MECHANICAL
Small Spiker Model D
CONTENTS
SERVICE
Jaw Mounting Assembly.................................................................................................................. M-5
Anvil Assembly ................................................................................................................................ M-6
Anvil Removal ................................................................................................................................. M-8
Removing a Stuck Anvil Sleeve ...................................................................................................... M-9
Using the Anvil Spring Compression Tool..................................................................................... M-10
Installing Hammer Lifting Bail........................................................................................................ M-12
Kent Hammer Removal ................................................................................................................. M-13
Kent Hammer Installation .............................................................................................................. M-14
Workhead Plate Removal (Using the Hinged Locking Collar)....................................................... M-15
TROUBLESHOOTING ........................................................................................................................ M-16
MAY/2010 (49453903)
Section M-1
MECHANICAL
Small Spiker Model D
JAW ASSEMBLY
Shut down machine and LOTO.
1. Align the bottom hole in the guide rod with the
hole in the face of the jaw mounting. Insert guide
rod into jaw mounting.
2. Insert ice pick or other small device into hole on
face of jaw mounting and turn the guide rod until
the ice pick enters the hole in the guide rod.
Holes are now aligned for inserting the guide rod
pins.
3. Insert bolt from spike tray side of feeder frame,
apply nut and torque to 10 ft./lbs.
4. Insert the jaws into the bottom of the jaw
mounting.
5. Insert the jaw pins with its hole angled to line up
with angled hole on back leg of jaw mounting.
6. Insert cotter pins. Note: if holes do not line up,
Insert ice pick or other small device into angled
hole and turn the pin until the ice pick enters the
hole in the jaw pin. Hold pin in place while
removing device and insert the cotter pins.
The following procedure creates energy in the spring
when compressed. Failure to keep the energy stored
may cause severe bodily harm or death.
7. Slide the jaw spring over the rod eye.
8. Using the jaw spring compression tool (Nordco
P/N 81380010), compress the spring far enough
to allow insertion of the tip of the rod eye through
the hole on the jaw mounting.
9. Once you have inserted the tip end, slide the eye
end over the post on the jaw.
10. Insert the spring pin through hole in post of jaw.
Section M-2
MAY/2010 (49453903)
MECHANICAL
Small Spiker Model D
ANVIL ASSEMBLY
Shut down machine and LOTO.
1. Insert anvil into hammer.
2. Insert anvil pin.
3. Insert anvil pin retaining pin.
4. Screw in plug.
5. Slide sleeve adapter flange up the anvil.
6. Screw slotted nuts into place. Add cotter
pins to fully lock nuts in place.
7. Slide spacing ring up anvil until it rests over
the sleeve adapter flange.
NOTE: Setscrews on sleeve adapter flange are not
installed at this time. See Step 17.
8. Pry open jaws on jaw mounting.
9. Slide anvil sleeve up through jaws and
through hole in jaw mounting.
10. Place anvil sleeve spring on anvil sleeve.
MAY/2010 (49453903)
Section M-3
MECHANICAL
Small Spiker Model D
ANVIL ASSEMBLY (Continued
11. Thread guide rods through holes in the
workhead mounting plate.
12. Add washers to guide rods.
13. Place hairpin cotter in bottom hole on guide
rod. (Will be moved to a different location
during workhead setup).
14. Attach spring compression tool (Nordco P/N
80180060) to holes in spacing ring and pull
down to compress spring. This will expose
holes on sleeve adapter flange.
NOTE: Detailed instructions for the use of this
spring compression tool can be found on page
M-10.
15. Flip up tool to lock retaining tabs under lip of
sleeve adapter flange.
16. Line up holes in anvil sleeve with holes in
sleeve adapter slange.
17. Insert and tighten setscrews (3 or 4
depending on type of sleeve and flange).
18. Flip tool down to release spring compression
and remove tool.
19. Slide spacing ring back over the sleeve
adapter flange making certain all setscrew
holes are covered.
20. Apply and tighten clamp over spacing ring to
hold in place.
