SPIKER MODEL SS-D. Operation and Maintenance Manual. Applies to S/N and Above Reorder Part: Last Revision: Rev A JULY 2014

Transcription

1 Operation and Maintenance Manual Applies to S/N and Above Reorder Part: Last Revision: Rev A JULY 2014 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 blue pages behind each tab.

2 Release/Revisions Release/Rev Date Change Description REV - May 2010 Original Release of Manual REV A 7/9/2014 Added decibel chart to Section 1, General Specifications

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: Milwaukee, Wisconsin (414) sales@nordco.com Milwaukee, 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 CONTENTS TABLE OF CONTENTS SECTION 1 SAFETY AND GENERAL INFO Understanding Key Safety Alert Words Follow Safety Instructions General Safety Tips Safety Prior to Working Safety While Starting the Machine Safety While Operating/Traveling Safety While Parked Safety During Maintenance Safety Alerts Lockout/Tagout Requirements Lockout/Tagout Procedures GENERAL INFORMATION Machine Specifications SECTION 2 PRE-OPERATION AND OPERATION Before Operation Getting to Know the Machine Operator s Station Workhead Components Propulsion/Drive System Boom/Winch Gager (Optional) Nipper (Optional) Controls Left Operator Valve Banks Right Operator Valve Banks Remote Operator Control Box Engine Indicator Light Box Feed Control Box Travel/Work Lights Feed Control Box Timer Controls Misc. Operator Station Controls (Throttle, Pump Control, etc.) Brakes Remote Controls and Indicators Preparing the Machine for Work Pre-Operational Checklist Lockups Workheads Guide Roller Assembly Turntable Boom and Winch Nippers (Optional) Gager (Optional) Travel Machine Setup Jaw Depth/Rail Height Adjustment Workhead Up Adjustment Workhead Down Adjustment Gaging Speed Adjustments (Optional Gager) Gager Pointer Adjustments (Optional Gager) Machine Operation Machines without Nipper and Gager Machines with Gager, without Nipper Machines with Gager and Nipper Winch Operation Emergency Stopping Continued on other Side - MAY/2010 ( ) Contents - 1

6 CONTENTS SECTION 2 PRE-OPERATION AND OPERATION (Continued) After Operation Parking or Locating Machine Rotating Machine Shutting Down Machine Towing SECTION 3 MAINTENANCE Nordco s Service Network Requesting Assistance Service Network Map/Contact Numbers Lubrication and Maintenance Schedules Daily Service and Maintenance Weekly Service and Maintenance Monthly Service and Maintenance Quarterly Service and Maintenance Yearly Service and Maintenance TAB 1 MECHANICAL MECHANICAL TROUBLESHOOTING... Blue Pages MECHANICAL PARTSHEETS... FIGURE Operator Station Operator Platform B Front Controls A Valve Bank Controls A Axles, Demountable 3-Inch Brakes Brakes Brake Unit Detail Drive System B Frame Additions Battery System Lights and Horns Misc. Frame Accessories Decals and Plaques A Steps Engine and Pumps John Deere Engine... 7-E-2 Pump... 7-P Hydraulic Tank A Oil Cooler Fuel Tank Carriage LH Workhead (Guns 1 and 2) B RH Workhead (Guns 3 and 4) B Guide Rollers A Workhead B Tray and Feed LH Tray and Feed (W/Square End Feed Cylinder) A-1 RH Tray and Feed (W/Square End Feed Cylinder) A-2 Pattern Adjust (Electric) A Nippers (Optional) Continued on other Side - Contents - 2 MAY/2010 ( )

7 CONTENTS TAB 1 MECHANICAL (Continued) MECHANICAL PARTSHEETS (Continued)... FIGURE Gager (Optional) Gauger Frame A-1 Gauger Rail In Levers A-2 Gauger Rail Out Levers A-3 Gager Indicator Buggy B Gager Pointer A Boom and Winch Turntable A TAB 2 HYDRAULIC HYDRAULIC TROUBLESHOOTING... Blue Pages Functional Hydraulic Shematic , Rev. C TAB 3 ELECTRICAL ELECTRICAL TROUBLESHOOTING... Blue Pages Functional Electrical Shematic , Rev. A Feed Control Box , Rev. A Operator Control Box , No Rev. Frame Harness , No Rev. Junction Box Cabling , No Rev. TAB 4 COMPONENT DATA Cylinder Sheets Kent Hammer Sundstrand Pump Charlynn Motor Hatz Engine MAY/2010 ( ) Contents - 3

8 CONTENTS This page intentionally left blank Contents - 4 MAY/2010 ( )

9 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. MAY/2010 ( ) Section 1-1

