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Nordco TRIPP HD Operation Manual

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TRIPP Model "HD"
Operation Manual
Including Routine Maintenance
Starting Machine S/N 760700
Reorder Manual P/N 49457607
Revision: RevB
March 2016

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Summary of Contents for Nordco TRIPP HD

  • Page 1 TRIPP Model “HD” Operation Manual Including Routine Maintenance Starting Machine S/N 760700 Reorder Manual P/N 49457607 Revision: RevB March 2016...
  • Page 2 REVISION HISTORY Release / Rev Date Change Description Rev A June 2015 Initial manual version for TRIPP-HD Rev B March 2016 Added information for Cummins Tier 4 engine.
  • Page 3 Information regarding operation and maintenance of specific OEM parts not manufactured by Nordco can be found at the back of this manual, behind the tab marked “Component Data”. This manual is broken down into sections, which have been separated by index tabs: “Mechanical Tab”...
  • Page 4 Additional copies of this manual are available either as a part (Operation Manual only) or a whole (Operation and Parts Manuals), at a nominal cost, through the Nordco Part Sales Department. Additional service information, parts, and application information is also available through the below...
  • Page 5 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: Facilities Manager Nordco Inc. 245 W. Forest Hill Avenue Oak Creek, WI 53154...

  • Page 7: Table Of Contents

    ABOUT THIS MACHINE ............5-1 Contents-1 MAR 2016 49457607 TRIPP HD RevB...
  • Page 8 TABLE OF CONTENTS OPERATORS CENTER CONSOLE ..........5-2 UPPER CENTER CONSOLE .
  • Page 9 CATERPILLAR ENGINE FAULT CODES ........7-21 Contents-3 MAR 2016 49457607 TRIPP HD RevB...
  • Page 10 TABLE OF CONTENTS Contents-4 MAR 2016 49457607 HD TRIPP RevB...

  • Page 11: Safety Instructions And Information

    Replace all Nordco and OEM parts with genuine components of the machine, and should not be Nordco or OEM parts. Use of Non-OEM parts could ignored. compromise the safety of your machine.

  • Page 12: General Safety Tips

    • NEVER climb onto the machine while it operate this machine. is in motion. • Use the “PRE START-UP CHECKS” on page 6-1 to check the machine for obvious faults. Repair and/or replace components as necessary PRIOR to operating the machine. MAR 2016 49457607 TRIPP HD RevB...

  • Page 13: Safety While Starting The Machine

    MACHINE and travel. Lockup points are those Nordco recommends the use of a Command position. areas required to be locked up prior to This means that the machine is never running unless working, propelling through crossings,...

  • Page 14: Non-Operational Safety

    Be careful, there is a danger of scalding when working with engine oils. cause serious injury or death. 7. Use only Nordco supplied repair parts for this machine. Use of non-OEM designed parts could  comprise the integrity of this machine.

  • Page 15: Safety Procedures

    5. Place a TAGOUT card/notice in close proximity to the ignition switch. 6. Turn the Battery Disconnect Switch (BDS) to the OFF position. This turns off the power to the control circuits on the machine. See Figure 1-1. MAR 2016 49457607 TRIPP HD RevB...

  • Page 16: Safety Features

    LOCKUPS” on page 3-1. components such as the fuel tank and the frame assembly. Hand or grab rails have also been added in some areas. These features provide safer access to components when servicing or making repairs. MAR 2016 49457607 TRIPP HD RevB...

  • Page 17: Safety Decals On This Machine

    Logic Box Face / Battery Box 5642 0010 Lockout Area Logic Box Face 5642 0011 Lockout Area Battery Box 5642 0012 Lockup Points All areas requiring / Lockups for travel. Table 1-1: Safety Decals on this Machine MAR 2016 49457607 TRIPP HD RevB...
  • Page 18 SAFETY INSTRUCTIONS AND INFORMATION MAR 2016 49457607 TRIPP HD RevB...

  • Page 19: Logout/Tagout

    For machines with a remotely located BDS (usually next to the battery box itself): Close the cover to the disconnect switch and place a LOCKOUT lock on the box after you have switched it to the OFF position. MAR 2016 49457610 TRIPP HD RevB...

