TABLE OF CONTENTS. Understanding the Troubleshooting Instructions...2 Signal Light...2 Harness Connections...2 Inspection...2

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1 TRIPP Model D ELECTRICAL TABLE OF CONTENTS Understanding the Troubleshooting Instructions...2 Signal Light...2 Harness Connections...2 Inspection...2 LVDT Setup/Adjustments...2 Basic Troubleshooting...3 PLC Troubleshooting and Adjustments...6 Specifications...6 Maintenance...6 Potentiometer Adjustments...6 PLC Troubleshooting...7 PLC Battery Replacement...7 Programming the PLC...8 OCT/2008 ( ) Section E-1

2 ELECTRICAL TRIPP Model D ELECTRICAL SYSTEM UNDERSTANDING TROUBLESHOOTING INSTRUCTIONS Before you use the troubleshooting charts, you must understand a few basic symbols, key words, and components. SIGNAL LIGHT Signal lights (A) are located on proximity switches, DIN cables, and DIN suppression modules. if the machine is started. If your visual inspection does not indicate the possible malfunction refer to the electrical system troubleshooting guide that follows. To avoid possible personal injury and/or engine damage from accidental engine startup, always disconnect the battery before servicing the machine. Never shut off battery disconnect switch with engine running. This could cause damage to the voltage regulator, alternator, and/or electrical system. HARNESS CONNECTIONS Harness connections are checked from the source to the connection either to a junction box or the logic box (in other words, both ends of harness). 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: 1. Look for bare wires that could cause grounds or shorts. Shorted wires can damage the charging system. 2. Look for loose or broken wires. 3. Inspect all connections, especially battery connection points. Cleaning harness connectors or ground connections can often correct what appears to be a malfunction. 4. Check the battery electrolyte level. Continued loss of electrolyte fluid indicates overcharging or cracked battery case. 5. Inspect for overheated parts after the unit has been stopped for a while. They will often smell like burned insulation. Put your hand on the alternator. Heat in these parts, when the machine has not been operated for some time, is a sure clue to charging circuit problems. LVDT TROUBLESHOOTING Through the use of these troubleshooting charts, you may be required to adjust the LVDT s. Adjusting the LVDT s may require two workers: 1. At the PLC, make certain that the LH Max Rail Lift and RH Max Rail Lift potentiometers are set at At the RH Control Console, make certain that the RH Rail Height Potentiometer is set to it s minimum position (LH Rail Height Pot will have no effect on the lifting). 3. Unplug the LVDT on the left side of the Rail Lift Assembly. Run the automatic rail lift cycle. LH side of rail lift assembly should lift considerably higher than the right. Plug the cable back into the LVDT. 4. At the RH Control Console, make certain that the LH Rail Height Potentiometer is set to it s minimum position (RH Rail Height Pot will have no effect on the lifting). 5. Unplug the LVDT on the right side of the Rail Lift Assembly. Run the automatic rail lift cycle. RH side of rail lift assembly should lift considerably higher than the left side. Plug the cable back into the LVDT. 6. At the RH Control Console, make certain that both the LH and RH Rail Height POTs have been returned to their original positions. Many electrical failures cannot be detected even if Section E-2 OCT/2008 ( )

3 TRIPP Model D ELECTRICAL BASIC TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Battery uses too much water Cracked battery case. High Ambient Temperature. Shorted Cell. Battery being Overcharged. Replace battery. Refill with water. Check specific gravity. Alternator problem. Check, repair or replace alternator. Cracked Battery Case Frozen battery Keep battery fully charged in cold weather. Replace battery. Low Battery Output Starting Motor will not turn. Hourmeter does not work. Voltmeter does not work. Engine Oil Pressure Gauge does not work. Low water level. Dirty or wet battery top causing discharge. Corroded or loose battery cables. Broken Battery post. Wrong size replacement battery. Defective ignition switch Bad helper solenoid Battery disconnect switch turned off. Corroded battery terminals. Hourmeter Hourmeter relay shorted Corroded or failed hourmeter groundwire. Key switch and /or Battery Disconnect switch. Voltmeter Regulator Pressure Gauge. Add distilled water. Clean and wipe dry battery top. Clean and tighten battery cables. Wiggle battery post by hand. If post wiggles or turns, replace battery. Replace battery with type specified under "Machine Specifications". Replace Turn switch to "ON" position. Inspect and clean if necessary. Replace Hourmeter. Check relay. Replace wiring harness. Replace groundwire. Make certain they are on. Replace meter. Replace gauge. Engine Oil Pressure High Oil Viscosity Drain and add correct oil as OCT/2008 ( ) Section E-3

