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Nordco CX Operation And Maintenance Manual

24-volt spiker/hammer w/programmable logic
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24-Volt Spiker/Hammer
w/Programmable Logic
Replacement
Operation and
Maintenance
Manual
Applies to S/N 410950 - 411171
All Tier 3 Engines
Reorder Part: SEE NEXT PAGE
Last Revision: Rev. -
JANUARY 2020
Read and fully understand the precautions contained in this manual before operating
or servicing this machine. Refer to Section 1 for important safety information.

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Summary of Contents for Nordco CX

  • Page 1 24-Volt Spiker/Hammer w/Programmable Logic Replacement Operation and Maintenance Manual Applies to S/N 410950 - 411171 All Tier 3 Engines Reorder Part: SEE NEXT PAGE Last Revision: Rev. - JANUARY 2020 Read and fully understand the precautions contained in this manual before operating or servicing this machine.
  • Page 2 Release/Revisions Release/Rev Date Change Location/Description Rev. - January Re-Write of all existing CX Hammer Operation 2020 Manuals. Combines All Tier 3 Operation manuals into one replacement manual. Re-Order Information OPERATION MANUAL ONLY: PART NUMBER S/N RANGE DESCRIPTION OM410004 S/N 410950-411171...
  • Page 3 This manual is a guide for the operation and routine maintenance of a NORDCO Railroad Maintenance Machine. It covers product technical information, basic operating and maintenance procedures, and safety information and is provided for use by the qualified personnel who will supervise, operate or service the equipment described herein.
  • Page 4 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: Production/Facilities Manager NORDCO Inc. 245 W. Forest Hill Avenue Oak Creek, WI 53154...

  • Page 5: Table Of Contents

    CONTENTS CX Hammer with PLC TABLE OF CONTENTS PREFACE SAFETY ..................................1-1 Understanding Key Safety Alert Words ........................1-1 General Safety Tips ..............................1-2 Safety During Work ............................1-2 Safety During Travel ............................1-3 Safety During Maintenance ..........................1-3 Safety Alerts ................................1-4 Lockout/Tagout Requirements ..........................
  • Page 6 CONTENTS CX Hammer with PLC Section 4: OPERATION MACHINE OPERATION ..............................4-1 Work Operation ............................... 4-1 Spike Driving (without Nippers) ..........................4-2 Spike Driving (with Nippers in Automatic Mode) ..................... 4-2 Spike Driving (with Nippers in Manual Mode) ......................4-2 Spike Driving While Gaging Rail ..........................

  • Page 7: Safety

    Replace all NORDCO and OEM parts with genuine NORDCO or MAY result in minor or moderate injury. OEM parts. Use of non-OEM parts could compromise the safety of your machine.

  • Page 8: General Safety Tips

    SAFETY CX Hammer with PLC GENERAL SAFETY TIPS under the machine is clear of obstructions and personnel. • Only trained and authorized personnel Use care when climbing onto the should be allowed to operate this machine. machine. Always use the steps In addition, all personnel at the worksite and handrails provided.

  • Page 9: Safety During Maintenance

    STARTING When leaving a machine engine running, MACHINE make certain that the parking brake is NORDCO recommends the use of a applied and the electrical interlock button has been activated. Command position. This means that the machine is never running unless someone NEVER stop and park this machine on an is at or near the main control panel.

  • Page 10: Safety Alerts

    SAFETY CX Hammer with PLC MACHINE SAFETY MACHINE SAFETY ALERTS ALERTS DANGER ALERTS WARNING ALERTS Improper use of this machine for any type of operation can cause serious injury or death. Failure to engage all lockup devices To avoid serious injury or death,...

