Nordco M2 Operation And Maintenance Manual

Ballast regulator and snow clearing (br/sc) machine

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Model M2

Ballast Regulator and Snow Clearing

(BR/SC) Machine

OPERATION AND

MAINTENANCE MANUAL

October 2000

Re-Order: 49458501

Table of Contents

Troubleshooting

Summary of Contents for Nordco M2

Page 1 Model M2 Ballast Regulator and Snow Clearing (BR/SC) Machine OPERATION AND MAINTENANCE MANUAL October 2000 Re-Order: 49458501...
Page 3 This manual is a guide for the operation and routine maintenance of a NORDCO Railroad Maintenance Machine. It covers product technical information, basic operating and maintenance procedures, and safety information and is provided for use by the qualified personnel who will supervise, operate or service the equipment described herein.
Page 4 If you are interested in receiving this information, please refer to the Name, model, and Serial Number of your machine when calling or writing, and direct your inquiries to: Vice-President of Operations NORDCO Inc. 245 W. Forest Hill Avenue Oak Creek, WI 53154...
Page 5: Table Of Contents
CONTENTS Model M2 BR/SC Machine TABLE OF CONTENTS SAFETY ................................1 Understanding Key Safety Alert Words....................1 Follow Safety Instructions ........................1 General Safety Tips..........................1 Safety Alerts ............................4 Lockout/Tagout Procedures ........................7 GENERAL INFORMATION .........................10 About this Manual..........................10 Optional Equipment..........................10 Machine Specifications..........................11 Parts Ordering Information........................13 OPERATION BEFORE OPERATION..........................15...
Page 6 CONTENTS Model M2 BR/SC Machine MAINTENANCE AND SERVICE GENERAL ..............................49 LUBRICATION AND MAINTENANCE CHART ..................51 LUBRICATION AND MAINTENANCE BY DAY/WEEK/MONTH/ETC............52 Daily Instructions ...........................56 Weekly Instructions ..........................60 Monthly Instructions ..........................61 Quarterly Instructions ..........................62 Yearly Instructions ..........................63 RECOMMENDED SPARE PARTS ..................See Appendix A TROUBLESHOOTING GENERAL ..............................65...
Page 7 CONTENTS Model M2 BR/SC Machine MECHANICAL PARTS SHEETS FIGURE ASSEMBLY FIGURE 1. CAB ASSEMBLY (OPERATOR STATION) 1-1 Seats ............................ E-30270 1-2 Defroster ............................1-3 Air Conditioner ........................D-38200 1-4 Heater ..............................1-5 Steps, Right Hand ........................C-33040 1-6 Steps, Left Hand ........................C-33041 1-7 Upper Control Console......................D-33533...
Page 8 CONTENTS Model M2 BR/SC Machine FIGURE 8. HYDRAULIC TANKS 8-1 Hydraulic Tank ........................D-32240 8-1-1 Hydraulic Tank Heater ....................C-38007 FIGURE 10. FUEL TANKS 10-1 Primary Fuel Tank.......................D-33271 10-1-1 Tank Drain Assembly ....................A-38219 10-2 Secondary Fuel Tank (Optional) ..................D-38211 10-3 Dual Tank Level Sending Unit Kit ..................D-38393 FIGURE 13.
Page 9 CONTENTS Model M2 BR/SC Machine PNEUMATIC PARTS SHEETS FIGURE ASSEMBLY BASE MACHINE 80 Main Machine ........................D-32650 80-1 T-2000 Air Dryer (Optional)..................C-38385 80-2 Air System Quick Disconnect ..................A-38053 80-3 Air System Drain ......................B-38043 80-4 Brake Pressure ......................B-38081 80-5 Parking Brake ......................C-38249 SAFETY LOCKS 81-1 Safety Locks........................C-38116...
Page 11: Safety
DO NOT use this machine for machine operations other than for which it was intended. NORDCO is not responsible for any modifications made without authorization or written approval. Replace all NORDCO and OEM parts with genuine NORDCO or OEM parts. Use of non-OEM parts could compromise the safety of your machine.
Page 12 SAFETY DURING WORK NORDCO recommends the use of a Command position. This means that the machine is never running unless someone is at or near the main control panel or remote control boxes. To prevent injury to personnel or damage to the machine, it is highly recommended to: 1.