4 ELECTRICAL TRIPP Model D PROBLEM POSSIBLE CAUSE SOLUTION Gauge always reads "HIGH" specified under "RECOMMENDED LUBRICANTS" Engine Oil Pressure Gauge always reads "LOW" Horn does not sound Backup Alarm does not sound. Travel Lights do not work. Engine Oil Pressure Gauge defective. Defective pressure sensor Low oil level. Low oil viscosity. Gauge defective. Defective pressure sensor. Wiring Harness Connection at horn loose. Horn circuit breaker blown. Horn broken. Horn Switch. Connection at alarm loose. Backup Alarm Backup Alarm switch not turned on Backup alarm switch faulty. Connection at light loose. Light circuit breaker blown. Light switch defective. Check wiring harness. Repair or replace Replace sensor Stop engine, check level. If low fill to desired level. Drain and add correct oil as specified under "RECOMMENDED LUBRICANTS" Replace gauge. Replace sensor. Reset circuit breaker. Check horn, repair or Check switch, repair or Check alarm, repair or Turn on. Check switch, repair or Reset circuit breaker Repair or replace switch. Section E-4 OCT/2008 ( )

5 TRIPP Model D ELECTRICAL PROBLEM POSSIBLE CAUSE SOLUTION Replace bulb or socket. Bulb or socket in light defective. Work Lights do not work. Connection at light loose. Light circuit breaker blown. Reset circuit breaker. Cooling Fan not working Brake Lights do not work Light switch defective. Bulb or socket in light defective. Loose connection at back of fan Loose connection on relay.. Connection at light loose. Light Circuit breaker blown. Repair or replace switch. Replace bulb or socket. Reset circuit breaker. Din Cable Light not illuminating Bulb or socket in light defective. Bad solenoid coil. Loose din cable connection at solenoid. Loose din cable connection at junction box. Loose junction box connection at logic box. Replace bulb or socket. Replace coil. OCT/2008 ( ) Section E-5

6 ELECTRICAL TRIPP Model D PLC TROUBLESHOOTING/ADJUSTMENTS Always ensure that the PLC does not come into contact with high-voltage equipment or power equipment. Damage to PLC may occur. Under NO circumstances should the power supply terminals/cables be connected to any other terminal on this unit. Damage to PLC may occur. Specifications: Battery Type F2-40BL (Mitsubishi) NORDCO P/N Battery Life years Low Battery Indication..... Batt.V LED is ON Maintenance: Check input/output terminals for corrosion. Check for loosening of terminals due to vibration. PLC POTENTIOMETER ADJUSTMENTS POTENTIOMETER RH Max Rail Lift LH Max Rail Lift FUNCTION Adjusts maximum time RH Rail Lift UP is energized during the Automatic Rail Lift Cycle Adjusts maximum time LH Rail Lift UP is energized during the Automatic Rail Lift Cycle Rail Lift Raise Delay Adjusts time delay between clamps closing and Rail Lift UP Rail Lift Lower Delay Adjusts time delay between Rail Lift DOWN and Clamps opening Rail Lift Clamp Delay Rail Lift Jog Duration (Optional) Adjusts time delay between Rail Clamp CLOSE and Rail Lift UP Adjusts time duration for manual rail lift jog NOTE: The run/stop switch must be in the STOP position in order to program the PLC. Under normal operating conditions, the run/stop switch is in the RUN position. Refer to Drawing for more information on the PLC s and controls. Section E-6 OCT/2008 ( )

