MODEL C/CX HAMMER ROLLER GAGER. Operation and Maintenance Manual

MODEL C/CX HAMMER ROLLER GAGER Operation and Maintenance Manual Applies to S/N 410400 and Above or Upgrades to PLC Last Revision: Rev. - MAY 2004

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

TABLE OF CONTENTS SAFETY...1 Follow Safety Instructions...1 Gager Safety Alerts...2 BEFORE OPERATION...3 Machine Component Descriptions/Locations...3 Gager Buggy...3 Gager Roller Cylinder...4 Instruments and Controls...4 GAGER SET-UP...6 Lock-Up Devices...6 Roller Buggy Wheel Height Adjustment...7 Gager Calibration...8 Gager Lever Roller Height Adjustment (Rail Height Adjustment)...9 OPERATION...10 Pre-Operational Checklist...10 Operation Procedures...11 After Operation...12 MAINTENANCE AND SERVICE...13 General...13 Safety During Maintenance...13 Lubrication - General...13 Gager Lever Assembly...14 Gager Buggy Assembly...15 Periodic Adjustments...16 Gager Cylinder Relief Valve...16 Programming the Gager Meter...17 TROUBLESHOOTING...19 MAY/04 (4945-5283D/E) i Contents

SAFETY Please read and comply with all of the safety precautions in both the Model C/CX Machine Manuals and this optional equipment manual. GENERAL DO NOT use this option for work 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 These safety instructions are in addition to those listed in the SAFETY section of the Model C/CX Machine manuals. These instructions only apply to the use of the Roller Gager. It is important that you understand ALL of the safety instructions before you operate this piece of optional equipment. Learn how to operate the Roller Gager and how to use controls properly. 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. MAY/04 (4945-5283D/E) Safety, Page 1

MODEL C ROLLER GAGER SAFETY 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. 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. MAY/04 (4945-5283D/E) Safety, Page 2

BEFORE OPERATION It is always a good practice to become familiar with the components of the machine you are using. The Roller Gager is comprised of two roller cylinder assemblies, the gager buggy assembly, and the pulse and gager logic boards located inside the logic box. To better understand their function, you have to understand the concept of bringing a rail to gage. Track gage is the distance between rail heads. See Figure 1. Standard track gage is 56-1/2" but gage may vary at crossings, switches and curves. The process of adjusting track gage is called gaging. The roller gager on the Model C/CX Machine accomplishes this in two basic steps: 1. An LVDT inside the Gager Buggy measures the actual distance between rail heads and relays this information electronically to a meter located in the center of the logic box. 2. The roller cylinders will bring the rail to gage depending on the signal received at the meter. If narrow - pulled in to gage, if wide - pulled in to less than gage and then out to gage. After that has been done, spikes can be driven. GAGER BUGGY The Roller Buggy is made up of a three piece frame (left, center and right). See Figure 2. The left frame (located in the left workhead area) houses the LVDT that measures the actual distance (gage) between rail heads and relays this information to a meter located in the upper right hand corner of the logic box. A wheel and roller assembly allows the buggy to ride the rail continuously during gaging operations. See Figure 3. MAY/04 (4945-5283D/E) Operation, Page 3

GAGER ROLLER CYLINDER ASSEMBLY After the signal is sent to the logic system a signal is sent back to the gager roller assembly. See Figure 4. The outside cylinders/lever arms will push the rail in to a position slightly under gage, moving both the rail and the tie plate. The inside cylinders/lever arms push the rail out to a selected gage position and snug against the outside edge of the tie plate. INSTRUMENTS AND CONTROLS All of the controls and instruments for the optional Roller Gager Assembly are described in the following table. Carefully read the machine s OPERATION instructions and these instructions in their entirety before attempting to operate the machine. Almost all of the instruments needed for using the Roller Gager are located on the logic box panel shown in Figure 5, below. MAY/04 (4945-5283D/E) Operation, Page 4

