RK16

OPERATOR’S HANDBOOK
Models RK275, RK285, RK290,

RK300, RK320 & RK330
10750 Telge Rd. • Houston, Texas 77095

RK16
Revision 1
STEWART & STEVENSON JULY
RK16 — RAIL KING OPERATOR’S HANDBOOK 2019
FRONT MATTER REV. 1
1. TABLE OF CONTENTS
FRONT MATTER
1. Table Of Contents ................................................................................................ 1
2. Introduction ........................................................................................................... 5
2.1 Revision Record ........................................................................................................ 5
2.2 Translation Notice ...................................................................................................... 5
2.3 Copyright Notice ........................................................................................................ 5
2.4 Proprietary Notice ...................................................................................................... 5
2.5 Technical Assistance ................................................................................................. 6
3. How To Use This Manual ..................................................................................... 7
CHAPTER 1 – SAFETY INSTRUCTIONS

1. Safety Instructions ................................................................................................ 3
1.1 General ...................................................................................................................... 3
1.2 Eye Protection ........................................................................................................... 4
1.3 Protective Clothing ..................................................................................................... 4
1.4 Foot Protection .......................................................................................................... 4
1.5 Lifting ......................................................................................................................... 5
1.6 Batteries ..................................................................................................................... 5
1.7 Refueling .................................................................................................................... 5
1.8 Platforms .................................................................................................................... 5
1.9 Precautions When Working On or Around Rail King ................................................. 6
1.10 Responsibilities On Rail King, Cars, or Trains .......................................................... 7
1.11 Getting On or Off Rail King and Cars ........................................................................ 8
1.12 Operating Handbrakes .............................................................................................. 8
1.13 Coupling and Uncoupling Cars and Rail King ........................................................... 9
1.14 Blocking and Coupling ............................................................................................ 10
1.15 Movement of Cars ................................................................................................... 10
1.16 Operating Track Switches ....................................................................................... 11
1.17 Working On or Around Tracks................................................................................. 11
1.18 Electrical Facilities, Equipment, and Apparatus ...................................................... 11
1.19 Rail King Operating On Roadwheels ...................................................................... 12
1.20 Miscellaneous ......................................................................................................... 13
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FRONT MATTER REV. 1
1. TABLE OF CONTENTS (CONT)
CHAPTER 2 – VEHICLE DESCRIPTION

2. Vehicle Description ............................................................................................... 3
2.1 Introduction ................................................................................................................ 3
2.2 Vehicle Frame and Cab ............................................................................................. 3
2.3 Diesel Engine ............................................................................................................. 8
2.3.1 Fuel System ............................................................................................................ 8
2.3.2 Lubrication System .................................................................................................. 8
2.3.3 Cooling System ....................................................................................................... 8
2.3.4 Air Intake System .................................................................................................. 10
2.3.5 Exhaust System .................................................................................................... 10
2.4 Drivetrain ................................................................................................................. 10
2.5 Hydraulic System ..................................................................................................... 11
2.6 Steering System ...................................................................................................... 11
2.7 Roadwheel Brake System........................................................................................ 11
2.8 Railwheel Brake System .......................................................................................... 11
2.9 Parking Brake System ............................................................................................. 11
2.10 Electrical System .................................................................................................... 12
2.11 Coupler System ...................................................................................................... 12
2.12 Air System ............................................................................................................... 13
2.13 Train Airbrake System ............................................................................................ 16
2.14 Remote Control System (Optional Equipment) ....................................................... 16
2.15 Control Chief Transmitter (Optional Equipment) ..................................................... 16
CHAPTER 3 – CONTROLS AND INDICATORS

3. Controls and Indicators ......................................................................................... 3
3.1 Introduction ................................................................................................................ 3
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FRONT MATTER REV. 1
CHAPTER 4 – OPERATING INSTRUCTIONS

4. Operating Instructions .......................................................................................... 3
4.1 Prestart Checks ......................................................................................................... 3
4.2 Starting Rail King ....................................................................................................... 6
4.3 Transmission Operation ............................................................................................. 8
4.4 Roadwheel Operation .............................................................................................. 10
4.4.1 Friction Drive ......................................................................................................... 10
4.5 Placing Vehicle on Rail ............................................................................................ 10
4.5.1 Friction Drive ......................................................................................................... 10
4.6 Coupling Rail King to Railcar ................................................................................... 11
4.7 Weight Transfer ....................................................................................................... 12
4.8 Stopping ................................................................................................................... 13
4.9 Train Air Brake System ............................................................................................ 13
4.10 Uncoupling .............................................................................................................. 14
4.11 Removing Vehicle from Rail .................................................................................... 15
4.12 Shutdown Procedure .............................................................................................. 15
4.13 Remote Control Operation (Optional Equipment) ................................................... 16
4.14 Loading the Rail King for over the Road Transport................................................. 19
4.15 Unloading the Rail King from the RGN Trailer ........................................................ 20
CHAPTER 5 – RAILROAD HAND SIGNALS

5. Railroad Hand Signal ............................................................................................ 3
5.1 Use of Hand Signals .................................................................................................. 3
5.2 Standard Hand Signals .............................................................................................. 3
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FRONT MATTER REV. 1

CHAPTER 6 – PERIODIC MAINTENANCE
6. Periodic Maintenance ........................................................................................... 3
6.1 Introduction ................................................................................................................ 3
6.2 Periodic Maintenance Schedule ................................................................................ 3
6.2.1 Frame ...................................................................................................................... 6
6.2.2 Coupling System ..................................................................................................... 6
6.2.3 Engine ..................................................................................................................... 6
6.2.4 Rail-Drive System ................................................................................................... 6
6.2.5 Road-Drive System ................................................................................................. 6
6.3 Hydraulic Valve Adjustments ..................................................................................... 6
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FRONT MATTER REV. 1
2. INTRODUCTION
2.1 Revision Record
Check each revision received and insert the revised and supplementary pages in your
manual (if applicable).
REV REVISION TECH PUBS PART SALES ORDER

DATE WO NUMBER NUMBER
0 MAY 2010 3117107 RK16 NA
1 JULY 2019 4129831 RK16 NA
2
3
2.2 Translation Notice

This operation and maintenance manual is written in English. If the equipment owner trans-
lates this manual using in-house personnel or a professional service, then the equipment owner
acknowledges responsibility for the accuracy of the translated manual. Stewart & Stevenson
assumes no responsibility for unit operation errors, damage to or improper use of equipment,
improperly trained personnel, improperly maintained equipment, or failure to follow normal safe-
ty precautions outlined in this manual or in the vendor literature that may result from inaccura-
cies in the translated manual.
2.3 Copyright Notice

Unpublished work © 2010 & 2019 Stewart & Stevenson. The information in this publication,
including text, images, and links, which may change at any time, is provided AS IS by Stewart &
Stevenson without warranty of any kind, either expressed or implied, including but not limited to,
the implied warranties of merchantability, fitness for a particular purpose, or non-infringement.
Stewart & Stevenson is a registered trademark of Stewart & Stevenson LLC.
2.4 Proprietary Notice

This work contains the CONFIDENTIAL and PROPRIETARY INFORMATION of
Stewart & Stevenson. Neither this document nor any information disclosed herein shall be re-
produced in any form, used, or disclosed to others for any reason, including manufacturing,
without the expressed written permission of Stewart & Stevenson. All pages of this document
are original pages of published material produced on or before the publication release date of
May, 2010, unless otherwise noted by a revision (REV) number.
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FRONT MATTER REV. 1
2.5 Technical Assistance

The information and instructions in this handbook are intended to acquaint the operator with
the important operating features of the Stewart & Stevenson Rail King® Mobile Railcar Mover.
The various controls, gauges, switches, and operating features are explained and illustrated
throughout this handbook. Direct any questions concerning the operation of the Rail King to:
Stewart & Stevenson

10750 Telge Rd.
Houston, TX 77095
Phone: (281) 345-5110, (855) 744-9481

Parts e-mail: parts@railking.net
Service e-mail: service@railking.net
Sales e-mail: sales@railking.net
Web Site: www.RailKing.net
All information in this manual is based on the latest production information available at the
time of publication. Direct any questions concerning the contents or format of this manual to:
Stewart & Stevenson Technical Services

ATTN: Manager, Technical Documentation
581 Garden Oaks BLVD
Houston, TX 77018
Phone: (713) 803-0700

Fax: (713) 803-0721
Email: techpub@ssss.com
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FRONT MATTER REV. 1
3. HOW TO USE THIS MANUAL
NOTE: Stewart & Stevenson recommends that the Rail King® railcar mover
operator thoroughly review the contents of this handbook before attempting
to operate the railcar mover.
This handbook is divided into six chapters. Refer to the Table of Contents in the Front Matter
section for details of the contents of the respective chapter.
Warnings, Cautions, and Notes are used throughout this handbook. The forms and explanations
are as follows:
Indicates a potentially hazardous situation, which, if not avoided,

could result in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided,

could result in minor or moderate injury, or serious damage to equip-
ment. It may also be used to alert against unsafe practices.
NOTE: Is used to notify personnel of installation, operation, or maintenance

information that is important, but not hazard related.
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FRONT MATTER REV. 1
THIS PAGE INTENTIONALLY LEFT BLANK
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STEWART & STEVENSON MAY
RK16 — RAIL KING® OPERATOR’S HANDBOOK 2010
CHAPTER 1 — SAFETY INSTRUCTIONS REV. 0
TABLE OF CONTENTS
1. Safety Instructions .................................................................................................... 3
1.1 General ........................................................................................................................... 3
1.2 Eye Protection ................................................................................................................ 4
1.3 Protective Clothing ......................................................................................................... 4
1.4 Foot Protection ............................................................................................................... 4
1.5 Lifting .............................................................................................................................. 5
1.6 Batteries ......................................................................................................................... 5
1.7 Refueling ........................................................................................................................ 5
1.8 Platforms ........................................................................................................................ 5
1.9 Precautions When Working On or Around Rail King ...................................................... 6
1.10 Responsibilities On Rail King, Cars, or Trains ................................................................ 7
1.11 Getting On or Off Rail King and Cars ............................................................................. 8
1.12 Operating Handbrakes ................................................................................................... 8
1.13 Coupling and Uncoupling Cars and Rail King ................................................................ 9
1.14 Blocking and Coupling .................................................................................................. 10
1.15 Movement of Cars ........................................................................................................ 10
1.16 Operating Track Switches ............................................................................................ 11
1.17 Working On or Around Tracks ...................................................................................... 11
1.18 Electrical Facilities, Equipment, and Apparatus ........................................................... 11
1.19 Rail King Operating On Roadwheels ............................................................................ 12
1.20 Miscellaneous ............................................................................................................... 13
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1. Safety Instructions
1.1 General
General rules cannot be written to cover every possible situation that may arise with each
job function, task, or procedure. Certain definite responsibilities, therefore, rest with you. They
are the following:
1. Protect yourself.
2. Protect your fellow employees.
3. Protect and take proper care of tools and equipment.
4. Reporting any unsafe condition, equipment, or operation to the proper authorities.
If you should find yourself unsure of an operating procedure, consult

your supervisor for guidance.
5. Make sure that you understand these rules and special instructions. Ask your supervisor
to explain any that are not clear to you.
6. Ensure that the equipment, material, and tools that you use are in good condition. Re-
port all defects to your supervisor.
7. Report to your supervisor, as soon as possible, any on-duty injury in which you are in-
volved and any off-duty emergency medical treatment that you receive.
8. While on duty, do not play jokes on fellow employees and do not scuffle, wrestle, fight, or
engage in horseplay with fellow employees.
9. Tranquilizers, alcoholic beverages, and drugs that cause drowsiness or affect alertness
must not be used by employees on duty, nor for 24 hours prior to going on duty. Illegal
drugs are strictly forbidden.
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1.2 Eye Protection

1. Wear suitable goggles, eye shield, face shield, or other protective equipment when per-
forming operations that are known to be dangerous or when directed by your supervisor.
2. Avoid looking directly at flame, sparks, and glare from cutting and welding equipment,
unless wearing proper eye protection.
1.3 Protective Clothing

1. Wear suitable clothing to perform your duties. Do not wear long coats, long ties, or
loose, torn, or baggy clothing when working on or around equipment or where wearing
such clothing would be hazardous.
2. Wear trousers without cuffs and fasten the bottom of trouser legs snugly against ankles
to avoid tripping or falling where there is danger of getting trouser legs caught.
3. Do not wear wristwatches or finger rings while working around moving machinery or per-
forming other work that involves the danger of catching such articles on equipment or
machinery.
4. Do not wear wristwatches or finger rings while working on or with electrical equipment.
5. Wear welder's spats, leggings, or other protective clothing and equipment when cutting
or welding metals.
6. Wear heat protection clothing and equipment when conditions warrant.
1.4 Foot Protection