  • Page 20: Safety Security

    Nordco has provided the means to Lockout/Tagout this machine. IMPORTANT Nordco cannot be held responsible for injury caused by failure to comply with your company’s Lockout/Tagout Procedures. ONLY qualified and trained personnel are to install Logout/Tagout devices on this machine.
  • Page 21 3) Turn the Battery Disconnect Switch to the OFF position. 4) Close, secure, and tag the disconnect switch box. NOTE This cuts off the hydraulic pressure/flow to the filters and the directional control valves of the machine. MAR 2016 49457610 TRIPP HD RevB...

  • Page 22: Maintaining Inaccessible Components

    Tie Gripper Open/Close Cylinder Extend the Tie Gripper/Exchanger Workhead all the way out on the side being serviced. Lower the Exchanger workhead. Tilt the gripper head and place a support under the gripper jaws. TIE EXCHANGER ASSEMBLY Lockup Cylinder (Air) Lower the assembly to the rail. MAR 2016 49457610 TRIPP HD RevB...

  • Page 23: Lockups

    Figure 3-1 Figure 3-2: Rear Lockups Figure 3-3: Front Lockups MAR 2016 49457610 TRIPP HD RevB...

  • Page 24: Lockup Controls

    LOCK: Controls the pneumatic cylinders to place mechanical locks on the hydraulic lift cylinders. UNLOCK: Controls the pneumatic cylinders to release the mechanical locks on the hydraulic cylinders. MAR 2016 49457610 TRIPP HD RevB...

  • Page 25: Travel Mode

    TRAVEL/WORK switch, which is located on the right side of the center operators console. When switched into TRAVEL mode, the workheads raise or retract. This allows insertion of lockups, inflates the air springs, and disables the hand controllers. MAR 2016 49457610 TRIPP HD RevB...
  • Page 26 LOCKUPS MAR 2016 49457610 TRIPP HD RevB...

  • Page 27: General Machine Specifications

    Dry Weight (with Pump Drive) 2,500 lbs. (1,134 kg) Continuous BHP 185 HP @ 2350 rpm Oil Capacity 34 Quarts (32 liters) Coolant Capacity 13 Quarts (11.9 liters) Maximum Oil Temp 280° F (138° C) MAR 2016 49457610 TRIPP HD RevB...
  • Page 28 257.4° F (125° C) HYDRAULIC SYSTEM Pressure Settings: MANIFOLDED Relief Valve - Main Pump ----- 3,000 psi (200 bar) Compensator - Main Pump ---- 2,500 psi (172 bar) Main Pump Make/Model Oil Gear PVG Type Piston Pump MAR 2016 49457610 TRIPP HD RevB...
  • Page 29 All rights reserved. In view of the constant improvements to our equipment, the specification data and other technical information included in this manual are subject to change. No part of this manual may be reproduced in any form or by any means without our written permission. MAR 2016 49457610 TRIPP HD RevB...

  • Page 30: Overall Machine Physical Dimensions

    GENERAL MACHINE SPECIFICATIONS OVERALL MACHINE PHYSICAL DIMENSIONS See Figure 4-1. Figure 4-1: MACHINE DIMENSIONAL INFORMATION MAR 2016 49457610 TRIPP HD RevB...

  • Page 31: Railway Line Clearance

    GENERAL MACHINE SPECIFICATIONS RAILWAY LINE CLEARANCE Figure 4-2 MAR 2016 49457610 TRIPP HD RevB...
  • Page 32 GENERAL MACHINE SPECIFICATIONS MAR 2016 49457610 TRIPP HD RevB...

  • Page 33: Operator System Familiarization

    These grippers cannot be used at the same time. machine at all times. Additional copies of the Operation There are two or three control panels (depending on Manual only can be ordered from Nordco Parts Sales how your cab is equipped) and a joystick control at 1-800-647-1724.

  • Page 34: Operators Center Console

    Shown here is the diagram of the operators center The center console is then detailed in additional console. See Figure 5-1. following figures. See Figures 5-2 and 5-3.  Figure 5-1: Center Control Console MAR 2016 49457610 TRIPP HD RevB...

