Nordco C Manuel utilisateur

2001

MODEL C

24-Volt Spiker/Hammer

w/Programmable Logic

OPERATION AND

MAINTENANCE MANUAL

Last Revision: September 2002

Re-Order: 49455283D

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, at a nominal cost, through our Part

Sales Department. Additional service information, parts, and application information is

available through these Nordco product support resources:

NORDCO Sales: Milwaukee, Wisconsin

(414) 766-2180

[email protected]

NORDCO Parts: 1-800-647-1724

mailto:[email protected]

NORDCO Service: 1-800-445-9258

[email protected]

We ask that if you have any comments or suggestions about this manual, let us hear from you. We are

here to be of service to you, our customers. Direct your comments and inquiries to:

Technical Documentation Department

NORDCO Inc.

245 W. Forest Hill Avenue

Oak Creek, WI 53154

HAZARDOUS MATERIAL DATA

In an effort to provide information necessary for your employee safety training program and to meet the

requirements of OSHA Hazard Communication Standard 1910.1200, we have OSHA Form 20 Safety Data

Sheets available that cover the material contained in this machine.

If you are interested in receiving this information, please refer to the Name, model, and Serial Number of

your machine when calling or writing, and direct your inquiries to:

Vice-President of Operations

NORDCO Inc.

245 W. Forest Hill Avenue

Oak Creek, WI 53154

Fax: (414) 766-2299

Phone: (414) 766-2288

2003 Model C w/Programmable Logic CONTENTS

TABLE OF CONTENTS

SECTION 1 – PREFACE

SAFETY ........................................................................................................................................................................... 5

Understanding Key Safety Alert Words...................................................................................................................... 5

Follow Safety Instructions .......................................................................................................................................... 5

General Safety Tips.................................................................................................................................................... 6

Safety During Work ............................................................................................................................................... 6

Safety During Travel.............................................................................................................................................. 7

Safety During Maintenance ................................................................................................................................... 7

Safety Alerts ............................................................................................................................................................... 8

Lockout/Tagout Requirements ................................................................................................................................. 11

OSHA Recommended Lockout/Tagout Procedures................................................................................................. 12

Lockout Sequence............................................................................................................................................... 12

Restoring Equipment to Service.......................................................................................................................... 13

Informational Chart - Model C Energy Sources........................................................................................................ 14

Safety Decals on this Machine ................................................................................................................................. 16

GENERAL INFORMATION............................................................................................................................................ 10

About this Manual..................................................................................................................................................... 10

Optional Equipment.................................................................................................................................................. 10

Machine Specifications............................................................................................................................................. 11

Parts Ordering Information ....................................................................................................................................... 13

SECTION 2 - OPERATION

BEFORE OPERATION .................................................................................................................................................. 15

Operator’s Station .................................................................................................................................................... 15

Rail Clamps .............................................................................................................................................................. 16

Carriage.................................................................................................................................................................... 16

Carriage Guide Wheel.............................................................................................................................................. 16

Workhead ................................................................................................................................................................. 16

Manifolds .................................................................................................................................................................. 16

Propulsion/Drive System .......................................................................................................................................... 17

Boom/Winch ............................................................................................................................................................. 17

Logic Box Control Panel........................................................................................................................................... 17

Bulk Loader (optional) .............................................................................................................................................. 17

Nipper Assembly (optional) ...................................................................................................................................... 18

Gager (optional) ....................................................................................................................................................... 17

Operator Station Controls......................................................................................................................................... 19

Logic Box Control Panel................................................................................................................................... 19

Remote Control Boxes ..................................................................................................................................... 27

Footswitches .................................................................................................................................................... 29

Hand Controllers .............................................................................................................................................. 30

Remote Controls .............................................................................................................................................. 31

Preparing the Machine for Work............................................................................................................................... 32

Pre-Operational Checklist ........................................................................................................................................ 33

Engine Operation ..................................................................................................................................................... 34

START-UP CHECKS ..................................................................................................................................................... 35

Lock-Up Devices ...................................................................................................................................................... 36

PROPELLING AND BRAKING...................................................................................................................................... 44

MACHINE SET-UP......................................................................................................................................................... 45

Jaw Depth/Rail Height Adjustment....................................................................................................................... 45

Workhead Ready Adjustment................................................................................................................................... 46

Workhead Spike Pattern Adjustment ...................................................................................................................... 47

Nipper Height Adjustment ........................................................................................................................................ 48

Nipper Hooks Close Pressure Switch ...................................................................................................................... 49

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2003 Model C w/Programmable Logic CONTENTS

MACHINE OPERATION................................................................................................................................................. 49

Work Operation ........................................................................................................................................................ 50

Spike Driving (without Nippers) ................................................................................................................................ 51

