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Nordco C Installation, Operation And Maintenance Manual
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Nordco C Installation, Operation And Maintenance Manual

24-volt spiker/hammer w/programmable logic
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2001
MODEL C
24-Volt Spiker/Hammer
w/Programmable Logic
OPERATION AND
MAINTENANCE MANUAL
Last Revision: September 2002
Re-Order: 49455283D

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Summary of Contents for Nordco C

  • Page 1 2001 MODEL C 24-Volt Spiker/Hammer w/Programmable Logic OPERATION AND MAINTENANCE MANUAL Last Revision: September 2002 Re-Order: 49455283D...
  • 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

    Lockout/Tagout Requirements ..........................11 OSHA Recommended Lockout/Tagout Procedures....................12 Lockout Sequence............................... 12 Restoring Equipment to Service.......................... 13 Informational Chart - Model C Energy Sources......................14 Safety Decals on this Machine ..........................16 GENERAL INFORMATION............................10 About this Manual..............................10 Optional Equipment..............................10 Machine Specifications.............................
  • Page 6 APPENDICES APPENDIX A - SUGGESTED SPARE PARTS APPENDIX B - PERIODIC ADJUSTMENTS - HYDRAULICS APPENDIX C – PERIODIC ADJUSTMENTS - LOGIC BOARDS APPENDIX E – ROLLER GAGER INSTRUCTIONS (Optional Equipment) APPENDIX F – BULK LOADER INSTRUCTIONS (Optional Equipment) APPENDIX G – TORQUE CHART...
  • Page 7 CONTENTS 2003 Model C w/Programmable Logic PARTS SHEETS (Last Revision in Bold/Parenthesis) FIGURE Last Revision MECHANICAL Operator’s Station (4/98)............................41A-1 Axles, Insulated (8/98) Fine Thread - Discontinued - See Notes on Part Sheet (8/98) ............41A-2-1 Rev A Coarse Thread (S/N 410200 and Above) (10/00) ..................41A-2-1A Axles, Non-Insulated..............................
  • Page 8 CONTENTS 2003 Model C w/Programmable Logic ELECTRICAL Logic Box.............................. 9641 0435 Rev. D Electrical Schematic ..........................9641 0568 Rev. E Logic Schematics Mother Board #1............................9641 0142 Mother Board #1............................9641 0542 Mother Board #2............................9641 0144 Mother Board #2............................9641 0544 Mother Board #3............................

  • Page 9: Safety

    DO NOT use this machine for work 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.

  • Page 10: General Safety Tips

    Use safety-toed work boots. SAFETY DURING WORK NORDCO recommends the use of a Command position. This means that the machine is never running unless someone is sitting at the control station. To prevent injury to personnel or damage to the machine, it is highly recommended to: Make certain that no one is in the path of this machine.

  • Page 11: Safety During Travel

    SAFETY 2003 Model C w/Programmable Logic SAFETY DURING WORK (Continued) There are lockups on this machine that are used for both work and travel. These should be kept clear and free of debris, grease, etc. See Lockup section for instructions on their use.

  • Page 12: Safety Alerts

    SAFETY 2003 Model C w/Programmable Logic SAFETY ALERTS WORDING 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 13 SAFETY 2003 Model C w/Programmable Logic SAFETY ALERTS WORDING 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 14 SAFETY 2003 Model C w/Programmable Logic MODEL C MACHINE SAFETY ALERTS WORDING 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 nstructions can result in serious engine damage.
  • Page 15 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 16 SAFETY 2003 Model C w/Programmable Logic LOCKOUT/TAGOUT – PROCEDURES MACHINES WITH MANUAL LOCKUPS Energy Source When servicing to be locked or performing out: maintenance on: Use this procedure: Electrical Electrical 1) Turn the ignition switch to the OFF position (logic box). If...
  • Page 17 SAFETY 2003 Model C w/Programmable Logic Energy Source When servicing to be locked or performing out: maintenance on: Use this procedure: inside of the workhead well, close to the rail clamp housing. Insert lockup pin into hole in rail clamp housing. (Look for “Lockup Point”...
  • Page 18 SAFETY 2003 Model C w/Programmable Logic LOCKOUT/TAGOUT – PROCEDURES MACHINES WITH POWER LOCKUPS Energy Source When servicing to be locked or performing out: maintenance on: Use this procedure: Electrical Electrical 1) Turn the ignition switch to the OFF position (logic box). If working on the...
  • Page 19 SAFETY 2003 Model C w/Programmable Logic Energy Source When servicing to be locked or performing out: maintenance on: Use this procedure: on housing) This will cut off hydraulic pressure to rail clamp cylinders and will prevent “drifting” down of the rail clamp arms.

