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Nordco Super Claws LS-2, Operation And Maintenance Manual

The Nordco Super Claws LS-2 is a powerful and versatile construction equipment designed for heavy-duty operations. To ensure optimal performance and longevity, it is essential to have the Operation And Maintenance Manual. Download the comprehensive manual for free from our website manualshive.com, where user manuals are readily available for download.

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GENERAL

  

Super Claws Model LS-2

 

 

 

 

 

 
Section 2-2 

 

MAR/2006 (4945-3500) 

 

SPECIFICATIONS

™

 

 

GENERAL

 

 

Machine Name........................................................................................................Super Claws Spike Puller 
Model.......................................................................................................................................................... LS-2 

Gross Weight ........................................................................................................................ 7,250 lbs/3291 kg* 
Length ............................................................................................................. 14 feet (168 inches)/4.25 meters  
Width.......................................................................................................7 feet 6 inches (90 inches)/2.3 meters  
Height....................................................................................................8 feet 6 inches (102 inches)/2.6 meters  
Travel Speed.......................................................................................................... 24 mph maximum (39 km/h) 
Work Speed ............................................................................................................... 5 mph maximum (8 km/h) 
Towing Speed ........................................................................................................ 20 mph maximum (32 km/h) 
Rated Draw Bar Pull ............................................................................................................. 1,650 lbs. (750 kg) 
Turntable.........................................................................................................................Hydraulically Operated 
Wheel Base........................................................................................................... 7 feet (84 inches)/2.1 meters 
Pulling Force (maximum) ................................................................................................ 30,500 lbs. (135.7 kN) 
 

CAPACITIES

 

 
Fuel Tank 
      Standard Tank .......................................................................................................... 12.8 gallons (48 liters) 
      Optional Tank............................................................................................................. 28 gallons (106 liters) 
Hydraulic Oil Tank 
      Standard Tank ........................................................................................................ 32.5 gallons (123 liters) 
      Optional Tank............................................................................................................. 45 gallons (170 liters) 
Oil Cooler ............................................................................................................................100 gpm (378 L/mn) 
 

ENGINE

 

 
ENGINE (OPTION) 
Make/Model ..................................................................................................................John Deere 4024D, Tier 2 
Type ....................................................................................................................................................... 4 Cylinder 
Oil Capacity................................................................................................................................ To be determined 
Coolant Capacity……………………………………………………………………………………2.7 Quarts  (2.6 liters) 

  

 

HYDRAULIC SYSTEM 
 

Pressure Settings: 
     Relief Valve - Main Pump ........................................................................................................... 3,000 psi (200 bar) 
     Compensator - Main Pump ........................................................................................................ 2, 500 psi (172 bar) 
Main Pump Make ........................................................................................................................... Vickers PVM Series 
Control Valves.................................................................................................................................. Vickers Manifolded 

 
 
ELECTRICAL SYSTEM

 

Battery......................................................................12 Vdc (Dual 12V DC batteries), 1150 Cold Cranking Amps 
Ground ..................................................................................................................................................... Negative 
Alternator (John Deere)…………………………………………………………………………………………...75 Amp 

 
AXLE DRIVE SYSTEM 

 

Drive Type........................................................................................................................... Dual Axle Chain Drive  
Propulsion Motor Type............................................................................................................................ Hydraulic 
 

 

™

Items or capacities may vary according to options on your machine. 

* Approximate weight.  Actual weight may vary according to options on your machine.  Actual weight of 
your machine is as stenciled. 

Summary of Contents for Super Claws LS-2

Page 1: ...Reorder Part 49453500 Last Revision Rev MARCH 2006 Read and fully understand the precautions contained in this manual before operating or servicing this machine Refer to Section 1 for important safety information Component Troubleshooting can now be found on the blue pages behind each tab ...

Page 2: ......

Page 3: ... should remain with the machine at all times Additional copies of this manual are available either as a part Operation Manual only or a whole operation and parts manual at a nominal cost through our Part Sales Department Additional service information parts and application information is available through these Nordco product support resources NORDCO Sales Milwaukee Wisconsin 414 766 2180 sales no...

Page 4: ... we have OSHA Form 20 Safety Data Sheets available that cover the material contained in this machine 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 Fax 414 766 2299 Phone 414 766 2288 ...

