operation and maintenance manual - nordco spiker/hammer w/programmable logic operation and...

24-Volt Spiker/Hammer w/Programmable Logic

Operation and

Maintenance Manual

Applies to S/N 410604 & Above

W/John Deere 4045 Engine Reorder Part: 49454102

Last Revision: Rev. - NOVEMBER 2005

Read and fully understand the precautions contained in this manual before operating or servicing this machine. Refer to Section 1 for important safety information.

This manual is a guide for the operation and routine maintenance of a NORDCO Railroad Maintenance Machine. It covers product technical information, basic operating and maintenance procedures, and safety information and is provided for use by the qualified personnel who will supervise, operate or service the equipment described herein. Measurements in this manual are given in both metric and customary U.S. unit equivalents. Personnel responsible for the operation and maintenance of this equipment should thoroughly study the manual before commencing operation or maintenance procedures.

This manual should be considered a permanent part of your machine and should remain with the machine at all times. Additional copies of this manual are available either as a part (Operation Manual only) or a whole (operation and parts manual), at a nominal cost, through our Part Sales Department. Additional service information, parts, and application information is available through these Nordco product support resources:

NORDCO Sales: Milwaukee, Wisconsin (414) 766-2180

[email protected] NORDCO Parts: Milwaukee, Wisconsin

1-800-647-1724 [email protected]

Oshawa, Ontario, Canada (905) 579-4058, Ext. 224 [email protected]

NORDCO Service: 1-800-445-9258

[email protected] We ask that if you have any comments or suggestions about this manual, let us hear from you. We are here to be of service to you, our customers. Direct your comments and inquiries to:

Technical Documentation Department

NORDCO Inc. 245 W. Forest Hill Avenue

Oak Creek, WI 53154

HAZARDOUS MATERIAL DATA In an effort to provide information necessary for your employee safety training program and to meet the requirements of OSHA Hazard Communication Standard 1910.1200, we have OSHA Form 20 Safety Data Sheets available that cover the material contained in this machine. If you are interested in receiving this information, please refer to the Name, model, and Serial Number of your machine when calling or writing, and direct your inquiries to:

Vice-President of Operations

NORDCO Inc. 245 W. Forest Hill Avenue

Oak Creek, WI 53154

Fax: (414) 766-2299 Phone: (414) 766-2288

CX Hammer with PLC CONTENTS

MAR/2005 (49454100) i Contents

TABLE OF CONTENTS SECTION 1 – PREFACE SAFETY ........................................................................................................................................................................1-1

Understanding Key Safety Alert Words................................................................................................................... 1-1 General Safety Tips................................................................................................................................................. 1-2 Safety During Work ............................................................................................................................................ 1-2 Safety During Travel........................................................................................................................................... 1-3 Safety During Maintenance ................................................................................................................................ 1-3 Safety Alerts ............................................................................................................................................................ 1-4 Lockout/Tagout Requirements ................................................................................................................................ 1-6 Safety Decals on this Machine ................................................................................................................................ 1-8

GENERAL INFORMATION........................................................................................................................................... 1-9

Machine Specifications.......................................................................................................................................... 1-10 SECTION 2 - OPERATION BEFORE OPERATION ................................................................................................................................................. 2-1

Operator’s Station ................................................................................................................................................... 2-1 Carriage................................................................................................................................................................... 2-2 Carriage Guide Wheel............................................................................................................................................. 2-2 Workhead ................................................................................................................................................................ 2-2 Manifolds ................................................................................................................................................................. 2-2 Propulsion/Drive System......................................................................................................................................... 2-2 Boom/Winch ............................................................................................................................................................ 2-2 Logic Box Control Panel.......................................................................................................................................... 2-2 Bulk Loader (optional) ............................................................................................................................................. 2-2 Gager (optional) ...................................................................................................................................................... 2-2 Nipper Assembly (optional) ..................................................................................................................................... 2-3 Operator Controls.................................................................................................................................................... 2-4 Preparing the Machine for Work............................................................................................................................ 2-15 Pre-Operational Checklist ..................................................................................................................................... 2-16 Engine Operation .................................................................................................................................................. 2-17

START-UP CHECKS .................................................................................................................................................. 2-18 Lock-Up Devices ................................................................................................................................................... 2-19

PROPELLING AND BRAKING...................................................................................................................................2-27 MACHINE SET-UP...................................................................................................................................................... 2-28

Jaw Depth/Rail Height Adjustment.................................................................................................................... 2-28 Workhead Ready Adjustment................................................................................................................................ 2-29 Workhead Spike Pattern Adjustment ................................................................................................................... 2-30

MACHINE OPERATION.............................................................................................................................................. 2-31 Work Operation ..................................................................................................................................................... 2-31 Spike Driving (without Nippers) ............................................................................................................................. 2-31 Spike Driving (with Nippers in Automatic Mode) ................................................................................................... 2-31 Spike Driving (with Nippers in Manual Mode) ....................................................................................................... 2-32 Winch Operation.................................................................................................................................................... 2-32 EMERGENCY STOPPING..........................................................................................................................................2-32 AFTER OPERATION .................................................................................................................................................. 2-33

Parking or Locating Machine................................................................................................................................. 2-33 Rotating Machine .................................................................................................................................................. 2-33 Without Turntable Lockup (S/N 410500-410587).......................................................................................... 2-33 With Turntable Lockup (S/N 410500-410587)............................................................................................... 2-34 With Turntable Lockup (S/N 410587 & Above) ............................................................................................. 2-35 Towing........................................................................................................................................................... 2-37

Continued on Next Page

CX Hammer with PLC CONTENTS

MAR/2005 (49454100) ii Contents

SECTION 3 - MAINTENANCE AND SERVICE GENERAL ..................................................................................................................................................................... 3-1 LUBRICATION AND MAINTENANCE CHARTS..........................................................................................................3-3

APPENDICES APPENDIX E – ROLLER GAGER INSTRUCTIONS (Optional Equipment)

CX Hammer SAFETY

MAY/2012 (All CX Hammers) Section 1-1

SAFETY Please read and comply with all of the safety precautions in this manual BEFORE operating this machine. GENERAL DO NOT use this machine for machine operations other than for which it was intended. NORDCO is not responsible for any modifications made without authorization or written approval. Replace all NORDCO and OEM parts with genuine NORDCO or OEM parts. Use of non-OEM parts could compromise the safety of your machine. FRA regulations require that a copy of this Operation Manual be kept on the machine at all times. Additional copies of the Operation Manual only can be ordered from Nordco Parts Sales at 1-800-647-1724. FOLLOW SAFETY INSTRUCTIONS Carefully read all safety messages in this manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate this machine without instruction. Failure to understand the contents of this manual could result in serious personal injury or death.

SAFETY ALERT SYMBOLS! These are the safety-alert symbols. These symbols means pay attention! Your safety

is at risk!

DANGER is used to indicate a definite hazardous situation which, if not avoided, WILL result in severe bodily harm or even death.

WARNING indicates a potentially hazardous situation which, if not avoided, COULD result in severe bodily harm or even death.

CAUTION indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

CAUTION without the safety “!” means that failure to follow the alert may result in machine damage.

SAFETY means that the following points are instructions for safely operating the machine or the specific component of the machine.

SAFETY CX Hammer

Section 1-2 MAY/2012 (All CX Hammers)

GENERAL SAFETY TIPS Only trained and authorized personnel should be allowed to operate this machine. In addition, all personnel at the worksite (gang) should be aware of the safety concerns and their individual responsibilities prior to working this machine.

1. Handle fuel safely. It is highly flammable

and prolonged breathing of fumes may cause bodily harm.

2. Prepare for emergencies. Keep a first aid kit

and fire extinguisher handy. 3. Protect against flying pieces of metal and

debris by wearing safety glasses or goggles. 4. Wear good-fitting pants and shirt, no baggy

or loose clothing. 5. Protect your head and eyes from flying

debris by wearing a hard hat and safety goggles/glasses.

6. Wear leather gloves to protect your hands

from vibration or flying metal particles. 7. Use safety-toed work boots. SAFETY PRIOR TO WORKING All personnel at the worksite (gang) should be aware of the safety concerns and their individual responsibilities prior to working this machine:

• Review the operating instructions if you are unsure of anything.

• Use the “pre-operational checklist” to check the machine for obvious faults. Repair or replace as necessary PRIOR to operating the machine.

• Before climbing onto the machine, make certain the area around and under the machine is clear of obstructions and personnel.

• Use care when climbing onto the machine. Always use the steps and handrails provided. (If an area does not have tread grips, walkways, or other methods to access the area, then DO NOT attempt to access that area.)

• Make seat and control adjustments PRIOR

to starting the machine. ALWAYS wear a seatbelt.

• Know the weather forecast and plan your work speeds accordingly.

• There are guards on this machine. These are to be removed ONLY when service or maintenance is being performed on that area of the machine. Make certain they have been re-installed PRIOR to starting the machine.

• Check and service the fire extinguisher (if so provided) at regular intervals. Make certain all personnel are trained in its use. Note - Non-use of fire extinguisher still requires that it be recharged at the interval stated on its last inspection notice.

• Keep the stairs, cab entry platform and cab interior free and clear of ice, tools and personal items. Use the accessories provided on the machine (tool box, cup holder, coat hook, etc.) to properly store your gear.

• Never climb onto the machine while it is in motion.

• There are lockups on this machine that are used for both work and travel. These should be kept clear and free of debris, grease, etc. See Lockup section for instructions on their use.

• Inspect safety decals and replace when they become unreadable or are damaged. (See “Safety Decals” at the end of this Safety section).

CX Hammer SAFETY


SAFETY WHILE STARTING THE MACHINE NORDCO recommends the use of a Command position. This means that the machine is never running unless someone is at or near the main control panel. To prevent injury to personnel or damage to the machine, it is highly recommended to:

1. Only start and operate the machine from the operator’s seat.

2. Use the “STARTUP Checklist” to check the

machine controls and gauges to make certain all systems are operating correctly.

SAFETY WHILE OPERATING/TRAVELING

1. Never allow more riders than seats and seatbelts

allow. This machine was designed to be operated by two people.

2. The machine is to be operated from the

Operator’s seats only. Do NOT stand and operate this machine.

3. Press the EMERGENCY STOP pushbutton on

the center control console in emergencies and potentially dangerous situations.

4. If personnel or bystanders are near the machine

during operation, give a warning signal using the air horn. If they fail to respond to this warning, stop operation immediately.

5. Slow down the work cycle and use slower travel

speeds in congested or populated areas. 6. Halt work if visibility is poor. Strong rains, fog,

and extremely dusty conditions can affect visibility in your work area. Wait for the weather to improve before continuing work.