1. Protective shoes are recommended. Thin-soled, open-toe, or cloth shoes and/or un-
buckled overshoes should not be worn.
2. Employees engaged in cutting or welding operations should wear welder's spats or

leggings.
3. When weather conditions make wearing of protective work rubbers or boots necessary,
extra precautions should be taken to prevent slipping.
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1.5 Lifting
1. Lifting beyond normal physical capabilities is prohibited.
2. Avoid jerking or lifting from twisted positions.
3. Obtain help to lift heavy or cumbersome objects.
1.6 Batteries
1. Store batteries in well-ventilated rooms only.
2. Keep flames and open sparks away from batteries.
3. Storage battery compartments must be open while recharging.
4. Wrenches or metal objects must not be placed where they can fall on batteries.
1.7 Refueling
1. Do not refuel while engine is running or when within close range of any open fires,
sparks, or flames.
2. Absolutely no smoking is allowed while refueling.
3. Avoid fuel spills when refueling.
1.8 Platforms
1. Do not step on surfaces covered with oil, grease, wet paint, or other slippery substances,
if you can avoid it.
2. Use sawdust or sand on platforms, steps, etc., that are wet, frosted, or greasy.
3. Do not walk or stand where tools, materials, or other objects that are used overhead
may fall. If you must go into such danger zones, make sure those working above know
of your presence. Always wear a hardhat.
4. Use a handline to lower objects from an elevation. Do not drop anything unless you are
certain that it is safe to do so.
5. Walk up and down stairs one step at a time, checking to make sure that your footing is
secure. Keep your hands out of your pockets and use the handrail where available.
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1.9 Precautions When Working On or Around Rail King®

1. Keep engine compartment, cab, catwalks, steps, and grab irons clear and free of oil,
grease, rags, and other refuse material.
2. Never hose down the cab floor.
3. Keep all tools in their assigned places.
4. Restore all appliances used in taking fuel, water, or sand to secure positions clear of the
tracks.
5. Place proper tag on starting control panel before doing any work on engine or drive com-
ponents.
6. Keep fire extinguishers filled, available, and inspected. Avoid overexposure to fire extin-
guisher fumes.
7. Know how to use fire extinguishers and learn where extinguisher is located on the Rail
King.
8. Never use metal-cased flashlights around electrical equipment.
9. Do not start engine until all workers have been notified and are in a safe position.
10. Do not keep engine running in buildings or shops that are not adequately ventilated.
11. Do not leave Rail King unattended for any reason until you:
• Shut off the engine
• Apply parking brake and/or block wheels
12. Do not leave an engine running if there are signs of trouble in its cooling, lubricating, or
fuel systems or signs of mechanical defects.
13. Keep hands and tools clear of radiator fan blades, belts, and other moving engine com-
ponents. Never try to install, remove, or adjust any V-belts while equipment is operating.
14. Keep hands in the clear when testing injector fuel spray nozzles. Do not smoke or have
an open flame nearby when injector fuel spray nozzles are being tested.
15. Do not open a train brake line shutoff valve while vehicles are being coupled or uncoupled
or at any other time when doing so might subject someone to injury. See that all person-
nel have cleared the area before you open a train brake line shutoff valve.
16. Do not climb on top of the Rail King while it is moving.
17. Do not step to platform or other side elevation from side door of moving cars or the Rail
King.
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18. Keep cab doors closed while the Rail King is moving. Use windows and fans for venti-
lation.
19. Do not use fingers to wipe lube oil from engine dipstick. Always use a clean, lint-free cloth.
20. Shut engine off before adding oil to the crankcase.
21. Have a fire extinguisher ready when using oxy, acetylene, or electric welding equipment
around the Rail King.
22. Do not weld or burn around fuel tank vents.
23. Make sure that no tools are left lying in engine compartment, cab, or near any electrical or
moving equipment after maintenance work is performed on the Rail King.
24. Notify other employees and make sure parking brake is set before draining main air reser-
voir.
25. Do not perform any maintenance or operation function on the Rail King unless you are
suitably trained and qualified to perform the specific task.
26. Do not work under the Rail King if it is up on its roadwheels unless substantial, stable
blocks or work jacks capable of withstanding one and one-half times (1½) the weight of the
Rail King have been placed under the frame to support the vehicle. The Rail King can
drop from its roadwheel support position in the event of a mechanical or hydraulic failure.
1.10 Responsibilities On Rail King, Cars, or Trains

1. Do not operate or ride on Rail King unless in an assigned seat.
2. Do not ride between the Rail King and car or between two coupled units.
3. Do not ride, stand, or place any part of your body on or between the side or end of the car
because any lumber, pipe, or other lading may likely shift.
4. Do not use the endgate of a gondola as a handhold.
5. Do not sit or lie under cars.
6. When riding on a railcar—if required for setting railcar brakes—maintain a lookout in the
direction the Rail King or railcar is moving, being alert for structures alongside of (or over)
the track and for cars on an adjacent track, that could strike you, injure you, or knock you
off a car.
7. Take extra precaution to prevent falling through openings when unloading materials from
cars.
8. Do not put clothing, tools, or other objects on ladder rungs and keep as close as possible
to equipment when going up or down ladders on cars or the Rail King.
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9. Do not ride on ends of moving cars except when operating handbrakes.
10. Notify operator in order that he may protect workers making emergency repairs under or
around cars.
11. Notify operator when emergency work is complete and workers are clear of cars.
1.11 Getting On or Off Rail King and Cars

1. Do not get on or off moving equipment.
2. Look for ground irregularities and make certain that there is no immediate movement on
adjacent tracks when getting off equipment.
3. Have foot placed firmly on the ground or other support before releasing handhold when
getting off standing equipment.
4. Face Rail King or car when getting on or off.
1.12 Operating Handbrakes

1. Test car handbrakes prior to usage.
2. Take position appropriate for the type of handbrake to be operated on car. Make sure that
position offers secure footing and firm handhold.
3. Do not swing from side ladder to end ladder until reaching a point level with the brake plat-
form.
4. Do not use any part of adjacent car for footrest when applying or releasing brakes.
5. Check brakewheel, lever, pawl, and ratchet for defects before operating handbrakes.
6. Keep completely clear of revolving wheel when releasing brakes.
7. Apply sufficient handbrakes to prevent cars left standing on tracks from rolling out and
blocking other tracks. Block wheels when necessary.
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1.13 Coupling and Uncoupling Cars and Rail King

1. Do not go between or in front of moving Rail King, cars, or other equipment.
2. Make certain that equipment is not going to move and check for approaching cars before
going between idle Rail King or cars.
3. Before crossing tracks in front of or behind standing cars or Rail King, allow sufficient dis-
tance from equipment to cross without danger—at least 20 ft.
4. Do not signal to move while someone is between cars or between Rail King and cars.
5. Do not expect signal to move when you know that someone is between cars or between
Rail King and cars.
6. Watch for moving equipment on adjacent tracks when stepping from between standing
Rail King or cars.
7. Do not step in front of Rail King or cars or on track between them after signal to move is
given.
8. Do not use both hands or both feet on uncoupling lever of moving cars. Stop equipment if
lever cannot be operated with one hand or one foot.
9. Pay close attention to footing and avoid stumbling or falling when cutting off cars from the
ground.
10. Do not insert thumb or fingers in bottom hole of coupler to adjust lockpin.
11. Do not step in front of moving Rail King or cars to adjust coupler, knuckle, or lockpin and
do not attempt to adjust them when they are about to come together.
12. Hold hose firmly with one hand when using angle cock to reduce brake pipe pressure.
13. Take the following precautions and all other measures necessary to prevent injury when
coupling onto or moving cars:
• Ensure that no one is under or between cars when coupling and uncoupling
• Ensure that transfer plates and skids are in the clear
14. When necessary to uncouple hose by hand, be sure both angle cocks are closed and
have a firm hold on the hose before breaking the connection. Remember that trapped air
pressure will cause hoses to whip.
15. When coupling or uncoupling air hose, both feet must not be placed between rails. Take
necessary precautions to avoid being struck by swinging air hose.
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1.14 Blocking and Coupling

1. Use of a switchman, in addition to a Rail King operator, is optional; however, where possi-
ble, it is recommended to increase safety and efficiency of car-moving operations.
2. Carry suitable blocks on the Rail King for use in blocking operations.
3. Blocks are to be placed and removed only by hand and with the Rail King or cars station-
ary. Kicking blocks out from under the wheels can result in serious injury.
4. Wheels are to be blocked and handbrakes are to be set on all cars spotted on a grade to
prevent them from rolling back when uncoupled.
5. To prevent cars from rolling away when uncoupled, the switchman must block on both
sides of the car wheel before signaling “back up.”
6. Do not kick or hold Rail King drawbar in position to make a coupling while either the car or
the Rail King is moving.
1.15 Movement of Cars

1. Care and good judgment must be used in switching to avoid damaging car contents and
equipment. Before moving, it must be determined that the necessary couplings have been
made and that sufficient blocking of loads within the cars has been provided.
2. Contents of car must be balance-loaded before weight transfer is taken so that the car will
not tip.
3. To avoid blocking of cars on intersecting track, the standard rule on clearance is to be ob-
served—8 ft, 6 in from the centerline of a straight track and 11 ft, 6 in from the centerline of
a curved track. This clearance rule will apply except where yard tracks running parallel to
one another will not permit. In any event, cars must not be left on switches, crossovers, or
adjacent to one another without allowing sufficient clearance for passing cars and for em-
ployees who may be riding the side of cars.
4. Cars or tanks containing acid, oil, or any hazardous or flammable material must be han-
dled with extreme care. Even a minor accident could take on serious proportions.
5. When a car which has been spotted is about to be moved, coupling should be delayed
until it is determined that:
• No one is in, on, or under the car.
• No obstructions to car movement exist.
• Car is properly loaded.
6. A spotted car in the process of being loaded or unloaded may be moved when it becomes
necessary, but not until the operator contacts the foreman in charge of loading, who deter-
mines whether it is clear to do so.
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7. The headlight and rear light of the Rail King should be turned on as a minimum precaution
during the following periods:
• Between the hours of sunset and sunrise
• Daylight hours when visibility may be reduced by clouds and during rain, fog, snow,
or sleet which adversely affect visibility
8. Do not extend any part of the body beyond the outside clearance line of the cab or car
without exercising extreme care.
1.16 Operating Track Switches

1. Look in both directions for moving equipment on adjacent tracks and keep clear of it.
2. Position yourself so as not to be struck by or caught between the moving Rail King or cars
and switch lever or stand.
3. Stay clear of switch travel lever and keep hands and feet where they will not be caught by
a lever or ball.
4. Position feet securely and lift with legs. Do not lift with back.
5. Do not operate switches until you warn employees who may be repairing or cleaning them
and make certain such employees are in a safe position.
1.17 Working On or Around Tracks

1. The Rail King should not be operated in an area where work is being done on or around
tracks. If the Rail King must be operated, then work should be stopped and the track se-
cured for safe operation. Rail King should then proceed with caution.
2. All workers should clear the area until Rail King operation is complete.
1.18 Electrical Facilities, Equipment, and Apparatus

1. Unauthorized persons are forbidden to make repairs to any electrical equipment.
2. Do not tamper with electrical wires, equipment, or apparatus.
3. Do not use water to extinguish electrical fires. If possible, use dry chemical extinguishers,
carbon dioxide gas extinguishers, sand, or carbon tetrachloride vapors. When an extin-
guisher is used in a confined area, guard the area until vapors have dissipated.
4. Do not touch wire or any other object hanging from, or in contact with, an electrical distri-
bution system. Instruct someone to guard the area, if possible, and report hazard to the
supervisor at once.
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5. Do not allow materials or equipment to be placed where they will block access to electrical
switches. All electrical wires and conductors are to be considered live at all times, unless
employee has positive knowledge to the contrary. Do not depend on weatherproof cover-
ing of wires for protection.
6. Do not climb on top of cars, locomotives, Rail King, or other high equipment in electrified
territory, unless authorized to do so.
7. Take special precautions when working near live wires.
8. Do not use hand lines with metal cores, steel measuring tapes, or measuring equipment
containing metal strands when working near live electrical equipment or wires.
1.19 Rail King Operating On Roadwheels
If you should find yourself unsure of an operating procedure, you

should contact your supervisor for guidance.
1. Do not operate Rail King unless you:

• Are qualified and authorized to do so
• Are in good physical condition, including eyesight and hearing
• Have a valid driver's license or permit in your possession
• Know and obey in-plant rules
• Know that the vehicle is in good operating condition, giving particular attention to the
tires, steering gear, brakes, windshield wipers, lights, horn, and mirrors (All windows
and mirrors should be kept clean to ensure complete visibility)
2. Employees should remain seated while vehicles are in motion.
3. Do not get on or off moving vehicles, except in extreme emergencies.
4. Do not allow hands, feet, or other parts of the body to project to the side or rear of the
vehicle, except when giving hand signals.
5. Do not exceed plant speed limit.
6. Be on constant alert for pedestrians, trucks, forklifts, and other mobile plant equipment.
7. Always keep Rail King under complete control (i.e., be able to stop quickly to avoid injury
to people or damage to property).
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8. Whenever Rail King is parked for an extended period of time, lower the Rail King so that
the railwheels are on the ground.
9. Always set the parking brake, turn off the ignition, and remove the key whenever leaving
the Rail King unattended.
10. The engine must be running whenever hydraulic control switches on the instrument panel
are moved.
1.20 Miscellaneous
1. Keep work areas clean and orderly. Keep all hand tools and materials in designated
places.
2. Remove all material that endangers footing found in pathways, between tracks, alongside
single tracks, in yards, or elsewhere where they present a hazard.
3. Do not puncture or burn disposable pressurized containers. Consult supervisor if in doubt

as to the proper method of disposal.
4. Look before stepping in any direction while working on Rail King, cars, scaffolds, or other
equipment.
5. Do not jump from Rail King to other places of similar height. Use handrails and ladders
where available.
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CHAPTER 2 — VEHICLE DESCRIPTION REV. 1
TABLE OF CONTENTS
2. Vehicle Description ................................................................................................... 3
2.1 Introduction ..................................................................................................................... 3
2.2 Vehicle Frame and Cab .................................................................................................. 3
2.3 Diesel Engine ................................................................................................................. 8
2.3.1 Fuel System ............................................................................................................ 8
2.3.2 Lubrication System .................................................................................................. 8
2.3.3 Cooling System ....................................................................................................... 8
2.3.4 Air Intake System .................................................................................................. 10
2.3.5 Exhaust System .................................................................................................... 10
2.4 Drivetrain ...................................................................................................................... 10
2.5 Hydraulic System .......................................................................................................... 11
2.6 Steering System ........................................................................................................... 11
2.7 Roadwheel Brake System ............................................................................................ 11
2.8 Railwheel Brake System ............................................................................................... 11
2.9 Parking Brake System .................................................................................................. 11
2.10 Electrical System .......................................................................................................... 12
2.11 Coupler System ............................................................................................................ 12
2.12 Air System .................................................................................................................... 13
2.13 Train Airbrake System .................................................................................................. 16
2.14 Remote Control System (Optional Equipment) ............................................................ 16
2.15 Control Chief Transmitter (Optional Equipment) .......................................................... 16
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2. Vehicle Description
2.1 Introduction
The Rail King® is a railcar-moving vehicle, used primarily in switching operations. The Rail
King, which is generally used within a plant area, is also well suited for other industrial railcar-
moving applications. It is equipped with four roadwheels and four railwheels, which allow the
vehicle to operate both on the road and on conventional rails. For coupling purposes, the Rail
King is equipped with front and rear hydraulically and pneumatically controlled couplers that can
be used separately to push, to pull, or together to push and pull at the same time. All working
functions are controlled from within the operator's cab. The Rail King utilizes the weight transfer
method when moving railcars. This method borrows weight from the railcar being moved by
hydraulically raising the coupler to give added traction to the Rail King.
NOTE: When describing the Rail King, the part of the vehicle that contains
the steering wheel is considered the front. Left and right sides are described
when facing forward. Refer to Figure 1 and Figure 2 for various features of
the Rail King.
2.2 Vehicle Frame and Cab

Frame — Vehicle frame is made of heavy-duty, all-welded, 2-inch steel plate. The railwheel
drivetrain and axles, vehicle engine, and coupling assemblies are attached to the frame. The
rigid frame assembly supports the road- and rail-drive components, as well as vehicle cab, cab
platform, and engine auxiliary systems. For vehicle dimensions for the full-width cab and the
side mount cab, refer to Figure 3 and Figure 4, respectively.
Platform and Catwalk — Platform surrounded by tubular-metal safety guards has been in-
stalled on the rear of the vehicle. The platform is wider than the cab to protect the cab sheet
metal. A catwalk, mounted on the platform, allows the switchman to cross over the machine
without going through the cab.
Operator’s Cab — Insulated, fabricated sheet metal cab is provided for operator comfort
and protection. The full-width cab and large, tempered safety glass windows allow the operator
to see down both sides of the railcar when negotiating curves. Standard cab equipment in-
cludes operator controls, two seats, front and rear wipers, heater, and two defrost fans.
4129831 3 of 16
Figure 1 Rail King Full-Width Cab Features
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Figure 2 Rail King Side-Mount Cab Features
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Figure 3 Rail King Full-Width Cab Vehicle Dimensions
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Figure 4 Rail King Side-Mount Cab Vehicle Dimensions
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2.3 Diesel Engine

The Rail King is equipped with an in-line, 6-cylinder, 4-cycle, turbocharged diesel engine,
which is rated at 133 bhp to 204 bhp (depending on the model) when operating at 1900 rpm to
2200 rpm (depending on the model).
2.3.1 Fuel System

All models operate on diesel fuel. Use either Grade No. 1-D or Grade No. 2-D fuel as de-
fined by ASTM designation D975 for diesel fuels. For more information on fuel specifications,
refer to Figure 5 and to the engine manuals.
Diesel fuel is delivered by a distributor-type mechanical fuel transfer pump to the engine.
The fuel flows through a strainer and an engine-mounted replaceable fuel filter element to the
fuel injection pump. The pump is driven by an intermediate gear in the timing gear train, mesh-
ing with crankshaft gear. The fuel is then sprayed into the combustion chamber through injection
nozzles in the cylinder head.
2.3.2 Lubrication System

The engine is supplied with lubricating oil by a gear pump driven by the crankshaft. The lu-
bricating oil passes through a full-flow oil filter in the main oil gallery of the cylinder block. To en-
sure the engine lubrication, the oil filter is provided with a bypass valve that opens when the fil-
ter element is restricted. Engine oil is cooled by means of an oil cooler before flowing to the oil
filter. A bypass valve located between oil pump and main gallery relieves any pressure buildup
in this area.
An oil viscosity based on the expected air temperature range should be used during the pe-
riod between oil changes. Refer to the engine manuals for full engine specifications.
2.3.3 Cooling System

The engine has a pressurized cooling system, which effectively dissipates the heat gener-
ated by the engine. The system consists of a radiator, water pump, multi-blade fan, and one or
two thermostats. For coolant specifications, refer to the engine manual.
During the warm-up period, the thermostat remains closed and coolant is directed through
bypass to the suction side of the water pump. The coolant then circulates through the cylinder
block and water pump to provide a fast warm-up period.
After the engine has reached operating temperature, the thermostat opens and coolant is
pumped from the bottom of the radiator, from the bottom hose, into the cylinder block. Coolant
circulates through the block and around the cylinder liners. From the block, coolant is then di-
rected through the cylinder head and into the thermostat housing. With the thermostat open,
coolant passes through the housing into the top of the radiator. Coolant then circulates through
the radiator to dissipate heat.
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Figure 5 Diesel Fuel Specifications
NOTE: At altitudes above 5000 feet (1500 m), use Grade No. 1-D for all
temperatures. If the engine is operated under “standby” conditions, use
Grade No. 1-D for all temperatures. To prevent higher wear for corrosive
combustion products, fuel-sulfur content of less than 0.5% is preferred.
Excessive white smoke at startup could be the result of low-cetane fuel. The
cetane number should be no less than 40 to assure satisfactory startup and
overall performance. At low temperatures and/or higher, a cetane number of
more than 45 is recommended.
The cloud point should be at least 10 ºF (6 ºC) below the lowest expected air
temperature at the startup time. Wax, which can separate from fuel, can
also plug the filter.
4129831 9 of 16
2.3.4 Air Intake System

Air for engine combustion is drawn through a replaceable cartridge-type air filter. Under
suction generated by the engine, unfiltered air flows through the air inlet tube and is forced into
a high-speed centrifugal motion by tilted fins in the element. By this circulating action, most of
the dust and dirt particles are separated from the air and collected in the dust-unloading valve.
The remaining dirt is removed as the air flows through the primary element.
2.3.5 Exhaust System

Engine exhaust emissions exit through a sound-attenuating, spark-arresting muffler.
2.4 Drivetrain
Transmission/Torque Converter — A 4-speed, forward and reverse automatic shift trans-
mission (John Deere “Funk” Model DF Series 150 “Analog”) is mounted to the engine flywheel
housing and drives the railwheels directly. The transmission is coupled to a torque converter
assembly. The drivetrain is equipped with a spring-applied, air-released driveline brake.
Forward motion and reverse motion speeds are obtained through the use of electrically
controlled solenoids and hydraulically actuated multiple wet-disc clutches. These clutches are
power-absorbing members that can be engaged at full engine power.
The clutches in these units are hydraulically applied and spring released. Because the
clutches are hydraulically controlled, there is automatic compensation for normal wear, which
eliminates the need for adjustment. Each clutch uses a composition friction plate and a polished
steel reaction plate.
The power from the engine is transmitted to the DF-150 Transmission through a torque
converter. The use of the torque converter has two distinct advantages:
1.) The converter is essentially a fluid drive, there being no direct mechanical connection
between the engine and transmission assembly. This feature creates a very smooth
and shock-free drive eliminating engine stalling.
2.) The converter multiplies torque during heavy pull-down loads. When loads are light, the
converter transmits the engine power directly at almost engine speed and there is no
torque multiplication. The net result is an action like a transmission, with infinitely varia-
ble and automatic speed ratios. The need for shifting gears, although present, is greatly
reduced.
Railwheel Drivetrain — A John Deere spiral-bevel gear set, designed for bi-directional op-
eration, transfers power to limit slip differentials and internal planetary axles. Railwheels are
made of heat-treated cast steel. The wheels are tapered tread and contoured to AAR specifica-
tions.
Railwheel Sanders — Each railwheel is equipped with a railwheel/track sander. The sand-
ers are mounted to the cab platform above each wheel. The sanders are filled through a top-
mounted access cover. The sand is dispensed under pressure through flexible rubber hoses to
the railwheel/track interface. The air-operated sanders provide additional traction by dispensing
sand directly onto the rail in front of or behind the railwheels.
NOTE: Stewart & Stevenson recommends the use of TrackGlass Recycled

Glass Traction Media for enhanced tractive effort. It can be ordered from the
S&S Rail King Parts Department or your local authorized Rail King dealer.
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Roadwheel Drivetrain — The front roadwheels are driven by a friction drive transmitted from
the railwheel-drive axle. In the fully retracted position, the roadwheels are completely disen-
gaged from the rail axle. Four hard rock, lug-type tires are used for maximum traction on a va-
riety of road surfaces.
2.5 Hydraulic System

The hydraulic system is used to 1) raise, lower, steer the roadwheels, 2) move the front and
rear couplers, and 3) brake the railwheels. Hydraulic fluid is contained in a reservoir mounted
under the cab platform. A sight glass has been installed on the side of the reservoir to show the
hydraulic fluid level. Hydraulic fluid is pumped at 2500 psi to the various control valves and ac-
tuators used in Rail King switching operations.
2.6 Steering System

The Rail King is equipped with power steering, providing steering control of the rear
roadwheels.
2.7 Roadwheel Brake System

Each steering roadwheel is equipped with a drum-type, dry-friction brake assembly. The
brakes are air-powered and are actuated by a foot-operated brake pedal located in the cab.
2.8 Railwheel Brake System

The railwheels are equipped with hydraulically actuated, inboard, multiple wet-disc brakes.
The brakes are spark-free for use in hazardous environments. An automatic adjustment feature
reduces routine maintenance requirements.
NOTE: The railwheels provide braking for the Rail King only. The train air-
brake system is independent.
2.9 Parking Brake System
On full width cab models (RK320 & RK330), there are two park brake
release valves located on the center console. In order for the parking
brake to be applied, both valves must be in the “out” position.
The Rail King has a one-caliper, spring-applied, air-released disc brake mounted on the
output flange of the transmission. The parking brake is set and released by means of an air-
operated valve located on the instrument panel located in the cab. To apply the parking brake,
pull the valve out. To release the parking brake, push the valve in.
NOTE: The parking brake is intended for the Rail King only. The parking
brake will not hold empty or laden rail cars.
4129831 11 of 16
2.10 Electrical System

The following paragraphs describe the theory of operation of the electrical system.
Engine Starting and Battery Charging Circuits — With the engine shift lever in Neutral
(NEUT) and ENGINE STOP and START switch S1 in START position, relay K1 is energized
and the contacts of engine starting contactor K1 close. Starting solenoid L1 is energized and
applies 12-volt battery voltage to engine starting motor B1. The battery charging alternator G1
maintains battery BT1 in a charged condition and supplies power to the various 12 VDC engine
accessory circuits.
Engine Run Relay Circuit — At the same time that the ENGINE STOP and START switch
S1 is being actuated to crank the engine, battery voltage is applied through the closed contacts
of S1 (RUN) to engine ECM allowing engine to start and run.
Light Circuit — PARKING LIGHTS switch S12, when placed in the ON position, applies
12 VDC from battery BT1, 2 through fuse F4 to the following lamps: left TAIL/STOP lamp DS6,
right TAIL/STOP lamp DS7, left rear TAIL/STOP lamp DS8, and right rear TAIL/STOP DS9.
HEAD LIGHTS switch S0 energizes front head lamps DS2 and DS3. HEAD LIGHTS switch S11
energizes rear headlamps DS4 and DS5.
2.11 Coupler System

