LB Foster PROTECTOR IV Maintenance Manual

PROTECTOR® IV TRACKSIDE

F

RICTION MANAGEMENT SYSTEM

Installation, Operation &

Maintenance Manual

for TOP OF RAIL

www.lbfoster.com

TABLE OF CONTENTS

Welcome ..........................................................................................................................................................................................................3

Introduction ...................................................................................................................................................................................................3

!"#$%&'(#)*+#&,&-./0123")$./ ..............................................................................................................................................................4

Site Selection .................................................................................................................................................................................................6

Electrical Power (Solar Panel) ..................................................................................................................................................................7

Electrical Power (AC Power) ..................................................................................................................................................................10

TOR Installation ..........................................................................................................................................................................................10

Smart Wheel Sensor Installation .........................................................................................................................................................13

Operation & Start Up ..............................................................................................................................................................................13

Servicing & Maintenance .......................................................................................................................................................................18

Troubleshooting ........................................................................................................................................................................................20

AC Wiring Diagram for 200/25 Unit ..................................................................................................................................................24

DC Wiring Diagram for 200/25 Unit ..................................................................................................................................................25

AC Wiring Diagram for 800/100 Unit ................................................................................................................................................26

DC Wiring Diagram for 800/100 Unit ...............................................................................................................................................27

200/25 AC and DC Tank Part Numbers ............................................................................................................................................28

200/25 AC and DC Stainless Steel Tank W/ Bronze Double Pump and

Twin Hose Part Numbers........................................................................................................................................................................29

800/100 AC and DC Tank Part Numbers ..........................................................................................................................................30

Solar Panel and Pole Kit Part Numbers ............................................................................................................................................31

Double Pump Motor Assembly Part Numbers ..............................................................................................................................31

Distribution System Piping Summary ............................................................................................................................................... 32

Quick Hose Coupling Part Numbers .................................................................................................................................................32

MC-4TR Distribution Bar Part Numbers ...........................................................................................................................................33

TOR XL-Bar Part Numbers .....................................................................................................................................................................34

TOR ML-Bar Part Numbers ....................................................................................................................................................................35

TOR Foam Bar 24” Part Numbers ........................................................................................................................................................36

TOR Foam Bar 36” Part Numbers ........................................................................................................................................................36

Mounting Clamp Part Numbers ..........................................................................................................................................................37

Quick Mounting Clamp Part Numbers .............................................................................................................................................38

Top of Rail Bar & Clamp Assembly Options ...................................................................................................................................39

Smart Wheel Sensor Part Numbers ...................................................................................................................................................40

Smart Wheel Sensor w/Quick Clamp Part Numbers ...................................................................................................................41

Glossary of Terms ......................................................................................................................................................................................42

Customer Service Contact Information ............................................................................................................................................43

Page 2PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

WELCOME

Thank you for purchasing the PROTECTOR IV TOR Trackside Friction Management System. The PROTECTOR IV
TOR system is part of L.B. Foster’s family of friction management products designed to improve conditions at

)4*&54**673"$6&$/)*38"%*9&:*&"3*&%./0;*/)&$/&.23&<3.;2%)=#&">$6$)(&).&<*38.3+&"/;&"3*&%.++$))*;&).&<3.?$;$/1&

the level of product quality, innovative engineering and customer support that you have come to expect from
us.

The purpose of the PROTECTOR IV TOR trackside friction management system is to control friction to an
intermediate level on the railhead in order to reduce rail wear and the onset of corrugations, reduce wheel
noise and limit the initiation of rolling contact fatigue (RCF) and gauge corner cracking (GCC). This is achieved

>(&;$#)3$>2)$/1&"&83$%)$./&+.;$0*3@&ABCDEF-A&).&)4*&).<&.8&)4*&3"$64*";9

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the top of the rail and distributed along the rail by the wheels. When the water in the liquid solution evaporates,

"&)4$/&;3(&06+&3*+"$/#&)4")&<3.?$;*#&83$%)$./&+"/"1*+*/)&>*/*0)#9&ABCDEF-A&*#)">6$#4*#&"/&$/)*3+*;$")*&%.G
*K%$*/)&.8&83$%)$./&LMNO9PQR&"/;&)4*3*8.3*&4"#&/.&;*)3$+*/)"6&*S*%)&./&>3"T$/1&.3&)3"%)$./9&

INTRODUCTION

Safety First

There are no special hazards or potential risks regarding this equipment that cannot be made safe by good
working practice.