CONTROL OR INSTRUMENT FUNCTION This switch is a 3-position switch that controls the main functions of the roller gager. The switch positions and their functions are as follows: Gage: Turns the gager electronic system ON. Readout meter will light up and remain on until this switch is turned to the OFF position. OFF: Turns the gager electronic system OFF. MONITOR: Used to monitor the rail gage WITHOUT the use of the gager. Readout meter will remain on until switch is manually returned to center. READOUT METER: Indicates rail gage. Meter scale is digital and reads to the thousandths of an inch. This meter has been pre-programmed prior to sale. Instructions for reprogramming in the event of catastrophic failure are included in the maintenance section of this appendix. The buttons at the bottom of the readout meter are used for reprogramming the meter. This switch is a two position switch that controls the work operations of the gager itself. SELECT: Activates the potentiometer allowing you to set the gage. GAGING: Performs the actual gaging of the rail. Gager SELECT Potentiometer: The gage select switch must be in the SELECT mode before the potentiometer functions. This pot is used by the operator to change the desired gage for varying track conditions such as crossings, switches, steep curves, etc. MAY/04 (4945-5283D/E) Operation, Page 5

LOCKUPS Certain machine components have lock-up features for use during highspeed travel, towing, or during machine storage. Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or extensive damage to the machine. ROLLER GAGER The Roller Gager lever arms are equipped with lockup pins. See Figure 9. When removing lockups, it may be necessary to raise the cylinders slightly to release tension. To raise the cylinders, place the Work/Travel Switch located on the Operator s Control box to the Travel position. ROLLER BUGGY The Roller Buggy is locked up on both the left frame and right frame by a chain/hook assembly. The buggy must be raised off the rail to a point the chain/hook will easily attach to the eye on the frame. To lower the buggy, turn the crank handle counter clockwise, to raise the buggy turn the crank handle clockwise. MAY/04 (4945-5283D/E) Operation, Page 6

GAGER SETUP/ADJUSTMENTS Prior to using the gager on any track conditions, the adjustment and calibration procedures given in this section must be performed. 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. ROLLER BUGGY WHEEL HEIGHT ADJUSTMENT The Roller Buggy must ride on the rail so that the buggy guide roller rides against the inside of the rail at the correct height. To adjust the Roller Buggy height proceed as follows: 1. Lower Roller Buggy to track with enough slack in cable to allow the weight of the buggy to rest on rail. 2. Make certain that the buggy guide roller on the right frame is on the inside of the rail. 3. Push on end of left frame until buggy guide roller snaps onto the inside of rail. 4. Locate locknut and adjustment screw as shown in Figure 10. Loosen nut. Note: Right Frame side is shown, left frame side is opposite. 5. 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 11. 6. Tighten locknut. 7. Repeat steps 4 through 6 for the right Roller Buggy guide roller. MAY/04 (4945-5283D/E) Operation, Page 7

ROLLER GAGER CALIBRATION The roller buggy should be calibrated weekly or anytime there is a suspected reading problem. Note: Meter has been pre-programmed and should not require re-programming. Calibrate the roller buggy as follows: 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 right frame is on the inside of the rail. 6. Push on end of left 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: Right Frame side is shown, left 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 11. 9. Turn on electrical power to machine. DO NOT TURN ON THE MACHINE! 10.. Adjust the following switches: A) Put Select Switch in GAGING position. B) Put Gage Switch in either MONITOR or GAGE position. MAY/04 (4945-5283D/E) Operation, Page 8