Two weight-transfer couplers are installed on the Rail King, one at the front of the vehicle
and one at the back. The couplers are used to attach the Rail King to railcars during switching
operations. Refer to Figure 6 for details of the coupler system.
The couplers are made of fabricated steel, and slide on high-density, self-lubricating nylon
bearings. This heavy-duty coupler system operates on a center pivot, housed in a synthetic rub-
ber cushion, which is pressed in on both sides of the frame.
Coupling Mechanism — The couplers move horizontally and vertically through the use of
hydraulic actuators. This enables the couplers to align with railcar couplers for connection to the
Rail King.
Railcar Knuckle — Air-operated coupler knuckles are used to connect the Rail King to rail-
cars.
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Figure 6 Coupler System
2.12 Air System

The air system is used for roadwheel braking, uncoupling, and sanding operations. The
controls and indicators for the air system are located in the Rail King cab. Refer to Figure 7 and
Figure 8 for a schematic of the pneumatic system.
Two engine-mounted air compressors provide 130 psi air, which is contained in three cylin-
drical reservoirs mounted on the cab platform. From the reservoirs, the air is directed to the vari-
ous control actuators and valves used in Rail King switching operations.
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Figure 7 Side-Mount Cab Pneumatic System Schematic

(Rail King Models RK275, RK285, RK290, & RK300)
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Figure 8 Full-Width Cab Pneumatic System Schematic

(Rail King Models RK320 & RK330)
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2.13 Train Airbrake System

The train airbrake system supplies air to the railcars to operate their airbrakes. It does not
control the brakes on the Rail King. The brakes on the Rail King are separate and are air over
hydraulics, while the brakes on a railcar are air only.
Two air pressure gauges are located on the Rail King control panel. One gauge indicates
the reservoir pressure, which is set at 130 psi. The other gauge indicates brake line pressure,
which is the air pressure in the brake line on each car. It varies between 70 and 90 psi, depend-
ing on in-plant requirements. The brake line pressure is factory-set at 90 psi.
2.14 Remote Control System (Optional Equipment)

The Rail King can be equipped with a remote control (RC) system which allows the Rail
King railcar mover to be operated remotely up to a distance of 3500 feet without signal repeat-
ers. The RC system controls most functions of the Rail King such as throttle control (pneumatic
or electronic), brake control (Rail King and trainline), coupling/uncoupling functions, and track
sanding functions.
NOTE: The remote control system is to be used only when the Rail King is
on the railroad tracks. Interlocks prevent operation when the roadwheels are
down.
The RC system consists of the portable Control Chief transmitter. Various electrical and
pneumatic components are installed on the Rail King to interface with the RC system.
2.15 Control Chief Transmitter (Optional Equipment)

The Control Chief transmitter is a handheld device used by the operator to control the Rail
King unit. Controls on the transmitter allow one-hand operation of the throttle and brake horn
and sand functions. Indicators provide system and Rail King status information. An aural alarm
warns of system problems.
The unit’s battery pack allows 8 to 12 hours of continuous use. A built-in antenna provides
reliable line-of–sight service up to 3,500 feet without the use of repeaters.
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CHAPTER 3 — CONTROLS AND INDICATORS REV. 0
TABLE OF CONTENTS
3. Controls and Indicators ............................................................................................. 3

3.1 Introduction ..................................................................................................................... 3
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3. Controls and Indicators
3.1 Introduction
If you should find yourself unsure of an operating procedure, you

should contact your supervisor for guidance.
This section describes the controls and indicators used in the Rail King®. The specific pur-
pose and function (or purpose) of each control and indicator are also given. Before operating
the vehicle, the operator should become completely familiar with the information provided in this
section. Refer to Figure 1 through Figure 5 and their accompanying tables for details.
Depending on the model, the Rail King has either a side-mount cab (Models RK275,
RK285, RK290, & RK300) or full-width cab (Models RK320 & RK330). On the side-mount cab,
the Rail King is equipped with a front (F) and a rear (R) control station. From the steering (F)
wheel control station, the vehicle can be operated on road or rails. From the (R) control station,
the vehicle can be operated on rails only.
On the full-width cab, the Rail King is equipped with left-hand (LH) and right-hand (RH) con-
trol stations. From the steering (LH) wheel control station, the vehicle can be operated on roads
or rails. From the opposite (RH) control station, the vehicle can be operated on rails only. In be-
tween and behind the stations, a system control panel is provided for additional controls and
indicators. The system control panel contains engine-operating gauges, system switches and
indicators, and other operating controls. When operating the vehicle, ensure that all controls are
in their proper positions and system indicators are at their proper settings.
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Figure 1 Side-Mount Cab Operator’s Controls
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Table 3-1, Side-Mount Cab Operator’s Controls
Item Name of Control or Indicator Function
1 Station, Control Control station for vehicle road and rail operations.
2 Pedal, Brake Controls roadwheel and railwheel brake system.
3 Pedal, Accelerator Controls vehicle speed during roadwheel and railwheel

operation.
4 Shift Lever, Transmission Speed and Controls speed and direction of vehicle during roadwheel
Direction and railwheel operation. Automatic three-position shift lever,
(F) for forward operation, (N) for neutral, and (R) for reverse
operation.
5 Steering Wheel, Roadwheel Controls steering of vehicle through the rear road-drive axle.
6 Fan, Vent Operator cooling fan.
7 Light, Dome Illuminates interior cab.
8 Control Panel, System Contains controls and indicators for railcar coupler and
vehicle operation. Refer to Figure 2 for configuration and
descriptions of controls.
9 Cable, Horn Operates horn. (Pull to sound horn).
NOTE: Horn should be used as a signaling device, not as a

communication device.
10 Heater Provides cab heat for operator.
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Figure 2 Side-Mount Cab System Control Panel (Sheet 1 of 3)
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Table 3-2, Side-Mount Cab System Control Panel
1 Control Lever, TRAIN AIR BRAKES Controls train (railcar) air brakes. Used to APPLY or
RELEASE brake pressure.
2 Switch, COUPLER RELEASER Two-position rocker switch that controls the operation of
front and rear coupler disengage mechanism.
3 Switch, Railwheel SANDER Three-position rocker switch that controls the application of
sand to both FRONT and REAR rails. (FRONT - OFF -
REAR).
4 Switch, Front Coupler Sideshift Three-position rocker switch that controls the left and right
movement of the front coupler mechanism. (LEFT - OFF -
RIGHT).
5 Switch, FRONT COUPLER Three-position rocker switch that controls the up & down
UP/DOWN movement of the front coupler mechanism. (UP - OFF -
DOWN).
6 Switch, Rear Coupler Sideshift Three-position rocker switch that controls the side move-
ment of the rear coupler mechanism. (LEFT –OFF - RIGHT).
7 Switch, REAR COUPLER UP/DOWN Three-position rocker switch that controls the up and down
movements of the rear coupler. (UP - OFF – DOWN).
8 Indicator, Air Filter Indicates when air filter service is required. (Located on
engine air inlet filter).
9 Gauge, TACHOMETER & Engine Indicates engine rpm and total engine operating time (in
Hour Meter hours).
10 Indicators, Roadwheels (Red) These indicators will illuminate when the roadwheels are not
completely retracted.
NOTE: These lights must be out when operating Rail King

on the rails.
11 Switch, RAIL KING FRONT Three-position rocker switch that controls the up & down
Raise/Lower movement of the front roadwheels. (UP - OFF - DOWN).
12 Switch, RAIL KING REAR Three-position rocker switch that controls the up and down
Raise/Lower movement of the rear roadwheels. (UP – OFF – DOWN).
NOTE: Switches 2, 3, 4, 5, 6, 7, 11, & 12 are momentary

switches. When the switch is pressed the mechanism will
move in the desired direction. When the switch is released,
the mechanism will stop and the switch will return to the
OFF position.
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8 of 22 3117107
Table 3-2, Side-Mount Cab System Control Panel (Cont)
13 Control, TRAIN AIR DISCHARGE Controls railcar air brakes. Pull to CHARGE; push to
(Railcar Brakes) DISCHARGE.
14 Gauge, Reservoir Air Pressure & Indicates reservoir air pressure & train air brakes system
Train Air Brakes Pressure pressure.
RED – MAIN REServoir.
WHITE – BRAKE PIPE Pressure.
15 Switch, REAR WIPERS Three-position rocker switch that controls the rear wind-
shield wipers. (HIGH - OFF - LOW).
16 Switch, AIR DRYER HEATER Two-position rocker switch that controls the air dryer heater.
(ON - OFF).
17 Switch, FRONT HEAD LIGHTS Three-position rocker switch that controls the front head
lights. (HIGH - OFF - LOW).
18 Switch, REAR HEAD LIGHTS Three-position switch that controls the rear head lights.
(HIGH - OFF - LOW).
19 Switch, CAB LIGHTS Three-position rocker switch that controls the cab lights.
(WHITE - OFF - RED).
20 Switch, TRACK LIGHTS Two-position rocker switch that controls track lights. (ON -
OFF).
21 Switch, PARKING LIGHTS Two-position rocker switch that operates the parking lights.
(ON - OFF).
22 Gauge, FUEL TANK Indicates fuel level in fuel tank.
23 Switch, CAB HEATER Three-position rocker switch that controls the cab heater.
(LOW - OFF - HIGH).
24 VOLTMETER Indicates battery voltage when the vehicle’s ignition switch is

in the START position. Indicates alternator voltage when
unit is in operation.
25 Switch VENT FAN Two-position rocker switch that controls the cab vent fan(s).
(ON - OFF).
26 Gauge, CONVERTER OIL TEMP Indicates transmission oil temperature.
27 Switch, FRONT WIPERS Three-position rocker switch that controls the front wind-
28 Gauge, TRANS LED Indicates transmission gear selection FWD, REV, or NEUT
for direction and 1, 2, 3, and 4 for speed. Indicates trans-
mission error codes.
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Table 3-2, Side-Mount Cab System Control Panel (Cont)
29 Indicator, STOP ENGine (Red) This indicator will illuminate when an engine shutdown down
is required. (Low oil pressure, high temperature, engine
overspeed, etc.)
30 Blank
31 Indicator, WAIT TO START (Amber) This indicator will illuminate when the engine is safe to start
Optional when using the optional pre-heat system.
32 Indicator, ENGine CHECK (Amber) This indicator will illuminate when an engine check is
required. (Engine running with a fault).
33 Gauge, ENGine OIL PRESSURE Indicates engine oil pressure.
34 Blank
35 Gauge, ENGINE COOLANT Indicates engine coolant temperature.
36 Switch, Engine STARTER A key-type switch with a spring-return that controls the
engine operation. (STOP - RUN - START).
37 Switch, AIR COMPRESSOR Two-position toggle switch that controls the auxiliary air
compressor. (ON - OFF).
38 Control, VEHICLE EMERGENCY Controls Rail King Park brakes (Pull to apply/Push to
BRAKE (Yellow Knob) release).
Not Alarm, WARNING, LOW AIR Audible alarm when air pressure is low. (Located inside
Shown PRESSURE gauge panel).
Optional Indicator, SEQUENCE Indicates the Rail King remote control switch and control
valve settings are conflicting. (Installed on units with the
optional remote control system.)
Optional Control Switch, NORMAL/REMOTE Two-position rotary switch that controls electrical power to
the remote control system. (Installed on units with the op-
tional remote control system.)
Optional Control, NORMAL - DOWN/REMOTE Push/Pull knob at top of the control panel that controls air to
- UP the remote control system. (Pull to apply/Push to remove).
(Installed on units with the optional remote control system.)
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Figure 3 Full-Width Cab Operator’s Controls
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Table 3-3, Full-Width Cab Operator’s Controls
1 Station, Control Left-hand control station for vehicle road and rail operation.
2 Pedal, Brake Controls roadwheel and railwheel brake system.
3 Pedal, Accelerator Controls vehicle speed during roadwheel and railwheel

operations.
4 Shift Lever, Roadwheel & Railwheel, Controls speed and direction of vehicle during roadwheel
Transmission Speed and Direction and railwheel operation. Automatic three-position shift lever:
(F) for forward operation, (N) for neutral operation, and (R)
for reverse operation.
5 Shift Lever, Railwheel Transmission Controls speed and direction of vehicle during railwheel
Speed and Direction operation. Automatic three-position shift lever: (F) for for-
ward operation, (N) for neutral operation, and (R) for reverse
operation.
6 Control Panel, System Contains controls and indicators for railcar coupler and
vehicle operation. Refer to Figure 4 for configuration and
descriptions of controls.
7 Not Shown
8 Steering Wheel, Roadwheel Controls steering of vehicle through the road-drive axle.
9 Control Station, Rail Drive Right-hand control station for vehicle rail operation only.
10 Fan, Vent Operator cooling fan.

