Model C Spiker/Hammer CONTENTS

TABLE OF CONTENTS

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

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

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

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

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 D – ADVANCED TROUBLESHOOTING CHARTS

APPENDIX E – ROLLER GAGER INSTRUCTIONS (Optional Equipment)

APPENDIX F – BULK LOADER INSTRUCTIONS (Optional Equipment)

APPENDIX G – TORQUE CHART

PARTS SHEETS

(Last Revision in Bold/Parenthesis)

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

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

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