10 SAFETY GENERAL SAFETY TIPS Only trained and authorized personnel should be allowed to operate this machine. In addition, all personnel at the worksite (gang) should be aware of the safety concerns and their individual responsibilities prior to working this machine. 1. Handle fuel safely. It is highly flammable and prolonged breathing of fumes may cause bodily harm. 2. Prepare for emergencies. Keep a first aid kit and fire extinguisher handy. 3. Protect against flying pieces of metal and debris by wearing safety glasses or goggles. 4. Wear good-fitting pants and shirt, no baggy or loose clothing. 5. Protect your head and eyes from flying debris by wearing a hard hat and safety goggles/glasses. 6. Wear leather gloves to protect your hands from vibration or flying metal particles. 7. Use safety-toed work boots. SAFETY PRIOR TO WORKING All personnel at the worksite (gang) should be aware of the safety concerns and their individual responsibilities prior to working this machine: obstructions and personnel. Use care when climbing onto the machine. Always use the steps and handrails provided. (If an area does not have tread grips, walkways, or other methods to access the area, then DO NOT attempt to access that area.) Make seat and control adjustments PRIOR to starting the machine. ALWAYS wear a seatbelt. Know the weather forecast and plan your work speeds accordingly. There are guards on this machine. These are to be removed ONLY when service or maintenance is being performed on that area of the machine. Make certain they have been re-installed PRIOR to starting the machine. Check and service the fire extinguisher (if so provided) at regular intervals. Make certain all personnel are trained in its use. Note - Non-use of fire extinguisher still requires that it be recharged at the interval stated on its last inspection notice. Keep the stairs, cab entry platform and cab interior free and clear of ice, tools and personal items. Use the accessories provided on the machine (tool box, cup holder, coat hook, etc.) to properly store your gear. Never climb onto the machine while it is in motion. There are lockups on this machine that are used for both work and travel. These should be kept clear and free of debris, grease, etc. See Lockup section for instructions on their use. Inspect safety decals and replace when they become unreadable or are damaged. (See Safety Decals at the end of this Safety section). 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 Section 1-2 MAY/2010 ( )

11 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: 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 OPERATING/TRAVELING WHILE 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. When leaving a machine engine running, make certain that the parking brake is applied and the electrical interlock button has been activated. NEVER stop and park this machine on an incline unless the machine wheels have been chocked. SAFETY DURING MAINTENANCE The following guidelines are suggested when performing maintenance: 1. Always chock the wheels 2. Alert others in the area that service or maintenance is being performed on this machine. 3. Become familiar with, and use, your company s lockout/tagout procedures when performing maintenance on this machine. See LOCKOUT/TAGOUT REQUIREMENTS later in this Safety Section for a chart on energy sources located on this machine. 4. Do not start the engine if repairs or work is being performed alone. You should always have at least two people working together if the engine must be run during service. One person needs to remain in the command position (at the controls), ready to stop the machine and shut off engine if the need arises. 5. Collect oils and fuels and dispose of them properly. There is a danger of scalding when working with engine oils. 6. Use only Nordco supplied repair parts for this machine. Use of non- OEM designed parts could comprise the integrity of this machine. 7. There are welding cautions on this machine. Pay attention to them PRIOR to welding. 8. Kits supplied by Nordco have welding instructions included. Welding of any components NOT of Nordco s manufacture or failure to follow these instructions may affect the stability of this machine. SAFETY SAFETY WHILE PARKED MAY/2010 ( ) Section 1-3

12 SAFETY MACHINE SAFETY ALERTS ALERTS DANGER ALERTS Improper use of this machine for any type of operation can cause serious injury or death. To avoid serious injury or death, make certain that the area around and under the machine is clear of all personnel and obstructions BEFORE travelling or working. Serious injury or death can result from reaching into working components while machine is running. Make all observations from a distance and SHUT OFF machine while making adjustments. Shut off engine when checking battery electrolyte level. Do not check or fill battery in presence of open flame, sparks, or when smoking. Battery fumes are flammable and/or explosive and if ignited will result in severe bodily injury or death. Do not ride on tow bar between the machine and the towing vehicle. Falling from a moving vehicle may cause serious injury or death. 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 machine could occur; unless directed otherwise. Failure to comply could result in personal injury and/or damage to the machine. Exhaust emissions caused by the use of the engine on this machine may cause cancer, birth defects, or other reproductive harm if inhaled. Disconnect the battery before servicing this machine. Failure to do so could result in personal injury from accidental engine startup. MACHINE SAFETY Section 1-4 MAY/2010 ( )

13 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 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. See next page for suggested lockout/tagout procedure list. MAY/2010 ( ) Section 1-5

14 SAFETY LOCKOUT-TAGOUT PROCEDURES The following procedures are designed to lead the operator through the steps required to shut the machine down and prepare it for performing mechanical maintenance work. These procedures are intended to release potentially dangerous stored energy forms and make the machine safe to begin repairs. SAFETY PROCEDURES LOCKOUT/TAGOUT 1. Chock wheels to prevent accidental rolling of machine on grade. 2. If you have not already done so, determine which components are to have maintenance. Place all machine mechanical systems or workheads in the full up and locked positions. 3. Refer to the list on the next page to determine what procedures are required when mechanical locking up of equipment is not feasible for maintenance. Then continue on with Steps Turn the ignition switch to the OFF position. This turns off the power to the control circuits on the machine. Place a TAGOUT card in close proximity to the ignition switch. 5. Turn the battery disconnect switch (BDS) to the OFF position. a. For machines with the BDS on the left side of the center (front) control console: Place a TAGOUT card on the switch after you have switched it to the OFF position. b. For machines with a remotely located BDS (usually next to the battery box itself): Close the cover to the disconnect switch and place a LOCKOUT lock on the box after you have switched it to the OFF position. 6. Bleed off hydraulic pressure. 7. 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. Section 1-6 MAY/2010 ( )

15 SAFETY This list is for specific components in an assembly, where maintenance cannot be performed with the assembly in the full up and/or locked position. After completing the steps required, continue on with Steps 4-7 on the previous page. When performing maintenance on: NIPPERS Nipper Up/Down Cylinder WORKHEADS Hammer Secure as follows: Lower Nipper Assembly to tie. MAY/2010 ( ) Section 1-7

