TABLE OF CONTENTS Bolt and Screw Torque Values...2 SAE...2 Metric...2 Troubleshooting Propulsion...3 Brakes...3 Rail Lift...3 Tie Exchanger...5 JUNE/2004 (4945-7600) Mechanical, Page 1
BOLT AND SCREW TORQUE VALUES There are several areas on this machine where specific torque values are required. Nordco only uses Grade 5 or Grade 8 bolts. These are identified on the exploded view parts sheets. The following values are industry standards for torqueing bolts: SAE Grade and Head Markings Grade 5 Grade 8 Size N m lb-ft N m lb-ft 1/4 (.250) 12 9 17 12.5 5/16 (.3125) 25 18 35 26 3/8 (.375) 44 33 63 46 7/16 (.4375) 70 52 100 75 1/2 (.500) 110 80 150 115 9/16 (.5625) 155 115 225 160 5/8 (.625) 215 160 300 225 3/4" (.750) 375 280 550 400 7/8 (.875) 625 450 875 650 1 925 675 1300 975 Metric Grade and Head Markings Grade 8.8 Grade 10.9 Grade 12.9 Size N m lb-ft N m lb-ft N m lb-ft M6 11 8.5 17 12 19 14.5 M8 28 20 40 30 95 75 M10 55 44 80 60 95 70 M12 95 70 140 105 165 120 M14 150 110 225 165 260 190 M16 240 175 350 255 400 300 M18 330 250 475 350 560 410 Bolts, screws, and nuts should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. For example, if Grade 5 was called out but Grade 8 was used, you would torque to the requirements of Grade 5. Always turn off machine when performing maintenance, making adjustments, or whenever unintended movement of machine could occur; unless directed otherwise. Failure to comply could result in personal injury and/or damage to the machine. SYSTEM Mechanical, Page 2 JUNE/2004 (4945-7600)
GUIDE Machine will not propel. 1. Main pump not developing. 2. Brakes not releasing. Propulsion relief setting too low. 4. Defective motor or broken drive chain. 5. Rail Lift cycle is not completed. GUIDE behind the Hydraulic Tab of this Manual. 2. See next problem. Increase relief setting. 4. Repair or replace motor or chain. 5. Allow cycle to complete or set Work/ Travel switch to TRAVEL Brakes will not release Brakes will not apply. Rail Lift will not Unlock 1. Low Air Pressure. 2. Parking Brake Set. Faulty Brake Canister. 4. Defective or disconnected switch at Propulsion Manifold 5. Circuit Breaker Blown. 1. Brake Pedal valve not shifting. 2. Faulty Brake Canister. Brake shoes worn. 1. Unlock is not actuated. 2. Low Air Pressure. Down Force on up/down cylinder 4. Din le on Rail Lift Manifold not at a. Din connector disconnected from b. Disconnected from c. Disconnected from TRIPP d. Connector disconnected from Rocker e. Faulty Rocker f. Broken or damaged wiring g. Blown Output fuse 1. See PNEUMATIC (AIR) SYSTEM TS GUIDE behind Pneumatic Tab 2. Push in Parking Brake Valve on Center Console to release Parking Brake. Repair or Replace canister. 4. Replace or Repair Pressure or run Machine in Service Brake Mode 5. Reset Circuit Breaker CB9 1. Check valve spool for free motion. 2. Repair or Replace canister. Inspect shoes and replace if necessary. 1. Position Rail Lift up/down switch to Unlock 2. See PNEUMATIC (AIR) SYSTEM TS GUIDE behind Pneumatic Tab Raise LH & RH up/down cylinders using rocker switches. 4. a. Reconnect Din cable to Junction Box. b. Reconnect Din connector to Junction box c. Reconnect Junction Box to d. Reconnect to TRIPP e. Reconnect connector to Rocker. f. Repair or Replace. JUNE/2004 (4945-7600) Mechanical, Page 3
