Anchor Applicator Model BAAM

Transcription

1 Anchor Applicator Model BAAM Operation and Maintenance Manual Applies to S/N and Above Reorder Part: Last Revision: Rev. - OCTOBER 2010 Read and fully understand the precautions contained in this manual before operating or servicing this machine. Refer to Section 1 for important safety information. Component Troubleshooting can now be found on the colored pages behind each tab.

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3 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: NORDCO Parts: Oak Creek, Wisconsin (414) sales@nordco.com Oak Creek, Wisconsin parts@nordco.com NORDCO Service: service@nordco.com 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

4 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 , 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 Fax: (414) Phone: (414)

5 Anchor Applicator Model BAAM CONTENTS Table of Contents Section 1 - Safety Safety Alert Symbols (and Definitions) Section 2 - General About this Manual Machine Specifications Machine Dimensional Information Section 3 Pre-Operation and Startup General About this Machine Controls and Instruments Machine Start Controls Gauges and Counters Lights and Alarms Work/Travel Controls Electrical Interlock/Emergency Stop Workhead Functions Manual Setup Controls Workhead Functions Automatic Mode Controls Power Lockups Cab Wipers and Fans Service Indicator Lights Filter Indicator Lights Remote Workhead Box (Manual Mode Controls) Footswitch Controls Miscellaneous Controls (Remote on Machine) Preparing the Machine for Work Preoperational Checklist Engine Operation Startup Checklist Lockups Workhead and Guide Rollers Turntable Control Valve Turntable Cylinder Boom and Winch (Optional) Travel Engine Speeds Propelling and Braking At Travel Speeds At Work Speeds On Steep Grades Continued on Next Page - SEPT/2005 ( ) Contents - i

6 SETUP Anchor Applicator Model BAAM Section 4 Machine Setup Workhead Setup and Adjustments Rail Stop Adjustment Ready Position Adjustment and Setting Apply Height Adjustment and Setting Verifying Correct Workhead Setup Changing Anchor Holders Tray Adjustments Tray Lateral Adjustment Top Tray Guide Adjustment Tray Stop Pin and Stop Tube Locations Bottom Tray Guide (Fair Anchors Only) Changing Anchor Holders Section 5 Operation Emergency Shutdown Emergency Procedures Machine Abort Functions Automatic Mode Manual Abort Automatic Mode Auto Abort Operating in Automatic Mode Manual Operation Restart After Abort Winch Operation Emergency Pump Operation Brake Release Other Functions After Operation General Parking or Locating Machine Rotating the Machine Towing Section 6 Mechanical Parts Section 7 Hydraulics Section 8 Electrical Section 9 Component Data (OEM Support Literature) Section 10 Customer Order Sheets Contents - ii SEPT/2005 ( )

7 Anchor Applicator Model BAAM SAFETY 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 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. 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 means that the following points are instructions for safely operating the machine or the specific component of the machine. 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. FEB/2006 ( ) Section 1-1

8 SAFETY Anchor Applicator Model BAAM 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. Wear adequate protective gear: a. Safety Glasses b. Good-fitting pants and shirt c. Safety-toed work boots d. Leather gloves e. Hard hat 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: 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 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). 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.) Section 1-2 FEB/2006 ( )

9 Anchor Applicator Model BAAM 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 or remote control boxes. To prevent injury to personnel or damage to the machine, it is highly recommended to: 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 SAFETY DURING MAINTENANCE 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 one person. 2. The machine is to be operated from the Operator s seat 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 continuining work. 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. FEB/2006 ( ) Section 1-3

10 SAFETY MACHINE SAFETY ALERTS Anchor Applicator Model BAAM machine could occur; unless directed otherwise. Failure to comply could result in personal injury and/or damage to the machine. 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. 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. 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. When machine is to be turned using the turntable, raise machine only high enough for the wheels to clear the rail. MACHINE SAFETY ALERTS CAUTION ALERTS When dry cycling the workhead, the machine MUST be mounted on the jackstands or damage to the workhead will occur. 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. Always turn off machine when performing maintenance, making adjustments, or whenever unintended movement of Section 1-4 FEB/2006 ( )

11 Anchor Applicator Model BAAM SAFETY LOCKOUT AND/OR TAGOUT REQUIREMENTS The following list suggests lockout procedures to use on all components of the machine that require lockout due to the storage of various forms of energy. It is your company s responsibility to Lockout/Tagout Procedures based on this list, train you in their proper and safe use, and to periodically inspect your work area to LOCKOUT-TAGOUT PROCEDURES verify that you are complying with the procedures. Lockout/Tagout Procedures must be followed! NORDCO has provided the means to lockout this machine. NORDCO cannot be held responsible for injury caused by failure to comply with your company s 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. Apply parking brakes by pushing in parking brake button located on the center (front) control console. 2. Chock wheels to prevent accidental rolling of machine on grade. 3. 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. 4. When mechanical locking up of equipment is not feasible for maintenance lower the component to the ground prior to working on the equipment. 5. 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. 6. Turn the battery disconnect switch (BDS) to the OFF position. Place a lockout/tagout device on the switch. 7. Bleed off hydraulic pressure. 8. 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 (ie., moving a hydraulic cylinder). Proper precautions should be taken. FEB/2006 ( ) Section 1-5

12 SAFETY Anchor Applicator Model BAAM 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. Safety Decals on this Machine are: PART NO. DESCRIPTION LOCATION General Machine Cautions Inside Cab Caution! Watch Your Step Each stairway Danger! Pinch Points On workhead Warning! Hand Hazard On workhead Danger! Before Servicing... Logic Box Sides Caution! Before Welding... Logic Box Face Battery Box Lockout Area Logic Box Face Lockout Area Battery Box Lockup Points All areas requiring Lockups for travel. Also need turntable warning. Section 1-6 FEB/2006 ( )

13 Anchor Applicator Model BAAM GENERAL GENERAL This manual contains operation and maintenance information for the Anchor Applicator Model BAAM with Tier 2 Engine, manufactured by NORDCO INC., Oak Creek, Wisconsin. Information regarding the operation and maintenance of this machine can be found behind the appropriate tabs. 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. Behind each index tab is a blue colored section for troubleshooting the applicable section. 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 all electrical schematics, logic box, control box, and cable drawings for the machine; and troubleshooting instructions Component Data includes parts breakdowns and service instructions for components installed on the machine that are not of NORDCO s manufacture FEB/2006 ( ) Section 2-1

14 GENERAL Anchor Applicator Model BAAM SPECIFICATIONS GENERAL Model... Model BAAM Gross Weight* With Empty Anchor Bin 23,000 lbs (10,422 kg) With Full Anchor Bin 35,000 lbs (15,890 kg) Length... 21ft 8in (meters) Width... 8ft 6in (meters) Working Clearance...10 feet (3.05 meters) Height... 9 feet 3 inches (2.82 meters) Wheel Base feet 10-1/2 inches (4.22 meters) Travel Speed (Maximum) 25 mph (40 km/h) Rated Draw Bar Pull (on rail) lbs (818 kg) CAPACITIES Fuel Tank (Painted Green)...50 gallons ( liters) Hydraulic Oil Tank (Painted Blue)...70 Gallons ( liters) Oil Cooler gpm (378.5 L/mn) Anchor Bin Anchors ENGINE (OPTION) Make/Model... Cummins B3.3, Tier 2 Type...Turbocharged, Inline 4-Cylinder Continuous BHP...80HP 2200 rpm Oil Capacity.8.4 Quarts (8.0 liters) Coolant Capacity 4.8 Quarts (4.5 liters) ENGINE (OPTION) Make/Model... John Deere 5030T, Tier 2 Type...Turbocharged, Inline 5-Cylinder Continuous BHP...77HP 2200 rpm Oil Capacity 11.8 Quarts (11.2 liters) Coolant Capacity 20 Quarts (21 liters) HYDRAULIC SYSTEM (MANIFOLDED) Pump Make/Model... Sauer Danfoss Type...Piston Pump Pressure Settings Relief Valve Setting (High System Pressure) psi (200 bar) Compensator psi (172 bar) ELECTRICAL SYSTEM Battery...24 Vdc (Dual 12V DC batteries), 1150 Cold Cranking Amps Ground...Negative Alternator (Cummins)...65 Amp Alternator (John Deere)...75 Amp AXLE DRIVE SYSTEM Drive Type...Dual Axle Chain Drive Propulsion Motor Type... Hydraulic 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. Section 2-2 FEB/2006 ( )

15 Anchor Applicator Model BAAM GENERAL BRAKES Type... Spring Applied/Hydraulically Released Style...Four Wheel Cobra-Style 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. Dimensional Information FEB/2006 ( ) Section 2-3