SAFETY WHILE PARKED When leaving a machine engine running, make certain that the parking brake is applied and the electrical interlock button has been activated. NEVER stop and park this machine on an incline unless the machine wheels have been chocked.

SAFETY DURING MAINTENANCE The following guidelines are suggested when performing maintenance:

1. Always chock the wheels 2. Alert others in the area that service or

maintenance is being performed on this machine.

3. Become familiar with, and use, your company’s lockout/tagout procedures when performing maintenance on this machine. See LOCKOUT/TAGOUT REQUIREMENTS later in this Safety Section for a chart on energy sources located on this machine.

4. Do not start the engine if repairs or work is being performed alone. You should always have at least two people working together if the engine must be run during service. One person needs to remain in the command position (at the controls), ready to stop the machine and shut off engine if the need arises.

5. Collect oils and fuels and dispose of them properly. There is a danger of scalding when working with engine oils.

6. Use only Nordco supplied repair parts for this machine. Use of non-OEM designed parts could comprise the integrity of this machine.

7. There are welding cautions on this machine. Pay attention to them PRIOR to welding.

8. Kits supplied by Nordco have welding instructions included. Welding of any components NOT of Nordco’s manufacture or failure to follow these instructions may affect the stability of this machine.

SAFETY CX Hammer


MACHINE SAFETY ALERTS

DANGER ALERTS Improper use of this machine for any type of operation can cause serious

injury or death. To avoid serious injury or death, make certain that the area around and under the machine is clear of all personnel and obstructions BEFORE travelling or working.

Serious injury or death can result from reaching into working components while machine is running. Make all observations from a distance and SHUT OFF machine while making adjustments. Shut off engine when checking battery electrolyte level. Do not check or fill battery in presence of open flame, sparks, or when smoking. Battery fumes are flammable and/or explosive and if ignited will result in severe bodily injury or death. Do not ride on tow bar between the machine and the towing vehicle. Falling from a moving vehicle may cause serious injury or death.

MACHINE SAFETY ALERTS

WARNING ALERTS

Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or extensive damage to the machine. Remove hoses/fittings only when system is not pressurized. High pressure leaks can cause personal injury. If equipped with accumulator, isolate using ball valve. Always turn off machine when performing maintenance, making adjustments, or whenever unintended movement of machine could occur; unless directed otherwise. Failure to comply could result in personal injury and/or damage to the machine. Exhaust emissions caused by the use of the engine on this machine may cause cancer, birth defects, or other reproductive harm if inhaled. Disconnect the battery before servicing this machine. Failure to do so could result in personal injury from accidental engine startup.

CX Hammer SAFETY


LOCKOUT-TAGOUT PROCEDURES

The following procedures are designed to lead the operator through the steps required to shut the machine down and prepare it for performing mechanical maintenance work. These procedures are intended to release potentially dangerous stored energy forms and make the machine safe to begin repairs.

SAFETY PROCEDURES LOCKOUT/TAGOUT

1. Chock wheels to prevent accidental rolling of machine

on grade. 2. If you have not already done so, determine which

components are to have maintenance. Place all machine mechanical systems or workheads in the full up and locked positions.

3. Refer to the list on the next page to determine what procedures are required when mechanical locking up of equipment is not feasible for maintenance. Then continue on with Steps 4-7.

4. Turn the ignition switch to the OFF position. This turns off the power to the control circuits on the machine. Place a TAGOUT card in close proximity to the ignition switch.

5. Turn the battery disconnect switch (BDS) to the OFF position.

a. For machines with the BDS on the left side of the center (front) control console: Place a TAGOUT card on the switch after you have switched it to the OFF position.

b. For machines with a remotely located BDS (usually next to the battery box itself): Close the cover to the disconnect switch and place a LOCKOUT lock on the box after you have switched it to the OFF position.

WARNING: See the following pages for bleeding off of hydraulic pressures and oil flow BEFORE any maintenance or repairs are done on any hydraulic component.

6. Follow all of your company’s lockout/tagout rules before proceeding. Note: When working on machine components, be aware that moving components during repairs may create energy (i.e., moving a hydraulic cylinder). Proper precautions should be taken.

SAFETY CX Hammer


BLEEDING OFF HYDRAULIC PRESSURE

For tasks beyond his/her capabilities, the Machine Operator MUST seek assistance through the Foreman or Supervisor for the services of a Work Equipment Mechanic or other "qualified" person. If you are unsure of any of the tasks listed in this document, please consult your Supervisor and always refer to the operation/maintenance manual for this equipment.

The following procedures establish the MINIMUM requirements for the lockout of hydraulic components whenever maintenance is done. It shall be used before employees perform any servicing where unexpected energization or startup of the machine or release of stored hydraulic pressure or flow of oil could cause injury. All employees are required to comply with the restrictions and limitations imposed upon them during the use of Lockout. Authorized employees are required to identify the type and magnitude of the hydraulics that the machine utilizes, shall understand the hazards of hydraulics and shall use Due Diligence in controlling the energy. If in doubt, seek QUALIFIED assistance.

MACHINES WITH MANUAL LOCKUPS

1. Place the machine in the TRAVEL mode. This will raise work heads to allow insertion of the lockup devices.

2. Turn the ignition switch to the OFF

position.

3. Turn the battery disconnect switch to the OFF position and close, secure and tag the disconnect switch box.

4. Locate and insert the lockup devices. One for each gun assembly (four per machine). The lockups are located on the upper outside of each carriage. (Look for “Lockup Point” sticker).Lockup pin is fully inserted once the pin on the handle can be turned into the inside slot on the lockup bracket.

5. A secondary lockup key, located on the

proximity flag bracket on the side of the workhead, is then inserted into the hole on the top of the hammer side plate. This will prevent the primary lockup pin from moving out of position.

DRIVING AND GUIDE ROLLER CYLINDERS 6. Manually shift the directional control valve

to the hydraulic component (Driving Cylinders, Guide Roller Cylinders, Gager Cylinders) where service is to be performed to relieve trapped hydraulic pressure in the circuit. This will cut off hydraulic pressure/flow to the directional control valves and limit “drifting” down of the cylinders.

Shifting components directional control valves WILL NOT relieve

the trapped hydraulic pressure in the rod end (UP) circuit.

7. Using caution, crack open rod end hose

fittings 1/8 to 1/4 of a turn CCW at the gun cylinder being worked on. This will allow the pressurized oil to bleed off. Do not perform service on that component until the steady flow of oil has disappeared.

CX Hammer SAFETY


GAGER (OPTION) Product Support Bulletin 2011-001A "Gager Pressure Dump Valve Kits..." announced that kits had been created to assist in relieving pressure when performing maintenance on the gager. If your machine has the dump valve kit shown in Figure 3 installed, you need to just push the push button on the front bottom valve stack and the push button on the rear bottom valve stack to release the pressure. If your machine gager valve stack does NOT have the dump valves shown in Figure 3 installed, use these instructions.

1. Manually shift the directional control valve


Shifting components

directional control valves WILL NOT relieve the

trapped hydraulic pressure in the rod end (UP) circuit.

2. Using caution, crack open rod end hose

fittings 1/8 to 1/4 of a turn CCW at the gun cylinder being worked on. This will allow the pressurized oil to bleed off. Do not perform service on that component until the steady flow of oil has disappeared.

SAFETY CX Hammer


MACHINES WITH POWER LOCKUPS - Basic Hydraulic System (All) 1. Place the machine in the TRAVEL mode.

This will raise work heads to allow insertion of the lockup devices.

2. Place the lockup switches for the work heads (includes guide rollers) in the ENGAGE or UP position. Perform a visual inspection to verify that the lockups have engaged.

3. Turn the ignition switch to the OFF position.

4. Turn the battery disconnect switch to the

OFF position and close, secure and tag the disconnect switch box.

5. A secondary lockup key, located on the

proximity flag bracket on the side of the workhead, is then inserted into the hole on the top of the hammer side plate. DRIVING AND GUIDE ROLLER CYLINDERS

6. Manually shift the directional control valve to

the hydraulic component (Driving Cylinders and Guide Roller Cylinders) where service is to be performed to relieve trapped hydraulic pressure in the circuit. This will cut off hydraulic pressure/flow to the directional control valves and limit “drifting” down of the cylinders.

Shifting components cylinder directional control valves WILL NOT relieve the trapped hydraulic pressure in the rod end (UP) circuit.

7. Using caution, crack open rod end hose fittings 1/8 to 1/4 of a turn CCW at the gun cylinder being worked on. This will allow the pressurized oil to bleed off. Do not perform service on that component until the steady flow of oil has disappeared. GAGER (OPTION) Product Support Bulletin 2011-001A "Gager Pressure Dump Valve Kits..." announced that kits had been created to assist in relieving pressure when performing maintenance on the gager. If your machine has the dump valve kit

shown in Figure 2 installed, you need not do anything. Pressure had already been dumped automatically when you shut down the machine. If your machine gager valve stack does NOT have the dump valves shown in Figures 2 installed, use these instructions.

3. Manually shift the directional control valve


Shifting components directional control valves WILL NOT relieve the trapped hydraulic pressure in the rod end (UP) circuit.

4. Using caution, crack open rod end hose fittings 1/8 to 1/4 of a turn CCW at the gun cylinder being worked on. This will allow the pressurized oil to bleed off. Do not perform service on that component until the steady flow of oil has disappeared.

CX Hammer SAFETY


SAFETY DECALS ON THIS MACHINE Safety decals and plaques that have been placed on this machine are to be kept clean and legible. Replace any decals or plaques that have become illegible or are missing. When repairing or replacing components that had safety decals on them, it is your responsibility to replace the safety decals. These can be ordered from the Parts Sales Department. Refer to Figure 6-4 in the Mechanical Section for part numbers of all safety decals and plaques.

SAFETY CX Hammer


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CX Hammer with PLC GENERAL

MAR/2005 (49454100) Section 1-9

GENERAL This manual contains information for the CX Hammer machine manufactured by NORDCO INC., Milwaukee, Wisconsin. Information is provided in this manual for operation and maintenance of the machine. Information regarding operation and maintenance of OEM parts not of NORDCO manufacture can be found at the back of this manual, behind the tab marked “Component Data”. Become familiar with all safety instructions, controls and instruments before operating this machine. Follow all instructions carefully. ABOUT THIS MANUAL This manual has been broken down into sections which have been separated by index tabs:

Mechanical has individual parts breakdown drawings and lists for each assembly Hydraulic includes adjustment instructions and troubleshooting for the hydraulic system; and all piping and functional drawings for a standard machine and optional equipment Electrical, includes electrical schematics, distribution and control boxes, and cabling drawings for the machine; as well as troubleshooting instructions Component Data includes parts breakdowns and service instructions for components installed on the machine that are not of NORDCO’s manufacture. For example, the engine and pump.