Section M-4
MAY/2010 (49453903)
MECHANICAL
Small Spiker Model D
ANVIL REMOVAL
Center workhead between ties. Shut down machine
and LOTO.
1. Dig out 10-12” of ballast from under
workhead.
2. Remove hairpin cotters from guide rods.
The following step will allow the entire jaw assembly
to free fall to the ground. Use caution when
performing this step. Keep hands, arms, feet and
legs away from this area.
3. Remove cotter pins from slotted numbers on
the sleeve adapter flange. Remove nuts.
4. Remove anvil pin retaining pin plug.
5. Remove anvil pin retaining pin.
The following step may cause the anvil to free fall to
the ground. Use caution when performing this step.
Keep hands, arms, feet and legs away from this
area.
6. Remove and inspect the anvil pin. Replace
if worn.
7. Pull out the anvil.
MAY/2010 (49453903)
Section M-5
MECHANICAL
Small Spiker Model D
REMOVING A STUCK ANVIL SLEEVE
Center workhead between ties. Shut down
machine and LOTO.
1. Dig out 10-12” of ballast from under
workhead.
2. Remove hairpin cotters from guide rods.
The following step will allow the entire jaw
assembly to free fall to the ground. Use caution
when performing this step. Keep hands, arms,
feet and legs away from this area.
3.
Remove cotter pins from slotted numbers
on the sleeve adapter flange. Remove
nuts.
4.
Remove setscrews (3 or 4 depending on
the type of sleeve and adapter).
Using an anvil sleeve tool (Nordco P/N
81300001), slide the blunt end of the tool
into the grooves on the inside face of the
anvil sleeve adapter flange.
Using a light hammer, tap the end of the
tool to loosen the sleeve.
5.
6.
Section M-6
MAY/2010 (49453903)
Small Spiker Model D
MECHANICAL
USING THE ANVIL SPRING COMPRESSION TOOL
1. Rotate ring until holes are between
anvil bushing bolts as shown.
2. Insert tool between guide rod and
anvil.
MAY/2010 (49453903)
Section M-7
MECHANICAL
Small Spiker Model D
3. Rotate tool up so that the pins on the
inside of the tool can be placed in the
holes on the spacing ring. Note:
retaining tabs should be clear of bolt
(as shown).
4. Tighten handle.
5. Tighten handle locknut.
6. Pull handles of tool down to compress
spring.
7. Once setscrews are exposed, use
your thumb(s) to rotate the tool so that
the retaining tabs catch under the lip
of the anvil sleeve adapter flange.
This now enables you to remove the
setscrews for replacement of the anvil
sleeve or for screw replacement.
Reverse process to remove tool.
Section M-8
MAY/2010 (49453903)
Small Spiker Model D
MECHANICAL
HAMMER LIFTING BAIL KIT
(Nordco P/N 98410212)
INSTALLATION PROCEDURES
Hammer weighs in excess of 167
pounds. Handle it with care.
1. Loosen all four M16 capscrews on
top of the Hammer.
2. Remove two capscrews on one
side, parallel to the carriage shaft.
3. Install the lifting bracket with
hardware as shown. Hand tighten
only.
4. Tighten all four capscrews
sequentially as shown in lower
drawing and torque to 180 Ft. lbs.
MAY/2010 (49453903)
Section M-9
MECHANICAL
Small Spiker Model D
HAMMER
REMOVAL PROCEDURES
Hammer weighs in excess of 167
pounds. Handle it with care.
10.
1. Position gun carriages in the most
forward position and spread them to
maximize access to the hammer that
will be removed.
2. Perform appropriate Lock Out-Tag Out
procedure.
3. If you haven’t already done so, install
the hammer lifting bail as shown on
page M-10. Lifting bail will remain
permanently attached to hammer.
4. Disconnect and reposition electrical
cables as required to avoid damage
during hammer replacement.
5. Remove spike feed tray (Remove both
inner and outer trays if changing an
inside hammer – removing outer tray
will allow room for access)
6. Remove anvil assembly, guide rods,
and jaw mounting.
7. Remove the two hydraulic hoses from
Kent Hammer.