16 GENERAL Anchor Applicator Model BAAM --- Page Intentionally Left Blank -- Section 2-4 FEB/2006 ( )

17 Anchor Applicator Model BAAM GENERAL BEFORE OPERATION DO NOT use this machine for machine operations other than for which it was intended. 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 Carefully read all safety messages in this manual and on the decals located throughout the machine. 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. ABOUT THIS MACHINE It is always good practice to become familiar with the components of the machine you are using. WORK STATION (CAB) All the controls for running this machine are located on the main control panel in the cab, with the exception of a remote operator control box that duplicates the manual mode controls on the main control panel. The remote operator box also contains the Ready Position Set, Apply Height Set, Emergency Stop and horn buttons. This remote box is located next to the applicator workhead and is used to initially set up the machine for working operations. There are four (4) footswitches located in the cab. These control propulsion (forward and reverse), the Automatic Cycle Start/Stop footswitch used during actual machine operation, and the brake footswitch. PRE-OPERATION/STARTUP Refer to the Machine Setup Section of this manual for more information. During operation of the machine, the anchor holders flip back to pick up an anchor from the trays. The holders then flip back down, box the tie and position the anchors on the rail base in one smooth operation. The anchors are then fully snapped onto the rail with the clamp bars. HYDRAULIC SYSTEM The hydraulic system is comprised of four manifolds: The workhead manifold, the feed manifold, the lock-up manifold and the propel manifold. There are also a few remotely mounted valves for the turntable, bulk loader vibrator, dust collection system, and winch motor. The workhead manifold controls all the workhead functions as well as the brakes, bulk loader and guide wheels. The feed manifold controls the anchor tray escapement cylinders and the anchor holder grip cylinders. The lock-up manifold controls the workhead lockups, the guide roller lockups and the turntable lockup. The propel manifold controls the propel function only. Main system pressure is 2500 psi and is set at port "G1" on the propel manifold. Refer to the functional hydraulic schematics located behind the tab marked Hydraulics for specific information on the manifolds and valves. PROPULSION/DRIVE SYSTEM The machine is dual axle outboard driven, comprised of a single chain, two drive sprockets and a hydraulic motor. BOOM/WINCH (OPTIONAL) The boom/winch system is in place to allow the operator to easily lift bags of anchors into the Anchor Bin. The winch is capable of lifting loads up to 300 lbs. 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. Always use your seat belt when sitting in the operator seat. Always use the handrail and steps provided to climb on to and off of the machine. WORKHEAD There are several types of anchor holders available. When changing out tooling, remember to adjust the anchor trays to the correct width setting for the anchor being used. OCT/2009 ( ) Section 3-1

18 PRE-OPERATION/STARTUP MAIN CONTROL PANEL This machine uses Programmable Logic Controllers (PLC s) for all functions. The PLC is located inside the main control panel. The main control panel houses nearly all of the Anchor Applicator Model BAAM operator selectable items on the machine. The following pages detail the controls on this panel as well as those located remotely on the machine. Become familiar with their use BEFORE you operate the machine. Section 3-2 OCT/2009 ( )

19 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 1 MAIN CONTROL PANEL MACHINE START CONTROLS ` TABLE 1 MAIN CONTROL PANEL MACHINE START CONTROLS HOLD TO START (Optional) IGNITION PUMP ENGINE SPEED GLOW PLUGS (John Deere Only) HOLD TO START: Murphy Relay. Press and hold until engine starts and oil pressure reaches 30 psi (2 bar). Engine will not start if button is not held in while turning ignition switch. Release after engine catches. Switches power to all circuits. Activates starter (when held fully clockwise). USED FOR NORMAL ENGINE SHUTDOWN. 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. 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. When ambient temperature is below 32 F, hold button for 15 seconds prior to cranking engine. Do not use Ether when using Glow Plugs! Failure to follow this instruction may result in Severe bodily injury or death. OCT/2009 ( ) Section 3-3

20 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM ENGINE HOUR GAUGE OIL PRESSURE GAUGE TABLE 2 - MAIN CONTROL PANEL GAUGES AND COUNTERS Indicates hours used on engine. Also a way of calculating maintenance intervals for machine. Indicates oil pressure. Does not indicate oil level. Measurement in psi graduations. Normal reading varies according to engine supplied. John Deere is approximately 40 psi (2.5 to 3.5 bar). Cummins is approximately 75 psi (5 to 6 bar) Note: Low engine pressure will shutdown the machine at 20 psi if equipped with Murphy Shutdown system. WATER 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) if equipped with Murphy Shutdown system. VOLTAGE GAUGE FUEL GAUGE TACHOMETER COUNTER Indicates voltage of battery. Normal reading is volts. Measures the level of diesel fuel in the fuel tank. Do not allow to go into the red zone. Indicates engine speed in hundreds of rpm. Cycle Counter. Indicates the number of workhead anchor apply cycles. Section 3-4 OCT/2009 ( )

21 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 3 - MAIN CONTROL PANEL LIGHT/ALARM CONTROLS TABLE 3 - MAIN CONTROL PANEL LIGHT/ALARM CONTROLS LIGHT SWITCHES TRAVEL DIRECTION SWITCH ON (UP) OFF (DOWN) FORWARD (UP) REVERSE (DOWN) Turns on the desired lighting. Travel lights will illuminate on the direction selected by the Travel Direction Switch. Forward direction is Engine end first. If you are working in the forward direction, place the switch in the UP position. This will turn on the travel lights on the engine end and turn on the backup alarm when the machine travels in the opposite direction. Reverse direction is cab end first. If you are working in the reverse direction, place the switch in the DOWN position. This will turn on the travel lights on the cab end and turn on the backup alarm when the machine travels in the opposite direction. OCT/2009 ( ) Section 3-5

22 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 4 - MAIN CONTROL PANEL WORK/TRAVEL CONTROLS PROPEL SPEED Propelling through steep grades Use 4X when traveling in steep grades (in this case the Travel/Work Mode switch should be in the TRAVEL position). Switching from 2X to 4X while traveling in speeds in excess of 10 mph will result in dynamic braking. TRAVEL/WORK MODE Note: If machine is equipped with optional Crossing Alarm Switch Assembly (located on both the Cab end and Engine end of the machine), the switch MUST be raised during high speed travel and lowered into place for all other machine travel. Failure to raise the switch will result in damage to the switch. BRAKE MODE TABLE 4 - MAIN CONTROL PANEL WORK/TRAVEL CONTROLS 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. LOW/TURTLE (4X)(UP) HIGH/RABBIT (2X)(DOWN) TRAVEL (UP) WORK (DOWN) SERVICE (UP) Dual Axle Drive. Primarily used during working operations (non-travel mode). Travel/Work Mode switch should be in the WORK position. Single Axle Drive. Primarily used during travel operations (non-work mode). Travel/Work Mode switch should be in the TRAVEL position. Used during working travel through crossings, at switches, frogs and other rail obstructions. Also used during high speed (non-working) travel. When machine is placed in the travel mode, the travel speed switch should also be changed. Placing the machine in the Travel Mode will retract the workhead and raise the guide wheels to the lockup positions (See Lockups). Workhead functions will not operate when the machine is in TRAVEL MODE. Used when working operations are underway. When the machine is placed in the work mode, the travel speed switch should also be changed. When set to service, brakes are applied only when brake pedal is applied. NOTE: Engine will not start if switch is in SERVICE mode. DEADMAN (DOWN) When set to deadman, brakes are applied any time forward or reverse pedal is released. Section 3-6 OCT/2009 ( )

23 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 5 - MAIN CONTROL PANEL MISCELLANEOUS CONTROLS TABLE 5 - MAIN CONTROL PANEL MISCELLANEOUS CONTROLS ELECTRICAL INTERLOCK HORN (LOCATED ON THE MAIN CONTROL PANEL AND WORKHEAD CONTROL BOX.) EMERGENCY STOP (LOCATED ON THE MAIN CONTROL PANEL AND THE WORKHEAD CONTROL BOX) ELECTRICAL INTERLOCK: When pushed in, disables all electrical input to the workheads. Also locks brakes. Should be used during machine warmup or inspection. HORN: Push button 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. OCT/2009 ( ) Section 3-7

24 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 6 MAIN CONTROL PANEL - WORKHEAD FUNCTIONS MANUAL SETUP CONTROLS Section 3-8 OCT/2009 ( )

25 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP AUTOMATIC/MANUAL MODE TABLE 6 MAIN CONTROL PANEL - WORKHEAD FUNCTIONS MANUAL SETUP CONTROLS Mode Select Switch must be in MANUAL for controls to work. Except for the BOX/UNBOX switch, which works in Manual and Auto Modes. (Item in Parenthesis shows position of switch) AUTOMATIC/MANUAL MODE: Two position switch. AUTOMATIC (UP) Automatic mode is used for normal working operations. MANUAL (DOWN) Manual mode is used to set up the machine or for specialized single anchor application. Momentary Switch. Controls the tray ESCAPEMENT and anchor GRIP solenoid valves. Switches on the Main control panel have the same function as the switches on the Workhead control box. ESCAPEMENT GRIP (UP) ESCAPEMENT UNGRIP (DOWN) Momentarily holding and releasing the switch in this position to escape one anchor from the tray and grip it in the anchor holder. Momentarily holding and releasing the switch in this position to ungrip the anchor from the anchor holder. Momentary Switch. Controls the APPLY solenoid valves. Switches on the Main control panel have the same function as the switches on the Workhead control box. RETRACT (UP) Momentarily hold the switch in this position to retract the clamp from the rail after the anchor has been applied. Momentarily hold the switch in this position to apply the anchor onto the rail. APPLY (DOWN) Momentary Switch. Controls the WORKHEAD LIFT solenoid valve. Switch on the Main control panel has the same function as the switch on the Workhead control box. WORKHEAD UP (UP) Momentarily hold the switch in this position to raise the workhead. WORKHEAD DOWN (DOWN) Momentarily hold the switch in this position to lower the workhead. Momentary switch. Controls the BOXING solenoid valve. NOTE: This switch can be used in both Manual Mode and Automatic mode. Switch on the Main control panel has the same function as the switch on the Workhead control box. UNBOX (UP) BOX (DOWN) Momentarily hold the switch in this position to separate the anchor holders. Momentarily hold the switch in this position to move the anchor holders together. OCT/2009 ( ) Section 3-9