GENERAL CX Hammer with PLC

Section 1-10 MAR/2005 (49454100)

SPECIFICATIONS GENERAL Gross Weight ............................................................................................................................ 22,500 lbs (10,215 kg)* Length ...............................................................................................................................272 inches (6.9 m/6900 mm) Width.................................................................................................................................100 inches (2.5 m/2500 mm) Height................................................................................................................................106 inches (2.7 m/2700 mm) Travel Speed......................................................................................................................25 mph maximum (40 km/h) Rated Draw Bar Pull .........................................................................................................................1,650 lbs. (750 kg) Turntable....................................................................................................................................Hydraulically Operated Wheel Base.......................................................................................................................163 inches (4.1 m/4100 mm) Towing Speed....................................................................................................................20 mph maximum (32 km/h) Spiking Down Force.........................................................................................................................2,200 lbs. (9820 N) CAPACITIES Fuel Tank: .................................................................................................................................120 gallons (454 liters) Hydraulic Oil Tank......................................................................................................................100 gallons (379 liters) Oil Cooler .......................................................................................................................................100 gpm (378 L/mn) ENGINE Make/Model .................................................................................................................................... John Deere, 4045D Type ............................................................................................................................................... 4-Cylinder, 4-Stroke Idle Speed....................................................................................................................................................... 1150 rpm Continuous BHP .....................................................................................................................85 @2400 rpm - full load HYDRAULIC SYSTEM Pressure Settings: Relief Valve - Main Pump ........................................................................................................... 3,000 psi (200 bar) Compensator - Main Pump........................................................................................................ 2, 250 psi (172 bar) Main Pump Make............................................................................................................................Vickers PVH Series Control Valves..................................................................................................................................Vickers Manifolded ELECTRICAL SYSTEM Battery...............................................................................24 Vdc (Dual 12V dc Batteries), 1150 Cold Cranking Amps Ground............................................................................................................................................................. Negative DRIVE SYSTEM Drive Type........................................................................................................................... Single and Dual Axle Drive Propulsion Motor Type.................................................................................................................................... Hydraulic

- Continued on next Page -

Items or capacities may vary according to options on your machine. * Approximate weight. Actual weight may vary according to options on your machine. Actual weight of your machine is as stenciled.

CX Hammer with PLC GENERAL

MAR/2005 (49454100) Section 1-11

AXLE/WHEELS Front Axle Size.....................................................................................................................................3-inch, Standard Rear Axle Size .....................................................................................................................................3-inch, Standard

3-7/16 inch on machines equipped with bulk loader

Wheel Type....................................................................................................................................................Cast Steel Wheel Size......................................................................................................................... 16 inch ( 406 mm) diameter Brake Type..........................................................Four wheel shoe type, spring actuated, hydraulic release - standard

Air brakes - Optional All rights reserved. In view of the constant improvements to our equipment, the specification data and other technical information included in this manual are subject to change. No part of this manual may be reproduced in any form or by any means without our written permission.

GENERAL CX Hammer with PLC

Section 1-12 MAR/2005 (49454100)

This Page Intentionally Left Blank

CX Hammer with PLC PRE-OPERATION

MAR/2005 (49454100) Section 2-1

Before operating this machine, read and understand the Safety Section of this Manual. BEFORE OPERATION

Improper use of this machine for any type of operation can cause serious injury or death. It is always good practice to become totally familiar with the machines you are going to operate. OPERATOR'S STATION Almost all the controls for running this machine are located in the Operator’s Station. This includes but is not limited to the logic box, remote operator control boxes, propulsion and braking foot switches. There are three seats on the machine. The two facing the workheads are for the operators, the third - facing the operators - is for the loader, if used. Located next to each Operator’s seat is a Remote Operator Control Box. See Figure 1. These are used during work operations and, depending on the options installed on your machine, allow the operators to set the workhead pattern using electric actuators, lower the guide roller, sound horns, select method of braking (deadman or service) and mode of travel (work or travel), and stop the machine in the event of an emergency. Status of the brakes and travel mode selections can be seen by illuminated diodes on the box.

Each operator is responsible for a particular workhead on the machine. Each workhead consists of two gun assemblies (left and right). Each operator has two hand controllers that control the function of the guns in front of them. See Figure 2. The left operator controls guns 1 and 2, the right operator controls guns 3 and 4. Carriage movement is controlled by the right hand controller at each operator seat. Moving the hand controller forward and back, and left and right, allows you to center the carriage manually.

Foot switches are located on the flooring in front of both the left and right operators. The use of a toggle switch on the main control panel allows only one operator at a time to control the movement of the machine. This is done to prevent unintentional movement of the machine. You must select either right operator control or left operator control of the foot pedals.

Always use your seat belt when sitting in the operator’s seats.

Always use the handrails and steps provided to climb on to and off of

the machine.

PRE-OPERATION CX Hammer with PLC

Section 2-2 MAR/2005 (49454100)

WORKHEAD COMPONENTS CARRIAGE The position (forward/backward - left/right) is controlled by the right hand controller at each operator station. Hand controller movement (forward/backward - left/right) controls two hydraulic cylinders (one attached to the top of the carriage and the other attached to the Carriage Guide Wheel Assembly) which provide movement on the carriage guide shafts. CARRIAGE GUIDE WHEEL Located between the outer and inner carriages is the guide wheel. This guide roller functions as a workhead stabilizer and is controlled by a hydraulic cylinder (up and down movement of guide roller) and a second hydraulic cylinder controls the left/right movement of the carriage assembly. WORKHEAD The workhead assembly includes the driving cylinder, the hammer, and spike feeding and drive assembly. Hole pattern adjustments for workhead spacing are made using the pattern adjust switch located on the Operator Control Box. The up/down/ready condition of the workhead is controlled through a series of proximity switches mounted to the side of the carriage frame. The prox switch controls the ready position of the workhead. This controls the distance the workhead travels before actually driving in the spike. This switch is adjustable. See WORKHEAD ADJUSTMENTS later in this section. MANIFOLDS The Model CX hydraulic system uses a series of manifolds. More detailed information regarding the hydraulic system and manifolds is located behind the tab marked “HYDRAULICS”. This includes a layout of the machine and the locations of all hydraulic components. PROPULSION/DRIVE SYSTEM

The machine is propelled with both axles with a chain drive. There are two hydraulic motors; one located directly below the propulsion manifold on the engine end of the frame - the other located below the right operator on the operator end of the machine. BOOM/WINCH The boom/winch system is in place to allow the operator to easily lift kegs of spikes onto the rear storage deck. The winch is capable of lifting loads up to 300 lbs. It is not designed or intended to be used for towing. The boom and winch should be locked up for travel or when not being used. See lockup requirements in the Lockup section of this manual. Note: Boom/Winch is not supplied on a machine equipped with the optional Bulk Spike Loader System. LOGIC BOX CONTROL PANEL The control panel contains nearly all of the operator selectable items on the machine, with the exception of the remote operator control boxes. The control panel drawing on the next page is representative of a standard machine with gager. Refer to the following pages and become familiar with the controls on this machine! BULK LOADER (OPTIONAL) The bulk loader is hydraulically driven spike loader that is designed to “feed” spikes into the spike bin located between the two operators. Spikes are carried to the spike bin using a “push style” ram driven by a hydraulic cylinder. GAGER (OPTIONAL) The gager assembly is a series of 4 hydraulic cylinders and lever arms that are designed to position the rails into the proper gage prior to spiking operations. Used with the gager buggy, which sends an electrical signal to the digital meter on the logic box control panel, proper gage is determined and a signal sent back to the valves located on the gager manifold that begin the process of gaging. Valves open or close as necessary to move the lever arms in/out to position the rail into place. The gager levers must be locked up for


MAR/2005 (49454100) Section 2-3

travel. See lockup requirements in the LOCKUP section of this manual. Instructions for using the gager can be found behind the tab Customer Options. NIPPER ASSEMBLY Located in the center of the machine, between the workheads is the nipper assembly (See Figure to right). It is used to pull the tie up to the rail to secure the tie plate to the tie during spiking operations. A large hydraulic cylinder controls the up/down position of the nipper assembly, while a second and smaller hydraulic cylinder controls the open close position of the nipper tie hooks themselves. The nipper housing is supported by guide blocks, which are used to guide the nipper housing up and down. This assembly must be locked up for travel. See lockup requirements in the LOCKUP section of this manual.


Section 2-4 MAR/2005 (49454100)


MAR/2005 (49454100) Section 2-5

TABLE 1. CONTROL PANEL GAUGES

GAGE NUMBER

INSTRUMENT OR CONTROL

FUNCTIONAL DESCRIPTION

1 Engine Oil Pressure Gauge Indicates oil pressure. Does not indicate oil level. Measurement in psi graduations. Normal reading is 40-60 psi (3-4 bar). Note: Low engine pressure will shutdown the machine at

20 psi.

2 Engine

TEMPERATURE Gauge Indicates temperature of engine or cooling system. Normal reading is 180° F to 202° F (82° - 95° C) Note: High engine temperature will shutdown the machine at 248° F (120° C).

3 VOLTMETER Indicates voltage of battery. Normal reading is 22-27 volts.

4 TACHOMETER Indicates engine speed in hundreds of rpm. 5 HOURMETER Block numbers on gauge indicate engine hours.

6 FUEL GAGE Measures the level of diesel fuel in the fuel tank. Do not allow to go into the red zone.

7 HYDRAULIC OIL Temperature Gauge (Optional)

Indicates temperature of oil in hydraulic reservoir.


Section 2-6 MAR/2005 (49454100)

TABLE 2. ENGINE/PROPEL SPEED CONTROLS



SHUTDOWN OVERRIDE

Overrides engine shutdown for emergency travel purposes. Red pilot light is lit when engine shutdown override is activated. CAUTION: The engine is not protected from low oil pressure or high temperature damage in this mode.

EMERGENCY STOP

Press button to shut down engine. Pull out button to reset. See "EMERGENCY STOPPING" at the end of this OPERATION section.

PUSH TO START Press and hold until engine starts and oil pressure reaches 30 psi (2 bar). Engine will not start if button is not held in.

IGNITION Switches power to all circuits. Activates starter (when held fully clockwise). USED FOR NORMAL ENGINE SHUTDOWN.

ENGINE SPEED

The LOW speed (turtle) setting is for starting. Set switch to HIGH (rabbit) to operate machine. Return to LOW before shutting down engine. NOTE: Engine will not start if switch is in HIGH position when starting.

PUMP ON/OFF

Turns on hydraulic pump. Engine will not start if this switch is in the ON position when ignition switch is turned. This is done to reduce engine load during starting. After engine has started, turn on pump.