  • Page 11: Lockout/Tagout Requirements

    SAFETY CX Hammer with PLC LOCKOUT-TAGOUT PROCEDURES NORDCO has provided the means to lockout this machine. NORDCO cannot be held responsible for injury caused by failure to comply with your company’s Lockout/Tagout Procedures. The following procedures are designed to lead the operator through the steps required to shut the machine down and prepare it for performing mechanical maintenance work.
  • Page 12 SAFETY CX Hammer with PLC HAZARD DECALS ON THIS MACHINE Hazard decals and plaques that have been placed on this machine are to be kept clean and legible. Replace any decals or plaques that have become illegible or are missing.
  • Page 13 CX Hammer with PLC GENERAL This manual contains information for the CX Hammer machine manufactured by NORDCO INC., Oak Creek, Wisconsin. Information is provided in this manual for operation and maintenance of the machine. Become familiar with all safety instructions, controls and instruments before operating this machine. Follow all instructions carefully.
  • Page 14 GENERAL CX Hammer with PLC SPECIFICATIONS  GENERAL Gross Weight ..........................30,350 lbs (13,766 kg)* Length ..............................25’-8” (7.82 m) Width ................................. 8’-6” (2.60 m) Height ................................9’-10” (3 m) Travel Speed ........................25 mph maximum (40 km/h) Rated Draw Bar Pull .........................1,650 lbs. (750 kg) Turntable ............................
  • Page 15 GENERAL CX Hammer with PLC ELECTRICAL SYSTEM Battery ................24 Vdc (Dual 12V dc Batteries), 1150 Cold Cranking Amps Ground ................................Negative DRIVE SYSTEM Drive Type ........................... Single and Dual Axle Drive Propulsion Motor Type ............................ Hydraulic AXLE/WHEELS Front Axle Size............................. 3-inch, Standard Rear Axle Size .............................
  • Page 16 GENERAL CX Hammer with PLC This Page Intentionally Left Blank Section 1-12 JANUARY/2020 (OM410003)

  • Page 17: Section 2: Pre-Operation

    PRE-OPERATION CX Hammer with PLC Each operator responsible Before operating this machine, read and particular workhead on the machine. Each understand the Safety Section of this workhead consists of two gun assemblies Manual. (left and right). Each operator has two hand controllers that control the function of the guns in front of them.

  • Page 18: Carriage

    WORKHEAD ADJUSTMENTS later in this section. BULK LOADER (OPTIONAL) MANIFOLDS The bulk loader is hydraulically driven spike loader that is designed to “feed” The Model CX hydraulic system uses a spikes into the spike bin located between series manifolds. More detailed the two operators.

  • Page 19: Gager (Optional)

    PRE-OPERATION CX Hammer with PLC GAGER (OPTIONAL) The gager assembly is a series of 4 hydraulic cylinders and lever arms that are designed to position the rails into the proper gage prior to spiking operations. Used with the gager buggy, which sends...
  • Page 20 PRE-OPERATION CX Hammer with PLC Section 2-4 JANUARY/2020 (OM410004)
  • Page 21 PRE-OPERATION CX Hammer with PLC JANUARY/2020 (OM410004) Section 2-5...

  • Page 22: Engine Diagnostics

    PRE-OPERATION CX Hammer with PLC ENGINE DIAGNOSTICS (Tier 3 Engines Only) Turn the ignition switch to the first detent (power will come on, but engine is not started) and wait. The Powerview will come on, and a “WAIT TO START-PREHEAT” message will appear on the screen.
  • Page 23 PRE-OPERATION CX Hammer with PLC Instrument or Control Type of Control Functional Description Menu Key The Menu Key is touched to either enter or exit the menu screens. The Menu key is only used during factory setup procedures. (See Component Data Section for additional operation and setup instructions.)
  • Page 24 PRE-OPERATION CX Hammer with PLC HIDING FAULTS AND WARNINGS If you have hidden (hit the ENTER key at any fault condition), and have returned to the original 4-Up (or 1-Up) screen, the screen will now show icons in the upper right hand corner of a 1-UP screen or in the middle of the 4-UP screen (see figure below) to show you where the faults occurred.
  • Page 25 PRE-OPERATION CX Hammer with PLC JANUARY/2020 (OM410004) Section 2-9...
  • Page 26 PRE-OPERATION CX Hammer with PLC Section 2-10 JANUARY/2020 (OM410004)
  • Page 27 PRE-OPERATION CX Hammer with PLC JANUARY/2020 (OM410004) Section 2-11...
  • Page 28 PRE-OPERATION CX Hammer with PLC Section 2-12 JANUARY/2020 (OM410004)
  • Page 29 PRE-OPERATION CX Hammer with PLC JANUARY/2020 (OM410004) Section 2-13...
  • Page 30 PRE-OPERATION CX Hammer with PLC Section 2-14 JANUARY/2020 (OM410004)
  • Page 31 PRE-OPERATION CX Hammer with PLC JANUARY/2020 (OM410004) Section 2-15...
  • Page 32 PRE-OPERATION CX Hammer with PLC Section 2-16 JANUARY/2020 (OM410004)
  • Page 33 PRE-OPERATION CX Hammer with PLC TABLE 7. OPERATOR STATION CONTROLS The type of braking is selected on the Main Control Panel of the Logic Box. Both brake switches function at all times REGARDLESS of which operator is in control of the travel functions or which mode of brakes has been selected.
  • Page 34 PRE-OPERATION CX Hammer with PLC TABLE 8 OPERATOR STATION CONTROLS HAND CONTROLLER FUNCTIONS The joystick valve attached to the right handcontroller at each work station allows the operator to position the carriage (See Figure 10), while the buttons on the hand controller itself perform actual working operations.
  • Page 35 PRE-OPERATION CX Hammer with PLC TABLE 9 REMOTE CONTROLS AND INDICATORS Item Control or Instrument Function Emergency Pump Located on frame near the engine. Pump can be either electric or manual, (Optional) and is used when there is a loss of system pressure and movement of hydraulic cylinders is necessary.
  • Page 36 PRE-OPERATION CX Hammer with PLC Perform applicable preventative- Preparing the Machine for Work maintenance procedures MAINTENANCE AND SERVICE As with any machine, pre-operational checks preventative maintenance section. should be performed before using the machine. We suggest that you follow the...