Page 13 SAFETY Model M2 BR/SC Machine 11. Only the number of riders for which seats are available are allowed on this machine during work or travel operations. DO NOT ALLOW RIDERS ON THIS MACHINE IF SEATS ARE NOT AVAILABLE. 12. Never change the direction of work travel without first bringing the machine to a complete stop.
Page 14: Safety Alerts
SAFETY Model M2 BR/SC Machine MACHINE SAFETY ALERTS DANGER ALERTS Improper use of this machine for any type of operation can cause serious injury or death. To avoid serious injury or death, make certain that the area around and under the machine is clear of all personnel and obstructions BEFORE travelling or working.
Page 15 SAFETY Model M2 BR/SC Machine MACHINE SAFETY ALERTS WARNING ALERTS Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or extensive damage to the machine. Tighten fittings only when system is not pressurized. High pressure leaks can cause personal injury.
Page 16 SAFETY Model M2 BR/SC Machine MACHINE SAFETY ALERTS CAUTION ALERTS Before starting a new or overhauled engine that has been in storage, consult the engine manufacturer’s manual for initial start instructions. Failure to follow those instructions can result in serious engine damage.
Page 17: Lockout/Tagout Procedures
NORDCO has provided the means to lockout this machine. NORDCO cannot be held responsible for injury caused by failure to comply with your company’s Lockout/Tagout Procedures.
Page 18 SAFETY Model M2 BR/SC Machine LOCKOUT/TAGOUT – PROCEDURES Energy When servicing Source to or performing be locked maintenance on: out: Use this procedure: Electrical System Electrical 1) Turn the ignition switch to the OFF position. 2) Turn the battery disconnect switch to the OFF position and close (Work and Travel and lock the disconnect switch box.
Page 19 SAFETY Model M2 BR/SC Machine Energy When servicing Source to or performing be locked maintenance on: out: Use this procedure: High Speed V- Hydraulic 1) Lower plow until it rests on solid ground. Plow Gravity 2) Turn the ignition switch to the OFF position.
Page 20: General Information
GENERAL Model M2 BR/SC Machine GENERAL This manual contains information for the Model M2 Ballast Regulator machine manufactured by NORDCO INC., Oshawa, Ontario. Information is provided in this manual for operation and maintenance of the machine. Information regarding operation and maintenance of OEM parts not of NORDCO manufacture can be found at the back of this manual, behind the tab marked “Component Data”.
Page 21: Machine Specifications
GENERAL Model M2 BR/SC Machine SPECIFICATIONS GENERAL Weight Ballast Regulator ....................51,000 lbs (20,411 kg)* Ballast Regulator/Snow Clearing Machine (Except w/V-Plow)......55,000 lbs (21,318 kg)* Length Ballast Regulator ......................33 Feet (9.44 m) Snow Clearing Machine with Multi-Position Plow............34 Feet (9.44 m) Snow Clearing Machine with V-Plow................
Page 22 GENERAL Model M2 BR/SC Machine ELECTRICAL SYSTEM Battery....................Two 12 Vdc, 1300 Cold Cranking Amps Alternator ...............................160 AMP Ground ..............................Negative DRIVE SYSTEM Drive Type............................Dual Axle Drive Propulsion Type ....................... Hydraulic Motor Driven 4-Speed Transmission AXLE/WHEELS Axle Size ..............................5-inch Wheel Type............................Forged Steel Wheel Size........................24 inch ( 60 cm) diameter...
Page 23: Parts Ordering Information
The serial number of the machine. The exact quantities of assemblies or parts desired. Please identify these parts by part number and name. Specify the method of shipment desired. Call in your orders to: NORDCO PARTS SALES DEPARTMENT Milwaukee: Telephone: (414) 769-4607 Telephone: (414) 769-4608...
Page 24 GENERAL Model M2 BR/SC Machine THIS PAGE INTENTIONALLY LEFT BLANK 10/00 (4945-8501) General, Page 14...
Page 25: Operation
OPERATION Model M2 BR/SC Machine Before operating this machine, read and understand the Safety Section of this Manual. BEFORE OPERATION IMPROPER USE OF THIS MACHINE FOR ANY TYPE OF OPERATION CAN CAUSE SERIOUS INJURY OR DEATH. It is always good practice to become totally familiar with the machines you are going to operate.
