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Rail System 4000 User Manual

1. Move the back of the Buggy up to the tie with your center mark for the track Move your plumb bob to the center mark on the back of the buggy and repeat the procedure again Once both the front and rear of the buggy have been centered it is a good idea to check everything a second time just to be sure After you have set the wheel axel assemblies there are a couple of places on each wheel that you can measure to help ensure that the Buggy is set up properly Measure between the back of the wheel and the frame red arrow or measure the amount of the axel that is protruding from the axel mount yellow arrow All four assemblies should read very close to the same measurement If you find that the four assemblies are not measuring out to be in the same position it is very possible d that the Buggy is not correctly set up It is recommended that you repeat the setup procedure again Install the Tripod back onto the Buggy Ensure that the offset indicator located on the bottom front of the Tripod is Zeroed before securing the Tripod to the buggy The RS4000 Buggy and Tripod are properly set up and ready for use Rail Alignment 13 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT Deploying the RS4000 System for Use The following instructions are for a typical set up when tamping existing track If no offset is required both the Sensor and the Laser should be positioned at a Zer
2. until this input is satisfied Ensure that both of the limit switches are present connected properly and are in good working condition Limit Switch is engaged Ensure that the Servo is not completely to one end of travel activating one of the limit switches Limit Switch or Cable Damage Failure t is also possible that if a limit switch has failed it will appear to be engaged Replace the limit switch or the cable Fuse Issue Ensure that fuses F4 F5 amp F6 in the Panel are not blown and are making good contact The Left Center or Right indicator lights on the Panel will not turn on The Left Center or Right indicator lights on the Lightbar will not turn on Fuse Issue Ensure that fuses F1 F2 amp F3 in the Panel are not blown and are making good contact Indicator Damage Failure Send the Panel in for repair The Standby indicator light on the Panel will not turn on Fuse Issue Ensure that fuse F12 in the Panel is not blown and is making good contact Indicator Damage Failure Send the Panel in for repair The Power indicator light on the Panel will not turn on Fuse Issue Ensure that fuses F8 in the Panel is not blown and is making good contact Indicator Damage Failure Send the Panel in for repair The Limit indicator lights on the Lightbar will not turn on when the Servo reaches its limits Fuse Issue Ensure that fuses F6 in the Panel is not blown and is making good contact Indicator Damage
3. 40180 Interface PCB Will directly replace the original parts used in the Classic Panel Assembly 40504 Parts List Additional items Item No Part Number Description Not Pictured 40275 24VDC Converter Not Pictured 40276 6 Pin Power Connector w Wiring Harness 19 RS4000 Panel Mount Kit Part 40501 Rail Alignment 20 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40501 Parts List Item No Part Number Description 1 40071 Mounting Brackets 2 Ref Only 1 4 20 Nylon Lock Nut 3 Ref Only 1 4 Split Lock Washer 4 40280 Threaded Shock Mount 21 RS4000 Lightbar Kit Part 40601 Rail Alignment 22 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40601 Parts List Item No Part Number Description 1 40510 RS4000 LED Lightbar Assembly 2 40511 Lightbar Mounting Kit 23 RS4000 LED Lightbar Part 40510 Rail g 24 Olathe Ks 66062 913 334 8439 ilAli t cor RAIL ALIGNMENT 40510 Parts List Item No Part Number Description 1 743810 Sun Shield 2 40278 Latch 3 40011 Red LED Limit Indicator 4 40012 Yellow LED L R Indicator 5 40010 White LED Center Indicator 6 40023 Connector w Wiring Harness 7 40013 Light Indicator Grommet 8 40014 Yellow HO LED L R Indicator 9 40015 White HO LED Center Indicator 10 Ref Only 10 32 x 3 4 Pan Head Slot Screw 11 Ref Only 4 40 x 3 8 Pan Head Slot Screw 12 Ref Only 4 40 Hex Nut 13 Ref Only 1 4
4. Cannon w Scope 2 40531 Key Box Power Cable 3 40532 Case w Inserts 33 RS4000 Laser Cannon Part 40530 Rail Alignment 34 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40530 Parts List Item No Part Number Description 1 728124 Scope Assembly 2 728119 Scope Mount Set of 2 3 728120 Top Mount Base 4 729880 Vial Mount Ring 5 40069 Scope Mount Tube 6 40261 Vial Assembly 7 Ref Only 6 32 x 5 8 Pan Head Slot Screw 8 729741 Rear Cover Plate 9 Ref Only 6 32 x 3 4 Flat Head Slot Screw 10 Ref Only 10 24 x 3 16 Knurled Tip Set Screw 11 Ref Only 10 24 x 1 2 Knurled Tip Set Screw 12 743672 Power Cable Assembly 13 742905 Attenuator Knob 14 Ref Only 8 32 x 3 8 Flat Head Slot Screw 35 RS4000 Tripod Laser Mount Part 40535 Rail Alignment 36 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40535 Parts List Item No Part Number Description 1 40105 Front Support 2 40108 Catch Block 3 Ref Only 1 4 20 x 3 4 Socket Head Cap Screw 4 Ref Only 5 16 18 x 5 8 Socket Cup Point Set Screw 5 40144 Bumper 6 40181 Clamp Assembly 7 Ref Only 6 32 x 5 16 Socket Head Cap Screw 8 40106 Rear Support 9 Ref Only 10 32 x 1 2 Cone Point Set Screw 10 Ref Only 8 32 x 3 8 Socket Head Cap Screw 11 40141 Spring 12 Ref Only 1 2 13 x 1 2 Socket Head Set Screw 13 40125 Plug 14 40098 Rear Support Block 15 40134 Teflon Washer 16 40135
5. Failure Send the Panel in for repair 58 RAIL The Lightbar does not function Lightbar power has been interrupted Ensure that the cord from the Lightbar to the Panel is not damaged and is properly attached to the Lightbar and Panel Replace cable if damaged Fuse Issue Ensure that fuses F1 F2 F3 amp F6 in the Panel are not blown and are making good contact Bad connection inside Panel Ensure that the Lightbar connection J10 is properly seated and clean Lightbar Damage Failure Send the Lightbar in for repair The Servo does not function Servo power has been interrupted Ensure that the cord from the Servo to the Panel is not damaged and is properly attached to the Servo and Panel You can test for voltage in the power cord by using a voltage meter set for DC power You should see 24 VDC between the motor leads Use the Manual Left Right switch on the Panel to energize the circuit for this test Motor Damage Failure Replace the servo motor No signal from the Sensor f the Servo responds to the manual Left Right switch on the Panel refer to The Sensor is not responding to the Laser above Fuse Issue Ensure the fuse F13 in the Panel is not blown and is making good contact Bad connection inside the Panel Ensure that the Motor connection J3 is properly seated and clean Servo Damage Failure Send the Servo in for repair The Servo will not move in one direction Limit Switch