  • Page 37: Remote Operator Control Box

    PRE-OPERATION CX Hammer with PLC TABLE 10: PRE-OPERATIONAL CHECKLIST NORDCO recommends that the following checks be performed WITHOUT electrical power, due to a possible battery drain. MAIN CONTROL PANEL STATUS  Logic Box Cover Unlocked and Hooked in Up Position.

  • Page 38: Engine Operation

    PRE-OPERATION CX Hammer with PLC Exhaust emissions caused by the use of the engine on this machine may cause cancer, birth defects, or other reproductive harm if inhaled. Before starting a new or overhauled engine that has been in storage, consult the engine manufacturer’s manual for initial start instructions.

  • Page 39: Lock-Up Devices

    PRE-OPERATION CX Hammer with PLC TABLE 11. STARTUP CHECKS GAUGE READINGS CHECKED:  Tachometer/Hourmeter: 2400 rpm (no load)  Voltmeter: 26 to 28 Volts  Engine Temperature: 160° to 185° F (71° to 85° C)  Engine Oil Pressure: 40 to 60 psi, 3 to 4 bar, 276 to 414 kPa LIGHT/HORN STATUS ...
  • Page 40 PRE-OPERATION CX Hammer with PLC Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or damage to the machine. LOCK-UPS There are areas designated on the machine as lock-up points. Lock-up points are those areas...
  • Page 41 PRE-OPERATION CX Hammer with PLC WORKHEADS There is one lock-up device per gun assembly, two per workhead. They must be unlocked prior to performing service to the workhead or during work operations. Use the following procedure to lock or unlock the assemblies.
  • Page 42 PRE-OPERATION CX Hammer with PLC GUIDE ROLLER ASSEMBLY There is one lock-up device per guide roller assembly, two per machine. Both must be unlocked prior to performing service to the guide roller or during work operations. Use the following procedure to lock or unlock the assemblies.
  • Page 43 PRE-OPERATION CX Hammer with PLC GAGER BUGGY There are two lock-up devices on the gager buggy. These must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies. LOCATION LOCKUP PROCEDURE...
  • Page 44 PRE-OPERATION CX Hammer with PLC BOOM AND WINCH (OPTIONAL - NOT ON MACHINES WITH BULKBINS) LOCATION LOCKUP PROCEDURE WHEN USED 1. Pull down on the lock handle to At all times when boom and winch release the boom. are not being used and during working travel through crossings, at 2.
  • Page 45 PRE-OPERATION CX Hammer with PLC TURNTABLE There is one lock-up device on the turntable assembly. This must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies. LOCATION LOCKUP PROCEDURE...

  • Page 46: Propelling And Braking

    PRE-OPERATION CX Hammer with PLC TRAVEL 3. Put the Propel Speed switch in the LOW (4X) position. 4. Press the appropriate footswitch to propel the It is important that you read about and understand machine. all operating controls, Cautions, Warnings, and Dangers before traveling.