  • Page 35: Upper Center Console

    See “Emergency Engine Shutdown” on page 1-6. ENGINE Overrides engine shutdown for emergency travel purposes. SHUTDOWN OVERRIDE NOTICE The engine is NOT protected from low oil pressure or high temperature damage while in this mode. MAR 2016 49457610 TRIPP HD RevB...
  • Page 36 (used when exiting the cab is required). Pull to release the parking brakes. NOTE Some systems use a knob that is pulled out to apply brakes. Read the knob to know which applies to your machine. MAR 2016 49457610 TRIPP HD RevB...
  • Page 37 Check the alarm condition first before using the silence mode. Failure to address engine issues on a timely basis WILL cause engine failure. Alarm Buzzer Alarm sounds at high engine oil temperature and low air pressure. MAR 2016 49457610 TRIPP HD RevB...

  • Page 38: Lower Center Console

    This switch is used to select either the left or right tie exchanger LEFT/RIGHT arm for operation. SIDE Position of this switch alters the functions of the hand controllers. Refer to the hand controller description later in this section. MAR 2016 49457610 TRIPP HD RevB...
  • Page 39 Used for manual positioning of the rail lift assembly to clear switches, frogs, rail joints, and other obstructions. Gives approximately 10 inches fore/aft movement of the rail lift assembly. NOTE This assembly returns to center automatically at end of each cycle. MAR 2016 49457610 TRIPP HD RevB...
  • Page 40 LOCK: Controls the pneumatic cylinders to place mechanical locks on the hydraulic lift cylinders. UNLOCK: Controls the pneumatic cylinders to release the mechanical locks on the hydraulic cylinders. MAR 2016 49457610 TRIPP HD RevB...

  • Page 41: Powerview Gauge Display

    This hides the fault screen until you 1) correct the fault, or 2) you press the enter button again. MENU BUTTON The menu button is only used during factory setup procedures. (See Component Data Section for additional operation and setup instructions.) MAR 2016 49457610 TRIPP HD RevB...
  • Page 42 Faults can only be cleared when the fault has been corrected. SHUTDOWN THE MACHINE as soon as possible when you have encountered a Shutdown Fault. A complete list of faults, by engine, can be found in the Mechanical Preface. 5-10 MAR 2016 49457610 TRIPP HD RevB...
  • Page 43 OPERATOR SYSTEM FAMILIARIZATION Figure 5-4: Regen Control Gauge MAR 2016 49457610 TRIPP HD RevB 5-11...

  • Page 44: Engine Exhaust Regen Codes

    Both remain on the screen until the regen is complete and then this Indicator disappears and the Cleaning Indicator remains on until the exhaust temps reach normal operating temperatures. Normal machine operation then resume. 5-12 MAR 2016 49457610 TRIPP HD RevB...
  • Page 45 You need to run a REGEN, but have AUTO REGEN disabled. You need to run a Manual/Parked REGEN, but have AUTO REGEN disabled. AUTO REGEN is actively running. MANUAL/PARKED REGEN is actively running. Time to call John Deere for Service. MAR 2016 49457610 TRIPP HD RevB 5-13...

  • Page 46: Overhead Controls

    Lights show the status of the filters. CLEAN: Green LEDs indicate all filters are in optimum condition. BYPASS: Red LEDs and an alarm just above the bank of LEDs indicate a filter is dirty or clogged. 5-14 MAR 2016 49457610 TRIPP HD RevB...
  • Page 47 (KPH) and miles per hour (MPH). Odometer Odometer displays the mileage in MILES the machine has traveled. BOARDING Lights Two position switch, ON/OFF. Controls the boarding lights. PERIMETER Lights Two position switch, ON/OFF. Controls the perimeter lights. MAR 2016 49457610 TRIPP HD RevB 5-15...
  • Page 48 The system pressure is supplied by pumping with a hand lever or by switch on an electric pump. 5-16 MAR 2016 49457610 TRIPP HD RevB...

  • Page 49: Hydraulic Filters Status

    Backward Movement Raises the Tie Exchanger. Left Movement With RH Exchanger Enabled----- Retracts the RH Tie Exchanger workhead. With LH Exchanger Enabled----- Extends the LH Tie Exchanger workhead. Forward Movement Lowers the Tie Exchanger. MAR 2016 49457610 TRIPP HD RevB 5-17...

