Nordco M2 Manuel utilisateur

Model M2

Ballast Regulator and Snow Clearing

(BR/SC) Machine

OPERATION AND

MAINTENANCE MANUAL

October 2000

Re-Order: 49458501

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: Milwaukee, Wisconsin

(414) 766-2180

[email protected]

NORDCO Parts: Milwaukee, Wisconsin

1-800-647-1724

[email protected]

Oshawa, Ontario, Canada

(905) 579-4058, Ext. 224

[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

Model M2 BR/SC Machine CONTENTS

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TABLE OF CONTENTS

SAFETY ........................................................................................................................................................1

Understanding Key Safety Alert Words...................................................................................................1

Follow Safety Instructions .......................................................................................................................1

General Safety Tips.................................................................................................................................1

Safety Alerts............................................................................................................................................4

Lockout/Tagout Procedures....................................................................................................................7

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

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

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

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

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

OPERATION

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

Front Ballast Plow .................................................................................................................................15

Ballast Wing..........................................................................................................................................16

Broom....................................................................................................................................................16

Stone Deflector......................................................................................................................................16

Cab Controls .........................................................................................................................................18

Control Console ............................................................................................................................18

Engine and Pump Controls...........................................................................................................21

Left Valve Bank – Ballast Regulator..............................................................................................24

Left Valve Bank – Snow Wings.....................................................................................................27

Right Valve Bank – Ballast Regulator...........................................................................................29

Broom Valve Bank ........................................................................................................................31

Hydraulic Pressure Gauges..........................................................................................................32

Remote Controls...........................................................................................................................33

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

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

Preparing the Machine for Work ...........................................................................................................36

Pre-Operational Checklist .....................................................................................................................36

Lock-Up Devices...................................................................................................................................37

PROPELLING AND BRAKING (TRAVEL).................................................................................................38

MACHINE SET-UP......................................................................................................................................41

Height Adjustments ............................................................................................................................41

MACHINE OPERATION..............................................................................................................................43

Front Ballast and High Speed Plows.....................................................................................................43

Multi-Position Plows ..............................................................................................................................44

Ballast Wings ........................................................................................................................................44

Broom....................................................................................................................................................44

Snow Screw & Blower...........................................................................................................................45

EMERGENCY STOPPING..........................................................................................................................45

AFTER OPERATION...................................................................................................................................46

Parking or Locating Machine.................................................................................................................46

Rotating Machine ..................................................................................................................................46

Towing...................................................................................................................................................47

- Continued on Next Page -

Model M2 BR/SC Machine CONTENTS

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MAINTENANCE AND SERVICE

GENERAL ...................................................................................................................................................49

LUBRICATION AND MAINTENANCE CHART ..........................................................................................51

LUBRICATION AND MAINTENANCE BY DAY/WEEK/MONTH/ETC.......................................................52

Daily Instructions...................................................................................................................................56

Weekly Instructions...............................................................................................................................60

Monthly Instructions ..............................................................................................................................61

Quarterly Instructions ............................................................................................................................62

Yearly Instructions.................................................................................................................................63

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

TROUBLESHOOTING

GENERAL ...................................................................................................................................................65

ENGINE TROUBLESHOOTING .................................................................................................................66

ELECTRICAL TROUBLESHOOTING ........................................................................................................67

HYDRAULIC SYSTEM TROUBLESHOOTING..........................................................................................71

MECHANICAL TROUBLESHOOTING.......................................................................................................75

APPENDICES

APPENDIX A - SUGGESTED SPARE PARTS

APPENDIX B – OPTIONAL JOYSTICK CONTROLS

APPENDIX C – SNOW MACHINE CONVERSION

Model M2 BR/SC Machine CONTENTS

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MECHANICAL PARTS SHEETS

FIGURE ASSEMBLY

FIGURE 1. CAB ASSEMBLY (OPERATOR STATION)

1-1 Seats....................................................................................................................................E-30270

1-2 Defroster ............................................................................................................................................

1-3 Air Conditioner ....................................................................................................................D-38200

1-4 Heater ................................................................................................................................................