Page 26: Ballast Wing
OPERATION Model M2 BR/SC Machine BALLAST WING The ballast wing is designed to transfer ballast from the toe line to the shoulder, the shoulder to the toe line, or carry ballast from one location to another. It consists of front, rear, outer and inner doors. The Inner and Outer doors are tiltable.
Page 27 OPERATION Model M2 BR/SC Machine FIGURE 4. CONTROL CONSOLE 10/00 (4945-8501) Operation, Page 17...
Page 28: Cab Controls
OPERATION Model M2 BR\SC Machine TABLE FIG 4-1. CONTROL CONSOLE ENGINE AND PUMP CONTROLS AND GAUGES 10/00 (4945-8501) Operation, Page 18...
Page 29 OPERATION Model M2 BR\SC Machine TABLE FIG 4-1. CONTROL CONSOLE ENGINE AND PUMP CONTROLS AND GAUGES INSTRUMENT OR CONTROL SYMBOL FUNCTIONAL DESCRIPTION Indicates engine speed in hundreds of rpm. TACHOMETER Indicates temperature of engine or cooling system. Normal reading is 160° to 185° F (71° - 85° C).
Page 30 OPERATION Model M2 BR\SC Machine INSTRUMENT OR CONTROL SYMBOL FUNCTIONAL DESCRIPTION Measures air system pressure. Normal reading is 105 to AIR PRESSURE GAGE 120 psi. VACUUM GAGE Measures restriction in track pump suction line. Change suction line filters when reading exceeds 7" of mercury when hydraulic fluid is 100°...
Page 31: Engine And Pump Controls
OPERATION Model M2 BR\SC Machine FIG 4-2. CONTROL CONSOLE ENGINE AND PUMP CONTROLS AND GAUGES INSTRUMENT ENGINE SPEED FUNCTIONAL DESCRIPTION CONTROL Travel Direction and pump speed is controlled by the handle on the left. In order to switch speeds, you must lift up the handle “head” (or knob) to unlock the shift. Pull up and push or pull in travel direction and speed desired.
Page 32 OPERATION Model M2 BR\SC Machine TABLE FIG4-3. CONTROL CONSOLE MISCELLANEOUS ELECTRICAL CONTROLS INSTRUMENT OR CONTROL SYMBOL FUNCTIONAL DESCRIPTION Turn on to fill hydraulic reservoir. HYDRAULIC OIL FILL SWITCH Activates parking (spring loaded) brakes. Pull to apply, PARKING BRAKE push to release.
Page 33 OPERATION Model M2 BR\SC Machine INSTRUMENT OR CONTROL SYMBOL FUNCTIONAL DESCRIPTION Activates work lights. WORKLIGHTS SWITCH Optional. Makes suspension of machine very firm. This SUSPENSION is preferable for some work operations under 12 mph. LOCKOUT CONTROL NOTE: Do not lockout suspension when working or travelling at speeds greater than 12 mph.
Page 34: Left Valve Bank - Ballast Regulator
OPERATION Model M2 BR\SC Machine FIGURE OP-3. HYDRAULIC CONTROLS LEFT VALVE BANK 10/00 (4945-8501) Operation, Page 24...
Page 35 OPERATION Model M2 BR\SC Machine TABLE OP-3. HYDRAULIC CONTROLS LEFT VALVE BANK VALVE SYMBOL CONTROLS FUNCTIONAL DESCRIPTION Rear Template Door Extend Extends Rear Door (Rotates CCW) Push - Movement stops at last position Release - Retracts Rear Door (Rotates CW)
Page 36 OPERATION Model M2 BR\SC Machine VALVE SYMBOL CONTROLS FUNCTIONAL DESCRIPTION Ballast Wing Lift Lowers Wing to working position Push - Movement stops at last position Release - Raises Wing to travel position Pull - Inner Door Tilt Rotates upper portion of door toward cab...
Page 37: Left Valve Bank - Snow Wings
OPERATION Model M2 BR\SC Machine TABLE OP-3A. HYDRAULIC CONTROLS LEFT VALVE BANK "LONG" SNOW WINGS VALVE SYMBOL CONTROLS FUNCTIONAL DESCRIPTION Not Used Not Used Not Used Left Snow Wing Tilt Rotates upper portion of door toward cab Push - Movement stops at last position...