  • Page 20: Safety Decals On This Machine

    SAFETY 2003 Model C w/Programmable Logic SAFETY DECALS ON THIS MACHINE Safety decals and plaques that have been placed on this machine are to be kept clean and legible. Replace any decals or plaques that have become illegible or are missing.

  • Page 21: About This Manual

    Wisconsin. 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 22 ENGINE Make/Model ............................Deutz BF4L913 Type ........................Turbo-charged 4-cylinder, 4-stroke Idle Speed............................... 1100 rpm C ontinuous BHP ........................101 @ 2250 rpm - full load Make/Model .............................John Deere, 4045T Type ............................... 4-Cylinder, 4-Stroke Idle Speed............................... 1150 rpm C ontinuous BHP ........................105 @ 2250 rpm - full load Make/Model ........................
  • Page 23 GENERAL 2003 Model C w/Programmable Logic ELECTRICAL SYSTEM Battery................24 Vdc (Dual 12V dc Batteries), 1150 Cold Cranking Amps Ground ................................Negative DRIVE SYSTEM Drive Type............................. Dual Axle Drive Propulsion Motor Type............................ Hydraulic AXLE/WHEELS Front Axle Size............................. 3-inch, Standard Rear Axle Size ............................. 3-inch, Standard...

  • Page 24: Section 2 - Operation

    OPERATION 2003 Model C w/Programmable Logic 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 25: Rail Clamps

    OPERATION 2003 Model C w/Programmable Logic RAIL CLAMPS In front of each operator, on the frame inside the workhead area, are the rail clamp housings. During spiking operations a signal is sent from the logic control panel (inside the main control box) that pulses these clamps on and off to prevent the machine from lifting up and leaving the rail.

  • Page 26: Manifolds

    OPERATION 2003 Model C w/Programmable Logic MANIFOLDS The Model C hydraulic system uses a series of manifolds. More detailed information regarding the hydraulic system and manifolds is located behind the tab marked “HYDRAULICS”. This includes a layout of the machine and the locations of all hydraulic components.

  • Page 27: Nipper Assembly (Optional)

