C

Commander Series:
S SWX3
315/420/525
N 25/6030/70355/8040//840
Navigaator Serries: NVX502

Operration
n and
d Serrvice M
Manual
475--091744B

Shuttlewaagon Corporration
4116 Docctor Greaves Road
Grandview
w, Missouri 64030
(816
6) 767-03000
CAUTION:
Your Shuttlewagon should not be modified in any way. Such modifications may adversely
affect the performance, safety, or durability of your Shuttlewagon.

CAUTION: The maintenance and service instructions in this manual are for qualified personnel only. To
reduce the risk of injury, loss of limb, or death, do not perform any service to the
Shuttlewagon unless you are qualified to do so.

CAUTION: Only operate the equipment and/or railcar movers that you have been trained and certified
to operate.

Copyright © 2013 Shuttlewagon, a Nordco Company. Shuttlewagon, Commander and Navigator are registered
trademarks of Shuttlewagon Corporation in the USA and/or other countries.
All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means,
electronic, mechanical, or otherwise, for any purpose, without the express, written permission of Shuttlewagon, a
Nordco Company. Information in this document is subject to change without notice.
Shuttlewagon Corporation may have patents, patent applications, trademarks, registered trademarks, copyrights,
and/or other intellectual property rights covering subject matter contained in this document. Except as expressly
provided in any written license agreement from Shuttlewagon Corporation, the furnishing of this document does not
give any party any rights in, or license to use, any patents, trademarks, registered trademarks, copyrights, or other
intellectual property.
Other product and company names mentioned herein may be the trademarks of their respective owners.
T
Table of Co
ontents
s
Chapter 1 
C Introducttion .................................................. ................................................................... 1-1 
Using Thhis Manual ............................................................................................................................................ 1-1 
Docume ent and Safetty Conventio ons ................................................................................................................ 1-2 
Related Documentattion and Refe erences ........................................................................................................ 1-2 
Contact Us ......................................................................................................................................................... 1-3 
Shuttlew
wagon Warra anty .................................................................................................................................... 1-3 

Chapter 2 
C Shuttlew
wagon Safety endations .. ................................................................... 2-1 
y Recomme
ng the Shuttlewagon ............................................................................................................................ 2-1 
Operatin
O and Off the Shuttlewa
Getting On agon............................................................................................................. 2-2 
Workingg On or Around Tracks ........................................................................................................................ 2-2 
Couplingg and Uncouupling ................................................................................................................................ 2-3 
ng Switches and Derails ...................................................................................................................... 2-4 
Operatin
Blue Flags or Blue Light
L Signals..................................................................................................................... 2-5 

Chapter 3 
C Shuttlew wagon Exterior ................................. ................................................................... 3-1 
Driver’s and Passenger’s Sides ...................................................................................................................... 3-1 
Passeng ger’s Side, Lo
ower Compa artment ......................................................................................................... 3-3 
Deck and Engine ............................................................................................................................................... 3-5 

Chapter 4 
C wagon Cab ........................................ ................................................................... 4-1 
Shuttlew
e .............................................................................................................................................................. 4-1 
Console
Conttrol Console ........................................................................ ................................................................................. 4-1 
Heatting and Air Co onditioning (AC C) Controls .............................. ................................................................................. 4-5 
12 Volt
V Direct Curre ent (VDC) and Data Ports ............................ ................................................................................. 4-6 
Stora
age Slot and Console C Access s Panel................................... ................................................................................. 4-7 
Operator and Pass senger Seats ................................................. ................................................................................. 4-8 
Moving the Seat Forward an nd Backward .......................... ................................................................................. 4-8 
Rotating the Seat S .............................................................. ................................................................................. 4-8 
Adjusting Sea at Flotation .................................................... ................................................................................. 4-8 
Adjusting the Back of the Se eat.......................................... ................................................................................. 4-9 
Adjusting the Arm Rest ..................................................... ................................................................................. 4-9 
Stee
ering Wheel and d Foot Pedals............................................... ................................................................................. 4-9 
Cab Lighting .............................................................................. ............................................................................... 4-10 
Beveerage/Cup Hold ders .............................................................. ............................................................................... 4-10 
Fanss .......................................................................................... ............................................................................... 4-10 
Conttrol Console Screens.................................................................. ............................................................................... 4-11 
Homme Screen ............................................................................ ............................................................................... 4-12 
Diag
gnostics/Setting gs Screen ..................................................... ............................................................................... 4-15 
Engiine Screen........................................................................... ............................................................................... 4-16 
nsmission Screens ............................................................... ............................................................................... 4-17 
Tran
Tran
nsmission Calib bration Screen (ZF Transmissiion Only) ......... ............................................................................... 4-18 
The TRANSM MISSON CALIBR RATION screen n provides the caalibration proceddure that will neeed to be perform med after
every transmission service.................................................... ............................................................................... 4-18 
Vehiicle Screen .......................................................................... ............................................................................... 4-19 
Fan Drive Screen ...................................................................... ............................................................................... 4-21 
Remmote Control Sc creen ............................................................. ............................................................................... 4-22 
Switchman Controll Screen ........................................................ ............................................................................... 4-23 
TPMMS Screen (Tire e Pressure Mon nitoring System m) ................... ............................................................................... 4-24 
ESXX Screen .............................................................................. ............................................................................... 4-25 

i
Chapter 5 
C Operating the Shuttlewagon ....................... ................................................................... 5-1 
Steering g System ................................................................................................................................................ 5-1 
Steeering on the Ro oad ................................................................ ................................................................................. 5-1 
Steeering on the Ra ail................................................................... ................................................................................. 5-1 
Vehicle Brake
B System m ...................................................................................................................................... 5-1 
Discc Brakes ............................................................................... ................................................................................. 5-1 
Anti--lock Braking System
S (ABS) ................................................ ................................................................................. 5-1 
Trainn Brake System m................................................................... ................................................................................. 5-2 
Tractionn Control ................................................................................................................................................ 5-2 
Starting the Engine ........................................................................................................................................... 5-3 
Operatin ng in ROAD Mode M ................................................................................................................................. 5-4 
Mounting to the Ra ails ................................................................ ................................................................................. 5-4 
Operating in RAIL Mode ............................................................ ................................................................................. 5-6 
Moving Rail Car Fu undamentals ................................................. ................................................................................. 5-6 
Gradde and Curve Calculations
C .................................................. ................................................................................. 5-6 
Measuring Grrades ............................................................ ................................................................................. 5-6 
Measuring Cu urves ............................................................ ................................................................................. 5-7 
Combined Grrade and Curve e ............................................. ................................................................................. 5-8 
Coupling Railcars ...................................................................... ................................................................................. 5-8 
Connecting th he Railcar Air Brakes B .................................... ................................................................................. 5-9 
Pulling a Load ........................................................................... ............................................................................... 5-10 
Pulling Heavy y Loads and Cu urves...................................... ............................................................................... 5-10 
Unco oupling Railcarrs .................................................................. ............................................................................... 5-11 
Dismmounting from the t Rails ....................................................... ............................................................................... 5-11 
Operatin ng in Cold Weather
W ............................................................................................................................ 5-12 
Cummmins Engine Recommendati
R ons ........................................ ............................................................................... 5-12 
Coldd Weather Heatters ............................................................... ............................................................................... 5-12 
Heating Equip pment ........................................................... ............................................................................... 5-13 
Trannsmission Oil (F Funk DF Trans smission Recom mmendations) ............................................................................... 5-13 
Trannsmission Oil (Z ZF Transmissio on Recommend dations) .......... ............................................................................... 5-13 
Hydrraulic System Recommendati
R ions ....................................... ............................................................................... 5-14 
Air Compressor
C Re ecommendation ns .......................................... ............................................................................... 5-14 
Coldd Weather Rem mote Operation Starting and Stopping S .......... ............................................................................... 5-14 

Chapter 6 
C Troubles ps................................... ................................................................... 6-1 
shooting Tip
Operation Troublesshooting ........................................................ ................................................................................. 6-1 
Rail Wheel Troubleeshooting ...................................................... ................................................................................. 6-4 
Railc
car Moving/Stoopping Troubles shooting ................................. ................................................................................. 6-4 
creen Fault Codes ........................................ ................................................................................. 6-5 
Conttrol Console Sc

Chapter 7 
C Service and
a Mainten nance ............................ ................................................................... 7-1 
Service and Mainten nance Safety ..................................................................................................................... 7-1 
Towiing the Vehicle..................................................................... ................................................................................. 7-1 
Liftin
ng and Supportting the Shuttle ewagon ................................... ................................................................................. 7-1 
Perfo orming Maintennance and Rep pair......................................... ................................................................................. 7-2 
Elecctrical System Precautions
P ................................................... ................................................................................. 7-2 
Discconnecting the Battery for Serrvice ....................................... ................................................................................. 7-2 
Disaabling the Remo ote Controls.................................................. ................................................................................. 7-3 
Relieeving Hydraulicc Pressure .................................................... ................................................................................. 7-4 
Drainn the Air Syste
em and Relieve e Train Brake Pressure P .......... ................................................................................. 7-5 
Disaabling the Electrical System ................................................. ................................................................................. 7-5 
Replacin ng Lubricants and Filters s .................................................................................................................... 7-6 
O and Filter ................................................. ................................................................................. 7-6 
Repllacing Engine Oil
Repllacing the Fuel/Water Separa ator Filter ................................ ................................................................................. 7-7 
Repllacing the Fuel Filter ........................................................... ................................................................................. 7-8 

ii
 Replacing the Air Filter Element ............................................................................................................................... 7-9 
Replacing the Transmission Oil and Filter .............................................................................................................. 7-10 
Draining the Oil .............................................................................................................................................. 7-10 
Replacing the Transmission Oil Filter ............................................................................................................ 7-11 
Replacing the Drive Axle and Hub Oil .................................................................................................................... 7-12 
Servicing the Hydraulic System.............................................................................................................................. 7-13 
Relieve Hydraulic Pressure ........................................................................................................................... 7-13 
Replacing the Hydraulic Return Filter ............................................................................................................ 7-13 
Replacing the Hydraulic Pressure Filter ........................................................................................................ 7-14 
Replacing the Hydraulic Oil ........................................................................................................................... 7-15 
Replacing Engine Coolant ...................................................................................................................................... 7-16 
Replacing the Engine Coolant Filter ....................................................................................................................... 7-17 
Pre-Charging the Hydraulic Accumulator ............................................................................................................... 7-17 
Lubricating and Greasing ........................................................................................................................... 7-18 
Coupler Slides ......................................................................................................................................................... 7-18 
Lubricating Rail Wheel Bearing .............................................................................................................................. 7-19 
Removing the Rail Wheel Bearings ............................................................................................................... 7-19 
Re-Assembling the Rail Wheel Bearings ....................................................................................................... 7-20 
Replacing the Rail Wheel Spindle .......................................................................................................................... 7-21 
Routine Lubrications .............................................................................................................................................. 7-22 
Tests, Adjustments, and Settings ............................................................................................................. 7-22 
Checking the Rail Wheel Gauge ............................................................................................................................ 7-23 
Adjusting the Hydraulic System Pressures ............................................................................................................ 7-23 
Setting System Pressures ............................................................................................................................. 7-23 
Aligning Steering ........................................................................................................................................ 7-25 
Steering System ..................................................................................................................................................... 7-25 
Steering on the Road ..................................................................................................................................... 7-25 
Steering on the Rail ....................................................................................................................................... 7-25 
Synchronizing the Steering .................................................................................................................................... 7-26 
Steering Screen ............................................................................................................................................. 7-26 
Servicing the Battery .............................................................................................................................................. 7-27 
Disconnecting the Battery for Service............................................................................................................ 7-27 
Servicing the Air Conditioning .................................................................................................................. 7-28 
Welding Procedures ................................................................................................................................... 7-29 
Factory Settings and Troubleshooting ..................................................................................................... 7-30 
Enter Password Screen ......................................................................................................................................... 7-30 
Factory Settings Selection Screen ......................................................................................................................... 7-31 
Calibration Screens ................................................................................................................................................ 7-32 
Options Screen ...................................................................................................................................................... 7-33 
Settings Screen ...................................................................................................................................................... 7-34 
Change Password Screen ...................................................................................................................................... 7-35 
Reset Safety Control (RSC) Screen ....................................................................................................................... 7-35 
Throttle Ramping Screen ....................................................................................................................................... 7-36 
Diagnostic Codes........................................................................................................................................ 7-37 
Funk DF250 Transmission ..................................................................................................................................... 7-37 
ZF 3WG210 Transmission ..................................................................................................................................... 7-37 
Cummins QSB 6.7 Tier 3 Engines ......................................................................................................................... 7-37 
Cummins QSB 6.7 Tier 4 Engines ......................................................................................................................... 7-37 
Cummins QSC 8.3 Tier 3 Engines ......................................................................................................................... 7-37 
Cummins QSC 8.3 Tier 4 Engines ......................................................................................................................... 7-37 

iii
Chapter 8 
C Service Intervals and Specifica ations ......... ................................................................... 8-1 
Service Intervals ............................................................................................................................................... 8-1 
Specifications.................................................................................................................................................... 8-2 
uid Specifications .......................................... ................................................................................. 8-2 
Lubrrication and Flu
Trannsmission Oil (F
Funk Transmission Recomme endations) ...... ................................................................................. 8-3 
Hydrraulic Oil Recommendations ............................................... ................................................................................. 8-3 
Accuumulator Press sure Specifications ........................................ ................................................................................. 8-3 
Tire Specifications ..................................................................... ................................................................................. 8-3 
Torque Specification
S ns ...................................................................................................................................... 8-4 

Chapter 9 
C y ........................................................ ................................................................... 9-1 
Glossary

Chapter 10 
C Daily Inspection ............................................ ................................................................. 10-1 
Navigato
or Series Daiily Inspectionn ................................................................................................................. 10-1 
Comman nder Series Daily
D Inspecttion ............................................................................................................ 10-3 

iv
C
Chaptter 1
IIntro
oduc
ction
TThank you forr choosing Sh huttlewagon® ®. We are the leading desiggner and manuufacturer of rrailcar moverss for a
w oads, chemicaal, agriculturaal, intermodal, port authorities, and transit
wide range off industries including railro
ssystems. The Shuttlewagon ned for high pperformance, reliability, annd ease-of-opeeration.
n railcar moveers are design
SShuttlewagonn’s design help ps eliminate rail
r yard cong gestion becausse of its uniquue ability to m
move both onn and off
rrail by means of hydraulicaally raised andd lowered rail wheels. It iss the only purrpose-built Noorth Americann railcar
mmover that uses rubber tires. The result is better traction and improoved shock abbsorption insttead of steel w wheels
ffound on otheer railcar movvers. Because of its exceptiional design, a Shuttlewagoon can pull faar more cars tthan
ccomparably siized movers anda transport both loaded anda empty carrs more efficiiently. By purrchasing a
SShuttlewagonn, you’ve obtaained a state of
o the art, inno
ovative, and rreliable produuct that is backked by excepptional
ccustomer serv
vice.
TThis manual in divided into o two sections: the front co
ontains Operaator informatiion and in thee back is Servvice and
MMaintenance information.
i T information in this maanual applies to the Navigaator series of the Shuttlewaagon
The
rrailcar moverss.
TThe Shuttlewaagon offers thhe following standard
s featu
ures:
 Rail
R Guide Wheels
W with independe
ently contro
olled rail gea
ar system that allows ffor safer
ra
ail moves
 The
T Operato
or cab is ma
achine width
h at 120” an
nd a full 72”” in overall height
 Center
C Cons
sole that rottates 180 de
egrees
 The
T large en
ngine compa
artment allo
ows easy ac
ccess for m
maintenance
e and repairrs
 Pneumatic
P Tire
T Drive Sy
ystem for exceptional traction and a comforttable ride
 Traction
T Con
ntrol Assistt and Anti-lo
ock Brake S
System
 Available
A witth either a Funk
F DF, orr ZF 3WG trransmission
n (based on
n model size
e)

U
Using This Manual
M l
T
The following
g sections pro Shuttlewagon NVX Series Mobile
ovide informattion and instrructions on opperating the S
R
Railcar Mover:
Chapter 1 ction - provid
Introduc des a descriptiion of our raillcar mover, ddocument connventions, conntact
informattion, and warrranty.
Chapter 2 R ations – lists all of the saffety recommendations.
Safety Recommenda
Chapter 3 wagon Exteriior – describees exterior feaatures.
Shuttlew
Chapter 4 wagon Cab – describes thee features ins ide the cab an
Shuttlew nd the console screens.
Chapter 5 ng the Shuttllewagon – in
Operatin nstructions forr starting andd operating thee Shuttlewagoon
railcar mover.
m
Chapter 6 ps – provides information on common eerror conditio
Troubleshooting Tip ons.
Chapter 7 nance – this section
Service and Mainten s contaiins the servicee and maintennance
recommeendations.
Chapter 8 Service Intervals and Specificatiions – an exteension of the service and m
maintenance
chapter, this chapter offers
o a servicce schedule annd Lubricatioon/Fluid speciifications.

In
ntroduction 1-1
 Chapter 9 Glossary – the glossary list contains terms used in this manual and other important
operating terms.
Chapter 10 Daily Inspection – this chapter contains a daily inspection checklist for operators.

Document and Safety Conventions

Before you begin using the Shuttlewagon, familiarize yourself with the conventions used in this manual.
These are used for additional information about a procedure and to communicate warnings about potentially
hazardous procedures.
WARNING: This indicates that a condition may result in harm, serious injury, or death to you or other
persons if the warning is not heeded. Follow the advice provided with the warning.

CAUTION: This indicates that a condition may result in damage to your Shuttlewagon or its equipment
if the caution is not followed. Follow the advice provided with the caution.

NOTE: This indicates that interesting or helpful information is being provided.

Related Documentation and References

 Cummins Owner’s Manual, QSB6.7 and QSC8.3 Engine, Bulletin 4915973, 6-November-2007,
Copyright 2007, Cummins Inc.
 DF 250 Transmission Component Technical Manual, CTM147, 02SEP05, Funk Manufacturing
Company, Copyright 2005, Deere and Company, Moline, IL.
 ZF Ergopower 3WG210 Transmission Technical Data Manual, 5872 189 002, 2000/08, ZF Passau
GmbH, 94034 Passau
 ZF Ergopower 3WG210 Service Error Code List Manual, 5872 993 026, 97-09-18, ZF Passau
GmbH, 94034 Passau
 Federal Railroad Office of Safety information, as of January 26, 2013 on website
http://www.fra.dot.gov.
 Association of American Railroads, as of January 26, 2013 on website
https://www.aar.org/safety/Pages/default.aspx

1-2
Contact Us
Department Phone Number Fax Number

Shuttlewagon Missouri Office (816) 767-0300 (816) 763-0705

Parts Department
Missouri Parts Office (816) 569-6499 (816) 767-8711
Service Department
Missouri Service Office (816) 569-6488 (816) 303-8998
Technical Support for US, Canada, and Mexico
Missouri Technical Support Office (816) 569-6488 (816) 303-8998
Sales Department
Missouri Sales Office (816) 767-0300 (816) 763-0705

Shuttlewagon Warranty
Shuttlewagon, Inc. warrants to the purchaser of each new Shuttlewagon, that for a period of 2 years or 4,000
operating hours, whichever first occurs, Shuttlewagon, Inc. will repair or, at its discretion, replace any defective or
malfunctioning part of the Shuttlewagon.

The warranty period begins on the date the Shuttlewagon is delivered to the first owner, user, or lessee who
operates the same in regular service.

This warranty is limited to the repair or replacement of such parts as shall appear to Shuttlewagon, Inc. (or its
authorized dealer) to be defective in material or workmanship upon inspection at Shuttlewagon's factory; at a
place of business of an authorized Shuttlewagon dealer; or other location designated by Shuttlewagon.
Shuttlewagon's warranty does not obligate it to bear the cost of transportation expended in the replacement of
defective parts. Parts replaced, repairs, and modifications made under this warranty shall not in any way extend
the warranty period beyond the initial 2 year or 4,000 hours of operation.

This warranty does not apply to (1) parts that have been altered or repaired without the consent of Shuttlewagon,
(2) parts or assemblies improperly installed by a dealer, (3) malfunctions resulting from misuse, negligence,
alteration, accident, overloading, or lack of performance of regular maintenance service, (4) replacement of
maintenance items (such as filters, brake linings, lights, tires, and tubes) made in connection with normal
maintenance service, (5) loss of time, loss of use of the Shuttlewagon product, or other consequential damages or
miscellaneous expenses (meals, lodging, etc.) or, (6) overtime or premium labor rates.

This warranty is the only warranty applicable to the Shuttlewagon and is expressly in lieu of any other warranties,
expressed or implied, including any implied warranty or merchantability or fitness for a particular purpose.
Shuttlewagon, Inc. neither assumes nor authorizes any other person to assume for it, any other liability in
connection with the Shuttlewagon.

1-3
C
Chaptter 2
S
Shutttlew
wago
on Saafety
y
R
Reco
omm mend
datio
ons
TThis chapter contains
c impo ortant safety in
nformation. To
T reduce the risk of seriouus injury to yourself and others,
rread and undeerstand the immportant Safetty Recommen ndations beforre operating tthe Shuttlewaagon.
AAdditional saffety procedurres may be req quired by youur company, yyour insurancce carrier, or tthere may be specific
rrestrictions on he material beeing transportted on the raillcars you are moving.
n the particulaar nature of th
N
NOTE: These recommen ndations do noot supersede or
o overwrite yyour companyy rules, regulaations, standaard
operrating procedu
ures, or proceesses.
SSafety is every
yone’s respon nsibility so bee aware of your surroundinngs at all timees and maintaain clear
ccommunicatio on with the peeople around you. Use radiio or hand siggnals and if yoou are unsuree of a signal, tthen stop
aand do not prooceed until yoou know the correct
c signal.
IImproper pracctices, carelesssness, or ignooring warninggs can cause sserious injuriees and sometiimes death.