26 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 6 MAIN CONTROL PANEL - WORKHEAD FUNCTIONS MANUAL SETUP CONTROLS Mode Select Switch must be in MANUAL for controls to work. Except for the APPLY HEIGHT-RAISE and APPLY HEIGHT-LOWER pushbuttons, which work in both Manual and Auto modes. (Item in Parenthesis shows position of switch) Momentary Switch. Controls the WORKHEAD ROTATE solenoid valve. Switch on the Main control panel has the same function as the switch on the Workhead control box. OUT (UP) Momentarily hold the switch in this position to rotate the workhead away from the rail. Momentarily hold the switch in this IN position to rotate the workhead (DOWN) toward the rail. Momentary Switch. Controls the TOOL FLIP solenoid valve. Switch on the Main control panel has the same function as the switch on the Workhead control box. UP (UP) Momentarily hold the switch in this position to flip the anchor holders up to the feed position. DOWN (DOWN) Momentarily hold the switch in this position to flip the anchor holders down to the apply position. Momentary Pushbuttons. Used to record the workhead READY height and to raise or lower the workhead APPLY height. PUSH TO RECORD- READY POSITION APPLY HEIGHT- RAISE APPLY HEIGHT- LOWER Push this button during machine set-up to record the READY height. This records and sets a value in the PLC which is used to stop the workhead LIFT function above the tie during the AUTOMATIC CYCLE. The pushbutton on the Main control panel has the same function as the pushbutton on the Workhead control box. See Machine Set-up and Adjustments Ready Position in Section 4 for more detail. Push this button during machine set-up or during the AUTOMATIC CYCLE to raise the APPLY HEIGHT setting. This incrementally raises the previously recorded APPLY HEIGHT setting by approximately 1/16 each time the pushbutton is depressed. See Machine Set-up and Adjustments Apply Height in Section 4 for more detail. Push this button during machine set-up or during the AUTOMATIC CYCLE to lower the APPLY HEIGHT setting. This incrementally lowers the previously recorded APPLY HEIGHT setting by approximately 1/16 each time the pushbutton is depressed. See Machine Set-up and Adjustments Apply Height in Section 4 for more detail. Section 3-10 OCT/2009 ( )

27 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 7 - MAIN CONTROL PANEL (WORKHEAD FUNCTIONS) AUTOMATIC MODE CONTROLS TABLE 7 - MAIN CONTROL PANEL (WORKHEAD FUNCTIONS) AUTOMATIC MODE CONTROLS Mode Select Switch must be in AUTOMATIC for controls to work. Auto Cycle is begun by depressing the CYCLE START/STOP Footswitch. Mushroom style momentary pushbutton. Press anytime during the AUTOMATIC CYCLE to retract the workhead back to the lock-up (feed position). After the CYCLE ABORT pushbutton is depressed, the CYCLE START/STOP footswitch must be depressed to begin the AUTOMATIC CYCLE again. BOX DELAY/PREBOX: Potentiometer. Sets the time delay between when BOXING begins and workhead ROTATE IN begins. The greater the potentiometer value, the less the time delay (higher PREBOX). OCT/2009 ( ) Section 3-11

28 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 8 - MAIN CONTROL PANEL POWER LOCKUPS TABLE 8 - MAIN CONTROL PANEL POWER LOCKUPS All components should be in the LOCKED position during traveling. The workhead lock-ups are to be in the LOCKED position while making some workhead set-ups/adjustments. See Machine Set-up and Adjustments in Section 4 for more detail.the Turntable should always be in the LOCKED position except while using the Turntable. The workhead and guide wheel lock-ups are to be UNLOCKED during Working operations. LOCKED (RIGHT) UNLOCKED (LEFT) Push to right to engage lock-ups. Push to left to disengage lock-ups. Section 3-12 OCT/2009 ( )

29 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 9 - MAIN CONTROL PANEL CAB FEATURES AND WIPERS WIPERS ON/OFF (TURN CW/CCW) Turns desired wipers on or off. CAB FAN SWITCH ON (RIGHT) Turns on main power to all cab fans. Power to each fan is controlled by the toggle switches mounted on each fan motor. OFF (LEFT) CROSSING SWITCH INDICATOR Red LED LED will light up when the machine has entered a crossing and will remain lit until it has passed the crossing. Alarm Alarm will sound until the machine has passed the crossing. OCT/2009 ( ) Section 3-13

30 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 10 - MAIN CONTROL PANEL MISC. CONTOLS SERVICE INDICATOR LIGHTS TABLE 10 - MAIN CONTROL PANEL MISC. CONTOLS SERVICE INDICATOR LIGHTS TURNTABLE STATUS ENGINE ALARM Illuminated light will tell you what position the turntable is in. Do not attempt to propel the ma chine with the turntable DOWN. Alarm will sound when engine experiences high coolant temperature or low oil pressure or low coolant level (optional). Section 3-14 OCT/2009 ( )

31 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 11 - MAIN CONTROL PANEL FILTER STATUS INDICATORS TABLE 11 - MAIN CONTROL PANEL FILTER STATUS INDICATORS CLEAN Filter does not require servicing. BYPASS Alarm state. Filter requires servicing or element requires replacing. OCT/2009 ( ) Section 3-15

32 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 12 REMOTE OPERATOR BOX Section 3-16 OCT/2009 ( )

33 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 12 REMOTE OPERATOR BOX MANUAL MODE CONTROLS Mode Select Switch inside cab must be in MANUAL for controls to work. Except for the BOX/UNBOX switch, which works in Manual and Auto Modes. (Item in Parenthesis shows position of switch) AUTOMATIC/MANUAL MODE AUTOMATIC/MANUAL MODE: Two position switch. AUTOMATIC (UP) Automatic mode is used for normal working operations. MANUAL (DOWN) Manual mode is used to set up the machine or for specialized single anchor application. Momentary Switch. Controls the tray ESCAPEMENT and anchor GRIP solenoid valves. Switches on the Main control panel have the same function as the switches on the Workhead control box. ESCAPEMENT GRIP (UP) ESCAPEMENT UNGRIP (DOWN) Momentarily holding and releasing the switch in this position to escape one anchor from the tray and grip it in the anchor holder. Momentarily holding and releasing the switch in this position to ungrip the anchor from the anchor holder. Momentary Switch. Controls the APPLY solenoid valves. Switches on the Main control panel have the same function as the switches on the Workhead control box. RETRACT (UP) Momentarily hold the switch in this position to retract the clamp from the rail after the anchor has been applied. Momentarily hold the switch in this position to apply the anchor onto the rail. APPLY (DOWN) Momentary Switch. Controls the WORKHEAD LIFT solenoid valve. Switch on the Main control panel has the same function as the switch on the Workhead control box. WORKHEAD UP (UP) Momentarily hold the switch in this position to raise the workhead. WORKHEAD DOWN (DOWN) Momentarily hold the switch in this position to lower the workhead. Momentary switch. Controls the BOXING solenoid valve. NOTE: This switch can be used in both Manual Mode and Automatic mode. Switch on the Main control panel has the same function as the switch on the Workhead control box. UNBOX (UP) BOX (DOWN) Momentarily hold the switch in this position to separate the anchor holders. Momentarily hold the switch in this position to move the anchor holders together. OCT/2009 ( ) Section 3-17

34 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 12 REMOTE OPERATOR BOX MANUAL MODE CONTROLS Mode Select Switch inside cab must be in MANUAL for controls to work. Except for the BOX/UNBOX switch, which works in Manual and Auto Modes. (Item in Parenthesis shows position of switch) Momentary Switch. Controls the WORKHEAD ROTATE solenoid valve. Switch on the Main control panel has the same function as the switch on the Workhead control box. UP (UP) OUT (UP) Momentarily hold the switch in this position to rotate the workhead away from the rail. Momentarily hold the switch in this IN position to rotate the workhead (DOWN) toward the rail. Momentary Switch. Controls the TOOL FLIP solenoid valve. Switch on the Main control panel has the same function as the switch on the Workhead control box. Momentarily hold the switch in this position to flip the anchor holders up to the feed position. DOWN (DOWN) Momentarily hold the switch in this position to flip the anchor holders down to the apply position. Momentary Pushbuttons. Used to record the workhead READY height and to raise or lower the workhead APPLY height. PUSH TO RECORD- READY POSITION PUSH TO RECORD- APPLY HEIGHT Push this button during machine set-up to record the READY height. This records and sets a value in the PLC which is used to stop the workhead LIFT function above the tie during the AUTOMATIC CYCLE. The pushbutton on the Main control panel has the same function as the pushbutton on the Workhead control box. See machine set-up and adjustments section 4-1 for more detail. Push this button during machine set-up to record the APPLY height. This records and sets a value in the PLC which is used to stop the workhead LIFT function at the rail base during the AUTOMATIC CYCLE. See machine set-up and adjustments section 4-1 for more detail. Section 3-18 OCT/2009 ( )