16 SAFETY SAFETY DECALS ON THIS MACHINE Safety decals and plaques that have been placed on this machine are to be kept clean and legible. Replace any decals or plaques that have become illegible or are missing. When repairing or replacing components that had safety decals on them, it is your responsibility to replace the safety decals. These can be ordered from the Parts Sales Department. Refer to Figure 6-4 in the Mechanical Section for part numbers of all safety decals and plaques. Section 1-8 MAY/2010 ( )

17 GENERAL GENERAL This manual contains information for the Small Spiker Model SS-D. Information is provided in this manual for operation and maintenance of the machine. Information regarding operation and maintenance of OEM parts not of NORDCO manufacture can be found at the back of this manual, behind the tab marked Component Data. Become familiar with all safety instructions, controls and instruments before operating this machine. Follow all instructions carefully. ABOUT THIS MANUAL This manual has been broken down into sections which have been separated by index tabs: Mechanical has individual parts breakdown drawings and lists for each assembly Hydraulic includes adjustment instructions and troubleshooting for the hydraulic system; and all piping and functional drawings for a standard machine and optional equipment Electrical, includes electrical schematics, distribution and control boxes, and cabling drawings for the machine; as well as troubleshooting instructions Component Data includes parts breakdowns and service instructions for components installed on the machine that are not of NORDCO s manufacture. For example, the engine and pump. JULY/2014 ( ) Rev. A Section 1-9

18 GENERAL SPECIFICATIONS Gross Weight... 19, 700 lbs (8,936 kg)* Length feet 9 inches (6.1 m) Width... 8 feet 6 inches (2.51 m) Height... 9 feet 2 inches (2.80 m) Travel Speed mph maximum (40 km/h) Turntable... Hydraulically Operated, Removable Plate Wheel Base inches (4.1 m/4100 mm) Towing Speed mph maximum (32 km/h) Spiking Force... 2,200 lbs. (9820 N) CAPACITIES Fuel Tank gallons (132 liters) Hydraulic Oil Tank gallons (189 liters) Oil Cooler gpm (378 L/mn) Winch lbs. (136 kg) ENGINE Make/Model... John Deere 4024TF Type... 4-Cylinder (Inline 4-Cycle) Turbocharged Rated Horsepower... 66@2800 RPM Engine Operating RPM RPM HYDRAULIC SYSTEM Pressure Settings: Relief Valve - Main Pump... 3,000 psi (200 bar) Compensator - Main Pump... 2, 500 psi (172 bar) Main Pump (45 GPM)... Sundstrand Series 45 Manual Control Valves... Husco ELECTRICAL SYSTEM Battery Vdc,1125 CCA Ground... Negative Alternator Amp DRIVE SYSTEM Drive Type... Dual Axle Drive Propulsion Motor Type... Hydraulic, Charlynn 4000 Series AXLE/WHEELS Axle Size... 3-inch Diameter Wheel Type... Cast Steel Wheel Size inch ( 406 mm) diameter Brake Type... Four wheel Cobra style, spring actuated, hydraulic release - standard 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. 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. Section 1-10 Rev. A, JULY/2014 ( )

19 GENERAL DECIBEL RATING JULY/2014 ( ) Rev. A Section 1-11

20 GENERAL THIS SHEET INTENTIONALLY LEFT BLANK Section 1-12 Rev. A, JULY/2014 ( )

21 Before operating this machine, read and understand the Safety Section of this Manual. BEFORE OPERATION Improper use of this machine for any type of operation can cause serious injury or death. It is always good practice to become totally familiar with the machines you are going to operate. OPERATOR'S STATION Almost all the controls for running this machine are located in the Operator's Station. This includes but is not limited to the spike feed, engine, workhea, gager, and nipper controls as well as propulsion and braking. Located next to each Operator's seat is a Feed Control Box. These are used during work operations and allow operators to choose between Automatic Feed Operation and single feed operation. Each operator is responsible for the workhead on their side of the machine. Each workhead consists of two gun assemblies (left and right). Each operator has two hydraulic valve banks that control the function of the guns in front of them. The left operator controls guns 1 and 2, the right operator controls guns 3 and 4. Carriage movement is controlled by a valve in the right hand valve bank at each operator seat. Moving the hand controller forward and back, and left and right, allows you to center the spike over the tie plate. Foot pedals can be moved to either operator position. Always wear the seat belt properly when sitting in the operator's seats. Always use the handrails and steps provided to climb on to and off of the machine. WORKHEAD COMPONENTS CARRIAGE CENTERING PRE-OPERATION Carriage centering is controlled by a set of valves in the right valve bank at each operator station (Valve 4 as shown on Figures 1 and 2 later in this section.) WORKHEAD PATTERN ADJUST Workhead pattern adjustment (left/right, forward/backward) is now electrically controlled by using the remote operator control box located on the frame next to each operator. CARRIAGE GUIDE WHEEL Located between the outer and inner carriages is the guide rollerl. This functions as a workhead stabilizer and is positioned by a hydraulic cylinder (up and down movement of guide roller) and a second hydraulic cylinder controls the left/right movement of the carriage assembly. The guide wheel is controlled by the center valve handle on the right hand valve bank at each station. (Valve 5 as shown on Figures 1 and 2 later in this section.) PROPULSION/DRIVE SYSTEM The machine is driven on both axles with a chain sprocket system powered by a hydraulic motor located in both the front and rear of the machine. BOOM/WINCH The boom/winch system is in place to allow the operator to lift kegs of spikes onto the rear storage deck and dump them into the storage bin. The winch is capable of lifting loads up to 300 lbs. It is not designed or intended to be used for towing. The boom and winch should be locked up for travel or when not being used. See lockup requirements in the Lockup section of this manual. MAY/2010 ( ) Section 2-1