Page 5: ... considered a permanent part of your machine and should remain with the machine at all times Additional copies of this manual are available at a nominal cost through our Part Sales Department Additional service information parts and application information is available through these Nordco product support resources NORDCO Sales 414 769 4605 sales nordco com NORDCO Parts 414 769 4607 4608 1 800 647...

Page 6: ...have OSHA Form 20 Safety Data Sheets available that cover the material contained in this machine 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 P O Box 1562 Milwaukee WI 53201 Fax 414 481 3199 Tele 414 769 4631 hkietzke nordco com ...

Page 7: ...essages in this manual Learn how to operate the machine and how to use controls properly Do not let anyone operate this machine without instruction Failure to understand the contents of this manual could result in serious personal injury or death SAFETY ALERT SYMBOLS These are the safety alert symbols These symbols means pay attention Your safety is at risk DANGER is used to indicate a definite ha...

Page 8: ...to the machine Always use the steps and handrails provided If an area does not have tread grips walkways or other methods to access the area then DO NOT attempt to access that area Make seat and control adjustments PRIOR to starting the machine ALWAYS wear a seatbelt Know the weather forecast and plan your work speeds accordingly There are guards on this machine These are to be removed ONLY when s...

Page 9: ...ning work SAFETY WHILE PARKED When leaving a machine engine running make certain that the parking brake is applied and the electrical interlock button has been activated NEVER stop and park this machine on an incline unless the machine wheels have been chocked SAFETY DURING MAINTENANCE The following guidelines are suggested when performing maintenance 1 Always chock the wheels 2 Alert others in th...

Page 10: ...ling at travel speed can result in injury to personnel and or extensive damage to the machine Remove hoses fittings only when system is not pressurized High pressure leaks can cause personal injury 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 ...

Page 11: ...dangerous stored energy forms and make the machine safe to begin repairs SAFETY PROCEDURES LOCKOUT TAGOUT 1 Apply parking brakes by pushing in parking brake button located on the center front control console 2 Chock wheels to prevent accidental rolling of machine on grade 3 If you have not already done so determine which components are to have maintenance Place all machine mechanical systems or wo...

Page 12: ...ty decals These can be ordered from the Parts Sales Department Safety Decals on this Machine are PART NO DESCRIPTION LOCATION 5642 0001 General Machine Cautions Inside Cab 5642 0002 Caution Watch Your Step Each stairway 5642 0004 Danger Pinch Points On workhead 5642 0005 Warning Hand Hazard On workhead 5642 0006 Danger Before Servicing Logic Box Sides 5642 4501 Caution Before Welding Logic Box Fac...

Page 13: ...ing this machine Follow all instructions carefully ABOUT THIS MANUAL This manual has been broken down into sections which have been separated by index tabs Behind each index tab is a blue colored section for troubleshooting the applicable section Mechanical has individual parts breakdown drawings and lists for each assembly Hydraulic includes adjustment instructions and troubleshooting for the hyd...

Page 14: ...ydraulic Oil Tank Standard Tank 32 5 gallons 123 liters Optional Tank 45 gallons 170 liters Oil Cooler 100 gpm 378 L mn ENGINE ENGINE OPTION Make Model John Deere 4024D Tier 2 Type 4 Cylinder Oil Capacity To be determined Coolant Capacity 2 7 Quarts 2 6 liters HYDRAULIC SYSTEM Pressure Settings Relief Valve Main Pump 3 000 psi 200 bar Compensator Main Pump 2 500 psi 172 bar Main Pump Make Vickers ...

Page 15: ...Cast Steel Size 16 inch 406 mm diameter Brake Type Four wheel shoe type spring actuated deadman 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 Dimensional Information ...

Page 16: ...GENERAL Super Claws Model LS 2 Section 2 4 MAR 2006 4945 3500 Page Intentionally Left Blank ...

Page 17: ...ances are there to be more riders on this machine than seats available Always use your seat belt when sitting in the operator seat For additional information concerning the controls used in the Operator s Station including the hand controllers and Propulsion lever refer to Operator Station Controls later in this section WORKHEAD Each workhead assembly consists of the Pulling Frame the A shaped fra...