35 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP TABLE 13 FOOTSWITCH CONTROLS SWITCH # SWITCH FUNCTION BRAKE Press this foot switch to apply brakes no matter which MODE of brakes 1 you have sel ected. When in DEADMAN Mode, brakes apply automatically when a propel foot switch is released. When in Service Mode, the brake foot switch must be pressed for the brakes to apply. FORWARD PROPEL Press this foot switch to release brake and propel the machine in the 2 FOOT SWITCH forward direction (Engine end first). REVERSE PROPEL Press this foot switch to release brake and propel the machine in the 3 FOOT SWITCH reverse direction (Cab end first). 4 CYCLE START/STOP Momentarily press this foot switch in AUTO MODE to initiate the AUTOMATIC apply cycle. This will bring the workhead from the ready position through anchor feed and back to the ready position (one complete cycle). By momentarily pressing this foot switch a second time while the workhead is between the ready position and the anchor apply function, the workhead will stop. When this foot switch is pressed again the workhead will continue with the AUTOMATIC cycle from where it was stopped. This foot switch also initiates an AUTOMATIC apply cycle following a manual or automatic abort. Momentarily pressing the foot switch after an abort will feed new anchors and bring the workhead to the ready position. OCT/2009 ( ) Section 3-19

36 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TABLE 14 MISCELLANEOUS CONTROLS LOCATED REMOTELY ON MACHINE CONTROL OR INSTRUMENT HYDRAULIC OIL TANK SIGHT LEVEL HYDRAULIC OIL TEMPERATURE GAGE EMERGENCY PUMP (OPTIONAL) TOP-OFF PUMP (OPTIONAL) TURNTABLE CONTROL VALVE BATTERY DISCONNECT SWITCH FUNCTION Located on the hydraulic oil tank. It indicates the level of hydraulic oil in the tank. Located on the bottom of the hydraulic oil sight level gage. It indicates the temperature of the hydraulic oil. Normal operating temperature is F. Located on the frame near the engine. The pump is used when there is a loss of main hydraulic power and movement of hydraulic cylinders is necessary. Pump flow is supplied by pumping the hand lever or by momentarily holding the toggle switch (electric pump option). Located on the frame near the hydraulic tank. Pump is used for filling the hydraulic tank. The pump can be either manually operated or electrically operated. Release tank pressure before filling tank. The valve controls the upward/downward motion of the turntable. Moving the hand lever upward will extend the turntable cylinders and raise the machine. Moving the hand lever downward will retract the turntable cylinders and lower the machine. Moving the hand lever to the center position stops cylinder movement. The valve hand lever must be down and locked whenever the turntable is not being used. Located in lockable box next to the battery box. Two-position rotary switch marked ON/OFF. This switch must be turned OFF while servicing the machine. WINCH MOTOR CONTROL Located on the hand rail of the front platform. Movement of VALVE (OPTIONAL) the hand lever controls either lowers or raises the winch cable. BULK LOADER RAM Located on the anchor bin chute in the cab. Holding the CONTROL SWITCH momentary switch in the UP position extends the cylinder and pushes anchors into the cab. Holding the momentary switch in the DOWN position retracts the cylinder and lowers the pusher down into the bin. If the switch is continued to be held in the DOWN position after the cylinder has been fully retracted, the bulk loader vibrator will turn on and remain on as long as the switch is being held. BULK LO ADER DUST Located on the floor to the left of the operator seat. Pulling the T handle UP and COLLECTION VALVE rotating it 90 degrees in either direction will turn the dust collector blower ON. (Optional) Section 3-20 OCT/2009 ( )

37 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP PREPARING THE MACHINE FOR WORK As with any machine, pre-operational checks and preventative maintenance should be performed b efore 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. Perform the pre-operational inspection of the entire machine as shown to the right. Find defects and correct them before serious damage or failure results. 4. If necessary, follow any applicable instructions under MAINTENANCE FOR EXTREME CONDITIONS. 5. Pe rform applicable preventativemaintenance procedures in MAINTENANCE AND SERVICE section. 6. Be ready to operate the machine with an alert and safety-conscious attitude. 7. Understand the use of the machine's Lock-Ups. See LOCK-UPS section. PREOPERATIONAL CHECKLIST Main Control Panel Status: Gages Checked for broken glass Switches/buttons set as follows: Emergency Stop button PULLED OUT. Pump On/Off Switch is OFF. Ignition Switch is in the OFF position. Engine Speed Switch is set to LOW. Work and Travel Lights are OFF Electrical Interlock button is PUSHED IN. Brake Mode Switch set to DEADMAN. Workhead Control Box Status: Emergency Stop button PULLED OUT. Machine Fluid/Lubrication Check: Check Engine Oil Level Check Engine Coolant Level Check Hydraulic Tank Fluid Level Check Diesel Fuel Tank Level All grease fittings lubed Machine Inspection: Inspect for leaks Inspect all controls and cables/harnesses Machine Lockups/Guards in Place: Make certain lockup devices are in place for traveling and are clear of any debris Safety Decals Take a walk around the machine to make Certain decals are in place and readable. 8. Make sure the unit is setup for rail and tie size being worked on. Adjustments, if required, are described in the MACHINE SETUP. 9. Wear proper safety clothing. Before you begin the pre-operational checklist you should become familiar with the controls that you will be checking. Knowing these controls and their functions may will help you in troubleshooting the machine at a later time. NORDCO recommends that the following checks be performed WITHOUT electrical power, due to a possible battery drain. OCT/2009 ( ) Section 3-21

38 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM Engine Operation Before starting a new or overhauled engine that has been in storage, consult the engine manual for initial start instruction. Failure to follow those instructions can result in serious engine damage. 4. If the engine fails to start within 30 seconds, allow the starting motor to cool a few minutes before trying again. 5. Perform the startup check shown below: NOTE: Exhaust emissions caused by the use of this machine may cause cancer, birth defects or other reproductive harm If inhaled. 3. Avoid unnecessary idling. 1. Ensure the suction strainer valve 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 workhead control box have been pulled out. Set engine speed switch to LOW, pump switch to OFF, and braking mode switch to DEADMAN. NOTE: Engine will not start if the engine speed switch is set to HIGH. If the machine is equipped with the optional engine shut-down system, 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. STARTUP CHECKS Gauge Readings Checked: Tachometer: 2250 rpm (No load, high speed) Voltmeter: 25 to 27 volts Engine Temp: 160 to 185 F (71-85 C) Engine Oil Pressure: psi John Deere Engine: approx. 40 psi Cummins Engine: approx. 75 psi Light/Horn Status: Travel Lights Function (both directions) Backup Alarm Functions (both directions) Work Lights Function Brake/Marker Lights Function (both directions) Horn button functions Operator Controls Function Deadman Brakes function Service Brakes function Propulsion footswitches function Lockup Devices Lockup devices are engaged for travel Turntable (valve handle locked) Workhead lockup cylinders activated Guide roller lockup cylinders activated Winch boom locked in place (if equipped) Winch cable secured to mast (if equipped) If the machine is equipped with glow plugs, push and hold the momentary push button for 15 seconds prior to cranking the engine. NOTE: Engine will not start if engine speed switch is in HIGH position, emergency stop pushbuttons are pushed in, if the MO is not held in, if pump switch is ON, or if the braking mode switch is in SERVICE. Section 3-22 OCT/2009 ( )

39 Anchor Applicator Model BAAM PRE-OPERATION/STARTUP LOCK-UPS Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or damage to the machine. All components, with the exception of the optional boom are equipped with power lockups. The controls for these lockups are located on the main control panel in the cab. These are required to be in the locked up position prior to working travel through crossings, switches or other rail obstructions or during high speed travel (non-working travel). Use the following procedure to install or remove lock-ups. Workhead and Guide Roller Lockups 1. With the WORKHEAD LIFT, WORKHEAD ROTATE and GUIDE ROLLER lock-up switches in the UNLOCKED position, switch the machine from WORK MODE to TRAVEL MODE. This will automatically retract the workhead and guide rollers to their lockup positions. Turntable Control Valve Lockup To make certain that the turntable cannot be lowered without your knowledge, lock up the turntable control valve lever in the down position (only way it can be locked). Turntable Cylinder Lockups The turntable status indicator lights located on the main control panel show the status of the turntable position. When the green indicator light is illuminated, indicating both turntable cylinders are fully retracted, switch the TURNTABLE lockup switch to the LOCKED position. Boom and Winch Lock-ups The optional boom assembly has a boom interlock handle that enables the operators to unlock the boom to move the assembly along side the machine and over the center of the bulk loader bin. When the interlock handle is pulled down and rotated until the roll pin is in its seated, locked position, the boom has free swing movement. When locking up the boom, pull the interlock handle down and rotate it until the roll pin is free from its seated position. Release the handle. Swing the boom so that it is parallel with the track and the spring loaded pin engages the lock-up hole. 2. Switch the WORKHEAD LIFT, WORKHEAD ROTATE and GUIDE ROLLER lock-up switches to the LOCKED position. OCT/2009 ( ) Section 3-23