Lifting

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equipment beneath the tank or chains secured to the four lifting handles. The tanks are equipped with a
single-point lifting strap. Ensure that the tank doors are fastened and locked in place during moving. Never lift
a partially full or full tank using the handles.

NEVER VENTURE BENEATH A TANK BEING LIFTED.

Note: Tank handles are provided for a minimum of four people to manually manoeuvre the tank with the hopper
empty. Ensure the tank handles are not used in any other circumstances.

Live Rail Working

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for installation and removal. Only appropriate insulated tools should be used.

AC Power Supply

Ensure AC power source is isolated before connecting line to the power switch in the tank. Turn power switch
to OFF before touching any electrical connections or working in the tank.

Batteries

Ensure batteries are DISCONNECTED before touching electrical connections or working in the tank. Do not
cause shorting between the battery terminals. For operator safety, the batteries are sealed with no free acid

"/;&%6"##$0*;&"#&I/./G#<$66">6*9=

SHORTING BATTERY TERMINALS WILL CAUSE SPARKS AND CAN RESULT IN BURNS.

Page 3PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Digital Control Box

Ensure digital control box is switched OFF before working in tank.

Tools Required

The PROTECTOR IV unit comes equipped with an Allen wrench tool (for use on the pump mounting bolts). This
tool is required for installation and maintenance of the pump.

Along with the supplied tool, the PROTECTOR IV unit can be installed and maintained with a minimum number
of other tools. Ensure the following list of tools are available during the installation process (tools for the metric
equivalents are in brackets):

1. Pick and ballast fork

2. Large and medium size adjustable wrench

3. Medium pipe wrench

4. ½” drive reversible ratchet

5. 1” open-end wrench for sensor cable wall connector

6. 10 mm open-end wrench or socket for battery terminal

7. &YZ[\]&L^Q&++R&#.%T*)&.3&.<*/G*/;&53*/%4&).&+.2/)&#*/#.3&).&>3"%T*)

8. Slot and Phillips screwdrivers

9. Wire strippers and crimpers

10. Pliers or channel locks

11. For wiping bar and sensor bracket:
» 0 -250 ft.-lbs. (0-350 N-m) torque wrench
» ^G_]&LPO&++R&53*/%4&.3&#.%T*)
» Hammer (minimum weight 3 lb. (1 kg.))

BASIC SYSTEMS & CONFIGURATION

The following section is intended to provide a general overview of the operation of the PROTECTOR IV with a
brief description of key components.

Digital Control Box

The Digital Control Box (DCB) is the heart of
PROTECTOR IV’s control system. It provides
excellent adjustability of the amount of grease
that is pumped from the tank to the bars. It
also provides integrity checks for verifying the
electronic controls and motor(s) are working
properly. The LCD screen at the top of the box
displays all of the information for the operator.

Pump

A double gear pump is coupled to the electric
motor. The pump/motor assembly distributes the
grease to the rails.

Page 4PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Motor

The 12v DC electric motor receives power from the DCB to activate the pump.

Power Requirements

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also be powered by AC if ordered with an AC/DC voltage convertor.

A BATTERY IS AN EXPLOSION HAZARD — BATTERIES CONTAIN CORROSIVE MATERIALS AND PRESENT
A SAFETY HAZARD.

DC Powered Units

DC PROTECTOR IVs are powered using the provided solar panel. Supply requirements are 12v DC nominal.
Voltages in excess of 14.5v DC can cause permanent damage to electronic controls. The solar panel charge
controller ensures the batteries are not over charged.

AC Powered Units

Units operating with AC power are equipped with an AC/DC converter to produce DC power to maintain the
battery condition. The power supply requires 95-135v AC or 200-250v AC, 50-60Hz, single phase AC. Power is
to be supplied by the customer. The trickle charge to the battery is typically 13.8v DC.

Solar Panel

Every new PROTECTOR IV shipped with a solar package contains the following basic components:

• Solar panel with Lexan Vandal Guard and the voltage regulator mounted inside the clean hands section.