22 PRE-OPERATION GAGER (Optional) Located in front of the workhead bays. A wheel and roller assembly allows the indicator assembly to ride the rail continuously during gaging operations. A compression spring holds the assembly tight to the rail. The gage of the rail is indicated on the Gager Pointer Assembly in front of the operator. Two large hydraulic cylinders with levers control the in/out movement of the rail. These assemblies must be locked up for travel. See lockup requirements in the LOCKUP section of this manual. NIPPER ASSEMBLY (Optional) Located in the center of the machine, between the workheads is the nipper assembly. It is used to pull the tie up to the rail to secure the tie plate to the tie during spiking operations. A vertical hydraulic cylinder controls the up/down position of the nipper assembly, while a pair of hydraulic cylinders control the open/close position of the nipper tie hooks. This assembly must be locked up for travel. See lockup requirements in the LOCKUP section of this manual. Section 2-2 MAY/2010 ( )

23 PRE-OPERATION FIGURE 1. CONTROLS LEFT OPERATOR VALVE BANKS Control Valve Handle Position Functional Description 1 Turntable Up Down Lowers turntable to tie Raises turntable off of tie (Locked during travel) 2 Drive Gun 1 Fwd Rev Drives spike, lowers hammer Raises hammer 3 Fwd Drives spike, lowers hammer Drive Gun 2 4 Carriage Spotting 5 Guide Roller 6 Gager (Optional) Rev Fwd Rev Left Right Fwd Rev Fwd Right Back - Left Raises hammer Moves carriage forward Brings carriage back Moves carriage to right Moves carriage to left Lowers guide roller (for work) Raises guide roller (for travel) Pushes rail in Pushes rail out Retracts Gager Cylinders MAY/2010 ( ) Section 2-3

24 PRE-OPERATION FIGURE 2. CONTROLS RIGHT OPERATOR VALVE BANKS Control 1 Nippers 2 Drive Gun 3 3 Drive Gun 4 4 Carriage Spotting 5 Guide Roller Valve Handle Position Fwd Rev Left Right Fwd Rev Fwd Rev Fwd Rev Left Right Fwd Rev Functional Description Brings nipper down Brings nipper up Opens tie hook Closes tie hook Drives spike, lowers hammer Raises hammer Drives spike, lowers hammer Raises hammer Moves carriage forward Brings carriage back Moves carriage to right Moves carriage to left Lowers guide roller (for work) Raises guide roller (for travel) Section 2-4 MAY/2010 ( )

25 PRE-OPERATION FIGURE 3. CONTROLS REMOTE OPERATOR CONTROL BOX INSTRUMENT OR CONTROL POSITION FUNCTIONAL DESCRIPTION AUTO/MANUAL FEED Switch MANUAL Feed Feeds one spike into jaws at a time and requires use of single feed button. Single Feed Button Pattern Adjust Switches AUTO Feed Left Right FWD/BACK OPEN/CLOSE Feeds consecutive spikes into jaws without need for pushing feed button (unless a misfeed occurs). Push to feed spike in either manual or auto mode. (Note: required in Auto mode ONLY when misfeed occurs.) Feeds one spike into left gun on workhead Feeds one spike into right gun on workhead Moves the pair of workheads (not carriage) forward and backward. Opens or closes the gap between the workheads. MAY/2010 ( ) Section 2-5

26 PRE-OPERATION FIGURE 4. CONTROLS ENGINE INDICATOR LIGHT BOX ETHER SHOULD NEVER BE USED ON THIS ENGINE! Section 2-6 MAY/2010 ( )

27 PRE-OPERATION GAGE OR SWITCH NUMBER INSTRUMENT OR CONTROL FUNCTIONAL DESCRIPTION 1 Ignition Switch Switches power to all circuits when in the ON position. Turned to OFF position for normal engine shutdown. To start the engine: Turn the ignition switch to the first detent (power will come on, but engine will not turn over). The Wait to Start LED will come on and a message on the Engine Diagnostic Gauge will read Wait to Start Engine. When both the LED and the gauge message go out, continue turning the switch to start the engine. 2 Wait to Start LED Used in combination with Ignitions switch. (See above). When this light comes on, do NOT start the engine. When the light is off, it is OK to start the engine. 3 Hourmeter Indicates hours used on engine. Also a way of calculating maintenance intervals for machine. 4 Murphy Alarm Gauge Audible and visual warning that the engine is in an alarm state. Check the Diagnostic Gauge for alarm code. The audible alarm will sound whenever low oil pressure, high coolant temperature, or water in fuel conditions exist. This includes all signals that light up the amber warning indicator (intermittent alarm) or the red stop engine indicator (steady alarm). See next page for more details. 5 Engine Speed The LOW speed (turtle) setting is for starting. Set switch to HIGH (rabbit) to operate machine. Return to LOW before shutting down engine. NOTE: Engine will not start if switch is in HIGH position when starting. 6 Pump On/Off Turns on hydraulic pump. Engine will not start if this switch is in the ON position when ignition switch is turned. This is done to reduce engine load during starting. After engine has started, turn on pump. Turn pump off if you intend to idle for any length of time. 7 Engine Temp 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. 8 Emergency Stop Press button to shut down engine. Pull out button to reset. See "EMERGENCY STOPPING" at the end of this OPERATION section. 9 Engine Diagnostic Gauge See next pages for more details and page of the John Deere engine manual. MAY/2010 ( ) Section 2-7