O
Operatting the Shutttlewag
gon
N
NOTE: Only
y operate the equipment an
nd/or railcar movers
m that yyou have beenn trained and certified to opperate.
 The operatorr and passengeers of all Shu
uttlewagons mmust wear seatt belts where they are provvided.
 Never drive or
o operate any
y Shuttlewago on that has a kknown defectt that could afffect safe opeeration.
CA
AUTION: All
A defects mu
ust be reportted on the Daaily Vehicle IInspection R
Report.
 Riders are peermitted on Shhuttlewagons only when a seat is providded specificallly for the purrpose of
riding.
 The Shuttlewwagon operato or is responsib
ble for complliance with ruules and regullations involvving the
passengers, vehicle,
v and/oor equipment.
 While operatting the Shuttlewagon on trrack, if requirred, radios shhould be operaable and turneed on at
all times.
 Only move th he Shuttlewag gon when instructed to do so.
 Use the train brakes to sto
op the Shuttlew
wagon while in RAIL modde.
 Never use thee Low Rail Prressure Switcch when traveeling on a curvve.
 Sound the hoorn before:
 moving th he Shuttlewaggon
 entering a railroad crosssing
 entering or
o exiting a bu
uilding
CA
AUTION: The
T horns aree LOUD. Use the horns w hen your com
mpany policyy requires soounding
th
he horn.

2-1
Getting On and Off the Shuttlewagon
 Never get on or off a moving railcar mover.
 Ground persons must not get on or off a moving railcar mover or railcars.
 Before operators and ground persons get on or off the Shuttlewagon:
1. Face the Shuttlewagon and have a secure handhold and footing.
2. Watch for equipment on adjacent tracks, close clearances around you, possible obstructions
or irregularities, and any openings in the ground that may be difficult to easily stand on.
3. When conditions permit, get on or off on the side of the Shuttlewagon, away from main
track or close clearance.
4. Use three-point contact while using ladders.
 Ground persons must not get on or off equipment when a coupling is being made.
 Never get on or off equipment while carrying anything that will prevent a secure handhold or
otherwise interfere with safe movement.
 When getting on or off equipment, provided ladders must be used.

Working On or Around Tracks

Working on or around the rail tracks can be dangerous because it is easy to forget about what is going on around
you. Be sure to read and follow these safety recommendations:
 Employees working on or around tracks must always be alert to stay out of danger, exercising care
to avoid injury to themselves and others.
 Employees must respect the movement of engines, cars, or other equipment at any time, on any
track, in either direction. Never rely on others to give warning of moving equipment, except where
designated lookouts are provided.
 Never cross tracks immediately in front of moving trains, Shuttlewagons, or cars. When crossing
tracks, never go within 25 feet of the end of standing equipment and always be alert for sudden or
unexpected movement.
 Whistles, horns, or other warning devices must be sounded to alert others of approaching trains or
when placing the Shuttlewagon in motion.
 Employees on or about tracks, whether in the open, in shops, on bridges, or in tunnels must move to
a place of safety upon the approach of rolling equipment on the track where they are working or on
an adjacent track. Employees must always position themselves at a safe distance from moving
equipment and be alert for falling or protruding equipment.
 Never step on rail, frogs, switch point, guardrail, derail, interlocking equipment, retarder, loose
wheel detectors, or other similar equipment.
 All machines operating near a track must be alert to train movement and prepared to move
equipment quickly to avoid accidents. When not in use, all track equipment must be stored clear of
all tracks.
 Hands and feet must be kept clear of power switches, derails, and retarders.
 Never sit on:
 Rails or any portion of track structure except when required in the performance of duty.
 Docks, platforms, or any similar facilities that do not provide proper clearance for moving
equipment, railcars, and vehicles to pass by safely.
 Never engage in needless conversation nor become preoccupied with other affairs while fouling any
track.

2-2
  Cars left standing in the yard or shop tracks must have the hand brakes set and/or wheels blocked to
prevent movement.
 Never get on or off moving equipment traveling at an excessive rate of speed.
 Never sit on the steps of the Shuttlewagon. Never sit underneath the Shuttlewagon or near any
standing equipment, except in the performance of duty and only when proper safeguards have been
taken (such as brakes are set and/or wheels are blocked to prevent movement).
 Never ride on a crossover platform at the end of a railcar, or on the brake platform, except to release
or apply the hand brake.
 Never ride on any part of the coupler apparatus, center sill, side sill, or end sill of the framework of
the coupler.
 Never climb over or under couplers, or underneath standing cars or trains.
 If it becomes necessary to climb through standing coupled railcars, never step on an uncoupling
lever. Never place your hands, feet, or other parts of your body on a sliding sill or between a coupler
and end sill of the car.
 Before stepping between cars that are coupled to locomotive power, be sure to give the proper stop
signal and make sure it has been seen, understood, and obeyed.
 When stepping from between railcars, take due care to avoid being struck by moving equipment on
adjacent tracks.
 Never give a signal to move the Shuttlewagon, railcars, or any other equipment until the ground
person(s) and equipment are in the clear.
 When in between coupled railcars, never place your hands or feet on any part of the coupling
apparatus.
 When railcars are being coupled, stand in the clear. While adjusting the knuckle, stand with your
feet clear of the area under the knuckle.
 Unless proper protection is provided, never go between the Shuttlewagon and railcars for any reason
if clearance between them is close. When possible, a separation of at least one car length should be
made. Never use your foot to align the coupler.

Coupling and Uncoupling

 NEVER go between or in front of a moving Shuttlewagon or railcar to uncouple, open, close, or
arrange knuckles or couplers.
 NEVER place any part of the body on or between the coupler and end sill of the car, regardless of
whether the car is equipped with standard draft-gear arrangements, sliding sill arrangement, or end-
of-car cushioning device.
 NEVER adjust couplers, knuckles, or lock pins while the Shuttlewagon or railcars are moving or
about to couple. Stop movement and space cars at least one car length, or further (if necessary)
before adjusting coupler or knuckle.
 NEVER use a person’s feet to adjust couplers and knuckles.
 ALWAYS use uncoupling levers to open knuckles. When necessary to use hands to open knuckle on
standing equipment, keep both feet off of the rails.
 ALWAYS guard against unexpected movement of cars.
 ALWAYS use the uncoupling lever to uncouple cars.
 NEVER uncouple brake pipe connections by hand.
 NEVER look at the brake pipe hoses while Shuttlewagon or cars are being disconnected. Trapped air
or debris can be in the lines that can be propelled under pressure when disconnected.
 ALWAYS close shutoff valves to uncouple signal hose.

2-3
  ALWAYS use care when coupling or uncoupling air and auxiliary air to avoid injury.
 ALWAYS completely stop the Shuttlewagon and/or railcars from moving before attempting to
couple air hoses. Be sure the Shuttlewagon operator has been advised that the ground persons will
be between the equipment, and be sure it is safe to couple the air hoses before doing so.
 When handling air hoses, ALWAYS place one foot between the rails and the other foot outside the
rail for balance in the event of unexpected movement.

Operating Switches and Derails

 To operate the switches, the ground person(s) should stand with feet firmly planted so the body is in
a balanced position. Then lift, or pull, in a steady motion on the switch lever. When operating a
spring switch or dual control switch by hand, never attempt to rapidly force the lever over. You
should maintain a steady pressure against switch handle lever.
 Never stand in a position that your feet, hands, or other parts of the body could be struck by the
switch lever or by derail being placed on or being removed from the rail. Never use your feet to
operate switches except to operate the foot latch.
 When operating switches located between tracks, watch carefully for moving equipment on the
adjacent tracks.
 Never place your hands or feet between the switch point and rail. When operating switches and
derails, take the following precautions:
 Look for moving equipment on adjacent tracks and keep clear of it.
 Be sure that no one else is in a position to be injured.
 Be sure that no other obstructions will interfere with the operation.
 Check to see if switch points have been spiked. Do not remove a spike without proper authorization.
 Ask for help on switches that require excessive force to operate.
 Take a position squarely facing the switch or derail. Avoid standing in a twisted or awkward
position where you are off balance when throwing a switch or derail.
 Be sure switch locks and switch point locks, if any, are removed.
 Keep in the clear of any movement of switch parts while releasing latches.
 When lifting the lever, squat down and keep your back straight and then use your leg muscles to
avoid straining your back.
 When operating high switch stands, pull the lever toward you instead of pushing it away from you.
 Never lift or kick the switch lever with your feet.
 Be sure the switch points, or derails, have been moved to the proper position and they are secured
with the switch latch or switch lock before moving the Shuttlewagon or railcars.
 When not in use, keep the track derails and switch point derails in the derailing position.

2-4
Blue Flags or Blue Light Signals
Blue flags or blue light signals displayed signify that workmen are on, under, or between equipment.
When blue flag or blue signal is displayed:
 The cars or equipment must not be coupled.
 The cars or equipment must not be moved.
 Other cars or equipment must not be placed on the track so as to reduce or block the view of a blue
flag or blue signal.
 Rolling equipment may not pass a blue flag or blue signal.
Blue flags or blue signals must be displayed by each craft or group of workmen prior to their going on, under, or
between equipment or for track repairs. The same craft, or group, that displayed them may only remove blue flags
or blue signals.

2-5
C
Chaptter 3
S
Shutttlew
wago
on Ex
xterior
D
Driver’’s and Passe
enger’s
s Sides
s
Strobe Lig
ght

N
Navigato
or Sight Glas
ss Comm
mander
LED Ligh
hts

Couplerr

Rail W
Wheel
Sande r Box
Batterry Box
Fuel Tank

Rear
R
Mirro
or/Camera

Co
oupler

Glad Hand
Hose
Guard Rails

Ladder
Access
A Panels
s

3-1
 Name
Strobe Lights
Hydraulic Sight Glasses
(Hydraulic Reservoir)
Description
Two amber strobe lights mounted on the top of the cab that begin flashing when the
ignition switch is in the ‘ON’ position.
Hydraulic Sight Glasses – The sight level glasses are a visual indication of the
amount of hydraulic oil in the tank.
Hydraulic Fill Cap – Fill with hydraulic fluids.
The hydraulic filling area (fill cap) is on top of the hydraulic reservoir located
behind the cab. The sight level fill glasses are on the driver’s side of the reservoir.
The sight glasses can be viewed from the ground for quick and frequent inspection.
NOTE: Check the sight level with the rail units in the up position.
If hydraulic oil is to be added, see Hydraulic Oil Recommendations in Chapter 8.

Air Bell (optional item) Pneumatic air bell installed on the rear of the hood top.
NOTE: Follow the facility rules when using the air bell.

LED lights front and rear
LED lights continued
Four headlights, four brake lights, and one work light.
Two headlights and two brake lights on both Shuttlewagon front and rear.
One work light in rear above the coupler and one light illuminating each set of
stairs to deck.
The red brake lights are on when lights are on and brighten when the vehicle brakes
are actuated.
NOTE: Headlights and work lights are controlled by Front and Rear lighting
switch on the control panel.
Brake lights are controlled by the foot brake.

Sander Boxes Four total sander boxes, two on each side of the Shuttlewagon. Holds 100 lbs. of
track sand.
Battery Box One on the driver’s side deck of the Shuttlewagon. Inside the battery box is a
battery shutoff switch that is important when disconnecting power to the
Shuttlewagon. The battery box also contains a Shuttlewagon tool kit that is
supplied for the vehicle.
Fuel Tank The 90 gallon diesel fuel tank uses No. 2 Ultra-Low Sulfur Diesel fuel.
Ladders One on each side of the Shuttlewagon.
(8) Rail Wheels Rail wheels are used as guide wheels to maintain an on rail condition while running
on the track.
Couplers The front and rear sliding couplers can be moved from side to side and the coupler
can be released using the Coupler Position/Release switches on the control console.
Glad-hand Hose A rubber hose, with a locking and break-away mating head, that allows the
Shuttlewagon rail air brake system to connect to the train railcar air brake system
hose.

There are access panels that cover and protect the lower components of the Shuttlewagon and access panels on the
deck area to protect the engine. These panels must be removed for daily inspections and maintenance. These
access panels are removed by releasing the two lower latches and using the handles on the panel, lifting the door
off of the metal lip.

3-2
 Passenger’s Side, Lower Compartment
Removing the access panels reveals the air tanks, hydraulic accumulator, and components.

Tornado Air Dryers

Service Air (where applicable)
Reservoir
Vehicle Brake
Accessory Fluid Reservoirs
Air Reservoir
Vehicle Brake
Pressure Converters
Rail Air
Reservoir
NOTE: Air Knife Reservoir Air Dryer
is located on the deck

Drain Valves Cable Pull

Drain Valves

Navigator Passenger’s Side, Lower Compartment

Service Air
Reservoir

Accessory
Air Reservoir

Vehicle Brake
Fluid Reservoirs

Vehicle Brake
Pressure Converters

Drain Valves
(Ball and
Cable Pull) Air Dryer

Commander Passenger’s Side, Lower Compartment

NOTE: Rail Air and Air Knife
Reservoirs are located on the deck

3-3
IItem Descriptio
on
A
Air Tanks an
nd Drains There are three
t air tankss and five air tank drains.
The servicee and accessoory air tank drrains have puull cables to drrain moisturee from the
tanks.
H
Hydraulic Pis
ston The hydrauulic accumulaator system iss a safety backkup to the rail wheel downn
A
Accumulatorr pressures in the event th
he engine, trannsmission, orr the hydraulic pump malfuunctions.
It maintain
ns the hydraullic oil pressurre to the steel rail wheels. L
Located on drriver’s
side of eng
gine compartm ment.

T
Tornado Air Dryers The tornaddo air dryers dry
d the comprressed air so iit doesn’t freeeze the lines. The air
SW6030, SW7035,
S o remove dirt and contaminnants, as welll as moisture, to keep the aair
dryers also
SW8040 only… optional
S componentts working co orrectly.
o
on other mode
els
C
Cold Weathe
er Heaters Plug into an
a electrical su
upply outlet w
when ambient
nt temperaturee gets cold. Heaters
((optional) will keep fluids
f warm and from freezzing. Remembber to disconnnect from powwer
source befo
fore moving thhe Shuttlewaggon.

Warning
W Labbel on Cold W
Weather Box
The followwing heaters are
a available ffor use in coldd weather envvironments w where fuel
and oils neeed to be main m to flow freeely.
ntained at a teemperature thhat allows them
 Engiine Oil Pan Heater
H
 Tran nsmission Oil Heater
 Fuell Tank Heaterr
 Hydrraulic Oil Heater
 Engiine Water Heater
V
Vehicle Brak
ke Where the brake fluid iss stored.
R
Reservoir

3-4
Deck and Engine
The Shuttlewagon engine is accessible from the deck area. The access panels that protect the engine must be
removed before maintenance can be done.
The following areas are part of the operator’s daily inspection. It is important to become familiar with the location
of each of these.

Battery Box ZF Transmission Dip Stick (Driver’s Side)

Engine Oil Dip Stick

DF Transmission Dip Stick (Passenger’s Side)

Engine Oil Reservoir Coolant Reservoir

3-5
 Air Cleaner Housing (Tier 3) Windshield Wiper Reservoir

Engine Belts Hydraulic Accumulator

Item
Transmission Fluid Dip
Stick
Engine oil dip stick
Coolant Reservoir
Air Cleaner
Windshield Wiper
Reservoir
Engine Drive Belts
Hydraulic Accumulator
Description
For checking fluid levels in the transmission. Should be checked while the truck is
running on level ground at normal operating temperature. On the ZF transmission
the dip stick is located on the driver’s side. On the DF transmission the dip stick is
located on the passenger’s side.
For checking the fluid level in the engine.
On top of the hood is the cap to the coolant reservoir.
Where the air filter is located. It is used to filter out particles that are in the air.
Where the windshield wiper fluid is stored.
The belts assist in moving other parts on the engine.
Store hydraulic pressure in case of emergency.

3-6
C
Chaptter 4
S
Shutttlew
wago
on Ca
ab
T
The Shuttlewaagon cab is th
he where the operator
o has access
a to the ccomponents aand console ccontrols that ppower the
m
movement of the Shuttlewaagon and mon nitor the operrating conditioon.
B
Both of the Sh
huttlewagon doors
d can be locked
l on thee outside by a separate keyy.

C
Conso
ole
TThe control coonsole is the central
c hub fo
or all operatio
onal controls aand feature acccesses of thee Shuttlewagoon.
LLocated on thhe front windoow side of thee lower console is the clim
mate control unnit. On the dooor side of thee console,
yyou will find multiple
m com w as three 12-volt poweer points. On tthe back side of the
mputer diagnosstic ports, as well
ppivotal upper console, there is a narrow sleeve for ho olding the opeerator and servvice manualss for the machhine.

C
Control Console
e
T
The control co
onsole is wheere the operato
or controls an Shuttlewagonn, unless remoote control is set.
nd drives the S

Con
ntrol Consolee

4-1
Item Description
Blank Switches These switches are reserved for optional features
Transmission Shift F (Forward), N (Neutral), R (Reverse)
Lever When in reverse a backup alarm sounds. The transmission shift control has a lock
on the lever. To shift up, bump the shifter to the right, and to down shift, bump the
shifter to the left.
ZF transmissions - three speeds forward and three speeds reverse
“+” shift up
“-“ shift down
DF transmissions - four speeds forward and four speeds reverse
Note: 4th gear locked out at factory
“rabbit symbol” shift up
“turtle symbol” shift down
The ZF and DF transmissions are placed into gear different from each other.
The DF has a slip collar just below the shift handle that must be pulled upward
when going from neutral into gear.
The ZF requires that the button at the end of the shift handle be depressed when
shifting from neutral into gear.
NOTE: The transmission programming has a speed safety lockout and will not
allow a manual shift down if the engine RPM is above 1500.

NOTE: Shift lever must be in neutral with the parking brake ON for the engine to
start.

Wipers/Washers There are two knobs under WIPERS marked FRONT and REAR that control the
windshield wipers and washers.
 Turn the knob clockwise for Lo and Hi speed.
 Turn the knob counterclockwise to turn off.
 Press the knob in to activate the windshield washer.
Rail Pressure/ The rail wheel pressure switch is a two position momentary rocker switch that
High/Low Switch controls the hydraulic down force of the rail wheels. The switch is always in
HIGH position until the switch is depressed and held in LOW position. When
released it defaults to the high rail pressure setting.
Use of this rail wheel pressure switch is for when more traction is required in
adverse weather conditions.
HIGH position - full hydraulic down force is applied to the rail wheels.
LOW position - the hydraulic down force is reduced to allow more of the
Shuttlewagon’s weight to sit on the tires for greater traction during adverse
weather.
NOTE: The Speed Based Rail Pressure (SBRP) is the default rail pressure
system. The high/low rail pressure can be controlled manually using the
Rail Pressure High/Low Switch.

4-2
Item Description
Vehicle Brake This hand operated, spring-return lever applies the vehicle brakes when it is pulled
downward. When the lever is released, it automatically returns to the release
(OFF) position.
NOTE: The spring return hand lever has tight recoil, never allow it to “slam”
back into the release position.

Train Brake Emergency This two position knob controls the flow of air through the glad hand hose to the
Stop Button train brake system.
PUSH FOR EMERGENCY - immediately exhausts all air pressure in the service
line to the train brake to initiate an emergency stop of all rail cars.
PULL TO CHARGE - for normal service to charge all rail car brake lines and
reservoirs. This is the normal position of this knob.
Train Brake Reservoir This is a duplex gauge with white and red indicator needles that show the air
Gauge pressure for the train brake system.
White Needle - indicates the air pressure in the line to the attached railcar(s).
45–90 PSI is the normal range. 90 PSI is fully charged and released.
Red Needle - indicates the air pressure in the train brake air reservoir.
125-130 PSI is normal.
Train Brake Control This hand operated lever controls the railcar brake system. The railcar brake
Lever system is an air reduction type of system. From the Shuttlewagon control panel,
an electrical signal is sent to the proportional valve. Then the proportional valve
sends an air signal to the train brake relay valve. This controls the brake pipe
pressure to the railcars.
Release - is set to 90 PSI Apply - is set at 45 PSI
The hand operated lever has a friction hold to maintain the desired amount of
applied brake.
Horn Switch This switch momentarily activates the air horns on the top of the cab.
Depress the switch down to sound the air horns and release to stop the horns.
NOTE: A second horn switch is located in the center hub of the steering wheel.

Vehicle Throttle Pull the control lever down to apply throttle. The lever automatically returns to the
idle position when released.
NOTE: The rail throttle control lever is active ONLY in RAIL mode and
disabled when in ROAD mode.

The foot operated throttle pedal is disabled in RAIL mode, but it can be
configured to function in RAIL mode, if desired. If the throttle pedal is enabled in
RAIL mode, the control console throttle lever is DISABLED.
Lighting Front and Two position rocker switches with green indicator lights that are illuminated when
Rear Switches in the ON position. These switches control the headlights, the rail gear lights, and
the coupler lights.