Page 18: ...rs are activated in relation to the energized or de energized condition of the micro switches or limit switches The sequence chart describes each complete operating cycle step by step as it occurs during actual operation CONTROLS AND INSTRUMENTS Some controls and all of the instruments are located on the Main Control Panel Additional controls are located remotely on the machine Become thoroughly f...

Page 19: ...Super Claws Model LS 2 PRE OPERATION STARTUP MAR 2006 4945 3500 Section 3 3 MAIN CONTROL PANEL ...

Page 20: ...PRE OPERATION STARTUP Super Claws Model LS 2 Section 3 4 MAR 2006 4945 3500 MAIN CONTROL PANEL ENGINE AND PUMP CONTROLS AND GAUGES GAUGES AND MISC CONTROLS ...

Page 21: ...0 and 280 degrees F 76 and 110 degrees Celcius Engine TACHOMETER and HOURMETER Indicates engine speed rpms and total hours of engine operation Normal engine operating speed should be approximately 2800 rpm SHUTDOWN OVERRIDE Overrides engine shutdown for emergency travel purposes Red pilot light is lit when engine shutdown override is activated CAUTION The engine is not protected from low oil press...

Page 22: ...PRE OPERATION STARTUP Super Claws Model LS 2 Section 3 6 MAR 2006 4945 3500 MAIN CONTROL PANEL ENGINE AND PUMP CONTROLS AND GAUGES ENGINE AND PUMP CONTROLS ...

Page 23: ...ngine oil pressure reaches 25 psi PUMP ON OFF Switch Turns on hydraulic pump Engine will not start if this switch is in the ON position when ignition switch is turned This is done to reduce engine load during starting After engine has started turn on pump ENGINE SPEED Switch HIGH Speed LOW Speed Used during work travel and shutdown Used during normal work and travel operations Used for idling engi...

Page 24: ...PRE OPERATION STARTUP Super Claws Model LS 2 Section 3 8 MAR 2006 4945 3500 MAIN CONTROL PANEL WORK CONTROLS AND INDICATORS ...

Page 25: ...from the operator claws Open position CLAW PIN FRAME PIN Switch The switch is put in CLAW PIN position to insert or remove the CLAW HOUSING lock pin The switch is put in the FRAME PIN position until the cylinder bottoms out and returns the switch to HOLD position to insert or remove the frame pin Work Travel Switch In the WORK position the relay logic control system is in an automatic mode and wor...

Page 26: ...PRE OPERATION STARTUP Super Claws Model LS 2 Section 3 10 MAR 2006 4945 3500 MAIN CONTROL PANEL LIGHTS HORNS AND FANS ...

Page 27: ... horn to be activated Move the Travel Direction switch to the DOWN position for rear travel lights and front horn to be activated WORK LIGHTS Place switch in ON or OFF position as needed Note These lights MUST be ON when working STROBE LIGHTS Place switch in ON or OFF position as needed NOTE If your machine is equipped with strobe lights these MUST be ON when working FAN SWITCH This switch control...

Page 28: ...PRE OPERATION STARTUP Super Claws Model LS 2 Section 3 12 MAR 2006 4945 3500 MAIN CONTROL PANEL MISCELLANEOUS CONTROLS ...

Page 29: ...NAL SYMBOL FUNCTION HYDRAULIC FILTER STATUS INDICATOR LIGHTS Green Light Filter Element OK Red Light Filter Element needs cleaning SET OFF CYLINDER OPTIONAL Switch in DOWN position raises machine Switch in UP position lowers machine CASE DRAIN FILTER STATUS INDICATOR LIGHTS OPTIONAL Green Light Filter Element OK Red Light Filter Element needs cleaning ...

Page 30: ...PRE OPERATION STARTUP Super Claws Model LS 2 Section 3 14 MAR 2006 4945 3500 OPERATOR CONTROLS HAND CONTROLS ...

Page 31: ...andle forward moves the machine forward Speed is dictated by the amount forward you push the handle The more forward the faster the machine will travel REVERSE TRAVEL Pulling the propulsion handle toward you moves the machine in reverse Speed is dictacted by the amount you pull the handle The further back the faster the machine will travel in reverse BRAKING Releasing the propulsion handle applies...