Page 38 OPERATION Model M2 BR\SC Machine FIGURE OP-4. HYDRAULIC CONTROLS RIGHT VALVE BANK 10/00 (4945-8501) Operation, Page 28...
Page 39: Right Valve Bank - Ballast Regulator
OPERATION Model M2 BR\SC Machine TABLE OP-4. HYDRAULIC CONTROLS RIGHT VALVE BANK VALVE SYMBOL CONTROLS FUNCTIONAL DESCRIPTION Rear Template Door Extend Extends (CW) rear door Push - Movement stops at last position Release - Retracts (CCW) rear door Pull -...
Page 40 OPERATION Model M2 BR\SC Machine VALVE SYMBOL CONTROLS FUNCTIONAL DESCRIPTION Ballast Wing In/Out Moves wing away from cab while working Push - Movement stops at last position Release - Moves wing toward cab while working Pull - Ballast Wing Lift...
Page 41: Broom Valve Bank
OPERATION Model M2 BR\SC Machine FIGURE OP-5. HYDRAULIC CONTROLS BROOM VALVE BANK TABLE OP-5. HYDRAULIC CONTROLS BROOM VALVE BANK VALVE SYMBOL CONTROLS FUNCTIONAL DESCRIPTION Broom Lift Push - Lowers Broom Assembly Release - Movement stops at last position Pull -...
Page 42: Hydraulic Pressure Gauges
OPERATION Model M2 BR\SC Machine FIGURE OP-6 HYDRAULIC PRESSURE GAUGES INSTRUMENT OR CONTROL FUNCTIONAL DESCRIPTION Charge Pressure. CHARGE PRESSURE LH Valve Bank Pressure. LH VALVE BANK RH Valve Bank Pressure. RH VALVE BANK Track Drive pressure. TRACK DRIVE SCREW DRIVE Screw Drive pressure.
Page 43: Remote Controls
OPERATION Model M2 BR/SC Machine TABLE OP-7 REMOTE CONTROLS AND INDICATORS Item Control or Instrument Function Emergency Pump Located on frame near the engine. Pump is used when there is a loss of system pressure and movement of hydraulic cylinders is necessary. System pressure is supplied by pumping hand lever or by switch on electric pump.
Page 44: Engine Operation
OPERATION Model M2 BR/SC Machine EXHAUST EMISSIONS CAUSED BY THE USE OF THIS MACHINE CAUSE CANCER, BIRTH DEFECTS OTHER REPRODUCTIVE HARM IF INHALED. BEFORE STARTING A NEW OR OVERHAULED ENGINE THAT HAS BEEN IN STORAGE, CONSULT THE ENGINE MANUFACTURERS MANUAL FOR INITIAL START INSTRUCTIONS.
Page 45: Start-Up Checks
OPERATION Model M2 BR/SC Machine TABLE OP-8. STARTUP CHECKS AND PROCEDURES GAUGE READINGS CHECKED: ⌧ Tachometer/Hourmeter: 2250 rpm (under load) ⌧ Voltmeter: 13 to 15 Volts ⌧ Engine Temperature: 160° to 185° F (71° to 85° C) ⌧ Engine Oil Pressure:...
Page 46: Preparing The Machine For Work
OPERATION Model M2 BR/SC Machine Preparing the Machine for Work As with any machine, pre-operational checks and preventative maintenance should be performed before using the machine. We suggest that you follow the guidelines listed below before actually operating the machine.
Page 47: Lock-Up Devices
OPERATION Model M2 BR/SC Machine LOCK-UPS FAILURE TO ENGAGE ALL LOCKUP DEVICES BEFORE PROPELLING AT TRAVEL SPEED CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO THE MACHINE. Use the following procedures to install or remove lock-ups. Note: With the exception of the suspension lockout, all lockups are to be in place during travel.
Page 48: Propelling And Braking (Travel)
OPERATION Model M2 BR/SC Machine TRAVEL It is important that you read about and understand all operating controls, Cautions, Warnings, and Dangers before traveling. To avoid serious injury or death, make certain that the area around and under the machine is clear of all personnel and obstructions BEFORE travelling or working.
Page 49 OPERATION Model M2 BR/SC Machine pump control lever in the opposite direction and follow the instructions outlined in item #3, above. NEVER CHANGE DIRECTION OF THE MACHINE WITHOUT FIRST BRINGING THE MACHINE TO A COMPLETE STOP. 6. To Stop : Slowly move the pump control lever to the neutral position.