11. Read the output on the Gager Monitor. It should match what you have measured. If it does not match, an adjustment to the LVDT has to be made. Continue with Step 12. 12. Loosen the capscrew and move the LVDT housing until the meter reads the gage measurement obtained in Step 3. (Moving LVDT in decreases gage, moving LVDT out increases gage.) See Figure 12. 13. After adjustment has been completed turn off power to machine. GAGER LEVER ROLLER HEIGHT ADJUSTMENT The lever rollers must be positioned correctly to prevent the rail from tipping over as it is pushed. Each lever roller must contact the rail at or just below the center of the rail web. (Figure 13 shows the outside lever as an example.) Both the outside and inside lever roller heights must be adjusted to every different rail size as follows: 1. Locate spiking machine on level straight track. 2. Make certain all gager clamp lockpins have been installed. To install lockpins, put machine in Travel mode using Work/Travel switch to raise the cylinders. Put lockpins in place before continuing with the adjustment. 3. Once the lockpins are in place you have access to the lever arms on the gager. 4. Refer to Figure 14. Remove pin and castle nut. Place the required spacers on the lower end of the roller shaft according to the rail size as shown in Table 2 and as shown in Figure 14. 5. Store extra spacers at top of roller shaft. Re-Install castle nut and pin. TABLE 2. SPACERS Rail Size (lb./yd) Spacers Required 85-100 No Spacer 112-115 1/2" 132-140 3/4" 155 1/4, 1/2, and 3/4" (ALL) MAY/04 (4945-5283D/E) Operation, Page 9

OPERATION PRE-OPERATIONAL PROCEDURES After it has been set-up for the correct track size and gage, operation of the Roller Gager is simple and, for the most part, automatic. However, before attempting to operate the Roller Gager, make sure the following preliminary procedures have been performed. TABLE 3. PRE-OPERATIONAL CHECKLIST ITEM All preoperational, set-up and operation checklists for main machine have been followed. Roller Gager and Roller Buggy Lockups have been removed. The main machine has been set up for the desired rail gage. The Roller Buggy has been set-up for the desired rail gage. The Roller Buggy wheel height has been adjusted. The Roller Gager inside and outside roller wheels have been adjusted to be positioned near center of the rail web. Perform routine maintenance and service before operating this machine. See Maintenance and Service for these instructions. MAY/04 (4945-5283D/E) Operation, Page 10

OPERATION PROCEDURES Normal operation of the roller gager is as follows: 1. Make certain all lock-up devices have been removed: A) Gager Lever Arm Lockups (Qty: 4) B) Gager Buggy Lockup Chain/Hooks (Qty:2) 2. Lower the Gager Roller Buggy by cranking handle counterclockwise. 3. Set machine switches as follows: A) Put the machine in Work mode using the Travel/Work Switch on the Operator Control Box. B) Select the type of rail to be worked on (using the Welded/Jointed switch). Note: The position of this switch is critical during the Gaging/Spiking cycle. If in Welded mode, machine propulsion releases pressure at the gager cylinders, but the gager levers remain in position at the rail. If in Jointed mode, the gage levers will retract to a position determined by a delay setting. See Roller Gager Pulse Adjustment in themaintenance and Service section. C) Select desired gage by putting the Gage Select Switch in the Select position and adjust potentiometer as needed. D) Put the main gager switch to Gage.This will energize the gager logic control. The readout meter will remain on as long as the Gager is energized. E) Put the gage select switch to Gaging. 5. Begin gaging cycle by bringing any gun to the READY position. At this point the gaging sequences will begin with the outside cylinders pushing the rail in slightly less than gage and the inside cylinder then pushing the rail out to gage. 6. If the gage must be temporarily adjusted, proceed as follows: A) To widen the gage without knowing an exact gage, turn the Gager Select potentiometer on the meter box clockwise until the desired gage is reached, or if you know the gage you want to temporarily adjust to: B) Put Gage Select switch in Select position, and use potentiometer to select a specific gage and return the Gage Select switch to Gaging. MAY/04 (4945-5283D/E) Operation, Page 11

7. Drive spike. 8. Propel to the next gaging/spiking location. 9. When the machine is spotted at the new location, repeat the gaging procedure by performing steps 5 through 8. IMPORTANT! During an emergency the gager cylinders can be raised by putting the Travel/Work Switch in the Travel position. AFTER OPERATION The following procedures must be followed after gager operation: 1. Reset switches to the following positions: A) Put machine in Travel mode. B) Turn off gager. (Return main gager switch to center position). 2. Install gager lockup pins. 3. Lift Roller Buggy off track. This is done by pushing on the left frame end to compress the spring and allowing the buggy to raise up off the track. Crank handle clockwise to raise the buggy into lockup position. Install chain/hook to buggy (both sides of machine). MAY/04 (4945-5283D/E) Operation, Page 12