40 PRE-OPERATION/STARTUP Anchor Applicator Model BAAM TRAVEL It is important that you read about and understand all operating controls, Cautions, Warnings, and Dangers before traveling. Do not permit unauthorized personnel to ride on the decks outside the cab. Falling from a moving Vehicle will cause serious injury or death. Make certain that the area around and under The machine is clear of all personnel and obstructions before traveling or working. Failure to do so will cause serious injury or death. ENGINE SPEEDS Engine speed is controlled by the switch on the Main Control Panel. Engine speed settings are slow and fast. When idling, the switch should be set to LOW, for traveling or work operations, you should have the engine speed switch in the HIGH position. PROPELLING AND BRAKING Before traveling (either in work or travel modes) determine the method of braking and set the controls to either deadman (brakes automatically apply upon release of propulsion pedal) or service (brakes are applied only when brake pedal is applied). Propelling for Working Travel 1. Put the machine in the WORK position. 2. If equipped with the optional Crossing Alarm Assembly, the limit switches on both ends of the machine MUST be lowered. 3. All lockups should be unlocked with the exception of the turntable lockup. 4. Put the Propel Speed switch in the LOW (4X) position. 5. Press the appropriate footswitch to propel the machine. Propelling on Steep Grades (Work or Travel) Switching from 2X to 4X while traveling at speeds in excess of 10 mph will result in dynamic braking, which may cause bodily injury. 1. Put the machine in the TRAVEL position. 2. Put the Propel Speed switch in the LOW (4X) position. 3. Make certain that brakes function properly. 4. Press the appropriate foot switch to propel the machine. Propelling for Non-Working Travel (High Speed) 1. Put the machine in the TRAVEL position. 2. If equipped with the optional Crossing Alarm Assembly, the limit switches on both ends of the machine MUST be raised to the top of it s bracket channel. 3. Make certain that all lockups are engaged. 4. Put the Propel Speed switch in the HIGH (2X) position. 5. Press the appropriate foot switch to propel the machine. Section 3-24 OCT/2009 ( )

41 Anchor Applicator Model BAAM Machine Setup Instructions in this section are provided for changing the type of anchors to be used and for making adjustments to the machine to compensate for different rail sizes. Some of these procedures will be required as part of the scheduled routine maintenance and are referenced on the maintenance chart located in the Maintenance and Service section of this manual. Read and understand all OPERATION procedures, warnings, and cautions before making adjustments. 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. Workhead Set-up and Adjustments SETUP The following steps are required for the initial setup of the workhead for correct application of the anchors. These steps will also be required when different rail width and heights are encountered and when changing the style of anchor. Rail stop adjustment Ready position adjustment and setting Apply height adjustment and setting Verify correct workhead set-up If the style of anchor is to be changed the following will also be required: Changing anchor holders Tray adjustments NOTE: All workhead set-up and adjustments MUST be made with the BRAKE MODE switch in the DEADMAN position when it is necessary to have the machine running. 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. FEB/2006 ( ) Section 4-1

42 SETUP Anchor Applicator Model BAAM Rail Stop Adjustment The rail stops will have to be adjusted any time there is a change in rail base width or a different style of anchor is to be used. The rail stops have several markings on them to assist in the correct positioning for several different style anchors and rail base widths (see Fig. 1). 9. After both sides have been set up, continue with Ready Position Adjustment and Setting on next page (if applicable). Due to parts tolerances and component wear, these markings may only be approximate. See VERIFY CORRECT WORKHEAD SET-UP to determine if additional adjustments are required. Adjust the rail stop as follows: 1. Raise the workhead by either putting the TRAVEL/WORK switch in the TRAVEL position, or pressing the orange CYCLE ABORT button. Both are located in the cab overhead panel. 2. Put the WORKHEAD LIFT and WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the LOCKED position. 3. Shutdown the machine and perform LOTO (Lock Out-Tag Out). 4. Loosen two cap screws holding the Rail Stop to the Rail Clamp Bar. 5. Determine rail base width dimension and anchor type. 6. Position the rail stop so that the correct indicator marking on the rail stop aligns with the position indicator marking on the clamp bar (see Fig. 1). 7. Re-tighten two capscrews (torque to 85 ft-lbs) 8. Repeat the procedure on the opposite side. Section 4-2 FEB/2006 ( )

43 Anchor Applicator Model BAAM SETUP Ready Position Adjustment and Setting Ready position is the height that the workhead stops at during each automatic cycle. Since this is the position the workhead will be at while moving from tie to tie, this setting may need to be adjusted if a different rail height is encountered to assure that the workhead is always above the top of the tie or tie plates. The ready position should be set no lower than 2 above the top of the tie or tie plate (see Fig. 2). This should provide adequate clearance for any unforeseen obstruction. NOTE: The brakes will automatically apply anytime the workhead is below the ready position, regardless of the brake mode selected. To adjust to and set a new ready position proceed as follows: 1) Remove Lockout-Tagout (if applied) and restart machine. Put the BRAKE MODE switch (located in the cab overhead panel) in the DEADMAN position. 2) Put the WORKHEAD LIFT, WORKHEAD ROTATION, and GUIDE ROLLER power lockup switches (located in the cab overhead panel) in the UNLOCKED position. 3) Put the TRAVEL/WORK switch (located in the cab overhead panel) in the WORK position, making certain that both guide wheels contact the rail. A. Put the MODE SELECT switch (located in the cab overhead panel) in the AUTOMATIC position and depress the cycle start/stop foot pedal one time. This will automatically feed anchors into both anchor holders, flip the holders down into the apply position and lower the workhead down to the preexisting ready position. Put the MODE SELECT switch (located in the cab overhead panel) in the MANUAL position and using the WORKHEAD POSITION switch located on the cab control panel or on the workhead control panel, raise or lower the workhead to the desired ready height. When the new ready height is obtained depress the PUSH TO RECORD-READY POSITION pushbutton located on the cab control panel or on the workhead control panel; or B. Put the MODE SELECT switch (located in the cab overhead panel) in the MANUAL position and using the WORKHEAD POSITION switch located on the cab control panel or on the workhead control panel, lower the workhead to the desired ready height. When the new ready height is obtained depress the PUSH TO RECORD- READY POSITION pushbutton located on the cab control panel or on the workhead control panel. 5) Put the MODE SELECT switch (located in the cab overhead panel) in the AUTOMATIC position and depress the orange CYCLE ABORT pushbutton (located on the cab overhead panel). This will fully retract the workhead to the lock-up (feed) position. 4) Lower the workhead to the desired ready position and record setting. This can be done one of the two following ways: FEB/2006 ( ) Section 4-3

44 SETUP Apply Height Adjustment And Setting Apply height is the position that the workhead stops at prior to rotating in and applying anchors on to the rail during an automatic cycle. The apply height will have to be adjusted any time there is a change in rail height or a different style of anchor is to be used. To adjust to and set a new apply height proceed as follows: 1) Remove Lockout-Tagout (if applied) and start machine. Put the BRAKE MODE switch (located in the cab overhead panel) in the DEADMAN position. 2) Put the WORKHEAD LIFT, WORKHEAD ROTATION, and GUIDE ROLLER power lockup switches (located in the cab overhead panel) in the UNLOCKED position. Anchor Applicator Model BAAM anchor is aligned with the center of the rail base (See Fig 3). When the correct apply height is obtained depress the PUSH TO RECORD-APPLY HEIGHT pushbutton located on the workhead control panel; or MANUAL ANCHOR FEED Put the MODE SELECT switch (located in the cab overhead panel) in the MANUAL position. Using the ESCAPEMENT AND GRIP toggle switches located on the workhead control panel, feed an anchor into each anchor holder. 3) Put the TRAVEL/WORK switch (located in the cab overhead panel) in the WORK position, making certain that both guide wheels contact the rail. 4) Lower the workhead to the correct apply height and record setting. This can be done one of the two following ways: AUTOMATIC ANCHOR FEED Put the MODE SELECT switch (located in the cab overhead panel) in the AUTOMATIC position and depress the cycle start/stop foot pedal one time. This will automatically feed anchors into both anchor holders, flip the holders down into the apply position and lower the workhead down to the ready position. Depress the cycle start/stop foot pedal a second time, this will lower the workhead down to the pre-existing apply height and then rotate the workhead towards the rail. While the workhead is rotating toward the rail depress the cycle start/stop foot pedal at a point just short of when the throat of the anchor contacts the rail base, this will stop the workhead cycle at this point. Put the MODE SELECT switch (located in the cab overhead panel) in the MANUAL position. Using the WORKHEAD POSITION toggle switch and the WORKHEAD ROTATION toggle switch located on the workhead control panel, position the workhead such that the throat of the Using the WORKHEAD POSITION, TOOL ROTATION and WORKHEAD ROTATION toggle switches located on the workhead control panel, position the workhead such that the throat of the anchor is aligned with the center of the rail base (See Fig 3). When the correct apply height is obtained depress the PUSH TO RECORD-APPLY HEIGHT pushbutton located on the workhead control panel. 5) Put the MODE SELECT switch (located in the cab overhead panel) in the AUTOMATIC position and depress the orange CYCLE ABORT pushbutton (located on the cab overhead panel). This will fully retract the workhead to the lock-up (feed) position. NOTE: Occasionally, during automatic operation on worn rail or on a transition section of rail, the apply height setting may require further adjustment due to the temporary change in rail height. This can be done using the APPLY HEIGHT-PUSH TO RAISE and APPLY HEIGHT-PUSH TO LOWER pushbuttons located on the cab Section 4-4 FEB/2006 ( )