Page 50 OPERATION Model M2 BR/SC Machine PARKING/EMERGENCY BRAKES Your machine is equipped with a fail-safe brake system. If there is a loss of air pressure, the brakes are spring applied. The parking brake is activated by a valve located on the control panel. This valve exhausts air from the spring brake chambers, permitting spring force to apply the service brakes.
Page 51: Machine Setup
OPERATION Model M2 BR/SC Machine Machine Setup There are some adjustments which may have to be made due to varying conditions such as rail height and base width. Adjustments must be made to compensate for these conditions before operations can begin.
Page 52 OPERATION Model M2 BR/SC Machine with special winter grader blades. If cut-outs are left exposed, the tie jumper must remain in place. Otherwise, use of the tie jumper is optional. It may be left on for the sake of convenience.
Page 53: Machine Operation
OPERATION Model M2 BR/SC Machine MACHINE OPERATION TO AVOID SERIOUS INJURY OR DEATH, MAKE CERTAIN THAT THE AREA AROUND AND UNDER THE MACHINE IS CLEAR OF ALL PERSONNEL AND OBSTRUCTIONS BEFORE TRAVELLING OR WORKING. FAILURE TO ENGAGE ALL LOCKUP DEVICES BEFORE PROPELLING AT TRAVEL SPEED CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO THE MACHINE.
Page 54: Multi-Position Plows
OPERATION Model M2 BR/SC Machine To operate the front ballast plow: Raise or lower the plow using the valve handles in the center console. Determine whether "float" or "conventional" mode will be used for operation. Remember, "float" should be used during all working operations.
Page 55: Snow Screw & Blower
OPERATION Model M2 BR/SC Machine lowered and rotated to the desired position so that the broom flail hoses just contact the top of the ties. To operate: 1. Raise or lower the broom using the valve handles at the right side of the center console.
Page 56: After Operation
OPERATION Model M2 BR/SC Machine AFTER OPERATION Parking or Locating Machine Park or locate machine on level track area, if possible; and where it will not be exposed to excessive dust. If the machine was towed, disconnect towing vehicle and set the brakes.
Page 57: Towing
OPERATION Model M2 BR/SC Machine Towing Machines with Powershift Transmissions In an emergency situation when time does not permit the removal of the drive shafts, and providing that the distance to be towed is less than 10 miles, it is permissible to leave the engine running, with the transmission in neutral before towing.
Page 58 OPERATION Model M2 BR/SC Machine This page left blank intentionally 10/00 (4945-8501) Operation, Page 48...
Page 59: Maintenance And Service
NOTE: Engine lubrication and maintenance instructions are included in this manual as a reference tool only. It is NOT meant to substitute for the instructions given in the Engine Manufacturer’s Manual. If you no longer have a manual, contact Nordco Parts Sales for the local distributor of your engine. 10/00 (4945-8501)
Page 60 MAINTENANCE Model M2 BR/SC Machine LUBRICATION AND MAINTENANCE CHART 10/00 (4945-8501) Maintenance and Service, Page 50...
Page 61: Lubrication And Maintenance Chart
MAINTENANCE Model M2 BR/SC Machine 10/00 (4945-8501) Maintenance and Service, Page 51...
Page 62: Lubrication And Maintenance By Day/Week/Month/Etc
MAINTENANCE Model M2 BR/SC Machine LUBRICATION AND MAINTENANCE DAILY (OR 8 HOURS, WHICHEVER COMES FIRST) Check Engine Oil Level and Quality Check Engine Coolant Level and Quality Check Fuel Filter Inspect Cooling Fan on Engine (Cummins Engine Only) Inspect Drive Belt (Cummins Engine Only)
Page 63 MAINTENANCE Model M2 BR/SC Machine WEEKLY (OR 40 HOURS, WHICHEVER COMES FIRST) Perform all Daily Lubrication and Maintenance Procedures Check Battery Condition Oil Brake Adjust turnbuckle Grease Brake Lever Pivot and Suspension Arm Pivot Check Transmission Fluid Level/Quality (4-Speed Transmission Only) Check Fluid Level –...
