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CX Hammer with PLC ELECTRICAL APRIL/2012 Rev A (49454112) Section E-1 CONTENTS SERVICE Programmable Logic Controller ....................................................................................................... E-3 PLC Battery Replacement ........................................................................................................ E-3 Replacing the EEPROM (Memory Chip) .................................................................................. E-3 Reprogramming the EEPROM................................................................................................. E-3 Potentiometer Adjustments ...................................................................................................... E-4 Remote Power Controllers (RPC’s) ................................................................................................. E-5 Diagnostics and Replacement ................................................................................................. E-5 RPC Chart ................................................................................................................................ E-6 Gager Meter/LVDT Setup................................................................................................................. E-7 Programming the Gager Meter ................................................................................................ E-7 Setting up the Gager Buggy LVDT ........................................................................................... E-8 TROUBLESHOOTING ........................................................................................................................... E-9 DRAWINGS (In order of appearance) ELECTRICAL SCHEMATICS S/N 410604 and Above ............................................................................................. (97411017DWG) LOGIC BOX QUICK REFERENCE CHARTS S/N 410604 and Above ..................................................................................... 41CX-61A (56406219) CANBUS (Not PLC) Machines Only..................................................................... 41CX-62 (56406175) LOGIC BOXES S/N 410604 and Above ........................................................................................ 41E-70A (31440028) CABLING DRAWINGS S/N 410500 and Above ........................................................................................ 41CX-75 (97411010) HARNESSES Engine ................................................................................................................................... 22311158 Operator Box ......................................................................................................................... 22311159 Manifold Din Cables .............................................................................................................. 22311600 Junction Box Prox Switch ...................................................................................................... 22311601 Fuel Level Cable ................................................................................................................... 22311603 Remote Cable Micro 3-Pole (F) Packard .............................................................................. 22311604 Manifold Din Cables .............................................................................................................. 22311606 Remote Cable Micro 3-Pole (F) Packard .............................................................................. 22311614 Hydraulic Temp Switch Cable ............................................................................................... 42350005 Cab Harness ......................................................................................................................... 42350018 Footswitch ............................................................................................................................. 96410050 Canopy (Short) ...................................................................................................................... 96410206 Hand Controller ..................................................................................................................... 96410265 Workhead .............................................................................................................................. 96410850 LH Manifold ........................................................................................................................... 96410851 RH Manifold........................................................................................................................... 96410852 Nipper .................................................................................................................................... 96410853 Pattern Adjust ........................................................................................................................ 96410854 Gager .................................................................................................................................... 96410855 Hydraulic Tank Junction Box ................................................................................................. 96410856

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  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-1

    CONTENTS

    SERVICE Programmable Logic Controller ....................................................................................................... E-3 PLC Battery Replacement ........................................................................................................ E-3 Replacing the EEPROM (Memory Chip) .................................................................................. E-3 Reprogramming the EEPROM ................................................................................................. E-3 Potentiometer Adjustments ...................................................................................................... E-4 Remote Power Controllers (RPC’s) ................................................................................................. E-5 Diagnostics and Replacement ................................................................................................. E-5 RPC Chart ................................................................................................................................ E-6 Gager Meter/LVDT Setup................................................................................................................. E-7 Programming the Gager Meter ................................................................................................ E-7 Setting up the Gager Buggy LVDT ........................................................................................... E-8

    TROUBLESHOOTING ........................................................................................................................... E-9

    DRAWINGS (In order of appearance)

    ELECTRICAL SCHEMATICS

    S/N 410604 and Above ............................................................................................. (97411017DWG) LOGIC BOX QUICK REFERENCE CHARTS

    S/N 410604 and Above ..................................................................................... 41CX-61A (56406219) CANBUS (Not PLC) Machines Only ..................................................................... 41CX-62 (56406175)

    LOGIC BOXES S/N 410604 and Above ........................................................................................ 41E-70A (31440028)

    CABLING DRAWINGS S/N 410500 and Above ........................................................................................ 41CX-75 (97411010)