45 Anchor Applicator Model BAAM overhead panel. Momentarily pressing and releasing these pushbuttons while in AUTOMATIC MODE will change the apply height setting incrementally from the original setting. Each time the pushbutton is pressed and released, the apply height setting will change by an increment of approximately 1/16. This new apply height setting will take effect on the following apply cycle and all cycles following until either a new apply height setting is made as described above or the incremental pushbuttons are pressed again. These incremental pushbuttons allow the operator to make small, temporary adjustments to the apply height without going through the entire set-up procedure as described in steps 1 through 5 above. SETUP Cylinders will retract and the machine will lower onto the track. 7. Insert the jackstand pin. 8. Lock up the set-off valve handle. 9. Put the power lockup switch for the TURNTABLE (located in the cab overhead panel) in the LOCKED position. Raising the Machine for Dry-Run Purposes Do not climb under machine when using turntable. Take all necessary precautions before raising the machine. Raise machine only to point where wheels clear the rail and then turn machine. These instructions apply only to machines that have the Dry-Run Kit installed (longer stroke cylinder and jackstands). To lift and insert jackstands, proceed with the following steps: 1. Locate the machine on a portion of the track that is free of rail joint bars. 2. Remove the pin holding the jackstands in place (4 places). 3. Put the power lockup switch for the TURNTABLE (located in the cab overhead panel) in the UNLOCKED position. 4. Unlock the set-off valve handle and unlatch the retaining chain from the lower bed. Slowly lift handle to lower turntable until the uppermost hole on the jackstands (4) are exposed. Insert pin removed under Step Center the hand lever on the valve to lock in place. 6. Once dry run has been completed, remove pin in jackstand and slowly move the Set-Off Valve hand lever downward. The Turntable FEB/2006 ( ) Section 4-5

46 SETUP Anchor Applicator Model BAAM Verify Correct Workhead Set-up 1) Put the MODE SELECT switch (located on the cab overhead panel) in the AUTOMATIC position and depress the cycle start/stop foot pedal to feed anchors and bring the workhead to the ready position. Verify that the new ready position setting is correct. NOTE: The measure strip located on the workhead frame (See Fig 4) is used as a troubleshooting tool for adjusting and setting the ready position. 2) Depress the cycle start/stop foot pedal a second time to bring the workhead to the apply height and begin to rotate toward the rail. While the workhead is rotating toward the rail depress the cycle start/stop foot pedal at a point just short of when the throat of the anchor contacts the rail base, this will stop the workhead cycle at this point. 3) Put the MODE SELECT switch (located on the cab overhead panel) in the MANUAL position. If necessary, use the WORKHEAD ROTATION toggle switch located on the workhead control panel to rotate the workhead closer to the rail. Verify the following: A. The throat of the anchor is aligned with the base of the rail (See Fig 3). If an adjustment is required, repeat the steps in APPLY HEIGHT ADJUSTMENT AND SETTING. NOTE: The measure strip located on the workhead frame (See Fig 4) is used as a troubleshooting tool for adjusting and setting the apply height. C. Any contact here may cause pre-mature wear or failure of the rail stop and clamp bar. If there is contact with the rail either the apply height setting is too high or the rail stop adjustment is incorrect (see step 4 below). 4) If the apply height is correct, momentarily hold the WORKHEAD ROTATION toggle switch (located on the cab overhead panel) to engage the throat of the anchor on to the rail base. Release the WORKHEAD ROTATION toggle switch and simultaneously push and hold both APPLY toggle switches. This will apply both anchors on to the rail at the same time. While holding the switches in the apply position, verify that the anchors are fully applied but not over driven. If the anchors are not fully applied, the rail stops will need to be adjusted inward (towards the cab) an amount equal to the under driven distance. If the anchors are over driven, the rail stops will need to be adjusted outward an amount equal to the over driven distance. See RAIL STOP ADJUSTMENT for making added adjustments. 5) Put the MODE SELECT switch (located on the cab overhead panel) in the AUTOMATIC position and depress the CYCLE ABORT pushbutton located on the cab control panel. This will fully retract the workhead to the lockup (feed) position. B. The rail stop does not contact the bottom of the rail as the workhead rotates under the rail (see Fig 5). Section 4-6 FEB/2006 ( )

47 Anchor Applicator Model BAAM Changing Anchor Holders Each time a different type of anchor is to be used, compatible anchor holders must also be installed. Refer to the table below for specific anchor holders for each type of anchor. To change anchor holders: Put the WORKHEAD LIFT and WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the UNLOCKED position. SETUP 7. Select type of anchor components to be used for the job (i.e., Fair, Channeloc, Woodings, Unit, etc.). 8. Note: The tool holder pin can be used with all anchor holders. 9. Install each anchor holder into the tool holders. Align holes and secure with holder pin and hairpin cotter. 10. Connect both anchor holder hoses to the quick disconnects. 1. Put the WORKHEAD LIFT and WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the UNLOCKED position. 2. Put the MODE SELECT switch (located in the cab overhead panel) in the MANUAL position. 3. Using the TOOL ROTATION switch (located in the cab overhead panel) rotate the anchor holders down fully. 4. Turn ignition key switch to OFF and perform machine LOTO (lockout-tagout). 5. Disconnect both anchor holder hoses at the quick disconnects (located on top of each pivot frame). 6. Remove hairpin cotters and holder pins from the anchor tool holder and remove the anchor holder. (See Fig. 6) 11. Each time tooling is changed for a different type of anchor, tray adjustments must be made to accommodate the new anchors. Proceed to TRAY ADJUSTMENTS before attempting to operate the machine. ANCHOR RAIL BASE WIDTH ANCHOR HOLDER LH (AS VIEWED FROM CAB) ANCHOR HOLDER RH (AS VIEWED FROM CAB) BOTTOM TRAY GUIDE TRAY STOP TUBE Fair 5-1/2 to Fair Fair V 5-1/2 to Super Fair Channeloc 5-1/2 to N/A Channeloc /2 to N/A Woodings 5-1/2 to 6 N/A Unit 5-1/2 to 6 N/A 5 Unit 5 N/A Unit 4 5-1/2 to 6 N/A Unit 5 5-1/2 to N/A N/A Traktite 5-1/2 to 6 N/A FEB/2006 ( ) Section 4-7

48 SETUP Anchor Applicator Model BAAM Tray Adjustments After installation of different anchor holders, the trays must be adjusted for proper anchor feeding. Detailed instructions on how to make adjustments to the trays follow on the next pages. All tray adjustments should be made after changing anchor holders. The following table should be used to determine the proper adjustment to be made when certain problems are encountered during setup. PROBLEM Anchors not being gripped in holder in correct orientation. Anchors binding in tray (will not freely slide down tray) Tray Lateral Adjustment ADJUST Lateral Tray Position. Anchor Guide Height. The trays must be positioned so that the center of each anchor holder will be approximately aligned with the center of each tray. Figure 7 shows the related position of each anchor type in its matching holder. To make lateral tray adjustments: 1. Put the WORKHEAD LIFT and WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the LOCKED position. 2. Put the MODE SELECT switch (located in the cab overhead panel) in the MANUAL position. 3. Using the TOOL ROTATION switch (located in the cab overhead panel), rotate the anchor holders up fully. 4. Turn ignition key switch to OFF and perform LOTO. 5. Inspect the alignment between the anchor holders and trays. If the tray(s) require adjustment, loosen the jam nuts on the applicable turnbuckle assembly and turn the hexagon turnbuckle lug in the direction needed to align the tray with the anchor holder (See Figure 8). 6. Remove the LOTO and put the WORKHEAD LIFT and WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the UNLOCKED position. 7. Verify correct tray alignment by manually feeding anchors into the holder. To manually feed anchors, momentarily hold the applicable ESCAPEMENT GRIP toggle switch located on the workhead control panel. This will escape one anchor from the tray and grip it in the anchor holder. Section 4-8 SEPT/2005 ( )