28 PRE-OPERATION FIGURE 5. ENGINE DIAGNOSTICS Turn the ignition switch to the first detent (power will come on, but engine is not started) and wait. The Powerview will come on, and a WAIT TO START-PREHEAT message will appear on the screen. A light (Wait to Start) next to the ignition switch will turn on. When the message disappears and the light goes out, it is safe to start the engine. Section 2-8 MAY/2010 ( )

29 PRE-OPERATION Instrument or Control Type of Control Functional Description Menu Key The Menu Key is touched to either enter or exit the menu screens. Left Arrow The Menu key is only used during factory setup procedures. (See Component Data Section for additional operation and setup instructions.) Use the left to move to the left or upward in a 4-Up screen. You can use the left arrow at any time to return to the previous screen. Right Arrow Use the right arrow key to move to the right or downward in a 4-Up screen, or to move to the next set of 4 controls. Warning Light Shutdown Derate Light Screen Display Enter Key Amber LED LED status lights are located on the upper left and upper right sides of the powerview. When they are lit, the screen will tell you the fault, the code number for the fault, and the method to correct the fault. Red LED LED status lights are located on the upper left and upper right sides of the powerview. When they are lit, the screen will tell you the fault, the code number for the fault, and the method to correct the fault. The enter key is used when a fault occurs. Generally, any fault that occurs will come up on the screen at the time it happens. In order to go back to the original status screen you have to push the enter key once. NOTE: This will hide the fault screen until you 1) correct the fault, or 2) you press enter again. The Amber Warning LED signals an ACTIVE FAULT code. When the light comes on, an abnormal condition exists. It is not necessary to shut down the engine immediately, but problem should be corrected as soon as possible. This light will remain on until all faults are corrected. Note: There may be more than one fault if <NEXT or MORE> appears at the bottom of the screen. You can also hide the faults by hitting the ENTER key. (Hitting the enter key again will take you back to the fault). NOTE: Ignoring active fault codes (warnings or shutdown) could result in severe engine damage. The Red Shutdown Derate LED signals a fault has occurred that requires immediate action. Shutdown the engine, but do not turn the switch to the off position. You must go through the codes on the screen and correct the problems prior to restarting the engine. (The Powerview remembers the errors). NOTE: Ignoring active fault codes (warnings or shutdown) could result in severe engine damage. Used to monitor engine and engine controls. MAY/2010 ( ) Section 2-9

30 PRE-OPERATION HIDING FAULTS AND WARNINGS If you have hidden (hit the ENTER key at any fault condition), and have returned to the original 4-Up (or 1-Up) screen, the screen will now show icons in the upper right hand corner of a 1-UP screen or in the middle of the 4-UP screen (see figure below) to show you where the faults occurred. (In the 4-up shown below, the exclamation point appears in the middle and at the status that is showing a fault the oil pressure.) Remember, the screen will show a <NEXT or MORE> if more than one error has occurred. Scroll through the screen until you find the individual component that has a fault. Highlight the component and press the ENTER key to read the fault. Each fault icon has a different meaning and different methods to correct. These are: NOTE: Faults can only be cleared when the fault has been corrected. encountered a Shutdown Fault. SHUTDOWN MACHINE as soon as possible when you have Section 2-10 MAY/2010 ( )

31 PRE-OPERATION FIGURE 6. ENGINE DIAGNOSTICS John Deere Diagnostic Trouble Codes MAY/2010 ( ) Section 2-11

32 PRE-OPERATION FIGURE 6. ENGINE DIAGNOSTICS (Continued) John Deere Diagnostic Trouble Codes Section 2-12 MAY/2010 ( )

33 PRE-OPERATION FIGURE 6. ENGINE DIAGNOSTICS (Continued) John Deere Diagnostic Trouble Codes MAY/2010 ( ) Section 2-13

34 PRE-OPERATION FIGURE 7. FEED CONTROL BOX TRAVEL LIGHTS INTERNATIONAL SYMBOL INSTRUMENT OR CONTROL Travel Lights FWD/REV FUNCTIONAL DESCRIPTION Select light for direction of travel, DOWN for reverse travel, UP for forward travel. This switch also enables the travel alarm, in which the alarm will sound whenever the machine is traveling in a direction OPPOSITE of the position of the switch. Travel Lights TRAVEL LIGHTS Turns work or travel lights ON or OFF. HORN Press to sound horn. Section 2-14 MAY/2010 ( )

35 PRE-OPERATION FIGURE 8. FEED CONTROL BOX TIMER CONTROLS (Inside Box) TIMER CONTROL FEED DURATION POTENTIOMETER DIP SWITCH LED FUNCTIONAL DESCRIPTION Will increase/decrease amount of time push signal is sent to feed cylinder. (Will not effect speed) Must not be reset. In the event that you experience problems with escapement duration, make certain that the switches are set to the configuration shown above. Timing is set for seconds. Shows status of timer. Slow Blinking: Supply ON, Relay OFF Fast Blinking: Supply ON, timing in progress, Relay OFF Continuous Light: Supply ON, Relay ON MAY/2010 ( ) Section 2-15

36 PRE-OPERATION FIGURE 9 MISC. OPERATOR STATION CONTROLS Control or Instrument Throttle Controls Pump Control Valve Brake Lock Valve Gage Indicator (Opt.) Function Engine speed is increased by pulling the throttle lever back toward the operator and decreased by pushing the lever away from the operator. Note: For normal operation the engine should be run with the throttle pulled all the way back. Push in the button to stop the pump during starting and warmup. Pull out the button to start the pump for work or travel. Close the valve when you need to release brakes using emergency hand pump. Shows the gage of the track. (56-1/8 is normal) Section 2-16 MAY/2010 ( )