PROPEL SPEED

2X (High)

4X (Low)

This machine is equipped with Dual Axle Drive. This switch selects the speed at which track or work travel is accomplished. This switch is used in conjunction with the Travel/Work Mode switch. Single Axle Drive. Primarily used during travel operations (non-work mode). Travel/Work Mode switch should be in the TRAVEL position. Dual Axle Drive. Primarily used during working operations (non-travel mode). Travel/Work Mode switch should be in the WORK position. Propelling through steep grades Use this 4X when traveling in steep grades (in this case the Travel/Work Mode switch should be in the TRAVEL position). Switching from 4X to 2X while traveling in speeds in excess of 10 mph will result in dynamic braking.


MAR/2005 (49454100) Section 2-7

TABLE 3. LIGHTS, FANS & ALARM CONTROLS

INTERNATIONAL SYMBOL



STROBE LIGHT (Optional)

Turns strobe light on or off.

HEATER FAN (Optional)

Three position switch, with return to center being the OFF position.

BACKUP ALARM

A three position switch (center is OFF) that is used to sound an alarm when you travel in direction opposite of your working direction. If you are working in a forward direction (engine end first) push switch DOWN. If working in reverse (Operator end first) push switch UP.

TRAVEL LIGHTS

Turns travel lights ON or OFF. Three position switch, center position is OFF. Select light for direction of travel, DOWN for reverse travel, UP for forward travel. NOTE: On some machines this switch has been replaced with a 2-position ON/OFF switch that turns ALL travel lights and beacon/strobe on or off.

WORK LIGHTS

Turn working lights ON or OFF


Section 2-8 MAR/2005 (49454100)

TABLE 4. TRAVEL & WORK CONTROLS

SYMBOL INTRUMENT OR CONTROL


RAIL TYPE Set this switch according to the rail type WELDED (Switch Up) or JOINTED (switch Down). In WELDED mode, gager lever rollers stay in contact with web of rail during travel. In JOINTED mode, gager lever rollers pulse up during travel to clear rail joint bars.

NIPPERS

When in auto, nippers are applied automatically with any workhead set signal. When in manual mode, nippers are applied and reset using handcontroller.

TRAVEL PEDALS Position of switch determines which operator is responsible for the propulsion of machine. Both brake switches function at all times REGARDLESS of which operator is in control of the travel functions or which mode of brakes has been selected. NOTE: For machines equipped with MTS system, right hand pedals MUST be selected.

OPERATION MODE

GREEN LIGHT

YELLOW LIGHT

Lights will illuminate depending on position of switch Travel mode has been selected. Work mode has been selected. NOTE: This switch is used in conjunction with the PROPEL Speed switch in Table 2.


MAR/2005 (49454100) Section 2-9

SYMBOL INTRUMENT OR CONTROL


ELECTRICAL INTERLOCK

When pushed in, disables all electrical input to hand controllers and workheads. Also locks brakes. Should be used during machine warmup or inspection.

BRAKE MODE

DEADMAN(GREEN LIGHT)

SERVICE(YELLOW LIGHT)

Lights will illuminate depending on position of switch Both brake switches function at all times REGARDLESS of which operator is in control of the travel functions or which mode of brakes has been selected. This allows the “non-control” operator to apply brakes if his spiking operations are not completed before the “control” operator presses the propulsion switches. Deadman brakes have been selected when the green light is lit. When set to deadman, brakes are applied any time forward or reverse pedal is released. When set to service (yellow light is lit), brakes are applied only when brake pedal is applied.

HORN Press to sound horn.

EMERGENCY STOP Press button to shut down engine. Pull out button to reset. See "EMERGENCY STOPPING" at the end of this OPERATION section.


Section 2-10 MAR/2005 (49454100)

TABLE 5. CONTROL PANEL MISC. CONTROLS

SYMBOL INTRUMENT OR

CONTROL FUNCTIONAL DESCRIPTION

FILTER STATUS LIGHTS

GREEN LIGHT

RED LIGHT

Lights will give status of return & pressure line filters and optional case drain filter. Filter does not require servicing. Alarm state. Filter requires servicing or element requires replacing.

POWER LOCKUPS

Engage

Disengage

Spring actuated lockup. Normal position of the switch should be in the UP position (engage). Auto engages when machine is set to “travel” mode. You should always verify that the lockup has properly engaged. Lockup does not engage in either the travel or work mode and lockups must be set either manually or by returning switch to the engage mode.


MAR/2005 (49454100) Section 2-11

TABLE 6 OPERATOR STATION CONTROLS REMOTE OPERATOR CONTROL BOX

Control or Instrument

Function

Travel Mode (Green Light). When in Travel Mode, hand controllers are disabled and all hydraulically controlled components will move to UP position for locking. Working Mode (Yellow Light). Switch in Down position. Hand Controllers are enabled.

Press button to sound horn.

Press button to shut engine down. Pull out button to reset. See "EMERGENCY STOPPING" at the end of this OPERATION section.

Remote pattern adjustment for forward/backward Remote pattern adjust open and close.

Brake Mode. Lights will illuminate depending on position of switch. Green Light (Deadman): When set to deadman, brakes are applied any time forward or reverse pedal is released. Yellow Light (Service): When set to service, brakes are applied only when brake pedal is applied.

Raises and lowers guide roller. Down: lowers roller for work. (Turns on automatically when gun goes to ready during work cycle) Up: raises roller for lockup and travel. (Turns on automatically when machine is placed in TRAVEL MODE.)


Section 2-12 MAR/2005 (49454100)

TABLE 7. OPERATOR STATION CONTROLS

The type of braking is selected on the Main Control Panel of the Logic Box. Both brake switches function at all times REGARDLESS of which operator is in control of the travel functions or which mode of brakes has been selected. This allows the "non-control" operator to apply brakes if spiking operations are not completed before the "control" operator presses the propulsion switches.


Function

Brake Footswitch or Air Brake Foot Treadle

Press this footswitch to apply brakes no matter which MODE of brakes you have selected. When in DEADMAN, brakes apply automatically when travel switch is released, but can be overridden by either operator if a travel switch is pressed. When in the SERVICE brake mode, either operator must press the brake switch in order for the brakes to apply.

Reverse Propel Footswitch

Press this Footswitch to release brake and propel the machine in reverse.

Forward Propel Footswitch

Press this Footswitch to release brake and propel the machine forward.


MAR/2005 (49454100) Section 2-13

TABLE 8 OPERATOR STATION CONTROLS HAND CONTROLLER FUNCTIONS The joystick valve attached to the right handcontroller at each work station allows the operator to position the carriage (See Figure 10), while the buttons on the hand controller itself perform actual working operations. Refer to the item numbers listed on Figure 9 for cross reference in the Table.

Item

Function

Description

1.

Set

Brings workhead down to READY position, lowers guide wheels on both sides of machine. (Note: some machines have switches on the remote operator control box for lowering the guide wheel. If this switch is not used, the guide wheel will lower when pushing this button.)

2.

Drive

Drives spike as long as button is held.

3.

Override

Manually turns on hammer function while moving gun down

4.

Nippers (Manual Only)

Either operator controls this function. Pressing this button on the right handcontroller engages nippers. Pressing this button on the left hand controller disengages nippers. (Nipper Set button not functional in auto-nipper mode)

5.

Load

Feeds spike into jaws.


Section 2-14 MAR/2005 (49454100)

TABLE 9

REMOTE CONTROLS AND INDICATORS

Item


Function

1

Emergency Pump (Optional) Top Off Pump (Optional)

Located on frame near the engine. Pump can be either electric or manual, and is used when there is a loss of system pressure and movement of hydraulic cylinders is necessary. System pressure is supplied by pumping hand lever or by switch on electric pump. The top off pump can be either an electric or manual pump that is used for filling the hydraulic tank. Release tank pressure before filling tank.

2

Turntable Valve Hand Lever

The lever controls the upward/downward motion of the Turntable Cylinder and the machine. Moving the valve hand lever up extends the cylinder and raises the machine. Moving the lever down retracts the cylinder and lowers the machine. Moving the lever to the center position stops cylinder movement. The valve hand lever must be down and locked whenever the cylinder is not being used.

3

Battery Disconnect Switch

Located inside of battery box. Two position switch marked with "ON/OFF" plaque. This must be OFF and locked during service.

4

Winch Motor Control Valve Hand Lever

The lever is mounted on the winch boom. Moving the valve hand lever up raises the load, midway stops the winch spool motion, and down lowers the load.

5

Fuel Tank Level Gauge

Located on side of fuel tank, this tube indicates the level of fuel in the tank.

6

Spike Bin Cylinder Hand Lever

Located next to the spike bin, between the RH operator seat and the spike bin, pulling handle down lifts bin, lifting handle up lowers bin.

7

Hydraulic Oil Tank Sight Level

Located on hydraulic oil tank, it indicates the level of hydraulic oil in the tank.

8

Hydraulic Oil Temperature Gauge

Located on the bottom of the hydraulic oil sight level. Indicates temperature of the hydraulic oil. Normal operating temperature is 80° to 150° F (49° to 66° C).

9

Hydraulic Reservoir Vent Valve (Optional)

Located on the main frame in front of the left gager assembly. Valve should be opened during top off of tank until overflow goes out valve, then valve should be closed to allow pressurization of tank. NOTE: Valve should be opened whenever maintenance is performed on the hydraulic system.


MAR/2005 (49454100) Section 2-15

Preparing the Machine for Work As with any machine, pre-operational checks and preventative maintenance should be performed before using the machine. We suggest that you follow the guidelines listed below before actually operating the machine. 1. Position the machine on level track

so fluid levels can be accurately checked and filled if necessary.

2. See TOWING section if machine is

to be towed to worksite. 3. Know and understand the use of

all machine controls and instruments as described in Tables OP-1 through OP-6.

4. Perform the pre-operational

inspection of the entire machine as specified in Table OP-7, on the next page. Find defects and correct them before serious damage or failure results.

5. If necessary, follow any applicable

instructions under MAINTENANCE FOR EXTREME CONDITIONS.

6. Perform applicable preventative-maintenance procedures in MAINTENANCE AND SERVICE section.

7. Be ready to operate the machine

with an alert and safety-conscious attitude.

8. Understand the use of the machine's

Lock-Ups. See LOCK-UPS section. 9. Make sure the unit is setup for rail size

being worked on. Adjustments, if required, are described in the MACHINE SETUP.

10. Wear proper safety clothing. 11. Determine who will be in the

COMMAND position for operating the controls for the nipper, gager, and guide rollers.

Before you begin the pre-operational checklist you should become familiar with the controls that you will be checking. Tables OP-1 through OP-6 explain each control you will be using, and each control’s function. Knowing these controls and their functions may will help you in troubleshooting the machine at a later time.