4-3
Item Description
Engine Warning Light The engine warning light and engine stop lights are illuminated when the ignition
and is first turned on indicating the system self-test/diagnostics are happening. Note:
Engine Stop Light Before engaging the starter on initial start-up, allow a few moments for these
indicators to flash on and then off (this allows for the onboard computers to begin
communicating with each other before engine is fully energized).
Engine Warning Light is illuminated when a potentially damaging trouble code is
detected. Correct malfunction immediately.
Engine Stop Light is illuminated if engine warning light malfunction was not
corrected or if a potentially catastrophic error code has been detected
CAUTION: Correct malfunctions immediately or the engine will be
automatically shut down to prevent damage.

Ignition Switch Ignition switch uses a key and has four positions.
ACC – Not enabled at the present time
OFF – All systems are off and the key can be removed. Must be in OFF position
to remove the key.
IGN – Energizes all circuits. After the engine starts, the key returns to this
position.
START – Energizes the starter and the key must be held in position until the
engine starts. Release the key and it automatically returns to the IGN position.
Park Brake On and Off Two position rocker switch with an amber indicator light that illuminates when in
Switch the ON position.
CAUTION: NEVER leave the cab unless this switch is ON!

NOTE: This switch MUST be ON to start the engine

The transmission gear indicator on the gauge screen will display PARK when this
switch is ON.
Coupler Release This is a three position momentary rocker switch. Press to release a coupler and
Switch when the switch is not pressed it returns to the center position (off).
(Front and Rear)  Press UP to release the front coupler.
 Press DOWN to release the rear coupler

Coupler Positioning This is a three position momentary rocker switch. Press to move a coupler and
Switches when the switch is not pressed it returns to the center position (off).
(Front and Rear)  Press and hold UP to move the coupler towards the passenger’s side.
Release when desired position is reached.
 Press and hold DOWN to move the coupler towards the driver’s side.
Release when desired position is reached.
Note: Manually adjusting the coupler is ONLY necessary when initially
connecting to rail cars. Once connection has been made the coupler will
slide side to side as needed while moving cars along the rail.
Control Console This is a color display to use for monitoring and controlling the systems on the
Screen Display Shuttlewagon. For more details see Control Console Screens later in this chapter.

4-4
Heating and Air Conditioning (AC) Controls
This Shuttlewagon has independently controlled heating and air conditioning systems. Each thermostat dial must be
oriented properly to prevent the two systems from working against each other. A separate knob controls the mix
of fresh and recirculated air. Both systems, heat and A/C, will run most efficiently with 100% recirculated air.

HVAC Evaporator
The heat and air conditioning systems can operate simultaneously. Carefully read the information in the table
below to better understand operation of the system.

Knob Description
Heater Temperature Control Knob
Turn knob to the 3 o’clock position to turn heat OFF. Turn knob clockwise to
increase the heat, with the 6 o’clock position being heat on HIGH.
NOTE: Be sure heat is completely off (3 o’clock) when using AC.

AC ON/OFF Knob
With the indicator located at the filled in circle, the A/C is ON. With the indicator
located at the empty circle the A/C is OFF.
NOTE: Be sure AC is off (9 o’clock) when using heat.

Fresh Air Knob

Fresh air and recirculated air mixture is controlled by this selector knob. For 100%
recirculated air, turn the knob to the 2 o’clock position as shown. For any mixture
of recirculated and fresh air, turn the knob CLOCKWISE to a position between 2
o’clock and 10 o’clock. For 100% fresh air, the knob should be in the 10 o’clock
position as shown.

4-5
 Fan Speed Knob
The fan knob has three speeds: lo/med/high. Turn the fan switch to the 9 o’clock
position for OFF and the 12 o’clock position for HIGH

12 Volt Direct Current (VDC) and Data Ports

There are three connections on the lower control console near the door of the driver’s side.

12 VDC Port

USB Port Engine Data Port

VDC and Data Ports

12-Volt DC Accessory Plug
Remove plastic insert from the port to install a charging adapter for radios, phones, or computers that require a
12-Volt DC charge. Replace the plastic insert when finished.

NOTE: Each of the three 12-volt plug ports runs on a separate 30 amp circuit.

Engine Service Tool Port

This plastic-capped cable receptacle is used to plug in computers for troubleshooting engine error codes and
diagnostic readouts. Remove the cap to plug the cable into the port. Replace cap when finished.
USB Data Port
This plastic-capped cable receptacle is used to plug in computers for programming the Opus A6. Lift the cap to
plug the cable into the port. Lower cap when finished.

4-6
Storage Slot and Console Access Panel
On the passenger’s side of the control console is a storage slot where the Shuttlewagon operator and service
manual and daily operating paperwork can be stored. Below the storage slot is an access panel where the remote
control receiver is housed. Press the metal clips in to remove the panel.
12 VDC Port
(On top of Upper
Console)

Storage Slot

12 VDC Port

Console Access Panel

Console Access Panel

4-7
O
Operato
or and Pa
assenge
er Seats
s
CAUTION: The operato
or and passengers of the Shuttlewagoon must wearr seat belts w
when the engiine is on.

T
There are two
o seats in the cab,
c an operattor and a passsenger seat.

Arm rest ad
djuster

Back rest adjuster

Seat belt
Side to side
adjustmeent lever

Front to back
Seat rotation lever adjustmeent lever
Flotation lever

Operator/Passenger S
Seat

Moving
g the Seat Forward and Backwa
ard
CAUTIION: Adjustt the seat befo
ore driving and
a make surre the seat iss locked securely by tryin
ng to
move forward
f and backward without
w usingg the lever.

1. Underr the front edge of the seatt cushion pulll the slide adjjustment lev ver outwards aand hold
whilee sliding the seeat forward or
o backward.
2. When n in the position you desiree, release the llever and makke sure the seeat is locked iin place.

Rotatin
ng the Seatt
1. Be su
ure the seat is completely forward
fo beforee rotating.
2. Locatte the seat ro
otation lever ono the right s ide of the seaat below the seat cushion, ppull out
and hold
h while rottating the seatt left and righht to the desireed position.
3. Releaase the lever to lock the seaat in place.

Adjustiing Seat Fllotation

4. Locatte the air ride
e seat control button towaards the frontt of the cab.
5. Push the lever in and hold until raised to desiired position.. Release leveer.
6. To lowwer the seat level,
l pull lev
ver out and hoold to desired position. Rellease lever.

4-8
 Adjusting the Back of the Seat
1. Locate the back rest adjuster lever on the left side on the seat.
2. To adjust the seat back rearward, pull the back rest adjuster lever up and hold while
leaning back on the seat.
3. To adjust the seat back forward, pull the back rest adjuster lever up while leaning forward
a little to allow the seat to automatically come forward to the upright position, or the desired
position.
4. Release the lever to lock the seat in place.

Adjusting the Arm Rest

1. Adjust the arm rest completely back or down parallel to the seat by pulling out on the lever
located under the arm rest.
2. The up and down arm rest adjustments are controlled by turning the knob in or out
accordingly.
3. Release the lever to lock the arm rest in place.

Steering Wheel and Foot Pedals

The operator sits in the driver’s seat when using the steering wheel and foot pedals to maneuver the Shuttlewagon.

Horn

Press in towards
steering column
to adjust the
steering wheel Vehicle
angle brake pedal

Throttle pedal

Steering Wheel and Foot Pedals

Steering Wheel
The steering wheel can be tilted in several positions.
1. On the rubber boot on the column, press the button marked PUSH towards the steering column and
hold while moving the steering wheel to the desired position.
2. Release the button to lock into position.
3. The horn is located in the center of the steering wheel.
Foot Pedals
 Vehicle Brake Pedal – pedal on the left that is used for stopping in both ROAD and RAIL mode.
 Throttle Pedal – pedal on the right used for acceleration in ROAD mode but can be set to operate in
RAIL mode.

4-9
Cab Lighting
The cab is equipped with a ceiling mount light and two interior spot lights.
NOTE: The cab ceiling light is not a push button light. It is a toggle switch light.
The ceiling light has a three-position toggle switch:
 Left (Shuttlewagon Rear) – Red light for less glare during night operation.
 Right (Shuttlewagon Front) – White illuminating light.
 Center - Off
The spot lights are located in the upper rear corners on each side of the inside of the cab. These lights can be
directed to wherever extra lighting is needed in the cab.
NOTE: All interior overhead lighting is hard-wired directly to the battery and if left “ON” could cause the
battery to drain. Turn off lighting before exiting the cab.

Beverage/Cup Holders
There are two beverage/cup holders, one on each side of the cab. When not in use they can be folded up and out
of the way.

Fans
There are two fans located near the ceiling; one on the operator’s side and one on the passenger’s side. The fans
have two speeds, low and high, and can be adjusted to face in any direction.

 
 
 
 
 
 
 
 
 
 
 

4-10
 C
Control Console
e Screen
ns
TThis section discusses
d eachh of the contro
ol console scrreens and how
w each is usedd in operatingg the Shuttlew
wagon.
TThere are twoo main areas/sscreens for op
perating the Shhuttlewagon: HOME and D DIAGNOSTIICS/SETTING GS. In
eeach of these main screens there can be other screenss available.

DIAGN
NOSTICS/SETIN
NGS
BUTTOON

Fun
nction Buttons
(Both Sides)

Message Bann
ner

AAt the top leftt corner of every screen thee two main sccreens can be easily accesssed. If you aree already on oone of the
mmain screens youy will havee the other maain screen as an a option to nnavigate to.A
At the bottom oof every screeen is a
mmessage bann ner that displaays the curren
nt operating sttatus such as, READY TO O OPERATE orr it might disp play a
d not understtand the message or code see Chapter 6,, Troubleshoooting Tips, forr more detailss.
ffault. If you do

B
Button Description
HOME –Th his displays th
he engine opeerating gauges and is the fiirst screen to display whenn
the Shuttlew
wagon is startted.

DIAGNOST TICS/SETTIN NGS –This sccreen is for m

monitoring speecific systemss of the
machine, acctivating featu
ures that are not
n part of staandard operatiion and

TThere are screeen buttons onn the left sidee of the screen
n and functionn buttons on tthe right side of the screenn. These
bbuttons corresspond to the in
nformation prrinted on the screen next too the button.
TToward the bo ottom of everry screen is a white
w banner displaying thhe status of thhe Shuttlewaggon railcar moover. In
oour example it displays: REEADY TO OP PERATE. Fau ult Messages ccan display inn this banner wwhen the
SShuttlewagonn is not operating properly. For a list of fault
f codes, seee Chapter 6,, Troubleshoooting Tips.

T
The three butttons and knob
b on the right side of the co
ontrol consolee screen:
Button/ Descriptio
on
Knob
Return – This
T button is not currently
y being used.

ape) – This bu
ESC (Esca utton closes th
he current scrreen and takees you back onne screen.

4-11
 Home – No
o matter wherre you are in the control coonsole screenns, pressing thhe Home buttoon will
take you baack to the gau
uge screen.

The knob on
o the right up
pper corner will
w not be useed by operatorrs. It is used ffor programm
ming the
control con
nsole.

H
Home Screen
WWhen the Shu uttlewagon is started the Sh
huttlewagon Ram
R logo willl appear in thhe middle of tthe screen forr a few
sseconds beforre the HOME screen displaays. It providees important iinformation aabout the Shutttlewagon’s ggeneral
ooperating statu
us and contains the controlls most comm
monly used inn daily operatiion.

WWhen a gaugee is blue in co olor it is withiin normal opeerating param

meters. An oran
ange gauge deenotes either a warning
oor critical info
ormation for the
t operator. A red gauge denotes that tthe machine sshould be stoppped and turnned off as
ssoon as safely y possible to address
a a major issue in thee system.

N
NOTE: Wheen the Shuttleewagon electrric disconnectt has been shuut off the rebooot can take aabout two minnutes.
HOM
OME Screen

FRONNT Rail Gear and REAR R Rail Gear and

Steeer Lock Controls Steer Lock Controls

T
This table co
ontains a description of each
e of the ittems on the H
HOME screen.
Engine Item
m De
escription
Fu
uel level in thee 90 gallon taank.

Front and
a rear rail wheel
w pressurre in PSI (wheen rail wheelss are DOWN))

Th
he tire speed in
n miles per hour (MPH).

Th
his is the batteery volt meterr.

4-12
Engine Item Description
This indicates the engine oil pressure.

Engine Revolutions Per Minute (RPM). The rpm an engine operates in varies depending
on the Commander series. The idle is typically 800 RPM. The over speed is
approximately 150 rpm.
Commander Series Maximum rated power Engine Speed
315 (QSB Engine) 2500 rpm 2350
420 (QSB Engine) 2500 rpm 2350
525 (QSB Engine) 2500 rpm 2350
Engine coolant temperature. The maximum top tank temp is 225 degrees F. After that,
the engine will derate. If the temperature continues to rise, the engine will shut down.

Transmission oil temperature.

Hydraulic oil temperature.

The transmission gear the Shuttlewagon is currently set to. Located just above the
message banner.

Steering position: A blue line down the center represents straight ahead.
An orange line through the center is NOT straight ahead.

NOTE: Navigator machines will show approximate steering angle

position while Commander series machines will just show straight or not
straight.

Tire Pressure: The number over each tire represents the tire pressure in
that tire in psi. The number will turn orange when less than 120 psi or
greater than 140 psi.
The arrows select a steering mode (active mode highlighted in green):
 ROAD – Two-Wheel Drive. The rail wheels are up and the steering
is operating.
 TRANSFER – Raise and lower the rail wheels in TRANSFER
mode. Steering is operating.
 RAIL – Four-Wheel Drive. The rail wheels are down and the
steering is locked out.
To raise the rail wheels you must push and hold the UP button until you
hear the wheels reach their UP position (you will feel it). The UP button
can be feathered to bring it up only a little bit. This makes it easier
when you need to mount the rail.

4-13
Engine Item
m De
escription
The UP or DOWN
D button raises and loowers the rail wheels. This function
is only availaable in TRAN NSFER modee.
 FRON NT RAIL WHE EELS – use th he UP and DO OWN buttonss on left
side off screen. “U” is press and hhold to raise tthe gear up. ““D” is
press and
a release too lower the geear down.
 REAR R RAIL WHEE ELS – use thee UP and DOW WN buttons oon right
side off screen. “U” is press and hhold to raise tthe gear up. ““D” is
press and
a release too lower the geear down.
Th
he button nextt to this selecttion is depres sed to reset ann engine alarm
m.

Onn Navigator machines

m onlyy, the button nnext to this selection can bee used when rrail gear
is up
u to lock thee correspondin ng steering (ffront or rear) w
while allowinng the oppositte end of
thee machine to steer
s with thee steering wheeel.

Thiis lock symbo

ol will appearr over the lockked axle to inndicate that it will not steerr.

Thiis float symbool will appearr over each axxle when the rrail gear has bbeen loweredd. This
dennotes that the axle will floaat with the currve of the raill and will nott move with thhe
steeering wheel.

Tier 4 Enginnes Only…

DEF – when n diesel exhauust fluid is low
w this indicatoor will illumiinate
HEST – wheen the exhausst temperaturee exceeds normal operatingg
conditions thhis indicator w
will illuminatte. HEST willl also be activve during
regenerationn
REGEN – when
w regeneraation is neededd this indicatoor will illuminate
INHIBIT – when
w the operrator wishes tto prevent reggeneration andd has
selected this option in thee engine diagnnostic/settings screen this iindicator
will illuminaate.

4-14
Diagnostics/Settings Screen
The DIAGNOSTICS/SETTINGS MENU can be accessed from any screen that has the icon displayed.

DIAGNOSTICS/SETTINGS MENU Screen

Button Description
Switchman screen allows the Switchman control option (if installed) to be turned on
Switchman and off
Remote screen allows the remote control option (if installed) to be turned on and off as
Remote well as to track whether or not the remote is ready for operation.
Fuel screen tracks fuel consumption for the machine.
Fuel
ESX screen provides details on each input and output of the on board controllers for
ESX diagnostic and troubleshooting purposes.
Engine screen provides more detailed information about the engine including the
Engine manufacturer’s engine fault codes.
Transmission screen provides more detailed information about the transmission
Transmission including manufacturer’s transmission fault codes.
Vehicle screen provides rail speed, tire speed, and computer information about the
Vehicle vehicle. This is the only screen to visually see tire vs. rail wheel speeds.
Factory settings screen –This screen is used only by Shuttlewagon authorized
Factory technicians to set system configurations for the operation of the Shuttlewagon. It is
Settings password protected. Changes in this area can cause damage to the electronics and the
overall health of the Shuttlewagon.
Hydraulics screen provides temperature and pressure information on the hydraulic
Hydraulics system, accumulator, and rail.
TPMS (tire pressure monitoring system) provides details on the system and current
TPMS pressure readings.

4-15
Engine Screen
The engine diagnostics screen contains information only. The only action that can be taken on this screen is
clicking the NEXT or PREV buttons to view more engine fault codes.

Engine Screen
In addition to a number of engine diagnostic reading the following information and options are also
available:
Item Description
Engine Fault Codes SPN - Suspect Parameter Number – This is a three-digit code assigned to
each component for identification purposes.
FMI – Failure Mode Identifier – This code identifies the type of failure that
has been reported for the component.
NOTE: Use the up and down arrows to view additional codes if more than
one is active
Inhibit Regen Tier 4 Engines Only… Regeneration of the exhaust system can be inhibited
by pressing the Inhibit Regen Switch.
Manual Regen Tire 4 Engines Only… To initiate a regeneration of the exhaust system,
place the vehicle transmission in “Park” then press the Manual Regen
Switch.
The regeneration process will take about 45 minutes to complete, during
this time the engine will rev up and the exhaust system will become very
hot. The HEST (High Exhaust System Temp) indicator lite on the HOME
screen will illuminate during this process.
Fast Idle Fast Idle: Toggles between normal idle speed and a custom fast idle
setting. Using a faster idle speed after initial startup is useful to charge the
rail car brake reservoir and railcar brake system.
NOTE: Parking brake must be engaged. The shifter must be in neutral or
the fast idle will not engage. If parking brake is disengaged the fast idle
automatically disengages.

4-16
Transmission Screens
The TRANSMISSON screen provides more detailed information about the transmission. For more
information on transmission specifications, see Chapter 8, Service Intervals and Specifications.

Transmission Screen

Item Description
TRANS GEAR This is the gear the transmission is currently in.
TRANS INPUT SPEED This is the engine output speed displayed in RPMs that the transmission is
operating in.
TRANS OUTPUT The output speed in RPMs being applied to the axle drive lines.
SPEED
TRANS OIL TEMP The transmission oil temperature.
TRANS FAULT CODE The transmission fault code displays codes taken from the transmission
manual.
NOTE: Use the NEXT and PREV button to view more codes.
CALIBRATION Press this button and follow the procedure on the following page to
calibrate the transmission.

4-17
Transmission Calibration Screen (ZF Transmission Only)

The TRANSMISSON CALIBRATION screen provides the calibration procedure that will need to be
performed after every transmission service.

NOTE: Use the fast idle setting on the Engine screen to maintain a consistent engine speed while calibrating

Transmission Calibration Screen (ZF)

 
 

4-18
Vehicle Screen
The vehicle screen contains information for diagnosing the operation of the vehicle.
NOTE: This screen contains information relating to the vehicles computer software revision level that
might be important when diagnosing a vehicle problem.

Vehicle Screen

Item Description
ESX 1 REV This is the computer software revision level number. The heartbeat here
indicates that the CAN 1 network is operating correctly.
ESX 2 REV This is the computer software revision level number. The heartbeat here
indicates that the CAN 1 network is operating correctly.
DISPLAY REV This is the computer software revision level number.
PCLIENT This is the software that controls the control console screen.
BSP This is the software that controls the control console screen.
BACKLIGHT One of the settings will be outlined in yellow. Rotate the knob (both
INTENSITY directions) to move to a different setting. Push the knob on the chosen
setting to change the outline to green and rotate the knob to change the
setting. Push the knob again to change the outline back to yellow. Press
SAVE to store the new setting.
RAIL SPEED This is where the rail wheel encoder speeds are monitored.
TIRE SPEED This is where the tire speeds are monitored.
FOOT THROTTLE Toggles between the control console throttle active in RAIL mode and
ACTIVE ON RAIL having the foot throttle active as in rail mode. (Setting in automatically
retained in memory)
T/C & ABS DELAY Toggles between the standard traction control settings and the optional
settings.
Set and use the optional settings for when the track conditions are bad
and you want more delay before traction control engages.

4-19
Item Description
ON = Winter driving, more slip allowed (2.0 MPH slip/spin)
OFF = Summer driving, less slip allowed (0.5 MPH slip/spin)
NOTE: Traction control defaults to “OFF” whenever the Shuttlewagon
is turned off.
4WD ON ROAD This is a momentary selection for use in ROAD mode. To put the
Shuttlewagon into four-wheel drive:
1. Press the button and hold in ON position.
2. Release the button to return to two-wheel drive.
DO NOT use four‐wheel drive on dry pavement. Axle differential carrier 
damage will occur.
ICE BREAKER Toggles between OFF and ON. Can only be used in RAIL mode. When
the Ice Breaker is ON the message “ICE BREAKER ON, TRACTION
REDUCED” will be displayed and rail pressure will be held at 1500psi.
If the Shuttlewagon is taken out of RAIL mode or turned off, the Ice
Breaker defaults to OFF and must be turned back on.

4-20
Fan Drive Screen
The fan drive screen provides a button to manually reverse the fan and fan drive control information.

FAN DRIVE Screen

4-21
Remote Control Screen
The remote control screen controls the optional remote control function ON/OFF. When enabled (ON), the
remote control unit has control of the railcar mover when the remote control is turned on and
communicating.