Spike Driving (with Nippers in Automatic Mode) ...................................................................................................... 51

Spike Driving (with Nippers in Manual Mode) .......................................................................................................... 52

Winch Operation....................................................................................................................................................... 53

EMERGENCY STOPPING ............................................................................................................................................. 53

AFTER OPERATION ..................................................................................................................................................... 54

Parking or Locating Machine.................................................................................................................................... 54

Rotating Machine ..................................................................................................................................................... 54

Towing...................................................................................................................................................................... 55

SECTION 3 - MAINTENANCE AND SERVICE

GENERAL ...................................................................................................................................................................... 57

LUBRICATION AND MAINTENANCE CHART ............................................................................................................. 60

RECOMMENDED LUBRICANTS .................................................................................................................................. 61

LUBRICATION AND MAINTENANCE INSTRUCTIONS (BY ASSEMBLY) ................................................................. 62

Removing and Replacing Jaw Mountings ........................................................................................................ 80

Removing and Replacing Jaws........................................................................................................................ 81

PERIODIC ADJUSTMENTS ....................................................................................................See Appendices B and C

RECOMMENDED SPARE PARTS .........................................................................................................See Appendix A

SECTION 4 - TROUBLESHOOTING

GENERAL ...................................................................................................................................................................... 83

ADVANCED TROUBLESHOOTING CHARTS.......................................................................................See Appendix D

ENGINE TROUBLESHOOTING .................................................................................................................................... 84

ELECTRICAL TROUBLESHOOTING ........................................................................................................................... 85

HYDRAULIC SYSTEM TROUBLESHOOTING ............................................................................................................. 90

MECHANICAL TROUBLESHOOTING .......................................................................................................................... 94

LOGIC SEQUENCE CHART

APPENDICES

APPENDIX A - SUGGESTED SPARE PARTS

APPENDIX B - PERIODIC ADJUSTMENTS - HYDRAULICS

APPENDIX C – PERIODIC ADJUSTMENTS - LOGIC BOARDS

APPENDIX E – ROLLER GAGER INSTRUCTIONS (Optional Equipment)

APPENDIX F – BULK LOADER INSTRUCTIONS (Optional Equipment)

APPENDIX G – TORQUE CHART

9/02 (4945-5283D) ii Contents

2003 Model C w/Programmable Logic CONTENTS

PARTS SHEETS

(Last Revision in Bold/Parenthesis)

FIGURE Last Revision

MECHANICAL

Operator’s Station (4/98)............................................................................................................................................41A-1

Axles, Insulated (8/98)

Fine Thread - Discontinued - See Notes on Part Sheet (8/98) ........................................................41A-2-1 Rev A

Coarse Thread (S/N 410200 and Above) (10/00) ......................................................................................... 41A-2-1A

Axles, Non-Insulated.............................................................................................................................................. 41A-2-2

Fine Thread - Discontinued - See Notes on Part Sheet (10/00) ......................................................41A-2-2 Rev A

Coarse Thread (S/N 410200 and Above) (10/00) ............................................................................. 41A-2-1A, Rev A

Axle, Rear (for machines equipped with Bulk Loader Only) (8/98)..............................................................41A-2-3 Rev A

Brakes, Hydraulic (2/99) .................................................................................................................................41A-3 Rev B

Drive System (Propulsion), Dual Axle (2/99) ..................................................................................................41A-5 Rev B

Frame Accessories (10/00)

Rear Platform (10/00)............................................................................................................................41A-6-1 Rev B

Batteries - Discontinued (10/00)............................................................................................................41A-6-2 Rev A

Batteries - S/N 410200 and Above (10/99) ................................................................................................... 41A-6-2A

Lights and Horns - Discontinued (10/00)...............................................................................................41A-6-3 Rev B

Lights and Horns - S/N 410200 and Above (10/99) ...................................................................................... 41A-6-3A

Engines

John Deere (S/N 410200 through 410214) ..................................................................................................... 41A-7-1

John Deere (S/N 410215 and Above) ........................................................................................................... 41A-7-1A

Cummins Diesel .............................................................................................................................................. 41A-7-2

Hydraulic Tank...........................................................................................................................................................41A-8

Oil Cooler...................................................................................................................................................................41A-9

Fuel Tank .................................................................................................................................................................41A-10

Carriage (Left Operator)....................................................................................................................................... 41A-11-1

Carriage (Right Operator) .................................................................................................................................... 41A-11-2

Guidewheel

Regular Duty (S/N 410200 through 410286)(10/00) ..................................................................................... 41A-12-1

CP Rail Version (S/N 410200 and Above) (8/00) .......................................................................................... 41A-12-2

BNSF Version (8/00) ..................................................................................................................................... 41A-12-3