  • Page 47: Machine Setup

    SETUP CX Hammer with PLC JAW DEPTH/RAIL HEIGHT ADJUSTMENT Machine Setup Clips are to be inserted in guide-rods at different There are some adjustments which may have to be positions for various rail heights. There are two made due to varying conditions such as rail height and...

  • Page 48: Workhead Ready Adjustment

    SETUP CX Hammer with PLC WORKHEAD READY ADJUSTMENT above the tie plate. Shut of engine using ignition key. The READY position is the point where the workhead assembly stops descending before the spike is actually Verify the 1/2" distance. If distance is correct, driven in.

  • Page 49: Workhead Spike Pattern Adjustment

    SETUP CX Hammer with PLC Workhead Spike Pattern Adjustments Adjustments to the outer workhead are done using the right hand controller. The inner workhead is adjusted in relation to the outer workhead using two electric actuators, one connected under the inner and outer workheads, the other is located on the upper carriage between the workheads.

  • Page 50: Gager Setup/Adjustments

    SETUP CX Hammer with PLC 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 machine when performing maintenance, making adjustments, or whenever unintended movement of machine could occur;...
  • Page 51 SETUP CX Hammer with PLC 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: Locate the machine on level straight track.
  • Page 52 SETUP CX Hammer with PLC switch to raise the cylinders. Put lockpins in place before continuing with the adjustment. Once the lockpins are in place you have access to the lever arms on the gager. Refer to Figure 14. Remove pin and castle nut.
  • Page 53 SETUP CX Hammer with PLC USING THE WALKWAY (Optional Equipment) To lower the walkway (and use the ladder) 5. Turn handle of lockpin to unlock the pin. Remove the pin. 6. Holding the walkway, allow the walkway to slowly lower Never climb onto platform while machine is running.
  • Page 54 SETUP CX Hammer with PLC USING THE LADDER FOR ACCESS TO THE BULKBIN (Optional Equipment) Never climb onto ladderwhile machine is running. Always maintain three points of contact while climbing to platform. Failure to follow may result in severe bodily injury or death.

  • Page 55: Machine Operation

    OPERATION CX Hammer with PLC MACHINE OPERATION To avoid serious injury or death, make certain that the area around and under the machine is clear of all personnel and obstructions before travelling or working. Failure to engage all lockup devices...

  • Page 56: Spike Driving (Without Nippers)

    OPERATION CX Hammer with PLC SPIKE DRIVING (WITHOUT NIPPERS) SPIKE DRIVING (WITH NIPPERS IN MANUAL MODE) 1. Press and release the LOAD pushbutton to load spikes into jaws. 1. Set the Nipper AUTO/MANUAL switch to the MANUAL position. 2. Press and release the SET pushbutton on the hand controller.

  • Page 57: Spike Driving While Gaging Rail

    OPERATION CX Hammer with PLC pushing the rail in slightly less than gage and SPIKE DRIVING WHILE GAGING RAIL the inside cylinder then pushing the rail out to gage. Normal operation of the roller gager is as follows: 5. If the gage must be temporarily adjusted, 1.

  • Page 58: Winch Operation

    OPERATION CX Hammer with PLC Winch Operation Your machine is equipped with a hydraulic winch for loading materials onto the deck of the machine. In order for the winch to be fully operational, it must have the interlock pin set so that the boom can swing fully from left to right without the lock resetting in another hole.

  • Page 59: Emergency Procedures

    OPERATION CX Hammer with PLC EMERGENCY PROCEDURES EMERGENCY CAUSES 1. If a hydraulic hose fails: a. Shut down the machine immediately. b. Determine the cause of the failure. c. Correct the condition. 2. If any indications on the gauges in the Cab are not within the normal range: a.
  • Page 60 OPERATION CX Hammer with PLC This page intentionally left blank Section 4-6 JANUARY/2020 (OM410004)

  • Page 61: Shutdown

    SHUTDOWN CX Hammer with PLC AFTER OPERATION Parking or Locating Machine General Park or locate machine on level track area, if possible; and where it 1. Set the Travel/Work Mode switch will not be exposed to excessive to the TRAVEL position. This will dust.
  • Page 62 SHUTDOWN CX Hammer with PLC 10. Slowly move the Turntable Valve hand lever downward. Rotation Procedures Turntable Cylinder will retract and the machine will lower onto the To lift and rotate the machine, proceed with track. the following steps: 11. When...