    OPERATION 2003 Model C w/Programmable Logic NIPPER ASSEMBLY Located in the center of the machine, between the workheads is the nipper assembly (See Figure 5). It is used to pull the tie up to the rail to secure the tie plate to the tie during spiking operations.
  • Page 28 OPERATION 2003 Model C w/Programmable Logic FIGURE 7. CONTROL PANEL 09/02 (4945-5283D) Section 2, Before Operation, Page 5...
  • Page 29 Engine Indicates temperature of engine or cooling system. TEMPERATURE Gauge Normal reading is 180° F to 202° F (82° - 95° C) Note: High engine temperature will shutdown the machine at 248° F (120° C). VOLTMETER Indicates voltage of battery. Normal reading is 22-27 volts.
  • Page 30 OPERATION 2003 Model C w/Programmable Logic TABLE 2. ENGINE CONTROLS 09/02 (4945-5283D) Section 2, Before Operation, Page 7...
  • Page 31 OPERATION 2003 Model C w/Programmable Logic TABLE 2. ENGINE CONTROLS INTERNATIONAL INSTRUMENT OR SYMBOL CONTROL FUNCTIONAL DESCRIPTION SHUTDOWN Overrides engine shutdown for emergency travel purposes. OVERRIDE Red pilot light is lit when engine shutdown override is activated. CAUTION: The engine is not protected from low oil pressure or high temperature damage in this mode.
  • Page 32 OPERATION 2003 Model C w/Programmable Logic TABLE 2. LIGHTS, FANS & ALARM CONTROLS 09/02 (4945-5283D) Section 2, Before Operation, Page 9...
  • Page 33 OPERATION 2003 Model C w/Programmable Logic TABLE 2. LIGHTS, FANS & ALARM CONTROLS INTERNATIONAL INSTRUMENT OR SYMBOL CONTROL FUNCTIONAL DESCRIPTION STROBE LIGHT Turns strobe light on or off. (Optional) HEATER FAN Three position switch, with return to center being the OFF (Optional) position.
  • Page 34 OPERATION 2003 Model C w/Programmable Logic TABLE 3. TRAVEL & WORK CONTROLS 09/02 (4945-5283D) Section 2, Before Operation, Page 11...
  • Page 35 OPERATION 2003 Model C w/Programmable Logic TABLE 3. TRAVEL & WORK CONTROLS SYMBOL INTRUMENT OR CONTROL FUNCTIONAL DESCRIPTION RAIL TYPE Set this switch according to the rail type WELDED (Switch Up) or JOINTED (switch Down). In WELDED mode, clamps and gager lever rollers stay in contact with web of rail during travel.
  • Page 36 OPERATION 2003 Model C w/Programmable Logic SYMBOL INTRUMENT OR CONTROL FUNCTIONAL DESCRIPTION ELECTRICAL When pushed in, disables all electrical input to hand INTERLOCK controllers and workheads. Also locks brakes. Should be used during machine warmup or inspection. BRAKE MODE Lights will illuminate depending on position of switch...
  • Page 37 OPERATION 2003 Model C w/Programmable Logic TABLE 4. CONTROL PANEL MISC. CONTROLS SYMBOL INTRUMENT OR CONTROL FUNCTIONAL DESCRIPTION FILTER STATUS Lights will give status of return & pressure line filters. LIGHTS GREEN LIGHT Filter does not require servicing. RED LIGHT Alarm state.

  • Page 38: Operator Station Controls

    OPERATION 2003 Model C w/Programmable Logic FIGURE 5 OPERATOR STATION CONTROLS REMOTE OPERATOR CONTROL BOX The Remote Operator Control Box shown below is all-inclusive and is for symbol reference purposes only. This configuration may not reflect the box that is on your machine.
  • Page 39 OPERATION 2003 Model C w/Programmable Logic TABLE 5 OPERATOR STATION CONTROLS REMOTE OPERATOR CONTROL BOX Control or Instrument Function Travel Mode (Green Light). When in Travel Mode, hand controllers are disabled and all hydraulically controlled components will move to UP position for locking.

  • Page 40: Footswitches

    OPERATION 2003 Model C w/Programmable Logic TABLE 6 OPERATOR STATION CONTROLS The type of braking is selected on the Main Control Panel of the Logic Box. Both brake switches function at all times REGARDLESS of which operator is in control of the travel functions or which mode of brakes has been selected. This allows the "non-control"...
  • Page 41 OPERATION 2003 Model C w/Programmable Logic TABLE 7 OPERATOR STATION CONTROLS HAND CONTROLLER FUNCTIONS The joystick valve attached to the right handcontroller at each work station allows the operator to position the carriage (See Figure 10), while the buttons on the hand controller itself perform actual working operations. Refer to the item numbers listed on Figure 9 for cross reference in the Table.
  • Page 42 OPERATION 2003 Model C w/Programmable Logic TABLE 8 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 (Optional) system pressure and movement of hydraulic cylinders is necessary. System pressure is supplied by pumping hand lever or by switch on electric pump.

  • Page 43: Preparing The Machine For Work

    OPERATION 2003 Model C w/Programmable Logic Preparing the Machine for Work with machine, pre-operational checks preventative maintenance should be performed before using the machine. We suggest that you follow the guidelines listed below before actually operating the machine. Position the machine on level track so fluid levels can be accurately checked and filled if necessary.

  • Page 44: Pre-Operational Checklist

    OPERATION 2003 Model C w/Programmable Logic TABLE 9: PRE-OPERATIONAL CHECKLIST NORDCO recommends that the following checks be performed WITHOUT electrical power, due to a possible battery drain. MAIN CONTROL PANEL STATUS ⌧ Logic Box Cover Unlocked and Hooked in Up Position.