    HARNESSES Engine ................................................................................................................................... 22311158 Operator Box ......................................................................................................................... 22311159 Manifold Din Cables .............................................................................................................. 22311600 Junction Box Prox Switch ...................................................................................................... 22311601 Fuel Level Cable ................................................................................................................... 22311603 Remote Cable Micro 3-Pole (F) Packard .............................................................................. 22311604 Manifold Din Cables .............................................................................................................. 22311606 Remote Cable Micro 3-Pole (F) Packard .............................................................................. 22311614 Hydraulic Temp Switch Cable ............................................................................................... 42350005 Cab Harness ......................................................................................................................... 42350018 Footswitch ............................................................................................................................. 96410050 Canopy (Short) ...................................................................................................................... 96410206 Hand Controller ..................................................................................................................... 96410265 Workhead .............................................................................................................................. 96410850 LH Manifold ........................................................................................................................... 96410851 RH Manifold ........................................................................................................................... 96410852 Nipper .................................................................................................................................... 96410853 Pattern Adjust ........................................................................................................................ 96410854 Gager .................................................................................................................................... 96410855 Hydraulic Tank Junction Box ................................................................................................. 96410856

  • ELECTRICAL CX Hammer with PLC

    Section E-2 APRIL/2012 Rev A (49454112)

    This Page left Intentionally Blank

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-3

    PROGRAMMABLE LOGIC CONTROLLER PLC BATTERY REPLACEMENT When the “BATT.V” LED on the PLC box is illuminated, this indicates a low battery. Make certain you have a replacement battery (Nordco P/N 5197 001) in hand PRIOR to attempting to replace the battery.

    To install a new battery: 1. Turn off the PLC’s power supply by

    turning the machine’s ignition switch to the OFF position.

    2. Remove top cover to main (left hand) module.

    3. Remove battery from holder. 4. Disconnect battery from battery

    connector. 5. Connect new battery to connector. 6. Place battery back in holder. 7. Replace top cover to expansion

    module.

    If installation of a new battery does not correct the “BATT.V” problem, this may indicate a battery connection malfunction. Contact NORDCO Service for repair. REPLACING THE EEPROM (MEMORY CHIP)

    1. Turn off the PLC’s power supply by turning the machine’s ignition switch to the OFF position.

    2. Remove top cover to main (left hand) module.

    3. Lift the handle to the EEPROM and gently pull the chip from its socket.

    4. Insert new EEPROM into its holder.

    5. Replace top cover to expansion module.

    REPROGRAMMING THE EEPROM Reprogramming can only be done by Nordco Service personnel. If you want to verify that you have the latest version of this software, write down the Version number on the EEPROM label and contact Nordco’s Parts Sales Department. If there is a more recent version, they can assist you in the purchase of this upgrade.

  • ELECTRICAL CX Hammer with PLC

    Section E-4 APRIL/2012 Rev A (49454112)

    PLC POTENTIOMETER ADJUSTMENTS To increase time, turn pot clockwise, to decrease time – turn pot counterclockwise.

    Nipper Hooks Close Determines how soon the nipper raises the tie after the hooks close. Rail Out Fast Determines the amount of time that the gager inside arms remain on fast speed during the gaging cycle. This adjustment can be used to minimize gager cycle time. Gun Up Delay If any gun is at READY position and the machine is propelled, the gun will come up after a short time delay. This delay allows you to move the machine while the guns are down, in order to center the workhead over the tie plate. For example: If spiking operations were begun with the carriage positions too far forward and you needed to move the machine to position the workhead properly, the time delay would allow you to propel to the correct position and continue the spiking operation WITHOUT the workhead going to the UP position. DO NOT attempt to move the machine if tie is being held by the nippers. The nippers will reset if the propel pedal is pressed. Nipper Down Determines how soon the hooks close after the nippers start to come down. Gager Off This determines how far the arms pulse off the rail. Increasing this duration will make the arms pulse off the rail farther.

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-5

    RPC DIAGNOSTICS AND REPLACEMENT This machine is equipped with Remote Power Controllers. These RPC’s have an integrated status system built into the front of the units. Refer to the chart on the next page to find out which RPC controls which functions on the machine. RED Led is Illuminated This indicates that a wire break (or open circuit) has occurred past the RPC (between the RPC and the Solenoid valve/light). Refer to the chart on the next page for locations of solenoids/junction boxes for each RPC. GREEN Led is Illuminated The GREEN Led indicates that an output signal has been received from the PLC. This is an NORMAL status signal. Both RED and Green Led’s are Illuminated If both the RED and GREEN led’s are lit (red will come on first), this indicates a wire break (or open circuit) or a short circuit has occurred past the RPC (between the RPC and the Solenoid valve/light). Refer to the chart on the next page for locations of solenoids/junction boxes for each RPC.

