Ride-On Adzer Model B Operation and Maintenance Manual Applies to S/N 250171 and Above Reorder Part: 49455042 Last Revision: Rev. A MAY 2005 Read and fully understand the precautions contained in this manual before operating or servicing this machine. Refer to Section 1 for important safety information. Component Troubleshooting can now be found on the blue pages behind each tab.
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) 766-2180 sales@nordco.com Milwaukee, Wisconsin 1-800-647-1724 parts@nordco.com Oshawa, Ontario, Canada (905) 579-4058, Ext. 224 oshsales@nordco.com NORDCO Service: 1-800-445-9258 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
HAZARDOUS MATERIAL DATA In an effort to provide information necessary for your employee safety training program and to meet the requirements of OSHA Hazard Communication Standard 1910.1200, we have OSHA Form 20 Safety Data Sheets available that cover the material contained in this machine. If you are interested in receiving this information, please refer to the Name, model, and Serial Number of your machine when calling or writing, and direct your inquiries to: Vice-President of Operations NORDCO Inc. 245 W. Forest Hill Avenue Oak Creek, WI 53154 Fax: (414) 766-2299 Phone: (414) 766-2288
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. 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. SAFETY ALERT SYMBOLS! These are the safety-alert symbols. These symbols means pay attention! Your safety is at risk! SYMBOL MEANING DANGER typically defines the most serious hazards. DANGER usually means that improper use could result in severe bodily harm or even death. WARNING means that improper use could result in bodily harm and/or extensive machine damage. CAUTION means that improper use could result in machine damage. 2/99 (4945-5042) Section 01-1
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. General guidelines include: 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, face and eyes from flying debris by wearing a hard hat, safety face shield 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 DURING WORK AND TRAVEL 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. Make certain that no one is in the path of this machine and that all personnel have left the area before operating this machine. Anyone standing near the machine is at risk of being injured. Make certain they keep away from the workhead and any other moving assembly during working operations. 2. Slow down the work cycle and use slower travel speeds in congested or populated areas. Use a commonly understood signal so that others can warn the operator to slow or halt work in a possible hazardous situation. 3. Halt work if visibility is poor. Strong rains, fog, and extremely dusty and blowing conditions can obscure visibility in your work area. Wait for weather to improve before continuing work. 4. There are standard guards in place on this machine. These are to be removed only when service or maintenance is being performed in that area. Reinstall guards after work has been completed. 5. Check and service the fire extinguisher (if so provided) at regular intervals. Make certain all personnel are trained in its use. 6. There are lockups on this machine that are used for during work and/or travel. These should be kept clear and free of debris, grease, etc. See Lockup section for instructions on their use. 7. Inspect safety decals and replace when they become unreadable or are damaged. (See Safety Decals at the end of Section 01). SAFETY DURING MAINTENANCE Alert others in the area that service or maintenance is being performed on this machine. 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. 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. 2/99 (4945-5042) Section 01-2
SAFETY MACHINE SAFETY ALERTS DANGER ALERTS WORDING Improper use of this machine for any type of operation can cause serious injury or death. FOUND ON PAGE 14 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. 30, 33, 37 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. 31 Removing or modifying the seat extension bracket can result in serious bodily injury or death. This bracket prevents cutter head from being raised while someone is in the operator seat. 14, 33 2/99 (4945-5042) Section 01-4
SAFETY MACHINE SAFETY ALERTS WARNING ALERTS WORDING Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or extensive damage to the machine. 28, 30 FOUND ON PAGE Tighten fittings only when system is not pressurized. High pressure leaks can cause personal injury. 44, 63 If guide rollers are not adjusted correctly, the machine could derail, which may result in personal injury or property damage. The operator must be seated in the operator s seat before engaging clutch, and must remain seated when the clutch is disengaged and until the cutter head stops spinning. Failure to comply may result in personal injury or property damage. Before engaging the clutch, make certain that all foreign material is swept from the ties, broken spikes are driven into the tie below the level of the cut to be made, and that the ballast is cribbed. Failure to comply may result in personal injury or property damage. 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. 31, 37, 57, 67 Exhaust emissions caused by the use of the engine on this machine may cause cancer, birth defects, or other reproductive harm if inhaled. 26, 58 Disconnect the battery before servicing this machine. Failure to do so could result in personal injury from accidental engine startup. 37, 58, 59 2/99 (4945-5042) Section 01-5