8. Secure hammer with a nylon strap
attached to the lift bail
9. Disconnect the upper pattern adjusting
11.
Section M-10
12.
13.
14.
electric actuator so that the work heads
can be spaced apart to remove the
mounting hardware (only if the inside
hammer needs to be removed).
Remove the 2ea. ½ x 7-inch cap
screws that retain the hammer set
plates on either side of the hammer.
Loosen all 7ea. 5/8 x 7-1/2-inch cap
screws from the hammer mounting
plates
Completely remove the 3ea. 5/8 x 71/2 in cap screws surrounding the
hammer along with the shims, spacers
and washers; remember the order of
the shims, spacers, and washers.
Separate the two plates on either side
of the hammer until the hammer is
free; you may need to loosen the
remaining 5/8 cap screws (#11) to
spread the plates far enough.
Once the hammer is free of the plates,
carefully lift it out of the carriage using
a crane and a nylon-lifting strap; it may
be necessary to lift the hammer in
between the two horizontal carriage
shafts.
When lifting the hammer out of the
machine use extreme caution to avoid
damaging horizontal carriage shafts.
MAY/2010 (49453903)
Small Spiker Model D
HAMMER
INSTALLATION PROCEDURES
Hammer weighs in excess of 167
pounds. Handle it with care.
1. Insure the machine has been Locked
Out-Tagged Out, and safe for
performing maintenance.
2. If you haven’t already done so, install
the lifting bail (see instructions on page
M-10). Lifting bail remains
permanently attached to hammer.
3. Using a crane and a nylon-lifting strap,
lift hammer over gun carriage.
4. Lower the hammer down; may need to
lower down in between the two main
carriage support shafts.
5. Position the hammer in the hammer
set plates, install and torque down the
2ea. ½ in. cap screws.
6. Install the mount shims on each side of
MECHANICAL
7. Install the three 5/8 in. cap screws and
spacers to the mounting plates.
8. Remove nylon lifting strap & clevis
from hammer.
9. Re-install the anvil, sleeve assembly
and the jaw mounting.
10. Torque down all seven 5/8 x 7-1/2 in.
cap screws to the hammer mounting
plates.
11. Remove the nylon lifting strap.
12. Re-install the hydraulic hoses.
13. Reconnect and properly route any
electrical cables that were
disconnected during hammer removal.
14. Remove Lock Out-Tag-Out and start
machine. Raise gun assembly. Lock
gun assembly in the up position.
15. Shut off machine and perform Lock
Out-Tag Out procedures.
16. Reinstall spike feed trays.
17. Start machine and test gun function.
hammer as noted in gun hammer
removal.
MAY/2010 (49453903)
Section M-11
MECHANICAL
Small Spiker Model D
WORKHEAD PLATE REMOVAL
Removal of the workhead plate may cause
the workhead guide shafts (2) to fall unless
they are held in place PRIOR to removal of
the plate.
Your toolbox includes two hinged locking
collars. These are used to hold both shafts
during removal of the workhead plate. To
install:
1. Lower the workhead slightly until a two
to three inch gap appears between the
carriage frame and the upper guide
block on the hammer.
2. Remove the screw and washer from
the locking collar. Open the collar and
slide it around the guide shaft as close
to the carriage frame as possible.
3. Place the washer between the two
inside faces of the collar where it
closes and insert and tighten the
screw. Repeat for the second collar.
Note: Once work has been completed, the
collar MUST be removed from the shafts or
they may cause inability to engage
lockups, and interference with and possible
damage to the workhead.
Section M-12
MAY/2010 (49453903)
MECHANICAL
Small Spiker Model D
TROUBLESHOOTING - GENERAL
Troubleshooting is a matter of quickly and logically isolating the cause of a problem and taking
corrective action. Operating experience, a thorough understanding of the information in this manual,
and accurate maintenance and operation records are the best troubleshooting tools an operator can
have. The Model CX Hammer Machine is a group of rather simple systems. If you understand the
basic workings of these systems individually and how they relate to each other, troubleshooting
becomes a relatively simple task.
This is intended to give you basic troubleshooting guidelines for the mechanical systems on this
machine.