  • ELECTRICAL CX Hammer with PLC

    Section E-6 APRIL/2012 Rev A (49454112)

    RPC CONTROLS JB/PORT # MANIFOLD/VALVE STACK 0 Gun 1 Load JB1-1 LH Guide Roller Manifold 1 Gun 1 Down JB5-8 Left Manifold 2 Gun 1 Up JB5-7 Left Manifold 5 Gun 2 Load JB1-2 LH Guide Roller Manifold 6 Gun 2 Down JB5-6 Left Manifold 7 Gun 2 Up JB5-5 Left Manifold 12 LH Guide Roller Down JB1-3 LH Guide Roller Manifold 13 LH Guide Roller Up JB1-4 LH Guide Roller Manifold 14 Brakes OFF JB5-4 Left Manifold 17 Brake Lights On Canopy Harness 20 Nipper Hooks Closed JB6-8 Left Manifold 21 Nipper Down & Lock JB6-4 Propulsion Manifold 22 Nipper Up JB6-6 Propulsion Manifold 30 Gun 3 Load JB3-1 RH Guide Roller Manifold 31 Gun 3 Down JB7-8 RH Manifold 32 Gun 3 Up JB7-7 Right Manifold 35 Gun 4 Load JB3-2 RH Guide Roller Manifold 36 Gun 4 Down JB7-6 Right Manifold 37 Gun 4 Up JB7-5 Right Manifold 42 RH Guide Roller Down JB3-3 RH Guide Roller Manifold 43 RH Guide Roller Up JB3-4 RH Guide Roller Manifold 44 - Open - 45 - Open - 46 - Open - 47 At Gage Light Gager Harness 50 Gager Outside Arms Up JB8-5 Right Manifold 51 Gager Outside Arms Down JB8-3 Right Manifold 52 Gager Inside Arms Up JB8-4 Right Manifold 53 Gager Inside Arms Down JB8-6 Right Manifold 54 Gager Inside Arms Fast JB8-8 Right Manifold 55 Gager Rail In Lock JB8-7 Right Manifold 56 Gager Rail Out Lock (RH) JB8-2 Right Manifold 57 Gager Rail Out Lock (LH) JB8-1 Right Manifold

    NOTE: Output lights on PLC would be Y-(RPC #). For example Output light on PLC for RPC 55 would be Y-55.

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-7

    PROGRAMMING THE GAGER METER The Digital Gage Meter (Nordco P/N 5017 4011) is pre-programmed at the factory. If for some reason, the programming has been lost, it must be re-calibrated before use. Use the following procedure to properly calibrate the meter: GENERAL SETUP

    1. Slide unit out of case and make sure

    jumper is in position 2, and the other jumper is on B+C.

    2. Slide unit back into case. 3. Turn on the main power at the key

    switch and then turn the Gage/Monitor switch to the GAGER position. This will turn on both the Gage Monitor and the gager buggy LVDT (for use in later steps).

    METER PROGRAMMING General Information For every programmable function there are two alternating displays. The first display is the “parameter” you will be adjusting (will be in bold letters in these instructions).

    The second display is the “Selection” or “Value” you will be adjusting (will be in bold italic letters in these instructions). For these instructions, “x” means an arbitrary number. Setting the Parameters 1. Press the “Par” button on the meter

    once. The display should alternate between “Pro” and “No”.

    2. When the display shows “No”, press the “F1” button on the front of the display once. The display should read “1-InP”.

    3. Press the “Par” button on the meter once. The display should alternate between “range” and “xxxx”

    4. Press the “F1” button seven (7) times. The display should read “20u”.

    5. Press the par button on the meter once. The display should alternate between “dEcPnT” and “0.00”

    6. When the display shows “0.00”, press the “F1” button once. The display should read “0.000”

    7. Press the “Par” button on the meter once. The display should alternate between “round” and “0.001”.

    8. When the display shows “0.001” press the “F1” key twice. The display should read “0.005”

    9. Press the “Par” button on the meter four (4) times. The display should alternate between “InP1” and “x.xxx”

    10. When the display shows “x.xxx”, press and hold the “F1” button until the display reads “0.412”.

    11. Press the “Par” button on the meter once. The display should alternate between “dSP1” and “x.xxx”

    12. When the display shows “x.xxx”, press and hold the “F1” or “F2” button until the display reads “56.125”.

    13. Press the “Par” button on the meter once. The display should alternate between “InP2” and “x.xxx”

    14. When the display shows “x.xxx”, press and hold the “F1” or “F2” button until the display reads “4.95”.

    15. Press the “Par” button on the meter once. The display should

  • ELECTRICAL CX Hammer with PLC

    Section E-8 APRIL/2012 Rev A (49454112)