SAFETY MACHINE SAFETY ALERTS CAUTION ALERTS WORDING Before starting a new or overhauled engine that has been in storage, consult the engine manufacturer s manual for initial start instructions. Failure to follow those instructions can result in serious engine damage. FOUND ON PAGE 26, 58 Do not adjust clutch while engine is in operation. Do not adjust clutch above maximum torque. This may cause clutch component failure. Never shut off battery disconnect switch with the engine running. This could cause damage to the voltage regulator, alternator, and/or electrical system. 58, 59 2/99 (4945-5042) Section 01-6
SAFETY LOCKOUT AND/OR TAGOUT PROCEDURES (2/99) It is your company s responsibility to develop Lockout/Tagout Procedures, 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. ENERGY SOURCES (2/99) The list on the following pages provides information on energy sources located on this machine and instructions for inserting manual lockups, if applicable. It is your company s responsibility to incorporate these instructions into their Lockout/Tagout Procedures. 2/99 (4945-5042) Section 01-7
SAFETY LOCKOUT/TAGOUT ENERGY SOURCES (2/99) MACHINES WITH MANUAL LOCKUPS When servicing or performing maintenance on: Electrical System (All Electrical Components) Energy Source to be locked out: Electrical Use this procedure: 1) Turn the ignition switch to the OFF position (logic box). If working on the logic box, continue on to step 2, otherwise close and lock the logic box cover. 2) Turn the battery disconnect switch to the OFF position and close and lock the disconnect switch box. This will cut off electrical power supply to the machine. Engine Electrical 1) Turn the ignition switch to the OFF position (logic box). Close and lock the logic box cover. 2) Turn the battery disconnect switch to the OFF position and close and lock the disconnect switch box. This will cut off electrical power supply to the machine and prevent accidental startup of engine while servicing. Propulsion System Adzer Workhead Crawlers (Two per machine) Hydraulic Hydraulic Gravity Hydraulic Gravity 1) Turn the ignition switch to the OFF position (logic box). Close and lock the logic box cover. 2) Turn the battery disconnect switch to the OFF position and close and lock the disconnect switch box. This will cut off hydraulic pressure to hydraulic components of the machine. 1) Disengage clutch by releasing the cutter head control lever at the operator station. 2) Turn the ignition switch to the OFF position and close and lock the logic box cover. 3) Turn the battery disconnect switch to the OFF position and close and lock the disconnect switch box. 4) Wait until cutter head has stopped spinning and then pull back on cutter head control lever until lockpin can be inserted into lockup bracket. (Look for Lockup Point sticker) Note: Lockup pin is fully inserted once the pin has gone through the lockup bracket and into the cutter head control lever. 5) Release the cutter head control lever. This will cut off the electrical power supply and all hydraulic pressure. In addition this will prevent drifting down of the workhead. 1) Turn the ignition switch to the OFF position and close and lock the logic box cover. 2) Turn the battery disconnect switch to the OFF position and close and lock the disconnect switch box. 3) Locate and insert the lock lockup pins. The pins are chainedto the inside of the frame next to the derail bars. 4) Insert lockup pin into hole in crawler frame. (Look for Lockup Point sticker on housing) This will cut off hydraulic supply and will prevent crawler frame movement. Cyclone Boom Motion 1) Move boom to desired location. 2) Insert lockup pin into hole on boom. (Look for Lockup Point 2/99 (4945-5042) Section 01-8
SAFETY When servicing or performing maintenance on: Energy Source to be locked out: Use this procedure: sticker on boom.) This will prevent unintended movement of boom when performing service on the cyclone or boom. 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 5642 0001 General Machine Cautions Inside Logic Box Cover 5642 0002 Caution! Watch Your Step Frame, by Step 5642 0004 Danger! Pinch Points 5642 0005 Warning! Hand Hazard 5642 0006 Danger! Before Servicing... Logic Box Sides 5642 0007 5642 0010 Lockout Area Logic Box Face 5642 0011 Lockout Area Battery Box 5642 0012 Lockup Points All areas requiring Lockups for travel Or maintenance 2/99 (4945-5042) Section 01-9
GENERAL GENERAL This manual contains operation and maintenance information for the Ride On Adzer Model B manufactured by NORDCO INC., Milwaukee, 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: Operation includes all information necessary to operate the machine; Maintenance includes lubrication, maintenance, and adjustments instructions; Troubleshooting includes basic troubleshooting for all components on the machine; Appendix A includes suggested and recommended spare parts for the machine; Appendix B includes instructions for hydraulic adjustments; Mechanical has individual parts breakdown drawings and lists for each assembly (for optional equipment that requires additional drawings, see tab Customer Options); Hydraulic includes all piping and functional drawings for a standard machine (for optional equipment that requires additional drawings, see tab Customer Options); Electrical, includes all electrical schematics, logic box, control box, and cable drawings for the machine; Component Data includes parts breakdowns and service instructions for components installed on the machine that are not of NORDCO s manufacture; Customer Options, includes parts breakdowns, lists, and drawings for all equipment on the machine that is optional. OPTIONAL EQUIPMENT Optional equipment are those items that are not considered a vital operating part to the machine, but the customer wants them installed. A list of optional equipment installed on your machine can be found on the first page of the Customer Options tab. Minor options such as lights and horns can be found in the mechanical section of this manual, and major options such as Parts Sheets and instructions for the Optional Equipment have been included behind the tab Customer Options. It is recommended that you know what options you have on your machine. 5/2005 (4945-5042) Rev. A Section 02-1