49 Anchor Applicator Model BAAM SETUP SEPT/2005 ( ) Section 4-9

50 SETUP Anchor Applicator Model BAAM Top Tray Guide Adjustment The purpose of the top tray guide is to keep the anchors orientated correctly as they slide down the tray. The top guide should be set as low as possible without causing the anchors to bind in the tray, preventing them from sliding freely. To adjust the top guide: 1. Put the WORKHEAD LIFT and WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the LOCKED position. 2. Perform machine LOTO. 3. Loosen the two jam nuts on the adjustment screws. Adjust the screws until the anchors slide down the tray freely. See Figure Tighten the two jam nuts on the adjustment screws. Tray Stop Pin And Stop Tube Location The purpose of the tray stop pin and stop tube (if applicable) is to properly deflect the anchor into the anchor holder as it exits the bottom of the tray. Since there are multiple types of anchors having varying shapes, the location of the stop pin may have to change and a stop tube may have to be added to the pin. See Fig. 9. To change the location of the stop pin: Bottom Tray Guide (For Fair Anchors Only) To prevent Fair anchors from binding in the tray they must stand up straight as they slide down the tray. The bottom tray guide is a drop-in addition to the standard anchor tray. It has no adjustments and requires no tools to install. 1. Put the WORKHEAD LIFT and WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the LOCKED position. 2. Perform machine LOTO. 3. Remove the cotter pin from the stop pin. Move the stop pin to the correct hole location for the type of anchor being used. NOTE: If the anchor type requires a stop tube (see Figure 9), it should be placed on the stop pin. 4. Reinstall the cotter pin onto the stop pin. Section 4-10 SEPT/2005 ( )

51 Anchor Applicator Model BAAM SETUP This page intentionally left blank SEPT/2005 ( ) Section 4-11

52 Anchor Applicator Model BAAM MACHINE OPERATION EMERGENCY SHUTDOWN 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 on the cab control panel or on the workhead control panel. Never use the emergency shutdown system except in an emergency. DO NOT USE THIS METHOD AS A SHORTCUT TO TURNING OFF THE ENGINE!! EMERGENCY PROCEDURES If a hydraulic hose fails, shut down the machine immediately, determine cause of failure, correct condition. If indications on gauges are not within the normal range, shut down the engine normally. Repair before further operation. Emergency cylinder actuation requires the optional Emergency Pump. See Emergency Pump Operation later in this section. MACHINE ABORT FUNCTIONS OPERATION Before operating this machine you should be aware of the two types of ABORT features while in AUTOMATIC MODE. These ABORT features only operate in AUTOMATIC MODE and do not operate while in MANUAL MODE. AUTOMATIC MODE- MANUAL ABORT The automatic anchor apply cycle can be interrupted at any time by depressing the orange CYCLE ABORT button located on the cab overhead panel. This will retract the workhead back to the lock-up (anchor feed) position. Refer to RESTART AFTER ABORT for instructions on restarting the Automatic cycle. AUTOMATIC MODE- AUTO ABORT If the anchors do not apply within a fixed time period from the READY position due to an abnormal obstruction (anchors or a component of the workhead assembly contact the tie, the rail, a large stone, stiff ballast, etc.), the workhead will retract back to the lock-up (anchor feed) position. Refer to RESTART AFTER ABORT for instructions on restarting the Automatic cycle. NOTE: See Restart after Abort later in this section for instructions on how to restart after an abort in Automatic Mode. 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. 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. FEB/2006 ( ) Section 5-1

53 OPERATION OPERATING IN AUTOMATIC MODE While the machine can be operated in either the automatic or manual mode, automatic is the normal mode of operation. Manual operation is normally only used during emergency situations or while making adjustments to the workhead setup as described under WORKHEAD SETUP AND ADJUSTMENTS in Section 4 of this manual. To operate the machine in the AUTOMATIC mode, proceed as follows: 1. Put the WORKHEAD LIFT, WORKHEAD ROTATION and GUIDE ROLLER power lockup switches (located in the cab overhead panel) in the UNLOCKED position. 2. Put the MODE SELECT switch (located in the cab overhead panel) in the AUTOMATIC position and the TRAVEL/WORK switch (located in the cab overhead panel) in the WORK position, making certain that both guide wheels contact the rail. 3. With the workhead in the anchor feed (lockup) position and with anchors loaded into the trays (see Fig. 10), depress and release the START/STOP cycle footswitch. This will feed one set of anchors into the anchor holders and bring the workhead down to the READY position. 4. While at the READY position, again depress and release the START/STOP cycle footswitch. This will automatically apply the anchors, bring the workhead back up to the feed (lock-up) position, feed another set of anchors and bring the workhead back down to the READY position and stop. Anchor Applicator Model BAAM Care should be taken not to pre-box too far as this may cause the anchor to land on top of the ties causing an AUTO ABORT. 6. Depress the START/STOP footswitch to start another automatic apply cycle from the READY position. NOTE: When in SERVICE brake mode, the brake footswitch must be depressed in order to start an automatic apply cycle. When in DEADMAN Brake mode, both propulsion footswitches must not be depressed in order to start an automatic apply cycle. 7. Repeat Steps 5 and 6 to continue automatic anchor application. Remember! An automatic apply cycle can be either manually aborted or automatically aborted anytime during the cycle. (Refer to previous page for more details. A single anchor may be applied on one side of the tie as long as there is not an anchor already applied on the opposite side. Attempting to apply a single anchor when the opposite anchor is present may cause damage to the anchor holder or other parts of the workhead. NOTE: During an automatic cycle, if the START/STOP cycle footswitch is depressed anywhere between the READY position and the anchor apply function, the workhead will stop at that point. Depressing the footswitch again will re-start the automatic cycle from where it was stopped. 5. Depress the propulsion footswitch in the direction required to move the machine to the tie to be boxed and anchored. Position the machine so the tie is approximately centered between the anchor holders. NOTE: In situations where there are close tie spacings or the machine is not centered over the tie, the BOXING switch located on the cab control panel may be used to pre-box the anchors before starting an automatic cycle. Section 5-2 FEB/2006 ( )

54 Anchor Applicator Model BAAM MANUAL OPERATION The machine is normally operated in the automatic mode, however, all of the workhead functions can be operated independently by using the manual switches located on the cab control panel or the workhead control panel. Other than the BOXING switch, which can be used in either the MANUAL or AUTOMATIC mode, these switches will only operate in MANUAL mode. Manual operation is normally only used during emergency situations or while making adjustments to the workhead set-up as described under WORKHEAD SETUP AND ADJUSTMENTS in Section 4 of this manual. To operate the machine in MANUAL mode proceed as follows: 1. Put the WORKHEAD LIFT, WORKHEAD ROTATION, and GUIDE ROLLER power lockup switches (located in the cab overhead panel) in the UNLOCKED position. 2. Put the MODE SELECT switch (located in the cab overhead panel) in the AUTOMATIC position and the TRAVEL/WORK switch (located in the cab overhead panel) in the WORK position, making certain that both guide wheels contact the rail. NOTE: The MODE SELECT switch can be changed from AUTOMATIC to MANUAL at any time. If it is switched to MANUAL during an automatic cycle, the workhead will stop at that point. 3. Using the manual control switches located on either the cab control panel or the workhead control panel, the workhead functions can be moved to anywhere within their range. The following features have been implemented while using the manual control switches: When the workhead is raised using the WORKHEAD POSITION switch, the workhead will automatically UN-BOX the anchor tools. OPERATION When the LH APPLY switch is used, the anchor in the left hand anchor holder will automatically UNGRIP. When the RH APPLY switch is used, the anchor in the right hand anchor holder will automatically UNGRIP. When the anchor holders are rotated up using the TOOL ROTATION switch, the anchors in both the anchor holders will automatically UNGRIP. Momentarily holding and releasing the LH ESCAPEMENT-GRIP switch will escape one anchor from the LH tray and automatically grip it in the LH anchor holder. Momentarily holding and releasing the RH ESCAPEMENT-GRIP switch will escape one anchor from the RH tray and automatically grip it in the RH anchor holder. The LH ESCAPEMENT-GRIP and RH ESCAPEMENT-GRIP switches will only operate when the workhead is up in the feed (lock-up) position. NOTE: If the MODE SELECT switch is changed back to AUTOMATIC and the CYCLE START/STOP footswitch is depressed the workhead will start an automatic cycle from that point. A single anchor may be applied on one side of the tie as long as there is not an anchor already applied on the opposite side. Attempting to apply a single anchor when the opposite anchor is present may cause damage to the anchor holder or other parts of the workhead. The workhead will raise and lower in slow speed when using the WORKHEAD POSITION switch. When either the LH APPLY or RH APPLY switches are used when the anchors are engaged on the rail (i.e. when manually applying anchors during workhead setup and adjustments), the workhead will automatically ROTATE into the rail. This allows the operator to manually apply anchors without having to hold the APPLY and WORKHEAD ROTATE switches simultaneously. FEB/2006 ( ) Section 5-3