Page 32: ...l Indicates temperature of the hydraulic oil Normal operating temperature is 120 to 150 F 49 to 66 C Battery Disconnect Switch 3 Located inside of battery box Two position switch marked with ON OFF plaque Set Off Valve 4 The lever controls the upward downward motion of the Turntable Cylinder and the machine Moving the valve hand lever UP extends the cylinder and raises the machine Moving the lever...

Page 33: ... failure results 4 If necessary follow any applicable instructions under MAINTENANCE FOR EXTREME CONDITIONS 5 Know and understand the use of all machine controls and instruments as described earlier in this Section 6 Perform applicable preventative maintenance procedures in MAINTENANCE AND SERVICE section 7 Be ready to operate the machine with an alert and safety conscious attitude 8 Understand th...

Page 34: ...led Out Work Lights Switch OFF down Travel Lights Switch OFF centered Ignition Switch OFF Position Engine Speed Switch LOW down Hydraulic Tank Full See Recommended Lubricants Fuel Tank Full Use only Diesel Fuel Engine Oil Full See Recommended Lubricants in Maintenance Section Inspect for Leaks Pay particular attention to hydraulic and fuel lines Inspect all controls wiring and switches for secure ...

Page 35: ...e storage These have been painted red and have a decal located next to or near the area requiring locking up The numbers before the lock up area are the numbers shown on the drawing on the opposite page Become familiar with all lock ups on this machine DESCRIPTION ITEM WHEN USED Pulling Frame 1 At all times when machine is in travel mode and during maintenance of the workhead pulling frame and cla...

Page 36: ... base width Adjustments must be made to compensate for these conditions before operations can begin Read and understand all OPERATION procedures warnings and cautions before making adjustments BRAKE RELEASE ADJUSTMENT During normal operation the brakes release when the propulsion lever is moved for forward or reverse travel A cam on the propel valve linkage actuates the Brakes Off limit switch ene...

Page 37: ...mup switch 6 Place a spike in one of the spike claws and check the distance between the spike tip and the tie plate This distance should be approximately one inch If not reposition limit switch on the baseplate as required to obtain correct one inch distance between spike tip and tie plate 7 Pull out the Electrical Interlock Warmup switch 8 Initiate operating sequence to check adjustment 9 Repeat ...

Page 38: ...PRE OPERATION STARTUP Super Claws Model LS 2 Section 3 22 MAR 2006 4945 3500 This page intentionally left blank ...

Page 39: ... have been pulled out Set engine speed switch to LOW and the pump switch to OFF Engine will not start if the engine speed switch is set to HIGH NOTE See Emergency Stopping Procedures at the end of the OPERATION section 3 Hold the Magnetic Override switch labeled ENGINE PROTECT OVERRIDE HOLD IN WHILE STARTING in and turn the ignition switch to the right until the engine starts Release the ignition ...

Page 40: ...ad 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 LIGHTS FUNCTION Travel Lights Work Lights Brake or Marker Lights HORNS ALARMS FUNCTION Travel Alarm Horn Button Horn Button Optional Remote Switches Backup Alarm Optional LOCK UP DEVICES ENGAGED See Lock ups Next Page ...

Page 41: ...t spike 3 When the spike clears the tie plate release the joystick the head will automatically return to the preset down position 4 Propel to next tie location and repeat steps 2 and 3 TIE WORK When spikes are to be pulled from randomly selected ties the tie work mode should be used This mode is similar to rail work except that the pulling head remains in the preset up position after each pull and...

Page 42: ... the UP override on the top solenoid and insert pin into hole on face of bottom solenoid DOWN override This will apply downward pressure on the pulling frame and will raise the pulling frame off of the rail 5 Release the DOWN override solenoid pin Releasing the Brakes 1 Disconnect the emergency pump output hose from the manifold see Step 1 above and reconnect it to the quick disconnect at the brak...

Page 43: ...ndle Slowly lift handle to lower turntable until it comes into contact with the ties 4 Move the Turntable Valve hand lever upward and hold until the machine is fully raised off the track Center the hand lever 5 Use manpower to rotate the machine The wheels should be directly above the track after rotating the machine 6 Slowly move the Set Off Valve hand lever downward The Turntable Cylinder will r...