(Not
Shown)
11 Light, Dome Illuminates interior cab.
12 Heater Provides cab heat for operator.
13 Cable, Horn Operates horn. (Pull to sound horn).
NOTE: Horn should be used as a signaling device, not as a

communication device.
14 Gauge, TRANS LED Indicates transmission gear selection FWD, REV, or NEUT
for direction and 1, 2, 3, and 4 for speed. Indicates trans-
mission error codes.
3117107 13 of 22
Figure 4 Full-Width System Control Panel (Sheet 1 of 3)
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Table 3-4, Full-Width System Control Panel
1 Gauge, TRAIN AIR BRAKES PRES & Indicates train air brakes system pressure and reservoir air
RESERVOIR AIR PRESsure pressure.
RED – MAIN REServoir
WHITE – BRAKE PIPE Pressure
2 Gauge, CONVERTER OIL TEMP- Indicates transmission oil temperature.

erature
3 Gauge, ENGINE COOLANT TEMP- Indicates engine coolant temperature.

erature
4 Gauge, ENGINE OIL PRESsure Indicates engine oil pressure.

5 TACHOMETER Indicates engine rpm and total engine operating time (in
hours).
6 Voltmeter Indicates battery voltage when the vehicle’s ignition switch is

in the START position. Indicates alternator voltage when
unit is in operation.
7 Gauge, FUEL LEVEL Indicates level in fuel tank.
8 Switch, CAB LIGHTS Three-position rocker switch that controls the cab lights.
(WHITE - OFF - RED).
9 Switch, TRACK LIGHTS Two-position rocker switch that controls the track lights. (ON
- OFF).
10 Switch, REAR HEAD LIGHTS Three-position rocker switch that controls the rear head
11 Switch, PARKING LIGHTS Two-position rocker switch that controls the parking lights.
(ON - OFF).
12 Switch, FRONT HEAD LIGHTS Three-position rocker switch that controls the front head
13 Switch, CAB HEATER Three-position rocker switch that controls the cab heater.
(HIGH - OFF - LOW).
14 Switch, AIR DRYER HEATER Two-position rocker switch that controls the air dryer heater.
(ON - OFF).
15 Switch, VENT FANS Two-position rocker switch that controls the cab vent fans.
(ON - OFF).
16 Switch, REAR WIPERS Three-position rocker switch that controls the rear wind-
17 Switch, FRONT WIPERS Three-position rocker switch that controls the front wind-
18 Switch, AIR COMPRESSOR Two-position rocker switch that controls the auxiliary air
compressor. (ON - OFF).
19 Indicator, WAIT TO START (Amber) This indicator will illuminate when the engine is safe to start
Optional when using the optional pre-heat system.
3117107 15 of 22
16 of 22 3117107
Table 3-4, Full-Width System Control Panel (Cont)
20 Switch, ENGINE STOP and START A key-type (spring-return) switch that controls the engine
stop, on, and start operation. (STOP - ON - START).
21 Indicator, ENGINE DIAGNOSTIC This indicator will illuminate when there is an engine check
(Amber) required. (Engine running with a fault).
22 Shift Selector, TRANSMISSION Two-position rocker switch that controls operator station for
transmission control, railwheel operation. Two-position shift
(RH [Right Hand] - LH ([Left Hand]).
23 Indicator, STOP ENGINE (Red) This indicator will illuminate when there is an engine shut-
down required. (Low oil pressure, high temperature, etc).
24 Blank
25 Control, TRAIN AIR DISCHARGE Control railcar air brakes. Pull to CHARGE; push to
(Railcar Brakes) DISCHARGE.
26 Switch, COUPLER RELEASE Two-position rocker switch that controls the operation of the
front or rear coupler disengage mechanism.
27 Control Lever, TRAIN AIR BRAKE Controls train (railcar) air brakes. Used to APPLY or
RELEASE brake pressure.
28 Control Lever, Vehicle BRAKE Controls roadwheel and railwheel brake system. Primarily to
be used for braking while on rail.
NOTE: The lever applies the Rail King brakes only. It does
not apply the railcar brakes.
29 Control Lever, ACCELERATOR Controls vehicle speed during roadwheel and railwheel
operations.
30 Switch, FRONT COUPLER Three-position rocker switch that controls the left and right
Sideshift movement of front coupler mechanism. (LEFT - OFF -
RIGHT).
31 Switch, FRONT COUPLER Three-position rocker switch that controls the up and down
UP/DOWN movement of the front coupler mechanism. (UP - OFF -
DOWN).
NOTE: Switches 26, 30, 31, 32, 33, 34, 36, & 37 are
momentary switches. When the switch is pressed, the
mechanism will move in the desired direction. When the
switch is released, the mechanism will stop and the switch
will
return to the OFF position.
32 Switch, Railwheel SANDER Three-position rocker switch that controls the application of
sand to both front and rear rails. (FRONT - OFF - REAR).
3117107 17 of 22
18 of 22 3117107
Table 3-4, Full-Width System Control Panel (Cont)
33 Switch, Rear COUPLER SIDE SHIFT Three-position rocker switch that controls the left and right
movement of the rear coupler mechanism. (LEFT - OFF -
RIGHT).
34 Switch, REAR COUPLER UP/DOWN Three-position rocker switch that controls the up and down
movement of rear coupler mechanism. (UP - OFF - DOWN).
35 Indicators, ROAD WHEELS (Red) These indicators will illuminate when the roadwheels are not
completely retracted.
NOTE: These lights must be out when operating Rail King

on the rails.
36 Switch, Front VEHICLE UP/DOWN Three-position rocker switch that controls the up and down
movement of the front of the Rail King. Located on road-
wheel drive side only. (UP - OFF - DOWN)
37 Switch, Rear VEHICLE UP/DOWN Three-position rocker switch that controls the up and down
movement of the rear of the Rail King. Located on road-
wheel drive side only. (UP - OFF - DOWN)
38 Control, SYSTEM PARK BRAKE Yellow knob located in recessed area of control panel that
controls the system park brake. (Pull to apply/Push to
release).
Not Alarm, WARNING, LOW AIR Audible alarm when air pressure is low. (Located inside
Shown PRESSURE gauge panel).
Optional Indicator, SEQUENCE Indicates the Rail King remote control switch and control
valve settings are conflicting. (Installed on units with the
optional remote control system.)
Optional Control Switch, NORMAL/REMOTE Two-position rotary switch that controls electrical power to
the remote control system. (Installed on units with the op-
tional remote control system.)
Optional Control, NORMAL - DOWN/REMOTE Push/Pull knob at top of the control panel that controls air to
- UP the remote control system. (Pull to apply/Push to remove).
(Installed on units with the optional remote control system.)
3117107 19 of 22
Figure 5 Optional Train Chief® Transmitter Controls
20 of 22 3117107
Table 3-5, Optional Train Chief® Transmitter Controls
1 Indicator, PWR/BAT A LED used to indicate these transmitter operational states:

Steady On LED – Ready, powered on with AC power or
battery
Off LED – Transmitter powered off
2 Button, E-STOP A push button used to stop the Rail King during any emer-
gency condition
3 Indicator, RF LINK A LED used to indicate the RF LINK is active.
4 Joystick, THROTTLE INCREASE/ A multi-position, spring return to center lever that provides
VEHICLE BRAKES nine steps (away from operator) for brake release and en-
gine throttle advance. When rotated toward the operator, it
provides five steps of vehicle brake application. When re-
leased, the lever returns to the center position.
5 Button, HORN A button used to activate the Rail King’s horn.
6 Toggle Switch, POWER ON/OFF A two-position toggle switch used to power on and power off
the transmitter.
7 Toggle Switch, FWD/N/REV Direction A three-position locking toggle switch used to select the
Select direction (Forward, Neutral, Reverse) of Rail King travel.
The switch requires a pull-up motion to change position.
8 Toggle Switch, TRAINLINE BRAKES A three-position toggle switch (maintain/off/ momentary)

APPLY/RELEASE used to operate the trainline brakes. The maintain (Release)
position releases the train line brakes. The off position holds
that last applied brake pressure. The momentary (Apply)
position increments the trainline brakes with each toggle.
9 Indicator, ALERT An audible alert device use to provide warnings for various
reasons.
10 Toggle Switch, FRONT/REAR A two-position toggle switch (maintain/maintain) used to

Coupler Select select the coupler (Front or Rear) to be controlled. Coupler
motion control is directed to the selected coupler.
11 Button, UNCOUPLE A button used to open the selected coupler.
12 Button, SAND A button used to dispense sand from the Rail King in the
direction of movement.
13 Joystick, COUPLER POSITIONING A multi-position, spring return to center lever that provides
LEFT/RIGHT and UP/DOWN left or right motion and up and down movement of the se-
lected coupler.
3117107 21 of 22
22 of 22 3117107
CHAPTER 4 — OPERATING INSTRUCTIONS REV. 1
TABLE OF CONTENTS
4. Operating Instructions............................................................................................... 3
4.1 Prestart Checks .............................................................................................................. 3
4.2 Starting Rail King ............................................................................................................ 6
4.3 Transmission Operation ................................................................................................. 8
4.4 Roadwheel Operation ................................................................................................... 10
4.4.1 Friction Drive ......................................................................................................... 10
4.5 Placing Vehicle on Rail ................................................................................................. 10
4.5.1 Friction Drive ......................................................................................................... 10
4.6 Coupling Rail King to Railcar ........................................................................................ 11
4.7 Weight Transfer ............................................................................................................ 12
4.8 Stopping ....................................................................................................................... 13
4.9 Train Air Brake System ................................................................................................. 13
4.10 Uncoupling .................................................................................................................... 14
4.11 Removing Vehicle from Rail ......................................................................................... 15
4.12 Shutdown Procedure .................................................................................................... 15
4.13 Remote Control Operation (Optional Equipment) ......................................................... 16
4.14 Loading the Rail King for over the Road Transport ...................................................... 19
4.15 Unloading the Rail King from the RGN Trailer .............................................................. 20
4129831 1 of 20
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4. Operating Instructions
4.1 Prestart Checks
If you should find yourself unsure of an operating procedure, contact

your supervisor for guidance.
Before using the equipment, the operator should carefully read the in-
structions in this section and become familiar with the Rail King® cab
operator’s controls and indicators.
To ensure safe, reliable operation, perform the following checks (see also Table 4-1,
Operator’s Checklist) before operating the vehicle:
1. Set parking brake by pulling the PARK BRAKE button (yellow).
2. Walk around and inspect vehicle for damage or missing equipment.
3. Check tires for damage, cuts, and cracks in sidewall and foreign objects in treads.
4. Check tire pressure. Cold tire pressure should be 100 psi.
5. Check engine for oil leaks.
6. Inspect for loose road/railwheel nuts.
7. Check for leaking planetary wheel-end housings (front axle only).
8. Check lights for damage.
9. Ensure fire extinguishers are fully charged and secured in place. Verify that the inspec-
tion date is current.
10. Check that sand boxes are filled with clean, dry sand. Add sand, if required.
NOTE: Stewart & Stevenson recommends the use of TrackGlass Recycled

Glass Traction Media for enhanced tractive effort. It can be ordered from the
S&S Rail King Parts Department or your local authorized Rail King dealer.
4129831 3 of 20
11. Look underneath vehicle for leaks of coolant, hydraulic fluid, transmission fluid, or lubri-
cating oil. If significant leaks in any of these systems are found, repair them before oper-
ating the vehicle.
12. Check that the engine oil is between the marks on the dipstick. Add oil, if required.
Do not loosen or remove radiator cap while coolant is hot. Hot coolant
escaping under pressure can cause severe burns.
13. Check that the engine coolant level is full in the radiator. Add coolant as necessary, but
do not overfill. Make a visual check for leaks.
14. Inspect the engine compartment for loose hardware, loose wires, and leaking lines or fit-
tings.
15. Check the hydraulic system reservoir sight glass for proper fluid level. Hydraulic fluid
should be between the marks on the sight glass. A low fluid level indicates a serious leak
in the system. Repair the leak before operating the vehicle.
16. Check fuel level gauge to ensure that the tank is full.
17. Inspect the train air compressor oil level at the dipstick. Add only 10w synthetic air com-
pressor oil if required.
18. When all mechanical checks are completed, move to the driver's seat in the cab. Check
the operation of the stoplights, taillights, headlights, rail lights, and dash panel lights.
NOTE: Fuel contamination from moisture condensation on the inner surfac-

es of the fuel tank can be minimized or eliminated by keeping the fuel tank
as full as possible. The fuel tank should always be topped off at the end of
the day’s operation maintenance routine.
4 of 20 4129831
Table 4-1, Operator’s Checklist (Pre- and Post-Shift)
DATE: SHIFT: S/N: MODEL:

NOT
WALK-AROUND INSPECTION OK OK COMMENTS
General Machine Condition
Engine Oil Level
Water and/or Anti-Freeze Level
Fan Belts (Visual Inspection)
Radiator & Hoses (Visual Inspection)
Train Air Compressor Oil Level
Transmission Fluid Level
Hydraulic Fluid Level
Drain Water from Air Tanks
Sandbox-Sand Level & Condition
Lube Front Coupler Beam (Visual Inspection)
Lube Rear Coupler Beam (Visual Inspection)
Hydraulic Hoses & Cylinders (Visual Inspection)
Railwheel Retaining Bolts (Visual Inspection)
Boarding Halter & Handrails (Visual Inspection)
Tire Condition
Train Air Hoses (Visual Inspection)
CHECKS MADE FROM OPERATOR’S SEAT

Fuel Level
Engine Oil Pressure
Transmission Pressure
Alternator Charging
Parking Brake Holding
Service Brakes Operational
Horn
Lights
Instrument Panel Gauges & Indicators
Operation of Front & Rear Coupler
Operation of All Controls
Cab Windows
Windshield Wipers (Front & Rear)
Brake Line Pressure
Cab Heater
Track Mirrors
Repairs Needed/Other Comments
Inspected By:
4129831 5 of 20
4.2 Starting Rail King®
To prevent a possible fatality or serious injury, ensure that all nearby

personnel are clear of the Rail King before starting the engine.
Use the following procedures to start the Rail King railcar mover:
1. Check that parking brake is applied and ROAD-DRIVE and/or RAIL-DRIVE Transmis-
sion Speed and Direction lever(s) are in Neutral (N) position.
To avoid overheating the starter motor, do not operate starter more

than 30 seconds without allowing a minimum cooling period of 2 min-
utes between start attempts.
2. To start engine, turn key-operated ENGINE STOP/START switch to START position.