  • Page 50: Left Hand Controller

    RH RAIL LIFT Manually controls the lifting and lowering of the right side rail. Switch he height of lift is set by the proximity switches. 5-18 MAR 2016 49457610 TRIPP HD RevB...
  • Page 51 Controls the tilt of the workhead jaws to assist in maneuvering Joystick rail ties. RAIL LIFT JOG (Option, not show). Control lifts both rails simultaneously. The DOWN Button height of lift is set by the potentiometer on the Programmable Logic Controller (PLC). MAR 2016 49457610 TRIPP HD RevB 5-19...
  • Page 52 OPERATOR SYSTEM FAMILIARIZATION 5-20 MAR 2016 49457610 TRIPP HD RevB...

  • Page 53: Machine Operation

    Power will come on, but the engine will not start. b. Wait for the PowerView to come on. c. When the PowerView screen comes on, a WAIT TO START – PREHEAT message appears on the screen. MAR 2016 49457610 TRIPP HD RevB...

  • Page 54: Travel Mode

    10. Place the TRAVEL switch in the FORWARD 10. Place the TRAVEL switch in the REVERSE position. position. 11. Press down on the forward travel foot pedal. 11. Press down on the reverse travel foot pedal. MAR 2016 49457610 TRIPP HD RevB...

  • Page 55: Work Mode

    (up/down extend/retract) are in the UNLOCK position for the proper side the ties are being removed to and inserted from. 2. Make sure that the RAIL LIFT LOCK/UNLOCK switch is in the UNLOCK position. MAR 2016 49457610 TRIPP HD RevB...

  • Page 56: Railway Towing

    “LOCKUPS” page 3-1. 2. Drain the air tanks. 3. Chock all wheels. 4. Remove the T-bolt from the back side of the air canister and insert it into the bottom of the brake canister. MAR 2016 49457610 TRIPP HD RevB...

  • Page 57: Braking

    8. Place the THROTTLE in the LOW position. 9. Place the hydraulic PUMPS switch to the OFF position. 10. Place the IGNITION switch to the OFF position. 11. Place the Battery Disconnect Switch to the OFF position. MAR 2016 49457610 TRIPP HD RevB...

  • Page 58: Emergency Procedures

    There are two EMERGENCY STOP controls. • One is located on the center operator’s console. • One is located to the right of the operator’s seat. These controls shut off the engine and electrical power. MAR 2016 49457610 TRIPP HD RevB...

  • Page 59: Routine Maintenance

    (at the controls), ready to stop the machine and shut off engine if required. REQUESTING ASSISTANCE If you have any questions regarding maintenance and service on this machine, please call: Nordco Service Department 1-800-445-9258 MAR 2016 49457610 TRIPP HD RevB...
  • Page 60 ROUTINE MAINTENANCE Figure 7-1: RAIL CLAMP LUBE CHART MAR 2016 49457610 TRIPP HD RevB...
  • Page 61 ROUTINE MAINTENANCE Figure 7-2: SUSPENSION / BRAKES / PROPULSION LUBE CHART MAR 2016 49457610 TRIPP HD RevB...
  • Page 62 ROUTINE MAINTENANCE Figure 7-3: TIE EXCHANGER LUBE CHART MAR 2016 49457610 TRIPP HD RevB...

  • Page 63: Machine Maintenance Schedules

    Grease Gripper Jaw Tilt Cylinder Pivot Point. - Reserved for Future Use - Fill Fuel Tank – End of Day. Inspect electrical connections/harnesses for tightness. Drain Air Tanks. Grease Brake Lever Pivot and Suspension Arm Pivot Grease Axle Bearings MAR 2016 49457610 TRIPP HD RevB...