1-5 Steps, Right Hand................................................................................................................C-33040

1-6 Steps, Left Hand ..................................................................................................................C-33041

1-7 Upper Control Console..........................................................................................................D-33533

1-8 Lower Control Console

1-8-1 Lower Control Console (Standard)............................................................................E-32077

1-8-2 Lower Control Console (Optional w/ECD Pump - ZF Transmission) ........................D-32321

1-9 Joystick Controllers (Optional)......................................................................................Not Available

1-10 Front Wipers .......................................................................................................................A-32235

1-11 Rear Wipers........................................................................................................................A-32236

1-12 Sliding Window Assembly (Heavy Duty).............................................................................C-38345

1-13 Heated Mirrors ....................................................................................................................C-38151

1-20 Miscellaneous Cab Accessories............................................................................................ Varies

FIGURE 2. AXLES AND SUSPENSION

2-1 Axles (Insulated) ..................................................................................................................E-16450

2-2 Axles Gear Housing.............................................................................................................E-16450

2-3 Suspension (Without Lockup)...............................................................................................D-32790

2-4 Suspension (With Lockup)....................................................................................................D-38405

2-5 Shock Absorbers (Cab End).................................................................................................C-33241

2-6 Shock Absorbers (Engine End).............................................................................................C-33240

FIGURE 3. BRAKES

3-1 Dual Shoe Brakes (Dual Canister)........................................................................................D-33261

3-2 Dual Shoe Brakes (Single Canister) .....................................................................................D-33580

3-3 Single Shoe Brakes (Single Canister).................................................................................D-25405?

FIGURE 5. DRIVE SYSTEM

5-1 Drive Line Assembly .............................................................................................................E-33336

5-2 Torque Arm Assembly (Engine End) ....................................................................................C-32678

5-3 Torque Arm Assembly (Cab End).........................................................................................C-27237

5-4 Drive Shaft Assembly (Cab End) ..........................................................................................A-32661

5-5 Drive Shaft Assembly (Engine End)......................................................................................A-32662

FIGURE 6. FRAME ACCESSORIES

6-1 Batteries................................................................................................................................D-38130

6-2 Tow Pin Assembly.................................................................................................................B-38241

6-3 Rail Sweep............................................................................................................................C-25400

FIGURE 7. ENGINES AND PUMPS

7-1 Cummins Diesel (M11-C300)...............................................................................................E-33301

7-1-1 Engine Shroud...........................................................................................................D-32740

7-1-1-1 Shroud Insulation (Optional).......................................................................C-32739

7-1-2 Engine Block Heaters................................................................................................C-38253

7-1-3 Cold Ether Start.........................................................................................................C-38038

7-1-4 Radiator Assembly.....................................................................................................D-32760

7-1-4-1 Radiator Seal Kit.................................................................................................C-33310

7-1-5 Intake/Exhaust Assembly..........................................................................................D-32730

7-1-6 Engine Air Intake Pre-Cleaner (Optional)..................................................................A-38026

7-1-7 Engine Coolant Heater ..............................................................................................D-38059

7-1-8 Engine Oil Remote Drain...........................................................................................B-32736

7-5 Pump Drives

7-5-1 Pump Drive w/Clutch (For Cummins Engines)..........................................................B-38297

7-5-2 Pump Drive w/Clutch (For Cummins Engines).............................................B-38299/800115

7-5-3 Pump Drive w/o Clutch (For Cummins Engines)..........................................B-38377/800111

7-5-4 Pump Drive w/o Clutch (For Cummins Engines)..........................................E-33301/800116

Model M2 BR/SC Machine CONTENTS

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FIGURE 8. HYDRAULIC TANKS

8-1 Hydraulic Tank ......................................................................................................................D-32240

8-1-1 Hydraulic Tank Heater...............................................................................................C-38007

FIGURE 10. FUEL TANKS

10-1 Primary Fuel Tank...............................................................................................................D-33271

10-1-1 Tank Drain Assembly ..............................................................................................A-38219

10-2 Secondary Fuel Tank (Optional).........................................................................................D-38211

10-3 Dual Tank Level Sending Unit Kit .......................................................................................D-38393

FIGURE 13. FRONT PLOWS

13-1 Two-Way Plow (Ballast or Snow)........................................................................................D-25111

13-1-1 Plow Blade...............................................................................................................B-25121

13-2 Versatile Plow .....................................................................................................................D-27600

13-3 Front V-Plow ......................................................................................................................E-29130

FIGURE 14. SIDE WINGS

14-1 Ballast Wing........................................................................................................................E-25710

14-1-1 Inner Door Cylinder (Optional)................................................................................C-38287

14-2 Snow Wing (Left Hand).......................................................................................................E-32300

14-2-1 Lower Curl (Left hand) (Optional)............................................................................D-33220

14-3 Snow Wing (Right Hand) ....................................................................................................E-32301

14-3-1 Lower Curl (Right Hand) (Optional).........................................................................D-33221

FIGURE 15. BROOM & DEFLECTOR

15-1 Standard Broom..................................................................................................................E-33260

15-1-1 Broom Liner.............................................................................................................C-38264

15-2 Clamp Style Broom Shaft....................................................................................................D-27730