6. Head Screw 65 Ref Only 3 8 Flat Washer 66 Ref Only 3 8 External Tooth Lock Washer 67 Ref Only 3 8 16 x 3 4 Hex Head Screw 68 Ref Only 1 4 20 x 1 Flat Head Screw 69 Ref Only 10 32 x 5 8 Round Head Screw 70 Ref Only 10 32 x 5 8 Hex Head Screw 71 Ref Only 10 24 Thd 1 Long x 1 4 Dia Shoulder Bolt 72 Ref Only 10 24 Hex Nut 73 Ref Only 8mm 1 25 Serrated Flange Nut 74 Ref Only 1 4 20 x 5 8 Button Head Screw 75 Ref Only 1 4 20 x 1 Hex Head Screw 76 Ref Only 10 32 x 3 16 Cup Point Set Screw Updated Part These parts must be replaced as a set in Yellow assemblies 56 Troubleshooting RAIL Symptom The Laser Cannon does not turn on Possible Causes and Solutions Low or dead battery Charge Battery Dirty or corroded contacts Clean Contacts Damaged Keybox cable Replace Keybox Cable Damaged power cable on the Laser Send the Laser in for service Never attempt to repair the laser on your own This items contains High Voltage electronic componets Personal injury or additional equipment damage could result The Lasers working distance is reduced Low battery Charge Battery Enviornmental conditions are affecting the Laser Heat shimmer rain snow ice fog and dust are all examples of conditions that will affect the working distance of the equipment Dirty or obstructed lens on the Laser and or Sensor Clean lenses Laser output is deminished Send Laser in for service The Sensor Servo w
7. Ks 66062 913 334 8439 www RailAlignment com Replacement Sensor Installation and Adjustments When installing a secondary replacement sensor into a system it is necessary to double check the alignment of the replacement Sensor to the center of the Servo assembly The process is simple String a plumb bob through the center line on the calibration plate If the plumb bob and string line up through the center of the pointer bottom of Servo directly above the scale then no adjustments are needed If the plumb bob and string do not line up through the center of the pointer then you must move the whole Sensor Mount in the necessary direction to align the pieces sone Do nor Set Loosen the four hex head bolts located on the bottom of the sensor mount directly below the Sensor You can access two from each end of the mount opening as pictured to the left With the bolts loose move the sensor mount left or right as required to properly align the Sensor to the system A 9 16 wrench is required to make the adjustment Once the Sensor is properly centered tighten the four hex head bolts The RS4000 Sensor and Servo are properly set up and ready for use Rail Alignment 11 Olathe Ks 66062 913 334 8439 www RailAlignment com Buggy Laser Cart Setup When setting up a brand new Buggy you will need to insert the wheel axel assemblies into the four mounting positions on the bottom corners of the buggy
8. Panel is in Standby mode Place the Simulator up to the window of the Sensor output Diode toward the window Activate the Simulator by pressing the red button on the housing Move the Simulator back and forth across the window of the Sensor and observe that both the lights on the Lightbar and the Panel are indicating an input from the Simulator If the Panel and Lightbar do not respond to the sensor troubleshoot the before moving on to the next step Note To ensure that the Simulator is functioning properly simply look at the output diode while activating it You should see a red flashing light being emitted from the diode Motor Lead Orientation It is possible that the leads for the Servo motor were oriented backwards when the initial connections were made It is simple and necessary to check Place the Panel in Automatic mode Place the Laser Simulator in front of the window of the Sensor and move it to either of the outside edges Activate the Simulator causing the Servo Assembly to start moving DO NOT MOVE THE SIMULATOR WITH THE SERVO Instead observe that the Sensor is trying to center on the Simulator If you are holding the Simulator to the right side of the Sensor window the Servo should be traveling to the right If the Servo is traveling to the left then the leads to the Servo motor are backwards and need to be corrected Limit Switch Orientation Do this step only after you have completed the Motor Lead Orientation check
9. Yellow Toggle Left Brown Toggle Ground Blue Toggle Right Once the power cable is energized turn the Panel on and ensure that it powers up Ifthe Panel does not turn on troubleshoot before moving on to the next step IMPORTANT If your system was configured with Power Cord Part Number 40255 but you are NOT using an external pendant to control Servo position DO NOT REMOVE THE INSULATORS FROM THE ENDS OF THE YELLOW BROWN AND BLUE WIRES DURING INSTALLATION Limit Switches Locate the two limit switch cables Part Number 40047 Mount the limit switches to the mount plates on the servo using the hardware provided with the Servo assembly located in cloth bag tied to the Servo The connector ends of the limit switch cables plug into the bottom of the Panel in locations E and F of the Panel Connection Diagram RAIL ALIGNMENT Lightbar Cable Locate the Lightbar cable Part Number 40048 Plug the appropriate connector into the Lightbar The connector on the opposite end of the cord plugs into the bottom of the Panel in location A of the Panel Connection Diagram NOTE This cable has similar 8 pin connectors on both ends One is male and one is female Ensure that the correct end is being connected to the intended components Servo Power Locate the Servo motor power cable Part Number 40049 Connect the bare cables to the terminal block with one of each of the two wires located across from one of each the wires from the motor The
10. connector plugs into the bottom of the Panel in location D of the Panel Connection Diagram Sensor Cable Locate the Sensor cable Part Number 40050 Plug the appropriate connector into the Sensor The connector at the opposite end of the cord plugs into the bottom of the Panel in location B of the Panel Connection Diagram NOTE This cable has similar 8 pin connectors on both ends One is male and one is female Ensure that the correct end is being connected to the intended components R R en A B C D E F MN MT Fi cor 12 et T a Panel Connection Diagram System Functions Check Lightbar Turn the Panel on and observe that each of the three high output LED lights on the Lightbar flash in sequence To check the red limit indicators have someone activate each of the two limit switches located on the Servo assembly If the Lightbar does not appear to turn on troubleshoot before moving on to the next step Servo Motor Check to ensure that the Servo motor is responding To do this use the Left Right motor control switch on the face of the Panel Ensure that a response is received for both directions If the Servo does not appear to turn on troubleshoot before moving on to the next step RAIL ALIGNMENT Sensor Check to ensure that the Sensor is watching for an input and communicating back to the Panel To do this use the Laser Simulator that was provided with the Sensor Ensure that the
