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Summary of Contents for Nordco CGS
- Page 1 APPENDIX A CGS HAMMER RAIL GAGER Operation and Maintenance Manual Applies to S/N 480025 and Above Last Revision: Rev. - JUNE 2007...
- 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: Vice-President of Operations NORDCO Inc. 245 W. Forest Hill Avenue Oak Creek, WI 53154...
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Page 5: Follow Safety Instructions
WARNING indicates a potentially hazardous situation These safety instructions are in addition to those which, if not avoided, COULD result in severe bodily listed in the SAFETY section of CGS Machine harm or even death. manuals. These instructions only apply to the use of the Rail Gager. -
Page 6: General Safety Tips
• Use the “STARTUP Checklist” to check the working with engine oils. machine controls and gauges to make certain all 6. Use only Nordco supplied repair parts for this systems are operating correctly. machine. Use of non-OEM designed parts •... - Page 7 APPENDIX A Curve Gang Hammer Model A CGS RAIL GAGER SAFETY ALERTS 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;...
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Page 8: Before Operation
The CGS Rail Gager consists of two assemblies, both of which MUST be locked up for travel (See Lockups later in this manual): Before Operation, Page 4... - Page 9 APPENDIX A Curve Gang Hammer Model A GAGER BUGGY The gager buggy consists of a three piece tubular frame with a roller assembly mounted to each end. These roller assemblies allow the buggy to ride the rail continuously during gaging operations. The LVDT frame houses the LVDT position sensor.
- Page 10 APPENDIX A Curve Gang Hammer Model A GAGER ASSEMBLY The gager assembly consists of a free floating frame, a rail clamp assembly, a pregaging lever and cylinder, a gaging cylinder, and two roller assemblies. The gager frame is supported by a cylinder which not only raises and lowers the assembly, but includes the lockup feature of the gager.
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Page 11: Instruments And Controls
APPENDIX A Curve Gang Hammer Model A INSTRUMENTS AND CONTROLS The gager meter box and portions of the Main Control Panel control the gager assembly in its entirety. An “At-Gage” light in front of the Spike Driver Operator will illuminate when the rail has reached gage, and is the signal for the operator to begin spiking. - Page 12 APPENDIX A Curve Gang Hammer Model A CONTROL OR INSTRUMENT FUNCTION This is a two position switch that controls the work operations of the gager itself. SELECT: Activates the potentiometer allowing you to set the gage. The digital meter will read the potentiometer position. GAGING: The digital meter will read the actual rail gage (LVDT position).
- Page 13 GAGER-RELATED ITEMS IN THE OPERATOR CONTROL BOX The following figures represent gager controls that are housed in the operator control box. These are for reference only. Refer to the Electrical Section of the CGS manual for details and most current drawings of these controls. JUNE/2007 (4945-4800)
- Page 14 APPENDIX A Curve Gang Hammer Model A Before Operation, Page 10 JUNE/2007 (4945-4800)
- Page 15 APPENDIX A Curve Gang Hammer Model A JUNE/2007 (4945-4800) Before Operation, Page 11...
- Page 16 APPENDIX A Curve Gang Hammer Model A Before Operation, Page 12 JUNE/2007 (4945-4800)
- Page 17 APPENDIX A Curve Gang Hammer Model A LOCKUPS Certain machine components have lock-up features for use during high- speed 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.
- Page 18 APPENDIX A Curve Gang Hammer Model A 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 eyes on the frame. To lower the buggy, turn the crank handle counter clockwise, to raise the buggy turn the crank handle clockwise.
- Page 19 APPENDIX A Curve Gang Hammer Model A GAGER SETUP/ADJUSTMENTS Prior to using the gager on any track conditions, the adjustment and alibration 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;...
- Page 20 APPENDIX A Curve Gang Hammer Model A Turn adjustment screw until buggy guide roller is lowered to a position 5/8" down from the top of the rail, or as shown in Figure 13. Tighten locknut. Repeat steps 4 through 6 for the Main Frame (Left) Roller Buggy guide roller.
- Page 21 APPENDIX A Curve Gang Hammer Model A 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.
- Page 22 APPENDIX A Curve Gang Hammer Model A GAGER LEVER HEIGHT ADJUSTMENT The gager levers on both the clamp side and the gaging side must be adjusted correctly to prevent the rail from tipping over as it is pushed. Each lever must contact the rail at or just below the center of the rail web. Both sides of the rail gager, clamp side and gaging side, must be adjusted for proper rail web contact as follows: 1.
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Page 23: Pre-Operational Procedures
APPENDIX A Curve Gang Hammer Model A PRE-OPERATIONAL PROCEDURES After it has been set-up for the correct rail size and gage, operation of the Rail Gager is simple, and for the most part, automatic. However, before attempting to operate the Rail Gager, make sure the following preliminary procedures have been performed. - Page 24 APPENDIX A Curve Gang Hammer Model A RAIL GAGER OPERATION PROCEDURES Normal operation of the rail gager is as follows: 1. Make certain all lock-up devices have been removed: a. Gager Assembly Lockup b. Gager Buggy lock-up Chain/Hooks (Qty: 2) 2.