Section 2-16 MAR/2005 (49454100)

TABLE 10: PRE-OPERATIONAL CHECKLIST NORDCO recommends that the following checks be performed WITHOUT electrical power, due to a possible battery drain.

MAIN CONTROL PANEL STATUS ⌧Logic Box Cover Unlocked and Hooked in Up Position. ⌧Gages checked for broken glass. ⌧Emergency Stop pushbutton is pulled out. ⌧Control Panel Switches set as follows:

⌧Pump ON/OFF switch is OFF ⌧Travel Alarm switch set to direction opposite of work travel. ⌧Strobe or Beacon switch is OFF ⌧Ignition switch is in OFF ⌧Engine Speed switch is set to LOW ⌧Work Lights are OFF ⌧Brake switch set to DEADMAN ⌧Shutdown Override switch is OFF ⌧Nipper Switch is set to MANUAL

REMOTE OPERATOR CONTROL BOX ⌧Check position of switches/pushbuttons:

⌧Travel/Working Mode switch is in TRAVEL ⌧Emergency Stop pushbutton is pulled out. ⌧Guide Roller switch is DOWN (Rollers UP)

MACHINE FLUID LEVEL CHECK (See recommended fluids in Maintenance Section) ⌧Hydraulic Oil Tank is full ⌧Fuel Tank is full ⌧ Engine Oil Reservoir is full MACHINE INSPECTION

⌧Inspect for Leaks. Pay particular attention to hydraulic and fuel lines. ⌧Inspect all controls, wiring and switches for secure mounting ⌧Operator controller covers removed and stored ⌧Battery Disconnect Switch OFF MACHINE LOCK-UPS AND GUARDS ⌧Make certain Mechanical Lock-Up devices are in place (for traveling) ⌧Propulsion Chain guard(s) in place ⌧Spike Deflector mats in place


MAR/2005 (49454100) Section 2-17

Exhaust emissions caused by the use of the engine on this machine may cause cancer,

birth defects, or other reproductive harm if inhaled.

Before starting a new or overhauled engine that has been in storage, consult the engine

manufacturer’s manual for initial start instructions. Failure to follow those instructions can result in serious engine damage.

Engine Operation NOTE: Avoid unnecessary idling. When prolonged idling is needed, maintain at least 800-1100 rpm. 1. Ensure the suction strainer valve (See Figure) on the

hydraulic oil tank is open and the Battery Disconnect Switch is on.

2. Make certain EMERGENCY STOP pushbuttons on

both the main control panel and remote operator control boxes have been pulled out. Set engine speed switch to LOW and the pump switch to OFF. Engine will not start if the engine speed switch is set to HIGH.

NOTE: See Emergency Stopping Procedures at the

end of the OPERATION section. 3. Switch brakes to DEADMAN to keep machine from

rolling. 4. Hold the Magnetic Override switch (MO) (labeled

ENGINE/PUSH TO START) in and turn the ignition switch to the right until the engine starts. Release the ignition switch (will spring back to centered position) and continue holding the MO switch until oil pressure reaches 30 psi (2 bar or 207 kPa). Allow 5-7 minutes of warmup if first start of the day.

NOTE: Engine will not start if engine speed switch is in HIGH position, emergency stop pushbuttons are pushed in, pump is in the ON position, or if the MO is not held in.

5. If the engine fails to start within 30 seconds, release the Push to Start pushbutton and allow the starting motor

to cool a few minutes before trying again. 6. Perform the startup check on the next page.


Section 2-18 MAR/2005 (49454100)

TABLE 11. STARTUP CHECKS GAUGE READINGS CHECKED: ⌧ Tachometer/Hourmeter: 2400 rpm (no load) ⌧ Voltmeter: 26 to 28 Volts ⌧ Engine Temperature: 160° to 185° F (71° to 85° C) ⌧ Engine Oil Pressure: 40 to 60 psi, 3 to 4 bar, 276 to 414 kPa LIGHT/HORN STATUS ⌧ LIGHTS FUNCTION:

⌧ Travel Lights ⌧ Work Lights ⌧ Brake or Marker Lights ⌧ HORNS/ALARMS FUNCTION:

⌧ Travel Alarm ⌧ Horn Button (Main Control Panel) ⌧ Horn Button (Remote Operator Boxes)

OPERATOR CONTROLS FUNCTION ⌧ Foot switches ⌧ Hand controllers LOCK-UP DEVICES ENGAGED (See Lock-ups - Next Page) ⌧ Turntable/Setoff: Valve handle locked in DOWN position. ⌧ Nipper Frame: Locked ⌧ Gager Buggy: Verify that buggy has been lifted off rail and locked up (hook and chain). ⌧ Gager Levers: Locked (Note: Gager is optional equipment) ⌧ Workheads: Locked ⌧ Winch Boom: Locked in place ⌧ Winch Cable: Secured to mast


MAR/2005 (49454100) Section 2-19

Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or

damage to the machine. LOCK-UPS There are areas designated on the machine as lock-up points. Lock-up points are those areas required to be locked up prior to working travel through crossings, switches or other rail obstructions or during high speed travel (non-working travel), as well as during maintenance and service of this machine – UNLESS lockup of the assembly prevents access to area being maintained. These have been painted red and have a decal located next to or on the area requiring locking up. All lockups, with the exception of the boom/winch and turntable, should be unlocked prior to performing work operations. The others should only be unlocked when required and then immediately relocked upon completion of lifting work. Some machines have been equipped with hydraulically operated lockups. Refer to customer options tab for more information on these lockups. Use the procedures on the following pages to install or remove lock-ups


Section 2-20 MAR/2005 (49454100)

WORKHEADS There is one lock-up device per gun assembly, two per workhead. They must be unlocked prior to performing service to the workhead or during work operations. Use the following procedure to lock or unlock the assemblies.

LOCATION LOCKUP PROCEDURE WHEN USED

Primary Lockup

Non-removable pin located on each workhead.

Secondary Lockup

1. Place machine in TRAVEL mode. This will raise workheads to allow the insertion of the lock pins.

2. Locate the lock-up devices.

The lock-ups are located on the upper outside carriage frames for each workhead.

3. Verify that the assembly is

fully raised. Push lock pin through assembly. (You will not be able to lock in place if assembly has not been fully raised.)

4. If the lock-up pin handle is in

the inner slot, the assembly is locked in place. If the pin handle is in the outer slot, the assembly has been unlocked.

5. Insert secondary lockup pin

into hole on top of hammer mounting bracket.

During working travel through crossings, at switches, frogs, and other rail obstructions, during high speed (non-working) travel.

NOTE: For machines with power lockups:

1. Put the Travel/Work switch in the TRAVEL position to raise workheads. 2. Place the Workhead Lockup switch in the ENGAGED position. 3. Verify that the workhead lockups have engaged. 4. Insert secondary lockup pin into hole on top of hammer mounting bracket.


MAR/2005 (49454100) Section 2-21

GUIDE ROLLER ASSEMBLY There is one lock-up device per guide roller assembly, two per machine. Both must be unlocked prior to performing service to the guide roller or during work operations. Use the following procedure to lock or unlock the assemblies.


Removable pin located on each guide roller assembly. Note: This hole is only accessible once the Guide roller assembly is raised.

1. Place machine in TRAVEL mode. This will raise guide roller assemblies to allow the insertion of the lock pins.

2. Locate the lock pins. They

should be stored on the frame between the workhead and the gager housing.


fully raised. (You will not be able to access hole if assembly has not been fully raised.)

4. Insert pin in hole on guide

roller shaft.

During working travel through crossings, at switches, frogs, and other rail obstructions, during high speed (non-working) travel. Both must be locked during maintenance and service on this machine.


1. Put the Travel/Work switch in the TRAVEL position to raise workheads. 2. Place the Workhead Lockup switch in the ENGAGED position. 3. Verify that the lockups have engaged.


Section 2-22 MAR/2005 (49454100)

GAGER LEVER ARMS There are two lock-up devices per gager housing, four total per machine. These must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies.


1. Place machine in TRAVEL mode. This will raise lever arms to allow the insertion of the lock pins.

2. Locate the lock pins. They

should be stored on the frame in front of the gager housing.


fully raised. Push lock pin through assembly.

4. Lower handle into slot on

frame. This will prevent the pin from slipping out of position during periods of heavy vibration.

During working travel through crossings, at switches, frogs, and other rail obstructions, during high speed (non-working) travel or when gager is not being used.


1. Put the Travel/Work switch in the TRAVEL position to raise workheads. 2. Place the Gager Lockup switch in the ENGAGED position. 3. Verify that the lockups have engaged.


MAR/2005 (49454100) Section 2-23

GAGER BUGGY There are two lock-up devices on the gager buggy. These must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies.


Handle located next to LH Workhead.

1. Using the crank handle (provided on earlier machines) or the ratchet (provided on later machines), raise the buggy to its highest point.

2. Secure chain/hook assembly to each side of buggy frame (one side in left workhead bay, one side in right workhead bay).



Section 2-24 MAR/2005 (49454100)

BOOM AND WINCH


1. Pull down on the lock handle to release the boom.

2. Swing boom in toward operators

until it can’t go any further. 3. Release the lock handle. Verify

that the lockpin has engaged. 4. Secure cable to boom.

At all times when boom and winch are not being used and during working travel through crossings, at switches, frogs, and other rail obstructions, during high speed (non-working) travel.


MAR/2005 (49454100) Section 2-25

NIPPERS

There is one lock-up device on the nipper assembly. This must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies.


Non-removable lock-up pin located on the nipper assembly behind the third operator seat, underneath the logic box.

1. Place machine in TRAVEL mode. This will raise the assembly to allow the insertion of the lock pin.

2. When handle is in outer slot,

nipper is unlocked. When handle is in inner slot, nipper is locked.



1. Put the Travel/Work switch in the TRAVEL position to raise workheads. 2. Place the Nipper Lockup switch in the ENGAGED position. 3. Verify that the lockups have engaged.


Section 2-26 MAR/2005 (49454100)

TURNTABLE There is one lock-up device on the turntable assembly. This must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies.

LOCATION LOCKUP PROCEDURE WHEN USED At set-off valve at front of workhead bay for guns 3 and 4. (Right Front).

1. Make certain turntable is completely raised.

2. Insert lock or pin at valve

handle.

At any time when turntable is NOT being used.

TURNTABLE WITH POWER LOCKUPS


1. Locate the Turntable Valve

and Turntable Lockup Box on the right hand side of the machine (in front of the workhead bay).

2. Verify that the Turntable is in the full UP position.

3. Using the toggle switch on the Turntable Lockup Box, place the switch in the ON position. The GREEN indicator light should come on indicating that the turntable cylinder lock is engaged.