    alternate between “dSP2” and “x.xxx”

    16. When the display shows “x.xxx”, press and hold the “F1” or “F2” button until the display reads “57.50”.

    17. Press the “Par” button on the meter once. The display should alternate between “Pr0” and “n0”.

    18. When the display shows “No”, press the “F1” button on the front of the display twice.

    19. 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. The display should then show “PLDC”

    Exiting the Meter Programming 22. Press the “Par” button on the front

    of the display seven (7) times. The display should show “End”. Leave the display at “End” and it should automatically exit the program after 2

    seconds and show a value on the display. The display will then read the current setting of the Gage Pot or the signal from the LVDT, depending on the position of the “Gage Select/Gaging” switch.

    Setting up the Buggy LVDT Place the Gager Buggy angled indicator wheels between the rails. Measure the actual gage at the wheels with a tape rule. Make note of this measurement. Loosen the LVDT clamp screw. Move the LVDT inside the gager buggy until the display records the measurement taken in Step 20. Tighten the clamp screw and recheck the display. If the display does not read the measured gage after tightening the screw, readjust and retighten as necessary until correct. To prevent the program from being altered, add a jumper wire between 7 and 8. NOTE: Whenever the program is to be checked or modified, this jumper should be disconnected between 7 and 8.

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-9

    ELECTRICAL TROUBLESHOOTING LECTRICAL SYSTEM UNDERSTANDING TROUBLESHOOTING INSTRUCTIONS Before you use the troubleshooting charts, you must understand a few basic symbols, key words, and components. SIGNAL LIGHT Signal lights (A) are located on proximity switches, DIN cables, and DIN suppression modules.

    HARNESS CONNECTIONS Harness connections are checked from the source to the connection either to a junction box or the logic box (in other words, both ends of harness). TESTING PROXIMITY SWITCHES AND DIN CABLES Troubleshooting the electrical system is not always a simple task. Testing prox switches, cables and junction boxes requires the use of a voltmeter and extensive use of the cabling diagrams in the electrical section. Testing cables requires the use of a voltmeter to determine whether or not power is getting to the components. On this machine, the voltmeter reading should be 24-volts. The Chart and Diagrams on the following pages outline the order for testing electrical components on this machine. If you are experiencing problems, troubleshoot the component from A to G. A: Check the status of the indicator lights on the RPC. B/C: Check the status of the indicator lights on the Output and Input portions of the PLC. D: Check the voltage at Control Box Plug (not the corresponding plug on the harness). E: Check the voltage at the harness. F: Check the voltage at the Junction Box Port. G: Check the voltage at the power pin for the switch or din cable.

  • ELECTRICAL CX Hammer with PLC

    Section E-10 APRIL/2012 Rev A (49454112)

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-11

    INSPECTION Inspect the electrical system for clues to the malfunction. Check to see if the unit can be operated without further damage to the system. Always check these items before turning on switches or running the machine: 1. Look for bare wires that could cause grounds or shorts. Shorted wires can damage the charging

    system. 2. Look for loose or broken wires. 3. Inspect all connections, especially battery connection points. Cleaning harness connectors or

    ground connections can often correct what appears to be a malfunction. 4. Check the battery electrolyte level. Continued loss of electrolyte fluid indicates overcharging or

    cracked battery case. 5. Inspect for overheated parts after the unit has been stopped for a while. They will often smell like

    burned insulation. Put your hand on the alternator. Heat in these parts, when the machine has not been operated for some time, is a sure clue to charging circuit problems.

    Many electrical failures cannot be detected even if the machine is started. If your visual inspection does not indicate the possible malfunction refer to the electrical system troubleshooting guide that follows.