GENERAL SPECIFICATIONS GENERAL Model... Model B Gross Weight*... 5700 lbs Length with Blower in Travel Position... 171 inches Length with Blower in Work Position... 152 inches Width with Blower in Travel Position... 127 inches Width with Blower in Work Position... 157 inches Height Hatz Engine... 97 inches Deutz Engine... 102 inches Wheel Base... 61.5 inches CAPACITIES Fuel Tank (Painted Green)... 36.8 gallons Hydraulic Oil Tank (Painted Blue)... 36 gallons Plate Storage... 35 plates on deck ENGINE Make/Model...Deutz F4L1011 Type... 4 Cylinder, Air Cooled Diesel Continuous BHP...48 HP @ 2300 RPM, Under Load HYDRAULIC SYSTEM Pump Make/Model... John Deere HPR 40 Type...Radial Piston Pump Rating...21.5 gpm @ 2000 rpm Relief Valve Setting (High System Pressure)...3000 psi System Pressure...2400 psi Pump Make/Model... Parker PAVC65 Type... Piston Pump Rating...23 gpm @ 2050 rpm Relief Valve Setting (High System Pressure)...3000 psi System Pressure...2400 psi ELECTRICAL SYSTEM Battery... 12 Vdc, 1150 Cold Cranking Amps Ground... Negative Alternator... 50 Amp DRIVE/WHEEL SYSTEM Drive Type...Hydraulically Driven Dual Crawlers/Chain Propulsion Motor Type... Hydraulic Wheel Type... Pressed Steel Flanged and Crawler Driven Wheel Size...14 inch diameter 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. 5/2005 (4945-5042) Rev. A Section 02-2
PRE-OPERATION Before operating this machine, read and understand the Safety Section of this Manual. BEFORE OPERATION It is always good practice to become totally familiar with the machines you are going to operate. IMPROPER USE OF THIS MACHINE FOR ANY TYPE OF OPERATION CAN CAUSE SERIOUS INJURY OR DEATH. Getting Familiar with Machine It is always good practice to become totally familiar with the machines you are going to operate. Only the operator should be on the machine during any operation. The Operator must be in his/her seat utilizing machine controls only as directed. Read and understand all operating instructions and observe all safety alerts before performing any machine operations. The primary purpose of the machine is to adze wood ties for proper placement of the various tie plate sizes. The operator should be in a seated position prior to operating the machine. A clutch hand lever engages the clutch causing the adzer head to spin and the operator raises or lowers the cutter head by use of a hand lever directly in front of him or her. The following paragraphs will take you on a visual tour of the machine. Our intention is to point out major components that will be addressed later in this manual. Operator s Station The operator station consists of the seat, control box, propulsion speed valve, the cutter head hand lever, the clutch lever, and the footswitches. Although there are a few controls remotely located on the machine these are the primary controls of the machine. The handle in front of the operator controls the up/down movement of the cutter head. The clutch lever located to the front right of the operator allows the operator to engage or disengage the clutch that turns the cutter head. The footswitches control the movement of the machine, forward or back (left or right). Propulsion speed of the machine is set by using the flow control valve located under the main control box. Storage of seat when not in use is in hole next to footswitches on frame. Always use your seat belt when sitting in the operator seat. 2/99 (4945-5042) Section 03-1
PRE-OPERATION Pivot Frame The pivot frame allows the up/down movement of the cutter head as well as the level and cant of the cutter head. This is done by adjusting the position of the two pivot frame screws (in relation to each other). The pivot frame houses the cutter unit, drive belt, engine, clutch and main pump. The engine acts as a counter-balance for the pivot frame. Crawler The machine can propel on gauged track and crossings without being lifted. The crawler ramp allows the crawler chain tread to transfer between ties and track. Each crawler is propelled by the use of a hydraulic drive assembly. Cutter Housing (Workhead) The cutter head and guard are available in various sizes depending on the area of tie to be adzed. The narrow guard, rubber flaps and welded chain prevent wood chips or other debris from flying out while adzing the tie. Guidewheels These are designed to be placed on the rail when you are working, to prevent the machine from leaving the rail. They are not designed to raise or lower the machine. Proper use is to lower the guidewheel assembly until it comes into contact with the rail. If guide rollers are not adjusted correctly, the machine could derail, which may result in personal injury or property damage. Debris Collector The high speed rotation of the adzer cutting head creates a lot of dust and flying wood particles during operation. Acting much like a vacuum cleaner, the debris collector removes this unwanted material and deposits it outside the track area. The debris collector consists of three main components: 1) a special cutter guard housing, 2) a blower that moves the debris from the cutter guard housing into the cyclone separator, and 3) the separator which deposits (by gravity) the debris alongside the track. Logic Box Control Panel The logic box control panel houses nearly all of the operator selectable items on the machine. The logic box drawing on the next page is representative of a standard machine. Become familiar with its functions before operating this machine! 2/99 (4945-5042) Section 03-2