- Page 25 APPENDIX A Curve Gang Hammer Model A 4. Initiate the gaging cycle by bringing either gun to the READY position (using either hand control, press the SET button). At this point the gaging sequence will begin: a. Rail gager will lower onto the rails. Note: This sequence only takes place when the rail type is set to JOINTED.
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Page 26: After Operation
APPENDIX A Curve Gang Hammer Model A AFTER OPERATION The following procedures must be followed after gaging operation: Reset switches to the following positions: a. Turn Gager GAGER/MONITOR/OFF switch to the OFF position. b. Switch GAGER UP/DOWN to GAGER UP. c. - Page 27 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.
- Page 28 APPENDIX A Curve Gang Hammer Model A GAGER ASSEMBLY Maintenance, Page 24 JUNE/2007 (49454800)
- Page 29 APPENDIX A Curve Gang Hammer Model A GAGER ASSEMBLY LUBRICATION Each Gager Assembly has fifteen (17) grease fittings. See Figures 16 and 17 opposite this page. 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.
- Page 30 APPENDIX A Curve Gang Hammer Model A 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.
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Page 31: Periodic Adjustments
APPENDIX A Curve Gang Hammer Model A PERIODIC ADJUSTMENTS PREGAGER 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: Install a pressure gage on the pressure tap on the gager hydraulic manifold. Remove cap on the relief valve (see photo below) adjustment. -
Page 32: General Setup
1. Press the “Par” button on the meter once. The display should alternate between “Pro” and “No”. The Digital Gage Meter (Nordco P/N 5017 4011) is 2. When the display shows “No”, press the “F1” pre-programmed at the factory. If for some reason, button on the front of the display once. - Page 33 APPENDIX A Curve Gang Hammer Model A 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.
- Page 34 APPENDIX A Curve Gang Hammer Model A THIS PAGE INTENTIONALLY LEFT BLANK Maintenance, Page 30 JUNE/2007 (49454800)
- Page 35 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 56406232) located inside the document box. Before you use this chart, you must understand a few basic symbols, keywords, components, and troubleshooting...
- Page 36 APPENDIX A Curve Gang Hammer Model A KEYWORD DESCRIPTION Input Light Input lights are the top lights on the PLC. They are designated by X## Output Lights Output lights are the bottom lights on the PLC. They are designated by Y##. RPC Lights RPC lights are located on the Remote Power Control board inside the logic box.
- Page 37 APPENDIX A Curve Gang Hammer Model A TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION MECHANICAL HYDRAULIC ELECTRICAL PROBLEM Gager cycle will not start. Lockup pins in place. LVDT less than desired gage: Is the “Gage Select/Gaging” switch Put machine in travel Rail-Out Valve not shifting.
- Page 38 APPENDIX A Curve Gang Hammer Model A TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION MECHANICAL HYDRAULIC ELECTRICAL PROBLEM Did workhead go to ready position? Note: Gager will not cycle if workhead did not cycle. If not, check handcontroller SET input lights (X6 or X13) The brakes must be set before the gauger cycle will activate.
- Page 39 APPENDIX A Curve Gang Hammer Model A TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION MECHANICAL HYDRAULIC ELECTRICAL PROBLEM Rail Gager assembly will not raise or Cylinder rod bent. If assembly does not raise: If assembly does not raise: lower. Replace cylinder.
- Page 40 APPENDIX A Curve Gang Hammer Model A TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION MECHANICAL HYDRAULIC ELECTRICAL PROBLEM Pregager Lever will not extend or retract Cylinder rod bent. If lever does not extend: If lever does not extend: Replace cylinder. Pregager OUT directional valve not Check for signal lights at Push shifting.
- Page 41 APPENDIX A Curve Gang Hammer Model A TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION MECHANICAL HYDRAULIC ELECTRICAL PROBLEM Main pump compensator not set correctly. Rail not being pushed in to less than Spring in Gager buggy LVDT out of adjustment. Adjust Adjust compensator to 2500 psi (Refer to gage during automatic sequence.
- Page 42 APPENDIX A Curve Gang Hammer Model A TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION MECHANICAL HYDRAULIC ELECTRICAL PROBLEM Rail not being pushed out to gage, Buggy sections not Main pump compensator not set correctly. Logic system malfunctioning. during automatic sequence. moving freely.
- Page 43 APPENDIX A Curve Gang Hammer Model A TABLE 5. BASIC TROUBLESHOOTING POSSIBLE CAUSE AND SOLUTION MECHANICAL HYDRAULIC ELECTRICAL PROBLEM 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.