  • Page 63: Towing

    SHUTDOWN CX Hammer with PLC Ensure that the coupling device Towing and rear frame members on the Maximum towing speed is 20 mph. Reduce towing vehicles will not interfere speed accordingly as dictated by weather with or restrict motion of any part of or track conditions.
  • Page 64 SHUTDOWN CX Hammer with PLC This page intentionally left blank Section 5-4 JANUARY/2020 (OM410004)
  • Page 65 Nordco RWE Service and Technical Support 1-800-445-9258 (USA and Canada) The process will be faster if you have the following information in hand before calling: 1. The Machine and Model Name: CX Hammer with PLC 2. The Serial Number JANUARY/2020 (OM410004)
  • Page 66 MAINTENANCE CX Hammer with PLC DAILY (OR 8 HOURS, WHICHEVER COMES FIRST) Key: =   = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK   Follow Engine Mfr’s recommendations for daily maintenance Check Engine Oil Level, fill as required.
  • Page 67 MAINTENANCE CX Hammer with PLC Detailed Daily Instructions D2. Check Engine Oil Level Check the oil level daily with the engine stopped. If necessary, add sufficient oil to raise the level to the proper mark on the dipstick. All diesel engines are designed to use some oil, so periodic addition of oil is normal.
  • Page 68 D30. Inspect wheels, brake system and axles Nordco recommends daily inspections of the brake system and to replace any components that are damaged or show signs of excessive wear. Nordco also recommends stopping distance tests be completed after the daily inspection (and replacement of components - if required). Stopping distance tests should be done prior to each use and as conditions change.
  • Page 69 Chock all of the wheels. 2. Nordco recommends the use of the emergency pump during the replacement of brake shoes, whether or not the engine and pump hydraulics are available.
  • Page 70 MAINTENANCE CX Hammer with PLC D31. Check and adjust the brake shoes as needed (Continued) 10. Place the new Brake Shoe (1) into the Brake Shoe Head (3) 11. Reinstall the Mounting Bolt (2) and Nut. Tighten to the proper specification.
  • Page 71 MAINTENANCE CX Hammer with PLC WEEKLY (OR 40 HOURS, WHICHEVER COMES FIRST) Key: =   = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily Lubrication and Maintenance Procedures Check Battery Condition.
  • Page 72 MAINTENANCE CX Hammer with PLC Detailed Weekly Instructions W3. Oil Propulsion Chains When inspecting the drive chain, the chain should be nearly taut, with 1/4" (.635 Cm) play when depressed at the center. If not, adjustment is necessary see below. If the chain is too tight, the eccentricity of the sprockets may cause the chain to stretch and/or break.
  • Page 73 MAINTENANCE CX Hammer with PLC W7. Check Suction Strainer Element Located on the side of the reservoir, remove and inspect the filter after the first 40 hours of operation and every year thereafter. Clean as required. To access filter: 1. Turn off engine, Make certain suction valve is closed (off)(ccw).
  • Page 74 MAINTENANCE CX Hammer with PLC W11. Grease Gager Buggy Wheels LUBRICATION The Gager Buggy has one grease fitting per buggy wheel assembly (Two total). Oil the adjustment screw to prevent rusting. Section 6-10 JANUARY/2020 (OM410004)
  • Page 75 MAINTENANCE CX Hammer with PLC MONTHLY (OR 150 HOURS, WHICHEVER COMES FIRST) Key: =   = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily and Weekly Lubrication and Maintenance Procedures ...
  • Page 76 MAINTENANCE CX Hammer with PLC QUARTERLY (OR 500 HOURS, WHICHEVER COMES FIRST) Key: =   = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily, Weekly and Monthly Lubrication and Maintenance Procedures Drain Fuel Tank.
  • Page 77 MAINTENANCE CX Hammer with PLC YEARLY (OR 2000 HOURS, WHICHEVER COMES FIRST) Key: =   = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily, Weekly, Monthly and Quarterly Lubrication and Maintenance...

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