Remote Control Screen

The following items are indicators. When all are green the items below are functioning and the vehicle is
ready to be operated remotely. The machine must also be in RAIL mode.
Button Description
Park Brake Switch Indicates parking brake is ON.
Manual/Switchman Indicates the outside e-stop buttons are pulled out (released).
E-Stops Released

Train Brake E-Stop Indicates the train brake emergency stop button is in the normal charging
Released position.
Shuttlewagon Ready Indicates onboard remote functions are enabled and pre-required conditions
are satisfied.
Ready To Start Transmitter Indicates the remote control transmitter has been turned on and warmed up.
This takes approximately ten seconds.
Remote Active Indicates the remote control is active and functioning properly but is not yet
communicating with the onboard R/C computer. R/C operating not yet
engaged.
Remote Linked Indicates good communication between the remote control and the onboard
systems. R/C operating is engaged.
Remote ESX CAN Shows the state of the system.

4-22
Switchman Control Screen
This screen allows the operator to enable and disable the switchman control system (if your vehicle is
equipped with this feature).

Switchman Control Screen

4-23
TPMS Screen (Tire Pressure Monitoring System)
This screen allows the operator to check tire pressure for individual tires.

TPMS Screen

Diagnostic Description

Sensor ID This is the sensor that corresponds to the position it is next to.

Position This is the position of the tire for which the sensor is reading

Pressure (PSI) This is the pressure reading of the tire for the corresponding position.

Sensor ID’s Detected This reading will scroll through all sensors that are transmitting to the
machine so they can be set appropriately.

4-24
ESX Screen
This screen provides real time input and output readings for the ESX controllers in the passenger’s side lower
console of the cab
Diagnostic
Vehicle Supply Voltage
Threshold Voltage
5V Voltage Supply
PIC Supply Voltage
Virtual Ground
ESX Diagnostics Screen – MAIN
Description
Should always closely match the battery voltage on the HOME screen
This is the minimum gate-to-source voltage differential that is needed to
create a conducting path between the source and drain terminals of the
transistors inside the controller. This must remain above XXXV to ensure
proper operation.
Pin 23 on each ESX controller is used to power many other devices on the
machine. It should have a constant 5V output with little variation
Should always be 5V
This is the case ground on each controller that should be connected to one
of the controller mounting screws. Without a secure case ground the
electrical system of the machine will not function properly.
4-25
ESX Diagnostics Screen - Inputs

ESX Diagnostics Screen - Outputs

4-26
C
Chaptter 5
O
Operatin
ng th
he Sh
huttle
ewagon
B
Before starting the engine, read and fully understand how the Shuuttlewagon opperates.

S
Steerin
ng Sys
stem
TThe steering system
s on the Navigator seeries consists of pivoting axxles on the frront and the reear of the vehhicle.
ng relative to a rigidly mou
IInstead of the wheels turnin unted axle, thhe axles themselves pivot. If brakes are applied,
ssteering becommes limited in
n movement.
TThe Commander series usees a conventio onal steer axlee on the frontt (cab end) off the vehicle.

S
Steering
g on the Road
WWhen the steeering wheel iss turned one direction,
d the front axle pivvots in that diirection whilee the rear axlee pivots in
tthe opposite direction.
d Thiss allows for a much smalleer turning radiius than woulld be possiblee with steeringg the
ffront or rear axles
a alone.
TThere is also the
t capabilityy of disabling steering on either
e axle. Thhis is useful w
when mountinng the vehiclee on the
rrails and re-aligning when coming off of the rail.

S
Steering
g on the Rail
O
Once rail wheeels are in the “down” posiition, steering
g of that axle iis disabled.

V
Vehicle
e Brak
ke Systtem
D
Disc Bra
akes
TThe vehicle brrake system consists
c of fou
ur disc brakess, one mounteed on each tirre wheel hub. The followinng tables
aare a list of th
he calipers perr axle for each
h model.
Model Co
onfiguration
SWX315-5
525 2 calipers
c on bo
oth axles
NVX5025--6030 2 calipers
c on bo
oth axles
NVX7035 2 calipers
c on fro
ont axle and 4 calipers on rrear axle
NVX8040 4 calipers
c on bo
oth axles
TThis is an air-over hydrauliic system whiich means thaat air pressuree applies force to the brakee fluid and thaat
ooperates the disc
d brakes. Th he air pressurre is controlleed by using thhe vehicle braake control levver on the conntrol
cconsole and thhe vehicle braake foot pedall.

A
Anti-lock Brakin
ng Syste
em (ABS
S)
T
The Shuttlewaagon is equipped with an anti-lock
a brak
ke system (AB
BS).
N
NOTE: The ABS is enabled ONLY wh hen in RAIL mode.
m When the ABS is aactive, ABS A
ACTIVE is dissplayed
on th
he control con
nsole screen.

5-1
The ABS is part of the vehicle brake system and has no effect on the railcar brakes. Antilock brakes reduce tire
lockup during hard braking. When the ABS detects wheel lockup, the ABS modulator valve automatically pumps
the brakes. This pulsation is felt in both the control console brake lever and the foot brake pedal. Maintain steady
pressure on the brake lever and/or brake foot pedal and do not pump.
NOTE: When the ABS is operating, NEVER manually pump the brake pedal or lever; let the ABS do the work.

Train Brake System

CAUTION: For optimum safety, you must always hook up the train brake system before moving railcars.
This rule applies whether moving loaded or empty cars.
The purpose of a pressure reduction system is to provide emergency braking to railcars in the event a car becomes
uncoupled or an airline ruptures. This air brake system is the standard design on all Association of American
Railroad (AAR) railcars in the United States, Canada, and Mexico.
When the Shuttlewagon is coupled to a railcar and the railcar brake air system is aired or charged, the railcar
brakes are held released by air pressure. As long as the air pressure charging the railcar air brake system is equal
to the auxiliary pressure on the railcar, the railcar brakes remain released.
If a pressure reduction occurs in the railcar brake system, as when the train air brake control is used (lever moved
down), the railcar brakes are applied.

Basic Air Brake Block Diagram

Traction Control
A traction control system is standard on this railcar mover. The traction control functions ONLY in the RAIL
mode. For more information on RAIL mode, see the Control Console Screens section in Chapter 4, Shuttlewagon
Cab.
If the traction control system is engaged, TRACTION CONTROL ACTIVE is displayed in the message banner and
the engine will derate to control the wheel slippage. Throttle control will return after the tire slippage returns to
pre-set acceptable levels.
Traction control example: If you have applied too much throttle for the conditions and the tires begin to slip or
spin, the traction control will manage the slipping and reset. Then ease back into the throttle.
NOTE: Even with traction control, during a hard pull, some tire slippage will occur. This is normal and the
traction control system is set so that it will not activate until a larger amount of slippage occurs.

5-2
When slippery conditions exist, use any combination of the following to reduce wheel slippage or spinning:
 Traction Control
 Sanders
 Air Knife
 Reducing the rail wheel pressure slightly using the rail pressure high/low switch

Starting the Engine

CAUTION: Be sure to perform the pre-shift inspection before operating the Shuttlewagon.

CAUTION: Do not start or operate the Shuttlewagon where there are or can be combustible vapors. This
can cause engine over-speed.

CAUTION: Do not operate the engine at low idle (normal is 800 RPMs) for long periods (fifteen minutes)
with engine coolant temperature below the minimum specified temperature. This can result
in:
* Fuel dilution of the lubricating oil
* Carbon buildup in the cylinder
* Cylinder head valve sticking

1. Put the key in the ignition switch.

2. Turn the ignition switch to the ON position.
3. Wait until both the engine warning and engine stop lights have gone out before proceeding.
4. Wait for the console screen to display the GAUGE screen.

CAUTION: To prevent damage to the starter, NEVER crank the engine for more than thiry seconds. If
it does not start, let the key return to the ON position. Wait two minutes before attempting
to start the engine again.

5. Turn the ignition switch to the START position and release when the engine starts.

NOTE: If needed, go to the SET (settings) screen to set fast idle to ON to charge the railcar.

NOTE: Before operating the Shuttlewagon under load, let the engine idle three to five minutes.

NOTE: When turning off the machine you must wait at least seven seconds before attempting to restart. If
restarted before seven seconds, the throttle is disabled until conditions are satisfied. Turn off, wait
seven seconds, then restart.

5-3
Operating in ROAD Mode
=
CAUTION: The vehicle brakes and the railcar brakes will not function properly if the air pressure is
low. It is very important that hydraulic and air pressures build to the correct pressures
before moving the Shuttlewagon.

UNDER NO CIRCUMSTANCES should the Shuttlewagon be moved if air pressures do not

build to the correct settings.

NOTE: Before releasing the parking brake, verify that the message bar at the bottom of the screen displays
“Ready to Operate”

1. Check that the area around the vehicle is clear of personnel.

2. Be sure passengers are seated with seatbelt fastened.
3. Set the Shuttlewagon to ROAD mode.
4. Be sure the rail wheels are in the UP position
5. Check the brake pressure in the rail brake pressure gauge.
 Rail brake reservoir pressure (white needle) should be at least 65 PSI.
 Rail brake pipe pressure (red needle) should be at least 90 PSI.
6. Verify that the Vehicle Brake Low Pressure audible alarm has stopped sounding. This alarm continues
until vehicle brake air pressure is higher than 65 PSI (the minimum pressure required to operate the
vehicle brakes).
7. Apply the vehicle service brake.
8. Release the parking brake.
9. Select the desired transmission speed.
10. Verify the vehicle service brakes are functioning properly by releasing and reapplying the brakes. If the
vehicle service brakes fail to work, place the transmission in Neutral, apply the parking brake, and turn
off the engine.
CAUTION: Have the vehicle brake system inspected and repaired, if needed. Never attempt to move the
vehicle until they are operating properly.

11. If the vehicle service brakes are functioning properly, proceed carefully.

Mounting to the Rails

This procedure will go much faster and easier if the operator has a helper on the ground to guide the operator
when aligning the tires/rail wheels with the rails.

CAUTION: NEVER travel on the rail in TRANSFER mode! If the rail wheels are accidently raised during
rail operation, the Shuttlewagon will derail.

WARNING: NEVER operate the Shuttlewagon on rail if the indicated rail wheel down pressure does not
follow the HIGH pressure shown in the following table.

5-4
 Model Low Pressure PSI High Pressure PSI
SWX315 450 700

SWX420 450 700

SWX525 600 850

NVX5025 500 700

NVX6030 500 750

NVX7035 525 850

NVX8040 850 1175

To mount the Navigator series Shuttlewagon to the rails:

1. Start this procedure with the rail wheels from either end of the vehicle.
2. Select an improved crossing or area that is flush with the track before you begin.
3. Maneuver the vehicle over a crossing.
4. Line up front or rear of the Shuttlewagon with the rail, while the ground person directs you for correct
rail wheel alignment. The front or rear can be installed on the rail first, depending on the correct
alignment of the rail wheels.
5. Use the rear camera/mirror to line up the rear rail wheels with the rails.
NOTE: Because both of the axles steer on the Navigator series and with four rail wheels on each axle, it is
necessary to have the tires aligned and centered on the rail. This allows all four rail wheels to line
up with the rails.

6. Once the rail wheels are aligned with the track, set the controls from ROAD mode to TRANSFER mode.
7. Lower the aligned set of rail wheels to the rail and check rail wheel pressure reading for correct rail
pressure (see chart above). The axle steering is disabled when the rear wheels are lowered. Be sure all of
the rail wheels are engaged with the rail.
8. Align the other set of rail wheels over the track by driving in the same direction as the first set of
lowered rail wheels and steering the axle while the ground person directs you for correct alignment of
the rail wheels.
NOTE: For best results, align the second set of rail wheels over the rail by traveling in the direction of the
first set of lowered rail wheels.

9. Use the front camera/mirror to align the front rail wheels with the rail.
10. Lower the other rail wheels to the rail, and check rail wheel pressure reading for correct rail pressure
(see chart above).
11. Make sure that all rail wheel flanges are inside the rail, and not sitting on top of the rail.
12. Set the Shuttlewagon from TRANSFER mode to RAIL mode. This locks the rail wheels DOWN.

To mount the Commander series Shuttlewagon to the rails:

13. Select an improved crossing or area that is flush with the track before you begin.
14. Maneuver the vehicle over a crossing.
15. Use the rear mirror to line up the rear rail wheels with the rails.
16. Once the rail wheels are aligned with the track, set the controls from ROAD mode to TRANSFER mode.
17. Lower the rear set of rail wheels to the rail and check rail wheel pressure reading for correct rail
pressure (see chart above).

5-5
 18. Align the front set of rail wheels over the track by steering in the required direction. Use the front mirror
to align the front rail wheels with the rail.
19. Lower the front rail wheels to the rail, and check rail wheel pressure reading for correct rail pressure
(see chart above).
20. Make sure that all rail wheel flanges are inside the rail, and not sitting on top of the rail.
21. Steer the front axle to position it in the straight ahead condition.
22. Set the Shuttlewagon from TRANSFER mode to RAIL mode. This maintains the rail wheels DOWN and
locks the steering.

Operating in RAIL Mode

Before operating the Shuttlewagon in RAIL mode, inspect the rails for any obstructions, track conditions, and
make note of any grades and curves. Even the slightest grade or curve can affect pulling power and stopping
distance.
NOTE: A combination of grade and curve occurring together will have a cumulative effect on decreasing the
pulling power.
The track conditions also affect railcar operation. Wet, muddy, or icy track conditions will further reduce pulling
power and stopping distance.

Moving Rail Car Fundamentals

Grade
Grade Level Reduction
0.5% About a 50% Reduction
1.0% About a 66% Reduction
1.5% About a 75% Reduction

Curve
Each degree of curve is approximately a 1 car reduction in pulling capability.
Weather
Type Reduction
Rain, Frost, or Snow About a 50-75% Reduction
Drawbar Pull
Commander Drawbar Pull Capacity Navigator Drawbar Pull Capacity
SWX315 27,000 lbs. NVX5025 38,000 lbs.
SWX420 30,000 lbs. NVX6030 45,000 lbs.
SWX525 35,000 lbs. NVX7035 50,000 lbs.
NVX8040 60,000 lbs.

Grade and Curve Calculations

Measuring Grades
To find the percentage of grade level, place a level device that displays percentage on the rail to determine
the grade or stretch a 100' line as shown below. When the line is level, measure the number of inches above
the rail ("A" below). Each inch represents one percent of the grade level.

5-6
 NOTE: Your site may have grade records on file.

Measuring Grades

Measuring Curves
To find the degree of a curve, a line sixty-two feet long with a mark at the mid-point (thirty one feet) on the
outside of the inner rail flange. Measure the distance from the mid-point mark vertically to the rail flange.
Each one inch increment equals one degree of track curvature.

Rise Radius Degree Rise Radius Degree

1 5766 1 18 321 18
2 2883 2 19 304 19
3 1922 3 20 289 20
4 1442 4 21 275 21
5 1153 5 22 263 22
6 961 6 23 252 23
7 824 7 24 241 24
8 721 8 25 232 25
9 641 9 26 223 26
10 577 10 27 215 27
11 525 11 28 207 28
12 481 12 29 200 29
13 444 13 30 193 30
14 412 14 31 187 31
15 385 15 32 182 32
16 361 16 33 176 33
17 340 17 34 171 34

CAUTION: On tracks with twenty degrees or more of a curve, consult with a factory representative to
determine the degree of curve.

5-7
 Combined Grade and Curve
The table can be used to determine the curve/grade resistance of a track curve in degrees. You must know the
degree of the curve and the grade percentage to find the curve/grade resistance in the table.
The grade resistance is then used in the formula to determine the tractive effort requirements:
tractive effort requirements = (gross railcar weight) x (number of railcars) x (curve/grade resistance)
Example:
5 cars @ 131 tons each on 1% grade and 10 degree curve
5 x 131 x 40 = 26,200 lbs. tractive effort
Total Resistance Chart
Degree of the Track Curve
0 1 2 4 6 8 10 12 14 16 18 20 22 24 26
0% 10 11 12 14 16 18 20 22 24 26 28 30 32 34 36
Grade
.5% 20 21 22 24 26 28 30 32 34 36 38 40 42 44 46
Percentage
1.0% 30 31 32 34 36 38 40 42 44 46 48 50 52 54 56
1.5% 40 41 42 44 46 48 50 52 54 56 58 60 62 64 66
2.0% 50 51 52 54 56 58 60 62 64 66 68 70 72 74 76
2.5% 60 61 62 64 66 68 70 72 74 76 78 80 82 84 86
3.0% 70 71 72 74 76 78 80 82 84 86 88 90 92 94 96

NOTE: Adverse weather conditions may affect track performance.

Coupling Railcars
WARNING: NEVER
* adjust couplers, knuckles, or lock pins while the Shuttlewagon or railcars are moving or
about to couple. Stop movement and space cars at least one car length, or further (if
necessary), before adjusting coupler or knuckle.
* use a person’s feet to adjust couplers and knuckles.
* operate the uncoupling lever while riding on a railcar or Shuttlewagon railcar mover.

WARNING: NEVER:
* go between or in front of a moving Shuttlewagon or railcar to uncouple, open, close, or
arrange knuckles, couplers, or ball valves.
* place any part of the body on or between coupler and end sill of car, regardless of
whether the car is equipped with standard draft gear arrangements, sliding sill
arrangement, or end-of-car cushioning device.
* uncouple brake pipe connections by hand.
* look at the brake pipe hoses while Shuttlewagon or cars are being disconnected. Trapped
air or debris can be in the lines that can be propelled under pressure when disconnected.

5-8
WARNING: ALWAYS:
* use unco oupling leverrs to open knnuckles. Wheen necessary to use handss to open knu uckle on
standingg equipment,, keep both feet
f off of thee rails.
* guard ag gainst unexpected movem ment of cars.
* use the uncoupling
u leever to uncouuple cars.
* close shuutoff valves to
t uncouple signal
s hose coonnections b by hand.
* use care when coupliing or uncou upling air andd auxiliary aair connection ns to avoid in
njury.
* completeely stop the Shuttlewagon
S n and/or raillcars from m moving beforee attempting to
couple air
a hoses. Be sure the Shu uttlewagon op perator has b been advisedd that the groound
persons will be betwween the equipment, and b be sure it is ssafe to couple the air hoses
before doing
d so. When handling air hoses, AL LWAYS placce one foot b between the rrails and
the otheer foot outsid
de the rail forr balance in tthe event of u unexpected mmovement.

CAUTION: Before couplling the Shutttlewagon, bee sure the areea around th
he railcar is clear of persoonnel
and obstaclles.

T
To couple the Shuttlewago on:
1. Mov ve the Shuttleewagon close to the selected railcar and aalign the couppler by watchhing the coupller
posiition in the miirror.
2. Alig gn the Shuttleewagon coupler with the raailcar coupler using the Co oupler Positio oning switchh on the
conttrol console for
fo the approp priate coupler being alignedd. Move the ccoupler lateraally from side to side
until it is aligned with the railccar coupler.

Control Console - Coupler

C Positi
tioning Switch
hes

CAUTIION: Be suree the ground person is cleear and not b

between the rrailcar and S
Shuttlewagon
n.
3. Oncce the couplers are aligned, move the Sh huttlewagon sllowly towardss the railcar uuntil the coupllers join
togeether. They shhould automattically lock together.
4. Testt that the coupplers have lockked by slowlyy backing awaay from the raailcar. There sshould be a nooticeable
resisstance that ind
dicates that th
he couplers haave locked toggether.
5. Placce the transmiission in neutrral (N) and set the parking brake.

Connec
cting the Railcar
R Air Brakes
NOTE: The normall time to charge (release) railcar air brakkes is three too five minutess (at 800 RPM
M idle)
for the firstt railcar and one
o minute forr each additioonal railcar inn the consist. A
At 1600 RPMM this is
slightly oveer one minutee for the first railcar
r and appproximately thirty secondds each additioonal
railcar.

5-9
 To connect the rail air brake hoses:
1. On the control console, push the train brake e-stop button in to exhaust all air pressure in the
service line to the train brake.
2. Mate the glad hand hoses together to establish a connection allowing air to flow into the rail
brake system.

Glad Hand Hoses Connected

3. In the cab on the control console, pull out on the train brake e-stop button. This allows air to
charge the railcar air brake system, which releases the railcar brakes.
4. Slowly open the train brake hose air supply ball valve.

Air Supply Ball Valve

5. Make sure all glad hand hoses are connected and all ball valves are open between railcars.
Release all hand brakes and verify all chocking devices are removed.
6. Close the rear most ball valve on the last railcar in the consist.
7. When system is fully charged, test functionality of the brake system by applying then
releasing the train brakes.

Pulling a Load
Heavy loads can be eased in the OPPOSITE DIRECTION of the intended pull to allow slack between the
couplers. You can gain as much as six to eight inches of free travel for each coupled car. Using this technique, the
Shuttlewagon starts pulling one car at a time, and the momentum of the moving car helps start the remaining cars.
Maintain a steady increase of power so as not to lose the momentum gained.

Pulling Heavy Loads and Curves

When moving through a tight curve (caution should start at 18º or more), PULL rather than push the car or
consist, if possible.

5-10
 NOTE: In the diagrram below, no
otice the coup
pler reaction when pullin
ng versus pusshing cars arround a
tight curve.