When engine starts, release switch.
3. Allow engine to idle. Check all temperature and pressure gauges and ensure all systems
are operating within normal parameters (see Table 4-2).
Table 4-2, Normal Operating Parameters

Parameter Range
Engine Oil Pressure – Low Idle (minimum allowed) 15 psi
Engine Oil Pressure – At Rated Speed (minimum 45 psi
allowed)
Coolant Temperature 160–225 °F
Converter Oil Temperature 160–250 °F
Hydraulic Oil Pressure 2500 psi
Reservoir Air Pressure 100–130 psi
Railcar Brake Pressure 90 psi
4. Check STOP ENGine and ENGINE CHECK lights.
NOTE: The ENGINE CHECK light will illuminate and stay on continuously
while the engine is running and the STOP ENGINE light will illuminate con-
tinuously or be flashing if any of the conditions (faults) occur.
6 of 20 4129831
To avoid irreparable damage to the engine, do not continue to operate

the engine, unless it is unsafe to shut it down.
NOTE: Refer to the Cummins Troubleshooting and Repair Manual to re-

trieve engine fault codes.
5. When engine coolant temperature reaches 160 °F, leave engine running and check
transmission oil level. Oil should be between marks on dipstick. If low, shut down engine
and add oil as required. Do not over-fill.
To prevent possible fatality or serious injury, do NOT touch the air or

hydraulic lines.
6. Visually check air and hydraulic lines for leakage.
7. Check operation of air horn.
NOTE: Horn should be used as a signaling device, not a communication

device.
8. Ensure that the cab-mounted run beacon is operating.
4129831 7 of 20
4.3 Transmission Operation

The Funk Transmission is a 4-speed, forward or reverse automatic shift. The gear speed,
forward or reverse, can only be selected while the shift selector is in the neutral position and the
machine is at a full stop. The direction and the gear speed cannot be changed while the ma-
chine is moving. If the speed or direction of travel (forward or reverse) is changed while the ma-
chine is moving, the machine will continue in the same direction and speed as first selected.
Use the following procedure to operate the Rail King transmission:
1. (Side-mount cab models proceed to step #2) On full-width cab models, place
TRANSMISSION SHIFT SELECTOR rocker switch in the Left Hand or Right Hand
position, indicating the station (roadwheel or railwheel) in which the machine is to be
operated.
2. Ensure that parking brake is engaged and that the TRANSMISSION SPEED and
DIRECTION shift lever is in the neutral position.
3. Turn the ENGINE STOP/START switch to the START position. Allow the engine to start
and all pressures and temperatures to stabilize. The TRANS LED indicator will indicate
N1 when engine is operating. Do not idle the engine for long periods of time.
Idling the diesel engine for long periods of time produces sulfuric ac-
id, which breaks down the oil and eats into bearings, rings, valve
stems and engine surfaces.
4. Release the parking brake, but maintain pressure on the foot brake. If unit is placed in
gear and the park brake is then released, the unit will not move. The park brake must be
released before putting the unit in gear.
NOTE: The machine may be started with the roadwheels in the UP or

DOWN position or from the roadwheel or railwheel control station.
5. Place the TRANSMISSION SPEED and DIRECTION shift lever in the desired gear
speed. The TRANS LED will indicate N1, N2, N3, or N4. Ensure that the gear speed se-
lected is the top speed required for your operation.
8 of 20 4129831
When operating with NO LOAD, the machine will shift rapidly from first
gear to the highest gear selected and accelerate to top speed. Top
speed is about 15 mph on the railwheels and about 9 mph on the
roadwheels.
NOTE: The shifting of the transmission speed is governed by engine rpm

and load.
6. Place the TRANSMISSION SPEED and DIRECTION shift lever in the desired direction
(F-forward or R-reverse). The TRANS LED will indicate F1, F2, F3, or F4 for forward and
R1, R2, R3, or R4 for reverse.
NOTE: With TRANSMISSION SPEED and DIRECTION shift lever in for-

ward: when operating on the roadwheels and the TRANS LED indicates F1,
F2, F3, or F4 the machine will move in reverse; when operating on the rail-
wheels and the TRANS LED indicates F1, F2, F3, or F4 the machine will
move forward.
NOTE: With TRANSMISSION SPEED and DIRECTION shift lever in re-

verse: When operating on the roadwheels and the TRANS LED indicates
R1, R2, R3, or R4 the machine will move forward; when operating on the
railwheels and the TRANS LED indicates R1, R2, R3, or R4 the machine
will move in reverse.
7. Release the pressure on the brake and press accelerator pedal.
NOTE: Engine response versus pedal movement may feel different from a
mechanical governed engine. The electronic accelerator pedal assembly is
designed to communicate “percentage” accelerator pedal travel to the en-
gine’s electronic control module. The engine will respond accordingly to the
operator’s demand.
8. Once the task is completed, the Rail King Rail Car Mover should be placed in a desig-
nated parking area and Shutdown Procedures should be accomplished.
9. If the machine is to be towed, the roadwheels must be in the full down position. It will be
necessary to run the engine at idle speed to lubricate the clutches. If the engine cannot
run, towing must be limited to three miles per hour and for a distance not exceeding one
mile (maximum). If these conditions are to be exceeded, the drive shafts must be dis-
connected and towing is permissible at speeds not to exceed the machine recommend-
ed speeds.
4129831 9 of 20
4.4 Roadwheel Operation

4.4.1 Friction Drive
Use the following procedures to operate the Rail King on roadwheels:
1. Press the front rocker switch marked ROADWHEELS FRONT in the UP position. Ensure
that the front roadwheels are fully lowered prior to releasing the switch. Press the rear
rocker switch marked ROADWHEELS REAR in the UP position. Ensure that rear road
wheels are fully lowered prior to releasing the switch.
2. Press brake pedal and push PARK BRAKE button (yellow) on dashboard to release
parking brake.
3. Place the TRANSMISSION SPEED and DIRECTION shift lever in the desired direction
(F-forward or R-reverse). The TRANS LED will indicate F1, F2, F3, or F4 for forward and
R1, R2, R3, or R4 for reverse.
4. Release brake pedal and press accelerator pedal to desired speed, depending on exist-
ing conditions, required to move railcar safely to the desired locations.
To prevent possible fatality or serious injury to nearby personnel, en-

sure that rear axle area is clear before turning the steering wheel.
5. Steer the vehicle by turning the steering wheel in the desired direction. The vehicle is
steered through use of the rear axle, so care must be taken when maneuvering around
personnel and equipment.
6. To stop the Rail King on the road, the following three methods can be employed:
• Release accelerator pedal and press brake pedal.
• Release accelerator pedal. The vehicle will come to a gradual stop.
• Place the ROAD-DRIVE transmission selector lever in the neutral (N) position. The
vehicle will come to a gradual stop.
4.5 Placing Vehicle on Rail

4.5.1 Friction Drive
Approach rails at an improved crossing only. Perform the following procedures:
1. Maneuver the Rail King so that it is parallel over the rails. Observe the position of the
front railwheels relative to the top of the rails. Flanges on the railwheels must be on the
inside of the rails.
10 of 20 4129831
2. When the Rail King has been correctly positioned, place the transmission speed and
direction shift lever in the neutral (N) position, then press the front rocker switch marked
ROADWHEELS FRONT to the DOWN position. By pressing the rocker switch, the
vehicle's front rail-wheels can be settled onto the rails. Ensure that the roadwheels are in
the full up position prior to releasing the switch.
3. Place transmission speed and direction shift lever in the reverse (R) position. Press the
accelerator pedal slowly and steer the Rail King to position rear railwheels over the rails.
Stop the Rail King by releasing the accelerator pedal and pressing the brake
pedal.
4. Using the same procedure as in step (2), press the rear rocker switch marked
ROADWHEELS FRONT/REAR in the DOWN position. Allow the rear railwheels to
slowly settle onto the rails.
5. Ensure that the roadwheels are in the full up position.
NOTE: The roadwheels will be in the full up position when the red indicator
light for the roadwheels is extinguished.
6. Drive a short distance forward to ensure that the Rail King is securely settled and posi-
tioned onto the rails.
4.6 Coupling Rail King to Railcar
To avoid damage to equipment, always approach railcar at minimum

speed. Use extra caution when rails are wet or icy because stopping
distance increases under these conditions.
NOTE: For maximum traction, couple the vehicle in a pushing position. For
maximum visibility, couple the vehicle in a pulling position. Check the weight,
number, and position of cars to be moved. In difficult areas such as sharp
curves, traction may be lost, especially when pulling cars. If this happens,
reverse direction for a short distance and then stop. Now resume normal di-
rection with more power to gain momentum. Sanding the rail while reversing
direction will also increase traction.
4129831 11 of 20
Approach the railcar, sanding the rails if track conditions indicate a need for extra traction.
Stop short of the railcar coupler and perform the following procedures:
To prevent possible fatality or serious injuries, ensure that personnel

are clear of the Rail King and railcars before beginning coupling oper-
ations.
1. Align the vehicle's coupler to match the position of the railcar coupler.
2. Press the rocker switch marked FRONT or REAR COUPLER, LEFT/RIGHT in the direc-
tion required to align the couplers.
3. Move the control lever marked FRONT or REAR COUPLER, UP/DOWN to the position
required to align the couplers. Height is correct when the railcar mover's coupler knuckle
will enter the railcar's coupler fully.
4. Move the Rail King gently against the railcar with enough force to close and lock the ve-
hicle's coupler. Test the coupler to ensure that it has properly locked prior to attempting
to transfer load or move the cars. If the coupler is not properly coupled, recheck align-
ment and repeat coupling with slightly more force until couplers are securely locked.
4.7 Weight Transfer
Be careful when lifting rail car to transfer weight. Lifting an empty rail
car body too high may lift the rail car off its wheel track. Reduce pres-
sure as body begins to rise. When moving more than one car, always
couple to the heaviest car whenever possible. Do not attempt to move
any railcar that is not properly loaded or ready for movement.
NOTE: In cold weather conditions, the railcar's journal grease may thicken.
It may become necessary to individually move the railcars back and forth to
warm the grease, giving the Rail King greater moving capacity.
Perform the following steps to transfer weight with the Rail King:
1. Press the rocker switch marked FRONT or REAR COUPLER, UP/DOWN to the UP po-
sition. Continue raising coupler until full weight of transfer is achieved and then sound
the horn.
2. Release the railcar parking brake manually and remove wheel blocks. Move transmis-
sion speed and direction shift lever to the desired direction. Press the accelerator pedal
slowly to start load. After load is moving, depending on existing conditions, increase
speed required to safely move the railcar to the desired location.
12 of 20 4129831
4.8 Stopping
When stopping the Rail King without a load, remove pressure on the accelerator pedal and
gently press the brake pedal. When stopping under load, anticipate the stop point and adjust
speed accordingly to bring the railcar(s) to a smooth halt. If the operator remains in the cab and
the stop is to be momentary, the engine may be left running; otherwise, the engine should be
shut down.
4.9 Train Air Brake System

