store.
Shuttlewagon, Inc.
4116 Dr. Greaves Rd
Grandview MO 64030
816.767.0300
Service Fax: 806.303.8998
Parts Fax 816.767.8711