MAINTENANCE GENERAL It is important to the life and operation of the equipment to perform the preventive maintenance procedures provided in this section on a regularly scheduled basis. This schedule is called out in bold letters. Maintenance should be scheduled according to equipment usage and weather conditions. Adverse weather conditions may require more frequent intervals. SAFETY DURING MAINTENANCE Alert others in the area that service or maintenance is being performed on this machine. Become familiar with, and use, lockout-tagout procedures when performing maintenance on this machine. See LOCKOUT-TAGOUT REQUIREMENTS in the Safety Section of the Machine 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 engine if the need arises. Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or extensive damage to the machine. 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. LUBRICATION The grease fittings should be serviced with a multi-purpose type grease. Nordco recommends the use of NGLI #2 greases such as Lubriplate 3000 or Texaco MolyTex EP2. See the Recommended Lubricant Chart in the Manual for additional recommended lubricants. MAY/04 (4945-5283D/E) Maintenance and Service, Page 13

GAGER LEVER ASSEMBLY LUBRICATION Each Gager Lever Assembly has eight (8) grease fittings. See Figure MS-1. Each grease fitting lubricates a bushing (or bearing) at or near the grease point. Greasing should be done on a daily basis. Failure to grease all the fittings may cause premature bushing failure. Weather conditions affect the time intervals of greasing. In general, a small amount of grease should be ok. The grease fittings should be wiped clean before servicing. Dirt and/or grit that is forced into the grease fitting may cause it to clog. When servicing sleeve bearing fittings, inject a sufficient quantity of lubricant to force the old grease out until the new clean grease is visible. Grease hardens with age. If the machine has been in storage over a long period of time, or when you notice that the grease is getting hard, the assembly with the bearing in it should be taken apart, cleaned, and relubricated. INSPECTION Periodic inspection of the bushings (or bearings) for wear and possible breakdown should be done when performing the greasing. Inspect the lever rollers for wear on a monthly basis. Replace if you find excessive wear. Inspect hardware for proper fit and secure all loose nuts and bolts. MAY/04 (4945-5283D/E) Maintenance and Service, Page 14

GAGER BUGGY ASSEMBLY LUBRICATION The Gager Buggy has one grease fitting per buggy wheel assembly (Two total). Each grease fitting lubricates a bushing (or bearing) at or near the grease point. Greasing should be done on a daily basis. Failure to grease all the fittings may cause premature bushing failure. Weather conditions affect the time intervals of greasing. In general, a small amount of grease should be ok. Overgreasing may cause seal failure. The grease fittings should be wiped clean before servicing. Dirt and/or grit that is forced into the grease fitting may cause it to clog. When servicing sleeve bearing fittings, inject a sufficient quantity of lubricant to force the old grease out until the new clean grease is visible. Grease hardens with age. If the machine has been in storage over a long period of time, or when you notice that the grease is getting hard, the assembly with the bearing in it should be taken apart, cleaned, and relubricated. The adjusting nut on the buggy roller assembly needs to be oiled with engine oil on a monthly basis to prevent buildup of rust. See figure to right. INSPECTION Inspect the buggy rollers and wheels for wear on a monthly basis. Replace if you find excessive wear. Check the LVDT for loose or broken wires on a monthly basis. broken or frayed wires, replace them immediately. If you notice Check the harness connection on a daily basis. If the harness is not connected properly, it may cause false readouts (or no readouts at all) on the gager meter. Inspect hardware for proper fit and secure all loose nuts and bolts. MAY/04 (4945-5283D/E) Maintenance and Service, Page 15