11. lieu of all other warranties expressed or implied The user of the RS4000 components is expected to follow all operating instructions periodically checking the components and the work as it progresses Checking and ensuring the calibration of the system and or its components is the responsibility of the user Calibration and maintenance is not covered by the above warrany Warranty Period 12 months from date of purchase Laser Specialists Inc 19879 W 156 St Olathe KS 66062 PH 913 780 9990 FX 913 780 9815 The only factory authorized service center for all of your Rail System 4000 components 60 RAIL Calibration The RS4000 components are calibrated to the defined accuracy specifications at the factory except where customer assembly is required Is is recommended to check your RS4000 components for calibration periodically before using them to ensure calibration is maintained If any factory set items require calibration send them to your nearest authorized service center Do not attempt component calibration unless you plan to change the calibration Calibration should be performed only by a qualified individual that understands basic calibration principles Transport When transporting the various components of the RS4000 always use the complete original Rail Alignment packaging case and or cardboard box When transporting the Laser in the field always make sure that you carry it in its carrying case
12. 10 and F11 in the Panel are not blown and are making good contact Bad connection inside Panel Ensure that the Sensor connection J2 is properly seated and clean Sensor Cable Damage Failure Replace the cable Sensor Damage Failure Send the Sensor in for Service 57 RAIL The Panel will not turn on Panel power has been interrupted Ensure that the power cord from the power source to the Panel is not damaged and is properly attached to the power source and Panel You can test for voltage in the power cord by using a voltage meter set for DC power Pin A of the connector into the Panel should have 24 VDC Pin B is the ground Fuse Issue Ensure that fuses FI amp F7 in the Panel are not blown and are making good contact Bad connection inside Panel Ensure that the 24 Volt Input J4 connection below fuse F7 and the Switches J5 connection are properly seated and clean Panel Damage Failure Send the Panel in for repair The Left and or Right indicator lights on the panel will not turn off The Left and or Right indicator lights on the Lightbar will not turn off Also one or both of the Red Limit indicators is illuminated Missing Limit Switch The panel is looking for both of the limit switches located on the Servo If the inputs from one or both of the switches is not present the Panel will indicate this to you by turning on the corresponding indicator light In addition the Panel will not function
13. 20 x 1 2 Hex Head Bolt 14 Ref Only 1 4 20 Nylon Lock Nut 25 RS4000 Lightbar Mounting Kit Part 40511 Rail Alignment 26 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40511 Parts List Item No Part Number Description 1 743809 Mount Pin 2 729887 T Bracket 3 40024 Hitch Pin 4 728128 Threaded Shock Mounts 5 729891 Adaptor Plate 6 729888 U Bracket 7 Ref Only Ya Slit Lock Washer 8 Ref Only 14 20 Nylon Lock Nut 9 Ref Only 14 20 x 2 Hex Head Bolt 27 RS4000 Sensor Kit Part 40602 Rail Alignment 28 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40602 Parts List Item No Part Number Description 1 40523 Vandal Cover 2 40520 RS4000 Sensor Assembly 3 40522 Sensor Mount Assembly Not Pictured 40521 Laser Simulator 29 RS4000 Sensor Mounting Kit Part 40522 Rail Alignment 30 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40522Parts List Item No Part Number Description 1 739903 Hitch Pin 2 Ref Only 10 32 x 5 8 Hex Head Bolt 3 Ref Only 10 Split Lock Washer 4 729873 Mount Frame 5 40520 RS4000 Sensor Assembly 6 40066 Mount Grommet 7 Ref Only 5 16 x 3 4 OD Flat Washer 8 Ref Only 5 16 18 x 1 Hex Head Bolt 9 741523 Lock Stable 31 RAIL ALIGNMENT RS4000 Laser Kit Part 40603 RAIL ALIGNMENT 40603 Parts List Item No Part Number Description 1 40530 Laser
14. 4VDC Panel Assembly 2 40504 RS4000 127 150V AC Panel Assembly 3 40501 Panel Mounting Kit 4 40503 Vandal Cover Not Pictured 40502 Panel Cable Set Cable Set includes the following items Quantity Part Number Description 1 40255 6 Pin Panel Power Cable 1 Alt 40046 3 Pin Panel Power Cable 2 40047 Limit Cable 1 40048 Lightbar Cable 1 40049 Servo Power Cable 1 40050 Sensor Cable 17 RS4000 Panel Part 40500 Rail Alignment Olathe Ks 66062 913 334 8439 www RailAlignment com 18 RAIL ALIGNMENT 40500 Parts List Item No Part Number Description 1 40016 Red LED Standby Indicator 2 40019 Yellow LED L R Indicator 3 40018 White LED Center Indicator 4 40017 Green LED Power Indicator 5 40036 On Off amp Standby Toggle Switch 6 40037 Left Right Toggle Switch 7 40038 Toggle Switch Boot 8 743790 Lock Stable 9 40058 Face Plate 10 40254 6 Pin Power Connector w Wiring Harness 10 Alt 40179 3 Pin Power Connector w Wiring Harness 11 40178 Servo Connector w Wiring Harness 12 40176 Lightbar Connector w Wiring Harness 13 40177 Limit Connector w Wiring Harness 14 40175 Sensor Connector w Wiring Harness 15 Ref Only 4 40 x 3 4 Phillips Pan Head Screw 16 40061 Standoff 17 Ref Only 4 40 Nylon Lock Nut 18 Ref Only 8 32 x 3 8 Socket Head Cap Screw 19 Ref Only 10 32 x 5 8 Pan Head Slot Screw 20 40060 Grommet 21 Ref Only 4 40 x 3 8 Pan Head Slot Screw 22 Ref Only 4 40 Hex Nut 23 40034 Main PCB 24