Page 64 MAINTENANCE Model M2 BR/SC Machine MONTHLY (OR 150 HOURS, WHICHEVER COMES FIRST) Perform all Daily and Weekly Lubrication and Maintenance Procedures - Reserved for Future Use - Change Engine Oil and Filters Check Brake Shoes for Wear Run Pressure Checks on Main Pump and Propulsion...
Page 65 MAINTENANCE Model M2 BR/SC Machine YEARLY (OR 2000 HOURS, WHICHEVER COMES FIRST) Perform all Daily, Weekly, Monthly, and Quarterly Lubrication and Maintenance Procedures Steam Clean Engine Radiator and Oil Cooler. Replace Air Dryer Canister (Optional) Inspect wheels for Excessive Wear...
Page 66: Daily Instructions
MAINTENANCE Model M2 BR/SC Machine DAILY MAINTENANCE INSTRUCTIONS D1. Engine - Check Engine Oil Level (Right Side of Machine Access) Check the oil level daily with the engine stopped. If necessary, add sufficient oil to raise the level to the proper mark on the dipstick.
Page 67 MAINTENANCE Model M2 BR/SC Machine D5. Engine - Inspect Drive Belt (Cummins Engine Only) Check the belts and tighten the fan drive, battery-charging alternator and other accessory drive belts. Belts should be neither too tight nor too loose. Belts that are too tight impose excess loads on the crankshaft, fan, and/or alternator bearings, shortening both belt and bearing life.
Page 68 MAINTENANCE Model M2 BR/SC Machine D12. Inspect Hoses and Fittings for Leaks 1. Look for loose or disconnected hoses. An oil spot below the machine is a good indication of a loose hose or hydraulic component. 2. Make certain shut-off valve on suction strainer is OPEN.
Page 69 MAINTENANCE Model M2 BR/SC Machine D30. Grease Broom Housing Pivot D31. Grease Broom Up/Down Guide Rod D32. Grease Broom Shaft Bearing D33. Lubricate Broom Drive Chain Chase D35. Grease Snow Wing Up/Down Cylinder Rod Ends D36. Grease Snow Wing Up/Down Pivot Plate D37.
Page 70: Weekly Instructions
MAINTENANCE Model M2 BR/SC Machine WEEKLY MAINTENANCE INSTRUCTIONS W1. Perform all Daily Lubrication and Maintenance Procedures W2. Check Battery Condition, Clean terminals The battery requires periodic servicing. Check the electrolyte level on a weekly (40 hour) basis. Add distilled water if necessary, but do not overfill. Overfilling can cause poor battery performance and/or early failure.
Page 71: Monthly Instructions
W16. Check Tie Jumper for Wear MONTHLY MAINTENANCE INSTRUCTIONS M1. Perform all Daily and Weekly Lubrication and Maintenance Procedures M2. Check Fan and Alternator Belts Check the belts and tighten the fan drive, battery-charging alternator and other accessory drive belts. Belts should be neither too tight nor too loose.
Page 72: Quarterly Instructions
MAINTENANCE Model M2 BR/SC Machine M8. Check Air Intake System M9. Lubricate Broom Drive Chain M10. Lubricate Snow Blower Drive Chain QUARTERLY MAINTENANCE INSTRUCTIONS Q1. Perform all Daily, Weekly, and Monthly Lubrication and Maintenance Procedures Q2. Drain Fuel Tank Tighten all fuel tank mountings and brackets. At the same time, check the seal in the fuel tank cap, the breather hole in the cap, and the condition of the fuel line.
Page 73: Yearly Instructions
MAINTENANCE Model M2 BR/SC Machine Q8. Change Pump Drive Fluid Q9. Test Insulation of Axles Q10. Replace Hydraulic Tank Breather Filters Q11. Replace Fuel Tank Breather Filters Q12. Lubricate Throttle Cable Q13. Test Engine Anti-Freeze Solution YEARLY MAINTENANCE INSTRUCTIONS Y1. Perform all Daily, Weekly, Monthly and Quarterly Lubrication and Maintenance Procedures Y2.
Page 74 MAINTENANCE Model M2 BR/SC Machine THIS PAGE INTENTIONALLY LEFT BLANK 10/00 (4945-8501) Maintenance and Service, Page 64...
Page 75: Troubleshooting
Operating experience, a thorough understanding of the information in this manual, and accurate maintenance and operation records are the best troubleshooting tools an operator can have. The Model M2 Ballast Regulator is a group of rather simple systems. If you understand the basic workings of these systems individually and how they relate to each other, troubleshooting becomes a relatively simple task.