15-3 Stone Deflector ...................................................................................................................D-27680

FIGURE 16. SNOW SCREW & BLOWER

16-1 Snow Screw and Blower (9-Feet) .......................................................................................D-27709

16-2 Snow Screw and Blower .....................................................................................................E-27187

FIGURE 22. TURNTABLE................................................................................................................D-33030

HYDRAULIC PARTS SHEETS

PIPING ASSEMBLIES

60 Main Machine......................................................................................................................D-33393

60-1 Ballast Wing...............................................................................................................C-32275

60-2 Snow Wing.................................................................................................................D-32277

60-3 Snow Blower..............................................................................................................D-33398

60-4 Transmission .............................................................................................................B-32283

60-5 Emergency Hydraulic Pump ......................................................................................D-38233

60-6 2nd Fuel Tank .............................................................................................................D-38211

60-7 Air Conditioning..........................................................................................................C-32718

Suspension w/Lockups .........................................................................See Mechanical, Figure 2-4

Heater ...................................................................................................See Mechanical, Figure 1-4

Inner Door Cylinder - Ballast Wing (Optional)................................. See Mechanical, Figure 14-1-1

FUNCTIONAL SCHEMATICS

65 Main Machine......................................................................................................................D-33394

65-1.....................................................................................................................................C-32396

65-2.....................................................................................................................................B-32282

65-3.....................................................................................................................................B-32276

MANIFOLDS

68 Main ....................................................................................................................................D-33292

Model M2 BR/SC Machine CONTENTS

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PNEUMATIC PARTS SHEETS

FIGURE ASSEMBLY

BASE MACHINE

80 Main Machine........................................................................................................................D-32650

80-1 T-2000 Air Dryer (Optional)........................................................................................C-38385

80-2 Air System Quick Disconnect ....................................................................................A-38053

80-3 Air System Drain........................................................................................................B-38043

80-4 Brake Pressure..........................................................................................................B-38081

80-5 Parking Brake ............................................................................................................C-38249

SAFETY LOCKS

81-1 Safety Locks.......................................................................................................................C-38116

81-2 Safety Locks - Front Plow..................................................................................................C-33358

81-3 Safety Locks - Turntable....................................................................................................D-32401

81-4 Safety Locks - Broom..........................................................................................................C33359

ELECTRICAL PARTS SHEETS

FIGURE ASSEMBLY

70 Main Machine (Up to S/N 9914, excluding 9815)........................................................................E-33060

70A Main Machine (S/N 9915 and Above, S/N M20100 and Above)...............................................E-33530

70-1 Upper Control Console (Up to S/N 9914, excluding 9815) ..............................................C-32330

70-1A Upper Control Console (S/N 9915 and Above, S/N M20100 and Above) .......................D-33531

70-2 Cab and Engine Shroud Emergency Shutdown..................................................................C-38085

70-3 Ammeter .............................................................................................................................C-38429

70-4 Air Conditioning...................................................................................................................B-33105

70-5 Upper Control Console........................................................................................................D-33531

70-6 Power Circuit and Gear Shift Lever (Up to S/N 9914, excluding 9815) .............................C-32333

70-6A Power Circuit and Gear Shift Lever (S/N 9915 and Above, S/N M20100 and Above) ....C-33532

70-7 Emergency Hydraulic Pump...............................................................................................B-33254

70-8 Illuminated Speedometer (Up to S/N 9914, excluding 9815).............................................D-38359

70-8A Illuminated Speedometer (S/N 9915 and Above, S/N M20100 and Above).....................D-38395

70-9 Work Lights........................................................................................................................C-38281

70-10 Beacon..............................................................................................................................C-38155

MISCELLANEOUS ELECTRICAL SCHEMATICS (ELSEWHERE IN MANUAL)

Air Dryer, T-2000 (Optional).........................................................................See Pneumatic, Figure 80-1

Batteries........................................................................................................See Mechanical, Figure 6-1

Brake Pressure Gauge.................................................................................See Pneumatic, Figure 80-4

Defroster........................................................................................................See Mechanical, Figure 1-3

Engine Sump and Block Heater................................................................ See Mechanical, Figure 7-1-2

Ether Start (Optional) ................................................................................ See Mechanical, Figure 7-1-3

Fuel Level Senders .....................................................................................See Mechanical, Figure 10-3

Heater............................................................................................................See Mechanical, Figure 1-4

Oil Tank Heater......................................................................................... See Mechanical, Figure 8-1-1

Parking Brake Warning Light .......................................................................See Pneumatic, Figure 80-5

Suspension w/Lockup ...................................................................................See Mechanical, Figure 2-4

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