15. 67 Clamp Block 4 40268 Pointer 5 40174 Scale 6 40263 Pin 7 40264 Knob 8 Ref Only 10 Flat Washer 9 Ref Only 10 External Tooth Lock Washer 10 Ref Only 10 32 x 1 2 Pan Head Slot Screw 11 Ref Only 1 4 20 x 3 8 Pan Head Slot Screw 12 Ref Only 1 4 External Tooth Lock Washer 13 Ref Only 1 4 Narrow Washer 14 Ref Only 3 8 Flat Washer 15 Ref Only 3 8 16 Lock Nut 51 RS4000 Canron Servo Part 40552 Pg1 of 3 Rail Alignment 52 Olathe Ks 66062 913 334 8439 www RailAlignment com RS4000 Canron Servo Part 40552 p520f3 6 cee D Rail Alignment 53 Olathe Ks 66062 913 334 8439 www RailAlignment com RS4000 Canron Servo Part 40552 p530f3 Rail Alignment Olathe Ks 66062 913 334 8439 www RailAlignment com 54 RAIL ALIGNMENT 40552 Parts List Pg1of2 Item No Part Number Description 1 40552 Canron Servo Assembly 2 40208 Outer Bearing 3 40212 Shim 4 40204 Bearing Spacer 5 40206 Bearing Block 6 40243 Mounting Bracket 7 40233 Drive Support Plate 8 40084 Standard Metric Scale 9 40234 Guide Rail 10 40242 Anchor Plate 11 40200 Limit Switch Mounting Bracket 12 40072 Limit Switch 13 40173 Jack Screw 14 40213 Support Rod 15 40077 Bellows Flexible Shield w Clamps SET 16 40191 Sensor Plate 17 40172 Brass Nut 18 40203 Nut Guide 19 40199 Pointer Bracket 20 40247 Stop Block 21 40024 Hitch Pin 22 40239 Trip Block 23 40235 Standoff 24 40249 Plug 25 40248 Extensi
16. 8 and the other is 27 then you would move the whole Sensor assembly in its mount in the proper direction to achieve a measurement of 27 7 8 from the plumb bob to either rail Photo to the left shows the location of two of the four bolts that hold the Sensor Mount NOTE In this example record the final measurement of 27 7 8 as it will used to set up the laser cart later Adjust the pointer and scale so that the string runs through the center Zero of both pieces Confirm that the string is still running through the center of the calibration plate on the Sensor as you do this process Rail Alignment 9 Olathe Ks 66062 913 334 8439 www RailAlignment com WARNING The calibration plate between the two red arrows in the picture to the left is set at the factory _for each specific Sensor assembly This plate may not be in the same exact position for each individual Sensor However unless someone has changed the position of the plate or the Sensor is malfunctioning it correctly indicates the true center for that specific Sensor and should not be changed Do not attempt component calibration unless you plan to change the calibration Calibration should be performed only by a qualified individual that understands basic calibration principles If you feel that your Sensor is not correctly calibrated send it in for adjustment Rail Alignment 10 Olathe
17. ALIGNMENT Rail System 4000 User Manual New Product amp Parts Sales Rail Alignment 18907 W 158th Olathe KS 66062 913 334 8439 Warranty Service Center Laser Specialists 19879 W 156 Olathe KS 66062 913 780 9990 Copyright 2009 Rail Alignment LLC Olathe KS 66062 Version 1 Dec09 Table of Contents Component Specifications Set up Component Layout Peripheral Cables System Function Check Motor Lead Orientation Limit Switch Orientation Servo Sensor Setup Buggy Cart Setup System Deployment Component Breakdown RS4000 Panel RS4000 Lightbar RS4000 Sensor RS4000 Laser Cannon RS4000 Tripod Laser Mount RS4000 Laser Cart Buggy RS4000 Plasser Servo Assembly RS4000 Jackson Servo Assembly RS4000 Canron Servo Assembly Trouble Shooting Warranty Care and Transport Calibration Transportation Storage Cleaning and Drying Windows Maintenance Safety Direction Laser Classification FCC Statement Copyright Information RAIL 4 15 4 5 5 6 6 7 8 11 12 13 14 15 16 56 16 21 22 27 28 31 32 35 36 37 38 39 40 44 45 51 52 56 57 59 60 61 62 61 61 61 61 61 62 62 63 62 63 63 63 Rail System 4000 Component Specifications RS4000 24VDC Panel Part 40500 Input Power Requirements 24 VDC 2 VDC RS4000 127 150VAC Panel Part 40504 Input Power Requirements 127 to 150V AC 2 VAC Sensor Power Output 12 VDC amp 12 VDC Servo Power Output 24 VDC Lightbar Power Output 12 V
18. DC Dimensions Weight 14 lbs 6 35kg Height 6 38 16 2cm Width 11 5 29 2cm Length 13 75 34 9cm WARNING Using a Halogen Lightbar with the 40500 or 40504 Panel can result in catastrophic damage to the panel RS4000 Lishtbar Part 40510 Input Power Requirements 12 VDC supplied by the Panel Dimensions Weight 21 5 lbs 9 75kg Height 3 5 8 9cm Width 6 75 17 1cm Length 60 25 153cm RS4000 Sensor Part 40520 Input Power Requirements 12 VDC amp 12VDC supplied by the panel Center Range 25 6 4mm from center Sensor Detecting Range 20 to 2000 6m to 610m Dimensions Weight 10 75 105 4 88kg Height 3 25 8 2cm Width 11 25 28 5cm Length 6 75 17 1cm Sensor Detection Range is affected by multiple environmental conditions and may vary RS4000 Laser Cannon Part 40530 Input Power Requirements 12 VDC 2 VDC Beam Deflection 1 from center or 1 per 100 1m per 100m Minimum Output Power 1 8 mW on SP401 meter Beam Size 8 at 20 20mm at 6m 2 4 at 2000 50 100mm at 610m Focal Distance 300 91m Sweep Rate 10 15 pulses per second Dimensions Weight 9 25 lbs 4 2kg Height 6 15 2cm Width 3 7 6cm Length 26 5 67 3cm RAIL ALIGNMENT RS4000 Setup Before you install the RS4000 system check to ensure that nothing was damaged or lost during shipping If anything is damaged or missing co
19. Description 1 40551 Jackson Servo Assembly 2 40215 Bearing Block 3 40230 Bearing 4 40228 Shim 5 40221 Bearing Spacer 6 40218 Lower Bearing Block 7 40186 Drive Support Plate 8 40217 Support Plate Spacer 9 40084 Standard Metric Scale 10 40220 Scale Spacer 11 40200 Limit Switch Mounting Bracket 12 40072 Limit Switch 13 40173 Jack Screw 14 40213 Support Rod 15 40077 Bellows Flexible Shield w Clamps SET 16 40191 Sensor Plate 17 40172 Brass Nut 18 40203 Nut Guide 19 40199 Pointer Bracket 20 40189 Limit Switch Actuator 21 40043 5X5 Cast Housing 22 40197 Cover Plate 23 40078 Jack Screw Bearing 24 40209 Bearing Retainer 25 40205 Bearing Spacer 26 40271 Non Metallic Washer Shim 27 40227 Crank Shaft 28 40226 Sleeve 29 40225 Non Metallic Shoulder Washer 30 40085 Terminal Block 31 40214 Motor Mounting Plate 32 40075 24VDC Servo Motor 33 40076 Motor Arm 34 40281 Servo Motor Assembly w Sleeve 35 Ref Only 8 32 x 3 4 Flat Head Screw 36 Ref Only 10 24 x 3 4 Pan Head Slot Screw 37 Ref Only 10 Split Ring Lock Washer 38 Ref Only 1 4 20 x 3 Hex Head Screw 39 Ref Only 1 4 Flat Washer 40 Ref Only 10 24 x 2 Pan Head Slot Screw 41 Ref Only 10 External Tooth Lock Washer 48 Drau ALIGNMENT 40551 Parts List Ps 2 or 2 Item No Part Number Description 42 Ref Only 1 4 20 x 1 2 Hex Head Screw 43 Ref Only 1 4 20 x 3 4 Pan Head Slot Screw 44 Ref Only 1 4 Flat Washer 45 Ref Only 1 4 20 Hex Nut 46 Ref Only 1 4 20 x 3 4 Hex Head S