The train air brake system supplies air to the railcars to operate their air brakes. It does
NOT control the brakes on the Rail King. The Rail King brakes are separate and are air over
hydraulics, while the brakes on a railcar are air only.
Two air pressure gauges are located on the Rail King control panel. One gauge indicates
the reservoir pressure that is set at 130 psi. The second gauge indicates brake line pressure,
which is the air pressure in the brake line on each car. Depending on in-plant requirements, the
pressures can vary between 70 and 90 psi. The factory setting for the brake line pressure is 90
psi.
Perform the following steps to operate the Rail King train air brakes:
Rail King strongly recommends the use of the train air braking system
for all switching operations. Overloading and premature failure of the
Rail King rail axle brakes can occur if the train air brake system is not
used for stopping the unit while under load.
1. Once the coupler has been engaged, the operator should connect the train air brake
system.
NOTE: The train air brake system supplies air to the railcars to operate the
individual railcar brakes. The train air brake system does NOT control the
brakes on the Rail King.
2. Connect the hoses between the Rail King and the railcar. If the Rail King is connecting to
more than one railcar, ensure that all hoses are connected and the ball valves are open
between each of the railcars.
3. Ensure the ball valve on the last railcar, the opposite end of the Rail King, is closed. This
will create a closed system and allow all the railcars’ braking systems to be charged.
4. Pull up on the train air charge valve to begin charging the system. Ensure that the modu-
lating valve is in the full release position.
5. Observe the train air pressure gauge. The train air brakes will disengage when the air
pressure has reached 90 psi.
4129831 13 of 20
6. Prior to moving any cars, the operator should test the train air brake system to ensure
proper operation. Slowly move the lever on the modulating valve toward the apply posi-
tion. The operator will hear air escaping from the valve. Observe the air pressure gauge.
The train air pressure will begin to decrease.
7. Once the pressure has decreased, the brake rods on the railcar should begin to move,
applying the brakes.
To prevent possible fatality or serious injuries, do not remove the

wheel chock until the hand brakes have been released.
8. Once the railcar train air brakes have been applied, release the railcar hand brakes and
remove the wheel chocks.
9. Move the modulating valve lever to the full release position. This will increase the train
air brake pressure, releasing the railcar train air brakes. Observe the air pressure gauge;
once the pressure has reached 90 psi, the railcars can be moved.
10. Move the modulating valve lever to the Apply position to apply the train air brakes. This
will slow the movement of the railcars. Once the railcars have been stopped, move the
lever to the Full Release position to move the railcars again.
NOTE: The further the lever is moved, the faster the pressure will decrease.
It is important to note that the application of the train brakes does not hap-
pen immediately. Proper judgment of speed and distance is important.
11. Once the railcars have been moved to the desired location, push in the train air charge
valve, chock the wheels, and set the railcar hand brakes. Uncouple from the rail cars
and slowly pull away. The train air brake system hoses will automatically disconnect.
12. In the event of an emergency while the railcars are being moved, the Rail King has the
ability to rapidly apply the train air brakes. Push the train air brake charge valve. This will
dump the air pressure to the railcars, applying the brakes.
4.10 Uncoupling
After the railcar(s) has been positioned at the desired location, manually set the railcar
brake. Release the weight transfer by pressing the rocker switch marked FRONT or REAR
COUPLER, UP/DOWN to the DOWN position, to relieve all pressure. Press the appropriate
FRONT or REAR COUPLER UNCOUPLER rocker switch to disengage the coupler knuckle.
Move the Rail King slowly away from the railcar to ensure that the coupler is disengaged.
14 of 20 4129831
4.11 Removing Vehicle from Rail

Move the Rail King to an improved crossing or where the ground is level with the rail (refer
to Roadwheel Operation description in this section). After vehicle has been raised to its road-
wheels, drive vehicle from rail.
4.12 Shutdown Procedure

After the last operation of the day, perform the following steps to shutdown:
1. Halt vehicle at its parking location.
2. Position transmission speed and direction shift lever(s) in the neutral (N) position.
3. Apply parking brake (yellow button) by pulling it out.
4. Turn off all accessory equipment (lights, etc.).
5. To stop engine, turn key-operated ENGINE STOP/START switch to STOP position.
To allow adequate cool down of the pistons, cylinders, bearings, and

turbocharger, allow the engine to idle 3–5 minutes before engine shut-
down after a full-load operation. Refer to the Cummins Operation and
Maintenance Manual for more information.
NOTE: If vehicle is moved from track and stored for any extended period,
the vehicle should be lowered to its railwheels.
Perform a walk-around inspection of Rail King. Log and/or report items such as the
following:
1. Check for unusual leaks, spills, or fluid losses.
2. Inspect for body, tire, or component damage.
3. Check for missing parts, such as wiper blades, beacon light, etc.
4. Check for any equipment defects that could affect safety or subsequent operation.
5. Fill fuel tank to prevent moisture condensation.
6. Close all cab windows and doors.
7. Ensure that all lights and accessories are turned off and remove key from the ENGINE
STOP/START switch.
4129831 15 of 20
4.13 Remote Control Operation (Optional Equipment)
NOTE: This section is under development. It will be updated at a future

date and the revised pages sent out in a revision package.
To set up the Rail King for radio remote control operation, perform the following steps:
To prevent possible fatality or serious injury, ensure the road wheels

are fully raised as indicated by both Road Wheel lights extinguished.
1. Ensure the Rail King is in proper working order and on the tracks in rail configuration.
Ensure the parking brake is applied, NORMAL/REMOTE manual valve is in the
NORMAL position (pushed in) and NORMAL/REMOTE rotary switch is in NORMAL po-
sition.
2. Start the engine and let idle to build up air pressure.
3. Close the train air hose valves at each end of the Rail King. Ensure the train air dis-
charge valve on the dash is pulled out.
4. In the cab, pull up the knob on the RADIO/REMOTE valve (red button), which is located
on the control panel. The CHECK RADIO indicator will blink and the service brakes are
applied.
5. Turn the NORMAL/REMOTE rotary switch to REMOTE position.
6. Release the parking brake. The CHECK RADIO indicator will stop blinking. If this indica-
tor continues to blink, the Rail King is not ready for radio remote control operation.
7. Set up the Control Chief® transmitter for operation.

• Ensure the battery pack is fully charged.
• Ensure all switches and levers on the transmitter are in their nominal position.
• Ensure the transmitter is not tilted.
16 of 20 4129831
8. Begin operating the Rail King by remote control.

• Apply power to the transmitter by moving the POWER ON/OFF toggle switch to ON
position. The transmitter’s alarm will beep once and the transmitter’s LEDs will initial-
ize. After completion of the self-test, the PWR/BAT and RF LINK LEDs will illuminate
and the others will extinguish.
• Press the HORN button on the right side of the transmitter to establish a link be-
tween the transmitter and the Rail King. The Rail King horn should sound, the trans-
mitter’s RF LINK LED should illuminate, and the transmitter’s alarm should beep, in-
dicating the Rail King’s brakes are being activated.
NOTE: If the Rail King’s horn doesn’t sound but the transmitter alarm
sounds, check all transmitter switch settings and press the HORN button
again. If the Rail King’s horn doesn’t sound and the transmitter alarm doesn’t
sound, check all the switch settings on the Rail King, including the E-Stops
on the side of the Rail King. Press the HORN button again once the switch-
es are in the correct position. Once control of the Rail King is established,
the transmitters RF LINK LED will start blinking. This LED indicator will re-
main illuminated when the NORMAL/REMOTE rotary switch is set to
REMOTE.
9. Release the trainline brakes by moving the APPLY/RELEASE toggle switch to

RELEASE position.
NOTE: To change the Rail King’s direction, the brakes must be fully ap-
plied.
10. Select the direction of travel with the FWD/N/REV toggle switch.
11. Move the THROTTLE INCREASE/VEHICLE BRAKE joystick up to release the Rail King
brakes. Continue to advance by moving the joystick up to accelerate the Rail King. The
further the joystick is moved up from the center position, the more the pressure that is
applied to the throttle.
12. Apply the Rail King brakes by moving the THROTTLE INCREASE/VEHICLE BRAKE
joystick to the down position. The further the joystick is moved down from the center po-
sition, the more the pressure that is applied to the brakes.
4129831 17 of 20
Rail King strongly recommends the use of the train air braking system
for all switching operation. Overloading and premature failure of the
Rail King axle brakes can occur if used to stop unit while under load.
13. Remotely apply the train air brakes by moving the TRAINLINE BRAKES APPLY/
RELEASE toggle switch to the APPLY position; pressure is incrementally decreased
with each toggle of the switch and is maintained at the center off position. To dump the
train air, hold the toggle switch in the APPLY position for three (3) seconds.
14. If the Rail King must be stopped quickly, push the E-STOP button in the middle of the
transmitter.
NOTE: After an E-Stop occurs, the operator must restart the system by
returning all transmitter switches to their idle position and pressing the
HORN button on the transmitter to re-establish the communication link.
15. Remote control of the Rail King may be ended by first bringing the Rail King to a stop
and moving the POWER switch to OFF position. After a four-second delay, the controller
will command an E-Stop.
16. Return the Rail King to manual control.
To prevent unauthorized operation, secure the transmitter and key in

separate locations.
• At the Rail King, place the trainline brake valve to the EMERGENCY position.
• Set the NORMAL/REMOTE switch on the cab control panel to MANUAL to remove
electrical power to the receiver/controller.
• Set the parking brake.
• Push in the NORMAL - DOWN/REMOTE - UP valve on the control panel to remove
air supply to the receiver/controller.
• Turn the key switch to OFF and remove the key.
18 of 20 4129831
4.14 Loading the Rail King for over the Road Transport
To avoid injury to personnel, always use lifting equipment, supports,

and chains with a safe minimum capacity of one and a half times that
of the object being lifted or supported. Never attempt to lift Rail King
by its cab.
NOTE: Transport of the Rail King may be subject to customs, federal and/or
local rules and regulations. Contact the appropriate agencies regarding
special permits and additional safety requirements prior to shipment. The
Rail King is designed to be hauled on a minimum 8.5 foot wide RGN
(removable goose neck) type trailer. Refer to the technical specifications for
the dimensions and weight for each Rail King model.
To load the Rail King onto the RGN trailer:
1. Ensure the Rail King is in road wheel operating position. Prepare the trailer for loading
by following the manufacturer’s recommend procedure for the trailer. Be sure to place
suitable ramps in front of the trailer to allow the Rail King sufficient clearance to easily
drive onto the trailer. It is preferred to load the rear (steer axle) end of the Rail King onto
the trailer first.
2. With the help of a spotter, slowly drive the Rail King up the ramps and onto the trailer,
steering the unit as required. Ensure the train air hoses on each end are clear and will
not be pinched while loading.
The steer axle road wheels may be at the very outer edges of the
trailer during the loading/unloading process. Use extreme caution to
avoid over-steering and possibly causing the Rail King to slip off the
edge of the trailer. Severe damage to the Rail King and/or trailer as
well as bodily injury or death to yourself or bystanders could result.
3. Once the Rail King has been located to the desired spot on the trailer, shift the transmis-
sion lever into Neutral and apply the parking brake. Position hardwood blocks on trailer
in such locations as necessary to support the Rail King frame at the front and rear
bumper or under the rail wheels. Once the blocks are in place, slowly lower both ends of
the Rail King until the entire weight of the unit is supported by the blocks. Leave the road
wheels in the down position so they are also resting on the trailer, but not supporting any
weight.
4. Shut down the Rail King and close all windows, ensuring they are latched closed so that
they will not open. Turn off all switches, close both cab doors, and lock (if required). If
additional protection is required for the windows, cover the windows with heavy card-
board, using bands around the cab.
5. Attach chains of sufficient strength from Rail King frame to tie-down points on trailer. Use
at least four (4) chains (2 front and 2 back) to prevent the Rail King from shifting on the
trailer during transport. Tighten all chains and binders securely.
4129831 19 of 20
6. Ensure that the sandbox lids are tied down for transport (or remove them and put them
in the cab).
NOTE: Be sure the lids are secured properly. Failure to secure the sandbox
lids may result in the lids inadvertently coming off during transport.
4.15 Unloading the Rail King from the RGN Trailer

To remove the Rail King from the trailer:
1. Prepare the trailer for unloading by following the manufacturer’s recommend procedure
for the trailer.
2. Remove all chains and binders from the Rail King. Install suitable ramps in front of the
trailer to allow the Rail King sufficient clearance to easily drive off the trailer.
3. Remove banding and cardboard from windows (if installed).
4. Start the Rail King and allow the engine to idle until all pressures are correct and the unit
has warmed up.
5. Raise the Rail King to the fully raised (road wheel operation) position.
6. Remove any blocks or other material from the floor of the trailer.
7. With the help of a spotter, release the parking brake, shift the transmission into gear,
and slowly drive the Rail King from the trailer.
The steer axle road wheels may be at the very outer edges of the
trailer during the loading/unloading process. Use extreme caution to
avoid over-steering and possibly causing the Rail King to slip off the
edge of the trailer. Severe damage to the Rail King and/or trailer as
well as bodily injury or death to yourself or bystanders could result.
8. Once the Rail King is on the ground, inspect the unit for any damage that might have
occurred while in transport. Replace sand box lids (if removed for transport).
20 of 20 4129831
CHAPTER 5 — RAILROAD HAND SIGNALS REV. 0
TABLE OF CONTENTS
5. Railroad Hand Signal ................................................................................................ 3
5.1 Use of Hand Signals ....................................................................................................... 3
5.2 Standard Hand Signals ................................................................................................... 3
3117107 1 of 4
2 of 4 3117107
5. Railroad Hand Signal

5.1 Use of Hand Signals
Railroad hand signals are used to communicate messages from ground workers to rail
vehicle operators. Hand signals must be used when switching rail cars to ensure safe and
efficient operation.
5.2 Standard Hand Signals

Figure 1 shows the standard hand signals used in railcar switching operations. Study these
signals carefully and know when and how they are used.
3117107 3 of 4
STOP
Swing right arm in front of you at right angle to track.
REDUCE SPEED
Hold right arm out horizontally to track.
PROCEED
Raise lower right arm vertically.
BACK UP
Swing right arm in a vertical circle at right angle to track.
APPLY BRAKES
Swing right arm back and forth above head.
Figure 1 Railroad Hand Signals
4 of 4 3117107
CHAPTER 6 — PERIODIC MAINTENANCE SCHEDULE REV. 1
TABLE OF CONTENTS
6. Periodic Maintenance ............................................................................................... 3
6.1 Introduction ..................................................................................................................... 3
6.2 Periodic Maintenance Schedule ..................................................................................... 3
6.2.1 Frame ...................................................................................................................... 6
6.2.2 Coupling System ..................................................................................................... 6
6.2.3 Engine ..................................................................................................................... 6
6.2.4 Rail-Drive System .................................................................................................... 6
6.2.5 Road-Drive System ................................................................................................. 6
6.3 Hydraulic Valve Adjustments .......................................................................................... 6
4129831 1 of 12
2 of 12 4129831
6. Periodic Maintenance
6.1 Introduction
The maintenance section is a guide for use under normal operating conditions. Normal
operating conditions include:
1. Operating with engine at normal operating temperature.
2. Operating at maximum horsepower rating.