• Solar panel cable wired to the panel at the factory.

• Solar panel pole kit (if ordered).

Smart Wheel Sensor

PROTECTOR IV assemblies are equipped with a bi-directional smart wheel sensor as standard. This can be

%./0123*;&8.3&./*&5"(&.<*3")$./&$8&3*H2$3*;9&D4*&#*/#.3&;*)*%)#&)4*&<"##"1*&.8&*"%4&)3"$/&"/;&#*/;#&"&#$1/"6&

to the DCB.

The sensor primarily consists of a small but very strong magnet connected to the control circuitry. When a

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control circuit. The magnet itself is encased within the body of the sensor block, surrounded by a protective
plastic casing.

There is a short length of cable attached to the sensor with a pigtail connection. This mates to a length of cable
feeding directly to the DCB. The wheel sensor is delivered with a bracket designed for mounting to the rail, and
shims to adjust the sensor height.

Tank

The tank is designed with two separate sections; the materials section that contains the grease and the
components section. The tank body should be secured to a base to ensure its stability and for drainage.
Typically, tanks are mounted to wooden ties or sleepers or a concrete pad.

Distribution Hoses

The distribution hoses are used to distribute the grease from the tank to the rails. The hoses can be installed
once the tank and the distribution bars are in place on the rails.

Page 5PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Bars

The bars are designed to distribute grease to the gauge face of the rail. When applied properly, this reduces

83$%)$./&*d<*3$*/%*;&>*)5**/&)4*&54**6&V"/1*&"/;&)4*&1"21*&8"%*&.8&)4*&3"$6&54$%4&$/&3*)23/&5$66&*d)*/;&)4*&3"$6&

and wheel life, reduce noise and improve tracking through curves.

SITE SELECTION

INSTALLATION AND MAINTENANCE OF THE PROTECTOR IV SYSTEM REQUIRES PERSONNEL TO BE
ON-TRACK, INCLUDING BETWEEN THE RAILS. PRECAUTIONS MUST BE TAKEN TO ENSURE THAT
THERE WILL BE NO TRAFFIC WHILE DOING THIS WORK.

Proper site selection for the PROTECTOR IV is one of the most important considerations associated with

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performance of the unit depends upon attaining as many of the following general considerations as possible:

1. It should be positioned on level stable ballast. The base can be made from either cut wooden sleepers

L#2<<6$*;&$8&3*H2$3*;R&.3&"&%./%3*)*&<";9&B+>*;&)4*&>"#*&$/&)4*&>"66"#)&"/;&"Kd&)4*&%">$/*)&).&)4*&>"#*@&6"1&

screws are provided for a timber base.

2. Locate the unit as close to the curve in the track as possible. Avoid locating the unit inside a curve. This is

particularly important if noise reduction is the primary goal.

IT IS NOT RECOMMENDED TO INSTALL A UNIT IN A CURVE. THE EFFECT OF HAVING THE WHEELS
HUGGING THE HIGH RAIL CAUSES PREMATURE WEAR AND TEAR ON THE WIPING BARS. WIPING BARS
LOCATED ON THE LOW RAIL ARE LESS EFFECTIVE IN DEPOSITING GREASE. DO NOT INSTALL BARS
CLOSER THAN 100 ft. (30.5 m) TO AN INSULATED JOINT. THIS WILL MINIMIZE ANY POTENTIAL GREASE
BUILD-UP AT THE JOINT WHICH COULD AFFECT SIGNALING.

3. In areas with multiple curves, select a site in a short tangent section of track between curves. At this

location the grease material is carried in both directions and into adjacent curves.

4. Select a site where there is no pronounced railhead wear and railhead is in excellent condition. If transposed

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before attempting to install the wiping bars.

5. Select a site where the tie conditions are good and install the unit as close to zero grade as possible.

J/#)"66$/1&)4*&2/$)&$/&"&6.%")$./&54*3*&)4*&)"/T&.2)6*)&$#&6.5*3&)4"/&)4*&)3"%T&5$66&3*;2%*&*K%$*/%(9

6. '*6*%)&"&#$)*&)4")&<3.?$;*#&"%%*##&).&)4*&2/$)&8.3&3*126"3&+"$/)*/"/%*&"/;&3*066$/19

7. Install the tank far enough from the track to safely clear the operation of ballast regulators, snow plows, and

.)4*3&)3"%T&*H2$<+*/)@&>2)&%6.#*&*/.214&).&"66.5&)4*<<6(&4.#*&).&>*.3)*/*;&8.3&+"d$+2+&*K%$*/%(9

8. Select a site where power source can be easily routed to the unit. Be sure the length and size of the power

cable does not cause an unacceptable line loss. In remote locations with no AC power availability, the solar
panel option is recommended.