55 OPERATION RESTART AFTER ABORT When a manual or automatic abort occurs during an automatic apply cycle, the workhead will ungrip the anchors from the anchor holders and bring the workhead back up to the lock-up (feed) position and stop. In order to restart an automatic apply cycle following either a manual or an automatic abort proceed as follows: 1. Correct the operating fault. If a stone or object in the ballast is causing the operating fault, remove the object. 2. Check to be certain that both anchors ungripped and dropped out of the anchor holders. When a restart is carried out after an abort the first function is to feed new anchors into the anchor holders. If this occurs when anchors are already present in the holders, it will cause a double feed and may result in damage to workhead components. If either or both anchors remain in the anchor holders following an abort, proceed as follows: Anchor Applicator Model BAAM in the cab overhead panel) in the AUTOMATIC position and depress the orange CYCLE ABORT pushbutton located on the cab overhead panel to retract all functions back to the lock-up (feed) position. When all foreign objects have been cleared and with the anchor holders empty, depress the CYCLE START/STOP footswitch. This will automatically feed two new anchors and bring the workhead down to READY position. If the operating fault was due to the machine not being centered over the tie, either re-spot the machine using the propulsion footswitches or use the BOXING switch on the cab control panel to pre-box the workhead so the anchor holders don t interfere with adjacent ties. Depress the CYCLE START/STOP footswitch to initiate the automatic apply cycle. Switch the MODE SELECT switch to MANUAL Engage the workhead rotate lock-up located on the cab control panel. The workhead lift lock-up should remain disengaged at this time. Using the WORKHEAD POSITION switch located on the cab control panel, lower the workhead approximately 6 inches so that the jammed anchors are fully clear of the trays. Using the TOOL ROTATION switch located on the cab control panel rotate the anchor holders fully down to the apply position. Using the WORKHEAD POSITION switch, raise the workhead back up to the lockup position. Engage the workhead lift lock-up located on the cab control panel. Remove the anchor(s) from the anchor holders. NOTE: At this point the anchor holders should be un-gripped so if an anchor is still present it means that it is jammed in the holder. Lightly tapping the anchor with a long handle tool in the sideways direction should loosen the anchor enough to remove it. Put the WORKHEAD ROTATION power lockup switches (located in the cab overhead panel) in the UNLOCKED position. Put the MODE SELECT switch (located Section 5-4 FEB/2006 ( )

56 Anchor Applicator Model BAAM Winch Operation (Optional) Your machine may be equipped with an optional hydraulic winch for loading anchors into the bulk bin. 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 locking handle on the boom mast down and rotating it until the spring pin is seated in the notch on the chamfered tube. To move the winch assembly, pull down on the locking handle until pin releases from hole. Move to new location, release handle. To raise a load: To stop a load: To lower the load: Pull valve handle up. Release valve handle. Pull valve handle down. 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 PUMP OPERATION OPERATION emergency pump disconnect. 2. To operate other functions, connect hose to the corresponding manifold at a P port disconnect (disconnect may not be provided). 3. Operate emergency pump and manually override control valve of desired function. AFTER OPERATION General 1. Put ALL power lockup switches (located in the cab overhead panel) in the LOCKED position. 2. Follow all instructions given in the LOCKUPS section of this manual. 3. Press the Electrical Interlock Button on the Cab Control Panel. 4. Set engine speed to low position and turn pump off. Let engine idle for 5 minutes. 5. Shut off engine by returning ignition switch to the full counterclockwise position. BRAKE RELEASE MACHINE MAY MOVE WHEN BRAKES ARE RELEASED. 1. Connect hose (supplied with machine) to hand or electric emergency pump disconnect. 2. To release brakes, connect other end of hose to brake disconnect located on the workhead manifold. 3. Turn brake shut-off valve (located next to disconnect) to the OFF position in order to isolate brake system. 4. Operate emergency pump to pump off brakes. OTHER FUNCTIONS 1. Connect hose (supplied with machine) to hand or electric Never shut off battery disconnect switch with the engine running. This will cause damage to the voltage regulator, alternator, and/or electrical system. 6. Return all switches to their "Pre-Operational" state using the Pre-Operational Checklist as a guide. 7. Close the workhead control panel cover and secure with padlock. 8. Turn off battery disconnect switch. Lock battery box. Parking or Locating Machine Park or locate machine on level track area, if possible; and where it will not be exposed to excessive dust. If the machine was towed, disconnect towing vehicle and set the brakes. Move the towing vehicle well clear of the parked machine. FEB/2006 ( ) Section 5-5

57 OPERATION Rotating the Machine track. Anchor Applicator Model BAAM 8. Lock up the set-off valve handle. Do not climb under machine when using turntable. Take all necessary precautions before raising the machine. The machine has a standard turntable which allows the machine to be lifted off of the tracks and rotated. The only function of this turntable is to rotate the machine. The machine can be equipped with a Dry Run option, which not only allows the machine to be rotated, but raised to a point where jackstands can be used for dry run testing. With either configuration, when using the setoff cylinder for rotating the machine, DO NOT lift the machine past the point where the wheels have cleared the rail. To lift and rotate the machine, proceed with the following steps: 1. Locate the machine on a portion of the track that is free of rail joint bars. 2. Put the power lockup switch for the TURNTABLE (located in the cab overhead panel) in the UNLOCKED position. 3. Unlock the set-off valve handle and unlatch the retaining chain from the lower bed. Slowly lift handle to lower tu 4. rntable until it comes into contact with the rails. Raise machine only to point where all wheels clear the rail and then turn machine. 5. Hold valve hand lever until all wheels clear the rail. Center the hand lever on the valve to lock in place. 6. Use manpower to rotate the machine. The wheels should be directly above the rails after rotating the machine. 7. Slowly move the Set-Off Valve hand lever downward. The Turntable Cylinders will retract and the machine will lower onto the 9. Put the power lockup switch for the TURNTABLE (located in the cab overhead panel) in the LOCKED position. Raising the Machine for Dry-Run Purposes Do not climb under machine when using turntable. Take all necessary precautions before raising the machine. Raise machine only to point where wheels clear the rail and then turn machine. These instructions apply only to machines that have the Dry-Run Kit installed (longer stroke cylinder and jackstands). To lift and insert jackstands, proceed with the following steps: 1. Locate the machine on a portion of the track that is free of rail joint bars. 2. Remove the pin holding the jackstands in place (4 places). 3. Put the power lockup switch for the TURNTABLE (located in the cab overhead panel) in the UNLOCKED position. 4. Unlock the set-off valve handle and unlatch the retaining chain from the lower bed. Slowly lift handle to lower turntable the uppermost hole on the jackstand (4) is exposed, insert pin. 5. Center the hand lever on the valve to lock in place. 6. Once testing has been completed, remove pin in jackstands (4) and slowly move the Set-Off Valve hand lever downward. The Turntable Cylinders will retract and the machine will lower onto the track. 7. Lock up the set-off valve handle and insert jackstand pins. 8. Put the power lockup switch for the TURNTABLE (located in the cab overhead panel) in the LOCKED position. Section 5-6 FEB/2006 ( )

58 Anchor Applicator Model BAAM OPERATION Towing Do not ride on tow bar between the machine and the towing vehicle. Falling from a moving vehicle may cause serious injury or death. Maximum towing speed is 20 mph. Reduce speed accordingly as dictated by weather or track conditions. 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. Put ALL power lockup switches (located in the cab overhead panel) in the LOCKED position. 2. Follow all instructions given in the LOCKUPS section of this manual. 3. Make certain turntable has been raised and the set-off valve handle locked. 4. Remove drive chain(s) if machine is to be towed a long distance. 5. Inspect the towing vehicle coupler for damage or loose parts. 6. Back towing vehicle to the machine and engage the couplers. Keep hands and fingers clear of the coupling device and all other pinch points. 7. Ensure that the coupling device is fully engaged, closed and locked. 8. Install Brake Lock Pins. See Brake Assembly in Maintenance and Service for instructions on installing brake lock pins. 9. 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. 10. When towing is complete, engage brake by removing the Brake Lock Pins. FEB/2006 ( ) Section 5-7

59 OPERATION Anchor Applicator Model BAAM Intentionally left blank Section 5-8 FEB/2006 ( )

60 NORDCO'S SERVICE NETWORK Need assistance? It's only a phone call away! If you experience problems, contact your original sales representative first. If you cannot reach him, we suggest that you contact the representative closest to your work area BEFORE calling NORDCO's Service Manager. 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) (Wisconsin) (USA and Canada) The process will be faster if you have the following information in hand before calling: 1. The Machine and Model Name: Anchor Applicator Model BAAM (for example) 2. The Serial Number SERVICE NETWORK See Next Page for Detailed Representative Listing by Railroad/Contractor Map No. Service Provided By Location Phone Number 1 Nordco Service Manager Oak Creek, WI (800) (414) Russell Railway Supply Company Minneapolis, MN (952) & 4 James H. Lynde (West Sales Mgr) Overland Park, KS (913) North American Equipment Company Nicholasville, KY (859) Dwayne Lambing (East Sales Mgr) Kenesaw, GA (770) North American Equipment Sales Company West Seneca, NY (716) Doylestown, PA (215) North American Equipment Sales (Canada) Ltd. Dundas, ON Canada (905) International: American Equipment Co (Ameco) Boca Raton, FL (561) FEB/2006 ( ) Section 6-1