37 PRE-OPERATION FIGURE 10 OPERATOR STATION CONTROLS Control or Instrument Coast Pedal (Left Pedal) Reverse Propel Pedal Forward Propel Pedal Function Brakes release when pressed. (Brakes automatically apply when pedal is released) NOTE: On/OFF Action Press this pedal to propel the machine in reverse. (Alarm will sound) Press this pedal to propel the machine forward. REMOTE CONTROLS AND INDICATORS Item Control or Instrument Function 1 Emergency Pump (Optional) Located on frame near the toolbox. Pump is used when there is a loss of system pressure and movement of hydraulic cylinders is necessary. System pressure is supplied by pumping hand lever or by switch on electric pump. (Lever and hose supplied in toolbox) 3 Battery Disconnect Switch Located front right corner of machine inside black steel box. Two position switch marked with "ON/OFF" plaque. This must be OFF and locked during service. 4 Winch Motor Control Valve Hand Lever The lever is mounted on the winch boom. Moving the valve hand forward or back raises or lowers the load. The center position holds/stops the winch. 5 Fuel Tank Level Gauge Located on top of fuel tank, this tube indicates the level of fuel in the tank. Engine can be damaged if fuel runs out. 6 Hydraulic Oil Tank Sight Level 7 Hydraulic Oil Temperature Gauge Located on hydraulic oil tank, it indicates the level of hydraulic oil in the tank. Part of the hydraulic oil sight level. Indicates temperature of the hydraulic oil. Normal operating temperature is 80 to 150 F (49 to 66 C). Preparing the Machine for Work MAY/2010 ( ) Section 2-17

38 PRE-OPERATION As with any machine, pre-operational checks and preventative maintenance should be performed before performing work operations. Nordco suggests that you follow the guidelines listed below before performing work. 1. Position the machine on level track so fluid levels can be accurately checked and filled if necessary. 2. See TOWING section if machine is to be towed to worksite. 3. Know and understand the use of all machine controls and instruments as described earlier in this manual. 4. Perform the pre-operational inspection of the entire machine as specified on the next page. Find defects and correct them before serious damage or failure results. 5. If necessary, follow any applicable instructions under MAINTENANCE FOR EXTREME CONDITIONS. 6. Perform applicable preventative-maintenance procedures in MAINTENANCE AND SERVICE section. 7. Be ready to operate the machine with an alert and safety-conscious attitude. 8. Understand the use of the machine's Lock-Ups/Lock-outs. See LOCK-UPS section. 9. Make sure the unit is setup for rail size being worked on. Adjustments, if required, are described in the MACHINE SETUP. 10. Wear proper safety clothing. 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. Section 2-18 MAY/2010 ( )

39 PRE-OPERATION FIGURE 11. PRE-OPERATIONAL CHECKLIST NORDCO recommends that the following checks be performed WITHOUT electrical power, due to a possible battery drain. MAIN CONTROLS STATUS Battery Disconnect Switch OFF Gages checked for broken glass. Emergency Stop pushbutton is pulled out. The following switches are in the OFF position: Pump On/Off Ignition Travel Lights Work Lights Engine throttle is set to low MACHINE FLUID LEVEL CHECK (See recommended fluids in Maintenance Section) Hydraulic Oil Tank is full Fuel Tank is full Engine Oil Reservoir is full MACHINE INSPECTION Inspect for Leaks. Pay particular attention to hydraulic and fuel lines. Inspect all controls, wiring and switches for secure mounting MACHINE LOCK-UPS AND GUARDS Make certain Mechanical Lock-Up devices are in place (for traveling) Propulsion Chain guard in place Toolbox closed and secured MAY/2010 ( ) Section 2-19

40 OPERATION Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or damage to the machine. LOCK-UPS There are areas designated on the machine as lock-up points. Lock-up points are those areas required to be locked up prior to working travel through crossings, switches or other rail obstructions or during high speed travel (non-working travel), as well as during maintenance and service of this machine UNLESS lockup of the assembly prevents access to area being maintained. These have been painted red and have a decal located next to or on the area requiring locking up. All lockups, with the exception of the boom and winch, should be unlocked prior to performing work operations. The boom and winch should only be unlocked when required and then immediately relocked upon completion of lifting work. Use the procedures on the following pages to install or remove lock-ups: Section 2-20 MAY/2010 ( )

41 OPERATION WORKHEADS There is one lock-up device per gun assembly, two per workhead. They must be unlocked prior to performing service to the workhead or during work operations. Use the following procedure to lock or unlock the assemblies. LOCATION LOCKUP PROCEDURE WHEN USED 1. Using the Drive Gun valve During working travel through handles (2 & 3 in Figure crossings, at switches, frogs, below) at each workstation, and other rail obstructions, pull the handle back toward during high speed (nonworking) travel. you. This will raise workheads to allow the insertion of the lock pins. Primary Lockup Non-removable pin located on each workhead. 2. Locate the lock-up devices. The lock-ups are located on the upper outside carriage frames for each workhead. 3. Verify that the assembly is fully raised. Push lock pin through assembly. (You will not be able to lock in place if assembly has not been fully raised.) 4. If the lock-up pin handle is in the inner slot, the assembly is locked in place. If the pin handle is in the outer slot, the assembly has been unlocked. Secondary Lockup 5. Insert secondary lockup pin into hole on top of hammer mounting bracket. MAY/2010 ( ) Section 2-21