Page 44: ...OPERATION SHUTDOWN Super Claws Model LS 2 Section 4 6 MAR 2006 4945 3500 This page intentionally left blank ...

Page 45: ...5 9258 USA and Canada SERVICE NETWORK No Representative Phone Number 1 Nordco Service Manager Milwaukee 1 800 445 9258 2 Russell Railway Supply 612 835 5125 3 James H Lynde 913 648 7379 4 James H Lynde 913 648 7379 5 North American Equipment Company 859 885 3353 6 Dwayne Lambing 770 424 0401 7 North American Equipment Company 716 675 2040 8 North American Equipment Ltd Canada 905 628 9997 9 Intern...

Page 46: ...ervice interval D Daily W Weekly M Monthly Q Quarterly and A Annually for this point of the machine Maintenance instructions are given for each and are separated by Service Interval Designation 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 ...

Page 47: ...ness Page 6 7 MIS C D16 Fill Fuel Tank end of day Page 6 7 WEEKLY OR 40 HOURS WHICHEVER COMES FIRST SEE PAGE W1 Perform all Daily Lubrication and Maintenance Procedures Page 6 8 W2 Check Battery Condition Page 6 8 W3 Oil and Tighten Propulsion Chains Page 6 9 W4 Oil Propulsion Chain Adjusting Nuts Page 6 9 W5 Grease Wheel Bearings Page 6 9 W6 Check Suction Strainer Elementa Page 6 9 W7 Reserved fo...

Page 48: ...nance Procedures Page 6 15 Q2 Reserved for Future Use Page 6 15 Q3 Replace Fuel Filters Page 6 15 Q4 Check Cooling System Hoses Page 6 15 Q5 Test Hydraulic Oil Cleanliness Page 6 15 Q6 Replace Hydraulic Tank Breather Filters Page 6 15 Q7 Replace Fuel Tank Breather Filters Page 6 15 Q8 Test Engine Anti Freeze Solution Page 6 15 Q9 Reserved for Future Use Q10 Reserved for Future Use MISCELLANEOUS Q1...

Page 49: ...ne Inspect Cooling Fan on Engine Cummins Engine Only Warning Personal injury can result from a fan blade failure Never pull or pry on the fan This can damage the fan blade s and cause fan failure NOTE Rotate the crankshaft by using the engine barring gear Check for cracks loose rivets and bent or loose blades Check the fan to make sure it is securely mounted Tight the capscrews if necessary Replac...

Page 50: ...em with hydraulic oil be sure that the fluid is as specified and that it is clean Do not use cloth strainers or fluid that has been stored in contaminated containers Care should be taken to keep the hydraulic oil free of dust water sealing compounds and other foreign matter While using the sight gauge verify oil quality If oil becomes dark or milky colored it should be changed immediately NOTE Alw...

Page 51: ...ttle cracked or leaking hoses Hoses with their outer cover worn through or otherwise damages should be considered unfit for further service D15 Inspect Electrical Connections Harnesses for Tightness Daily inspection of the harnesses connected to the controllers operator control boxes both left and right control boxes footswitches and logic box are required Harnesses that may not have proper connec...

Page 52: ...if ignited will result in severe bodily injury or death Make certain that the Battery Disconnect Switch A is in the OFF position Inspect the terminals and cable clamps regularly Clean battery terminals and cable clamps when corrosion is visible Have excessively corroded or damaged parts replaced To get best performance out of the battery make certain that the terminal side of the battery terminals...

Page 53: ... a weekly basis 40 hours to prevent rust buildup W5 Grease Wheel Bearings Periodic inspection of the axle bearings and spacers for wear and breakdown are required to keep this machine functioning properly Inspect hardware for proper fit and secure all loose nuts and bolts Check spacers for wear The wheel bearing grease fittings are located on the underside of the pillow blocks Weather conditions a...

Page 54: ...located at the top of each side of the pulling frame This fitting needs greasing on a weekly basis W12 Oil Limit Switch Cam The Limit Switch Cam requires oiling on a weekly basis to prevent rust buildup on the threads W13 Grease Claw Housing Tubes 2 W14 Oil Claw Housing Adjusting Screws 2 W15 Grease Claw Housing Toggle Slide Plate 2 ...