7 TRIPP Model D ELECTRICAL PLC TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION PLC POWER Light does not turn on when ignition switch is on 1. Circuit Breaker Blown 2. Fuse Blown in PLC 3. 24V DC Service Supply on PLC is overloaded 1. Reset Circuit Breaker CB6 2. Contact Nordco Service 3. Disconnect any wires from the 24V DC service supply on PLC PLC BATT.V Light is on 1. PLC Internal Battery is Low 1. Replace PLC battery (See battery replacement on next page) Replaced battery, but battery light is still ON 1. Battery Connector malfunction 1. Contact Nordco Service PLC PROG-E Light is flashing All PLC outputs not at 24V DC CPU.E Light is ON 1. PLC Internal Battery is Low 2. Check ground wire 3. Program error 1. PLC Run/Stop switch on STOP 2. Electrical Interlock pushbutton in 3. Circuit Breaker Blown 1. Memory chip installed or removed while the unit was still powered 1. Replace PLC battery (See battery replacement on next page) 2. Disconnect and reconnect ground wire 3. Contact Nordco Service 1. Position switch to RUN 2. Pull out Electrical Interlock pushbutton 3. Reset Circuit Breaker CB6 1. Reset PLC Power OFF Power ON and trigger RUN input PLC BATTERY REPLACEMENT Make certain you have replacement battery in hand before attempting to replace the battery. Failure to replace battery in less than 20 seconds causes loss of data held in PLC s ram. Procedure: 1. Turn off the PLC s power supply by turning ignition switch to OFF. 2. Remove cover to expansion board. 3. Remove battery from holder. 4. Disconnect battery from battery connector. 5. Connect new battery to connector. 6. Place battery in holder. 7. Replace expansion board cover. OCT/2008 ( ) Section E-7

ELECTRICAL TRIPP Model D PROGRAMMING THE PLC 1. Make certain that the battery switch (on the machine) is turned ON. 2. Make sure the ignition key is in the OFF position. 3.

8 ELECTRICAL TRIPP Model D PROGRAMMING THE PLC 1. Make certain that the battery switch (on the machine) is turned ON. 2. Make sure the ignition key is in the OFF position. 3. Remove cover on main (left) PLC module. Once the cover is removed you ll see a removable program (memory) chip and a cable (programming) port. 4. Remove the program chip. On the bottom side of the chip there is a switch. Slide the switch to the left and reseat the chip onto the PLC. 5. Put the Run/Stop switch in the STOP position. 6. Using the program loader, plug the cable into the programming port on the PLC. 7. Turn the ignition key to the ON position to power up the system. (You don t need the engine running to load the program). 8. On the program loader there are 2 buttons. Make sure the WR light is illuminated. With the new program chip in the program loader, press the ENT button twice. 9. Once the ENT light turns off, turn the Ignition switch to the OFF position. 10. Unplug the program loader. 11. Put the Run/Stop switch in the RUN position. 12. Remove the program chip from the PLC and slide the switch to the right. Reseat the chip into the PLC. 13. Current version is now loaded. Make certain new sticker is placed on program chip that states the latest version number. Section E-8 OCT/2008 ( )

TABLE OF CONTENTS. Understanding the Troubleshooting Instructions...2 Signal Light...2 Harness Connections...2 Inspection...2

TABLE OF CONTENTS. Understanding the Troubleshooting Instructions...2 Signal Light...2 Harness Connections...2 Inspection...2 TRIPP Model B ELECTRICAL TABLE OF CONTENTS Understanding the Troubleshooting Instructions...2 Signal Light...2 Harness Connections...2 Inspection...2 LVDT Setup/Adjustments...2 Basic Troubleshooting...3