20. Find a section of level track with good gauge Place the Buggy on that section of track If the Laser Tripod is mounted on the Buggy it will need to be removed before you can proceed old Buggies Measure the width of the Buggy across the top of the frame where the Tripod would normally be sitting Should be approximately 51 7 Make a pencil mark in the center of the frame approximately 25 Measure and mark the rear bar of the buggy also Tie a plumb bob on the center mark that you measured and marked Ensure that the offset scale is Zeroed to the center mark at this point Measure the width of the track from the inside of the ball on one side to the inside of the ball on the opposite side Mark the center of the measurement on a tie below the Buggy Move the front of the Buggy with the plumb bob attached and hanging from your center mark over the center mark on the tie Move the Buggy left or right as required to position the center of the Buggy over the center of the track NOTE Only worry about the front of the Bu at this point since that is where the plumb bob is located With the Buggy centered move the wheel axel assemblies on the front of the Buggy out to the ball of the track Double check that the Buggy is still properly centered after you move the wheels Tighten the set screws with a 3 16 allen wrench Rail Alignment 12 Olathe Ks 66062 913 334 8439 www RailAlignment com
21. Ref Only 1 4 20 x 3 4 Socket Head Screw 58 Ref Only 1 4 20 Split Ring Lock Washer 59 Ref Only 5 16 18 x 3 Hex Head Screw 60 Ref Only 5 16 18 Hex Nut 61 Ref Only 6 32 x 3 8 Pan Head Slot Screw 62 Ref Only 6 Split Ring Lock Washer 63 Ref Only 10 32 x 5 8 Hex Head Screw 64 Ref Only 10 24 Thd 1 Long x 1 4 Dia Shoulder Bolt 65 Ref Only 10 24 Hex Nut 66 Ref Only 8mm 1 25 Serrated Flange Nut 67 Ref Only 1 4 20 x 5 8 Button Head Screw 68 Ref Only 1 4 20 x 1 Hex Head Screw 69 Ref Only 10 32 x 3 16 Cup Point Set Screw 70 40211 Crank Shaft For use w Plsr Motor 71 40210 Sleeve For use w Plsr Motor Updated Part These parts must be replaced as a set in Yellow assemblies For use with Rail Alignment standard servo motor and its parts only This part will not work with the optional Plasser Theurer motor or its parts Available directly from Plasser Plasser Theurer Servo Motor Part EL T34 00P Plasser Theurer Servo Motor Arm Part EL T34 03 SHORT 44 RS4000 Jackson Servo Part 40551 Ps of 3 Rail Alignment 45 Olathe Ks 66062 913 334 8439 www RailAlignment com RS4000 Jackson Servo Part 40551 g2 ot 3 Rail Alignment 46 Olathe Ks 66062 913 334 8439 www RailAlignment com RS4000 Jackson Servo Part 40551 s3 of 3 Rail Alignment 47 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40551 Parts List Ps 1 of 2 Item No Part Number
22. Wave Washer 17 40133 Knob w Lock Insert 18 Ref Only 3 8 5 16 18 x 3 4 Socket Head Shoulder Bolt 19 Ref Only 8 32 x 3 8 Socket Head Cap Screw 20 40259 Line Adjustment Assembly 21 Ref Only 5 16 18 x 1 Socket Head Cap Screw 22 40096 Spacer Wear Plate 23 40092 Wear Plate 24 Ref Only 10 32 x 1 2 Socket Head Cap Screw 25 40132 Snap Ring 26 40097 Spacer Wear Plate 27 Ref Only 10 32 x 4 Socket Head Cap Screw 28 40145 Knob Assembly w Swivel Pad 29 40095 Pointer 30 Ref Only 6 32 x 3 8 Socket Head Cap Screw 31 Ref Only 10 32 x 9 16 Socket Head Cap Screw 32 40099 Spacer Wear Plate 33 Ref Only 10 32 x 1 2 Socket Head Cap Screw 34 40127 Spacer Washer 35 Ref Only 10 Split Lock Washer 36 Ref Only 10 32 x 1 2 Socket Head Cap Screw 37 40128 Spacer Washer 38 40158 Front Clamp Frame w Insert 39 40159 Rear Clamp Frame w Inserts Will directly replace the original parts used in the Classic Tripod Assembly 40105 amp 40106 must also include 40181 to repair an Classic Tripod Assembly 37 RS4000 Cart Buggy Part 40540 amp 40541 40540 56 5 Buggy 40541 42 Buggy DETAIL A Rail Alignment 38 Olathe Ks 66062 913 334 8439 www RailAlignment com 40540 amp 40541 Parts List RAIL Item No Part Number Description 1 40148 Wheel Axel Assembly Complete 2 Ref Only 3 8 16 x 5 8 Socket Head Cap Screw 3 40279 Storage Pin 4 40074 Battery Box 5 40083 Metric Standard Scale 6 Ref Onl
23. When transporting RS4000 components by rail air ship or motor vehicle always use the complete original packaging case and or cardboard box or its equivalent to protect it against damage from impact shock and vibration After transport or after long periods of storage inspect each RS4000 component for damage and proper functionality Remove any RS4000 components from service and contact your service provider if you find that any of your equipment has been damaged or does not function properly Storage Temperature Limits 40 to 158 F 40 to 70 C Respect the temperature limits when storing the components particularly in summer if the components are in an none climate controlled enclosure Damp components must be unpacked Dry the components the case and any accessories at not more then 108 F and clean them Do not repack until everything is completely dry Cleaning and Drying Windows Never touch windows with your fingers Use only a clean soft lint free cloth for cleaning If necessary moisten the cloth with water or pure alcohol Use no other liquids these may attack the polymer components and cause failure Maintenance Warning Only Rail Alignment authorized workshops are entitled to repair these products DO NOT ATTEMPT TO OPEN THE LASER ASSEMBLY Continued next page 61 RAIL It is the user s responsibility each time the laser is set up to visually inspect the laser housing to verify that it has not bee
24. above It is possible that the limit switches were oriented backwards during the initial setup It is simple and necessary to check Place the Panel in Automatic mode With the Laser Simulator in hand orient yourself around the Servo assembly so that you can reach the front of the Sensor and both limit switches Place the Laser Simulator against the window of the Sensor and move it to either of the outside edges Activate the Simulator causing the Servo Assembly to start moving Active which ever limit switch the Servo is moving toward and ensure that the Servo travel stops When the limit switch is released the Servo travel should start again If the limit switch that the Servo is traveling toward does not stop the Servo when it is activated then the switches are probably REVERSED Quickly check to see if the other switch causes the Servo to stop If the switches are backward simply disconnect the connections on the bottom of the panel in locations E and F and reconnect them in the opposite locations Servo Sensor Setup IMPORTANT Find and mark a section of level track with good gauge Place the front of the Buggy with the Servo on that section of track This same section of track will be used to setup the laser cart in a later step Turn on the power to the Rail System 4000 Remove the vandal cover from the RS4000 Receiver and place it out of harms way not on top of the Receiver for this process Center the Servo assembly by usin