PRE-OPERATION NOTE: Early machines in the Ride-On-Adzer Model B category did not have International Symbols on the Control Box Plaques. However, layout is still the same. 2/99 (4945-5042) Section 03-3
PRE-OPERATION MAIN CONTROL PANEL ENGINE AND PUMP CONTROLS AND GAUGES (Includes Horns and Lights) CONTROL OR INSTRUMENT Key Switch INTERNATIONAL SYMBOL FUNCTION The electrical system is energized by turning the key to the right. Electrical power is cut off and the engine will stop when the key is turned to the full left or vertical (OFF) position. Engine OIL PRESSURE Gauge Engine OIL TEMPERATURE Gauge Indicates oil pressure, not oil level. Normal reading is 60-80 psi. Indicates engine oil temperature measurement. Normal operating temperature is between 170 and 280 degrees F (76 and 110 degrees Celcius) MAGNETIC OVERRIDE Switch This switch must be held in until engine starts and engine oil pressure reaches 25 psi. Engine TACHOMETER and HOURMETER Indicates engine speed (rpms) and total hours of engine operation. Normal engine operating speed should be approximately 2800 rpm. Engine CIRCUIT BREAKER VOLTMETER Must be depressed to reset engine circuit breaker (10-15 amp) if it trips Indicates voltage of battery charge. Normal reading is 12-15 volts. WORKING LIGHTS Switch Two position switch to turn working lights on or off. 2/99 (4945-5042) Section 03-4
PRE-OPERATION CONTROL OR INSTRUMENT HORN Pushbutton INTERNATIONAL SYMBOL FUNCTION Depress switch to sound horn. TRAVEL LIGHTS Switch Three position switch. Center position is off. Select direction of travel. Up for left, down for right. (NOTE: On some machines travel lights have been wired so that when switch is turned on both travel lights illuminate. ENGINE SPEED Switch HIGH Speed LOW Speed Used during work, travel, and shutdown. Used during normal work and travel operations. Used for idling engine for extended periods of time, or for idling engine for machine shutdown. Auto Shutdown Switch and Light Circuit Breaker #1 (CB1) Turning on switch will disable Engine Protection System which shuts engine down in the event of high temperature or low oil pressure. The light will also illuminate indicating override is enabled. This should only be used in extreme cases of emergency, as catastrophic damage to engine may result. Protects the Magnetic Override Switch (MO), Timer Module, Engine High Speed Solenoid, and Oil Cooler. (NOTE: On machines with only 2 circuit breakers, CB1 controls the Engine Run Solenoid as well). Circuit Breaker #2 (CB2) Protects the Blower, Propulsion, and Engine gauges. Circuit Breaker #3 (CB3)(For Options) Protects the travel lights, work lights, and filter lights. Circuit Breaker #4 (CB4)(For Options) Protects the Engine run solenoid Engine Preheat Light (Optional) For cold weather start kit. Circuit breaker for this option is located on the engine. Light is illuminated when engine has warmed up. 2/99 (4945-5042) Section 03-5
PRE-OPERATION MAIN CONTROL PANEL MACHINE FUNCTION CONTROLS AND GAUGES CONTROL OR INSTRUMENT BLOWER SWITCH INTERNATIONAL SYMBOL FUNCTION Two position switch. Turns blower motor on or off. 2/99 (4945-5042) Section 03-6
PRE-OPERATION OPERATOR STATION CONTROLS AND INDICATORS CONTROL OR INSTRUMENT ITEM # FUNCTION Vacuum Gage 1 Indicates the amount suction occuring in the suction hose between the adzer cutting head and the blower housing. Normal operation would see the indicating needle move up and down. If the needle continues to rise (with no fluctuation) the suction hose is becoming clogged. Reverse Propel 2 Press this footswitch to propel the machine Footswitch Forward Propel 2 Press this footswitch to propel the machine Footswitch Clutch Lever 3 Located in front of the operator and to the right of the spindle guard. Controls movement of the cutter head drive belt. Push the lever completely to engage the clutch, pull the lever completely to disengage the clutch. Cutter Head Lever 4 Located directly in front of the operator. Mechanically controls the up/down motion of the cutter head. Push the lever to lower the cutter head, pull the lever to raise the cutter head. Propulsion Speed Flow Control Valve 5 Located directly beneath the control box, this valve is used to adjust the propulsion speed of the crawlers. 2/99 (4945-5042) Section 03-7
PRE-OPERATION REMOTE CONTROLS AND INDICATORS CONTROL OR INSTRUMENT ITEM # FUNCTION Hand Pump (Optional) 1 Located on frame near the engine. 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. Hydraulic Oil Tank Sight Level 2 Located on hydraulic oil tank, it indicates the level of hydraulic oil in the tank Hydraulic Oil Temperature Gauge 2 Located on the bottom of the hydraulic oil sight level. Indicates temperature of the hydraulic oil (from 0 to 300 F/-18 to 149 C). Normal operating temperature is 120 to 150 F (49 to 66 C). Battery Disconnect Switch 3 Located inside of battery box. Two position switch marked with "ON/OFF" plaque. Guide Wheels 4 There are two guide rollers, located near each running wheel. It is not to be used as a method for raising the machine off rail. Filter Indicator Box (Optional) 5 Used to give visual status of optional pressure filter. Green light indicates filter is ok, red light indicates service required. (NOTE: Some units may be equipped with filter indicator boxes for both the pressure filter and the return filter.) 2/99 (4945-5042) Section 03-8