Prolonged periods of idling and operation before normal temperatures develop are abusive
to the engine.
When working within the engine compartment, beware of rotating

devices, such as fan, belts, etc.
Engine exhaust piping and manifolds may still be hot. Move carefully
to avoid burns. If time permits allow unit to cool down before attempt-
ing any maintenance of service.
Table 6-1 is the recommended periodic maintenance schedule for rou-

tine operating conditions. If Rail King® is operated in unusual or harsh
environment, modify the schedule as necessary.
Periodic maintenance intervals are based on hours of operation as shown on the engine
hour meter. Table 6-2 defines the lubricants that are to be used in the Rail King®. Refer to the
engine service manual for fuel specifications. Other fluids should not be used without first con-
sulting a Stewart & Stevenson Rail King technical representative.
6.2 Periodic Maintenance Schedule

Refer to Table 6-1 and perform the maintenance as required. The operator should always
verify proper engine operation, as shown by instrument panel gauges, and listen for unusual
noises, giving attention to unusual vibrations. Report or investigate any unusual conditions.
4129831 3 of 12
Table 6-1, Generation 4 Rail King Periodic Maintenance Schedule
Periodic Maintenance Task 250 Hours 500 Hours 750 Hours 1000 Hours
Engine oil and filter I X I X

Engine air filter X X X X
Coolant filter X X
Coolant level and SCA content A X
Upper and lower radiator hoses C X
Flush coolant system X
Fuel filter I X I X
Fuel strainer I I
Transmission filter X X
Transmission fluid C C C X
Hydraulic filter X X
Hydraulic fluid C C C X
Auxiliary air compressor filters - cartridges I I I X
Auxiliary air compressor oil C X C X
Battery cables I I I I
Grease coupler beams X X X X
Grease all grease fittings X X X X
Wear plates C C
Engine thermostat C
Engine fan belt and tensioner C X
Turbo charger C
Crank shaft damper C
Coupler system I I I I
Rail wheels C C C C
Train air pressure I I
Pilot air valve C C C C
Hydraulic pressures A
Front and rear differential oil X X
Front and rear differential wet brakes C C
4 of 12 4129831
Table 6-1, Generation 4 Rail King Periodic Maintenance Schedule (Cont)
Periodic Maintenance Task 250 Hours 500 Hours 750 Hours 1000 Hours
Air dryers C C C X
Park brake on transmission C A C A
Brakes on road wheels C A C A
Drive hub oil and play C C C X
Wheel bearings C C
Tire pressure C C C C
Engine belt tensioner C X
Unit safety and proper operation check list C C C C
Oil analysis Customer Option
KEY:
I = Inspect & Clean X = Change
A = Inspect & Adjust C = Check
NOTE: The interval at which periodic maintenance is performed can change

depending on the equipment’s operating environment. This chart is only a
guide for proper maintenance in a good working environment. Changes will
need to be made to this schedule if the Rail King® is located in an unfavora-
ble environment. Please contact the S&S Rail King® service department for
help in accessing your maintenance needs.
4129831 5 of 12
6.2.1 Frame
Maintenance is restricted to corrosion prevention through the use of paint. Exposed metal
surfaces (except the coupling slide bars) should be sanded, primed, and painted.
6.2.2 Coupling System

Coupling slide bars are self-cleaning through daily use. If the Rail King® is to be idle for a
period of time, a light coating of oil should be applied to all four surfaces of each coupling slide
bar.
6.2.3 Engine
For engine service and repair procedures, refer to the Cummins engine manual (not
provided by Stewart & Stevenson).
NOTE: Stewart and Stevenson does not supply Cummins engine manuals.
To obtain engine-specific manuals, register your engine on Cummins’ web
site at https://prodreg.cummins.com/prodreg/productRegistration.do.
6.2.4 Rail-Drive System

Refer to the applicable Funk Transmission Model DF Series 150 (Analog) manufacturer’s
manual located in the Rail King Service Manual (Chapter 6).
6.2.5 Road-Drive System

Brakes — Refer to the manufacturer’s manual provided as part of the Rail King Service
Manual (Chapter 6).
Roadwheels — Tires are hard rock lug, 16-ply, with tubes. Worn or damaged tires should
be replaced. New tubes should be mounted with new tires.
6.3 Hydraulic Valve Adjustments

Refer to the Rail King Service Manual (Table 3-1 in Chapter 2, Section 3) for hydraulic
valve adjustment procedures. The Stewart & Stevenson drawings referenced for the hydraulic
system are located in the Rail King Service Manual (Chapter 5).
6 of 12 4129831
Figure 1 Servicing Chart Points (See Table 6-2)
Table 6-2, Servicing Chart Points (See Figure 1)

Item Number Fluid Item Number Fluid
1 Engine Oil 6 N/A
2 Transmission Oil 7 Chassis Lubrication
3 Hydraulic Oil 8 Diesel Fuel
4 Engine Coolant 9 Waterproof Chassis Lubricant
5 Axle Oil 10 Train Air Compressor Oil
4129831 7 of 12
Table 6-3, Generation 4 Rail King Filter and Fluid Quick Reference
Fluid / Fluid Reservoir Filter P/N Filter Manufacturer Manufacturer Check
Maintenance Type Capacity* (Qty/Unit) Manufacturer Recommended Recommended
Area (Factory Fluid Change Filter Change
(Component) Fill) Interval Interval
Every 500
hours or when it
Engine Oil Shell
LF3970 Cummins appears cloudy Every 500 Every
(QSB6.7 Rotella 21 quarts
(P550428) (Donaldson) or dirty hours shift
Tier 3) 15w-40
(whichever
occurs first)
Engine Air Primary
When indicator
Filters P608666 Every
N/A N/A Donaldson N/A shows
(QSB6.7 Safety shift
restriction
Tier 3) P601560
Primary -
Replace every
Engine Fuel FF5421
Off- 40 gallons 500 hours or
Filters (P550881) Cummins Every
Highway or N/A sooner if re-
(QSB6.7 Prefilter (Donaldson) shift
Diesel 75 gallons striction is not-
Tier 3) FS19732
ed
(P550848)
Every 1000
hours or when it
Shell John Deere /
Transmission YZ104780 appears cloudy Every 500 Every
Donax 9 gallons Funk
Oil (DF150) (P550417) or dirty hours shift
TC 10w (Donaldson)
(whichever
occurs first)
Auxiliary Air
Every 500 Every
Compressor N/A N/A 4562 Stellar N/A
hours shift
Intake Filter
Every 500
hours or when it
Auxiliary Air Stellar appears cloudy Every
1 quart C0087 Stellar N/A
Compressor Synthetic or dirty shift
(whichever
occurs first)
1200 Every 500
Series** hours or when it
Shell
5 gallons appears cloudy Every
Rail Axles Donax N/A N/A N/A
1400 or dirty shift
TD
Series** (whichever
7 gallons occurs first)
Road Wheel Mobil- N/A N/A N/A Repack every N/A Every
Hubs grease 1000 hours or shift
XHP when other
222 service is per-
formed
8 of 12 4129831
Table 6-3, Generation 4 Rail King Filter and Fluid Quick Reference (Cont)
Fluid / Fluid Reservoir Filter P/N Filter Manufacturer Manufacturer Check
Maintenance Type Capacity* (Qty/Unit) Manufacturer Recommended Recommended
Area (Factory Fluid Change Filter Change
(Component) Fill) Interval Interval
Mobil-
Coupler Slide grease Every
N/A N/A N/A As needed N/A
Bar XHP shift
222
Mobil-
All Other Grease As needed or Every
N/A N/A N/A N/A
Grease Points XHP every 250 hours shift
222
Every 500
Every 1000
hours or when
hours or when it
Shell the filter indica-
appears cloudy Every
Hydraulic Tank Donax 25 gallons P169555 Donaldson tor shows
or dirty shift
TD restriction
(whichever
(whichever
occurs first)
occurs first)
Air Dryer N/A N/A 107796 Bendix N/A Replace Every
(2 on the unit) desiccant filters shift
every 2000
hours
or annually
TrackGlass 50 lbs. 24900172 Every
(traction aid)*** shift
* Actual capacity may be greater due to coolers, lines, and drains. Always verify fluid level through sight
gauge or dip stick per the manufacturer's recommendations prior to operation.
** 1200 series axles are used on the RK275 & RK285. 1400 series axles are used on the RK290,
RK300, RK320, & RK330.
*** Also available in 400 lb. drum (P/N 24900173). Sold individually or by the pallet.
NOTE: This information is meant to be used as a quick reference guide only

and does not supersede the component manufacturer's recommendations.
Please consult your manufacturer's manual for this information when estab-
lishing maintenance intervals and procedures.
NOTE: Stewart & Stevenson highly recommends the use of an engine oil
analysis program to monitor engine lubricants and coolant. The service
criteria of the analysis supersede this recommendation when performed in
accordance with Cummins’ specifications.
4129831 9 of 12
Notes
10 of 12 4129831
Notes
4129831 11 of 12
Notes
12 of 12 4129831

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OPERATOR’S HANDBOOK

Models RK275, RK285, RK290,

10750 Telge Rd. • Houston, Texas 77095

CHAPTER 1 – SAFETY INSTRUCTIONS

1. TABLE OF CONTENTS (CONT)

CHAPTER 2 – VEHICLE DESCRIPTION

CHAPTER 3 – CONTROLS AND INDICATORS

1. TABLE OF CONTENTS (CONT)

CHAPTER 4 – OPERATING INSTRUCTIONS

CHAPTER 5 – RAILROAD HAND SIGNALS

1. TABLE OF CONTENTS (CONT)

REV REVISION TECH PUBS PART SALES ORDER

2.2 Translation Notice

2.3 Copyright Notice

2.4 Proprietary Notice

2.5 Technical Assistance

Stewart & Stevenson

Phone: (281) 345-5110, (855) 744-9481

Stewart & Stevenson Technical Services

Phone: (713) 803-0700

3. HOW TO USE THIS MANUAL

Indicates a potentially hazardous situation, which, if not avoided,

Indicates a potentially hazardous situation, which, if not avoided,

NOTE: Is used to notify personnel of installation, operation, or maintenance

THIS PAGE INTENTIONALLY LEFT BLANK

THIS PAGE INTENTIONALLY LEFT BLANK

2. Protect your fellow employees.

3. Protect and take proper care of tools and equipment.

4. Reporting any unsafe condition, equipment, or operation to the proper authorities.

If you should find yourself unsure of an operating procedure, consult

1.2 Eye Protection

1.3 Protective Clothing

6. Wear heat protection clothing and equipment when conditions warrant.

1.4 Foot Protection

2. Employees engaged in cutting or welding operations should wear welder's spats or

2. Avoid jerking or lifting from twisted positions.

3. Obtain help to lift heavy or cumbersome objects.

2. Keep flames and open sparks away from batteries.

3. Storage battery compartments must be open while recharging.

2. Absolutely no smoking is allowed while refueling.

3. Avoid fuel spills when refueling.

1.9 Precautions When Working On or Around Rail King®

2. Never hose down the cab floor.

3. Keep all tools in their assigned places.

8. Never use metal-cased flashlights around electrical equipment.

16. Do not climb on top of the Rail King while it is moving.

20. Shut engine off before adding oil to the crankcase.

22. Do not weld or burn around fuel tank vents.

1.10 Responsibilities On Rail King, Cars, or Trains

4. Do not use the endgate of a gondola as a handhold.

5. Do not sit or lie under cars.

9. Do not ride on ends of moving cars except when operating handbrakes.

1.11 Getting On or Off Rail King and Cars

4. Face Rail King or car when getting on or off.

1.12 Operating Handbrakes

6. Keep completely clear of revolving wheel when releasing brakes.

1.13 Coupling and Uncoupling Cars and Rail King

1.14 Blocking and Coupling

1.15 Movement of Cars