25. and tamper Any questions regarding how or where the Servo is installed should be referred to the tamper manufacturer RAIL ALIGNMENT RS4000 Buggy The RS4000 aluminum Buggy will need to unpacked and partially assembled New from the factory the Buggy will not have the wheel axel or the bias clamp assemblies installed Those items along with a Flag Battery Box and Handle will be located in the shipping box with the Buggy frame Buggy setup is laid out in the Setup section of this manual RS4000 Tripod The Tripod assembly gets installed onto the RS4000 Buggy Ensure that the Tripod is oriented on the Buggy so that the red pointer located at the bottom rear of the front mount clamp is on the same side of the Buggy as the offset scale Tripod setup is laid out in the Setup section of this manual Route and Install Peripheral Cables Locate and un box the cable set that was supplied with the RS4000 Panel Panel Power Locate the power cable for the Panel This will either be Part Number 40046 3 Pin or Part Number 40255 5 Pin depending on how your system was configured The connector end of the cable plugs into the bottom of the Panel in location C of the Panel Connection Diagram Run the cable along the frame of the buggy back to the power source 24VDC for Panel Part Number 40500 and 127 150V AC for Panel Part Number 40504 40046 Pin Out 40255 Pin Out White Power Red Power Black Ground Black Ground
26. crew 47 Ref Only 1 4 Internal Tooth Lock Washer 48 Ref Only 1 8 x 3 4 Spring Pin 49 Ref Only 1 4 20 x 1 1 2 Hex Head Screw 50 Ref Only 1 4 20 x 1 Flat Head Screw 51 Ref Only 3 8 16 x 3 4 Hex Head Screw 52 Ref Only 3 8 External Tooth Lock Washer 53 Ref Only 3 8 Flat Washer 54 Ref Only 10 24 x 3 4 Flat Head Screw 55 Ref Only 5 16 18 x 3 1 2 Hex Head Screw 56 Ref Only 5 16 Internal Tooth Lock Washer 57 Ref Only 1 4 20 x 3 4 Socket Head Screw 58 Ref Only 1 4 Split Ring Lock Washer 59 Ref Only 5 16 18 x 3 Hex Head Screw 60 Ref Only 5 16 18 Hex Nut 61 Ref Only 6 32 x 3 8 Pan Head Slot Screw 62 Ref Only 6 Split Ring Lock Washer 63 Ref Only 10 32 x 5 8 Hex Head Screw 64 Ref Only 10 24 Thd 1 Long x 1 4 Dia Shoulder Bolt 65 Ref Only 10 24 Hex Nut 66 Ref Only 8mm 1 25 Serrated Flange Nut 67 Ref Only 1 4 20 x 5 8 Button Head Screw 68 Ref Only 1 4 20 x 1 Hex Head Screw 69 Ref Only 10 32 x 3 16 Cup Point Set Screw 70 40229 Stabilizer Pad 71 40222 Beveled Wheel Assembly w Bearings 72 40224 Wheel Bushing 73 Ref Only 1 2 13 x 3 Hex Head Screw 74 Ref Only 1 2 Flat Washer 75 Ref Only 1 2 13 Hex Nut 76 Ref Only 1 8 x 1 1 4 Spring Pin Updated Part These parts must be replaced as a set in Yellow assemblies 49 RS4000 Jackson Servo Extension Part 40231 50 RAIL ALIGNMENT 40231 Parts List Item No Part Number Description 1 40231 Extension Arm Assembly 2 40266 Knob Assembly 3 402
27. g the Left Right toggle switch on the RS4000 Control Panel Using the mounting points for the flexible shields indicated by the Red arrows in the picture to the left on the servo as a reference measure to verify that the distance on both sides is equal The mu rent should be roughly 10 7 8 11 on both the left and right side of the Servo assembly Next set pre load tension spring or the reference bias wheel for which ever rail you are going to start with E Next tie a plumb bob to the lock stable on the top of the sensor mount Align the string so that it is hanging directly through the center of the calibration plate on the face of the Sensor assembly as pictured to the left Ensure that the string hangs far enough down to align the pointer ee En and scale also Al gnment 8 Olathe Ks 66062 913 334 8439 www RailAlignment com NOTE If you have not chosen level track the measurement off of the plumb bob may not be accurate Level track is critical for this process Measure from the Reference Rail to the string and record the measurement Next move the Servo Platform to the opposite rail and ensure that the string is above center mark Measure from the gauge side of the opposite Reference rail to the string and record the second measurement The two measurements should be the same if not split the difference ALIGNMENT Do Her bat For example if one side is 2
28. ght 2010 by Rail Alignment LLC All rights reserved Rail Alignment Proprietary Information NOTICE The information data contained herein is proprietary information of Rail Alignment LLC and is furnished for your controlled use and shall not be copied or otherwise reproduced nor in any manner disclosed to any third party without Rail Alignment s prior written consent Manual is subject to return on demand Rail Alignment 63 Olathe Ks 66062 913 334 8439 www RailAlignment com
29. iately if the equipment becomes unsafe Warning Adverse use can lead to injury malfunction and material damage It is the task of the person responsible for the RS4000 equipment to inform the user about hazards and how to counteract them The RS4000 equipment is not to be used until the user has been instructed how to work with it All users must follow the safety directions given by the manufacturer and the directions of the person responsible for the equipment Laser Classification AN Warning Avoid possible exposure to laser light Class 3R Laser Class 3R lasers are considered safe if handled correctly with restricted beam viewing and maintained in accordance with the instructions Changes or modifications not expressly approved by Rail Alignment could void the user s authority to operate this equipment 62 Illustration of the Safety Decals Affixed to the front of the Laser FCC Statement This equipment complies with limits for a Class A digital device pursuant to part 15 of the FCC rules This device complies with Part 15 of the FCC Rules Operation is subject to the following conditions 1 This device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Warning Changes or modifications not expressly approved by Rail Alignment could void the user s authority to operate the equipment Copyright Notice Copyri
30. ill not settle or it is constantly hunting The Laser was not properly aligned during set up Check the Laser and Scope to ensure properly alignment Send the unit in for calibration if necessary Moisture is present on the Lenes of the Laser and or Sensor Ensure that the Lenes on the Laser and Sensor are dry and free from obstruction System set up issues It is essential for all of the componets of the system to be set up correctly There are multiple components to include the Buggy Tripod Laser and Servo that are either adjustable or have adjustable parts that must be correctly set up Ensure that none of these items needs attention The Sensor is responding to an alternate input n most cases the Sensor will ignore white noise However it is possible that a Sensor facing the sun when it is low enough will incorrectly respond Shade the Sensor from the sun if the situation applies If this does not fix the problem it may be necessary to send the Sensor in for repair The Sensor is not responding to the laser Environmental conditions are affecting the system Ensure that the Lenes on the Laser and Sensor are dry and free from obstruction Also ensure that nothing is blocking the sensor from seeing the Laser in the work area Improper Laser Set up The Tripod that secures the Laser to the Buggy has multiple adjustments Ensure that the Laser is correctly oriented toward the Sensor Fuse Issue Ensure that fuse F7 F