  • Page 45: Engine Operation

    OPERATION 2003 Model C w/Programmable Logic Exhaust emissions caused by the use of the engine on this machine may cause cancer, birth defects, or other reproductive harm if inhaled. Before starting a new or overhauled engine that has been in storage, consult the engine manufacturer’s manual for initial start instructions.

  • Page 46: Lock-Up Devices

    2250 rpm (under load) ⌧ Voltmeter: 13 to 15 Volts ⌧ Engine Temperature: 160° to 185° F (71° to 85° C) ⌧ Engine Oil Pressure: 40 to 60 psi, 3 to 4 bar, 276 to 414 kPa LIGHT/HORN STATUS ⌧...
  • Page 47 OPERATION 2003 Model C w/Programmable Logic Failure to engage all lockup devices before propelling at travel speed can result in injury to personnel and/or damage to the machine. LOCK-UPS There are areas designated on the machine as lock-up points. Lock-up...
  • Page 48 OPERATION 2003 Model C w/Programmable Logic WORKHEADS There is one lock-up device per gun assembly, two per workhead. They must be unlocked prior to performing service to the workhead or during work operations. Use the following procedure to lock or unlock the assemblies.
  • Page 49 OPERATION 2003 Model C w/Programmable Logic GUIDE ROLLER ASSEMBLY There is one lock-up device per guide roller assembly, two per machine. Both must be unlocked prior to performing service to the guide roller or during work operations. Use the following procedure to lock or unlock the assemblies.
  • Page 50 OPERATION 2003 Model C w/Programmable Logic ROLLER CLAMPS There is one lock-up device per roller clamp housing, two per machine. Both must be unlocked prior to performing service to the guide roller or during work operations. Use the following procedure to lock or unlock the assemblies.
  • Page 51 OPERATION 2003 Model C w/Programmable Logic GAGER LEVER ARMS There are two lock-up devices per gager housing, four total per machine. These must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies.
  • Page 52 OPERATION 2003 Model C w/Programmable Logic GAGER BUGGY There are two lock-up devices on the gager buggy. These must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies. LOCATION...
  • Page 53 OPERATION 2003 Model C w/Programmable Logic BOOM AND WINCH There is one lock-up device guide roller assembly, two per machine. Both must be unlocked prior to adjusting the module and/or performing work. Both must be locked during maintenance and service, as well as travel through any type of rail obstruction and during high speed travel.
  • Page 54 OPERATION 2003 Model C w/Programmable Logic NIPPERS There is one lock-up device on the nipper assembly. This must be unlocked prior to performing service or during work operations. Use the following procedure to lock or unlock the assemblies. LOCATION LOCKUP PROCEDURE...
  • Page 55 OPERATION 2003 Model C w/Programmable Logic TRAVEL It is important that you read about and understand all operating controls, Cautions, Warnings, and Dangers before traveling. ENGINE SPEEDS Engine speed is controlled by the switch on the Main Control Panel located on the Logic Box.
  • Page 56 OPERATION 2003 Model C w/Programmable Logic 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 57 OPERATION 2003 Model C w/Programmable Logic WORKHEAD READY ADJUSTMENT The READY position is the point where the workhead assembly stops descending before the spike is actually driven in. The position of a movable proximity switch determines where the Ready position is. The goal of this adjustment is to get the tip of the spike 1/2"...
  • Page 58 OPERATION 2003 Model C w/Programmable Logic Workhead Spike Pattern Adjustments (Manual) Adjustments to the outer workhead are done using the right hand controller. The inner workhead is adjusted in relation to the outer workhead using two turnbuckle assemblies, one connected under the inner and outer workheads, the other is located on the upper carriage between the workheads.
  • Page 59 Left hand controller. This will open the tie hooks and raise the nipper frame assembly. B. Turn off machine. C. Loosen the prox switch adjusting handle (t-handle located on switch mounting plate). D. Pull down switch to lower the tie hook position, push up switch to raise the tie hook position.
  • Page 60 OPERATION 2003 Model C w/Programmable Logic HOOKS CLOSE PRESSURE SWITCH Indicates when hooks have closed. The nipper frame will pull up on the tie once the control system received a “hooks close” signal from the pressure switch. If hooks close on tie, but do not pull up, switch setting has to be lowered.

