Nordco C User manual

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
[phone]
[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: [phone]
Phone: [phone]

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

2003 Model C w/Programmable Logic SAFETY
SAFETY DURING WORK (Continued)
11. There are lockups on this machine that are used for both work and travel. These should be kept
clear and free of debris, grease, etc. See Lockup section for instructions on their use.
12. Inspect hazard decals and replace when they become unreadable or are damaged. (See Hazard
Decals at the end of this Safety section).
13. Seatbelts should be used at all times. Whenever the engine is running, the operator should be in
his/her seat at the operator station with the seat belt properly installed.
14. Keep the operator station floor and logic box console free of tools and/or personal items.
SAFETY DURING TRAVEL
Traveling in this machine requires all steps listed above, in addition:
1. Riders on this machine during travel are limited to the amount of seats available. Never allow the
total number of personnel riding on this machine to exceed the number of seats available.
2. Always make certain that lockups provided on this machine are free of debris or grease and are in
place prior to travel. When traveling on steep inclines, placing the machine in the deadman brake
mode is suggested.
3. Operate the machine carefully when bad weather conditions exist. Icy or wet conditions limit the
stopping ability of the brake system. Maintain a distance between machines that will allow you room
to stop.
4. Halt travel if visibility is poor. Strong rains, fog, and extremely dusty and blowing conditions can
obscure visibility in your area. Wait for weather situation to improve before continuing travel.
5. A travel alarm has been provided on this machine that signals others that you have changed your
direction of travel. Make certain it is working properly BEFORE travel. Use a signal person in high
traffic areas where noise may drown out the alarm and whenever the operators view is obstructed.
6. Anyone standing near the machine is at risk of being injured. Make certain they keep away from the
machine during travel operations.
SAFETY DURING MAINTENANCE
Alert others in the area that service or maintenance is being performed on this machine. Become familiar
with, and use, your company’s lockout-tagout procedures when performing maintenance on this machine.
See LOCKOUT-TAGOUT REQUIREMENTS later in this Safety Section.
Do not start the engine if repairs or work is being performed alone. You should always have at least two
people working together if the engine must be run during service. One person needs to remain in the
command position (at the controls), ready to stop the machine and shut off engine if the need arises.
9/02 (4945-5283D) Section 1, Safety, Page 3

2003 Model C w/Programmable Logic SAFETY
SAFETY ALERTS
WORDING
Improper use of this machine for any type of operation can cause serious injury
or death.
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.
Serious injury or death can result from reaching into driving components while
machine is running! Make observations from a safe distance.
Do not permit unauthorized personnel to ride in or on the machine, or on the
drawbard between the machine and the towing vehicle. Falling from a moving
vehicle may cause serious injury or death.
Shut off engine when checking battery electrolyte level. Do not check or fill
battery in presence of open flame, sparks, or when smoking. Battery fumes are
flammable and/or explosive and if ignited will result in severe bodily injury or
death.
9/02 (4945-5283D) Section 1, Safety, Page 4

2003 Model C w/Programmable Logic SAFETY
SAFETY ALERTS
WORDING
Improper use of this machine for any type of operation can cause serious injury
or death.
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 before propelling at travel speed can result
in injury to personnel and/or damage to the machine.
Tighten fittings only when system is not pressurized. High pressure leaks can
cause personal injury.
Always turn off machine when performing maintenance, making adjustments, or
whenever unintended movement of machine could occur; unless directed
otherwise. Failure to comply could result in personal injury and/or damage to the
machine.
Any machine can be hazardous when raised. Take all necessary precautions
before raising the machine. Do not, under any circumstances, climb under
machine when using the turntable.
To avoid serious personal injury, stay clear of brake springs when using
hydraulic compression to place brake lock pins.
Exhaust emissions caused by the use of the engine on this machine may cause cancer,
birth defects, or other reproductive harm if inhaled.
To avoid possible personal injury and/or engine damage from accidental engine
startup, always disconnect the battery before servicing this machine.
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2003 Model C w/Programmable Logic SAFETY
MODEL C MACHINE
SAFETY ALERTS
WORDING
Before starting a new or overhauled engine that has been in storage, consult the
engine manufacturer’s manual for initial start instructions. Failure to follow those
nstructions can result in serious engine damage.i
Never shut off battery disconnect switch with the engine running. This could cause
damage to the voltage regulator, alternator, and/or electrical system.
Make certain both operators have centered the guide rollers over the rail before
pressing the set button during the Workhead Adjustment procedures. Failure to
do so may result in damage to the machine, as the guide rollers are lowered
when the set button is pressed.
9/02 (4945-5283D) Section 1, Safety, Page 6