    To avoid possible personal injury and/or engine damage from accidental engine startup, always disconnect the battery before servicing the machine.

    Never shut off battery disconnect switch with engine running. This could cause damage to the voltage regulator, alternator, and/or electrical system.

  • ELECTRICAL CX Hammer with PLC

    Section E-12 APRIL/2012 Rev A (49454112)

    ELECTRICAL SYSTEM TROUBLESHOOTING

    PROBLEM

    POSSIBLE CAUSE

    SOLUTION

    Battery uses too much water

    Cracked battery case. High Ambient Temperature. Shorted Cell. Battery being Overcharged.

    Replace battery. Refill with water. Check specific gravity. Alternator problem. Check charging voltage ≈14.6V, repair or replace alternator.

    Cracked Battery Case

    Frozen battery

    Keep battery fully charged in cold weather. Replace battery.

    Low Battery Output

    Low water level. Dirty or wet battery top causing discharge. Corroded or loose battery cables. Broken Battery post. Wrong size replacement battery.

    Add distilled water. Clean and wipe dry battery top. Clean and tighten battery cables. Wiggle battery post by hand. If post wiggles or turns, replace battery. Replace battery with type specified under "Machine Specifications".

    Starting Motor will not turn.

    Battery disconnect switch turned off. Defective ignition switch Bad helper solenoid Corroded battery terminals.

    Turn switch to "ON" position. Repair or replace. Replace Inspect and clean if necessary.

    Hourmeter does not work.

    Hourmeter Wiring harness shorted Corroded or failed hourmeter groundwire.

    Replace Hourmeter. Replace wiring harness. Replace groundwire.

    Voltmeter does not work.

    Voltmeter Wiring harness Regulator

    Replace meter. Repair or replace. Repair or replace.

    Engine Oil Pressure Gauge does not work.

    Pressure Gauge Defective. Wiring harness.

    Replace gauge. Repair or replace.

    Engine Oil Pressure Gauge always reads

    High Oil Viscosity

    Drain and add correct oil as specified under

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-13

    PROBLEM

    POSSIBLE CAUSE

    SOLUTION

    "HIGH" Wiring harness Engine Oil Pressure Gauge defective. Defective pressure sensor

    "RECOMMENDED LUBRICANTS" Check wiring harness. Repair or replace Repair or replace. Replace sensor

    Engine Oil Pressure Gauge always reads "LOW"

    Low oil level. Low oil viscosity. Wiring harness Gauge defective. Defective pressure sensor.

    Stop engine, check level. If low fill to desired level. Drain and add correct oil as specified under "RECOMMENDED LUBRICANTS" Repair or replace. Replace gauge. Replace sensor.

    Horn does not sound

    Wiring Harness Connection at horn loose. Horn circuit breaker blown. Horn broken. Horn Relay. Horn Switch.

    Check harness, repair or replace. Tighten connection. Reset circuit breaker, see page 89 Check horn, repair or replace. Check relay. Check switch, repair or replace.

    Backup Alarm does not sound.

    Backup Alarm switch not turned on Wiring harness Connection at alarm loose. Backup Alarm Backup alarm switch faulty.

    Turn on. Check harness, repair or replace. Tighten connection. Check alarm, repair or replace. Check switch, repair or replace.

    Travel Lights do not work.

    Wiring harness Connection at light loose. Light circuit breaker blown. Light switch defective.

    Check harness, repair or replace. Tighten connection. Reset circuit breaker, see page 89 Repair or replace switch.

  • ELECTRICAL CX Hammer with PLC

    Section E-14 APRIL/2012 Rev A (49454112)

    PROBLEM

    POSSIBLE CAUSE

    SOLUTION

    Connection at switch loose. Connection at circuit breaker panel loose. Bulb or socket in light defective.

    Tighten connection. Tighten connection. Replace bulb or socket.

    Work Lights do not work.

    Wiring harness Connection at light loose. Light circuit breaker blown. Light switch defective. Bulb or socket in light defective.

    Check harness, repair or replace. Tighten connection. Reset circuit breaker. See next page. Repair or replace switch. Replace bulb or socket.

    Cooling Fan not working

    Loose connection at back of fan Loose connection at circuit breaker panel. Loose connection on relay.

    Tighten. Tighten. Tighten.