Page 55: ...ng clearance is 1 32 to 3 32 of an inch and is measured while holding the claw housing firmly against the roller frame Shims of various thickness have been provided with the machine to compensate for any pad wear Do no lubricate the areas of the pulling frame where the plastic wear pads slide The lubricant in the pads will attract dirt and abrasice grit that will cause premature wearing of the pad...

Page 56: ...xcessively overtightened belts can result in crankshaft breakage A loose belt will slip and may cause damage to accessory components Replace all belts in a set when one is worn Single belts of similar size should not be used as a substitute for a matched belt set Premature belt wear can result because of belt length variation M3 Change Engine Oil and Filters Drain oil while engine is still warm Ex...

Page 57: ...7 Remove brake shoe mounting hardware and replace brake shoe Make certain you have reinstalled the mounting hardware 8 Lower the brake bracket and reinstall the pin and cotter pin Repeat Steps 5 through 8 for all brake shoes that need replacing After that is done continue on with the following steps 9 Remove the brake lockup pins 10 Return machine to service following the Lockout Tagout procedures...

Page 58: ... obstructions every 200 hours of operation Blow out debris from cooler fins with low pressure compressed air as required M7 Check Air Cleaner Element and Air Cleaner Restriction on Engine Follow daily inspection procedures Look for torn air inlet piping or boots and loose or damaged clamps Have worn or damaged parts repaired or replaced as required Retighten any loose connections ...

Page 59: ...c Oil Cleanliness Proper fluid condition is essential for long and productive life of hydraulic components and systems Thorough precautions should always be observed to insure the hydraulic system is clean 1 Filter each change of oil to prevent introduction of contaminants into the system 2 Maintain the proper oil level and regularly service filters breathers and reservoirs 3 Take precautions to p...

Page 60: ...UCTIONS Y1 Perform all Daily Weekly Monthly and Quarterly Lubrication and Maintenance Procedures Y2 Steam Clean Engine Radiator and Oil Cooler Y3 Inspect Wheels for Excessive Wear Y4 Inspect Axle Bearings for Wear Y5 Inspect Suction Strainer Element Y6 Drain and Replace Hydraulic Oil In Tank ...

Page 61: ...W SPEED only long enough to circulate the oil through the engine then increase speed to warm up the engine Extended idling during extremely cold temperatures can cause incomplete combustion and heavy deposit formations on the valves Machine Storage 1 Park machine in a sheltered place if possible 2 Wet mud or snow should be cleaned from wheels axles and hubs before it freezes 3 When the machine is ...

Page 62: ...y to store machine in sheltered area when not in use Air Cleaners Check the air cleaner indicator frequently and reduce the service intervals for the air cleaner Clean the air cleaner as often as necessary to prevent it from becoming clogged Lubrication Lubricate the machine more often then specified in the Lubrication Chart Clean all fittings and openings thoroughly before lubrication to keep out...

Page 63: ...ing becomes a relatively simple task This general portion of the troubleshooting guide has been broken down into four sections engine hydraulics electrical and mechanical and is intended to give you basic troubleshooting guidelines Local conditions and operating methods may result in problems causes and remedies not covered in this guide To use the guide most efficiently locate a problem that matc...

Page 64: ...to the voltage regulator alternator and or electrical system The following precautions should be taken to minimize the possibilities of injuries from heated diesel fuel 1 Whenever possible it is recommended that the engine and fuel be given an opportunity to cool down to ambient temperature before performing service operations which could result in the spillage of fuel from the engine or machine f...

Page 65: ...cked 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 Many electrical failures cannot be detected even if the machine is started If your visual inspection does not ind...

Page 66: ...d tighten battery cables Wiggle battery post by hand If post wiggles or turns replace battery Replace battery with type specified under Machine Specifications Starting Motor will not turn Battery disconnect switch turned off Hydraulic pump in ON position Engine speed switch in HIGH position Defective ignition switch Corroded battery terminals Turn switch to ON position Turn switch to OFF position ...

Page 67: ...oil as specified under RECOMMENDED LUBRICANTS Repair or replace Replace gauge Replace sensor Horn does not sound Wiring Harness Connection at horn loose Horn circuit breaker blown Horn broken Horn Relay Horn Switch Check harness repair or replace Tighten connection Reset circuit breaker Check horn repair or replace Check relay Check switch repair or replace Backup Alarm does not sound Backup Alarm...