2003 Model C w/Programmable Logic SAFETY
LOCKOUT AND/OR TAGOUT PROCEDURES
It is your company’s responsibility to develop Lockout/Tagout Procedures, train you in their proper and safe
use, and to periodically inspect your work area to verify that you are complying with the procedures.
Lockout/Tagout Procedures must be followed!
This machine is completely locked out when the ignition switch and battery disconnect switch have
been turned to the “OFF” position and their respective covers closed and locked. HOWEVER, some
energy is stored in the cylinders and hoses; and these must be relieved of pressure prior to service
and maintenance.
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.
ENERGY SOURCES
The list on the following pages provides information on energy sources located on this machine and
instructions for inserting manual lockups, if applicable. It is your company’s responsibility to incorporate these
instructions into their Lockout/Tagout Procedures.
IMPORTANT NOTICE! (9/01)
Some machines have been equipped with optional Power Lockup devices. There are two
Energy Source lists, one for manual lockup and one for power lockup. Please make certain
you are referring to the correct list when shutting down energy sources.
9/02 (4945-5283D) Section 1, Safety, Page 7

2003 Model C w/Programmable Logic SAFETY
LOCKOUT/TAGOUT – PROCEDURES
MACHINES WITH MANUAL LOCKUPS
When servicing
or performing
maintenance on:
Energy Source
to be locked
out:
Use this procedure:
Electrical
System
(Logic Box,
Battery, Wiring
Harnesses,
Junction and
Control Boxes,
Prox Switches)
Electrical 1) Turn the ignition switch to the OFF position (logic box). If
working on the logic box, continue on to step 2, otherwise close
and lock the logic box cover.
2) Turn the battery disconnect switch to the OFF position and
close and lock the disconnect switch box.
This will cut off electrical power supply to the machine.
Engine Electrical 1) Turn the ignition switch to the OFF position (logic box). Close
and lock the logic box cover.
2) Turn the battery disconnect switch to the OFF position and
close and lock the disconnect switch box.
This will cut off electrical power supply to the machine and
prevent accidental startup of engine while servicing.
Propulsion
System
Hydraulic 1) Turn the ignition switch to the OFF position (logic box). Close
and lock the logic box cover.
2) Turn the battery disconnect switch to the OFF position and
close and lock the disconnect switch box.
This will cut off hydraulic pressure to hydraulic components of
the machine.
Workheads
(Two per
workhead, four
per machine)
Hydraulic
Gravity
1) Place the machine in the TRAVEL mode. This will raise
workheads to allow insertion of the lockup devices.
2) Turn the ignition switch to the OFF position and close and lock
the logic box cover.
3) Turn the battery disconnect switch to the OFF position and
close and lock the disconnect switch box.
4) Locate and insert the lock lockup devices. One for each gun
assembly (four per machine). The lockups are located below
the UP (top) prox switch on each side of the workhead. (Look
for “Lockup Point” sticker)
5) Lockup pin is fully inserted once the pin on the handle can be
turned into the inside slot on the lockup bracket.
6) Refer to the Kent or Allied Hammer Manual behind the
Component Data Tab for specific information regarding
releasing pressure inside the hammers, if so equipped.
7) Refer to Guide Roller Lockup procedure.
This will cut off electrical power supply and hydraulic pressure
to workhead, in addition to preventing “drifting” down of the
workhead.
Rail Clamps
(One per rail
clamp housing,
two per
machine)
Hydraulic
Gravity
1) Place the machine in the TRAVEL mode. This will raise rail clamps to
allow insertion of the lockup devices.
2) Turn the ignition switch to the OFF position and close and lock the
logic box cover.
3) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
4) Locate and insert the lock lockup pins. The pins are stored on the
9/02 (4945-5283D) Section 1, Safety, Page 8