    Brake Lights do not work

    Wiring harness. Connection at light loose. Light Circuit breaker blown. Bulb or socket in light defective. Switch on main logic board in wrong position.

    Check harness, repair or replace. Tighten connection. Reset circuit breaker. See page 98 Replace bulb or socket. See Appendix C, Periodic Adjustments for Main Board Settings.

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-15

    TROUBLESHOOTING 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 56406164 – Model C and 56406169 – Model CX) located inside the logic box. Before you use this chart, you must understand a few basic symbols, keywords, components, and troubleshooting Techniques: KEYWORD DESCRIPTION Input Light Input lights are the top lights on both PLC’s (Main and

    Extension). They are designated by X## Output Lights Output lights are the bottom lights on both PLC’s (Main and

    Extension). They are designated by Y##. RPC Lights RPC lights are located on the Remote Power Control board

    inside the logic box. They are designated as RPC##. Signal Lights Refer to lights on proximity switches, junction box ports, and

    DIN suppression modules. Harness connection Harness connections are checked from the source to the

    connection either to a junction box or the logic box. In other words, both ends of the harness.

    Potentiometers Potentiometers are located on the left (main) PLC (under the cover on the left side).

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-16

    TABLE 5. GAGER ADVANCED TROUBLESHOOTING PROBLEM

    POSSIBLE CAUSE AND SOLUTION MECHANICAL

    HYDRAULIC

    ELECTRICAL

    Gager cycle will not start. NOTE: Gager will not cycle if workhead did not cycle.

    Lockup pins in place. Put machine in travel mode and turn off machine. Remove lockup pins.

    LVDT less than desired gage:

    Rail-Out Valve not shifting. See Table 6, Common Solutions.

    LVDT more than desired gage:

    Rail-In Valve not shifting. See Table 6, Common Solutions.

    Is the “Gage Select/Gaging” switch in the GAGING position? Check Gager Circuit Breaker (CB20) to see if tripped. Check for signals at RPC51, Y51, RPC53, and Y53. Check for an input light from one of the ready prox switches (X51, X53, X21, X23). Did workhead go to ready position? Note: Gager will not cycle if workhead did not cycle. If no, check handcontroller ready input light (X6, X13, X36, X45) Check for RAIL-IN output (Y55). If not lit, replace interconnect cable between main PLC and PLC extension.

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-17

    TABLE 5. GAGER ADVANCED TROUBLESHOOTING PROBLEM

    POSSIBLE CAUSE AND SOLUTION MECHANICAL

    HYDRAULIC

    ELECTRICAL

    Gager will not reset at propel NOTE: Rail-in lock and rail out lock should turn off to release pressure in cylinder. Gager will not pulse off in jointed mode if lock valve is on.

    When in JOINTED RAIL mode:

    Rail-In and Rail-Out Lock Valves not shifting. See Table 6, Common Solutions.

    When in WELDED RAIL mode:

    Rail-In Lock and Rail-Out lock valve should turn OFF to release pressure in cylinder.

    Check Rail-In lock and Rail-Out lock are off (Y55, Y56, Y57) Check propel input at X0 or X1 Check potentiometer setting for Gager Off duration for jointed mode only. Check for faulty potentiometer board.

    Inside Cylinders will not retract and/or extend.

    Cylinder rod bent. Replace cylinder.

    If cylinder does not retract:

    Rail-Out lock valves not releasing Inside cylinder directional valve not shifting. See Table 6, Common Solutions.

    If cylinder does not extend: Pilot Operated Check Valve defective, replace valve.

    Inside cylinder directional valve not shifting. See Table 6, Common Solutions.

    If cylinder does not retract:

    Check for signal lights at Gager Inside Arms UP (Y52 and RPC52) Use propel pedal to release clamps, check Travel Pedal Inputs (X0 or X1)

    If cylinder does not extend:

    Is gager LVDT reading below selected gage setting? If yes, then check for signal lights at Gager Inside Arms Down (Y53 and RPC53)

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-18

    TABLE 5. GAGER ADVANCED TROUBLESHOOTING PROBLEM

    POSSIBLE CAUSE AND SOLUTION MECHANICAL

    HYDRAULIC

    ELECTRICAL

    Outside Cylinders will not retract and/or extend.

    Cylinder rod bent. Replace cylinder.