PERIODIC ADJUSTMENTS GAGER SIDE ARM RELIEF VALVE This adjustment requires that the machine be running. Take all necessary precautions for your safety. To test and adjust the cylinder relief valve proceed as follows: 1. Install a pressure gage on the pressure tap on the gager hydraulic manifold as shown in Figure MS-6. 2. Remove cap on the relief valve adjustment. Loosen the locknut on the relief valve and turn the adjusting screw outward (counter-clockwise) 3 or 4 turns. 3. Run gager through a complete cycle and note pressure when the rail is being pushed out. If pressure gage: A) reads greater than 500 psi, turn the adjusting screw out until the pressure gauge reads 500 psi. Run gager through another cycle and recheck pressure setting. B) reads less than 500 psi, turn the relief valve adjusting screw in until the pressure gauge reads 500 psi. Run gager through another cycle to verify the 500 psi reading. 6. Tighten the locknut and replace the cap. MAY/04 (4945-5283D/E) Maintenance and Service, Page 16

PROGRAMMING THE GAGER METER The Digital Gage Meter (Nordco P/N 5017 4011) is pre-programmed at the factory. If for some reason, the programming has been lost, it must be recalibrated before use. Use the following procedure to properly calibrate the meter: GENERAL SETUP 1. Slide unit out of case and make sure jumper is in position 2, and the other jumper is on B+C. 2. Slide unit back into case. 3. Turn on the main power at the key switch and then turn the Gage/Monitor switch to the GAGER position. This will turn on both the Gage Monitor and the gager buggy LVDT (for use in later steps). METER PROGRAMMING General Information For every programmable function there are two alternating displays. The first display is the parameter you will be adjusting (will be in bold letters in these instructions). The second display is the Selection or Value you will be adjusting (will be in bold italic letters in these instructions). 1. Press the Par button on the meter once. The display should alternate between Pro and No. 2. When the display shows No, press the F1 button on the front of the display once. The display should read 1-InP. 3. Press the Par button on the meter once. The display should alternate between range and xxxx 4. Press the F1 button seven (7) times. The display should read 20u. 5. Press the par button on the meter once. The display should alternate between decpnt and 0.00 6. When the display shows 0.00, press the F1 button once. The display should read 0.000 7. Press the Par button on the meter once. The display should alternate between round and 0.001. 8. When the display shows 0.001 press the F1 key twice. The display should read 0.005 9. Press the Par button on the meter four (4) times. The display should alternate between InP1 and x.xxx 10. When the display shows x.xxx, press and hold the F1 button until the display reads 0.412. 11. Press the Par button on the meter once. The display should alternate between dsp1 and x.xxx 12. When the display shows x.xxx, press and hold the F1 or F2 button until the display reads 56.125. 13. Press the Par button on the meter once. The display should alternate between InP2 and x.xxx 14. When the display shows x.xxx, press and hold the F1 or F2 button until the display reads 4.95. 15. Press the Par button on the meter once. The display should alternate between dsp2 and x.xxx 16. When the display shows x.xxx, press and hold the F1 or F2 button until the display reads 57.50. 17. Press the Par button on the meter once. The display should alternate between Pr0 and n0. 18. When the display shows No, press the F1 button on the front of the display twice. For these instructions, x means an arbitrary number. Setting the Parameters MAY/04 (4945-5283D/E) Maintenance and Service, Page 17

19. The display should alternate between Pr0 and 2-FnC. 20. When the display shows 2-FnC, press the Par button once. The display should alternate between Usr1 and n0 21. When the display shows no press the F1 button once. The display should then show PLDC Exiting the Meter Programming 22. Press the Par button on the front of the display seven (7) times. The display should show End. Leave the display at End and it should automatically exit the program after 2 seconds and show a value on the display. The display will then read the current setting of the Gage Pot or the signal from the LVDT, depending on the position of the Gage Select/Gaging switch. Setting up the Buggy LVDT Place the Gager Buggy angled indicator wheels between the rails. Measure the actual gage at the wheels with a tape rule. Make note of this measurement. Loosen the LVDT clamp screw. Move the LVDT inside the gager buggy until the display records the measurement taken in Step 20. Tighten the clamp screw and recheck the display. If the display does not read the measured gage after tightening the screw, readjust and retighten as necessary until correct. To prevent the program from being altered, add a jumper wire between 7 and 8. NOTE: Whenever the program is to be checked or modified, this jumper should be disconnected between 7 and 8. MAY/04 (4945-5283D/E) Maintenance and Service, Page 18