Note: Outside AC electrical currents from overhead power wires, third rail power or signal system power sources
can interfere with the wheel sensor detection capabilities.

9. Avoid selecting a site where trains routinely slow down or come to a complete stop.

10. Site selection should be in an area which will discourage acts of vandalism.

11. The grease works best where both the rails and wheels are clean.

Page 6PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

ELECTRICAL POWER (SOLAR PANEL

)

Solar Panel Location and Installation

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Southern exposure in the Northern Hemisphere and Northern exposure in the Southern Hemisphere. This will
ensure the most consistent exposure to sunlight through the course of a day. The panel should be unobstructed,
so that it receives direct sunlight during daylight hours all year long.

The standard units are DC powered and charged by a solar panel. This supplies power to either one or two 12v
batteries depending on the number of pumps. Brackets can be supplied so the solar panel can be mounted
to a pole attached to the tank, or a pole can be supplied that will allow the panel to be erected away from the
tank if this will provide better sunlight.

Solar Panel Mounted to Tank Solar Panel Mounted Away from Tank

Solar Panel Adjustment – NORTH AMERICA

The pivot arrangement included with the solar panel’s mounting bracket provides an adjustment for the angle

.8&)4*&<"/*69&D.&1"$/&+"d$+2+& *K%$*/%(&"/;&.2)<2)&83.+&)4*&#.6"3&<"/*6e&)4*&)$6)&"/16*&$#& >"#*;&2<./& )4*&

latitude of the location. Panels should always face south (see Figure 1).

Using the table below you can determine the optimal angle for your solar panel. The panel tilt is the latitude
+10º. This will optimize the panel’s ability to collect the sun’s energy. Use the angle gauge on the mounting
bracket to set the desired angle (see table below) or alternatively, use the distance from the pole to the base
of the panel, also included in this table.

Figure 1: Solar Panel Adjustment

Page 7PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Optimum Angle for Sunlight

Site Tilt Base

Latitude (degrees) Angle (degrees) Distance (inches) Distance (millimeters)

35 45 17-¾ 451
36 46 17-½ 444
37 47 17-³7[\ 437
38 48 16-157[\ 430
39 49 16-57f 423
40 50 16-³7f 416
41 51 16-¹7f 409
42 52 15-¹³7[\ 402
43 53 15-97[\ 395
44 54 15-¼ 388
45 55 15 381

Solar Panel – Tank Mounted Assembly Instruction

1. Before beginning the assembly ensure the side of the tank hangs over the tie.

2. Assemble the pole into one piece and mount the solar panel to the pole. Use four bolts to help position

the pole’s clamp blocks to the tank. These bolts must be 37f]&G^g&X-&d&^Gh]&)43*";#&"/;&>*&"<<3.d$+")*6(&
10” long.

3. Using the studs, position two of the clamp block halves at their mounting locations top and bottom. Screw

the four studs into the tapped holes in the tank body to properly locate the clamp blocks and help hold
their position during this assembly.

4. Raise the assembled pole and solar panel into the vertical position against the tank and into the clamp

block halves.

5. Turn the solar panel so that it is facing south.

6. Position the second pair of clamp block halves, sliding them over the studs and against the back halves.

Remove one stud at a time, replacing them with the provided Allen head bolts and lock washers. The solar
panel pole kit includes an Allen wrench for tightening these
four bolts.

Solar Panel – Away from Tank Assembly Instruction

Locate the panel so that the supplied cable (35 ft./10.7 meter long)
will reach the tank. Do not use a longer cable than the one supplied,
as longer lengths will result in a voltage drop which may not allow
the system to operate properly. If longer lengths are necessary,
please contact us.