Heavy Duty (S/N 410287 and Above) (10/00)............................................................................................... 41A-12-4

Workhead (Push Spiker)...................................................................................................................................... 41A-13-1

Workhead (Hammer)

One Piece Anvil............................................................................................................................................. 41A-13-2

Two Piece Anvil............................................................................................................................................. 41A-13-3

Tray/Feed, Left Hand ........................................................................................................................................... 41A-14-1

Tray/Feed, Right Hand......................................................................................................................................... 41A-14-2

Pattern Adjust, Manual......................................................................................................................................... 41A-15-1

Pattern Adjust, Hydraulic ..................................................................................................................................... 41A-15-2

Nippers (Standard Grade Cylinder) .........................................................................................................................41A-16

Gager Buggy............................................................................................................................................................41A-17

Gager (Standard Grade Cylinder)............................................................................................................................41A-18

Rail Clamps (Standard Grade Cylinder) ..................................................................................................................41A-19

Spike Bin ............................................................................................................................................................. 41A-20-1

Bulk Loader.......................................................................................................................................................... 41A-20-2

Boom and Winch......................................................................................................................................................41A-21

Turntable (Set-off)................................................................................................................................................ 41A-22-1

Turntable (Set-Off) with Indicator Assembly ........................................................................................................ 41A-22-2

Canopy ............................................................................................................................................................. 41A-23-1

Jackstands and Bumpers.........................................................................................................................................41A-24

HYDRAULIC

Piping Assembly ................................................................................................................................................ 9641 0374

Functional Schematics....................................................................................................................................... 9641 0670

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2003 Model C w/Programmable Logic CONTENTS

9/02 (4945-5283D) iv Contents

ELECTRICAL

Logic Box.............................................................................................................................................. 9641 0435 Rev. D

Electrical Schematic............................................................................................................................ 9641 0568 Rev. E

Logic Schematics

Mother Board #1.......................................................................................................................................... 9641 0142

Mother Board #1.......................................................................................................................................... 9641 0542

Mother Board #2.......................................................................................................................................... 9641 0144

Mother Board #2.......................................................................................................................................... 9641 0544

Mother Board #3.......................................................................................................................................... 9641 0138

Mother Board #3.......................................................................................................................................... 9641 0546

Main Board .................................................................................................................................................. 9641 0140

Main Board with Circuit Breakers ................................................................................................................ 9641 0871

Function Board ............................................................................................................................................ 9643 0102

Function Board with Circuit Breakers .......................................................................................................... 9643 0875

Gun Board ................................................................................................................................................... 9641 0213

Gun Board with Circuit Breakers ................................................................................................................. 9641 0873

Gager Board................................................................................................................................................ 9641 0215

Gager Board with Circuit Breakers.............................................................................................................. 9641 0881

Nipper Board ............................................................................................................................................... 9641 0103

Nipper Board with Circuit Breakers ............................................................................................................. 9641 0877

Pulse Board................................................................................................................................................. 9643 0105

Pulse Board with Circuit Breakers............................................................................................................... 9643 0879

Board LED Functions......................................................................................................................................... 9641 0411

Circuit Breaker/Relay Diagram .......................................................................................................................... 5640 6125

CABLES AND HARNESSES

Cabling Diagram ................................................................................................................................................ 9641 0677

Harnessess................................................................................... Various, in numerical order following Cabling Diagram

Board Path List

2003 Model C w/Programmable Logic SAFETY

SAFETY

Please read and comply with all of the safety precautions in this manual and those supporting optional

equipment for this machine.

GENERAL

DO NOT use this machine 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

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!

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.

9/02 (4945-5283D) Section 1, Safety, Page 1

2003 Model C w/Programmable Logic 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 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 DURING WORK

NORDCO recommends the use of a Command position. This means that the machine is never running

unless someone is sitting at the control station. 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. Before moving this machine, whether in work

or travel mode, make certain that all personnel have left the area before moving this machine.

2. Make certain that the steps and path for entering or exiting the machine are clear of mud, debris,

equipment, and any other obstacles that may prevent emergency exit from the machine.

3. Always use the steps and handles provided for entering or exiting this machine. DO NOT USE THE

CONTROLLERS AS HAND-HOLDS FOR ENTERING OR EXITING THE MACHINE!

4. NEVER exit the machine while the machine is moving.

5. 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.

6. 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.

7. Anyone standing near the machine is at risk of being injured. Make certain they keep away from the

workheads and any other moving assembly during working operations.

8. 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.

9. There are spike deflector mats on this machine . Do not remove them unless performing service or

maintenance in that area. Make certain that they have been reattached after work is completed.

10. 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.

9/02 (4945-5283D) Section 1, Safety, Page 2

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