TROUBLESHOOTING The following chart makes reference to PLC control lights located inside the logic box. These numbers correspond to the designation number (X55, Y55, and RPC55 for example) on the flip chart (Nordco P/N 56406164 Model C and 56406169 Model CX) located inside the logic box. Before you use this chart, you must understand a few basic symbols, keywords, components, and troubleshooting Techniques: KEYWORD Input Light Output Lights RPC Lights Signal Lights Harness connection Potentiometers DESCRIPTION Input lights are the top lights on both PLC s (Main and Extension). They are designated by X## Output lights are the bottom lights on both PLC s (Main and Extension). They are designated by Y##. RPC lights are located on the Remote Power Control board inside the logic box. They are designated as RPC##. Refer to lights on proximity switches, junction box ports, and DIN suppression modules. Harness connections are checked from the source to the connection either to a junction box or the logic box. In other words, both ends of the harness. Potentiometers are located on the left (main) PLC (under the cover on the left side). MAY/04 (4945-5283D/E) Troubleshooting, Page 19

TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION PROBLEM MECHANICAL HYDRAULIC ELECTRICAL Gager cycle will not start. NOTE: Gager will not cycle if workhead did not cycle. Lockup pins in place. Put machine in travel mode and turn off machine. Remove lockup pins. LVDT less than desired gage: Rail-Out Valve not shifting. See Table 6, Common Solutions. LVDT more than desired gage: Rail-In Valve not shifting. See Table 6, Common Solutions. Is the Gage Select/Gaging switch in the GAGING position? Check Gager Circuit Breaker (CB20) to see if tripped. Check for signals at RPC51, Y51, RPC53, and Y53. Did workhead go to ready position? Note: Gager will not cycle if workhead did not cycle. Gager will not reset at propel When in JOINTED RAIL mode: NOTE: Rail-in lock and rail out lock should turn off to release pressure in cylinder. Gager will not pulse off in jointed mode if lock valve is on. Check directional valves and lock valves for free movement. See Table 6, Common Solutions. Check Rail-In lock and Rail- Out lock are off (Y55, Y56, Y57) Check propel input at X0 or X1 Check potentiometer setting for Gager Off duration for jointed mode only. Check for faulty potentiometer board. When in WELDED RAIL mode: Rail-In Lock and Rail-Out lock valve should turn OFF to release pressure in cylinder. Check directional valves and lock MAY/04 (4945-5283D/E) Troubleshooting, Page 20

TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION PROBLEM MECHANICAL HYDRAULIC ELECTRICAL valves for free movement. See Table 6, Common Solutions. Inside Cylinders will not retract and/or extend. Cylinder rod bent. Replace cylinder. If cylinder does not retract: Rail-Out lock valves not releasing Inside cylinder directional valve not shifting. See Table 6, Common Solutions. If cylinder does not extend: Pilot Operated Check Valve defective, replace valve. If cylinder does not retract: Check for signal lights at Gager Inside Arms UP (Y52 and RPC52) Use propel pedal to release clamps, check Travel Pedal Inputs (X0 or X1) Inside cylinder directional valve not shifting. See Table 6, Common Solutions. If cylinder does not extend: Is gager LVDT reading below selected gage setting? If yes, then check for signal lights at Gager Inside Arms Down (Y53 and RPC53) Outside Cylinders will not retract and/or extend. Cylinder rod bent. Replace cylinder. If cylinder does not retract: Rail-In lock valves not releasing Outside cylinder directional valve not shifting. See Table 6, Common Solutions. If cylinder does not extend: Pilot Operated Check Valve defective, replace valve. If cylinder does not retract: Check for signal lights at Gager Outside Arms UP (Y50 and RPC50) Use propel pedal to release clamps, check Travel Pedal Inputs (X0 or X1) Outside cylinder directional valve not If cylinder does not extend: Is gager LVDT reading MAY/04 (4945-5283D/E) Troubleshooting, Page 21

TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION PROBLEM MECHANICAL HYDRAULIC ELECTRICAL shifting. See Table 6, Common Solutions. above selected gage setting? If yes, then check for signal lights at Gager Outside Arms Down (Y51 and RPC51) Rail not being pushed in to less than gage during automatic sequence. Spring in Gager buggy broken, replace if necessary. Main pump compensator not set correctly. Adjust compensator to 2500 psi (Refer to Service and Maintenance in the machine manual). LVDT out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual. Check for defective Pilot Operated Check Valve. Replace as necessary. Rail-In Valve not shifting. See Table 6, Common Solutions. Cable to buggie from junction box loose or defective. Check harness connections from junction box to logic box. Rail being pushed in too far. Buggy sections not moving freely. Spring in Gager buggy broken, replace if necessary. Buggy not riding on rail. Main pump compensator not set correctly. Adjust compensator to 2500 psi (Refer to Service and Maintenance in the machine manual). Rail-In Valve not shifting. See Table 6, Common Solutions. LVDT out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual. Cable to buggie from junction box loose or defective. Check harness connections from junction box to logic box. Check for signal light at Outside Arms DOWN. MAY/04 (4945-5283D/E) Troubleshooting, Page 22

TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION PROBLEM MECHANICAL HYDRAULIC ELECTRICAL Rail not being pushed out to gage, during automatic sequence. Buggy sections not moving freely. Incorrect spacer use on lever roller. Remove roller and put on proper spacer. (Rail Tipping.) Spring in Gager buggy broken, replace if necessary. Main pump compensator not set correctly. Adjust compensator to 2500 psi (Refer to Service and Maintenance in the machine manual). Gager cylinder relief valve not set correctly. Adjust cylinder relief valve. Check for defective Pilot Operated Check Valve. Replace as necessary. Rail-Out or Rail-In Valve not shifting. See Table 6, Common Solutions. Rail-In Lock Valves not holding. Replace if defective. Logic system malfunctioning. Check if LVDT is out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual. Check for light at Gager Inside Arms Down (Y53 and RPC 53). Cable to buggie from junction box loose or defective. Check harness connections from junction box to logic box. Rail being pushed out past gage. Incorrect spacer use on lever roller. Remove roller and put on proper spacer. (Rail Tipping.) Spring in gager buggy broken. Replace if defective. Buggy sections not moving freely. Main pump compensator not set correctly. Adjust compensator to 2500 psi (Refer to Service and Maintenance in the machine manual). 7 gpm flow control valve could be faulty. Replace as necessary. The rail out fast valve could not be shutting off properly or is stuck. Replace if necessary. The rail out valve is stuck. Replace if necessary. Logic system malfunctioning. Check if LVDT is out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual. Potentiometer board faulty or the rail out fast duration set too high. Check for no light on the RAIL OUT FAST (Y54) and Gager Inside Arms Down (Y53) MAY/04 (4945-5283D/E) Troubleshooting, Page 23

TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION PROBLEM MECHANICAL HYDRAULIC ELECTRICAL Meter not indicating proper gage. LVDT set incorrect. Adjust LVDT as instructed in the Operating Section of this manual. Loose harness connection at logic box, gager junction box, or at gager buggy. Check connections for proper fit. Defective meter. Replace meter. Amber at gage light not working. LED not working, replace with new Loose harness connection at the At-Gage box or at logic box. Check connections for proper fit. Check for AT GAGE output (Y47 and RPC47) MAY/04 (4945-5283D/E) Troubleshooting, Page 24

TABLE 6. COMMON SOLUTIONS POSSIBLE CAUSE AND SOLUTION PROBLEM MECHANICAL HYDRAULIC ELECTRICAL Valves Not Shifting Check if the LED light on the Din/Suppression Diode is lit. If no, see electrical. If yes, check valve solenoid and spool. Replace if defective. To check spool: Check for loose connections at valve, junction box, and logic box (both ends of each cable/harness). 1. Remove Coil 2. Remove solenoid stem 3. Rotate spool. MAY/04 (4945-5283D/E) Troubleshooting, Page 25

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