EXERCISE EXTREME CARE WHEN HANDLING THE SOLAR
PANEL AND WORKING WITH SOLAR PANEL WIRING. FAILURE
TO DO SO MAY RESULT IN EQUIPMENT DAMAGE OR BODILY
INJURY.

Gauge on Solar Panel Mounting Bracket
(Used to adjust the angle.)

Page 8PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Solar Panel Wiring

The 35 ft. (10.7 meter) long power cable is factory installed to the solar panel at the junction box with spade
terminals. The wall connector nut of the junction box is tightened securely, causing the bushing to grip the

%">6*&03+6(@&#.&"&6$H2$;&)$14)&#*"6&$#&8.3+*;9&'*%23*&)4*&%">6*&).&)4*&<"/*6G+.2/)$/1&<.6*&"#&3*H2$3*;9

Electrical Connections

Connect the solar panel to the PROTECTOR IV battery as follows:

1. Remove any cover you have placed over the panel and peel away the protective panel guard protection.

2. Perform the following tests before beginning installation:

a) Using a voltmeter capable of reading 25v DC, check the panel output between the battery (+) and (-) in

the junction box or at the end of the cable. If the panel output exceeds 15v DC, check regulator wiring
for proper connections, as shown in troubleshooting. Replace the regulator if defective.

b) Check the battery’s voltage. If the voltage is below 11.5v DC, the PROTECTOR IV will not function

properly and the battery will need to be charged.

Note: Charge battery through solar panel output until battery voltage exceeds 12v DC.

BEFORE PROCEEDING, MAKE SURE THE SOLAR PANEL IS COVERED TO ELIMINATE ELECTRICAL
POTENTIAL AND TO AVOID SHOCK HAZARD DURING THE NEXT PHASE OF ASSEMBLY.

3. Attach ring terminals to the solar panel cable wires, connecting the red wire to the positive battery terminal

and the black wire to the negative battery terminal.

ENSURE RED WIRE IS CONNECTED TO THE POSITIVE (+) AND BLACK WIRE IS CONNECTED TO THE
NEGATIVE (-) TERMINAL OF THE BATTERY. CROSSED WIRES WILL CAUSE EQUIPMENT DAMAGE.

Solar Charge Controller

Solar panel charge controller in use on the PROTECTOR IV, which is located inside the clean hands section of
the tank.

The wires should be attached as follows:

PV+ Positive lead from solar panel
BAT+ Positive lead from battery

Vset Not used

COM- Negative lead from battery or solar panel

COM- Negative lead from battery or solar panel

Photovoltaic Charge Controller

Page 9PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

ELECTRICAL POWER (AC POWER

)

AC Electrical Power and Battery Charger Connections

1. Remove the bolts on the battery terminals using a 10 mm socket or wrench. Look at battery and charger

safety precautions. Be careful not to short the battery terminals with a tool.

2. Through the terminal bolt, connect the ring terminals of red wire from the charger and from the control

box power harness to the positive battery terminal (+) and in the same manner connect the black wires to
the negative battery terminal (-).

3. !" #$%&'()*" )&)+,-'+'%." /$0," 1'-)" ,2)" $.',0" ,2-3$42" ,2)" 5$.+,'3." 637" %.*" 3.,3" ,2)" 3.839" *'0+3..)+," 637"

according to local regulations.

ALL WIRING MUST COMPLY WITH LOCAL AND NATIONAL ELECTRICAL CODES. USE ONLY THE WIRE
SIZES SPECIFIED IN THE INSTALLATION INSTRUCTIONS. WE RECOMMEND HAVING THE INSTALLATION
WIRED BY A CERTIFIED ELECTRICIAN.

ENSURE POWER SUPPLY CABLE GAUGE IS PROPERLY SIZED TO ALLOW FOR REQUIRED POWER LEVELS
GIVEN THE DISTANCE FROM THE ORIGINAL SOURCE.

TOR INSTALLATION

!"#$%&'()*"#+()+,'(-.

Top of rail distribution bars should be installed in a
position that agrees with the site selection criteria
mentioned previously in this manual. The common

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>.)4&3"$6#&.8&"&#$/16*&)3"%T&5$)4&2/$G;$3*%)$./"6&)3"K%9&

The set up described here is shown in Figure 2.