PRE-OPERATION PREPARING FOR OPERATION 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 specified on the next page. Find defects and correct them before serious damage or failure results. 4. If necessary, follow any applicable instructions under MAINTENANCE FOR EXTREME CONDITIONS. 5. Know and understand the use of all machine controls and instruments as described earlier in this Section. 6. Perform applicable preventative-maintenance procedures in MAINTENANCE AND SERVICE section. 7. Be ready to operate the machine with an alert and safety-conscious attitude. 8. Understand the use of the machine's Lock-Ups. See LOCK-UPS section. 9. Make sure the unit is setup for rail size being worked on. Adjustments, if required, are described in Section 04 - MACHINE SETUP. 10. Wear proper safety clothing. 2/99 (4945-5042) Section 03-8
PRE-OPERATION PREOPERATIONAL CHECKLIST Nordco recommends that the following checks be performed WITHOUT electrical power, due to a possible battery drain. Control Box Cover Unlocked and Hooked in Position Control Box Switches and Gauges: ITEM SHOULD BE Circuit Breakers All Gauges Emergency Stop Pushbutton Work Lights Switch (Optional) Travel Lights Switch (Optional) Blower Switch (Optional) Ignition Switch Engine Speed Switch Auto-Shutdown Switch (Optional) Pushed In Glass not broken Pulled Out OFF (down) OFF (centered) OFF (down) OFF Position LOW (down) OFF (down) Hydraulic Tank Full (See Recommended Lubricants) Fuel Tank Full (Use only Diesel Fuel) Engine Oil Full (See Recommended Lubricants in Maintenance Section) Inspect for Leaks. Pay particular attention to hydraulic and fuel lines. Inspect all controls, wiring and switches for secure mounting Make certain Mechanical Lock-Up devices are in place (for traveling) Battery Disconnect Switch OFF (Switch located in box) 2/99 (4945-5042) Section 03-9
PRE-OPERATION LOCK-UPS Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or extensive damage to the machine. Certain machine components have lock-up features for use during high-speed (non-working) travel or for machine storage. These have been painted red and have a decal located next to or near the area requiring locking up. The numbers before the lock-up area are the numbers shown on the drawing on the opposite page. Become familiar with all lock-ups on this machine. DESCRIPTION ITEM # WHEN USED Crawlers 1 The crawler lock-ups are used when lifting the machine off of or on to the track to prevent the crawler from resting on the pivot pin in the center Cutter Head (Workhead) of the crawler, limiting rocking movement of the crawler. 2 The cutter head is to be locked up only after the clutch has been disengaged (cutting head has stopped spinning). Pull back cutter head lever until lockpin can be inserted into the hole in the frame tube. Derail Bars 3 The lock-ups on the derail bars are for storage purposes when the derail bars are not used. Cyclone Boom 4 The cyclone boom has a 3-position lock-up. Two positions are for working, one is for travel and storage. When in travel position, the 5" flexible hose must be removed from the cyclone, the boom released and swung into a position parallel to the blower housing, the lockpin turned until the boom does not move, and the flexible hose inserted in the opening on the boom mast. This will prevent machine from riding over tube. Guide Wheels 5 After work has been completed raise guide wheels off of rail. Releasing the crank handle will lock the jackstand portion in position. 2/99 (4945-5042) Section 03-10
SET-UP MACHINE SETUP When the machine has reached the work site, certain adjustments and preparatory steps may be required. Adjustments can change the machine's operating limitations to compensate for various track or adzing area. Make certain that you have LOCKED OUT the machine before performing adjustments or maintenance. 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. GAUGE CUT ADJUSTMENT Check the distance from the inner face of the rail head to the cut to be sure the gauge is correct. If it is not, the wheel locations and the guide roller/jackstands have to be adjusted as described below. The running wheels may be loosened by means of the locking screws and tapered bushing in the running wheels. See Figure 3 and proceed as follows: 1. Loosen, but do not remove three locking screws on each wheel. 2. Using the guide roller/jackstands (both sides), lift unit just enough to remove weight from wheels and reposition wheels as required to obtain gauge. 3. Lower Unit and tighten locking screws on both wheels. 4. Once wheels have been secured in place, the guide wheels have to be re-adjusted so that the guide wheels straddle the rail. It is important that this be accomplished, otherwise the machine could derail. 5. Loosen screws on the guide wheel mounting plates and slide the assembly into the correct location. If more adjustment is necessary, the assemblies may be removed from the frame and inserted into the second set of holes. 2/99 (4945-5042) Section 04-1