Page 76: Engine Troubleshooting
TROUBLESHOOTING Model M2 BR/SC Machine ENGINE TROUBLESHOOTING When the temperature of diesel fuel is elevated, as occurs when the fuel is circulated through an operating engine, it may pose the following hazards which should be guarded against. Refer to the engine manual for details.
Page 77: Electrical Troubleshooting
TROUBLESHOOTING Model M2 BR/SC Machine ELECTRICAL TROUBLESHOOTING 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: Look for bare wires that could cause grounds or shorts.
Page 78 TROUBLESHOOTING Model M2 BR/SC Machine PROBLEM POSSIBLE CAUSE SOLUTION Battery uses too much water Cracked Battery Case Frozen battery Keep battery fully charged in cold weather. Replace battery. Low Battery Output Low water level. Add distilled water. Dirty or wet battery top causing Clean and wipe dry battery top.
Page 79 TROUBLESHOOTING Model M2 BR/SC Machine PROBLEM POSSIBLE CAUSE SOLUTION or replace Engine Oil Pressure Gauge defective. Repair or replace. Defective pressure sensor Replace sensor Engine Oil Pressure Low oil level. Stop engine, check level. If low Gauge always reads fill to desired level.
Page 80 TROUBLESHOOTING Model M2 BR/SC Machine PROBLEM POSSIBLE CAUSE SOLUTION Light defective. Replace light. Work Lights do not Wiring harness Check harness, repair or work. replace. Connection at light loose. Tighten connection. Light circuit breaker blown. Reset circuit breaker. Light switch defective.
Page 81: Hydraulic System Troubleshooting
TROUBLESHOOTING Model M2 BR/SC Machine HYDRAULIC SYSTEM Particularly after start-up of an installation, components should be checked regularly at short intervals for correct operation and possible leakage. INSPECTION Inspect the hydraulic system for clues to the malfunction. Check to see if the unit can be operated without further damage.
Page 82 TROUBLESHOOTING Model M2 BR/SC Machine Most leaks occur at fittings, but too often, finding the fitting that is leaking is difficult because the fluid runs along the hose and drips off at some other point. Leaks in high pressure lines sometimes are difficult to pin-point because the fluid comes out as a mist.
Page 83 TROUBLESHOOTING Model M2 BR/SC Machine HYDRAULIC SYSTEM TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Hydraulic pump does No hydraulic oil in tank (NOTE: if pump Check oil level. Refill tank. not develop pressure is run without oil in tank, pump damage will occur.)
Page 84 TROUBLESHOOTING Model M2 BR/SC Machine PROBLEM POSSIBLE CAUSE SOLUTION Suction line gate valve closed. Open valve and lock in the open position. Put in gear, check linkage if Four speed transmission not in gear. necessary. Inspect, repair or replace. Pump control block faulty.
Page 85: Mechanical Troubleshooting
TROUBLESHOOTING Model M2 BR/SC Machine MECHANICAL TROUBLESHOOTING INSPECTION Inspect the mechanical system for clues to the malfunction. Check to see if the unit can be operated without further damage. Always turn off machine when performing maintenance, making adjustments, or whenever unintended movement of machine could occur;...
Page 86 TROUBLESHOOTING Model M2 BR/SC Machine MECHANICAL SYSTEM TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Machine will not propel. Main pump not developing pressure. See Hydraulic Troubleshooting. Brakes not releasing. See next problem. Propulsion relief setting too low. Increase relief setting. Defective motor or broken drive shaft.
Page 87 TROUBLESHOOTING Model M2 BR/SC Machine PROBLEM POSSIBLE CAUSE SOLUTION 2-Way Plow won't lift Safety lock engaged. Disengage safety lock. or lower Obstruction at pinch points. Remove obstruction. Pressure bypass problem at lift cylinder. Adjust main relief or replace cylinder. Carrier bushings not lubricated.
Page 88 TROUBLESHOOTING Model M2 BR/SC Machine PROBLEM POSSIBLE CAUSE SOLUTION Damaged shifter fork spring Replace Transmission mounting bolts loose. Tighten Axle Vibration During Torque link pins or bearings are Repair or replace Speed Changes damaged. Axle Housing Running Parking brake left on...