  • Page 61: Machine Operation

    OPERATION 2003 Model C w/Programmable Logic MACHINE OPERATION Work 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 62: Spike Driving (Without Nippers)

    OPERATION 2003 Model C w/Programmable Logic SPIKE DRIVING (WITHOUT NIPPERS) 1. Press and release the LOAD pushbutton to load spikes into jaws. 2. Press and release the SET pushbutton on the hand controller. This will cause the corresponding driving cylinder to extend and stop.

  • Page 63: Spike Driving (With Nippers In Manual Mode)

    OPERATION 2003 Model C w/Programmable Logic SPIKE DRIVING (WITH NIPPERS IN MANUAL MODE) 1. Set the Nipper AUTO/MANUAL switch to the MANUAL position. 2. Press and release the NIPPER SET pushbutton on the right hand controller. This will cause the nipper frame to lower and stop once it contacts the tie.

  • Page 64: Winch Operation

    OPERATION 2003 Model C w/Programmable Logic Winch Operation Your machine is equipped with a hydraulic winch for loading materials onto the deck of the machine. In order for the winch to be fully operational, it must have the interlock pin set so that the boom can swing fully from left to right without the lock resetting in another hole.

  • Page 65: After Operation

    OPERATION 2003 Model C w/Programmable Logic AFTER OPERATION General Install lock-ups. See LOCK-UPS section. Press the Park Button on the Main Control Panel. Make certain brakes have been set to DEADMAN position. Set engine speed to low position and turn pump off.
  • Page 66 OPERATION 2003 Model C w/Programmable Logic Any machine can be hazardous when raised. Take all necessary precautions before raising the machine. Do not, under any circumstances, climb under machine when using the turntable. Attach winch cable hook to turntable base and lift off machine. Lower into position using the winch assembly.
  • Page 67 OPERATION 2003 Model C w/Programmable Logic Install Lock-Ups. See LOCK-UPS section. Make certain turntable has been raised. Remove drive chain(s) if machine is to be towed a long distance. Inspect the towing vehicle coupler for damage or loose parts. Back towing vehicle to the machine and engage the couplers.
  • Page 68 (414) 769-4603 (Wisconsin) 1-800-445-9258 (USA and Canada) The process will be faster if you have the following information in hand before calling: The Machine and Model Name: 2003 Model C w/Programmable Logic The Serial Number SERVICE NETWORK Representative Phone Number...

  • Page 69: Lubrication And Maintenance Chart

    MAINTENANCE 2003 Model C w/Programmable Logic LUBRICATION AND MAINTENANCE Service points on this machine (adjustments, inspections, lubrication, etc.) are indicated on the following illustration. The items listed on the chart are preceded by a “D1, W1, M1, Q1 and A1"...
  • Page 70 MAINTENANCE 2003 Model C w/Programmable Logic DAILY (OR 8 HOURS, WHICHEVER COMES FIRST) Key: = = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Follow Engine Mfr’s recommendations for daily maintenance Check Engine Oil Level, fill as required.
  • Page 71 MAINTENANCE 2003 Model C w/Programmable Logic Detailed Daily Instructions D2. Check Engine Oil Level 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. All diesel engines are designed to use some oil, so periodic addition of oil is normal.
  • Page 72 MAINTENANCE 2003 Model C w/Programmable Logic D28. 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 73 MAINTENANCE 2003 Model C w/Programmable Logic WEEKLY (OR 40 HOURS, WHICHEVER COMES FIRST) Key: = = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily Lubrication and Maintenance Procedures Check Battery Condition.
  • Page 74 MAINTENANCE 2003 Model C w/Programmable Logic Detailed Weekly Instructions W3. Oil Propulsion Chains When inspecting the drive chain, the chain should be nearly taut, with 1/4" (.635 Cm) play when depressed at the center. If not, adjustment is necessary see below. If the chain is too tight, the eccentricity of the sprockets may cause the chain to stretch and/or break.
  • Page 75 MAINTENANCE 2003 Model C w/Programmable Logic W7. Check Suction Strainer Element Located on the side of the reservoir, remove and inspect the filter after the first 40 hours of operation and every year thereafter. Clean as required. To access filter: 1.
  • Page 76 MAINTENANCE 2003 Model C w/Programmable Logic MONTHLY (OR 150 HOURS, WHICHEVER COMES FIRST) Key: = = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily and Weekly Lubrication and Maintenance Procedures Check Fan, Alternator and Generator Belts...
  • Page 77 MAINTENANCE 2003 Model C w/Programmable Logic M4. Check Brake Shoes for Wear Replace brake shoes when the pad is less than 1/4 (.64 cm) thick. To replace brake shoes: 1. Put the brake selection switch in the SERVICE modes. 2. Turn WORK/TRAVEL switch to the WORK mode.
  • Page 78 MAINTENANCE 2003 Model C w/Programmable Logic QUARTERLY (OR 500 HOURS, WHICHEVER COMES FIRST) Key: = = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily, Weekly and Monthly Lubrication and Maintenance Procedures Drain Fuel Tank.
  • Page 79 MAINTENANCE 2003 Model C w/Programmable Logic YEARLY (OR 2000 HOURS, WHICHEVER COMES FIRST) Key: = = Refer to Mfr’s Manual in Component Data = More Detailed Instructions Follow ITEM TASK Perform all Daily, Weekly, Monthly and Quarterly Lubrication and Maintenance...