Page 68: ...t in light defective Check harness repair or replace Tighten connection Reset circuit breaker See next page Repair or replace switch Replace bulb or socket Cooling Fan not working Loose connection at back of fan Loose connection at circuit breaker panel Loose connection on relay Tighten Tighten Tighten Brake Lights do not work Wiring harness Connection at light loose Light Circuit breaker blown Bu...

Page 69: ... worn crimped brittle cracked or leaking hoses Hoses with their outer cover worn through or otherwise damages should be considered unfit for further service Tighten fittings only when system is not pressurized High pressure leaks can cause personal injury While machine is running and before working inspect for leaks If the machine has not been run for some time oil may thicken causing a variety of...

Page 70: ...t Once you find the location of a leak the specific cause has to tbe determined before it can be corrected A scratch in a fitting seat or a cut in a seal lip that is big enough to leak excessively can still be too small to find with the naked eye The use of a magnifying glass would assist you HOSE LIFE Hose leakage or failure many times occurs where the end fitting grips the hose Check the system ...

Page 71: ...etting See Pressure Checks Refer to pump manual or replace pump Repair or replace Turn on Hydraulic pump excessively noisy Cold oil Low oil level Oil viscosity too high oil too thick System relief valve set too low Intake hose to pump restricted Defective pump Allow unit to warm up Check and add oil Drain and add correct oil as specified under RECOMMENDED LUBRICANTS Adjust pressure setting on reli...

Page 72: ... pump or pump shaft seal leaking Inspect oil for water Drain and add correct oil as specified under RECOMMENDED LUBRICANTS Drain and add correct oil as specified under RECOMMENDED LUBRICANTS Fill Inspect repair or replace Inspect repair or replace Hydraulic Oil Filter Restriction Indicator Light stays on all the time optional equipment Restricted hydraulic oil filter Hydraulic oil filter restricti...

Page 73: ...l 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 unless directed otherwise Failure to comply could result in personal injury and or damage to the machine ...

Page 74: ...eck valve spool for free motion and that solenoid is being energized Inspect spring and replace if necessary Inspect shoes and replace it necessary Power switch off Turn power switch on Pump switch off Turn pump switch on Circuit breaker tripped Determine cause of electrical overload and correct Workhead assembly does not operate Work Travel switch in Travel position Switch to Work position Pullin...

Page 75: ...ool for free motion and that solenoid is being energized Replace valve if necessary Claws will not open when CLAWS OPEN button is pushed Faulty hand controller Replace hand controller Claw Open Valve not shifting Check valve spool for free motion and that solenoid is being energized Replace valve if necessary Claws do not open when UP limit switch is tripped Timing Module Faulty Replace timing mod...

Page 76: ......

Page 77: ...STICK SPOTTING HEAD FORWARD SPOTTING HEAD BACK PULL JOYSTICK TOWARD OPERATOR CLOSE PULL JOYSTICK BACK PULLING HEAD GOING UP HEAD UP CLAWS OPENING TIMED CLAWS OPENED JOYSTICK RELEASED PROPELLING RELEASE JOYSTICK HEAD DOWN FAST HEAD GOING DOWN FAST HEAD DOWN SPOTTING HEAD FORWARD SPOTTING HEAD BACK PULL JOYSTICK TOWARD OPERATOR CLOSE PULL JOYSTICK BACK PULLING HEAD GOING UP HEAD UP CLAWS OPENING TIM...

Page 78: ...TICK SPOTTING HEAD FORWARD SPOTTING HEAD BACK PULL JOYSTICK TOWARD OPERATOR CLOSE PULL JOYSTICK BACK PULLING HEAD GOING UP HEAD UP CLAWS OPENING TIMED CLAWS OPENED JOYSTICK RELEASED PROPELLING RELEASE JOYSTICK HEAD DOWN FAST HEAD GOING DOWN FAST HEAD DOWN SPOTTING HEAD FORWARD SPOTTING HEAD BACK PULL JOYSTICK TOWARD OPERATOR CLOSE PULL JOYSTICK BACK PULLING HEAD GOING UP HEAD UP CLAWS OPENING TIME...

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