SET-UP GUIDE ROLLER ADJUSTMENT The guide rollers must be raised over crossings, through switches or wherever there is a change in rail height, to avoid damage to the assembly. Using crank handle on the jackstand, lower or raise the guide rollers as necessary. If guide rollers are not adjusted correctly, the machine could derail, which may result in personal injury or property damage. CUTTER HEAD CHANGEOUT If a different size cutter head is to be used or the existing head must be replaced, proceed with the following procedure: 1. Remove the pin connecting the clutch rod to the clutch handle and the pin connecting the clutch control lever rod to the clutch arm. 2. Slide the clutch control lever through the bracket on the belt guard toward the engine so that you can access the hinged cover of the belt guard. 3. Flip the hinged belt guard cover back and out of the way. 4. Use a wrench and remove the spindle nut. Carefully lower the spindle bolt and cutter head. Removing or modifying the seat extension bracket can result in serious bodily injury or death. This bracket prevents cutter head from being raised while someone is in the operator seat. 4. Lift and remove the operator seat from the frame tube. Move the Cutter Head Up/Down hand levers to remove weight on the ball lock pin. The pin secures the Cutter Head Up/Down hand levers to the frame bracket. Depress the pushbutton in the ball lock pin handle and remove it. Insert the ball lock pin in the holder on frame bracket. 5. Remove the cotter pin, washer and clevis pin that secured the Cutter Head Up/Down hand levers to the handle linkage. 2/99 (4945-5042) Section 04-2
SET-UP 6. Ensure that cutter head guard is the appropriate size for the cutter head to be installed. If replacement of the cutter head guard is necessary, refer to next page. Check the cutter bits with the gauge to ensure correct length before installing a different size cutter head. 7. Lift the cutter head A-frame. Install the cutter head onto the cutter spindle. Insert the spindle bolt through the cutter head. Secure the spindle bolt with the spindle nut. Lower the cutter head A-frame. 8. Move the Cutter Head Up/Down hand levers and align its hole with one of five holes in the handle linkage. Insert the clevis pin through the aligned holes. Install the washer onto the clevis pin. Secure the clevis pin with the cotter pin. CUTTER HEAD GUARD CHANGEOUT If replacement of the cutter head guard is necessary, proceed with the following steps:. 1. Remove the two wing nuts, washers, guard hooks and eyebolts. The cutter head guard will drop. 2. Attach the appropriate length eyeholts to the cutter head guard which will be installed. Attach the guard hooks to the eyebolts. 3. Install the cutter head guard. Ensure that the guard is positioned so that its recess slot allows visibility of the spindle housing grease fitting. 4. Install the washers onto the eyebolts. Secure the eyebolts to the spindle housing with wing nuts. CUTTER HEAD HAND LEVER ADJUSTMENT The operator may adjust this hand lever control if the push and pull distance is not comfortable. Adjustment may be accomplished quickly and easily by the following procedure. 1. Ensure that the ball lock pin is removed. 2. Remove the cotter pin, washer and clevis pin that secured the cutter head up/down hand levers to the handle linkage. 3. Move the cutter head up/down hand levers and align its hole with one of five holes in the handle linkage. 4. Insert the clevis pin through the aligned holes. Install the washer onto the clevis pin. Secure the clevis pin with the cotter pin. 2/99 (4945-5042) Section 04-3
SET-UP CUTTER BIT ADJUSTMENT The cutter bits are designed to be adjustable so that grinding is not required. Use the gauge and check the cutter bit length. The cutter bits require adjustment or replacement when they are not the correct length. Adjustment may be done when the cutter head is attached or removed. 1. Loosen the cutter head nut, bolt, lockwasher, washer and bit clamp which secured the bit. 2. Place the cutter gauge underneath the bit backing. Slide the old or a new cutter bit until its rests upon the cutter gauge notch. All the cutter bits should be set so that the cutting edge is exactly 3/4 inch below the bottom face of the cutter head. Install the cutter head bolt through the cutter head web. 3. Install the bit clamp, washer and lockwasher onto the bolt. Secure the parts in place with the cutter head nut. Repeat steps 1 through 3 for adjustment of additional cutter bits. PIVOT SCREW ADJUSTMENT The pivot screws are located next to each running wheel, on the outside of the pivot frame. The pivot screws must be adjusted, alternately, a few turns at a time to prevent binding of the frame pivot block. Turn screws until cutter head is parallel to the tie. CYCLONE ADJUSTMENTS The cyclone position is adjustable depending on what working environment you are in. The first position swings the cyclone to the outside of the rail, parallel to the operator. The second position is designed for working in cramped spaces and is positioned at a 45 angle from the operator. NOTE: The third position, parallel and next to the blower housing is for lock-up/travel purposes only. It is not intended to be used as a working position. See LOCK- UPS for more details. 2/99 (4945-5042) Section 04-4