  • Page 64: Detailed Daily Instructions

    Figure 7-4. A—Oil Dipstick B—Crosshatch Marks On Dipstick. C—Oil Filler Cap Refer to the GENERAL tabbed section later in this manual for details on the oil capacity of your engine. MAR 2016 49457610 TRIPP HD RevB...
  • Page 65 Figure 7-7. IMPORTANT Drain water into a suitable container and dispose of properly. 1. Turn off the engine. 2. Place a cup under the drain valve at the base of the filter. MAR 2016 49457610 TRIPP HD RevB...
  • Page 66 Maximum air intake restriction is 6.25 kPa (0.06 bar, 1.0 psi, 25 in. H2O). A clogged air cleaner element will cause excessive intake restriction, reduced air supply to the engine, and increase overall engine wear. A—Air Restriction Indicator Figure 7-8 MAR 2016 49457610 TRIPP HD RevB...
  • Page 67 Remove hoses/fittings only when system is not pressurized. D13. RAIL LIFT & STABILIZER > Grease Rail Lift Cylinder Pivots D14. RAIL LIFT & STABILIZER > Grease Rail Clamp Lever Pivot Pins Figure 7-9 MAR 2016 49457610 TRIPP HD RevB...
  • Page 68 Use only Diesel fuel. The pivot grease fittings are located on the brake lever pivot and the suspension arm pivot. See Figure 7-11. Figure 7-11 7-10 MAR 2016 49457610 TRIPP HD RevB...
  • Page 69 Grease hardens with age. When this occurs, the bearings should be disassembled, cleaned, and re-lubricated following the manufacturer’s instructions on the component data sheet. If supplied, check automatic greasing assemblies for proper charge. Figure 7-12 MAR 2016 49457610 TRIPP HD RevB 7-11...

  • Page 70: Weekly Schedule

    When inspecting the drive chain, the chain should be nearly taut, with 1/4 inch (0.635 Cm) play when depressed at the center. If play is not found, adjustment is necessary. See Figure 7-13. Figure 7-13: Proper Tension 7-12 MAR 2016 49457610 TRIPP HD RevB...
  • Page 71 4. Remove the six cap screws and lift off the front cover. 5. Reverse the process to reattach the cover. NOTE If for any reason the removal of suction line filter is necessary, you must seal the hydraulic tank to prevent external contamination. MAR 2016 49457610 TRIPP HD RevB 7-13...

  • Page 72: Monthly Schedule

    Belts should be neither too tight, nor too loose. Belts that are too tight impose excess load on the crankshaft, fan, and/or alternator bearings, shortening both belt and bearing life. Excessively overtightened belts can result in crankshaft breakage. 7-14 MAR 2016 49457610 TRIPP HD RevB...
  • Page 73 11. Remove the tag on the BATTERY DISCONNECT switch while following your defined Lock Out/Tag Out procedures. 12. Machine is now ready for normal operation. Figure 7-19 MAR 2016 49457610 TRIPP HD RevB 7-15...
  • Page 74 3/16 inch clearance between the brake pad and the Figure 7-22 wheel with the brake pedal off. 15. Remove the tag on the BATTERY DISCONNECT switch while following your defined Lock Out/Tag Out procedures. 7-16 MAR 2016 49457610 TRIPP HD RevB...
  • Page 75 (oil temperature has reached 100°F 37.8°C minimum). Before performing these checks, read understand OPERATION instructions, warnings and cautions. See Hydraulic Preface tabbed section, for detailed instructions for setting hydraulic pressures. MAR 2016 49457610 TRIPP HD RevB 7-17...

  • Page 76: Quarterly Schedule

    • Take precautions prevent moisture contamination. • Change fluid whenever contamination occurs, because even small amounts of water can affect system performance as well as induce corrosion and oil breakdown. 7-18 MAR 2016 49457610 TRIPP HD RevB...

  • Page 77: Yearly Schedule

    - Reserved for Future Use - - Reserved for Future Use - DETAILED YEARLY INSTRUCTIONS NOTE For Recommended Engine Service Intervals over one (1) year, refer to the Engine Manual or contact the Engine Manufacturer. MAR 2016 49457610 TRIPP HD RevB 7-19...

  • Page 78: General Engine Maintenance

    5° C (9° F) below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature. Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 121561. 7-20 MAR 2016 49457610 TRIPP HD RevB...

  • Page 79: Caterpillar Engine Fault Codes

    ROUTINE MAINTENANCE CATERPILLAR ENGINE FAULT CODES Shown here are normal Caterpillar engine fault codes. Figure 7-23: Caterpillar Engine Fault Codes Page 1 MAR 2016 49457610 TRIPP HD RevB 7-21...
  • Page 80 ROUTINE MAINTENANCE Figure 7-24: Caterpillar Engine Fault Codes Page 2 7-22 MAR 2016 49457610 TRIPP HD RevB...
  • Page 81 ROUTINE MAINTENANCE Figure 7-25: Caterpillar Engine Fault Codes Page 3 MAR 2016 49457610 TRIPP HD RevB 7-23...
  • Page 82 ROUTINE MAINTENANCE 7-24 MAR 2016 49457610 TRIPP HD RevB...

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