2003 Model C w/Programmable Logic SAFETY
When servicing
or performing
maintenance on:
Energy Source
to be locked
out:
Use this procedure:
inside of the workhead well, close to the rail clamp housing.
5) Insert lockup pin into hole in rail clamp housing. (Look for “Lockup
Point” sticker on housing)
This will cut off hydraulic pressure to rail clamp cylinders and will
prevent “drifting” down of the rail clamp arms.
Gager
(Optional)
Hydraulic
Gravity
1) Place the machine in the TRAVEL mode. This will raise the gager
lever arms to allow insertion of the lockup devices.
2) Turn the ignition switch to the OFF position and close and lock the
logic box cover.
3) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
4) Locate and insert the lock lockup pins. Depending on the S/N range
of your machine, the pins are either stored on the outside face of the
gager housing or on the frame next to the housing.
5) Insert lockup pin into hole in gager housing. (Look for “Lockup Point”
sticker on housing)
This will cut off hydraulic pressure to gager cylinder and will prevent
“drifting” down of the gager lever arms.
Nipper
(Optional)
(One per
machine)
Hydraulic
Gravity
1) Place the machine in the TRAVEL mode. This will raise nipper to
allow insertion of the lockup devices.
2) Turn the ignition switch to the OFF position and close and lock the
logic box cover.
3) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
4) Locate the nipper lockup pin. It is behind the 3rd operator seat. It is a
non-removable lockup pin.
8) Lockup pin is fully inserted once the pin on the handle can be turned
into the inside slot on the lockup bracket.
This will cut off hydraulic pressure to nipper cylinder and will prevent
“drifting” down of the nipper hooks.
Guide
Roller
(One per guide
roller, two per
machine)
Hydraulic
Gravity
1) Place the machine in the TRAVEL mode. This will raise guide roller to
allow insertion of the lockup devices.
2) Turn the ignition switch to the OFF position and close and lock the
logic box cover.
3) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
4) Locate the lockup pin.
5) Insert the lockpin into the guide roller. (Look for the “Lockup Point”
sticker)
This will cut off hydraulic pressure to guide roller cylinder and will
prevent “drifting” down of the roller assembly.
9/02 (4945-5283D) Section 1, Safety, Page 9

2003 Model C w/Programmable Logic SAFETY
LOCKOUT/TAGOUT – PROCEDURES
MACHINES WITH POWER LOCKUPS
When servicing
or performing
maintenance on:
Energy Source
to be locked
out:
Use this procedure:
Electrical
System
(Logic Box,
Battery, Wiring
Harnesses,
Junction and
Control Boxes,
Prox Switches)
Electrical 1) Turn the ignition switch to the OFF position (logic box). If working on the
logic box, continue on to step 2, otherwise close and lock the logic box
cover.
2) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
This will cut off electrical power supply to the machine.
Engine Electrical 3) Turn the ignition switch to the OFF position (logic box). Close and lock
the logic box cover.
4) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
This will cut off electrical power supply to the machine and prevent
accidental startup of engine while servicing.
Propulsion
System
Hydraulic 3) Turn the ignition switch to the OFF position (logic box). Close and lock
the logic box cover.
4) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
This will cut off hydraulic pressure to hydraulic components of the
machine.
Workheads
(Two per
workhead, four
per machine)
Hydraulic
Gravity
9) Place the machine in the TRAVEL mode. This will raise workheads to
allow insertion of the lockup devices.
10) Turn the ignition switch to the OFF position and close and lock the logic
box cover.
11) Turn the battery disconnect switch to the OFF position and close and
lock the disconnect switch box.
12) Locate and insert the lock lockup devices. One for each gun assembly
(four per machine). The lockups are located below the UP (top) prox
switch on each side of the workhead. (Look for “Lockup Point” sticker)
13) Lockup pin is fully inserted once the pin on the handle can be turned into
the inside slot on the lockup bracket.
14) Refer to the Kent or Allied Hammer Manual behind the Component Data
Tab for specific information regarding releasing pressure inside the
hammers, if so equipped.
15) Refer to Guide Roller Lockup procedure.
This will cut off electrical power supply and hydraulic pressure to
workhead, in addition to preventing “drifting” down of the workhead.
Rail Clamps
(One per rail
clamp housing,
two per
machine)
Hydraulic
Gravity
6) Place the machine in the TRAVEL mode. This will raise rail clamps to allow
insertion of the lockup devices.
7) Turn the ignition switch to the OFF position and close and lock the logic box
cover.
8) Turn the battery disconnect switch to the OFF position and close and lock the
disconnect switch box.
9) Locate and insert the lock lockup pins. The pins are stored on the inside of the
workhead well, close to the rail clamp housing.
10) Insert lockup pin into hole in rail clamp housing. (Look for “Lockup Point” sticker
9/02 (4945-5283D) Section 1, Safety, Page 10