Pulling
P vs. pu
ushing cars oon a curve
When pu ulling, the cou
uplers continu he centerline of pull. Whenn pushing maaximum or near
ue to follow th
maximum m loads aroun nd tight curvees, the couplerrs on the Shutttlewagon andd attached carr will tend to pivot
opposite to the direction of the curv ve until stopp
ped by the couupler housingg. At this poinnt, the line of ppush is
not followwing the centterline of the vehicle.
v The Shuttlewagonn, weighing leess than the looad, is now puushing
the load with
w couplerss angled. Thiss situation is more
m prevalennt when a currve and upgraade occur togeether,
rather thaan on level orr downgrade curve
c t car momeentum might nnot require the Shuttlewagon to
where the
apply maaximum push.

U
Uncoupling Railcars
1. Wheen railcar mov vement is com mpleted, push
h the train braake e-stop buttton in to exhaaust all air prressure in
the service
s line to
o the railcars.

CAUTIION: NEVER
R manually disconnect trrain brake h oses.

2. Use chocks and hand brakes s to secure thee railcars.

3. Releease the coupller by using th
he coupler re elease switchh.
4. Pulll away slowlyy from the railcars, the glad
d-hand connecctors will autoomatically dissengage.
5. If th
he couplers doon’t release, pull
p forward or o backwards to release thee tension of thhe couplers. R
Repeat
stepps 3 and 4 agaain.

D
Dismoun
nting fro
om the Rails
R
1. Brin
ng the Shuttleewagon to a co omplete stop at an improv ed crossing.
2. Placce the transmiission shifter to neutral an
nd set parking
g brake.
3. On the
t R/R screeen, set the Shu uttlewagon too TRANSFER R mode.
4. On right
r side of the t UP buttonn until the reaar rail wheels raise completely.
t screen, preess and hold the
5. On left
l side of th he screen, presss and hold th
he UP button uuntil the fronnt rail wheels rraise complettely.
6. Set the
t Shuttlewaagon to ROAD D mode.
7. Youu are now read dy to maneuv ver off the impproved crossiing and travell on the road.

5-11
Operating in Cold Weather
WARNING: DO NOT use starting fluids because it can cause an explosion, fire, personal injury, severe
damage to the engine, and property damage. The engine is equipped with an intake air
heater.

Cummins Engine Recommendations

The information in this section was taken from Cummins Owner’s Manual, QSB4.5 and QSB6.7 Engine, Bulletin
4915973, 6-November-2007, Copyright 2007, Cummins Inc.

NOTE: Start the engine and warm up in advance of anticipated operation in cold weather. Required warm up
time will vary depending on ambient temperatures, length of shutdown, and operating temperatures at
last shutdown. Typically a warm up is three to five minutes in extreme cold.

CAUTION: Although Cummins does not recommend long idle periods with low coolant temperature, the
engine must operate for sufficient periods of time to warm up the engine, transmission,
hydraulic system, and air compressor prior to operation under load.

 Typical minimum unaided cold start temperature: 10˚ F

 Typical cold start temperature using standard grid heater: -26˚ F
 After starting a cold engine, increase the engine speed slowly to provide adequate lubrication to the
bearings and to allow the oil pressure to stabilize.
 Idle the engine 3 to 5 minutes before operating with a load.
 Do not operate engine at low idle for long periods (15 minutes or more) with engine coolant
temperature below the minimum specification in maintenance specifications (160°F is typical). This
can result in fuel diluted oil, carbon buildup, valve sticking, and reduced performance.
 Cummins suggests additional cold weather operating aids such as coolant heaters, oil heaters, fuel
heaters, winter fronts, and thermostatic fan controls when operating below 32°F ambient. These aids
may be required below -10°F.

Cold Weather Heaters

CAUTION: Before moving the Shuttlewagon, be sure to unplug the standard engine block heater and any
auxiliary heaters.

CAUTION: Be sure when using the engine block heater and any optional heaters that you don’t overload
the circuits that are feeding them. Refer to the Cold Weather Package Amp Draw WARNING
label (see below) for the optional heater current requirements.

CAUTION: Remember to disconnect heaters from the power source before moving the Shuttlewagon.

5-12
 C
Cold Weatherr Box
Colld Weather Package
P Amp
p Draw

Heating
g Equipme
ent
The follo
owing heaterss are availablee for use in co
old weather ennvironments w
where fuel annd oils need too be
maintained at a tempeerature that alllows them to flow freely.
 Engine Oil Pan Heater
 Transmisssion Oil Heatter
 Fuel Tankk Heater
 Hydraulicc Oil Heater
 Engine Water
W Heater

T
Transmiission Oil
O (Funk
k DF Tra
ansmissiion Recommendations))
TThe Funk Traansmission Co ompany recom mmends that thet normal opperating oil teemperature bee between 1000°-200°F.
FFor Funk trannsmission recoommendation ns on oil typess and minimuum operating ttemperatures,, see Chapter 8,
SService Intervvals and Speciifications.
CAUTION: Transmissio on oil should
d be warm beefore operatiing the transmission undeer load. If th
he
transmissioon (converterr out) oil tem
mperature rem
mains below the normal ooperating range
after a reasonable warm m-up period, stop the macchine and waarm the oil b
by stalling the torque
converter.

A
Alternate Wa
arm-up Proce
edures
 Operate the transmission
t in
i neutral for approximatelly twenty minnutes or until the oil is warrmed to
the minimum m temperaturee.
 Preheat the trransmission fluid
f to the miinimum tempperature beforre operating tthe Shuttlewaagon (use
an auxiliary source
s such as
a an electric heater).
h
 If it becomess necessary to
o maintain thee recommendeed oil temperaature, operatee the machinee in a
higher gear.
N
NOTE: Thiss information taken from DF Series 250 T
D Transmissions (Analog) Com
mponent Techniical Manual, C
CTM147, 
02SE
EP05, Funk M
Manufacturing
g Company, C
Copyright 20005, Deere and Company, M
Moline, IL

T
Transmiission Oil
O (ZF Trransmis
ssion Re
ecomme
endation
ns)
TThe ZF Transmission Com mpany recommmends that thee normal operrating oil tem
mperature be bbetween 140°--194°F.
FFor ZF transm
mission recom mmendations on
o oil types an
nd minimum operating tem mperatures, seee Chapter 8, Service
IIntervals and Specification
ns.

5-13
CAUTION: Transmission oil should be warm before operating the transmission under load. If the
transmission (converter out) oil temperature remains below the normal operating range
after a reasonable warm-up period, stop the machine and warm the oil by stalling the torque
converter.

Alternate Warm-Up Procedures

 Warm up the transmission fluid by putting the transmission in neutral and increase engine speed to
about 1500 rpm.
 If it becomes necessary to maintain the recommended oil temperature, operate the machine in a
higher gear.
NOTE: This information taken from ZF Series Transmissions Component Technical Manual

Hydraulic System Recommendations

Electric heaters or a hydraulic heat generating system should be used if oil temperature remains below the normal
operating range after a reasonable warm up period. Lower operating temperatures are allowable with J20D or
other lower viscosity oils. For information on oil and operation and the minimum temperature for operation, see
Chapter 8, Service Intervals and Specifications.

Air Compressor Recommendations

Frequent engine starting and stopping may prevent the air compressor oil from reaching the normal operating
temperature of 185°F.
CAUTION: Operating below normal operating temperature may allow contamination of compressor oil
with water, and possible freezing in air system components.

Cold Weather Remote Operation Starting and Stopping

There may be an occasion to operate the Shuttlewagon remotely during cold weather. Using remote control during
normal operation in cold weather causes an extra draw on the battery and the performance is reduced. Warning
messages will appear on the remote display.

CAUTION: Frequently check the control console screen when using the remote control in cold weather
to make sure that minimum operating temperatures are being maintained.

NOTE: Electronic controls remain on when the engine is stopped using remote control, placing additional
demands on the Shuttlewagon batteries. Keep remote control shutdowns to less than 6 hours or turn off
remote control and shutdown the Shuttlewagon.

To turn on the remote control feature:

8. At the control console, turn the ignition on to start the engine.
9. After the warning lights go out and the GAUGE screen starts, select the remote control page button.
10. Press the remote control button to toggle from OFF to ON for remote operation.
To turn off the remote control feature:
1. When shutting down, disable remote operation on the remote control page by pressing the remote
control button to toggle back to OFF.
2. Shut down the vehicle using the ignition switch on the control console.

5-14
5-15
C
Chaptter 6
T
Trou
ubles
shoo
oting
g Tips
TThis chapter provides
p inforrmation to hellp you isolatee and resolve common erroor conditions. If you need
aassistance, calll Shuttlewagon Technical Support (816 6) 569-6488.
N
NOTE: For engine and trransmission trroubleshootin
ng, refer to thee manufacturrer’s service m
manuals suppllied with
the vehicle.
v

O
Operatio
on Troub
bleshoo
oting
Problem Po
ossible Cause
e
Heater not  A/C nott turned to “off” position
blowing waarm air
 Fans noot turned “on””
 Insufficcient engine coolant
 Engine coolant leak
 Air in coolant
c circuitt
AC not blow
wing  A/C nott turned to “on” position
cold air
 Heater knob
k is not tu
urned “off” coompletely
 Fans noot turned “on””
 Insufficcient refrigeraant charge
 Compreessor clutch not n engaging w when A/C turrned to “on”
 High prressure in systtem (due to hheat or over chharge) disenggaging the cluutch
Premature tire
t  Rear axle not engaged
wear  4WD not engaged
 Excessivee tire spin beccause load is ttoo heavy
 Railcar haand brakes noot released
 Contamin nants on the raail
 Rail wheeel pressure is set incorrectlly
 Railcar aiir brakes not fully
f charged
 Not usingg train brakes
 Over inflaated or under inflated tire
 Foot valv
ve malfunction n
 ABS tracttion control disabled
d
Premature brake
b  Rail car brakes
b not being used or noot used consisstently
rotor and pa
ad  Constant vehicle brakee applied whille moving
wear
Vehicle brakes  Low air pressure
p
will not app
ply  Air leaks in vehicle braake system
 Air in braake fluid
 Low brak ke fluid level in
i master cyliinder

6-1
Problem Possible Cause
 Axle seals leaking oil on brake pads
 Brake pads worn excessively or worn out
 Foot valve malfunction
Vehicle will not  Steering locked in RAIL mode
steer  Rail gear down
 Low hydraulic oil level
 Steering cylinder internal leak
 Low hydraulic pump pressure settings
 Hydraulic pump failure
 Steering relief valve not adjusted properly
 Steering control unit malfunction
Vehicle will not  Parking brake not released
move  Low hydraulic brake release pressure
 Transmission shift control malfunction
 Transmission malfunction, check fault codes
 Transmission oil level low
 Transmission solenoid malfunction
 Low air pressure
 Vehicle brakes not released
 ZF low accumulator pressure
Derailing  Excessive vehicle speed
 Rail wheel pressure set incorrectly
 Hydraulic pump pressure too low
 Moving more than vehicle rated capacity
 Bad track or conditions
 Rail wheel flanges worn out
 Rail wheel gauge out of tolerance
 Rail wheels loose on spindles
 Rail arm bushings seized or frozen
 Poor tire condition, low tire pressure, or incorrect tire size
Rail wheels  Low tire pressure
flanging to one  Vehicle brakes partially applied
side
 Track leaning to one side
 Wheel bearing play
 Hydraulic cylinder internal leak
 Rail gear out of alignment
Engine surges  Over-revving the engine causes the tires to slip causing the traction control system
during operation to activate and moderate engine RPMs
 Grounding issue in wiring, usually cab to chassis
Foot throttle not  Foot throttle may be disengaged if engine is shut down and restarted too quickly.
functioning

6-2
Problem Possible Cause
Traction control  Excessive tire wear or wrong tire size
malfunction -  Wheel speed sensor malfunctioning
tires slipping
 Transmission speed sensor malfunctioning
 Broken electrical connection
 Traction control is disabled in computer settings
 Wrong model size selected in computer settings
 ABS/ATC turned off
ABS malfunction  Excessive tire wear or wrong tire size
- tires locking up  Wheel speed sensor malfunctioning
 Transmission speed sensor malfunctioning
 Broken electrical connection.
 ABS is disabled in computer settings
 Wrong model size selected in computer settings
 ABS modulator valve malfunctioning
 Rail wheel is not turning freely
Hydraulic pump  Hydraulic oil cold
noise  Hydraulic oil contaminated
 Hydraulic pressure filter clogged
 Air in hydraulic oil
 Hydraulic return filter clogged
 Tank suction or case drain valve closed
 Hydraulic oil level low
 Hydraulic oil too hot
 Hydraulic pump malfunction
 Hydraulic pressure set too high
Control console  CAN Bus network has broken electrical connection
screen is ON but  Vehicle controller malfunctioning
display is
malfunctioning  Vehicle controller has lost power; check fuses and electrical connections
- Red block on  Operator panel malfunctioning
screen  Operator panel CAN Bus speed is set incorrectly
- Unexpected reset  Low electrical system voltage; vehicle controller or operator panel has reset
during operation
- Readouts show
no data or appear
faint
Operator panel  No power
does not turn ON  Check fuses and electrical connections
 Operator panel malfunctioning
 Low electrical system voltage

6-3
Rail Wheel Troubleshooting
Problem
Rail cylinder will not hold
pressure
Rail cylinders won’t raise
or lower smoothly or
evenly
Slow rail cylinder
movement
Railcar Moving/Stopping Troubleshooting
Problem
Will not pull cars
Railcar brakes will not
release
Railcar brakes will not
apply
Possible Cause
 Not in RAIL mode
 Rail control valve not in down position
 Regulating valves adjusted too low
 Rail cylinder leaking internally
 Hydraulic pump pressure setting out of adjustment
 Hydraulic pump malfunction
 Hydraulic oil level low
 Air in hydraulic system
 Cylinder leaking internally
 Hydraulic pressure settings low
 Regulating valve malfunction
 Rail arm bushings not lubricated
 Rail arm bushings binding
 Cylinder leaking internally
 Hydraulic oil level low
 Hydraulic pump not delivering sufficient volume of oil
 Rail arm bushings not lubricated
 Rail arm bushings binding
Possible Cause
 Rear axle not engaged
 Railcar hand brakes not released
 Railcar air brakes not fully charged
 Rail hydraulic pressure adjusted too high
 Railcar service brakes not released
 Moving more than rated vehicle capacity
 Severe track conditions
 Traction control malfunction
 Railcar air brakes not fully charged
 Railcar shutoff ball valve closed
 Rail air reservoir pressure too low
 Railcar hand brakes not released
 Contamination in rail brake pipe or valves
 Train brake control set incorrectly
 Train brake control handle out of adjustment
 Insufficient time to release railcar air brake system
 Rail air brake system not fully charged
 Contamination in rail brake pipe or valves
6-4
Problem
Railcar braking and
release time too long
Possible Cause
 Air hoses or valves not connected correctly
 Train brake control set incorrectly
 Shutoff valves not open between cars
 Railcar brakes defective
 Incorrect use of train brake control handle
 Contamination in rail brake pipe or valves
 Air leak in air system or railcars
 Rail air reservoir air pressure too low
 Compressor malfunction

Control Console Screen Fault Codes

This section contains a list of Fault Codes that can appear in RED on the white banner of the control console
screen. Listed below are some possible causes for the fault codes to help resolve common errors.
Problem Possible Cause
READY TO  No faults; ok to operate
OPERATE
ENGINE WARN  Engine fault; refer to engine fault codes
LAMP
ENGINE STOP  Engine fault; refer to engine fault codes
LAMP
ENGINE PROTECT  Engine fault; refer to engine fault codes
LAMP
RAIL PRESSURE  Rail pressure transducer, cable, or connection failure
FAULT  Low rail pressure
LOW HYDRAULIC  Hydraulic pressure transducer, cable, or connection failure
PRESSURE  Pump failure
 Hose break
 Ball valve closed
LOW AIR  Air pressure sensor, cable, or connection failure
PRESSURE FAULT  Compressor failure
 Hose break
 Ball valve closed
 Air Knifes in constant use
 Remote Control valve issues

6-5
STRAIGHT AHEAD  Commander series. Steer axle must be straight ahead in rail mode
FAULT
ACCUMULATOR  Accumulator pressure below normal range for more than 5 minutes
PRESSURE  Gas Pressure Sensor failure
SENSOR FAULT
TRANSMISSION  See transmission fault codes
FAULT
HYDRAULIC  Temp below or above normal operating temps
TEMPERATURE  Temp sensor, cable, or connection failure
FAULT
HAND THROTTLE  Hand throttle potentiometer, harness, or connection failure
FAULT
FOOT THROTTLE  Foot throttle potentiometer, harness, or connection failure
FAULT
BRAKE FAULT  Train brake potentiometer, harness, or connection failure
FUEL LEVEL  Fuel level sensor, harness, or connection failure
SENSOR FAULT
LOW FUEL LEVEL  Low fuel level
ENGINE  Engine fault; refer to engine fault codes
MALFUNCTION
LAMP
TRANSFER MODE  Shuttlewagon is in transfer mode
TRACTION  Wheels are slipping, so engine is de-rated to control slipping during acceleration
CONTROL ACTIVE
ABS ACTIVE  Anti-lock braking system is engaged due to tire slippage during braking
TRANSMISSION  Transmission fluid temperature is high
TEMP HIGH
NOT READY FOR  Remote needs to be turned on through the Opus display
REMOTE
E-STOP ACTIVE  Emergency button is depressed on Remote Control E-Stop
RADIO REMOTE  Shuttlewagon is actively controlled by remote control
ACTIVE
STANDBY MODE  Shuttlewagon is ready to go into remote mode just waiting for remote horn
ACTIVE button to be pressed
SWITCHMAN  Switchman control option is not turned on through the Opus display
CONTROL
DISABLED

6-6
EMERGENCY  Switchman control emergency stop button has been pressed
STOP o Put in neutral, turn park brake on, reset Switchman Control E-Stop,
press RESET on Opus display
 RSC has timed out
o Put in neutral, turn park brake on, press RESET on Opus display
APPLY PARK  Put in neutral, turn park brake on, press RESET on Opus display
BRAKE – PRESS
RESET
HIGH  Check air compressor; something is causing it to operate outside its normal
COMPRESSOR operating temperature
TEMP
LOW  Check air compressor; something is causing it to operate outside its normal
COMPRESSOR operating temperature
TEMP
COMPRESSOR  Check air compressor; something is causing it to operate outside its normal
DISABLED operating temperature
WAIT TO START  The engine is not ready to be started
LOW AIR  Not enough air pressure while in remote mode so Shuttlewagon is emergency
PRESSURE (E- stopped until air pressure builds to proper level. Possible issue with RCLBP
STOP, REMOTE) switch or circuit
STEER  Commander Series Dual Steer. Both axles must be straight ahead in rail mode
INTERLOCK
TRAIN BRAKE  Recalibrate train brake
CALIBRATION
NECESSARY
HAND THROTTLE  Recalibrate hand throttle
CALIBRATION
NECESSARY
FOOT THROTTLE  Recalibrate foot throttle
CALIBRATION
NECESSARY
IDLE SPEED  If engine’s RPMs are less than 800 RPM and greater than 2400 RPM
SETTING OUT OF
RANGE
STARTER  If starter runs for more than thirty seconds the starter cooling comes on for two
COOLING minutes for the starter to cool than it can be ran again
REMOTE START  Starter is turned over via the remote control
ACTIVE
J1939 OFFLINE  CAN network not working
ALERT – PRESS  Warning that RSC needs pressed before Shuttlewagon emergency stops
RESET SWITCH  (hand throttle switch)

6-7
RSC RESET  Press RSC reset on Opus display gauge screen
SWITCH FAULT
ENGINE  (Tier 4 engine only) High exhaust temperature or diesel particulate filter
EMISSIONS FLAG restriction will cause emissions flag to come on
ACTIVE
DIESEL  (Tier 4 engine only) If the diesel particulate filter is plugged then this fault will
PARTICULATE appear
FILTER
RESTRICTION
HIGH EXHAUST  (Tier 4 engine only) If exhaust temp is to high this fault will appear
TEMPERATURE
REGEN INHIBITED  (Tier 4 engine only) The regeneration process can be stopped until a later time
DIESEL  (Tier 4 engine only) Warning that the diesel particulate filter is nearing
PARTICULATE restriction
FILTER
RESTRICTION-
FLASH
AIR FILTER  Air filter is plugged and needs replaced
RESTRICTED
FRONT RAIL  Front rail pressure valve coil, circuit, connector failure
PRESSURE VALVE
COIL FAULT
REAR RAIL  Rear rail pressure valve coil, circuit, connector failure
PRESSURE VALVE
COIL FAULT
FAN DRIVE PWM  Fan drive coil, circuit, or connector issue
COIL OPEN FAULT
FAN DRIVE PWM  Fan drive coil, circuit, or connector issue
COIL SHORT
FAULT
FAN DRIVE  Fan drive coil, circuit, or connector issue
REVERSE COIL
OPEN FAULT
FAN DRIVE  Fan drive coil, circuit, or connector issue
REVERSE COIL
SHORT FAULT
FAN DRIVE  Fan drive transducer, circuit, or connector issue
PRESSURE
SENSOR FAULT
WARNING! FAN  Move Shuttlewagon to a safe location and shut engine off.
DRIVE PRESSURE
LOW! STOP
ENGINE!