At any time when turntable is NOT being used.


MAR/2005 (49454100) Section 2-27

TRAVEL It is important that you read about and understand all operating controls, Cautions, Warnings, and Dangers before traveling. ENGINE SPEEDS Engine speed is controlled by the switch on the Main Control Panel located on the Logic Box. Engine speed settings are slow and fast. When traveling either in the work or travel modes, you will have the engine speed in the FAST position.

Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or damage to the machine.

PROPELLING AND BRAKING This machine has been fitted with three (3) foot switches that control the propulsion of the machine. These are BRAKES, REVERSE, and FORWARD. 1. For long distance travel, operate machine with

the TRAVEL/WORKING switch in the TRAVEL position. (Putting the machine in the TRAVEL mode will bring all workheads into a raised position for lock-up).

2. Set the Propel Speed Switch to the 2X (High)

speed position. 3. See the Lock-ups sections and make sure lock-

ups are installed. 4. Press the appropriate foot switch to propel the

machine. Propelling at Work Speeds 1. For operating machine in Working mode, Lock-

ups should be unlocked. Refer to Lock-ups section.

2 Operate machine with the TRAVEL/WORKING

switch in the WORKING position.

3. Set the Propel Speed switch to the 4X (low)

speed position. 3. Press the appropriate foot switch to propel the

machine. Braking This machine is equipped with a SERVICE/DEADMAN SWITCH that allows the operator to select which mode of brakes they wish to use. With the switch in SERVICE, the brake foot switch is enabled and needs to be pressed to stop the machine during travel. With the switch in DEADMAN, the brake foot switch is disabled, allowing brakes to automatically apply when either reverse or forward Foot switches are released. TRAVELING ON A INCLINE Before traveling down an incline, test the brakes to make sure that they are fully functional. It is suggested that the Propel Speed switch be in the 4X (low) position when traveling steep inclines.

SETUP & OPERATION CX Hammer with PLC

Section 2-28 MAR/2005 (49454100)

Machine Setup There are some adjustments which may have to be made due to varying conditions such as rail height and base width. Adjustments must be made to compensate for these conditions before operations can begin.

Serious injury or death can result

from reaching into driving components while machine is running! Make observations

from a safe distance.

Always turn off machine when

performing maintenance, making adjustments, or whenever unintended movement of

machine could occur; unless directed otherwise. Failure to

comply could result in personal injury and/or damage to the

machine.

Read and understand all OPERATION procedures, warnings, and cautions before making adjustments.

JAW DEPTH/RAIL HEIGHT ADJUSTMENT Clips are to be inserted in guide-rods at different positions for various rail heights. Use the following table for selecting the correct clip location:

Clip Position

Rail Height (From top)

7"-8" 1 6-5/8" 2 6" 3 5-1/2" - 5-5/8" 4 5-3/16" 5

*Note: The bottom hole on the guide rod

(Clip position #5) is used to secure the jaw mounting in place when removal of the anvil tip is required. In order to do so, you must insert the guide rod spacer and then insert the clip into position #5.

The flat side of ALL clips MUST face the hammer. See lower figure to right.

CX Hammer with PLC SETUP & OPERATION

MAR/2005 (49454100) Section 2-29

WORKHEAD READY ADJUSTMENT The READY position is the point where the workhead assembly stops descending before the spike is actually driven in. The position of a movable proximity switch determines where the Ready position is. The goal of this adjustment is to get the tip of the spike 1/2" above the tie plate when in the READY position (see middle figure). 1. Turn off engine. Move the READY

proximity switch so that the top of the prox switch mounting plate is roughly 5" from the top of the prox switch mounting bracket. (See top figure.)

2. Make certain workhead lockups

are in the unlocked position. 3. Start engine. Set TRAVEL/WORK

switch on Remote Operator Control Box to WORK position.

4. Position outer gun over tie plate. 5. Make certain spikes are loaded

into the tray. Press and release the LOAD pushbutton on the hand controller to load spike into the jaws. Spikes should protrude from the jaws. If they don’t, see Troubleshooting Section at the end of these Operating Instructions.

Make certain both operators

have centered the guide rollers over the rail before pressing the set button during the Workhead Adjustment procedures. Failure to do so may result in damage to the machine, as the guide rollers are lowered when the set button

is pressed.

6. Press and release the SET pushbutton on the hand controller. This will cause the corresponding driving cylinder to extend and stop. The spike should be approximately 1/2" above the tie plate.

7. Shut of engine using ignition key. 8. Verify the 1/2" distance. If

distance is correct, procedure is complete. If not correct, repeat Steps 1-8 lowering prox switch 1/2" to 1" each time until the 1/2" distance is reached. (Note: moving prox switch down decreases the distance, moving prox switch up increases the distance.)

Note: Periodic adjustment of this switch may be

required as oil temperature ncreases


Section 2-30 MAR/2005 (49454100)

Workhead Spike Pattern Adjustments Adjustments to the outer workhead are done using the right hand controller. The inner workhead is adjusted in relation to the outer workhead using two electric actuators, one connected under the inner and outer workheads, the other is located on the upper carriage between the workheads. The guide wheel must be lowered into position before these adjustments can be made. NOTE: Guide wheel lowers when SET pushbutton is pressed or when guide roller switch on Remote Operator Control Box is set.

Make certain both operators

have centered the guide rollers over the rail before pressing the set button during the Workhead Adjustment procedures. Failure to do so may result in damage to the machine, as the guide rollers are lowered when the set button

is pressed. The controls for the electric pattern adjust are located on the operator control boxes next to each operator. LH Operator Box controls left workhead, RH box - right. To adjust the pattern: hold switch in direction required, release switch once you have reached correct position. GAGER The Gager on this machine is considered an option and the instructions for its use can be found behind the CUSTOMER OPTIONS tab of this manual. ELECTRICAL ADJUSTMENTS Electrical adjustments other than those for the proximity switches, are located in the MAINTENANCE AND SERVICE section of this manual.


MAR/2005 (49454100) Section 2-31

MACHINE OPERATION

Work Operation

To avoid serious injury or death,

make certain that the area around and under the machine is

clear of all personnel and obstructions before travelling or

working.

Failure to engage all lockup devices before propelling at

travel speed can result in injury to personnel and/or damage to

the machine.

1. Make certain all STARTUP procedures have been followed before beginning working operations.

2. Run the machine over the tie plate

to be spiked. 3. Make certain machine is in the

WORK mode. 4. On machines equipped with

gagers, verify the gage of the track and adjust the gager as necessary. (See Gager Operating Instructions behind the CUSTOMER OPTIONS tab of this manual).

5. Lower guide rollers. 6. Move the hand controller so the

spotting carriage is centered with one workhead on each side of the rail (carriage is centered, left to right). Use of the optional carriage centering assembly will do the same when using the switch on the Operator Control Box.

7. Position machine so inner

workhead is aligned with hole in tie plate.

8. Make certain all spike trays have

been filled.

SPIKE DRIVING (WITHOUT NIPPERS) 1. Press and release the LOAD

pushbutton to load spikes into jaws. 2. Press and release the SET pushbutton

on the hand controller. This will cause the corresponding driving cylinder to extend and stop.

3. Press and hold the DRIVE pushbutton

on the hand controller. This will drive the spike into the tie using the driving cylinders and the hammers.

NOTE: You may override the READY PROX switch settings at any time by pushing the override button on the hand controller (HAMMER machines only). This allows you to drive high spikes. Perform spiking operations as normal.

4. Propel to next tie. SPIKE DRIVING (WITH NIPPERS IN AUTO MODE) The auto nipper mode is started automatically when the SET pushbutton on the hand controller is pressed. 1. Set the Nipper AUTO/MANUAL switch

to the AUTO position. 2. Press and release the LOAD




on the hand controller. This will drive the spike into the tie using either the driving cylinders (on Push Spiker Machines) or the hammers (on Hammer Machines).

NOTE: You may override the READY PROX switch settings at any time by pushing the override button on the hand controller (HAMMER machines only). This allows you to drive high spikes. Perform spiking operations as normal.

5. Propel to next tie, this will reset the

nipper cycle until the SET button is


Section 2-32 MAR/2005 (49454100)

pressed again. SPIKE DRIVING (WITH NIPPERS IN MANUAL MODE) 1. Set the Nipper AUTO/MANUAL switch

to the MANUAL position. 2. Press and release the NIPPER SET

pushbutton on the right hand controller. This will cause the nipper frame to lower and stop once it contacts the tie. The nipper hooks will then close around the tie and the frame will pull up on the tie.

3. Press and release the LOAD




on the hand controller. This will drive the spike into the tie using the driving and the hammers.

6. Press and release the NIPPER RESET

pushbutton on the left hand controller. This will cause the tie hooks to open and the frame will move up to its work position.

7. Propel to next tie. Winch Operation Your machine is equipped with a hydraulic winch for loading materials onto the deck of the machine. In order for the winch to be fully operational, it must have the interlock pin set so that the boom can swing fully from left to right without the lock resetting in another hole. This is accomplished by pulling the interlock handle on the boom mast out until the spring compresses enough to allow the spring pin to move behind the bar located beneath the bracket. Releasing handle allows free movement of boom. To raise a load: Pull valve handle to left

To stop a load: Release valve handle To lower the load: Pull valve handle to right Under no circumstances is the winch to be used for towing or for lifting loads in excess of 300 pounds. After winch work is complete, secure cable to boom. Refer to LOCKUP section for instructions on locking up the boom and winch assembly. Emergency Procedures 1. If a hydraulic hose fails, shut down

the machine immediately, determine cause of failure, correct condition.

2. If indications on gauges are not

within the normal range, shut down the engine. Repair before further operation.

3. Emergency hydraulic operation in

the event of a catastrophic hydraulic system failiure requires the optional Hand Pump. Refer to Maintenance and Service Section for instructions.

EMERGENCY STOPPING The emergency shutdown should be used only when the engine does not respond to the normal stop engine procedure or in the event of an emergency where time is critical. To shut down the engine, push the EMERGENCY STOP pushbutton located in the upper center of the Logic Box control panel or on either Remote Operator Control Box. Never use the emergency shutdown system except in an emergency. DO NOT USE THIS METHOD AS A SHORTCUT TO TURNING OFF THE ENGINE!!


MAR/2005 (49454100) Section 2-33

AFTER OPERATION General 1. Set the Travel/Work Mode switch to the TRAVEL position. 2. Press the Electrical Interlock on the Main control panel. 3. Install lock-ups. See LOCK-UPS section. 4. Make certain brakes have been set

to DEADMAN position. 5. Set engine speed to low position

and turn pump off. Let engine idle for 5 minutes.