42 OPERATION GUIDE ROLLER ASSEMBLY There is one lock-up device per guide roller assembly, two per machine. Both must be unlocked prior to performing service to the guide roller or during work operations. Use the following procedure to lock or unlock the assemblies. LOCATION LOCKUP PROCEDURE WHEN USED 1. Using the Guide Roller Valve Handle (5 in Figure below), pull the handle toward you. This will raise guide roller assemblies to allow the insertion of the lock pins. 2. Locate the lock pins. They should be stored on the frame between the workhead and the gager housing. During working travel through crossings, at switches, frogs, and other rail obstructions, during high speed (nonworking) travel. Both must be locked during maintenance and service on this machine. Removable pin located on each guide roller assembly. Note: This hole is only accessible once the Guide roller assembly is raised. 3. Verify that the assembly is fully raised. (You will not be able to access hole if assembly has not been fully raised.) 4. Insert pin in hole on guide roller shaft. Section 2-22 MAY/2010 ( )

43 OPERATION TURNTABLE There are two lock-up devices on the turntable assembly. These must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies. At set-off valve at left Operator station. Left Operator, extreme left valve on left valve bank. (Padlock) LOCATION LOCKUP PROCEDURE WHEN USED 1. Make certain turntable is completely raised by pulling down on the turntable valve handle (1 in figure below). At any time when turntable is NOT being used. Rear of machine below tow-hitch point (push-pull handle) 1. Pull out to release mechanical turntable lock. Push back in to re-engage ONLY AFTER TURNTABLE IS RETRACTED! 2. Insert lock at valve handle. At any time when turntable is NOT being used. MAY/2010 ( ) Section 2-23

44 OPERATION BOOM AND WINCH LOCATION LOCKUP PROCEDURE WHEN USED 1. Swing boom in toward operators until it can t go any further. 2. Rotate lock handle 3. Secure cable to boom. At all times when boom and winch are not being used and during working travel through crossings, at switches, frogs, and other rail obstructions, during high speed (nonworking) travel. Section 2-24 MAY/2010 ( )

45 OPERATION NIPPERS LOCATION LOCKUP PROCEDURE WHEN USED 1. Using the control valve (1 on During working travel through drawing below), raise the crossings, at switches, frogs, assembly (travel position) to and other rail obstructions, allow the insertion of the lock during high speed (nonworking) pin. travel. 2. When handle is in outer slot, nipper is unlocked. When handle is in inner slot, nipper is locked. Non-removable lock-up pin located on the nipper assembly behind the feed control box. MAY/2010 ( ) Section 2-25

46 OPERATION GAGER LOCATION LOCKUP PROCEDURE WHEN USED During working travel through crossings, at switches, frogs, and other rail obstructions, during high Left side of machine speed (non-working) travel. The red pin on the left side of the machine is for road travel only (During transport on highways). It should be removed before operation and is not required for normal rail travel. Section 2-26 MAY/2010 ( )

47 OPERATION TRAVEL It is important that you read about and understand all operating controls, Cautions, Warnings, and Dangers before traveling. Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or damage to the machine. ENGINE SPEEDS Engine speed is controlled by the throttle lever located in front of the right operator. Engine speed should be set to maximum (pulled completely forward) when working or traveling. PROPELLING AND BRAKING Propelling at Work Speeds 1. Lock-ups should be unlocked. Refer to Lock-ups section 2. Press the appropriate foot pedal to propel the machine. Braking A deadman (or coast pedal) brake pedal has been provided on this machine. This pedal must be pressed to release the brakes. TRAVELING ON A INCLINE Before traveling down an incline, test the brakes to make sure that they are fully functional. MAY/2010 ( ) Section 2-27

48 OPERATION Machine Setup There are some adjustments which may have to be made due to varying conditions such as rail height and base width. Adjustments must be made to compensate for these conditions before operations can begin. Serious injury or death can result from reaching into driving components while machine is running! Make observations from a safe distance. Always turn off machine when performing maintenance, making adjustments, or whenever unintended movement of machine could occur; unless directed otherwise. Failure to comply could result in personal injury and/or damage to the machine. Read and understand all OPERATION procedures, warnings, and cautions before making adjustments. JAW DEPTH/RAIL HEIGHT ADJUSTMENT Haipin Clips are to be inserted in guide-rods at different positions for various rail heights. Use the following table for selecting the correct clip location: Rail Height Clip Position (From top) 7"-8" 1 6-5/8" 2 6" 3 5-1/2" - 5-5/8" 4 5-3/16" 5 WORKHEAD UP ADJUSTMENT The UP position is the point where the workhead assembly returns to at the end of each cycle. This switch does not require adjustment and is mentioned here only for reference. WORKHEAD DOWN ADJUSTMENT Rail height affects the adjustment of the down position. 1. Make certain the workhead lockups are unlocked. 2. Make certain the guide rods on the jaw mounting have been set for the correct rail height. 3. Using the fwd/back control valves on the right valve bank, move the carriage so that it is centered with one workhead on each side of the rail. 4. Using the left/right control valves on the right valve bank, position the inner workhead so that it is roughly aligned with the hole in the tie plate. 5. At the remote operator control box, place the selector switch to the MANUAL position. Press the button for the particular workhead (left or right) to release spike into jaws. 6. Using the DRIVE control valve on the left valve bank, lower the workhead until the sleeve opens the jaws and the spike falls out. Release control valve. *Note: The flat side of ALL clips MUST face the hammer. (See photo upper right) Section 2-28 MAY/2010 ( )