Local conditions and operating methods may result in problems, causes and remedies not covered in
this guide. To use the guide most efficiently, locate a problem that matches the one being experience
and, in a step-by-step method, check the causes listed until the correct remedy is found and the
problem solved.
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.
INSPECTION
Inspect the mechanical system for clues to the malfunction. Check to see if the unit can be operated
without further damage.
To avoid possible personal injury and/or engine damage from accidental engine startup, always
disconnect the battery before servicing this machine.
ENGINE TROUBLESHOOTING
Refer to the engine manual behind the component data tab for troubleshooting engine related
problems.
MECHANICAL PROBLEMS WITH HYDRAULIC SOLUTIONS
Refer to Hydraulic Troubleshooting behind the Hydraulic Tab for pressure setting instructions.
MAY/2010 (49453903)
Section M-13
MECHANICAL
Small Spiker Model D
MECHANICAL SYSTEM
TROUBLESHOOTING GUIDE
PROBLEM
POSSIBLE CAUSE
SOLUTION
Brakes not releasing.
See next problem.
Defective motor or broken drive chain.
Repair or replace motor or
chain.
Brakes will not release
Brake lock valve still in the LOCKED
position.
Turn handle to unlock valve.
Brakes will not apply.
Broken spring in brake chamber.
Inspect spring and replace if
necessary.
Brake shoes worn.
Inspect shoes and replace it
necessary.
Pump switch off.
Turn pump switch on.
Circuit breaker tripped.
Reset breaker.
Faulty prox switch.
Replace prox switch.
Faulty valve.
Replace valve.
Pump not producing pressure.
See Hydraulic Troubleshooting.
Spike feed mechanism not lubricated
properly.
Lubricate as necessary.
Feed cylinder and spring defective.
Repair or replace.
Faulty pushbutton on remote operator
control box.
Repair or replace.
Bent jaw.
Inspect and replace if
necessary.
Jaw or pins worn.
Inspect and replace if
necessary.
Pusher block sticking.
Lubricate as necessary.
Feed valve flow control not open far
enough.
Adjust flow control at feed valve
solenoid.
Machine will not
propel.
Workhead Assembly
does not operate.
Spike will not feed
when pushbutton is
pressed.
Spikes not feeding
completely into jaws.
Section M-14
MAY/2010 (49453903)
MECHANICAL
Small Spiker Model D
PROBLEM
Spikes not going in
straight.
POSSIBLE CAUSE
Spike finger not functioning properly.
SOLUTION
Check spike finger for proper
alignment. Repair or replace if
necessary.
Flow control not properly set.
Set flow control (if too fast or too
slow this will cause misfeed)
Jaw and tray not properly aligned.
Check for loose bolts or bent
components.
Jaws worn.
Replace jaws.
Rail being pushed out
too fast.
(Optional gager)
Gaging Speed Limit Switch set too high.
Readjust per instructions on
page 2-24 of the manual.
Gager Indicator not
showing proper gage.
(Optional gager)
Indicator needs to be adjusted
Readjust per instructions on
page 2-25 of the manual.
Rail being pushed out
past gage.
(Optional gager)
Gager cylinder relief valve not set
correctly.
Relief pressure should be set to
500 psi.
Main pump relief valve not set correctly.
Adjust relief valve to 3000 psi.
Main pump compensator not set
correctly.
Rail not being pushed
to gage.
(Optional gager)
Adjust compensator to 2500 psi.
Gager cylinder relief valve not set
correctly.
Relief pressure should be set to
500 psi.
Main pump relief valve not set correctly.
Adjust relief valve to 3000 psi.
Main pump compensator not set
correctly.
Adjust compensator to 2500 psi.
Nipper hooks do not
penetrate ballast
Nipper pressure set too low.
Set nipper pressure to 1500 psi.
Ties being broken
during nipping process
Nipper pressure set too high.
Set nipper pressure to 1500 psi.
MAY/2010 (49453903)
Section M-15
MECHANICAL
Section M-16
Small Spiker Model D
MAY/2010 (49453903)