2003 Model C w/Programmable Logic SAFETY
When servicing
or performing
maintenance on:
Energy Source
to be locked
out:
Use this procedure:
on housing)
This will cut off hydraulic pressure to rail clamp cylinders and will prevent
“drifting” down of the rail clamp arms.
Gager
(Optional)
Hydraulic
Gravity
6) Place the machine in the TRAVEL mode. This will raise the gager lever arms to
allow insertion of the lockup devices.
7) Turn the ignition switch to the OFF position and close and lock the logic box
cover.
8) Turn the battery disconnect switch to the OFF position and close and lock the
disconnect switch box.
9) Locate and insert the lock lockup pins. Depending on the S/N range of your
machine, the pins are either stored on the outside face of the gager housing or
on the frame next to the housing.
10) Insert lockup pin into hole in gager housing. (Look for “Lockup Point” sticker on
housing)
This will cut off hydraulic pressure to gager cylinder and will prevent “drifting”
down of the gager lever arms.
Nipper
(Optional)
(One per
machine)
Hydraulic
Gravity
5) Place the machine in the TRAVEL mode. This will raise nipper to allow insertion
of the lockup devices.
6) Turn the ignition switch to the OFF position and close and lock the logic box
cover.
7) Turn the battery disconnect switch to the OFF position and close and lock the
disconnect switch box.
8) Locate the nipper lockup pin. It is behind the 3rd operator seat. It is a non-
removable lockup pin.
16) Lockup pin is fully inserted once the pin on the handle can be turned into the
inside slot on the lockup bracket.
This will cut off hydraulic pressure to nipper cylinder and will prevent
“drifting” down of the nipper hooks.
Guide
Roller
(One per guide
roller, two per
machine)
Hydraulic
Gravity
6) Place the machine in the TRAVEL mode. This will raise guide roller to allow
insertion of the lockup devices.
7) Turn the ignition switch to the OFF position and close and lock the logic box
cover.
8) Turn the battery disconnect switch to the OFF position and close and lock the
disconnect switch box.
9) Locate the lockup pin.
10) Insert the lockpin into the guide roller. (Look for the “Lockup Point” sticker)
This will cut off hydraulic pressure to guide roller cylinder and will prevent
“drifting” down of the roller assembly.
9/02 (4945-5283D) Section 1, Safety, Page 11

2003 Model C w/Programmable Logic SAFETY
9/02 (4945-5283D) Section 1, Safety, Page 12
SAFETY DECALS ON THIS MACHINE
Safety 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.
When repairing or replacing components that had safety decals on them, it is your responsibility to replace
the safety decals. These can be ordered from the Parts Sales Department.
Safety Decals on this Machine are:
PART NO. DESCRIPTION LOCATION
5642 0001 General Machine Cautions Inside Logic Box Cover
5642 0002 Caution! Watch Your Step Frame, by Step
5642 0003 Danger! Do Not Climb Under Machine... Frame
5642 0004 Danger! Pinch Points On Workheads near spike
trays
5642 0005 Warning! Hand Hazard On Workheads
5642 0006 Danger! Before Servicing... Logic Box Sides
5642 0008 Caution! (For Optional MTS System) On MTS Box
5642 0009 Caution! (For Optional MTS System) On MTS Cable
5642 4501 Caution! Before Welding... Logic Box Face
Battery Box
5642 0010 Lockout Area Logic Box Face
5642 0011 Lockout Area Battery Box
5642 0012 Lockup Points All areas requiring