6. Shut off engine by returning

ignition switch to the full counterclockwise position.

To avoid possible personal injury

and/or engine damage from accidental engine startup, always

disconnect the battery before servicing this machine.

6. Return all switches to their "Pre-

Operational" state using the Pre-Operational Checklist as a guide.

7. Replace the operator hand control

covers, lower logic box cover, and secure them with padlocks.

8. Turn off battery disconnect switch.

Lock battery box. Parking or Locating Machine 1. Park or locate machine on level

track area, if possible; and where it will not be exposed to excessive dust.

2. If the machine was towed,

disconnect towing vehicle and set the brakes. Move the towing vehicle well clear of the parked machine.

Rotating Machine (without Turntable Lockup)

Any machine can be hazardous when raised. Take all necessary precautions before raising the machine. Do not, under any circumstances, climb under machine when using the turntable. 1. Attach winch (optional equipment)

cable hook to turntable base and lift off machine. Lower into position using the winch assembly.

NOTE: The only hand contact with the turntable base should be to position it correctly across ties. At this point, the turntable should still be attached to, and its weight supported by, the winch assembly.

2. Center turntable base across two

solid and level ties. Disconnect winch cable. Propel machine over turntable base.

3. Unlock set-off valve handle.

Slowly lift handle to lower turntable cylinder rod until it comes into contact with base.

4. Reposition machine as necessary

to allow rod to enter base. 5. Move the Turntable Valve hand

lever upward and hold until the machine is fully raised off the track. Center the hand lever.

6. Use manpower to rotate the

machine. The wheels should be directly above the track after rotating the machine.

7. Slowly move the Set-Off Valve

hand lever downward. The Turntable Cylinder will retract and the machine will lower onto the track.


Section 2-34 MAR/2005 (49454100)

Rotating Machine (S/N 410500 – 410587) Use of the Turntable and Turntable Lockup requires hydraulic and electrical power to the machine. To lift and rotate the machine, proceed with the following steps:

Any machine can be hazardous when raised. Take all necessary

precautions before raising the machine. Do not, under any circumstances, climb under

machine when using the turntable.

1. Attach winch (if supplied) cable

hook to turntable base and lift off machine. Lower into position using the winch assembly.

NOTE: The only hand contact with the turntable base should be to position it correctly across ties. At this point, the turntable should still be attached to, and its weight supported by, the winch assembly. NOTE: Use of the winch is not required if using an Aluminum turntable base.

2. Center turntable base across two

solid and level ties. Disconnect winch cable. Propel machine over turntable base.

3. Locate the Turntable Valve and

Turntable Lockup Box on the right hand side of the machine (in front of the workhead bay).

4. Unlock Turntable valve handle. Slowly lift handle to lower turntable cylinder rod until it comes into contact with base. 5. Reposition machine as necessary to allow rod to enter base. 6. Move the Turntable Valve hand lever upward and hold until the machine is fully raised off the track. Center the hand

lever. 7. Use necessary manpower to rotate the machine. The wheels should be directly above the track after rotating the machine. It is suggested to turn the machine in the clockwise direction. 8. Slowly move the Turntable Valve hand lever downward. The Turntable Cylinder will retract and the machine will lower onto the track. When the turntable is

fully retracted, reapply the lock on the turntable valve handle. 9. Using the toggle switch on the Turntable Lockup Box, place the switch in the ON position. The GREEN indicator light should come on indicating that the turntable cylinder lock is ON.


MAR/2005 (49454100) Section 2-35

Rotating Machine (S/N 410588 & Above)

Before you attempt to rotate the machine, it is important that you become familiar with the type of Turntable Cylinder on your machine. Refer to the drawing below to find the style of cylinder: Style 1 – External Lockup This cylinder requires that the lockup valve be overridden CONTINUALLY during the lowering of the turntable (raising machine). This is done by pulling out and holding the knob on the turntable manifold while lowering the turntable. This knob DOES NOT apply to raising the turntable (lowering machine). Style 2 – Internal Lockup This cylinder requires that the lockup valve be overridden only until the cylinder extends past the detent position when lowering the turntable (raising machine). This is done by pulling out and holding the knob on the turntable manifold until the cylinder has past the detent. This knob DOES NOT apply to raising the turntable (lowering machine). Using the Turntable Valve The turntable valve is located on top of the turntable manifold. It is item “A” in the sketch to the right. Lifting the valve handle lowers the turntable rod, which in turn, raises the machine. Lowering the valve handle raises the turntable rod, which in turn, lowers the machine. With the Style 1 and 2 cylinder designs it is necessary to bypass the lock valve in the

cylinder to lower the cylinder rod. This is done by pulling on the knob while lifting or lowering the valve handle on top of the manifold. The length of time for pulling is determined by the Style of cylinder you have on your machine.


Section 2-36 MAR/2005 (49454100)

Rotation Procedures To lift and rotate the machine, proceed with the following steps:

Any machine can be hazardous when raised. Take all necessary precautions before raising the machine. Do not, under any circumstances, climb under machine when using the turntable.

1. Attach winch (if supplied) cable hook to turntable base and lift off machine. Lower into position using the winch assembly.

NOTE: Use of the winch is not required if using an Aluminum turntable base.

2. Center turntable base across two solid and level ties. Disconnect winch cable. Propel machine over turntable base.

3. Locate the Turntable Manifold on

the right hand side of the machine (in front of the workhead bay).

4. Unlock Turntable valve handle (A

in drawing to right).

5. Depending on the style of turntable cylinder, lower the cylinder rod as follows:

a. Style 1 – External Lockup:

Pull out and continually hold knob (B) on manifold while pulling up on the valve handle (C) to lower the turntable cylinder rod until it comes close to the cylinder base.

b. Style 2 – Internal Lockup:

Pull out and hold knob (B) and pull up on valve handle until cylinder rod goes past detent then release knob. Continue pulling up on valve handle until rod comes close to the cylinder base.

6. Release valve handle (C) and knob

(B) (if applicable).

7. Reposition machine as necessary to allow rod to enter base.

8. Depending on the style of turntable

cylinder, raise the machine off the rails:

a. If your machine has the

Style 1 – External Lockup, you must pull out the knob and hold while moving the Turntable Valve hand lever upward. Hold until the machine is fully raised off the track.

b. If your machine has the Style 2 – Internal Lockup, simply move the hand lever upward until the machine is fully raised off the track.

9. Use necessary manpower to rotate

the machine. The wheels should be directly above the track after rotating the machine. It is suggested to turn the machine in the clockwise direction.

10. Slowly move the Turntable Valve

hand lever downward. The Turntable Cylinder will retract and the machine will lower onto the track.

11. When the turntable is fully

retracted, reapply the lock (A) on the turntable valve handle.


MAR/2005 (49454100) Section 2-37

Towing Maximum towing speed is 20 mph. Reduce speed accordingly as dictated by weather or track conditions.

Do not permit unauthorized

personnel to ride in or on the machine, or on the drawbard between the machine and the towing vehicle. Falling from a

moving vehicle may cause serious injury or death.

Remember that the machine weight may approach the weight of the towing vehicle. Maintain increased stopping distance accordingly. The following steps must be taken before towing your machine: 1. Install Lock-Ups. See LOCK-UPS

section. 2. Make certain turntable has been

raised. 3. Remove drive chain(s) if machine

is to be towed a long distance. 4. Inspect the towing vehicle coupler

for damage or loose parts. 5. Back towing vehicle to the machine

and engage the couplers. Keep hands and fingers clear of the coupling device and all other pinch points.

5. Ensure that the coupling device is

fully engaged, closed, and locked. 6. Install Brake Lock Pins. See

Brake Assembly in Maintenance and Service for instructions on installing brake lock pins.

To avoid serious personal injury, stay clear of brake springs when using hydraulic compression to

place brake lock pins.

8. Ensure that the coupling device and rear frame members on the towing vehicles will not interfere with or restrict motion of any part of the machine when maneuvering.

9. When towing is complete, engage

brake by removing the Brake Lock Pins.


Section 2-38 MAR/2005 (49454100)

This Sheet Intentionally Left BlanK

CX Hammer with PLC MAINTENANCE

MAR/2005 (49454100) Section 3-1

NORDCO'S SERVICE NETWORK Need assistance? It's only a phone call away! If you experience problems, contact your original sales representative first, he is the one listed on the front page of this manual. If you cannot reach him, we suggest that you contact the representative closest to your work area BEFORE calling NORDCO's Service Manager. See map on the next page for the alternate representative closest to your work area. REQUESTING ASSISTANCE If you have any questions regarding maintenance and service on this machine, please call your local Nordco Representative or: Nordco Service Manager (414) 766-2342 (Wisconsin) 1-800-445-9258 (USA and Canada) The process will be faster if you have the following information in hand before calling: 1. The Machine and Model Name: CX Hammer with PLC or CANBUS 2. The Serial Number

SERVICE NETWORK No. Representative Phone Number 1. Nordco Service Manager 1-800-445-9258 or (414) 769-4603 2. Russell Railway Supply (952) 835-5125 3. & 4. James H. Lynde (913) 648-7379 5. Stanley H. Smith Inc. (606) 885-3353 6. Dwayne Lambing (770) 424-0401 7. North American Equipment Company (716) 675-2040 or (859) 885-3353 8. North American Equipment Ltd. (Canada) (905) 628-9997 9. International: American Equipment (561) 997-2080

MAINTENANCE CX Hammer with PLC

Section 3-2 MAR/2005 (49454100)

DAILY (OR 8 HOURS, WHICHEVER COMES FIRST) Key: =

= Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow LOC ITEM SYM TASK

D1. Follow Engine Mfr’s recommendations for daily maintenance D2. Check Engine Oil Level, fill as required.

ENG .

D3.

Check Engine Air Cleaner Indicator (Optional)

D4. Check Case Drain Filter Indicator (Optional)(Requires machine running and working)

D5. - Reserved for Future Use - D6. Check Hydraulic Oil Level and Quality (Sight inspection at Gauge). Fill as req’d.

D7. Check Hydraulic Oil Filter Indicators at Logic Box (requires maching running and working)

D8. Inspect Hoses and Fittings for Leaks D9. Check Top Off Filter Indicator Gauge (Optional) while in Use

HYD

RA

ULI

C

D10. - Reserved for Future Use - D11. Grease Jaw Mounting Guide Shafts (2 per gun, 8 total) D12. Grease Hammer (1 per hammer, 4 total) D13. Grease Gun Up/Down Shaft (4 per gun, 8 total) D14. Grease Carriage Shaft (2 per carriage, 8 total) D15. Grease Guide Roller Up/Down Cylinder (2 fittings per cylinder) D16. Grease Guide Roller Up/Down Shaft (1 fitting per assembly) D17. - Reserved for Future Use - D18. - Reserved for Future Use - D19. - Reserved for Future Use - W

OR

KH

EAD

S &

G

UID

E R

OLL

ERS

D20. - Reserved for Future Use - D26. Fill Fuel Tank – End of Day D27. Inspect electrical connections/harnesses for tightness D28. Inspect hoses/connections for leaks D30. - Reserved for Future Use - M

ISC

.

