Command Control Culvert Loader Not Operating Smoothly

I had one and I gently filed the black horizontal beam the motor rides on the reduce friction.  Then carefully vacuumed and cleaned to ensure no debris got into the moving mechanism.  Not for everyone but it worked for me.

I have the last generation of NON-command culvert loader (paired with the unloader).  As in your situation, it was 'used', but not noticeably.  And the powered loader trolley action was smooth in both directions when I started it up.

The trolley and girder beam appear to be of the same construction, however.  I did remove the motor at one time to make an adjustment to the travel limit sensor/switch at the track end.  I didn't want to keep operating the motor to make this check, so I removed the motor in order to manually move the trolley.

I recall that the trolley rolled smoothly in both directions...as should yours.  I have never applied graphite to the mechanism, and I agree with you in avoiding its use if at all possible.

That said, I would check your beam.  Feel along the parallel surfaces that the trolley rollers contact to check for burrs or bumps.  If you have a set of vernier calipers you might check to be sure that the top and bottom surfaces are truly parallel.  An expansion of a few thousandths could make the difference.  If, in fact, there is a spot where the surfaces are expanded, you might try gently squeezing this area with an appropriate tool (use some plastic/wood/carboard/etc. shims so as to not mar the beam surfaces, though!)

The circumference of the rollers is less than the travel distance of the trolley.  If the bind is at the same location in each direction, I would doubt that the rollers are as suspect as might the beam be.  If there's enough play in the trolley assembly, see if you can rotate each roller slightly to a new position, and then check if the bind is as before, or has changed.

Lastly, I guess I'd try some gentle easing of the trolley assembly with a thin, flat blade.  (e.g., I have a couple of Xacto chisel blades that are too dull for useful cutting, but have served well in this sort of prying,)

Just some suggestions.  I'm hoping a Lionel tech familiar with this problem will also respond.

All in all, when the two accessories are properly functioning, they put on a great show...and have been very reliable!

KD

Thanks to both of you for your replies!!  Not sure that I’d want to file the beam, because that would likely mar the surface. I’ll be pulling this piece off the layout this weekend, so I can place it on workbench and measure the beam for any variance in height across its entire length. I’m not sure the issue is with the height though, as it may be with the thickness, since that’s what appears to be binding the trolley. I do think I’ll try compressing the beam just a bit with pliers, using thin shims to prevent marks on the beam. Thanks again for the suggestions!!

I also have the Culvert Loader/Unloader non-command pair.  I bought them new and hardly used them.  I suspect I expected more perfection then they are designed to give.  It didn't take too long before I tired of adjusting the limit switches in order to achieve acceptable operation.  The gondola detection wiring is also intermittent.  I finally got it to the always-on state so I could at least operate the affected unit.  My solution was also to pull the pair from my layout and they're not going back replacing them with a log unloader and sawmill.   Next step for the Culvert's is to find them a new owner with more patients than I.

@Pennsy Johnnie posted:

Thanks to both of you for your replies!!  Not sure that I’d want to file the beam, because that would likely mar the surface. I’ll be pulling this piece off the layout this weekend, so I can place it on workbench and measure the beam for any variance in height across its entire length. I’m not sure the issue is with the height though, as it may be with the thickness, since that’s what appears to be binding the trolley. I do think I’ll try compressing the beam just a bit with pliers, using thin shims to prevent marks on the beam. Thanks again for the suggestions!!

Yes, thickness of the beam is what I really meant.  And, NO,  I did not intend to suggest that you file the beam...unless there is, indeed, an edge burr that is causing the bind.

OTOH, the beam could be too thick in a certain area 90º to the roller flanges.  If there's no 'play' whatsoever horizontally in the bind zone due to the beam thickness in that direction, careful filing of the beam edges, instead of prying the riveted sides of the trolley to avoid the bind, could be an option.  Re-blacken with a Magic Marker pen.

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Steve...

Sorry you had so many problems with your pair.  The only limit switch I fussed with was on the loader.  Per a recommendation from a Forum member (a few years ago) I moved the limit switch at the track end of the beam.  It was moved 'outward' about an additional 3/8".

The problem was that the loader trolley would drop the culverts, but not squarely, or centered, into the gondola car.  I was surprised that it had to be moved that much more than the factory position.  But, it seems that the culvert drop is a bit 'on the fly'.  IOW, the trolley arms are moving to release the culvert before the trolley comes to a complete stop.

Long story shortened, I drilled a new mounting hole in the beam, reattached the limit switch, and it has operated perfectly/consistently/reliably.  Bingo!

No problems with the unloader.  They're a great pair...when they work properly, I'll admit.

The accessory I lost patience with is the 3656 cattle car/corral.  Lionel has remade many postwar accessories with improvements to operation, installation, and reliability.  Of course, in the hands of the hoi polloi that we are, there's always a hiccup or two to this day, isn't there?  But the 3656 combo has never been remade in an improved format.  It apparently has defied brainstorm meetings and cost analyses to remain the 75 year old conundrum it always has been from day one.   IMHO, of course.

KD

@Pennsy Johnnie posted:

Thanks to both of you for your replies!!  Not sure that I’d want to file the beam, because that would likely mar the surface. I’ll be pulling this piece off the layout this weekend, so I can place it on workbench and measure the beam for any variance in height across its entire length. I’m not sure the issue is with the height though, as it may be with the thickness, since that’s what appears to be binding the trolley. I do think I’ll try compressing the beam just a bit with pliers, using thin shims to prevent marks on the beam. Thanks again for the suggestions!!

I have one suggestion for you.  I noticed you are using FASTTRACK, Which raises the level of the Track up in comparison to the Unit.  I put cork under my Loadeer to make it equal to the height of theTrack.  That helped alot!!

FREDSTRAINS

As a follow up to my earlier post... After trying the various recommendations made here (thank you), I decided that I may try to just replace the beam that the gantry crane rides along, since when I look at it, there appears to be some warpage along the length of it.  I ordered a part that I thought would fit from Trainz, but it was for the original loader with tubular track.  The issue with the FastTrack versions is that the beam needs to be a little longer for it to span the wider width between the crane supports.  Does anyone have any ideas about where I could find one of those, or even the parts number, so I can continue the search?  There's no parts list in the instructions, and I can't find one online, so I'm at a loss.  Thank you!