  • Page 80: Section 4 - Troubleshooting

    The Model C Machine is a group of rather simple systems. If you understand the basic workings of these systems individually and how they relate to each other, troubleshooting becomes a relatively simple task.

  • Page 81: Engine Troubleshooting

    TROUBLESHOOTING 2003 Model C w/Programmable Logic 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 82: Electrical Troubleshooting

    TROUBLESHOOTING 2003 Model C w/Programmable Logic 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 83 TROUBLESHOOTING 2003 Model C w/Programmable Logic ELECTRICAL SYSTEM TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Battery uses too much Cracked battery case. Replace battery. water High Ambient Temperature. Refill with water. Shorted Cell. Check specific gravity. Battery being Overcharged. Alternator problem. Check charging voltage ≈14.6V, repair...
  • Page 84 TROUBLESHOOTING 2003 Model C w/Programmable Logic PROBLEM POSSIBLE CAUSE SOLUTION LUBRICANTS" Wiring harness Check wiring harness. Repair 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 85 TROUBLESHOOTING 2003 Model C w/Programmable Logic PROBLEM POSSIBLE CAUSE SOLUTION Connection at circuit breaker panel Tighten connection. loose. Bulb or socket in light defective. Replace bulb or socket. Work Lights do not Wiring harness Check harness, repair or work. replace.

  • Page 86: Hydraulic System Troubleshooting

    TROUBLESHOOTING 2003 Model C w/Programmable Logic 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 87 When pressure pulses flex a hardened hose, it fails by cracking. Every increase of 25° F (14°C) cuts hose life in half. Use a replacement hose rated for actual fluid temperatures. Keep a log of hose use so replacement can be made before failure occurs.
  • Page 88 TROUBLESHOOTING 2003 Model C w/Programmable Logic HYDRAULIC SYSTEM TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Hydraulic pump does No hydraulic oil in tank (NOTE: if pump is Check oil level. Refill tank. not develop pressure run without oil in tank, pump damage will occur.)
  • Page 89 TROUBLESHOOTING 2003 Model C w/Programmable Logic PROBLEM POSSIBLE CAUSE SOLUTION Checks) Oil lines damaged causing excessive internal restriction Inspect and repair. Travel relief set too low Check and reset Hydraulic Oil Foams Water in oil Inspect oil for water. Drain and add correct oil as specified under "RECOMMENDED...

  • Page 90: Mechanical Troubleshooting

    TROUBLESHOOTING 2003 Model C w/Programmable Logic 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 91 TROUBLESHOOTING 2003 Model C w/Programmable Logic MECHANICAL SYSTEM TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Machine will not Main pump not developing pressure. See Hydraulic Troubleshooting. propel. Brakes not releasing. See next problem. Propulsion relief setting too low. Increase relief setting.
  • Page 92 TROUBLESHOOTING 2003 Model C w/Programmable Logic PROBLEM POSSIBLE CAUSE SOLUTION Drive Cylinder will not UP Valve not shifting. Check valve spool for free retract when motion and that solenoid is pushbutton is released. being energized. UP prox switch faulty. Check connection, repair or replace.