6-8
4WD NOT  Transmission did not lock Shuttlewagon into 4WD
ENGAGED
ICE BREAKER ON,  Ice breaker uses high rail pressure. Shuttlewagon traction and braking will be
TRACTION reduced
REDUCED

6-9
C
Chaptter 7
S
Serv
vice and
a Main
ntenance
e
TTo help mainttain efficiencyy and power, inspect your vehicle regullarly and folloow the guidellines in this seection.
FFor service scchedules, referr to the Service Intervals taable in Chaptter 8, Service Intervals andd Specifications. When
tthe vehicle is operated in more
m uch as indicateed below, youu should insppect, replace, oor refill
extreme situations, su
mmore frequenttly.
 Operating in dusty conditiions or sandy areas.
 Extensive usee of brakes.
 Operating forr prolonged periods
p in cold
d temperaturees and/or extrremely humidd environmentts.

S
Service and Mainte
enance
e Safetty
TThis section contains
c impoortant safety in
nformation. To
T reduce the risk of seriouus injury to yoourself and otthers,
rread and undeerstand the im
mportant safetyy recommend dations beforee servicing thee Shuttlewagoon.
CAUTION: Service should only be performed
p by
y trained tecchnicians who are knowleedgeable aboout the
equipment and potentia al safety haza
ards.

SSafety is every
yone’s responnsibility so bee aware of your surroundinngs at all timees and maintaain clear
ccommunicatio on with the peeople around you.
WARNING: Improper practices,
p carelessness, or ignoring w
warnings can cause seriou
us injuries an
nd
sometimes death.

T
Towing the
t Vehiicle
CAUTION: If the vehiclle is on the rail, DO NOTT tow unless tthe engine iss running.
The engine must be run nning to prov
vide hydrauliic pressure too maintain rail wheel preessure
on the rails.

CAUTION: Never tow the

t vehicle without
w the en
ngine runninng or the drivve shafts discconnected.
If this occurrs the transm
mission parkiing brake wiill not releasee and will cau
use internal
transmissioon damage.
 Run engine ata idle speed to
t lubricate th
he clutches.
 Do not exceeed normal veh hicle speeds while
w towing.
 If the engine can’t be run, disconnect drive
d shafts froom transmisssion

L
Lifting and
a Supporting the Shu
uttlewagon
IIt is importantt to take precaautions when lifting or sup Shuttlewagon and wheneveer componentts are
pporting the S
bbeing removed from or insttalled on the Shuttlewagon n mobile railccar mover.
WARNING: Shuttlewag gon equipmeent can weigh
h anywhere ffrom 24,000 llbs. to 100,0000 lbs. and caan cause
severe perssonal injury or death. Alw
ways use bloocks or propeer stands to ssupport the p product
before perfforming any service work k. Do not woork on anythiing that is su
upported ON NLY by
lifting jack
ks or a hoist. When workiing on or undderneath thee equipment,, the lifts or ssupports
being used d MUST havee a load ratin
ng equal to orr greater thaan the weightt being suppoorted.

7-1
If the Shuttlewagon needs to be supported or suspended, use a load rating equal to or greater than the weight that
is being supported.

Performing Maintenance and Repair

Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from any systems that
utilize pressure.
CAUTION: DO NOT check for pressure leaks with your hand. High pressure oil or fuel can cause personal 
injury.

Electrical System Precautions

Most of the electrical safety requirements pertain to protecting the electronic equipment onboard. The exception is
for Shuttlewagons that are equipped with remote control equipment. When remote control is installed, the
following precautions must be taken before performing maintenance on the Shuttlewagon:
 Turn remote control unit OFF and remove key.
 Turn battery disconnect switch to the OFF position.

Disconnecting the Battery for Service

The Navigator is equipped with a battery disconnect switch on the inside of the battery box. This switch has been
provided to prevent remote starting while servicing the Shuttlewagon.
CAUTION: NEVER disconnect the batteries while the engine is running. Disconnecting batteries while
the engine is running can result in damaged electronic controls and equipment. ALWAYS
turn the ignition switch OFF before disconnecting batteries.

Battery Disconnect Switch

7-2
D
Disablin
ng the Re
emote Controls
C s
CAUTIION: Emerggency stop sw witches located d on the sides of the Shuttleewagon can m
maintain brak
ke
pressurre after the ig
gnition is turrned off.
The em
mergency stop p switches must
m be releassed prior to p performing m
maintenancee.

Red Emerggency
Stop Switc
ch
(one on ea
ach side)

Emergeency Stop Swiitch

1. The emergency stop
s switches are located on n each side o f the Shuttlew
wagon above the sander booxes and
shou
uld be put in the
t released position
p prior to turning thee ignition swiitch off for m
maintenance.
2. Appply the parkin
ng brake and place
p the transsmission in N (neutral).
3. On the
t control coonsole GAUG GE screen acceess the remotte control scrreen.
4. Set the
t REMOTE E CONTROL to t OFF (as indicated in thiis example).
Remote Control
ON/OFF buttton

Remotee Control Screeen

5. b turning thee ignition keyy to OFF and remove the kkey.
Disaable the electrrical system by
6. If neecessary, lock
k the cab doorrs to prevent access
a while disconnectingg the battery.
CAUTIION: NEVER R disconnectt the batteriees while the eengine is run
nning as it can
n result in daamaged
electronic controls and equipmeent.

7-3
 7. When the engine is stopped, in the battery box, turn the battery disconnect switch to the OFF position.

Battery Disconnect Switch

8. In the cab on the passenger side console, remove the access panel to verify that the remote control
receiver (MCU) power light is off.

Access
Panel

Access Panel to Remote Control Receiver

Relieving Hydraulic Pressure

Use the following procedure whenever a repair or maintenance procedure requires working on the hydraulic
system.
NOTE: Models with ZF Transmission requires additional step in orange box below.
1. Position the Shuttlewagon in a location where maintenance will be performed and on a level
surface where the rail gear can be put in the down position.
2. Leave the engine running.
3. Access the R/R screen.
4. Select the TRANSFER mode (TRANSFER will be highlighted).
5. Verify objects and personnel are clear of the Shuttlewagon and the ground is clear and sound
below the rail wheels.

7-4
 6. Use the DOWN buttons to lower the front rail wheels (left side of screen) and rear rail
wheels (right side of screen).
7. Use the UP arrow to select ROAD mode to dump the rail pressure.
8. Verify that the rail pressure displays show ZERO and that the rail wheels are resting on the
ground.
Models with ZF transmission ONLY: On Main Hydraulic Manifold – Remove solenoid connectors labeled
AC and AD. Connect AD in place of AC and go to step 9. After maintenance is complete, re-connect AC
and AD.
9. Access the DIAG screen. Access the HYDRAULIC screen. When the ACCUMULATOR
reading drops below 50psi the unit can be shut down.
10. Turn the engine OFF and remove the key.
CAUTION: NEVER disconnect the batteries while the engine is running because it can result
in damaged electronic controls and equipment.
11. When the engine is stopped, in the battery box, turn the battery disconnect switch in the OFF
position.

Drain the Air System and Relieve Train Brake Pressure

To drain the air system and relieve train brake pressure:
1. On the control console, press the red emergency stop knob to exhaust the train brake
pressure.
2. Pull the manual drain valves on all of the air reservoirs until all of the pressure is released
and fully open the drain valves for inline filter and main reservoir.

Disabling the Electrical System

1. Turn the ignition switch off and remove the key.
2. If necessary, lock the cab doors to prevent access while disconnecting the battery.
CAUTION: NEVER disconnect the batteries while the engine is running as it can result in
damaged electronic controls and equipment.
3. When the engine is stopped, in the battery box, turn the battery disconnect switch to the OFF
position.

7-5
Replacing Lubricants and Filters
This section contains the procedures for replacing filters and lubricants on the Shuttlewagon.

Replacing Engine Oil and Filter

The following steps are for replacing the engine oil and filter in the Cummins engine.
NOTE: Always change the oil when engine is warm and DO NOT over-tighten drain plugs and filters.
1. Run the engine until the water temperature reaches +140 F (+60 C) and then shut down the engine.
2. Place a drain pan with enough capacity to hold all the engine oil under the oil pan.
3. Loosen and remove the oil drain plug. The oil will begin to drain into the drain pan.
4. Inspect the magnetic drain plug for any metal shavings, chips, or any other matter. Wipe the oil drain
plug clean.
5. Visually check the condition of the used oil as it drains.
6. When oil has drained completely, reinstall the drain plug. Tighten to specified torque (differs with type
of oil pan/plug). For correct torque, refer to the Torque Specifications table in Chapter 8, Service
Intervals and Specifications.
7. Wipe the old filter and the outside of the oil filter head clean to prevent dirt or other debris from getting
into the engine.

Standard Cummins QSB and Tier 4 QSB Engine

QSC Engine Oil Filter Location

7-6
 8. Remove the old oil filter and gasket.
9. Check for any dirt or debris on the gasket surface of the filter head.
10. Using a clean cloth, apply a film of clean engine oil to the rubber gasket on the new filter to lubricate for
a good seal. Be sure not to get dirt or debris on the gasket.
11. Fill the new replacement filter with oil.
12. Thread the new replacement filter turning clockwise, onto the filter head until the filter gasket contacts
the filter head gasket surface and then hand tighten 3/4 turn.
13. Refill engine with new oil to specified capacity. For oil capacity, see Lubrication and Fluid
Specifications table in Chapter 8, Service Intervals and Specifications.
CAUTION: Failure to refill engine with oil will result in serious engine damage!

Replacing the Fuel/Water Separator Filter

Fuel Filter

Fuel/Water Separator

CAUTION: NEVER smoke when replacing a fuel/water separator filter.

1. Place a drain pan under the fuel/water separator filter.
2. Unscrew and remove the fuel/water separator filter.
3. Wipe the fuel/water separator filter head gasket surface clean of all dirt or other debris.
4. Apply a film of motor oil to the o-ring on the new replacement filter.
5. Fill the replacement filter with fresh fuel.
6. Thread the replacement filter onto the filter head until the gasket contacts the filter head gasket surface
and then hand tighten 3/4 turn.
7. Wipe the fuel/water separator filter clean of any fuel residue.

7-7
Replacing the Fuel Filter
1. Place a drain pan under the fuel filter.
2. Wipe the outside of the fuel filter head and the filter clean to prevent dirt or other debris from getting into
the engine when replacing the filter.
3. Unscrew and remove the fuel filter from the filter head.
4. Clean the filter head gasket mating surface of all dirt or other debris.
5. Apply a film of motor oil to the o-ring on the new replacement filter.
6. Fill the fuel filter with fresh fuel.
7. Thread the replacement filter onto the filter head until the gasket contacts the filter head gasket mating
surface and then hand tighten 3/4 turn.
8. If the engine is a QSC engine, prime the fuel system by turning the ignition switch to ON for 30 seconds,
then turn OFF. Repeat this three times before attempting to start the engine.

QSB Engine Fuel Filter Tier 4 QSB Engine Fuel Filter

QSC Engine Fuel Filter

7-8
Replacing the Air Filter Element
1. For the Tier 4 QSB engine, release 4 latches (2 on the top and 2 on the bottom). Pull to remove the
cover. Go to step 3.

Release latches

Tier 4 QSB Engine – Air Filter Canister

2. For standard QSB and QSC engines, release the air cleaner housing clamp and rotate the outer cover
counter-clockwise.

QSB and QSC Engines - Air Filter Canister

3. Gently rock the primary air filter element until it is loosened from filter seat and then remove from the
housing.
4. Gently rock the secondary air filter element until it is loosened from filter seat and then remove from the
housing.

Primary Filter Secondary Filter

5. Clean the filter seat area of the housing of all dirt or other debris to be sure the new replacement
elements seal completely.

7-9
 6. Insert the replacement secondary filter element into the seat of the filter housing and then insert the
replacement primary filter element into its seat of the filter housing.
7. For Tier 4 QSB engine reinstall the outer cover by pushing the cover on until the four latches snap into
place on the filter box.
8. For standard QSB and QSC engines, reinstall the outer cover by rotating the cover clockwise and then
tighten the clamp. Be sure the primary filter element fits correctly into the outer cover when installing.
9. Be sure the drain on the filter outer cover is pointed DOWN to prevent water from collecting inside the
filter housing.
10. Reset the filter life indicator.

Replacing the Transmission Oil and Filter

Draining the Oil
1. Place a drain pan under the transmission oil pan with enough capacity to contain all the old transmission
oil.
2. On the face of the transmission that bolts to the bell-housing/engine, LIGHTLY tap around the edges of
the transmission oil plug to loosen the threads.
3. Remove the transmission oil drain plug.

DF Transmission Drain Plug ZF Transmission Drain Plug

4. Visually check the condition of the used oil as it drains.

5. Inspect the magnetic drain plug for any metal shavings or chips and then wipe the drain plug clean.
6. Before replacing the drain plug, check the inside of the transmission through the drain plug hole for any
accumulated sludge.
7. If sludge is found in the transmission, flush it out with fresh transmission oil.
8. When oil has drained completely, reinstall the drain plug. Tighten to specified torque (see the Torque
Specifications table in Chapter 8, Service Intervals and Specifications).

7-10
Replac
cing the Tra
ansmission Oil Filterr
1. Wippe the filter heead and filter clean
c to preveent dirt or otheer debris from
m getting into tthe transmissiion when
replacing filter.

mission Filterr
DF Transm
ZF T
Transmission
n Filter
2. Remmove the old trransmission oil o filter.
3. Cheeck for any dirrt or debris on n the filter gassket surface oon the filter heead.
4. App ply a film of clean
c oil to thee rubber gaskket on the new w replacementt filter.
5. Fill the new replaacement filterr with transmiission oil andd thread onto tthe filter headd.
6. Threead the replaccement filter onto
o filter heaad until the gaasket contactss the filter head gasket surrface and
thenn hand tightenn 3/4 turn.
7. Rem move the transsmission dipsstick.
8. Fill the dipstick/ffiller tube witth transmissio on oil; initiallyy add five galllons.
9. Starrt the engine annd run at idle with the transmission in nneutral to circuulate the transmission oil tthrough
o the passagees in the transmission and oil
all of o cooler.
10. Whiile the enginee is running, check
c the tran
nsmission oil llevel on the ddipstick frequently. Add oiil, as
needded, to keep the
t oil level att the FULL mark m on the diipstick.
CAUTIION: Do nott overfill the transmission
t n or operate iit with the oiil level below
w the allowab
ble mark
on the dipstick.
Operatting below th he allowable mark can caause overheatting and dam mage to the
transm
mission will reesult.
11. Conntinue runningg the engine for
f 10-15 min nutes, cycling the transmisssion through aall of the gearrs and
returning to neutrral. Re-checkk the transmisssion oil level and top it to the FULL maark on the dippstick, if
neceessary.
12. Repplace the dipsttick in the dip
pstick/filler tu
ube.

7-11
Replacing the Drive Axle and Hub Oil
THIS PROCEDURE DOES NOT APPLY TO STEER AXLES WITH WHEEL-ENDS SEPARATE FROM
THE MAIN HOUSING OR MERITOR RIGID AXLES.
1. Move the truck so that at least one of the drain/fill plugs on the hubs is in the drain (down) position.
2. Drain the oil from the hubs with the drain/fill plugs in the drain (down) position.
3. Drain the oil from the bottom of the differential housing.
4. Inspect all magnetic drain plugs for any metal shavings or chips. Wipe clean.
5. When the oil has drained completely, reinstall the drain plugs. Tighten to specified torque. Refer to
torque table Chapter 8, Service Intervals and Specifications.
6. Continue moving the truck so that at least one of the drain/fill plugs on the hubs is in the drain (down)
position. Drain the remainder of the hubs, clean and reinstall the drain plugs.
7. Remove the breather from the top of the differential housing; clean in solvent and dry with compressed
air. Reinstall the breather.

Single Drain/Fill Plug in Drain Position Single Drain/Fill Plug in “two-bolts-up” Position

8. Move the truck so that at least one of the drain/fill plugs on the hubs is in the “two-bolts-up” from
horizontal position.
9. Remove the differential fill plug from the center of the differential housing.
10. Fill the differential with fresh oil until oil begins to flow from the fill plug hole and reinstall the
differential fill plug.
11. Fill the hubs with the drain/fill plugs in the “two-bolts-up” from horizontal position until the oil starts to
flow out of the drain/fill hole and reinstall the plugs.
12. Continue moving the truck so that at least one of the drain/fill plugs on the hubs is in the “two-bolts-up”
from horizontal position. Fill the remainder of the hubs, clean and reinstall the drain plugs.
13. Wait 15 to 30 minutes for oil to seek its own level across the housing and hubs.
14. DO NOT recheck the oil level in the differential housing. The oil level will be high.
15. Recheck the hubs with the drain/fill plugs in the “two-bolts-up” from horizontal position to make sure
the oil is at the bottom of the plug threads.
16. Reinstall the drain/fill plugs and tighten to the specified torque. Refer to specifications table in Chapter
8, Service Intervals and Specifications.
CAUTION: Failure to ensure the oil level is correct can result in low oil levels and damage to the axle and
hubs. The Axletech rigid axles should hold 26-27 quarts total, each, depending on drain time.
7-12
Servicing the Hydraulic System
CAUTION: Before performing any repair or maintenance on any part of the hydraulic system, the
hydraulic pressure must be relieved.

WARNING: Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or
related items are removed or disconnected. Be alert for possible pressure when
disconnecting a device from any system that may contain fluid under pressure.

Relieve Hydraulic Pressure

Perform the steps for Relieving Hydraulic Pressure found earlier in this chapter.

Replacing the Hydraulic Return Filter

The hydraulic return filter and housing is located on the top of the hydraulic oil reservoir.
NOTE: The engine and hydraulic pump must be OFF when performing this procedure.
1. Carefully clean around filter housing cap to prevent any dirt or other debris from entering the hydraulic
system.
2. Slightly loosen (one or two turns) the four filter housing cap bolts.

Hydraulic Return Filter Cap

3. Press down and rotate the filter housing cap clockwise until the bolt heads line up with the cut- outs in
the cap.
4. Lift off the filter housing cap.
5. Remove the spring and bypass valve assembly.

7-13
 Hydraulic Spring and Bypass Valve
6. Remove the used filter and replace with the new filter.
7. Replace the spring and bypass valve assembly in the order they were removed.
8. Reinstall the filter housing cap by pressing and rotating the cap counter-clockwise until the remaining
cap bolts are in their respective flanges.
9. Tighten the cap bolts.

Replacing the Hydraulic Pressure Filter

1. Close the pump case drain valve and the pump supply valve.
2. Turn the hydraulic pressure filter housing counter-clockwise to remove.

Hydraulic Pressure Filter

3. Remove the used filter and replace with new filter.
4. Reinstall the hydraulic pressure filter housing. Tighten to specified torque. Refer to the Torque
Specifications table in Chapter 8, Service Intervals and Specifications.
5. Open the pump case drain valve and pump supply valve.
CAUTION: Operating the hydraulic pump with the pump supply valve closed will result in
serious damage to the hydraulic pump.
6. Check hydraulic oil level in the sight glasses on the side of the hydraulic oil reservoir.

7-14
Replac
cing the Hy
ydraulic Oil
Install a ¾”
¾ ID hose onto
o the hose barb
b if needed
d.

Hyydraulic Oil Reservoir

R Dra
ain Ball Valvve and Hose B
Barb
1. Placce a drain pann or pail undeer the hydraulic system draain hose or vaalve (total cappacity of the hhydraulic
systtem is slightlyy over forty gallons).
g
2. Opeen the drain ball
b valve.
3. Wh hen oil is comp pletely draineed, close the ball
b valve andd remove hosee.
4. t hydraulic reservoir filleer cap and thee area aroundd it to prevent dirt or other debris
Carrefully clean the
from
m entering thee hydraulic sy ystem.
5. Remmove the filleer cap and fill the tank with h the specifiedd amount of hhydraulic oil.
6. Repplace the fillerr cap.
7. Starrt and idle thee engine until it reaches noormal operatinng temperaturre.
8. Cheeck the oil levvel in the hydrraulic reservo oir sight glassses. When thee oil is warm, it is visible aat the
botttom edge of th he upper sighht glass.
NO
OTE: Alwayys check the hydraulic
h oil level with thee oil warm annd with the raail wheels in R
ROAD
(up) position.
p Failu
ure to do so can result in innaccurate oil level readings.

7-15
Replacing Engine Coolant
WARNING: NEVER open the radiator surge tank cap or the radiator drain cock when engine and/or
coolant are hot. Hot coolant can cause severe burns.

1. Make sure engine and cooling system are both cool.

2. Remove the coolant surge tank cap.
3. Place a drain pan large enough to contain the full contents of the cooling system under the radiator drain
cock.
4. Open the radiator drain cock and drain all used coolant.
5. Close the radiator drain cock.
6. Fill the cooling system through the radiator surge tank cap filler hole.
7. When the radiator and surge tank are nearly full, start and idle the engine.
8. While the engine is idling, watch the coolant level in the surge tank and add coolant as needed to keep
the level visible in the sight glass.

Tier 4 QSB Engine Coolant

Standard QSB and QSC Engine Coolant Tank
and Sight Glass
9. With the engine running, use the bleeder valve in the cab (rear upper wiring chase behind evaporator) to
bleed air out of the system. Turn the heater knob to HOT (6 o’clock). Using a screwdriver, slowly open
the valve screw. Use a rag to catch coolant leakage. Wait for a steady small stream of coolant to show
that no air remains in the coolant. Close valve.

10. When the level of coolant remains constant in the surge tank, stop the engine.
11. Standard QSB and QSC Engines, add coolant to the surge tank until it is approximately one inch from
the top of the tank. On Tier 4 QSB Engines, add coolant to the surge tank until it is filled to the bottom
of the fill neck.
7-16
 12. Reinstall the surgge tank cap.
13. Addd coolant to thhe coolant reccovery tank until
u the level is halfway upp the sight glaass.
14. Insttall the coolan
nt recovery taank cap.