31. is Activated Check to ensure that the Servo is not at its travel limit in the direction you want it to move If it is you should have a Red Limit light illuminated on your Lightbar If you are trying to get the servo to move off of a limit switch but it will not respond it may be because the limit switches are reveresed This is easily figured out by determaining if the Servo motor is still attempting to drive the Servo in the direction that the limit switch that appears to be activated Activate the oposite side limit switch and see if the power to the motor is cut Switch the limit switch connections on the Panel if this is the problem No signal from the Sensor f the Servo responds to the manual Left Right switch on the Panel refer to The Sensor is not responding to the Laser above Fuse Issue Ensure that fuses F4 and F5 in the Panel are not blown and are making good contact Bad connection inside the Panel Ensure that the Motor connection J3 is properly seated and clean Servo Damage Failure Send the Servo in for repair System acts Nervous all the time and I have swapped out serveral componets in an attempt to try and pin point the issue with no change in behavior from the system Dirty Supply Power We have found that with some tampers there is a lot of noise in the supply power and or traveling on the ground If this noise is extremely bad it can cause the RS4000 system to act very nervou
32. late 22 40078 Jack Screw Bearing 23 40209 Bearing Retainer 24 40205 Bearing Spacer 25 40271 Non Metallic Washer Shim 26 40227 Crank Shaft For use w RA Motor 24 40226 Sleeve For use w RA Motor 28 40225 Non Metallic Shoulder Washer 29 40085 Terminal Block 30 40214 Motor Mounting Plate For use w RA Motor al 40075 RA 24VDC Servo Motor 32 40076 RA Motor Arm 33 40281 RA Servo Motor Assembly w Sleeve 34 40198 Motor Mount Plate For use w Plsr Motor 35 Ref Only 8 32 x 3 4 Flat Head Screw 36 Ref Only 10 24 x 3 4 Pan Head Slot Screw 37 Ref Only 10 Split Ring Lock Washer 38 Ref Only 1 4 20 x 4 Hex Head Screw 39 Ref Only 1 4 Flat Washer 40 Ref Only 10 24 x 2 Pan Head Slot Screw 43 RAIL 40550 amp 40553 Parts List Ps 2012 Item No Part Number Description 41 Ref Only 10 External Tooth Lock Washer 42 Ref Only 1 4 20 x 1 2 Hex Head Screw 43 Ref Only 1 4 External Tooth Lock Washer 44 Ref Only 1 4 Flat Washer 45 Ref Only 1 4 20 Hex Nut 46 Ref Only 1 4 20 x 3 4 Hex Head Screw 47 Ref Only 1 4 Internal Tooth Lock Washer 48 Ref Only 1 8 x 3 4 Spring Pin 49 Ref Only 1 2 20 x 5 8 Pan Head Slot Screw 50 Ref Only 1 4 20 x 1 Flat Head Screw 51 Ref Only 3 8 16 x 3 4 Hex Head Screw 52 Ref Only 3 8 External Tooth Lock Washer 53 Ref Only 3 8 Flat Washer 54 Ref Only 10 24 x 3 4 Flat Head Screw 55 Ref Only 5 16 18 x 3 1 2 Hex Head Screw 56 Ref Only 5 16 Internal Tooth Lock Washer 57
33. n damaged so as to allow access to laser light from the interior of the laser from any place other then its intended source If damage to the laser or a malfuntion is present discontinue use of the equipment and return it to your nearest service center for repair Safety Responsibilities Caution Use of controls or adjustments or performance of procedures other then those specified herein may result in hazardous laser light exposure N Warning HeNe laser power up to 4 75mW is emitted through the laser window Rail Alignment is responsible for supplying the product including the user manual and original accessories in a completely safe condition The manufucturers of non Rail Aligment accessories for any RS4000 components and or equipment controlled by the RS4000 system are responsible for developing implementing and communicating safety concepts for their products and are also responsible for the effectiveness of those safety concepts in combination with Rail Alignment product The person responsible for the RS4000 equipment must ensure that it is used in accordance with the instructions This person is also accountable for the training and the deployment of personnel who use the instrument and for the safety of the equipment in use The person in charge of the equipment has the following duties e To understand the safety instructions on the product and the instructions in the user manual e To inform Rail Aligment immed
34. ntact your salesman immediately Mount Components The Rail System 4000 is intended for use with several different models of equipment Each piece of equipment will accommodate this system differently This section of the manual is intended to be a general guide and is not specific to any one manufacturer RS4000 Panel The Panel assembly is generally mounted on the large deployable buggy provided with the tamper The Panel comes with a universal mounting kit that has multiple mounting positions Choose the right location for your specific equipment that will allow easy access to the RS4000 Panel and will also allow the cables to be routed to the peripheral components without issue RS4000 Lightbar The Lightbar assembly is generally mounted toward the front of the large deployable buggy provided with the tamper It would be helpful to mount the Lightbar up high and as far forward on the buggy as possible Ensure that nothing will be blocking the lights on either side of the Lightbar when the system is in operation The five small round indicators should face the tamper operator when properly installed Installation of the Universal Lightbar Mount may not require all of the pieces provided IMPORTANT Ensure that the rubber isolators used in the mounts are perpendicular with the Lightbar once everything is installed RS4000 Sensor and Servo The RS4000 Sensor is mounted directly to the top of the Servo that is used with your specific br