OPERATION Engine Operation Exhaust emissions caused by the use of the engine on this machine may cause cancer, birth defects, or other reproductive harm if inhaled. Before starting a new or overhauled engine that has been in storage, consult the engine manufacturer s manual for initial start instructions. Failure to follow those instructions can result in serious engine damage. NOTE: Avoid unnecessary idling. When prolonged idling is needed, maintain at least 800-1000 rpm. 1. Ensure the suction valve on the hydraulic oil tank is open and the Battery Disconnect Switch is on. 2. Make certain EMERGENCY STOP pushbutton on the main control panel has been pulled out. Set engine speed switch to LOW and the pump switch to OFF. NOTE: See Emergency Stopping Procedures at the end of the OPERATION section. 3. Turn the key switch to the right and hold the Magnetic Override switch (MO) (labeled ENGINE/PUSH TO START) in until the engine starts. Release the key switch (will spring back to centered position) and continue holding the MO switch until oil pressure reaches 30 psi (2 bar or 207 kpa). 4. If the engine fails to start within 30 seconds, release both switches allow the starting motor to cool a few minutes before trying again. 5. Engine should be allowed 5-7 minutes for warm-up if first start of the day. 6. Perform the following startup check. 2/99 (4945-5042) Section 05-1
OPERATION STARTUP CHECKS ITEM CHECK FOR Tachometer/Hourmeter 2250 rpm (under load) Engine Temperature Gauge 160 to 185 F(71 to 85 C) Voltmeter 13 to 15 volts Engine Oil Pressure Gauge Blower Travel Lights Work Lights Pressure Checks (Required once a month) 40 to 60 psi (3 to 4 bar) (276 to 414 kpa) Function Function Function 2,100 psi (145 bar) 3,200 rpm @ 7 gpm If any of these items have failed or are not performing correctly, see TROUBLESHOOTING section before operating this machine. 2/99 (4945-5042) Section 05-2
OPERATION MACHINE OPERATION Tie Adzing Procedure Ensure that the machine is ready for operation and that the operator knows the functions and locations of all the operating controls, instruments and indicators prior to starting and operating the machine. 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. 1. Make certain that the cyclone boom has been placed in the extended position for working and that the 5-inch flexible hose has been reattached (if removed for travelling). 2. Turn the ignition switch and hold the PUSH TO START (magnetic override switch) in until the engine starts and oil pressure reaches 30 psi. 3. Set Engine Speed switch to HIGH. 4. Propel the machine to line up the cutter head over the tie to be adzed. Before engaging the clutch, make certain that all foreign material is swept from the ties, broken spikes are driven into the tie below the level of the cut to be made, and that the ballast is cribbed. Failure to comply may result in personal injury or property damage. 5. Engage the clutch by pushing the CLUTCH LEVER forward until the cutter head begins to rotate. Release clutch lever. 6. Turn the Blower Switch located on the control box to the ON position. 7. Push the CUTTER HEAD LEVER until the cutter head bears down on the tie. Adze the tie just enough to obtain a good surface for gauge and level checks. See Checking Gage and Levelness, below. 8. Check the Vacuum Gage directly across from the operator as you are adzing. If the needle remains low and fluctuates this is normal. When the needle begins to rise and remains high, or continues to rise, this indicates that the suction tube between the cutter head and the blower housing is becoming clogged. 2/99 (4945-5042) Section 05-3
OPERATION 9. If gage reading is in the normal range, repeat process for remaining ties remembering to check the vacuum gage on a regular basis. If not, refer to CLEARING CLOGGED SUCTION TUBE, on next page. TRAVELLING THROUGH CROSSINGS DERAIL BARS Derail bars are used to prevent machine from derailing when traveling through crossings. Remove pin and lower derail bar into track channel at crossing. Reinsert pin below bar housing to prevent the bar from riding up the housing. Remove pin, lower bar and lock pin in place after you have gone through crossing. CRAWLER RAMP The crawler ramp is used for traveling through crossings or for placing crawlers on rail. The crawler ramp is stored in the left crawler housing. Remove pin holding ramp to crawler housing, slide out ramp and slide bracket end of ramp onto the rail head. CHECKING GAGE AND LEVELNESS Check the adzed tie by the following steps: A. Propel the machine clear of the adzed tie, release foot switch and disengage clutch (pull clutch lever toward you). B. Wait for the cutter head to stop rotating and then inspect the tie to make certain that the adzed area is properly located on the tie. (The distance between the inner rail head ball and the cut is correct.) If not correct, refer to GAUGE CUT ADJUSTMENT in Section 04 of this manual. C. Check the adzed tie area with a spirit level. If the cut is not level and square, refer to PIVOT SCREW ADJUSTMENTS in Section 04 of this manual. CLEARING CLOGGED SUCTION TUBE In the event that the Vacuum Gage gives a reading higher than normal, the suction tube line between the cutter head and the blower housing has become clogged. This is due to a variety of reasons, including but not limited to: adzing too fast (the suction line can t keep up with the continuous debris), adzing too deep (too much debris entering the tube at one time), or the tie being adzed is saturated with water (the debris is sticking together). It may even be a combination of all three. 2/99 (4945-5042) Section 05-4