R
Replacin
ng the Engine
E Coolant
C Filter

Cummins Engine
E Coolan
nt Filter

CAUTIION: Do nott remove the pressure capp from a hot engine. Waitt until the cooolant temperature is
below 50°C
5 [120°F]] before removing the preessure cap. H
Heated coolaant spray or ssteam
can cau
use personal injury.
1. Turn n the shutoff valves to the OFF position n.
2. Wippe the outside of the filter head
h and filteer to prevent ddirt or other ddebris from geetting into thee engine
wheen replacing th he filter. Unsccrew the filter and removee from the filtter head.
3. Appply a thin film
m of lubricatin ng oil to the gasket sealing surface beforre installing tthe new coolaant filter.
4. Instaall the coolan
nt filter on thee filter head. Tighten
T the fi lter until the ggasket contaccts the filter hhead
surfface.
CAUTIION: Mecha
anical over-tightening can
n distort the tthreads or d
damage the fiilter head.
5. Tigh
hten the coolaant filter an ad
dditional 1/2 to 3/4 of a turrn, or as speccified by the ffilter manufaccturer.
6. Retu
urn the shutofff valves to th
he ON positio on.
CAUTIION: The coolant shutofff valves MUS
ST be turned ON after filtter replacem
ment to preven
nt
engine damage.

7. Starrt engine and check coolan

nt level.

P
Pre-Cha
arging th
he Hydra
aulic Accumulattor
F
For pre-charging the hydraaulic accumulator, refer to manufacturerr’s instructionns on the DVD
D manual inccluded
w
with your veh
hicle.
CAUTION: The accumu ulator contaiins nitrogen gas under hiigh pressure.. Failure to rrelease pressu
ure
correctly may
m result in injury.
i

WARNING: NEVER usse oxygen or shop air. Th

his is extremeely dangerou
us.

7-17
When performing service or maintenance on the hydraulic accumulator, it is important to follow these
precautions:
 Release hydraulic pressure before attempting any maintenance or service.
 Pre-charge with DRY NITROGEN (N2) GAS ONLY!
 Never operate accumulator without nitrogen gas pre-charge.
 Use only approved charging and gauging equipment for pre-charging and pressure check.
 Wear proper eye protection.
 Wear steel toed shoes.
 Take proper safety precautions.

Lubricating and Greasing

This section contains lubrication procedures for the following:
 Coupler slides
 Rail wheel flange lubricators
 Rail wheels
 Rail wheel spindles
 Routine lubrications
 Rail unit cylinder bushings and rail arm bushings
 Drive shaft slip yokes
 Drive shaft u-joints

Coupler Slides
The coupler slides must be lubricated weekly (forty hours of operation), or more often if needed.
Indications that lubrication is needed:
 If the coupler slide movement is jerky or stiff, more frequent lubrication is necessary.
 If the grease on the slide is contaminated with dirt, grit, or other foreign matter.
Approximately once a month, or as needed:
1. Slide the coupler fully to one side.
2. Scrape off the old accumulated grease with a plastic scraper.
3. Slide the coupler fully to the other side and scrape off the remaining accumulated grease.
4. Manually apply a light coat of grease to the front, back, top, and bottom sides of the coupler slide.
5. With the coupler fully to one side, inject 2-3 shots of grease in both fittings.
6. Move the coupler to the center; inject 2-3 shots of grease in both fittings.
7. Move the coupler fully to the other side and repeat the greasing.
8. Move the coupler from one side to the other several times to distribute the grease evenly over the
surfaces.

7-18
L
Lubricatting Rail Wheel Bearing
g
T
This procedurre covers:
 Removing th he rail wheel bearings
b
 Inspecting thhe bearings annd races
 Re-packing the
t wheel beaarings
 Re-installingg the rail wheeel

Remov
ving the Ra
ail Wheel Bearings
B
CAUTIION: Be suree the hydrau
ulic pressure is relieved b efore attemp
pting to disasssemble rail w
wheel
components. Failurre to do so may
m result in sserious injurry.

1. Raise rail wheelss to the road (UP)

( position
n.
2. Sup
pport the rail wheel
w assemb blies with app
propriate bloccks or stands tto provide cleearance to rem
move
wheeels.
WARNING:
W Use
U a hoist with
w a sling orr other approopriate meth hod of supporting and rettaining
the
t rail wheeel before rem
moving the beearing retainiing hardwarre. Failure too do so
may
m cause peersonal injurry and equipm ment damagge.

3. Sup
pport the rail wheel
w securelly while remo
oving the bearring retainingg hardware annd bearing whhile it is
bein
ng slid off thee spindle.

Example of a Rail Wheell Support

4. Remmove the rail wheel hubcap p retaining bo
olts.
5. Remmove the hubccap and rubbeer gasket seall assembly.
6. Release the tang on bearing reetainer lock washer
w from thhe bearing rettainer nut slot.
7. Remmove the outeer bearing retaainer nut with
h the tool suppplied in unit ttool kit.
8. Remmove bearing retainer lock k washer.
9. Remmove inner beearing retaineer nut with thee tool suppliedd in unit tool kit.
10. Remmove bearing retainer flat washer.
w
11. Remmove outer beearing from raail wheel asseembly.
12. Slid
de rail wheel off
o the spindlle.
13. Remmove inner sppindle seal fro
om rail wheel assembly.
14. Clean and inspecct rail wheel bearings.
b
OTE: Replaace the rail wh
NO heel bearings if scored or ddamaged.
15. Clean and inspecct bearing cup
ps.

7-19
 NOTE: Replace the bearing cup/race if scored or damaged.

Re-Assembling the Rail Wheel Bearings

1. Re-pack the inner rail bearing, or pack a new replacement bearing.
2. Install the inner bearing in the inner bearing race.
3. Install the inner spindle seal. Seat it flush with the inner face of the rail wheel hub.
CAUTION: Make sure not to damage the inner spindle seal when performing the next step.

4. Support the rail wheel securely and carefully slide it directly onto the spindle.

Rail Wheel Lined Up with Spindle Rail Wheel Installed on Spindle

5. Re-pack the outer bearing or pack a new replacement bearing.
6. Install the outer bearing on spindle in the outer bearing race.
7. Install the bearing retainer flat washer.
8. Install the bearing retainer nut with the bevel facing out.

Flat Washer and Bearing Retaining Nut

9. Torque the inner bearing retainer nut to 100 ft./lbs.
10. Spin the rail wheel several revolutions in each direction.
11. Loosen the bearing retainer nut and re-torque to 50 ft./lbs.
12. Spin the rail wheel several revolutions in each direction and torque again to 50 ft./lbs.
13. Install the bearing retainer lock washer with the lock tangs facing outward.

7-20
 Tanged Lock Washer with Outer Retaining Nut

14. Install the second bearing retainer nut with the bevel toward the bearing retainer lock washer and torque
to 35-45 ft/lbs. to hold bearing retainer lock washer against bearing retainer nut.
15. Bend a tang on the lock washer into one of the notches on the second bearing retainer nut. If none of the
notches and tangs match up, tighten the retainer slightly until one tang and notch line up.
CAUTION: When lining up the notch and tang, DO NOT tighten the second bearing retainer
nut tighter than 45 ft./lbs. If necessary, loosen and re-torque to 35-45 ft./lbs. to get
the tang and notch to line up.

16. Add a layer of grease over the bearing, retainers, and nuts before installing hub cap.
17. Re-install the hubcap and rubber gasket seal assembly with the retaining bolts. Torque the bolts to
correct specification (see the Torque Specification table in Chapter 8, Service Intervals and
Specifications).

Replacing the Rail Wheel Spindle

Before performing this procedure, remove the rail wheel from the spindle.
1. Remove the rail wheel. Refer to the steps for Removing the Rail Wheel Bearing above.
2. Remove all eight bolts from the rail wheel spindle.
3. Screw two 5/16-18 x 1” bolts into the jacking holes on the spindle. Tighten alternately to force the
spindle out of its seat in the rail arm.
4. Clean all old thread locker and debris from the holes in the rail arm before installing new rail wheel
spindle.
5. Position new rail wheel spindle with keeper slot along the neutral axis.
CAUTION: When replacing rail wheel spindles, new bolts MUST be used. Re-torqueing used bolts may
cause bolt failure and major equipment damage.
6. Use eight new 1/2-13 x 2-1/4” grade 8 bolts when installing the new spindle.
7. Torque the bolts to 80 ft./lbs.
CAUTION: Use Loctite 271 or equivalent on the threads or major equipment damage can occur.

Use the encoder arm spindle for the left front spindle and the non-encoder arm spindles for the other three
spindles. To locate the correct part number, refer to the Shuttlewagon Parts book on the DVD supplied with
your Shuttlewagon or on the Shuttlewagon website at http://panel.shuttlewagon.com

7-21
Routine Lubrications
Listed below are three areas in the Shuttlewagon that should be routinely lubricated. When lubricating these areas
apply approximately two shots of grease in each fitting. Applying more grease only pushes the grease out of the
bushing or bearing and does not provide any additional benefit. For more information on lubrication see Chapter
8, Service Intervals and Specifications.
 Front/Rear Coupler Slides - 3 top/3 bottom
 Drive shaft slip yokes
 Drive shaft u-joints

Tests, Adjustments, and Settings

This section contains procedures for:
 Checking the rail wheel gauge
 Adjusting the hydraulic system pressure
 Aligning and installing the steering cylinder
 Servicing the battery
 Servicing the air conditioning
 Welding procedures

7-22
C
Checkin
ng the Ra
ail Whee
el Gauge
e
T
The rail gaugee on both fron
nt and rear raiil units is 53”” to 53-3/16” m
measured from inside the fflange on onee rail
w
wheel to insid
de the flange on
o the opposite rail wheel.

53” to 53-3/16”

Measurin
ng the Rail G
Gauge

A
Adjustin
ng the Hydraulic
c System
m Pressures
Setting
g System Pressures
P
1. Plug a 0-3,000 0 PSI gauge to
o the system pressure
p test pport (PTP). Thhe PTP port hhas a quick dissconnect
fiitting and is lo
ocated on the reservoir sidee of the maniifold, lower leeft, under the mounting braacket.

Pressure Test
T Port (PTP
P) on Main H
Hydraulic Maanifold

2. Sttart the engin

ne and warm the o temperaturre to between 100° & 140°° F.
t hydraulic oil
NOTE: Be sure the rail wheels are
a in the fully
y raised positi
tion.
7-23
NOTE: Before adjustment can be made, loosen the jam nuts on the adjusting screws. At the final setting,
hold the adjustment screw in place while tightening the jam nuts.
3. Set the hydraulic pump standby pressure by using the lower adjusting screw that is located on the
hydraulic pump. Adjust the screw to 450 PSI on the installed gage.
4. Access the R/R screen and select TRANSFER mode.
On the right side of the screen, push the REAR RAIL WHEELS UP button and hold while adjusting
the relief valve and maximum pressure settings (steps four AND five)
Loosen the jam nut on the upper adjustment screw and turn the screw clockwise to increase pressure.
Pressure should not go higher than 2850 PSI + 30 psi.
If relief valve is out of range, lower the pressure by turning the upper adjustment screw out and
releasing the rear rail wheels UP button.
Adjust the main system pressure relief (clockwise to increase, counterclockwise to decrease).
Push and hold rail wheels UP button and increase pressure using the upper adjustment screw to test
relief pressure.
Repeat if needed.
When main system pressure relief is set, proceed to step five.
5. Using the upper adjusting screw, adjust the maximum pump pressure to 2600 PSI. Hold the adjusting
screw while tightening the jam nut.

Hydraulic Pump Pressure Adjusting Screw

7-24
 Steeering
Reliief Valve

Mainn Pressure
Relieef Valve

Relief
R Pressu
ure Adjustmen
nt Screws
6. Setting the steeering relief prressure:
a. Turn th he steering wheel
w completeely in either ddirection untill it hits the stoop. Apply connstant
pressu
ure on the steeering wheel to hold it in possition.
b. Adjustt the steering relief pressuree adjusting sccrew to 2200 PSI.

A
Aligning
g Steerin
ng (Na
avigator Only)
S
Steering
g System
m
TThe steering system
s on the Shuttlewago on consists of pivoting axlees on both thee front and thee rear of the vvehicle.
ng relative to a rigidly mou
IInstead of the wheels turnin unted axle, thhe axles themselves pivot.

Steerin
ng on the Road
R
When thee steering whheel is turned one
o direction, the front axlle pivots in thhat direction w
while the rearr axle
pivots in the opposite direction. Thhis allows for much a smalller turning cirrcle than wouuld be possiblle with
steering on
o one end allone.
There is also the capabbility of disab
bling steering
g on either axlle. This is useeful when mounting the veehicle on
the rails.

Steerin
ng on the Rail
R
Once thee vehicle is mo
ounted on thee rails and is in
i RAIL modde, steering inpput is disableed. The axles are
allowed to
t float and pivot as guided
d by the rail wheels.
w This aallows operattion on tighterr curves than a fixed
axle.

7-25
Synchronizing the Steering (Navigator Only)
The wheels on the Shuttlewagon railcar mover do not get out of alignment as it is usually understood, since the
wheels are fixed on the ends of the axles. What happens instead, is that the front and rear rotating axles get out of
synchronization with each other. This applies only to ROAD operation.
Some possible causes of the axles becoming unsynchronized are:
 When dismounting from the rails, the axles may be pivoted due to a curve in the rail.
 When disabling the steering on one axle and using the other to steer may result in the axles getting
out of line with each other.
 Small inaccuracies or leakage in the hydraulic steering system may contribute to this condition.
To synchronize the axles: With the engine running, on the HOME screen, observe the relative position of each
axle.

Steering Screen
This screen is used to see the position of the front and rear axles. The front and rear steering position
indicators will display an orange center line whenever the front or rear axle’s wheels are not aligned with the
wheels straight ahead. The center line will be blue when the axle is straight.
This screen shows the position of front and rear axles.

Center
Alignment

FRONT REAR
Steer Steer
Lock Lock

Steering Screen
To align steering:
1. Push the REAR steer lock button and make sure a lock icon appears over the rear axle on the screen
2. Using the indicator on the screen, center the front steering axle. When the axle wheels are aligned with the
body of the vehicle, the center line will turn from orange to blue. Stop turning the steering wheel at this point.
3. Push the FRONT steer lock button and make sure a lock icon appears over the front axle on the screen
4. Using the indicator on the screen, center the rear steering axle. When the axle wheels are aligned with the body
of the vehicle, the center line will turn from orange to blue. Stop turning the steering wheel at this point.
5. Push the FRONT steer lock button again and make sure the lock is no longer on either axle. Steering is now
synchronized.

7-26
S
Servicin
ng the Ba
attery
TThe Shuttlewaagon is equipped with speccial Absorbed d Glass Mat (AAGM) deep ccycle batteries in order to hhandle
tthe power req
quirements of the remote coontrol start/sto
op feature. W
When using thee remote conttrol system too shut
ddown the Shuuttlewagon, so
ome of the eleectronic contrrols must rem ain powered on to allow reemote restartiing.
CAUTION: Do not use the
t remote co ontrol start/sstop feature ffor extended shutdown peeriods. The b
battery
voltage may
y drop too low
w to restart the
t engine.

TThe AGM deeep cycle batteeries offer sup perior performmance comparred to a standdard lead-acidd battery. Repplace the
AAGM battery with the sam me AGM type battery that iss installed in the Shuttlewaagon. A standdard lead-acidd battery
mmay lack eitheer the deep cy
ycle capabilityy or the crank
king amps reqquired for thiss application and may fail
pprematurely.
 These batteriies are sealed and do NOT require the adddition of waater or acid.
 Do not remov ve any labels or open the battery
b case.
 Do not exposse to diesel fu uel.
 If charging iss required from m a source otther than the eengine alternaator, do not exxceed 15 voltts.
 Check the vo oltage if using
g a battery chaarger.

Discon
nnecting th
he Battery for
f Service
e
The Shutttlewagon is equipped
e with
h a battery dissconnect swittch inside the battery box. This switch hhas been
provided
d to prevent reemote starting
g while serviccing the Shutttlewagon.
CAUTIION: Never disconnect
d th
he batteries while
w the enggine is runnin
ng. Always tuurn the ignitiion
switch off first. Oth
herwise, dam
mage to the eleectronic conttrols may ressult.

Battery Disconnect
D Sw
witch

7-27
Servicing the Air Conditioning
WARNING: NEVER connect refrigerant can/tank to HIGH side! Can or tank may explode and cause
personal injury.

NOTE: Always go by the pressure gauge reading when charging the A/C system, not by weight of refrigerant.
The air conditioning system installed on the Shuttlewagon is a typical automotive A/C system. The refrigerant
used is R-134a and the system is serviced using automotive air conditioning procedures and equipment.
1. Completely evacuate the system using a vacuum pump.
2. Charge the system with R-134a refrigerant (approximately three to four pounds) until you reach the
pressure and temperature readings in the following table.
3. If oil was evacuated, replace with 8 oz. of PAG 100 oil. If the compressor is replaced (pre-charged with
oil), add an additional 2 oz. of oil for a system total of 8 oz.
NOTE: Rule of thumb for high side pressure is ambient temperature (F) + 100 = High Side Pressure
Low Side  Evaporator High Side Ambient Temperature
Reading  Temperature  Readings  (Fahrenheit) 
(P (F h h (P
16-29 33-50 115-200 70-80

19-39 33-60 140-235 80-90

25-43 40-65 165-270 90-100

37-51 48-65 210-310 100-110

NOTE: Follow all applicable local, state, or federal laws that apply to the handling and recycling of air
conditioning refrigerants.

A/C High and Low Side Connections

7-28
W
Weldin
ng Proc
cedure
es
PProper weldinng proceduress are required in order to av
void damage to the enginee’s ECM, senssors, and otheer
eelectronic com
mponents.
WARNING: ALWAYS disconnect batteries
b befo
ore welding oon the Shuttllewagon.
RRemove the assembly
a from
m the machinee that is to be welded. If thhe assembly caannot be removed, the folllowing
pprocedure muust be followed when weldiing on a mach hine equippedd with electroonic componeents. This proccedure is
cconsidered thee safest methood and should
d provide min nimal risk of eelectronic com
mponent dam mage.
TTo weld:
1. Disconnect the neegative (-) batttery cable(s) and open the battery discoonnect switch..
2. Disconnect all con nnectors from
m ALL electro onic devices, iincluding, butt not limited tto:
 Engine Contrrol Unit (ECM M)
 Transmission n Control Unitt (TCU)
 Vehicle Conttroller(s) (ESX X)
 Operator Pan nel (OPUS)
 Radio Remotte Controller (ESXR)
(
 Radio Remotte Receiver
 Shuttle Trak Transmitter
 Tire Pressuree Monitoring System Receeiver
6. Disconnect any ex xternal groundd straps from electronic coomponents.
NOTE: Never placee welder grou mponents.
und cables on electronic com
7. Placee welder grou
und cables as close as possiible to assembbly being wellded (no moree than two feeet).
CAUTIION: Improp
per groundinng can cause damage to b
bearings, hyd
draulic compoonents, electrrical
components, and otther equipmeent.

7-29
 Factory Settings and Troubleshooting
Enter Password Screen (Authorized Personnel)
After selecting Factory Settings on the Diagnostics/Settings menu you will be asked for a password. Use
the knob to enter your password. Then press the knob to verify.

Enter password screen

7-30
Factory Settings Selection Screen (Authorized Personnel)
Use this screen to select which type of system settings you wish to configure.  
 
WARNING Do not press SET DEFAULTS unless instructed to do so
 Set Defaults - DO NOT select this setting unless directed to do so by a factory service
representative. This resets ALL configurable settings to the generic factory
values!
 Calibration
 Options
 Settings
 Change Password
 Reset Safety Control
 Throttle Settings
 Status and Error Message Banner

 
Factory Settings Selection screen 

WARNING: NEVER SELECT “Set Defaults” unless instructed to by a qualified Shuttlewagon service
technician.
This option erases any customized configuration settings made for this vehicle type and the
individual vehicle.
 Calibrations – The factory calibrations screens.
 Options - Opens the factory options screen which allows enabling and disabling installed optional
equipment and systems.
 Settings - Opens the settings screen.
 Change Password - Opens the change password screen where you can enter and save a new
password.
 Reset Safety Control - Opens the reset safety control screen.
 Throttle Settings - Opens the throttle ramping set screen, allowing you to adjust the throttle
response rate to throttle lever input.

7-31
Calibration Screens
There are many sensors and output devices present on the machine, some of which may require periodic
calibration or need to be calibrated when they are replaced. This section will explain the terminology
used on the calibration screens and how to calibrate the sensors that may require calibration.

Pressure transducers, steering transducers and fuel level sensors should not require calibration. They are
engineered to specific specifications that should not need adjustment.

Train brake, hand throttle and foot throttles may need to be calibrated periodically and will need to be
calibrated if replaced. The following procedure walks through this process using the train brake
potentiometer as an example.

Train Brake Calibration Screen

Min CTS – Minimum Counts Min EU – Minimum Engineering Units
Max CTS – Maximum Counts Max EU – Maximum Engineering Units
Input – Actual Counts

One of the settings will be outlined in yellow. Rotate the knob (both directions) to move to a different
setting. Push the knob on the chosen setting to change the outline to green and rotate the knob to change
the setting. Push the knob again to change the outline back to yellow.