35. o setting on the offset scales If an offset is required make the appropriate adjustments at this point Remove and secure the Vandal Covers from the RS4000 Panel and Sensor Turn the Panel power on and ensure it is in Standby mode With the Buggy Laser Cart lowered down and setting on the track place the Cannon Laser into the Laser Mount on the Buggy with the Laser pointing toward the tamper Place a fully charged deep cycle 12 Volt battery into position in the bottom of the Buggy Push the Buggy ahead of the tamper to the desired distance Working distance will vary depending on equipment condition proper set up and environmental conditions It is possible to achieve working distances of more than a half mile with the new RS4000 systems Make sure the Buggy is on a track with good line It may be set at the beginning of a curve or at the edge of a fixed obstruction If working in an area with multiple lines of track keep in mind proper clearances and measure track centers Secure the Buggy to the line rail that the tamper is set up for using the clamp assembly that is on the Buggy Connect the battery leads from the Key Box cable to the deep cycle battery in the bottom of the Buggy Then plug the Laser into the Key Box cable Ensure that the Laser is emitting a beam Level the Laser by rotating it left or right in the Tripod cradles until the bubble in the level vial is centered level vial located on the rear of the Laser ab
36. on Arm 26 40043 5X5 Cast Housing 27 40197 Cover Plate 28 40078 Jack Screw Bearing 29 40209 Bearing Retainer 30 40205 Bearing Spacer 31 40271 Non Metallic Washer Shim 32 40227 Crank Shaft 33 40226 Sleeve 34 40225 Non Metallic Shoulder Washer 35 40085 Terminal Block 36 40214 Motor Mounting Plate 37 40075 24VDC Servo Motor 38 40076 Motor Arm 39 40281 Servo Motor Assembly w Sleeve 40 Ref Only 1 4 20 x 4 Hex Head Screw 41 Ref Only 1 4 Flat Washer 55 RAIL ALIGNMENT 40552 Parts List Pg2of2 Item No Part Number Description 42 Ref Only 1 4 20 Hex Nut 43 Ref Only 1 4 Split Ring Lock Washer 44 Ref Only 1 4 20 x 3 4 Hex Head Screw 45 Ref Only 1 4 Internal Tooth Lock Washer 46 Ref Only 1 8 x 3 4 Spring Pin 47 Ref Only 1 4 20 x 2 Hex Head Screw 48 Ref Only 1 4 20 x 5 8 Pan Head Slot Screw 49 Ref Only 1 4 Flat Washer 50 Ref Only 1 4 External Tooth Lock Washer 51 Ref Only 1 4 20 x 1 2 Hex Head Screw 52 Ref Only 10 External Tooth Lock Washer 53 Ref Only 10 24 x 2 Pan Head Slot Screw 54 Ref Only 10 24 x 3 4 Pan Head Slot Screw 55 Ref Only 10 Split Ring Lock Washer 56 Ref Only 6 32 x 3 8 Pan Head Slot Screw 57 Ref Only 6 Split Ring Lock Washer 58 Ref Only 1 4 20 x 3 4 Socket Head Screw 59 Ref Only 5 16 18 x 3 Hex Head Screw 60 Ref Only 5 16 Internal Tooth Lock Washer 61 Ref Only 5 16 18 Hex Nut 62 Ref Only 5 16 18 Flat Head Screw 63 Ref Only 5 16 18 x 3 1 2 Hex Head Screw 64 Ref Only 10 32 x 1 1 2 Round
37. ove the power cable Aim the Laser toward the Receiver by adjusting the vertical and horizontal position with the Tripod until one of the three indicator lights on the Lightbar is activated The two outside indicators on the Lightbar are Amber and indicate that you are on one of the outside edges of the Sensor The center indicator is White Adjust the Laser using the Tripod until you get the center white indicator to activate When the center white light on the Lightbar starts flashing continuously the Laser is Zeroed on the Receiver and the system can be placed into Automatic mode 14 RAIL ALIGNMENT With the system in automatic mode watch for a few seconds to ensure that the Sensor remains locked onto the Laser and hold its position If it holds the system is ready for use If the receiver moves in one direction more then 4 Running then the system is not correctly Zeroed Switch the system back into to Standby mode manually re center the Servo using the Left Right switch on the Panel and repeat the Zeroing process With the RS4000 system properly set up you are ready to begin tamping 15 RS4000 Component Breakdown RS4000 Panel Kit Part 40600 amp 40604 40600 24VDC Panel Kit 40604 127 150V AC Panel Kit Rail Alignment 16 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL ALIGNMENT 40600 amp 40604 Parts List Item No Part Number Description 1 40500 RS4000 2
38. s It may be nesecary to filter the supply power with a good line conditioner to correct this problem 59 RAIL Product Indentification The Rail System 4000 product model numbers listed below each have an external identification label on them Enter the serial numbers below along with the purchase dates Retain this information for your records refer to it when you need to contact us with questions or concerns Serial Purchase Date Panel Model 40500 Lightbar Model 40510 Sensor Model 40520 Laser Model 40530 Warranty Rail Alignment LLC Rail Alignment warrants to the original end user Customer that this product will be free from defects in workmanship and materials under normal use and provided any and all operating and maintenance instructions are strictly respected in particular in case of extreme and or continuous applications use of the product Any evidence of an attempt to repair a Rail System 4000 RS4000 component by other than factory authorized personnel using Rail Alignment certified replacement parts will automatically void the warranty Rail Alignments liability under this warranty is limited to repairing or replacing any product returned to a factory authorized service facility for that purpose The foregoing states the entire liability of Rail Alignment in connection with the RS4000 components and they shall not be held responsible for any consequential damage of any kind The foregoing is in
39. y 1 4 20 x 2 1 4 Hex Head Bolt 7 Ref Only 1 4 Flat Washer 8 Ref Only 1 4 Split Lock Washer 9 Ref Only 1 4 20 Hex Nut 10 40081 Whip Flag 11 40274 Handle 12 40269 Bias Clamp Assembly Complete 13 40273 Bias Clamp Bracket 14 Ref Only 5 16 18 x 3 Hex Head Bolt 15 Ref Only 5 16 Split Lock Washer 16 Ref Only 5 16 18 Hex Nut 39 RS4000 Plasser Servo Part 40550 amp 40553 Pg 1 of 3 Rail Alignment 40 Olathe Ks 66062 913 334 8439 www RailAlignment com RS4000 Plasser Servo Part 40550 amp 40553 Pg 2 of 3 Rail Alignment 41 Olathe Ks 66062 913 334 8439 www RailAlignment com RS4000 Plasser Servo Part 40550 amp 40553 Pg 3 of 3 Rail Alignment 42 Olathe Ks 66062 913 334 8439 www RailAlignment com RAIL 40550 amp 40553 Parts List Pg1of2 Item No Part Number Description 1 40550 Plasser Servo Assembly w o Motor 1 40553 Plasser Servo Assembly w RA Motor 2 40262 Wire Guide Assembly Complete 3 739903 Hitch Pin 4 40189 Limit Switch Actuator 5 40208 Outer Bearing 6 40212 Shim 7 40204 Bearing Spacer 8 40072 Limit Switch 9 40200 Limit Switch Mounting Bracket 10 40206 Bearing Block 11 40186 Drive Support Plate 12 40084 Standard Metric Scale 13 40173 Jack Screw 14 40213 Support Rod 15 40077 Bellows Flexible Shield w Clamps SET 16 40191 Sensor Plate 17 40172 Brass Nut 18 40203 Nut Guide 19 40199 Pointer Bracket 20 40043 5X5 Cast Housing 21 40197 Cover P

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