49 OPERATION 7. Loosen DOWN prox switch mounting nut and adjust mounting position until sensor on prox is triggered by the target bar and the signal led on switch lights up. Tighten switch mounting nut at that position. Note: Periodic adjustment of this switch may be required as oil temperature increases. Gaging Speed Adjustments (Optional Gager) There is a limit switch on the gager indicator assembly that controls slow speed Gage Out. The faster the slow speed, the shorter amount of time the operator has to read the gage at the pointer assembly in the operator station. Looking at the mounting bracket from the operator end of the machine, left holes speed up the gaging out process, right holes slow it down. MAY/2010 ( ) Section 2-29

50 OPERATION ROLLER GAGER BUGGY 1. Locate the machine on level straight track. 2. Turn off machine. 3. Before lowering the gager buggy, measure distance between the rail balls as shown in Figure11 at a point closest to the gager buggy. 4. Lower Roller Buggy to track with enough slack in cable to allow the weight of the buggy to rest on rail. 5. Make certain that the buggy guide roller on the left frame is on the inside of the rail. 6. Push on end of right frame until buggy guide roller snaps onto the inside of rail. 7. Locate locknut and adjustment screw as shown in Figure 10. Loosen nut. Note: Left Frame side is shown, right frame side is opposite. 8. Turn adjustment screw until guide roller is lowered to a position 5/8" down from the top of the rail, or as shown in Figure Adjust Gage Pointer at Operator station using instructions on the next page. Section 2-30 MAY/2010 ( )

51 Gager Pointer Adjustments (Optional Gager) It is recommended that the accuracy of the gager pointer be checked, and calibrated as necessary, on a daily basis: 1. Make certain that the gager roller assembly is pinned in the Operating Position, with the indicator roller on the ball of the rail. 2. With a tape measure, measure the distance between the rails. 3. Verify that the distance measured is the distance indicated on the gager pointer. If the distance matches, you are set to go. 4. If it does not match, loosen the adjustment screw and stop (located in the faceplate opening on the gager pointer). Set the pointer to the correct distance and tighten the adjustment screw. OPERATION MAY/2010 ( ) Section 2-31

52 OPERATION MACHINE OPERATION To avoid serious injury or death, make certain that the area around and under the machine is clear of all personnel and obstructions before travelling or working. Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or damage to the machine. Work Operation Machines without Nipper and Gager: 1. Make certain all STARTUP procedures have been followed, and all adjustments made, before beginning working operations. 2. Make certain all workhead lockups have been removed. 7. Drive spikes. Spike driving is controlled using the valve levers on the LH valve stack for each operator. Push appropriate levers forward to drive spikes, pull levers back to raise hammer. Work Operation Machines with Gager, without Nipper: 1. Make certain all STARTUP procedures have been followed, and all adjustments made, before beginning working operations. 2. Make certain all workhead and gager lockups have been removed. 3. Reinsert gager arm lockpins (A and B) to their original position. Pin up gager indicator roller assembly to the Operating position. 4. Make certain all spike trays have been filled. 5. Run the machine over the tie plate to be spiked. Move Guide Roller Valve handle to the full forward position to lower guide rollers to the rail. 3. Make certain all spike trays are filled. 4. Run the machine over the tie plate to be spiked. Move Guide Roller Valve handle to the full forward position to lower guide rollers to the rail. 5. Position machine so inner workhead is aligned with hole in tie plate. To verify position, put feed to manual, feed a spike and slowly push the Gun 1 or Gun 3 valve handle forward until spike tip is roughly ½ above the tie plate. Release handle. 6. Using the applicable valve lever on the right hand valve bank, adjust the workhead until spike is directly above hole in tie plate. 6. Verify the gage of the rail as indicated on the Gager Pointer assembly at the Operator Station. To adjust you must: Section 2-32 MAY/2010 ( )

53 a. Push rail all the way in (push gager valve handle forward) until cylinder bottoms out. behind the control box in front of OPERATION b. Bring rail out to correct gage (move gager valve handle to the right). c. Position machine so inner workhead is aligned with hole in tie plate. To verify position, put feed to manual, feed a spike and slowly push the Gun 1 or Gun 3 valve handle forward until spike tip is roughly ½ above the tie plate. Release handle. d. Using the applicable valve lever on the right hand valve bank, adjust until spike is directly above hole in tie plate. e. Make certain all spike trays have been filled. f. Drive spikes. Spike driving is controlled using the valve levers on the LH valve stack for each operator. Push appropriate levers forward to drive spikes, pull levers back to raise hammer. g. Retract gager cylinders by moving the gager valve hand to the full back and left position. This will provide full system pressure for the next gage adjustment. 7. Propel to next position. Work Operation Machines with Gager and Nipper: 1. Make certain all STARTUP procedures have been followed, and all adjustments made, before beginning working operations. 2. Make certain all workhead, gager and nipper lockups have been removed. (Nipper lockup is located the operator.) 3. Reinsert gager arm lockpins (A and B) to their original position. Pin up gager indicator roller assembly to the Operating position. 4. Make certain all spike trays have been filled. 5. Run the machine over the tie plate to be spiked. Move Guide Roller Valve handle to the full forward position to lower guide rollers to the rail. 6. Position machine so inner workhead is aligned with hole in tie plate. To verify position, put feed to manual, feed a spike and slowly push the Gun 1 or Gun 3 valve handle forward until spike tip is roughly ½ above the tie plate. Release handle. 7. Using the applicable valve lever on the right hand valve bank, adjust until spike is directly above hole in tie plate. 8. Push rail all the way in (push gager valve handle forward) until cylinder bottoms out. Verify the gage of the rail on the Gager Pointer assembly at the Operator Station 9. Bring rail out to correct gage (move gager valve handle to the right). 10. Move the Nipper Valve handle to the forward and right position. This will lower the nipper assembly and Section 2-33 MAY/2010 ( )