Move the Train Brake control handle from release to apply, and back, several times and note minimum
and maximum INPUT values. Set the MIN CTS and MAX CTS to match the minimum and maximum
INPUT values. Press the SAVE button before moving to the next screen.

Set the MIN EU to 1950 and MAX EU to 3900 and press SAVE. This will normally produce a range of 45 to
90psi train brake pressure.

If the train brake pressure settings are not suitable, MIN EU and MAX EU can be adjusted to change the 45psi
apply and 90psi release settings respectively. Press SAVE and the train brake pressure will change accordingly.

Press the SAVE button to save the current settings, or before exiting or moving to the next screen if changes have
been made.

7-32
Options Screen

 Emergency Stop - Enables and disables the exterior emergency stop buttons (if equipped).
 Switchman Control - Enables and disables the switchman control system (if equipped).
 Remote Control - Enables and disables the remote control system (if equipped).
 Dual Straight Ahead – Not used
 Tier 4 Engine – The Tier 4 engine is available in some areas of the country requiring that engine.
 Test Mode – Not used
 Auto Rail Pressure – Enables automatic rail pressure based on the speed of the machine in rail
mode.. When off, rail pressure will remain at the same level regardless of speed.

7-33
Settings Screen

Settings Screen
 ABS/ATC - Toggle ON and OFF the Anti-Lock Brakes and Automatic Traction Control function.
 Straight Ahead Interlock – Toggle ON and OFF to set or remove straight ahead interlock function.
 STD ATC Setting - Set the standard parameter for the automatic traction control.
 ATC ICE Setting - Set the ice parameter for the automatic traction control.
 Model - Displays the model number of the Shuttlewagon.
 Engine – Displays the engine used on the machine. Contact factory for identifying which number
corresponds to which engine.
 Transmission - Displays the transmission used on the machine. Contact factory for identifying
which number corresponds to which engine.

7-34
Change Password Screen
• Use the knob to set the new password. 
• Click SAVE to save the new password. 

Change password screen 
 
 

Reset Safety Control (RSC) Screen

This screen allows the operator to enable and disable RSC Option.

 RSC OPTION – Set to ON/OFF

 CYCLE TIME – Sets the amount of time to push reset switch.
 WARNING TIME – Sets the amount of time to sound if switch is not depressed & e-stop is applied
NOTE: The SAVE button saves changes made to the screens.

7-35
Throttle Ramping Screen
The throttle ramping settings control how fast the engine responds to the throttle control
inputs either from the console panel lever or the throttle pedal on the floor.

 Throttle Ramping - Toggles between the normal programmed ramping rate and a custom ramping
rate set using the controls in this screen.
 Minimum Value – Adjust the minimum value; if necessary. The factory default is 9.
 Ramping Rate - Adjust the ramping rate; if necessary. The factory default is 9.

7-36
Diagnostic Codes
Refer to Vendor Manuals provided on the DVD for Diagnostic Codes and
Troubleshooting for the following:
Funk DF250 Transmission
ZF 3WG210 Transmission
Cummins QSB 6.7 Tier 3 Engines
Cummins QSB 6.7 Tier 4 Engines
Cummins QSC 8.3 Tier 3 Engines
Cummins QSC 8.3 Tier 4 Engines

7-37
C
Chaptter 8
S
Serv
vice Inter
I rvalss and
d
S
Spec
cifica
ation
ns
TThis chapter describes
d the scheduled maaintenance reqquired for youur Shuttlewaggon. To assurre proper perfformance
aand long life, it is imperativ
ve that schedu
uled maintenaance be comppleted at the ddesignated inttervals. For m
more
information on scheduled maintenance,
m contact the Shuttlewagon
S Service Depaartment to speeak to a service
rrepresentativee.

S
Service Interrvals
TThe following
g table contain
ns required maintenance
m in mmins engine recommends servicing thee engine
ntervals. Cum
eevery 500 hou
urs or every 6 months, whiichever comess first.
N
NOTE: Use a funnel and slowly add liiquids. Whilee adding, checck fluid levelss periodicallyy as not to oveerfill.

Preventive Main
ntenance
e Intervals: Month
hly / Hourly 
6 moonth 12 mon nth 18 month  24 month
‐o
or‐ ‐or‐ ‐or‐  ‐or‐
      50 HRS 
5 500  HRS  1000 HRS  1500 HRS  2000 HRS
Oil      X
X    X   X    X  
Oil Filter      X
X   X  X    X  
Fuel Filtter: Primary      X
X    X   X    X  
Fuel Filter:: Secondary      X
X    X   X    X  
En
ngine 
Coolant Filter (QSC Only)     X
X   X  X   X 
Coolant         X 
Air Filtter: Primary              X  
Air Filter:: Secondary              X  
Oil   X      X      X  
Transsmission 
Filter   X    X
X    X   X    X  
Oil              X  
Breather    X   X 
Hyd
draulic 
Filterr (Pressure)      X
X    X   X    X  
Filtter (Return)      X
X    X   X    X  
Air Drye
er Desiccant              X  
Air Filtration  Cab Filter*        X      X  
Train Brake Relay Filter        X 
Axles 
A Axle & Pllanetary Oil           X  
Grease   X    X
X    X   X    X  
*The cab in
nterior air filter may
m be washed and
a reused. The exterior fresh aiir filter is of papper media and muust be replaced.

8-1
Specifications
Lubrication and Fluid Specifications
Component/Fluid Lubricant/Fluid Grade/ Capacity
-Manufacture/Model Specification Temperature Range
Engine Oil API CF4, CH4, CI4 SAE 15/40W 4.8 gal
Cummins Engine QSC / QSB All Seasons

Transmission Fluid HY-GARD JDM J20C 9.5 gal

ZF and DF -10° F to + 122° F
ZF and DF HY-GARD JDM J20D 9.5 gal
-40° F to + 68° F

Vehicle Brake System DOT 3 Brake Fluid SAE J1703 1 quart

All brake systems All Seasons

Radiator/Cooling System 50% Water / 50% Ethylene ASTM D 6210 9.0 gal
Glycol Anti-Freeze REF: Zerex (Red)
(Must meet Cummins 14603 Requirement)
Extended Life HD Fully-
Formulated

Drive Axle Oil API Class GL-5 SAE 85/140 7.0 gal
Axle Tech and Meritor Above +32 F (0 C)
Axle Tech and Meritor API Class GL-5 SAE 75/140 7.0 gal
Below +32 F (0 C)

Grease Points (without Single Point or Multi-purpose Lithium NLGI No. 1 As

Automatic Lube Option) All Seasons Needed
Rail Cylinder Bushings - 16
Rail Arms Bushings -8
Drive Axle Oscillation Pins - 4
Rail Axle Oscillation Pins - 4
Drive Shaft Slip Joints -2
Drive Shaft U-Joints -6
Front/Rear Rotation Bearings - 8
Front/Rear Coupler Slides - 3 top/3 bottom

Hydraulic System See Hydraulic Oil See Hydraulic Oil 42 gal

All hydraulic systems Recommendations Recommendations

Air Conditioning Refrigerant R-134a All seasons 3-4 lbs.

Oil (system total) PAG 100 8 oz.

Diesel Fuel Reservoir No 2 Ultra-Low Sulfur All Seasons 90 gal

8-2
Transmission Oil (Funk Transmission Recommendations)
The Funk Transmission Company recommends that the normal operating oil temperature be between 100°-200°F.
The following table contains the oil type and minimum operating temperature.
Oil Type Minimum Operating Temperature
Standard JDM J20C oil -10°F
Low viscosity JDM J20D oil -40°F

Hydraulic Oil Recommendations

Standard Viscosity oil
J20C
-3°F Minimum Cold Start Temperature
+106°F Minimum Operating Temperature
+170°F Maximum Operating Temperature
+205°F Maximum Short Term Temperature
Low Viscosity oil
J20D
-34°F Minimum Cold Start Temperature
+86°F Minimum Operating Temperature
+140°F Maximum Operating Temperature
+178°F Maximum Short Term Temperature

Accumulator Pressure Specifications

Pre-charge PSI Test Port
Low accumulator PSI on message bar 1600 ATP (main hydraulic manifold)
warning will go off at:
Full Charge 2350 ATP (main hydraulic manifold)
Recharge 1700 ATP (main hydraulic manifold)
Nitrogen Pre-charge Specification PSI Testing Parameters
CAUTION: Relieve hydraulic pressure and shut engine off prior to testing/charging.
Pre-charge @ 30 degrees F 400 Fill valve on top of accumulator
Pre-charge @ 70 degrees F 435 Fill valve on top of accumulator
Pre-charge @ 100 degrees F 460 Fill valve on top of accumulator

Tire Specifications
NOTE: Tire air pressure for non-original equipment tires should follow the tire manufacturer's specifications.

Original Equipment Tire PSI

Michelin 14.00 R 24 XKA 130
Bridgestone 14.00 R 24 VCH 130

8-3
Torque Specifications
Component Model Item or Fastener Torque
Engine Cummins OSB Oil filter Hand tighten ¾ turn after gasket contact
Cummins QSC
Oil drain plug Steel oil pan
M18 Metric Thread 44 ft./lb.
M22 Metric Thread 59 ft./lb.

Cast aluminum oil pan

M22 Metric Thread 44 ft./lb.

Drive Axles All Series Oil drain plugs 35 ft./lb.

Rail Wheel All Series Rail wheel retainer 100 ft./lb. to seat bearings
Assembly nut (Inner) 50 ft./lb. final torque
Rail wheel second 35-45 ft./lb.
retainer nut (outer)

Rail Wheel Spindle Spindle to rail arm 80 ft./lb. (Loctite 721)

mounting bolts

Hydraulic System All Series Pump compensator 7 ± 1 ft./lb.

pressure adjusting
screw locknut. NOTE: Reinstall protective cap

Pressure filter Hand tighten ¾ turn after gasket contact

Transmission Funk DF150/250 Oil filter Hand tighten ¾ turn after gasket contact
ZF 160/210

Vehicle Brake All series Cylinder cap 75 ft./lbs.

System
End plate bolts 165-210 ft./lbs.
Use Loctite 271 or equivalent on bolt
threads.
Bleeder screws 100-120 in./lbs.

Drive Wheels All Series Drive Wheel 475 ft./lbs.

lug nuts

8-4
C
Chaptter 9
G
Glos
ssary
y
Term Description
D
Air Brake Hose
H The
T flexible co
onnection bettween the braake pipes of cars and railcaar movers.
Air Compre
essor A power driveen air pump which
w suppliess compressedd air pressure for the operattion of
th
he railcar air brakes.
b
Air Gauge The
T instrumen
nt which indiccates the amouunt of air preessure in the reservoirs or bbrake
(Air Brake) pipe.
p
AAR Association
A off American Railroads
R
Brake Cylin
nder Cylinder
C contaaining a piston which is foorced outwardd by compresssed air to apply the
raailcar brakes. When air preessure is releaased it returnss to its normaal position by a
reeleasing sprin
ng coiled arouund the pistonn rod inside thhe cylinder.
Brake Shafft A shaft on whhich the chain is wound andd by which thhe power of a hand brake iss applied
(Hand Brak
ke) to
o the wheels.
Brake Wheel An
A iron wheell attached to the
t upper endd of the brake shaft which iis manually tuurned to
apply
a the railccar brakes.
Consist The
T make-up of
o a freight trrain by types oof cars and thheir contents.
Coupler An
A appliance for
f connectin
ng cars togetheer. Governmeent regulationns require thatt these
devices
d must couple
c autom
matically by im
mpact and muust be uncouplled without ggoing
between
b railcaars.
Knuckle Lo
ock The
T block thatt drops into position when the knuckle ccloses and hoolds it in placee,
preventing
p unccoupling.
Coupler Lo
ock Lift The
T part of thee mechanism rod, which inn moving liftss the knuckle lock so the kknuckle
de the couplerr head which is moved by tthe uncouplinng.
can open insid
DPF Diesel
D Particu
ulate Filter – filter
f on the T
Tier 4 engines equipped witth electronic eemission
controls.
Emergency y A quick reducction of brake pipe pressuree made when a consist muust be stoppedd in the
Application
n minimum
m distance possiblee. An emergenncy applicatioon may also ooccur when a brake
pipe
p connectio on is broken, or when brakke pipe hose cconnections between railcaars are
disconnected.
d
Emergency
y Brake The
T valve for applying the train brakes iin an emergenncy. It is connnected to the bbrake
Valve pipe
p by a bran nch pipe and operated
o by reeleasing the bbrake pipe air pressure intoo the
atmosphere.
a
Emergency y A part of the air
a brake systeem that provi des quick reccharge, graduaate release, annd high
Reservoir emergency cyllinder pressurre.
Flagman The
T brakeman
n assigned to duties
d at the rrear end of the train.
Flat Wheel A railcar wheeel that has flatt spots on thee tread of the w
wheel, usuallly from slidinng the rail
wheel
w and not releasing thee hand brake.
Full Service
e An
A application
n of the brakees resulting frrom a reductioon in brake piipe pressure aat a

9-1
Term Description
Application service rate until maximum brake cylinder pressure is developed.
Gage of Track The distance between the heads of the rails, measured at a point 5/8 inch below the top
of the rails. Standard gage is 56 and 1/2 inches.
Glad hand The metal attachments to which the train line air hoses connect.
Gradient (Brake The difference in brake pipe pressure between the front and rear of the train. It is the
Pipe) direct result of leakage or train line obstruction.
Ground man/ The ground man is the person in charge of all movement on the rail. He is also
Ground Person responsible for rail switches, derails, chocks, and switch positions.
Hand Brake The brake apparatus used to manually apply the brakes on a railcar.
Knuckle The pivoting hook like casting that fits into the head of a coupler and rotates around a
vertical pin to either the open position or closed position.
Knuckle Pin The pin holding the knuckle in the jaws of the coupler.
Load Limit The maximum load in pounds which the car is designed to carry.
Main Reservoir A tank on the railcar mover for storing the main air supply for charging air to the
(Air Brake) railcars for movement.
Narrow Gage When the distance between the heads of the rails is less than 56 and 1/2 inches.
On the Ground On the ties, not on the rails, as a derailed train.
Pivot Pin (Coupler) Another name for knuckle pin. It is called this because the knuckle, when opening,
swings about the pin as a pivot.
Power Switch A remote-controlled switch.
Pull the Pin Uncouple a car or cars by pulling up on the uncoupling lever.
Rail A length of track, usually 39 feet long.
Reduced Speed A speed that will permit stopping short of a train or obstruction.
Release Rod A small iron rod generally located at the side of a car for the purpose of operating the
air brake release valve.
Release Valve (Air A valve attached to the auxiliary reservoir for reducing the air pressure when the railcar
Brake) mover is detached as to release the air brakes.
Restricted Speed A speed that will permit stopping safely, watching for obstructions, switches not
properly lined or broken rail.
Sanders Devices operated by air for applying sand to the rail in front of or behind the drive tires.
Service A reduction of air pressure in the brake pipe at a rate that will produce an application of
Application the train brakes and a gradual speed reduction.
String Two or more railcars coupled together.
Switch A connection between two lines of track to permit railcars to pass from one track to
another.
Switch lock A fastener used to secure the switch or derail stand in place.
Switch Stand A device/location where a switch is thrown, locked, and its position indicated.
Switching To move railcars from one place to another within a defined territory.

9-2
Term Description
Track The space between the rails and space of not less than four feet outside of each rail.
Truck A term for the complete wheeled railcar assembly which supports the car body at the
end.
Wheel Flange The projecting edge or rim on the circumference of a car wheel to keep it on the rail.

9-3
C
Chaptter 10
D
Daily
y Ins
spection
B
Before operating the Shuttllewagon perfo
form a daily in
nspection usinng the Daily IInspection Chhecklist.
N
NOTE: Only
y operate the machine if yo
ou have been
n trained and ccertified to opperate it.

T
This section contains
c a Daiily Inspection
n Checklist that should be ccopied and ussed for daily iinspections.
P
Performing daaily inspection
ns is a requireement and an
n important paart of maintainning the Shutttlewagon.

IIn the area pro

ovided on thee Daily Inspecction Checklisst, make note of any problems found annd report them
m
immediately.

10-1
 Navigator Series Daily Inspection
Equipment ID #              DATE       
Employee ID #              SHIFT       
Engine Hour Meter Reading       

ITEM #  Location  Engine ON / OFF  DESCRIPTION  Yes  No 

1  Ground  Off  Tire Inflation / Condition (4)       
2  Ground  Off  Lug Nuts (12 ea. Wheel)       
3  Ground  Off  Drain Air Tanks (3 points)       
4  Ground  Off  Train Brake Lines & Seals (2)    
5  Ground  Off  Train Brake Ball Valve Closed (2)       
6  Ground  Off  Lubricate Coupler Slide Base (2)       
7  Ground  Off  Lubricate Coupler Knuckle (2)       
8  Ground  Off  Filled & Functional Sander Boxes (4)       
9  Ground  Off  Wheel Flange Lubricators (8)       
10  Ground  Off  Condition of Batteries & Cables       
11  Ground  Off  Headlights & Brake Lights (4)       
12  Ground  Off  Work Lights & Strobe Lights (2)       
13  Ground  Off  Brake Fluid Level       
14  Platform  Off  Engine Oil Level       
15  Platform  Off  Engine Coolant Level       
16  Platform  Off  Hydraulic Fluid Level       
17  Platform  Off  Windshield Washer Fluid Level       
18  Platform  Off  Radiator Hose Conditions       
19  Platform  Off  Air Cleaner Indicator       
20  Platform  On  Transmission Fluid Level    
21  Platform  Off  Drive Belt Conditions       
22  Cab  On  Seat Belt Functional       
23  Cab  On  Windshield Wipers       
24  Cab  On  Back Up Arm /Gear Shifts       
25  Cab  On  Steering Function    
26  Cab  On  Gauge Screen Readings       
27  Cab  On  Air Pressure       
28       Cab  On  Train, Vehicle, & Parking Brakes 
Working       
29  Cab  On  Mirrors (2‐4)       
30  Cab  On  Air Horn       
*** IN ADDITION TO THESE ITEMS, LUBRICATE ALL GREASE POINTS AND LISTEN / LOOK FOR ANY LEAKS  *** 
                 
Comments:                      
                      
                      
 
 
 Commander Series Daily Inspection
Operator ID:________________________________Date/Shift:________________Hour Meter:___________ 
 
 
ITEM #  Location  Engine ON / OFF  DESCRIPTION  OK  No 
 
  1  Ground  Off  Proper Tire Inflation/Condition (4) 
      2  Ground  Off  Lug Nuts Secure (per each wheel) 
  3  Ground  Off  Drain Air Tanks (4 points) 
  4  Ground  Off  Train Brake Hoses & Seals (2) 
 
5  Ground  Off  Train Brake Ball Valves Closed (2) 
 
 
6  Ground  Off  LUBRICATE Coupler Slide Base (2) 
  7  Ground  Off  Lubricate Coupler Knuckles (2)  
  8  Filled & Functional Sander Boxes 
  Ground  Off  (4) 
  9  Ground  Off  Wheel Flange Lubricators (4) 
  10  Ground  Off  Condition of Batteries & Cables 
 
11  Ground  Off  Headlights (4) & Brake Lights (4) 
 
  12  Ground  Off  Work Lights  & Strobe Lights 
  13  Ground  Off  Brake Fluid Level 
  14  Platform  Off  Engine Oil Level 
  15  Platform  Off  Engine Coolant Level 
  16  Platform  Off  Hydraulic Fluid Level 
 
17  Platform  Off  Windshield Washer Fluid Level 
 
  18  Platform  Off  Belt/Hose Conditions 
  19  Platform  Off  Air Cleaner Indicator 
  20  Platform  On  Look & Listen for Leaks 
  21*  Platform  On  Transmission Fluid Level 
  22*  Cab  On  Seat Belt Functional 
 
23  Cab  On  Windshield Wipers 
 
  24  Cab  On  Back Up Alarm/Gear Shifts 
  25*  Cab  On  Steering Straight Ahead Function 
  26  Cab  On  Console Display  
  27  Cab  On  Air Pressure Readings 
  28*  Cab  On  Vehicle & Parking Brakes 
  29  Cab  On  Train Brake & TB E‐Stop 
 
30  Cab  On  Mirrors/Windows Clean 
 
  31*  Cab  On  Air Horn     
  *** DO THE GREASE POINTS ON THE MACHINE NEED LUBRICATED?  *** 
   
  Comments: 
   
   
   
 
 
 
 24

15 19
26

28*
18
29
DF
TRANS
21*

20

23 31*
27 14

                 
                                   In‐Cab Console View                                                                          Passenger Side Engine View 
 
16

2
13
1

ZF
TRANS
21*

17

                
                                    Driver Side Engine View                                                                       Passenger Side View 
 

30

10

11 5
12
7

8
9

                
                                               Rear View                                                                                          Driver Side View                    
** ADDITITIONAL NOTES / COMMENTS ** 
#21* ‐ Transmission Dipstick found on opposite side of engine compartment, depending on transmission type.  See images above for locations. 
#22 – Seat Belts can be found on each mounted seat inside the cab, where the seat base and seat back come together.        
#25 – Steering straight ahead is checked by turning the steering wheel & watching the indicator box turn red/green in the ‘R/R’ screen on the display. 
#28* – Vehicle brakes are located both on the console and on the floor. Be sure to check both locations for proper function. 
#31* – The horn can be operated in two locations, on the console and on the steering column.  Be sure to check both locations for proper function.