g. Replace Rail Lift will not Lower Or Raise Rail Lift cylinder does not Jog when Jog button pushed on HC (Optional) Rail Clamps will not open or will not close. Rail Clamps will hold rail Erratic or irregular movement during rail lift sequence 1. Rail lift up/down cylinder is not unlocked. 2. Hydraulic Pump not developing Din le on Rail Lift Manifold not at a. Din connector disconnected from b. Disconnected from c. Disconnected from TRIPP d. Connector disconnected from Rocker e. Faulty Rocker f. Broken or damaged wiring g. Blown Output fuse JOG potentiometer not set correctly. Faulty or defective HC 2. Din le on Rail Lift Manifold not at a. Din connector disconnected from b. Disconnected from c. Disconnected from TRIPP d. Connector disconnected from Rocker e. Faulty Rocker f. Broken or damaged wiring g. Blown Output fuse Blown seal in clamp cylinder Clamp cylinder lock valve not functioning properly LVDT not set correctly GUIDE behind Hydraulic Tab. 2. Reconnect Din cable to. A. Reconnect to B. Reconnect to TRIPP C. Reconnect connector to D. Repair or Replace. E. Repair F. Replace Check JOG pot on PLC. Adjust as required. Repair or replace HC GUIDE behind Hydraulic Tab. 2. Reconnect Din cable to. A. Reconnect to B. Reconnect to TRIPP C. Reconnect connector to D. Repair or Replace. E. Repair F. Replace Inspect cylinder. Repair or replace. Inspect wiring connections. Inspect valve. Repair or replace as required. Refer to LVDT Adjustments in the ELECTRICAL Troubleshooting section behind the ELECTRICAL Tab Tie Exchanger 1. Unlock is not actuated. 1. Position Rail Lift up/down up/down 2. Low Air Pressure. switch to Unlock Mechanical, Page 4 JUNE/2004 (4945-7600)
cylinder will not unlock. Down Force on up/down cylinder 4. Din on Pneumatic Manifold not at B. Disconnected from C. Disconnected from TRIPP E. Faulty Rocker F. Faulty Relay G. Broken or damaged wiring 2. See PNEUMATIC (AIR) SYSTEM GUIDE on page1 in Appendix D. Raise LH & RH up/down cylinders using LH & RH enable switch and pulling back on the handcontroller. 4.. B. Reconnect to C. Reconnect to TRIPP D. Reconnect F. Replace G. Repair or Replace. Tie Exchanger will not Lower Tie Exchanger will not Raise 1. Machine in TRAVEL Mode 2. Tie Exchanger up/down cylinder is not unlocked. Hydraulic Pump not developing 4. Din on Workhead Manifold not at 5. Din connector disconnected from A. Disconnected from B. Disconnected from TRIPP C. Connector disconnected from Rocker D. Faulty Rocker E. Faulty Relay 1. Machine in TRAVEL Mode 2. Hydraulic Pump not developing Din on Workhead Manifold not at B. Disconnected from C. Disconnected from TRIPP E. Faulty Rocker (Work/Travel) 1. Place Machine in WORK Mode 2. See previous problem. See HYDRAULIC SYSTEM 4. Reconnect Din cable to. 5. A. Reconnect to B. Reconnect to TRIPP C. Reconnect D. Replace 1. Place Machine in WORK Mode 2. See HYDRAULIC SYSTEM. B. Reconnect to C. Reconnect to TRIPP D. Reconnect JUNE/2004 (4945-7600) Mechanical, Page 5
Tie Gripper will not close. Tie Grippers will not open. Tie Grippers will not Tilt. 2. Pressure Reducing Valve Din 5-12VDC B. Disconnected from C. Disconnected from TRIPP E. Faulty G. Faulty Resistor on Resistor Board H. Blown Circuit Breaker Directional Control Valve Din. B. Disconnected from C. Disconnected from TRIPP E. Faulty G. Faulty or Loose Relay 4. Blown Output Fuse 5. Faulty Handcontroller 2. Directional Control Valve Din. B. Disconnected from C. Disconnected from TRIPP D. Broken or damaged wiring E. Blown output fuse. F. No input to PLC Faulty Handcontroller Handcontroller Connector Disconnected 2. Directional Control Valve Din 2.. B. Reconnect to C. Reconnect to D. Reconnect connector to E. Repair or Replace. G. Repair or Replace. H. Reset Circuit Breaker CB8. B. Reconnect to C. Reconnect to TRIPP D. Reconnect connector to E. Repair or Replace. G. Replace or Tighten CR6 or CR7 4. Replace 5. Replace 2.. B. Reconnect to C. Reconnect to TRIPP D. Repair or Replace F. Repair or Replace Reconnect. Mechanical, Page 6 JUNE/2004 (4945-7600)
. B. Disconnected from C. Disconnected from TRIPP D. Broken or damaged wiring E. Blown output fuse. F. Faulty LH Joystick G. LH Joystick Connector Disconnected Faulty or Loose Relay 2.. B. Reconnect to C. Reconnect to TRIPP D. Repair or Replace F. Repair or Replace G. Reconnect. Replace or Tighten CR6 or CR7 JUNE/2004 (4945-7600) Mechanical, Page 7