D31. - Reserved for Future Use - *Optional Assemblies


MAR/2005 (49454100) Section 3-3

Detailed Daily Instructions

D2. Check Engine Oil Level Check the oil level daily with the engine stopped. If necessary, add sufficient oil to raise the level to the proper mark on the dipstick. All diesel engines are designed to use some oil, so periodic addition of oil is normal. If the oil level is constantly above normal and excess lube oil has not been added to the crankcase, contact the engine maker's authorized service outlet listed in the Engine Manual. Fuel or coolant dilution of lube oil can result in serious engine damage. Never operate the engine with the oil level below the "L" (low) mark or above the "H" (high) mark on the oil dipstick. Wait at least 15 minutes after shutting off the engine to check the oil. This allows time for the oil to drain to the oil pan. Check Engine Manufacturer’s Manual for Engine Oil

Capacity.

D6. Check Hydraulic Oil Level and Quality – Sight Inspection Only

Inspect the oil level on a daily basis (or every 10 hours of operation) by reading the sight gauge located on the side of the reservoir. At full level, the oil should be to the top of the sight gauge. The hydraulic system uses SAE-20 (ISO 46) oil. Before filling the system with hydraulic oil, be sure that the fluid is as specified and that it is clean. Do not use cloth strainers or fluid that has been stored in contaminated containers. Care should be taken to keep the hydraulic oil free of dust, water, sealing compounds and other foreign matter. While using the sight gauge, verify oil quality. If oil becomes dark or milky colored, it should be changed immediately. NOTE: Always add hydraulic oil to reservoir through a filter. NEVER OVERFILL RESERVOIR. Never use hydraulic brake fluid in lieu of hydraulic oil.


Section 3-4 MAR/2005 (49454100)

D27. Inspect Electrical Connections/Harnesses for Tightness Daily inspection of the harnesses connected to the controllers, operator control boxes (both left and right control boxes), footswitches, and logic box are required. Harnesses that may not have proper connection could cause problems in starting and stopping the machine. In addition to harness connections, the footswitch should be inspected on a regular basis to guard against wear, deterioration, etc. If you notice excessive wear or breakdown, replace the switch.

D28. Inspect Hoses and Fittings for Leaks

1. Look for loose or disconnected hoses. An oil spot below the machine is a good indication of a loose hose or hydraulic component. 2. Make certain shut-off valve on suction strainer is OPEN. Opening valve can often correct what appears to be a malfunction. 3. Inspect all vital hose connections, especially at main pump and the main pump hose connection at the manifold. 4. Look for cover damage and/or indications of twisted, worn, crimped, brittle, cracked, or leaking hoses. Hoses with their outer cover worn through or otherwise damages should be considered unfit for further service.


MAR/2005 (49454100) Section 3-5

WEEKLY (OR 40 HOURS, WHICHEVER COMES FIRST) Key: =


W1. Perform all Daily Lubrication and Maintenance Procedures W2. Check Battery Condition. W3. Oil Propulsion Chains W4. Oil Propulsion Chain Adjusting Nuts W5. Grease Brake Lever Pivot W6. Grease Axle Bearings

W7. Check Suction Strainer Elementa W8. Grease Nipper Hooks (1 per hook, 4 total) W9. Grease Nipper Guide Blocks (2 per block, 4 total) W10. Grease Gager Lever Housing* W13. Grease Gager Lever Arms* W14. Grease Gager Buggy Wheels* W15. - Reserved for Future Use - W16. - Reserved for Future Use - W17. - Reserved for Future Use -

MIS

CEL

LAN

EOU

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W18. - Reserved for Future Use - a. Check Suction Strainer Element first 40 hours of operation and yearly after initial inspection. *Optional Equipment


Section 3-6 MAR/2005 (49454100)

Detailed Weekly Instructions

W3. Oil Propulsion Chains When inspecting the drive chain, the chain should be nearly taut, with 1/4" (.635 Cm) play when depressed at the center. If not, adjustment is necessary see below. If the chain is too tight, the eccentricity of the sprockets may cause the chain to stretch and/or break. If the chain is too loose, the starting and stopping of the machine will shock load the chain, resulting in short chain life or failure. A worn or stretched chain will also cause short sprocket life as the load will not be carried by all of the teeth on the sprocket - resulting in excessive load on a few teeth. To adjust the drive chain: 1. Remove propulsion chain guard. 2. Unscrew the adjusting screw locknut, but do not remove it from the screw. 3. Turn adjusting screw clockwise (CW) to tighten the chain or counter-clockwise (CCW) to loosen the chain. 4. Once the desired tightness has been reached, tighten the adjusting screw locknut. 5. Reinstall the chain guard.

W6. Grease Axle Bearings

Periodic inspection of the axle bearings and spacers for wear and breakdown are required to keep this machine functioning properly. Inspect hardware for proper fit and secure all loose nuts and bolts. Check spacers (A) for wear. The wheel bearing grease fittings are located on the underside of the pillow blocks. Remote wheel bearing grease fittings for the wheels are located on the outside of the suspension arm. Weather conditions affect the time intervals of greasing. In general, a small amount of grease should be ok. Overgreasing may cause seal failure. Grease hardens with age. When this occurs, the bearing should be taken apart, cleaned, and relubricated following the manufacturer’s instructions on the component data sheet. If supplied, check automatic greasing assemblies for proper charge.


MAR/2005 (49454100) Section 3-7

W7. Check Suction Strainer Element Located on the side of the reservoir, remove and inspect the filter after the first 40 hours of operation and every year thereafter. Clean as required. To access filter: 1. Turn off engine, Make certain suction valve is closed (off)(ccw). 2. Remove padlock (1) and pull out plug attached to cable. 3. Using Allen wrench, turn screw (2) inside of plug housing clockwise to open (counterclockwise to close). 4. Remove six capscrews and lift off front cover. Reverse process to reattach cover. NOTE:If for any reason removal of suction line filter is necessary, you must seal the hydraulic tank to prevent external contamination.


Section 3-8 MAR/2005 (49454100)

MONTHLY (OR 150 HOURS, WHICHEVER COMES FIRST) Key: =


M1. Perform all Daily and Weekly Lubrication and Maintenance Procedures M2. Check Fan, Alternator and Generator Belts M3. Change Engine Oil and Filters M4. Check Brake Shoes for Wear

M5. Run Pressure Checks on Main Pump and Propulsion M6. Check Oil Cooler, clean as necessary M7. Grease Winch Boom M8. - Reserved for Future Use - M

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M9. - Reserved for Future Use -

Detailed Monthly Instructions

M2. Check Fan, Alternator and Generator Belts Check the belts and tighten the fan drive, battery-charging alternator and other accessory drive belts. Belts should be neither too tight nor too loose. Belts that are too tight impose excess loads on the crankshaft, fan, and/or alternator bearings, shortening both belt and bearing life. Excessively overtightened belts can result in crankshaft breakage. A loose belt will slip and may cause damage to accessory components. Replace all belts in a set when one is worn. Single belts of similar size should not be used as a substitute for a matched belt set. Premature belt wear can result because of belt length variation.


MAR/2005 (49454100) Section 3-9

M4. Check Brake Shoes for Wear Replace brake shoes when the pad is less than 1/4 (.64 cm) thick. To replace brake shoes: 1. Override the brake valve cylinder on the

main manifold until the cylinder collapses. 2. Once the cylinder has been collapsed,

close the brake shut-off valve located behind the left main manifold. This will trap oil in the cylinder and keep the cylinder collapsed.

3. Insert the Brake lockup pins. 4. Turn off machine, following

Lockup/Tagout procedures. 5. Remove the lower cotter pin and pin

holding brake shoe bracket to brake lever. (See Item #1 in Figure).

6. Lift up the brake bracket to gain access to

the brake shoe. 7. Remove brake shoe mounting hardware

and replace brake shoe. Make certain you have reinstalled the mounting hardware!

8. Lower the brake bracket and reinstall the

pin and cotter pin. Repeat Steps 5 through 8 for all brake shoes that need replacing. After that is done, continue on with the following steps: 9. Remove the brake lockup pins. 10. Return machine to service following the

Lockout/Tagout procedures. Turn on machine.

11. Open shut-off valve.

M5. Run Pressure Checks on Main Pump and Propulsion

Pressure checks should be performed every 250 hours or monthly after the engine and hydraulics have thoroughly warmed up (oil temperature has reached 100°F [37.8°C] minimum). Before performing these checks, read and understand all OPERATION instructions, warnings and cautions.


Section 3-10 MAR/2005 (49454100)

QUARTERLY (OR 500 HOURS, WHICHEVER COMES FIRST) Key: =


Q1. Perform all Daily, Weekly and Monthly Lubrication and Maintenance Procedures Q2. Drain Fuel Tank. Replace Fuel Filters. Q3. Check Cooling System Hoses Q4. Test Hydraulic Oil Cleanliness, replace filters as necessary Q5. Replace Hydraulic Tank Breathers Q6. - Reserved for Future Use - Q7. - Reserved for Future Use - M

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Q8 - Reserved for Future Use -

Detailed Quarterly Instructions

Q4. Test Hydraulic Oil Cleanliness Proper fluid condition is essential for long and productive life of hydraulic components and systems. Thorough precautions should always be observed to insure the hydraulic system is clean: 1. Filter each change of oil to prevent introduction of contaminants into the system. 2. Maintain the proper oil level and regularly service filters, breathers, and reservoirs. 3. Take precautions to prevent moisture contamination. Change fluid whenever contamination occurs because even small amounts of water can affect system performance as well as induce corrosion and oil breakdown.


MAR/2005 (49454100) Section 3-11

YEARLY (OR 2000 HOURS, WHICHEVER COMES FIRST) Key: =


Y1. Perform all Daily, Weekly, Monthly and Quarterly Lubrication and Maintenance Procedures

Y2. Steam Clean Engine Radiator and Oil Cooler Y3. Inspect Wheels for Excessive Wear Y4. Inspect Suction Strainer Element. Y5. Drain and Replace Hydraulic Oil in Tank. Replace all Filter Elements. Y6. - Reserved for Future Use - Y7. - Reserved for Future Use - M

ISC

ELLA

NEO

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Y8 - Reserved for Future Use -

operation and maintenance manual - nordco spiker/hammer w/programmable logic operation and...

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