    If cylinder does not retract: Rail-Out lock valves not releasing Outside cylinder directional valve not shifting. See Table 6, Common Solutions.

    If cylinder does not extend: Pilot Operated Check Valve defective, replace valve.

    Outside cylinder directional valve not shifting. See Table 6, Common Solutions.

    If cylinder does not retract: Check for signal lights at Gager Outside Arms UP (Y50 and RPC50) Use propel pedal to release clamps, check Travel Pedal Inputs (X0 or X1)

    If cylinder does not extend:

    Is gager LVDT reading above selected gage setting? If yes, then check for signal lights at Gager Outside Arms Down (Y51 and RPC51)

    Rail not being pushed in to less than gage during automatic sequence.

    Incorrect spacer use on lever roller. Remove roller and put on proper spacer. (Rail Tipping.)

    Check for defective Pilot Operated Check Valve. Replace as necessary. Rail-In Valve not shifting. See Table 6, Common Solutions.

    LVDT out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual. Cable to buggie from junction box loose or defective. Check harness connections from junction box to logic box.

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-19

    TABLE 5. GAGER ADVANCED TROUBLESHOOTING PROBLEM

    POSSIBLE CAUSE AND SOLUTION MECHANICAL

    HYDRAULIC

    ELECTRICAL

    Rail being pushed in too far. Buggy sections not moving freely. Spring in Gager buggy broken, replace if necessary. Buggy not riding on rail.

    Main pump compensator not set correctly. Adjust compensator to 2500 psi (Refer to Service and Maintenance in the machine manual). Rail-Out Valve not shifting. See Table 6, Common Solutions.

    LVDT out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual. Cable to buggie from junction box loose or defective. Check harness connections from junction box to logic box. Check for signal light at Rail-In DOWN (There isn’t such an output).

    Rail not being pushed out to gage, during automatic sequence.

    Buggy sections not moving freely. Incorrect spacer use on lever roller. Remove roller and put on proper spacer. (Rail Tipping.) Spring in Gager buggy broken, replace if necessary.

    Main pump compensator not set correctly. Adjust compensator to 2500 psi (Refer to Service and Maintenance in the machine manual). Gager cylinder relief valve not set correctly. Adjust cylinder relief valve. Rail-Out Valve not shifting. See Table 6, Common Solutions.

    Logic system malfunctioning. Check if LVDT is out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual.

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-20

    TABLE 5. GAGER ADVANCED TROUBLESHOOTING PROBLEM

    POSSIBLE CAUSE AND SOLUTION MECHANICAL

    HYDRAULIC

    ELECTRICAL

    Rail being pushed out past gage. Incorrect spacer use on lever roller. Remove roller and put on proper spacer. (Rail Tipping.) Spring in gager buggy broken. Replace if defective. Buggy sections not moving freely.

    Main pump compensator not set correctly. Adjust compensator to 2500 psi (Refer to Service and Maintenance in the machine manual). 7 gpm flow control valve could be faulty. Replace as necessary. The rail out fast valve could not be shutting off properly or is stuck. Replace if necessary.

    Logic system malfunctioning. Check if LVDT is out of adjustment. Adjust LVDT as instructed in the Operating Section of this manual. Potentiometer board faulty or the rail out fast duration set too high. Check for no light on the RAIL OUT FAST (Y ) and Gager Inside Arms Down (Y )

    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. Check connections for proper fit. Defective meter. Replace meter.

    Amber at gage light not working.

    LED not working, replace with new

    Loose harness connection at the “At-Gage” box or at logic box. Check connections for proper fit. Check for AT GAGE output (Y47 and RPC47)

  • CX Hammer with PLC ELECTRICAL

    APRIL/2012 Rev A (49454112) Section E-21

    TABLE 6. COMMON SOLUTIONS PROBLEM

    POSSIBLE CAUSE AND SOLUTION MECHANICAL

    HYDRAULIC

    ELECTRICAL

    Valves Not Shifting

    Check if the LED light on the Din/Suppression Diode is lit. If no, see electrical. If yes, check valve solenoid and spool. Replace if defective. To check spool: 1. Remove Coil 2. Remove solenoid stem 3. Rotate spool.

    Check for loose connections at valve, junction box, and logic box (both ends of each cable/harness).

    TROUBLESHOOTING E-9This Page left Intentionally BlankLECTRICAL SYSTEM