The top of rail wiping bars assembly can be installed

$/& "& 8.23& >"3& %./0123")$./@& "#& #4.5/& ">.?*9& D4$#&
<3.?$;*#& 3*H2$3*;& 83$%)$./& +.;$0*3& 8.3& "3*"#& 5$)4&
%./)$/2.2#&%23?")23*@&4$14&)3"K%&"/;&.)4*3&8"%).3#&
3*H2$3$/1& "& +"d$+2+& .8& 83$%)$./& +.;$0*39& D4*&

installation time required depends on the installer’s
familiarity with components and labor available to
complete the task.

3*%&'1+45+678('+!"#$%&'()*"#

/)01'+!"#$%&'()*"#2

• Two bars with single pump with distribution in center.

• Two bars with double pump and supply hoses routed from tank to bars.

A PASSING TRAIN CAN DAMAGE IMPROPERLY INSTALLED COMPONENTS. ALLOW SUFFICIENT TRACK
TIME TO FULLY COMPLETE INSTALLATION.

Page 10PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Install the MC-4TR® wiping bars as follows:

1. B/#23*&#*6*%)*;&)"/T&6.%")$./&$#%4&)4")&)4*&83$%)$./&+.;$0*3<<6(&4.#*L#R&%"/&>*&3.2)*;&83.+&)"/T&"/;&

where rail is in good condition.

2. D.&%./03+&%6"+<&6.%")$./#&+")*&5$)4&*d$#)$/1&%3$>#@&6"(&.2)&5$<$/1&>"3#&./&0*6;G#$;*&.8&3"$69

3. Ensure bars mounted on the same rail are located at a distance of 56 ½” (143 cm) between centers.

Note: Based on a 36” (91 cm) wheel diameter, the 56 ½” (143 cm) spacing allows bars to distribute material
uniformly over opposing sections of each wheel’s circumference. If track conditions do not permit a 56 ½” (143
cm) distance to be respected, install bars closer together but maintain at least one bar length in between.

4. Ensure inlet elbows clear rail hardware. On smaller rail sizes, it is best to attach the wiping bar supply hose

(and adapter where necessary) before assembling to rail. The piping adapter is used to gain additional
clearance with track hardware.

5. Loosely assemble wiping bars to mounting clamps.

6. Clean dirt and scale from rail in appropriate areas.

7. With a pick and ballast fork, remove ballast from selected cribs for installation of rail clamps.

8. Lay wiping bar assemblies adjacent to selected mounting locations.

9. Ensure mounting clamps are square to rail and fasten them to the base of rail. As the “J” bolt nuts are being

tightened using a hammer, occasionally tap clamp blocks driving the “V” slot on to the rail base. Torque
mounting bolts to approximately 200-250 ft-lbs (340 N-m).

10. When clamps are secured tighten the safety nuts.

11. Position wiping bar assemblies on top of rail clamp blocks and against rail.

12. Adjust the wiping bar height as follows:

a) Mount the TOR bar such that the tip of the seal is not

higher than the top of the railhead (shown in Figure 3 MC­4TR Wiping Bar Installation). A simple level can be used to
help establish this position.

DO NOT STORE EXTRA SPACERS UNDER THE HEAD OF
MOUNTING BOLTS.

b) Remove or add spacers between TOR clamps and wiping

bar mounting feet.

c) Adjust blade height until the inner (thin) blade is just at

top of the side of railhead. Store excess spacers in clean

Figure 3: MC-4TR Wiping Bar Installation

hands section of the tank.

Note: With newer rail, or where the radius has been ground on the top of the railhead, the curvature of the

-%'&2)%*"%&&310",2)").*"3:",2)"0)%&",3"6)"&3+%,)*"3.,3",2)"-%'&2)%*"%.*"0,'&&"6)"6)&31",2)";<=>";2'0"2)&?0",2)"@31"

3:":-'+,'3."/3*'()-":-3/",2)"6%-",3",2)"+3.,%+,"?%,+2"1',23$,"-'0A"3:"*%/%4)",3"A))?",2)"0)%&"6)&31",3?"3:"-%'&B"

the required lower bar mounting draws the seal end away from the contact patch.