OPERATION To clear a clogged tube: 1. Disengage the clutch by pulling the CLUTCH LEVER toward you. Cutter head should come to a complete stop before you continue on with the next steps. 2. Turn the Blower Switch on the control panel to the OFF position. 3. Pull the cutter head lever toward you until you can align the hole of the lockup bracket with the hole in the cutter head lever. Insert the lock pin, making certain that it has caught inside the frame bracket. The cutter head is now secured in the up position. 4. Turn the Engine Speed Switch to the LOW position. Let engine idle at LOW speed for approximately 5 minutes, then turn off engine using ignition switch. 5. Turn off battery using battery disconnect switch inside the battery box. Lock up battery box. 6. Unsnap the 6-inch bandlock tube clamp (with handlift) from the end of the blower housing. (Be careful not to lose the o-ring from the coupling.) Loosen the 6-inch clamp directly below the bandlock clamp and slowly pull out the suction tube. 7. Clean out the blower housing of any trapped debris. Inspect the end of the tube for any trapped debris and remove. This is usually the end of the tube that gets clogged. Additional debris may be in the tube, but should move through the tube once the major clog has been removed and there is enough suction to pull it through. 8. Replace tube inside clamps and tighten the 6 tube clamp and snap the 6-inch bandlock clamp tight. 9. Startup Machine again. If suction gage continues to read abnormally, repeat steps 1-6 above for the blower tube between the blower housing and the cyclone separator. 2/99 (4945-5042) Section 05-5
OPERATION SHUTTING DOWN Prepare the machine for shutdown following the procedures listed below: 1. Disengage the clutch by pulling the CLUTCH LEVER toward you. Cutter head should come to a complete stop before you continue on with the next steps. 2. Turn the Blower Switch on the control panel to the OFF position. 3. Pull the cutter head lever toward you until you can align the hole of the lockup bracket with the hole in the cutter head lever. Insert the lock pin, making certain that it has caught inside the frame bracket. The cutter head is now secured in the up position. 4. Turn the Engine Speed Switch to the LOW position. Let engine idle at LOW speed for approximately 5 minutes, then turn off engine using ignition switch. 5. Turn off battery using battery disconnect switch inside the battery box. Lock up battery box. 6. Lock cyclone in the travel position. Remove hose and secure it in the opening on the boom mast. 7. After the machine has been moved off track (stored), lock up the crawlers using the lock pins provided. 8. Return all switches to their Pre-Operational state, if you have not already done so. 9. Replace control box cover, and secure with padlock. 2/99 (4945-5042) Section 05-6
MAINTENANCE AND SERVICE GENERAL Sound service and maintenance practices will ensure that the machine continues to meet your demanding requirements. At each scheduled maintenance interval, perform all previous maintenance operations in addition to the ones specified. Refer to the Module Operating Instructions for maintenance and service related to the modules. NOTE: Recommended service intervals are for normal operating conditions. Service more often if engine is operated under adverse conditions (See Maintenance for Extreme Conditions later in this section). Neglecting maintenance can result in failures or permanent damage to equipment. SAFETY DURING MAINTENANCE Alert others in the area that service or maintenance is being performed on this machine. Become familiar with, and use, your company s lockout/tagout procedures when performing maintenance on this machine. See LOCKOUT-TAGOUT REQUIREMENTS in the Safety Section of this manual. 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 the engine if the need arises. 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. Disconnect the battery before servicing this machine. Failure to do so could result in personal injury from accidental engine startup. 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. 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. 2/99 (4945-5042) Section 06-1
MAINTENANCE AND SERVICE NORDCO'S SERVICE NETWORK Need assistance? It's only a phone call away! If you experience problems, contact your original sales representative first, he is the one listed on the front page of this manual. If you cannot reach him, we suggest that you contact the representative closest to your work area BEFORE calling NORDCO's Service Manager. See map on the next page for the alternate representative closest to your work area. REQUESTING ASSISTANCE If you have any questions regarding maintenance and service on this machine, please call your local Nordco Representative or: Nordco Service Manager (414) 769-4603 (Wisconsin) 1-800-445-9258 (USA and Canada) The process will be faster if you have the following information in hand before calling: 1. The Machine Name: Ride On Adzer Model B 2. The Type of Machine: Whether or not upgraded from an OPTO MACHINE 3. The Serial Number: The Serial Number plaque is located next to the rail clamp housing on the lower frame. No. Representative Phone Number 1. Nordco Service Manager 1-800-445-9258 or (414) 769-4603 2. Russell Railway Supply (612) 835-5125 3. Simkins Company, Inc. (310) 316-5270 4. James H. Lynde (913) 648-7379 5. Stanley H. Smith Inc. (606) 885-3353 6. Dwayne Lambing (770) 424-0401 7. Eastern Railway Supplies (716) 675-2040 8. Eastern Railway Supplies (Canada) Ltd. (905) 628-9997 International: American Equipment (561) 997-2080 MAINTENANCE INSTRUCTIONS Maintenance instructions (adjustments, lubrication, inspections, etc.) are given in this manual by assembly. The breakdown for each set of instructions is as follows: 2/99 (4945-5042) Section 06-2