How to Maintain Your Hi-Rail Equipment for Longevity

Due to the specialized nature of hi-rail equipment, there’s a lot of components (both on and off-rail) that need to be taken care of. Failure to keep on top of even the most basic maintenance tasks can spell disaster for your operations. Here’s how you can maintain your hi-rail gear to keep it running smoothly for years to come.

Tip 1: Regular Inspections

We cannot overstate the importance (and relative ease) of routine inspections. Identifying and resolving issues early on can prevent small problems from developing into large ones.

Check the Rail Gear Alignment: Misalignment can lead to uneven wear and tear on the wheels and track components, ultimately causing costly damage. Regularly inspect and adjust the rail gear alignment to ensure it’s parallel with the rail tracks.

Inspect the Hydraulic Systems: The hydraulic systems control the up-and-down movement of the rail gear. Leaks or pressure drops can impair functionality. Check the hydraulic fluids for the correct levels and look for any signs of leaks.

Examine the Brakes: Given the additional load and the unique stopping requirements on rail tracks, brake systems should be checked for wear and tear. Ensure the air brakes are responsive and the brake shoes and drums are in good condition.

If you oversee a fleet of hi-rail equipment and you don’t already use fleet maintenance software, then this has to change. Using this can help streamline processes, automate tedious tasks, and make sure you never miss an inspection again. 

Tip 2: Lubrication and Fluid Checks

Much like conventional heavy-duty vehicles, your hi-rail equipment relies on proper lubrication and fluid levels. Being vigilant about their application and quality helps to prevent overheating and reduce the risk of mechanical failure.  

Hydraulic Oil: Check the hydraulic oil regularly, ensuring it’s at the appropriate level and contaminant-free. Dirty or low hydraulic fluid can lead to sluggish operations or complete system failure.

Engine Oil: The engine is another critical component that requires regular attention. To keep it running smoothly, use the manufacturer-recommended oil type and replace it according to the service schedule.

Grease Moving Parts: Lubricate all moving parts, such as the pivot points on the rail gear and steering components, to reduce friction and wear. Greasing these components not only extends their life but also ensures smoother operation.

Tip 3: Maintaining Electrical Systems

The electrical systems in hi-rail vehicles are often more complex than in standard vehicles due to the added rail functionality. From lights to sensors, ensuring that the electrical components are in good working order is essential.

Battery Maintenance: The battery powers critical components, including the rail gear. Regularly check the battery’s charge using a multimeter and clean the terminals to prevent corrosion. A well-maintained battery ensures that your hi-rail equipment starts reliably every time.

Inspect Wiring: Check all wiring for signs of wear, fraying, or corrosion. Damaged wiring can lead to system failures, particularly in harsh weather conditions. Ensure that all connections are secure and that the wires are adequately insulated.

Tip 4: Tire and Track Wheel Care

Since hi-rail vehicles operate on both roads and rails, they are equipped with both tires and rail wheels. Maintaining these is crucial for safe and efficient operation.

Tire Maintenance: Tires should be checked regularly for proper inflation, tread wear, and any signs of damage. Operating on underinflated or worn-out tires can affect vehicle handling and safety, particularly when transitioning from road to rail.

Track Wheel Inspection: The rail wheels must be inspected for flat spots, wear, and alignment. Flat spots can cause the wheels to skip on the tracks, leading to dangerous driving conditions. Ensure that the wheels are aligned correctly to avoid unnecessary wear on both the wheels and the rail tracks.

Tip 5: Seasonal Maintenance Tips

Seasonal changes, especially in areas with harsh winters, require additional maintenance to keep hi-rail equipment in top shape.

Winterization: Cold weather can wreak havoc on hi-rail equipment. Before winter sets in, check antifreeze levels and ensure that the heating systems for both the cab and the rail gear are functioning. Consider using a lower-viscosity oil for the engine during the winter to improve cold starts.

Summer Precautions: High temperatures can cause hydraulic systems to overheat. During the summer, make sure all cooling systems are operational and that hydraulic fluid levels are checked more frequently. Inspect the air conditioning system to ensure it’s working efficiently for operator comfort.

Tip 6: Operator Training and Best Practices

Even the most well-maintained equipment can fail if not used properly. Ensuring that your operators are well-trained and follow best practices can significantly reduce wear and tear.

Proper Use of Rail Gear: Operators should be trained to deploy and retract the rail gear smoothly and at appropriate speeds. Jerky movements or improper deployment can cause mechanical stress on the system.

Regularly Scheduled Breaks: Hi-rail vehicles often operate for long hours, especially in demanding conditions. Encourage operators to take regular breaks to allow the equipment to cool down, which can prevent overheating and reduce wear on the engine and hydraulic systems.

Conclusion

Maintaining your hi-rail equipment is essential for ensuring safety, reliability, and longevity. You can extend the life of your hi-rail vehicles by adhering to a routine inspection schedule, monitoring lubrication and fluid levels, caring for electrical systems, and properly training your operators. Remember, if in doubt, seek out reliable, professional hi-rail repairs.

As with any specialized equipment, proactive maintenance is key to avoiding costly repairs and unexpected downtime. Follow these maintenance tips to keep your fleet running smoothly and your operations on track—literally.

Learn to stay one step ahead of breakdowns by reading our article about 7 preventive maintenance tips for hi-rail vehicles.