Page 11PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

13. '*%23*&)4*&+.2/)$/1&>.6)#&).&)4*&%6"+<&>6.%T#&)$14)*/$/1&)4*&3$14)&>.6)&03#)&).&*/#23*&)4*&).<&.8&3"$6&5$<$/1&

bars is pushed securely against the rail.

14. Occasionally tap the outside edge of the mounting foot with a hammer during tightening to insure TOR

wiping bars remain tight to the rail.

15. Torque mounting bolts to approximately 200-250 ft-lbs (340 N-m).

ML Top of Rail Wiping Bars

The installation of ML TOR distribution bars should be carried out using the same instructions as the MC-4TR
TOR distribution bars. Figure 4 illustrates how the installed bar should be assembled.

Figure 4: TOR -ML Wiping Bar Installation

Distribution Hose Installation

Install one main supply hose and four grease distribution unit hoses as follows:

1. Run main supply hose from tank, underneath the rail, to a position central to wiping bar assemblies.

2. C"(.2)&)4*&ij]&%./0123")$./&.8&?"6?*#&5$)4&+"$/&4.#*&"/;&;$#)3$>2)$./&4.#*#9&

3. D43*";&)4*&+"$/<<6(&4.#*&).&)4*&ij]&%./0123")$./&.8&?"6?*#&")&%*/)*3&)3"%T9&

4. D43*";&*"%4&4.#*&>*)5**/&ij]&%./0123")$./#&.8&?"6?*#&).&"/&$/;$?$;2"6&5$<$/1&>"39&

Note: Hoses supplied by the customer must be non-conducting, this ensures the hose system will not shunt signals.

All customer supplied hoses must be the same length as those supplied by L.B. Foster. If longer or shorter,

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*#(,2$1550(#'$!%$!"#$)1(06

Page 12PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

SMART WHEEL SENSOR INSTALLATION

The smart wheel sensor should be placed as far away from
the distribution bars as possible using the supplied cable.

1. Dig out the ballast from underneath the rail where the

sensor will be placed.

2. `6"%*& )4*& kG>.6)& 2/;*3/*")4& )4*& 3"$6& "/;& 0d& ).& )4*&

bracket with the full nut and Nyloc nut. These require

"& ^^G_]& LPO& ++R& 53*/%4& .3& #.%T*)9& D4*& >3"%T*)& 8.3&

the sensor must be placed on the gauge side of the
rail, preferably the rail adjacent to the tank. However,
if installing in areas with a conductor rail the smart
wheel sensor should be placed on the opposite rail.

3. Use the shims provided to set the height of the smart

Figure 5: Fully Fitted Sensor Bracket

wheel sensor. It should be set so that the top of the sensor is 2” below the top of the rail, any more than this

"/;&)4*&#+"3)&54**6&#*/#.3&+"(&8"$6&).&%.2/)&54**6#9&U/%*&)4*&%.33*%)&4*$14)&$#&#*)@&"Kd&)4*&#+"3)&54**6&
#*/#.3&).&)4*&>3"%T*)&2#$/1&)4*&8.23&>.6)#&<3.?$;*;9&F&%.33*%)6(&0))*;&#*/#.3&$#.5/&$/&l$123*&Q9

OPERATION & START UP

General Operation

Once the PROTECTOR IV is installed it is important to understand how it works in order to take full advantage
of all its capabilities. Below is a general theory of operation for the PROTECTOR IV.

D4*&>"#$%&2/$)&%./#$#)#&.8&"&)"/T&8.3&#).3"1*&.8&)4*&83$%)$./&+.;$0*3&"/;&"&&%6*"/&4"/;#&%.+<"3)+*/)&8.3&"66&

the electrical components, such as, the digital control box (DCB), motor, pump, battery and other mechanisms.
Electrical power is used to activate an electric motor that is directly coupled to the pump.

A rail-mounted wheel sensor senses the passage of each wheel on a moving train. As each wheel is detected

)4*&#*/#.3&#*/;#&"/&*6*%)3$%"6&<26#*&).&)4*&m-!9&D4*&m-!&)4*/&"%)$?")*#&)4*&<2+<@&54$%4&;3"5#&83$%)$./&+.;$0*3&

from the tank and forces it through the distribution hoses and wiping bars on to the rail. Wheels then pick up
the material and deposit it along the rail in a continuous cycle. A diagram of the cycle can be seen below.

Page 13PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual