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Spike Puller SP2R HYDRAULIC

JULY/2013 (4945-3100) Section H-1

TABLE OF CONTENTS

24 Volt Electric Hydraulic Pump Manually Inserted Work Head Lock Up Pins ..........................................................................................H-4 Hydraulic Work Head Lock Up Pins .........................................................................................................H-5 Emergency Hydraulic Hand Pump Manually Inserted Lock Up Pins ...............................................................................................................H-6 Hydraulic Lock Up Pins .............................................................................................................................H-6 24 Volt Electric Hydraulic Pump – Brake Lock Off ................................................................................H-7

Emergency Hydraulic Hand Pump – Brake Lock Off ............................................................................H-9 24 Volt Electric Hydraulic Pump – Turntable ........................................................................................H-11 Emergency Hydraulic Hand Pump – Turntable ....................................................................................H-12 Hydraulic Components Maintenance Schedule ........................... .......................................................H-13 Spike Puller Service Parts .........................................................................................................................H-14 Pressure Settings (General).......................................................................................................................H-16 General Hydraulic Repairs Procedures ............................................................ .....................................H-17 Pump Pressure Compensator ...................................................................................................................H-19 Main Pressure Relief Valve ..................................................................................................... .................H-20

Propel Cross Over Relief Valves .............................................................................................................H-21

Spike Puller Claws OPEN Flow Control Valve .....................................................................................H-23

Spike Puller Claws CLOSE Flow Control Valves .................................................................................H-23

Pull Cylinder Counterbalance Valve .......................................................................................................H-24 Pull Cylinder Extend Solenoid Valve ......................................................................................................H-25 Pull Cylinder Flow Control Cartridge ......................................................................................................H-26 Power Lock Up Pressure Reducing Valve .............................................................................................H-27 Power Lock Up Flow Control Valves .....................................................................................................H-28 Emergency Pump Pressure Relief Valve (Little Giant) .......................................................................H-29 Emergency Pump Pressure Relief Valve ..............................................................................................H-30 Full Flow Test Valve (OPTION) ................................................................................................................H-31 Warm Up System Valve (OPTION) ...........................................................................................................H-32 Hydraulic Reservoir .....................................................................................................................................H-33 Suction Line Filter ........................................................................................................................................H-34

HYDRAULIC Spike Puller SP2R

Section H-2 JULY/2013 (4945-3100)

Accumulator (Caution) ...............................................................................................................................H-35 Accumulator Pre-Charge Checking ........................................................................................................H-36 Accumulator Disassembly .........................................................................................................................H-38

Accumulator Assembly...............................................................................................................................H-40 . High Speed Valve - Lewis Bolt (Option) .................. .............................................................................H-42 Auxiliary Tool Manifold .............................................................................................................................H-43 Connecting 10 GPM Tools..........................................................................................................................H-43

Connecting 5 GPM Tools............................................................................................................................H-44 Auxiliary Manifold Pressure Relief Valve................................................................................................H-45 . TROUBLESHOOTING General .......................................................................................................................................................H-46

Inspection ..................................................................................................................................................H-46 Fluid Contamination .................................................................................................................................H-47 Filters .........................................................................................................................................................H-47

Locating Leak Sources ............................................................................................................................H-47

Hoses..........................................................................................................................................................H-47 Troubleshooting Guide ..............................................................................................................................H-48 Troubleshooting Post..................................................................................................................................H-52 .

DRAWINGS

HYDRAULIC SCHEMATIC

S/N 310002 and Above ..................................................................................................................97310003


JULY/2013 (4945-3100) Section H-3

Release/Revisions Release/Rev Date Change Description

Rev. A 7/23/2013 First Release


Section H-4 JULY/2013 (4945-3100)

24 Volt Emergency Pump Manually Inserted Work Head Lock Up Pins To store the SP2R work head (Claw Pin and A Frame) the emergency pump needs to be plumbed directly to the left manifold (GP) port (Figure 1) using a 3/8 inch diameter hydraulic hose, 3000 psi minimum working pressure. (Stauff fittings restrict hydraulic flow).

1. If the SP2R machine is equipped with a main pump ball valve; turn clockwise (CW) 90 degrees to the CLOSED position (Figure 2). (Indicator line on ball valve will be perpendicular to flow of the pressure line.) 2. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.) 4. Turn the battery disconnect switch to the ON position and the ignition switch to the ON position to activate controls.

5. Set the Travel/Work Mode switch to the TRAVEL position. 6. Set the Lock/Unlock switch to the UNLOCK position.

7. Cycle the emergency pump switch as you: 8. Hold the "CLAW PIN/FRAME PIN" switch (Figure 4) in the UP (CLAW PIN) position until you can manually insert the claw lock up pins. 9. Hold the "CLAW PIN/FRAME PIN" switch (Figure 4) in the DOWN (FRAME PIN) position until you can manually insert the frame lock up pins.

Operate the 24 volt emergency hydraulic pump in intervals for a maximum of 30 seconds to one minute, and then let electric motor cool for one minute before using again. The 24 volt emergency hydraulic pump is designed for emergency use ONLY and is NOT to be run continuously.

10. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. The accumulator ball valve handle will be parallel to flow of the pressure line.)

11. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position (Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.)

Figure 2

Main Pump Shut Off Valve

Accumulator Pump Shut Off Valve (OPEN) Position

Figure 3

Figure 1

Emergency Pump Pressure Connection @ Left Manifold


JULY/2013 (4945-3100) Section H-5

24 Volt Emergency Pump Work Head Hydraulic Lock Up Pins To store the SP2R work head (Claw Pin and A Frame) the emergency pump needs to be plumbed directly to the left manifold (GP) port (Figure 1) using a 3/8 inch diameter hydraulic hose, 3000 psi minimum working pressure. (Stauff fittings restrict hydraulic flow). To raise the SP2R work heads to the travel position with hydraulic power lock ups with an emergency pump: check that there are two power lock up pin shut off valves installed (Figure 7). 1. If the SP2R is equipped with a pump ball valve, turn clockwise (CW) 90 degrees to the CLOSED position (Figure 2). (Indicator line on ball valve will be perpendicular to flow of the pressure line.) 2. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.) 3. Turn the battery disconnect switch to the ON position and the ignition switch to the ON position to activate controls. 4. Set the Travel/Work Mode switch to the WORK position. 5. Set the Lock/Unlock switch (Figure 5) to the UNLOCK position. 6. Cycle the emergency pump switch until the "CLAW FRAME” power lock ups pins retract (Figure 6).

7. Turn the two "CLAW FRAME” power lock up pin shut off valves (Figure 7) to the CLOSED position (The ball valve handle will be perpendicular to flow of the pressure line.)

Operate the 24 volt emergency hydraulic pump in intervals for a maximum of 30 seconds to one minute, and then let electric motor cool for one minute before using again. The 24 volt emergency hydraulic pump is designed for emergency use ONLY and is NOT to be run continuously. 8. Set the Travel/Work Mode switch to the TRAVEL position. 9. Leave the Lock/Unlock switch (Figure 5) in the UNLOCK position. 10. Cycle the emergency pump switch until the Work Head Claw lifts to the travel position and is secured by the “CLAW PIN” power lock up hook. 11. Set the Work Head Lock/Unlock switch (Figure 5) from the Unlock position to the Center position. 12. Cycle the emergency pump switch until the "CLAW FRAME” lifts to the travel position. 13. Set the Lock/Unlock switch (Figure 5) from the center position to the LOCK position. 14. Turn the two "CLAW FRAME” power lock up pin shut off valves to the OPEN position (The ball valve handle will be parallel to flow of the pressure line.) Lock the valves in the open position to prevent the valves from being CLOSED without operator’s knowledge. 15. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. (The accumulator ball valve handle will be parallel to flow of the pressure line.) 16. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position (Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.)

Figure 4


Section H-6 JULY/2013 (4945-3100)

Emergency Hydraulic Hand Pump Manually Inserted Work Head Lock Up Pins To store the SP2R work head (Claw Pin and A Frame) the emergency pump needs to be plumbed directly to the left manifold (GP) port (Figure 1) using a 3/8 inch diameter hydraulic hose, 3000 psi minimum working pressure. (Stauff fittings restrict hydraulic flow). 1. If the SP2R is equipped with a pump ball valve, turn clockwise (CW) 90 degrees to the CLOSED position (Figure 2). (Indicator line on ball valve will be perpendicular to flow of the pressure line.) 2. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.) 3. Turn the battery disconnect switch to the ON position and the ignition switch to the ON position to activate controls. 4. Pressurize the emergency hydraulic hand pump by turning the pressure release knob (Figure 8) clockwise (CW) until tight. 5. Set the Travel/Work Mode switch to the TRAVEL position. 6. Using the emergency hydraulic hand pump stroke the pump lever downward repeatedly while holding the "CLAW PIN/FRAME PIN" switch (Figure 4) in the UP (CLAW PIN) position until you can insert lock up pins. 7. Using the emergency hydraulic hand pump stroke the pump lever downward repeatedly while holding the "CLAW PIN/FRAME PIN" switch (Figure 4) in the DOWN (FRAME PIN) position until you can insert lock up pins. 8. Release the emergency hydraulic hand pump by turning the pressure release knob (Figure 8) counterclockwise (CCW). 9. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN

position. The accumulator ball valve handle will be parallel to flow of the pressure line.)

Figure 5

Figure 6 Frame Lock Up Pin (Extended)

Figure 7

Claw Frame Lock Up Pin Shut Off Valves “OPEN”

Right Work Head

Left Work Head


JULY/2013 (4945-3100) Section H-7


Emergency Hydraulic Hand Pump Hydraulic Inserted Work Head Lock Up Pins To store the SP2R work head (Claw Pin and A Frame) the emergency pump needs to be plumbed directly to the left manifold (GP) port (Figure 1) using a 3/8 inch diameter hydraulic hose, 3000 psi minimum working pressure. (Stauff fittings restrict hydraulic flow). To raise the SP2R work heads to the travel position with hydraulic power lock ups with an emergency pump: check that there are two power lock up pin shut off valves installed (Figure 8). 1. If the SP2R is equipped with a pump ball valve, turn clockwise (CW) 90 degrees to the CLOSED position (Figure 2). (Indicator line on ball valve will be perpendicular to flow of the pressure line.)

2. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.) 3. Turn the battery disconnect switch to the ON position and the ignition switch to the ON position to activate controls. 4. Pressurize the emergency hydraulic hand pump by turning the pressure release knob (Figure 8) clockwise (CW) until tight. 5. Set the Travel/Work Mode switch to the WORK position. 6. Set the Lock/Unlock switch (Figure 5) to the UNLOCK position. 7. Using the emergency hydraulic hand pump stroke the pump lever downward repeatedly until the "CLAW FRAME” power lock up pins retract (Figure 6). 8. Turn the two "CLAW FRAME” power lock up pin shut off valves (Figure 9) to the CLOSED position (The ball valve handle will be perpendicular to flow of the pressure line.)

9. Set the Travel/Work Mode switch to the TRAVEL position. 10. Leave the Lock/Unlock switch (Figure 5) in the UNLOCK position. 11. Using the emergency hydraulic hand pump stroke the pump lever downward repeatedly until the "Claw Pin” lifts to the travel position and is secured by the “CLAW PIN” power lock up hook. 12. Set the Work Head Lock/Unlock switch (Figure

5) from the Unlock position to the Center position.

13. Using the emergency hydraulic hand pump stroke the pump lever downward repeatedly until the "CLAW FRAME is in the travel position. 14. Set the Lock/Unlock switch (Figure 5) from the center position to the LOCK position.

Emergency Hydraulic Hand Pump Control Valve

Figure 8


Section H-8 JULY/2013 (4945-3100)

15. Turn the two "CLAW FRAME” power lock up pin shut off valves to the OPEN position (Figure 9) (The ball valve handle will be parallel to flow of the pressure line.) Lock the valves in the open position to prevent the valves from being CLOSED without operator’s knowledge.

16. Release the emergency hydraulic hand pump by turning the pressure release knob (Figure 8) counterclockwise (CCW) so that the claw frame lock up pins engage (spring applied).

17. On machines with the Lewis Bolt Option, turn

the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. The accumulator ball valve handle will be parallel to flow of the pressure line.)


24 Volt Emergency Hydraulic Pump

Brake lock-off for towing the machine or to replace or repair brake shoes.

The brake lock-off valve (Figure 10) was designed to allow collapsing of the brake cylinder without having to energize any other components.

Nordco recommends the use of the emergency pump procedure during replacement of brake shoes, whether or not hydraulic power is available.

Verify that both work head lockups are engaged and the claws have been removed from the work heads. 1. Check that the turntable cylinder is raised all the way in the locked position. 2. With the machine on level track, chock ALL wheels to prevent movement.

Do not remove the wheel chocks during this emergency pump operation until the machine is hooked by tow bar to another machine with its brakes engaged, or before opening the brake lock off valve. The brakes will be disabled using this procedure.

3. If the SP2R machine is equipped, turn the main pump ball valve clockwise (CW) 90 degrees to the CLOSED position (Figure 2). (Indicator line on ball valve will be perpendicular to flow of the pressure line.) 4. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.)

Tools And Equipment Required For These Procedures (Found In Toolbox): Lock pins with hair pin cotter keys

Figure 9

Claw Frame Lock Up Pin Shut Off Valves “OPEN”

Left Work Head

Right Work Head


JULY/2013 (4945-3100) Section H-9

5. Turn the battery disconnect switch to the ON position. 6. Turn the ignition switch to the ON position. 7. Switch the Work/Travel switch to the TRAVEL position. 8. Switch the Brake Mode switch to the SERVICE position. 9. Cycle the emergency pump switch ON until the hydraulic brake cylinders have collapsed and the brakes are released enough to insert the lock pins. 10. Turn the brake lock-off valve to the CLOSED position (Figure 10). (CLOSED is perpendicular to the flow of the brake pressure line.)

Operate the 24 volt emergency hydraulic pump in intervals for a maximum of 30 seconds to one minute, and then let electric motor cool for one minute before using again. The 24 volt emergency hydraulic pump is designed for emergency use ONLY and is NOT to be run continuously.

11. Have someone install the two brake lock pins (1) and hairpin cotters (2) as shown in (Figure 11) on the two brake cylinder assemblies. Use the two access doors in the spike puller cab to get at the rear brake assemblies (Figure 12). 12. Turn the ignition switch and battery disconnect switch to the OFF position. 13. Replacing/repairing brake components: 14. Follow the procedures in the machine’s Operation Maintenance Manual for Replacing/repairing brake components.

15. Remove the brake lock pins and store in tool box. 16. Turn brake lock-off valve to OPEN position. 17. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. (The accumulator ball valve handle will be parallel to flow of the pressure line.)

18. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position (Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.) 19. Remove chock blocks at the machine’s wheels once brakes are engaged. 20. Towing the spike puller 21. Slowly move the towing machine and carefully install the tow bar and secure with the tow bar with locking pins. 22. Remove the propel drive chains from the spike puller if being towed long distance. 23. Follow steps 1-12 from above procedure to disengaged brakes with lock pins. 24. Remove chock blocks at the machine’s wheels.

EXERCISE CAUTION WHEN TOWING MACHINERY & ALLOW EXTRA STOPPING DISTANCE WHEN TOWING THIS MACHINE. REDUCE SPEED ACCORDINGLY AS DICTATED BY WEATHER OR TRACK CONDITIONS. MAXIMUM TOWING SPEED IS 20 MILES PER HOUR! 25. After the machine has been towed to new location, set the parking brakes and turn the engine off on the towing machine. 26. Install chock blocks at the SP2R’s wheels. 27. Remove the brake lock pins and store in tool box. 28. Turn brake lock-off valve to OPEN position.

OPEN the brake lock off valve. Brake operation is disabled with the brake lock valve closed. The brakes are normally spring applied! 29. Install the machine’s propel drive chains if removed.

30. Remove the tow locking pins and tow bar between the machines if machine was towed.


Section H-10 JULY/2013 (4945-3100)

31. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. (The accumulator ball valve handle will be parallel to flow of the pressure line.)


Emergency Hydraulic Hand Pump

Brake lock-off for towing the machine or to replace or repair brake shoes.

The brake lock-off valve was designed to allow collapsing of the brake cylinder without having to energize any other components.

Nordco recommends the use of the emergency pump during replacement of brake shoes, whether or not engine driven hydraulic power is available.

Verify that both work head lockups are engaged and the claws have been removed from the work heads.

1. Check that the turntable cylinder is raised all the way in the locked position.

2. With the machine on level track, chock ALL wheels to prevent movement.

Do not remove the wheel chocks during this emergency pump operation until the machine is hooked by tow bar to another machine, or before opening the brake lock off valve. The brakes will be disabled using this procedure. 3. If the SP2R machine is equipped with a main pump ball valve, turn clockwise (CW) 90 degrees to the CLOSED position (Figure 2). (Indicator line on ball valve will be perpendicular to flow of the pressure line.) 4. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.)

Figure 11

Brake Shut Off Valve Closed Position

Figure 10

Figure 12

Rear Brake Assembly Access Door

Tools and Equipment Required For These Procedures (Found In Toolbox): Lock pins with hair pin cotters Emergency Hand Pump Handle


JULY/2013 (4945-3100) Section H-11

5. Turn the battery disconnect switch to the ON position. 6. Turn the ignition switch to the ON position. 7. Switch the Work/Travel switch to the TRAVEL position. 8. Switch the Brake Model switch to the SERVICE position. 9. Pressurize the emergency hydraulic hand pump by turning the pressure release knob (Figure 8) clockwise (CW) until tight. 10. Using the emergency hydraulic hand pump handle, stroke the pump lever downward repeatedly until the hydraulic brake cylinders have collapsed and the brakes are released enough to insert the brake lock pins. 11. Turn the brake lock-off valve (Figure 10) to the CLOSED position. (CLOSED is perpendicular to the flow of the brake pressure line.) 12. Have someone install two brake lock pins (1) and hairpin cotters (2) on the two brake cylinder assemblies (Figure 11). Use the two access doors in the spike puller cab to get at the rear brake assemblies (Figure 12) . 13. Turn the ignition switch and battery disconnect switch to the OFF position. 14. Replacing/repairing brake components: 15. Follow the procedures in the machine’s Operation Maintenance Manual for Replacing/repairing brake components . 16. Remove the brake lock pins and store in tool box. 17. Turn brake lock-off valve to OPEN position. 18. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. (The accumulator ball valve handle will be parallel to flow of the pressure line.) 19. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position (Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.) 20. Remove chock blocks at the machine’s wheels once the brake are applied.

21. Towing the machine 22. Slowly move the towing machine and carefully install the tow bar and secure with the tow bar with locking pins. 23. Remove the propel drive chains from the spike puller if being towed long distance.

24. Follow steps 1-13 from above procedure to disengaged brakes with lock pins.

25. Remove chock blocks at the machine’s wheels.

EXERCISE CAUTION WHEN TOWING MACHINERY & ALLOW EXTRA STOPPING DISTANCE WHEN TOWING THIS MACHINE. REDUCE SPEED ACCORDINGLY AS DICTATED BY WEATHER OR TRACK CONDITIONS. MAXIMUM TOWING SPEED IS 20 MILES PER HOUR! 26. After the machine has been towed to new location, set the parking brakes and turn the engine off on the towing machine. 27. Install chock blocks at the SP2R’s wheels. 28. Remove the brake lock pins and store in tool box. 29. Turn brake lock-off valve to OPEN position.

OPEN the brake lock off valve. Brake operation is disabled with the brake lock valve closed. The brakes are normally spring applied! 30. Install the towed machine’s propel drive chains if removed. 31. Remove the tow locking pins and tow bar between the machines if machine was towed. 32. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. (The accumulator ball valve handle will be parallel to flow of the pressure line.) 33. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position (Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.)


Section H-12 JULY/2013 (4945-3100)

24 Volt Emergency Hydraulic Pump

Turntable Cylinder: If the machine has an engine or main hydraulic pump failure with the turntable cylinder rod extended use the following procedure. 1. The Turntable Valve (Figure 13) has a locking pin (A) & bracket that locks the turntable directional control valve (C) in the DOWN position. Machine is “DOWN” on track. Hydraulic oil is directed to retract side of the turntable cylinder in this position. Ensure the turntable valve is in the “DOWN” position. 2. If the SP2R machine is equipped with a main pump ball valve, turn clockwise (CW) 90 degrees to the CLOSED position (Figure 2). (Indicator line on ball valve will be perpendicular to flow of the pressure line.) 3. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.) 4. Turn the battery disconnect switch to the ON position and the ignition switch to the ON position to activate controls. 5. Set the Travel/Work Mode switch to the TRAVEL position. 6. Cycle the emergency pump switch ON until the turntable cylinder is high enough to allow the rotating of the turntable base. 7. Use the turntable hook and rotate the turntable base (Figure 14) until it is parallel to the rails, so that the turntable base will retract under the machine’s frame. 8. Cycle the emergency pump switch ON until the turntable cylinder is fully retracted (machine in “DOWN” position).

Operate the 24 volt emergency hydraulic pump in intervals for a maximum of 30 seconds to one minute at a time. The 24 volt emergency pump is designed for emergency use ONLY and is NOT to be run continuously.

9. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.)

10. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position

(Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.)

Figure 13

Figure 14

Turntable Base & Turntable Hook


JULY/2013 (4945-3100) Section H-13

Emergency Hydraulic Hand Pump

Turntable Cylinder:

1. If the machine has an engine or main hydraulic pump failure with the turntable cylinder rod

extended use the following procedure. 2. The Turntable Valve (Figure 13) has a locking pin (A) & bracket that locks the turntable directional control valve (C) in the DOWN position (MACHINE IS “DOWN” ON THE TRACK Hydraulic oil is directed to retract side of the turntable cylinder in this position. Ensure the turntable valve is in the “DOWN” position. 3. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position (Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.) 4. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) counterclockwise (CCW) 90 degrees to the CLOSED position. The accumulator ball valve handle will be perpendicular to flow of the pressure line.) 5. Turn the battery disconnect switch to the ON position and the ignition switch to the ON position to activate controls. 6. Set the Travel/Work Mode switch to the TRAVEL position. 7. Turn the emergency hydraulic hand pump pressure release knob (Figure 8) clockwise (CW) until tight. 8. Using the emergency hydraulic hand pump handle, stroke the pump lever downward repeatedly until the turntable cylinder is high enough to allow the rotating of the turntable base. 9. Use the turntable hook and rotate the turntable base (Figure 14) until it is parallel to the rails, so that the turntable base will retract under the machine’s frame. 10. Using the emergency hydraulic hand pump handle, stroke the pump lever downward repeatedly until the turntable cylinder is fully retracted (machine in “DOWN” position).

11. On machines with the Lewis Bolt Option, turn the accumulator shut off valve (Figure 3) clockwise (CCW) 90 degrees to the OPEN position. (The accumulator ball valve handle will be perpendicular to flow of the pressure line.) 12. Turn the main pump ball valve counterclockwise (CCW) 90 degrees to the OPEN position (Figure 2). (Indicator line on ball valve will be in line to the flow of the pressure line.)


Section H-14 JULY/2013 (4945-3100)

HYDRAULIC COMPONENT MAINTENANCE SCHEDULE

Hydraulic Component Maintenance Schedule

Item

10 Hours

(Day)

50 Hours (Week)

150 Hours

(Month)

500 Hours (3 Months)

2000

Hours (6 Months)

Hydraulic Oil Level I/F Oil Cleanliness I I/T Check Hydraulic Oil Filter Indicators (option)

I I

Check hoses & fittings for leaks

I I I

Check top off filter indicator Gauge (optional) while in use

I/R

Oil Cooler CL Pressure Checks T Test hydraulic oil cleanliness

I/R

Replace pressure filter I/R Replace return filter I/R Replace case drain filter (option)

I/R

Replace tank breathers I/R Drain & replace oil in hydraulic tank

I/R

Inspect suction strainer element

I/R

Steam clean oil cooler I/R Key: Some maintenance requires that a two step procedure be performed. For example, I/F requires inspection and Filling. A = Adjust C = Change CL = Clean I = Inspect L = Lube R = Replace S = Service T = Test F = Fill Hydraulic filters require inspection during the first 40 hours of service and at designated Intervals thereafter.

Monthly pressure checks are recommended. Fluctuation of hydraulic power may require more frequent checks.


JULY/2013 (4945-3100) Section H-15

SPIKE PULLER (SP2R) SERVICE PARTS Suction Strainer Element ...................................................................................................................................3894255

Gasket.....................................................................................................................................35552965 Return Filter Element .................................................................................................................................. ..3894289 Pressure Switch ...................................................................................................................... 5193975 Gasket Kit............................................................................................................................. (ALFT503) Pressure Filter Element .................................................................................................................................... 3894289 Pressure Switch....................................................................................................................... 5193970 Case Drain Filter (Option)

Element (KF30 10 Micron)......................................................................................................3880264

Pressure Switch...................................................................................................................... 5193970 Reservoir Breather/Air Relief Valve Element.................................................................................................................................... 1673251 Relief Valve.............................................................................................................................. 1677206 Reservoir Breather – Used with Dual Top Off Pump Assembly – Silica Jell Breather.....................................................................................................................................1673252 Dual Top-Off w/Electric Pump (Option) (2) Element - Schroeder LMZW10 (3.5 Micron)..................................................................... 3894262 Gauge Filter Service Indicator…….........................................................................................7030872 24 Volt Pump ..........................................................................................................................59427805 Manual Rotary Top-Off Pump (Option) Element (10 Micron) ................................................................................................................ 3890980 Rotary Top Off Pump ............................................................................................................59424150


Section H-16 JULY/2013 (4945-3100)

Hydraulic Oil Cooler 24V Motor & Fan ....................................................................................................................50211530 Temperature Switch Unit........................................................................................................ 5194800 Core .............................................................................................................................................507848 Pump Main Unloading Valve ....................................................................................................................37750013 Coil .............................................................................................................................................507848 Ball Valve ................................................................................................................................. 1607041 Hydraulic Tank Sight Gauge ……......................................................................................................................7030872 Hydraulic Oil Temperature Sending Unit Gauge...................................................................5193967 Emergency Pump (Option) 5.5 GPM @ 2500 RPMs Motor (24 Volt) .......................................................................................................................50210210 Pump ……...............................................................................................................................59420430 Accumulator Bladder …….............................................................................................................................7030872 Seal Kit .....................................................................................................................................5193967


JULY/2013 (4945-3100) Section H-17

Pressure Settings

GENERAL Pressure to the various devices in the Spike Puller hydraulic system is controlled by the Compensator, Pressure Reducing Valves, Counterbalance Valves, and Pressure Relief Valves. It is important for the proper operation of the machine that pressures are maintained at the correct levels as shown below. . Adjustments may also be necessary anytime the machine is not operating normally. Test and adjust pressure as shown on the following pages.

PRESSURE SETTINGS

Pump Pressure Compensator .....................................................................................................2450 PSI

Main Pressure Relief.....................................................................................................................3000 PSI Propel Cross Over Reliefs............................................................................................................2900 PSI Power Lock Up Pressure Reducing Valve.....................................................................................700 PSI Emergency Pump Relief Valve ................................................................................................... 1500 PSI

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.


Section H-18 JULY/2013 (4945-3100)

GENERAL HYDRAULIC REPAIR PROCEDURES

Follow the procedures established for your company’s lockout/tagout procedures of energy isolating devices whenever maintenance is done. It has to be done before performing any repairs where release of pressurized hydraulic oil or unexpected start-up of the machine could cause injury. See LOCKOUT/TAGOUT REQUIREMENTS in the Safety Section of the Operating & Maintenance Manual for a chart on energy sources located on this Spike Puller.

Only trained and authorized personnel should be allowed to operate and / or repair the Spike Puller.

If you are unsure of any of the tasks listed in this document, consult your Supervisor and always refer to the Operating and Maintenance Manual for the Spike Puller.

For tasks beyond a machine operator’s knowledge, experience and training, the machine operator must seek assistance from a supervisor, a trained mechanic, or other “qualified” person. Prior to performing any maintenance conduct a job briefings with any additional persons involved including those on adjacent equipment. There is a danger of scalding when working with hydraulic oil that has reached operating temperature.

All hydraulic circuit repairs should be performed with the machine’s BRAKE LOCK VALVE in the locked position and wheels chocked. Tighten all connections before applying pressure. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Serious personal injury or death may result if hydraulic oil penetrates the skin. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. The following procedure is designed to lead the operator / mechanic through the steps required to shut the machine down and prepare it for performing mechanical maintenance work. This procedure is intended to release stored hydraulic pressure to make the machine safe to begin repairs. 1. Start the engine and turn the hydraulic pump toggle switch to the ON position. 2. Turn the battery disconnect switch to the ON position and the ignition switch to the ON position to activate controls. 3a. SP2R with Lock Up Pins (“Manual Lock Up”), use the following procedure for either work head. Set the Travel/Work Mode switch to the TRAVEL position. Hold the "CLAW PIN/FRAME PIN" switch in the UP (CLAW PIN) position until you can insert lock up pins. Hold the "CLAW PIN/FRAME PIN" switch in the DOWN (FRAME PIN) position until you can insert lock up pins.


JULY/2013 (4945-3100) Section H-19

3b. SP2R with Power Lock Ups Pins, use the following procedure for either work head. Set the Travel/Work Mode switch to the TRAVEL position. The "Claw Pin” will rise to travel position and the “CLAW PIN” power lock up then engages.

Lift the Lock/Unlock switch from the Unlock position to the Center position. The "CLAW FRAME will raise to the travel position.

Lift the Lock/Unlock switch from the center position to the LOCK position. The "CLAW FRAME” power lock up engages the travel position.

Cylinders must have lock up devices installed to prevent a cylinder from drifting down and the

release of pressurized hydraulic oil during repairs of that hydraulic circuit.

4. Turn OFF the hydraulic pump toggle switch.

5. Turn the ignition switch to the OFF position. 6. Turn the battery disconnect switch to the OFF position and close, secure and tag the disconnect switch box.

7. Manually shift the hydraulic directional control valve for the circuit that is to be worked on to relieve the trapped hydraulic oil pressure! 8. Use caution and crack each hose fittings (1/8 – 1/4) of a turn (CCW) at the hydraulic cylinder (being worked on) to allow any pressurized oil to bleed off.

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.


Section H-20 JULY/2013 (4945-3100)

Pump Pressure Compensator

Install a pressure gage on the pressure port (GP) on the propulsion manifold on left side of machine. Start the engine, turn on the hydraulic pump and read the hydraulic pressure. If pump pressure is HIGHER than 2450 psi. Loosen pump pressure compensator adjusting screw lock nut. Turn the pump pressure compensator adjusting screw counterclockwise (CCW) until pressure reads 2450 psi. Tighten pump pressure compensator adjusting screw lock nut. If pump pressure is LOWER than 2450 psi. Loosen pump pressure compensator adjusting screw lock nut. Turn the pump pressure compensator adjusting screw clockwise (CW) until pressure reads 2450 psi. Tighten pump pressure compensator adjusting screw lock nut. Remove the pressure gage. If the pump pressure compensator adjustment does not increase to 2450 psi the main system relief may require adjustment/repair. The main system relief is set to 3000 psi for proper operation. THIS IS SYSTEM PRESSURE! When adjusting main pressure relief and/or cross over relief always return pump pressure compensator back to 2450 psi.

Pump System Pressure Compensator Adjusting Screw

System Pressure Port (GP)


JULY/2013 (4945-3100) Section H-21

Main Pressure Relief Valve

Install a pressure gage on the pressure port (GP) on the propulsion manifold.

On the propulsion manifold opposite side of the pressure tap is the Main Relief Valve (RVP). Remove protective cap and loosen the lock nut on relief valve adjusting screw and turn relief valve adjusting screw to full clockwise (CW) position (maximum pressure).

Loosen PUMP COMPENSATOR adjusting screw lock nut.

Turn pump pressure compensator adjusting screw counterclockwise (CCW) (about 2-3 turns), but do not remove screw. Leave enough thread engagement to prevent leakage.

Start engine and turn on the pump.

Turn pump compensator adjusting screw clockwise (CW) until 3000 psi has been reached.

Turn main relief valve adjusting screw (RVP) counterclockwise (CCW) until pressure at gauge just begins to drop. This is considered cracking pressure. Turn back the main relief valve adjusting screw 1/8 of a turn and tighten nut on valve and install protective cap. Turn the pump pressure compensator adjusting screw counterclockwise (CCW) until pressure reads 2450 psi.

Tighten pump pressure compensator adjusting screw lock nut. Remove the pressure gage.



Main Pressure Relief Valve (RVP)


Section H-22 JULY/2013 (4945-3100)

Propel Cross Over Relief Valve Page 1 of 2

MAKE CERTAIN BRAKES ARE FULLY ENGAGED AND CAN HOLD MACHINE STATIONARY BEFORE CONTINUING WITH THESE ADJUSTMENTS. FAILURE TO DO SO MAY CAUSE SEVERE BODILY HARM Turn Brake Shut –Off valve (above LH Front drive wheel) to CLOSED position to disable brakes. Handle will be perpendicular to hose. Install pressure gage on the pressure port label (GP) on the propulsion manifold. Loosen pump pressure compensating screw lock nut. Turn both (RVA & RVB) crossover relief valve adjustments screws to full clockwise (CW) position (maximum pressure). Start the engine and turn on the hydraulic pump. Turn pump compensator adjusting screw clockwise (CW) until 2900 psi has been reached. Manually override the propel reverse directional control valve (B) by pushing in the push pin while adjusting (RVB) adjustment screw counterclockwise (CCW) untill the engine rpm’s just begins to drop. This is considered cracking pressure. Turn back 1/8 of a turn and tighten locknut. Manually override the forward directional control valve (A) by pushing in the push pin while adjusting (RVA) adjustment screw counterclockwise (CCW) until the engine rpm’s just begins to drop. This is considered cracking pressure. Turn back 1/8 of a turn and tighten locknut and install protective cap. Turn the pump pressure compensator adjusting screw counterclockwise (CCW) until pressure reads 2450 psi.

Tighten pump pressure compensator adjusting screw lock nut. Remove the pressure gage. Open brake shut-off valve



Brake Shut Off Valve (Closed Position Shown)


JULY/2013 (4945-3100) Section H-23

Propel Cross Over Relief Valve Page 2 of 2

RVB Crossover Relief Reverse

RVA Crossover Relief Forward

Manual Override Push Pin

B Solenoid A Solenoid


Section H-24 JULY/2013 (4945-3100)

Spike Puller Claws OPEN Flow Control Valve

Loosen the lock nut to the claws OPEN flow control valve adjusting screw. Turn adjusting screw in clockwise to decrease flow or out counterclockwise to increase flow (speed). Tighten the OPEN flow control valve adjusting screw lock nut. To reset the spike puller claws OPEN flow control valve to factory setting, turn adjusting screw counterclockwise (CCW) all the way out, and then turn in clockwise 2 1/2 turns.

Spike Puller Claws CLOSED Flow Control Valve

Loosen the lock nut to the claws CLOSED flow control valve adjusting screw. Turn adjusting screw in clockwise (CW) to decrease flow or out counterclockwise (CCW) to increase flow (speed). Tighten the claws CLOSED flow control valve adjusting screw lock nut. To reset the spike puller claws CLOSED flow control valve to factory setting turn adjusting screw out counterclockwise (CCW) all the way out, and then turn in clockwise (CW) 3 1/2 turns.

Spike Puller Open Flow Control Valve

Spike Puller CLOSE Flow Control Valve


JULY/2013 (4945-3100) Section H-25

Pull Cylinder Counterbalance Valve

Pull cylinder should not drift down when the machine is shut down drift down during spike pulling operation. Start the engine, turn on the pump and place the work head lift lock up switch in the unlock position. To reset the pull cylinder counterbalance valve to factory’ initial setting: Loosen the pull cylinder counterbalance valve adjusting screw lock not. Turn the counterbalance valve adjusting screw clockwise (CW) all the way in. Then one turn counterclockwise (CCW) back out. Loosen the pull cylinder counterbalance valve adjusting screw lock not. If more adjustment to prevent drifting is needed, adjust in ¼ turn increments. Note: Over adjusting the pull cylinder counterbalance valve in clockwise (CW) will slow the speed of the cylinder as it travels down possibly to point where the cylinder will not move when the pull cylinder is actuated.

Pull Cylinder Counterbalance Valve


Section H-26 JULY/2013 (4945-3100)

Pull Cylinder EXTEND Solenoid Valve

When the extend button is pushed on the right or left operator joystick the pull cylinder will lower from the READY POSITION at a reduced rate of speed.

Pull Cylinder Extend Solenoid Valve


JULY/2013 (4945-3100) Section H-27

Pull Cylinder Flow Control Cartridge

The pull cylinder flow control cartridge maintains a constant 6 gpm hydraulic flow in the pull cylinder as it extends. With engine off, remove and inspect for debris in spool if problems with pull cylinder speed develop.

Pull Cylinder Flow Control Cartridge


Section H-28 JULY/2013 (4945-3100)

Power Lock Up Pressure Reducing Valve

Install a hydraulic pressure gage in the power lock up pressure port. Start engine and turn on the hydraulic pump. If the power lock up pressure is HIGHER than 700 psi. Remove the protective cap from the pressure reducing valve adjusting screw. Loosen the pressure reducing valve adjusting screw lock nut. Turn the power lock up pressure reducing valve adjusting screw out counterclockwise (CCW) until pressure reads 700 psi. Tighten the pressure reducing valve adjusting screw lock nut. Install the protective cap from the pressure reducing valve adjusting screw. If the power lock up pressure is LOWER than 700 psi. Remove the protective cap from the pressure reducing valve adjusting screw. Loosen the pressure reducing valve adjusting screw lock nut. Turn the power lock up pressure reducing valve adjusting screw out clockwise (CCW) until pressure reads 700 psi. Tighten the pressure reducing valve adjusting screw lock nut. Install the protective cap from the pressure reducing valve adjusting screw.

Power Lock Up Manifold Pressure Reducing Valve

Power Lock Up Manifold Pressure Port


JULY/2013 (4945-3100) Section H-29

Power Lock Up Flow Control Valve

To reset the power lock up flow control valve to factory specifications. Remove the power lock up flow control valve adjusting screw protective cap. Loosen the adjusting screw lock nut. Turn the power lock up flow control valve flow adjusting screw all the way in clockwise (CW) until it bottoms out.

Power Lock Up Flow Control Valve


Section H-30 JULY/2013 (4945-3100)

Emergency Pump Pressure Relief Valve (Little Giant)

Install a pressure gauge at the emergency pump pressure port. Turn on emergency pump switch and read pressure at gauge.

Operate the 24 volt emergency pump in intervals for a maximum of 15 seconds at a time. The 24 volt emergency pump is designed for emergency use ONLY and is NOT to be run continuously. If emergency pump pressure is HIGHER than 1500 psi. Remove the relief valve protective cap. Loosen the relief valve adjusting screw lock nut. Turn the emergency pump pressure relief valve adjusting screw counterclockwise (CCW) until pressure reads 1500 psi. Tighten the relief valve adjusting screw lock nut. Install the relief valve protective cap. If the emergency pump pressure is LOWER than 1500 psi. Remove the relief valve protective cap . Loosen the relief valve adjusting screw lock nut. Turn the emergency pump pressure relief valve adjusting screw clockwise (CW) until pressure reads 1500 psi. Tighten the relief valve adjusting screw lock nut. Install the relief valve protective cap. Remove the pressure gauge.

Emergency Pump Pressure Port (Little Giant)

Emergency Pump Pressure Relief Valve


JULY/2013 (4945-3100) Section H-31

24 Volt Emergency Hydraulic Pump Pressure Relief Valve

This will require, one person to operate controls and switches in cab & another person to read gauge and adjust emergency pump. Install a pressure gage at the emergency pump pressure port. Turn the battery disconnect switch to the ON position. Place emergency pump switch to the ON position read the maximum hydraulic pressure reached.

Operate the 24 volt emergency pump in intervals for a maximum of 30 seconds to one minute, and then let electric motor cool for one minute before using again. The 24 volt emergency pump is designed for emergency use ONLY and is NOT to be run continuously. If the emergency pump pressure is HIGHER than 2250 psi. Remove the pressure relief valve protective cap. Turn the emergency pump pressure relief valve adjusting screw counterclockwise (CCW) until pressure reads 2250 psi. Install the pressure relief valve protective cap. If the emergency pump pressure is LOWER than 2250 psi. Remove the pressure relief valve protective cap. Turn the emergency pump pressure relief valve adjusting screw clockwise (CW) until pressure reads 2250 psi. Install the pressure relief valve protective cap.

Emergency Hydraulic Pump Pressure Port

Remove Protective Cap

Emergency Pump Pressure Adjusting Screw


Section H-32 JULY/2013 (4945-3100)

Full Flow Test Valve (Option)

SCHROEDER TEST MATE SYSTEM

The Full Flow Test valve is installed on the SP2R as an option where the machine has a Schroeder Test Mate installed as an option. The base is permanently installed in the hydraulic circuit with through flow for in-line testing. Used by a qualified mechanic to install the hydraulic test equipment into the circuit for testing purposes.

Full Flow Test Valve

Schroeder Test Mate


JULY/2013 (4945-3100) Section H-33

Warm Up System Valve

This optional gate valve is used to warm up the hydraulic oil. The warm up system valve is installed on the SP2R as an option where the machine may be exposed to cold conditions to aid in bringing the hydraulic oil in the reservoir to operating temperature.

The SP2R should not be put into High speed or high pressure operation UNTILL the hydraulic fluid is warmed up to the minimum operational temperature of 70 degrees Fahrenheit / 21 degrees Celsius. The following conditions will occur: Pump cavitation – at lower temperatures the oil is too viscous (thicker) to easily flow into the pump inlet. There will be slow / sluggish operation of hydraulic components. Lubrication of hydraulic internal components will be reduced. Filters will be by passing because of the higher back pressure to flow. Thus contamination will not be removed until the temperature of the oil is at operational temperature. If equipped the Warm Up System Valve is located on the right side of the machine next to the high pressure filter. After starting the engine, turn on pump, and turn the gate valve counterclockwise (CCW) fully to the OPEN position before operating the SP2R when the temperature is below 32 degrees Fahrenheit / 0 degrees Celsius. When the oil in the reservoir reaches 120 degrees Fahrenheit / 48 degrees Celsius, close the gate valve by turning clockwise fully. When the air temperature is below 32 degrees Fahrenheit / 0 degrees Celsius, continue to monitor the hydraulic oil temperature through out the work day notably while the machine is idle.


Section H-34 JULY/2013 (4945-3100)

HYDRAULIC RESERVOIR

Oil Level Inspect the oil level on a daily basis (or every 10 hours of operation) by reading the sight gauge located on the left side of the reservoir. At full level, the oil should be to the top of the sight gauge. The SP2R hydraulic system uses SAE-20 (ISO 46) oil (UNLESS OTHERWISE STENCILLED ON THE HYDRAULIC TANK). See recommend lubricants in the maintenance section of this manual. Before filling the system 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. Inspection of Oil 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 as soon as possible.

NOTE: Never add hydraulic oil to reservoir by any other means than through a manual/electric pump and filter.

NEVER OVERFILL RESERVOIR. Never use hydraulic brake fluid in lieu of hydraulic oil.

Spike Puller CLOSE Flow Control Valve


JULY/2013 (4945-3100) Section H-35

Suction Line Filter

This machine is equipped with a lockout device as a replacement for a handle on the suction strainer. This lockout prevents the valve from being opened or closed without the operator’s knowledge. The suction line strainer is located on the right side of the reservoir, remove and inspect the filter after the first 40 hours of operation and refer to Hydraulic Component Maintenance Schedule inspection for designated intervals. To access suction line filter cartridge: Turn off engine. Remove Lock out device & plug. Turn socket head cap screw out counterclockwise OUT till it stops. Do not try removing screw! Remove the six front cover cap screws and lift off the front cover. Remove and clean suction line strainer. When suction line strainer is cleaned reinstall. Install front cover and six cap screws. Turn suction line socket head lock screw clockwise (IN) till it stops. Replace the plug. Put padlock (Lockout) back on.

If for any reason removal of suction line filter for any length of time necessary, you must seal the hydraulic tank to prevent external contamination. Contamination on the outlet side of the filters can be flushed into the system and cause malfunctions. Contamination on the inlet side reduces the life of the filter element.

Lock Out Device & Plug

Suction Filter Socket Head Lock Screw

Front Cover Cap Screws (6)


Section H-36 JULY/2013 (4945-3100)

ACCUMULATOR LEWIS BOLT (OPTION)

(2.5 Gallon)

The outflow of energy from discharging the accumulator assists the pull cylinder actuation speed when removing Lewis Bolts.

READ & UNDERSTAND ALL INSTRUCTIONS PRIOR TO SERVICING & MAINTAINING ACCUMULATOR!

Accumulators, gas bottles and hydraulic systems are inherently dangerous due to high pressure gases and fluids. DO NOT ATTEMPT to maintain these systems unless adequately trained, have experience with the items and systems in question, and can recognize the potential risks involved if mishandled. Always wear safety glasses. DO NOT USE automotive-type valve cores in high pressure accumulator gas valves.

Always use dry inert gas (dry nitrogen – N2) for pre-charging. NEVER USE AIR OR OXYGEN, due to the danger of combustion/explosion.


JULY/2013 (4945-3100) Section H-37

Accumulator Pre-Charge Checking Page 1 of 2

ACCUMULATOR CHARGING VALVE & GAUGE ASSEMBLY with NITROGEN CHARGING HOSE

Only qualified personnel should perform this procedure. Always wear safety glasses. The following procedure will require the use of a nitrogen charging assembly with a “T” handle gas cock in order to depress the valve core, allowing the entry or exhaust of nitrogen gas. The “T” handle of the gas cock also opens and closes the flow of gas through the gas cock. Turning the “T” handle clockwise opens the valve, turning counter-clockwise closes the valve. If you have not already done so, place all machine mechanical systems or work heads in the full up and locked positions. Turn the ignition switch to the OFF position. Turn the battery disconnect switch to the OFF position found in battery box. Close the cover to the battery disconnect switch and place a LOCKOUT lock on the box. Open the accumulator ball valve shows the valve in the open position. Handle will be parallel to the hydraulic flow through the valve. Install a pressure gauge the pressure port on the hydraulic pressure filter. Check that the pressure gauge reads zero psi before proceeding.

Hydraulic pressure on fluid end of the accumulator must be reduced to ZERO PSI. Remove the protective guard for the gas valve from bottom of accumulator. Remove the cap from the gas valve. Verify that the T-handle of the gas cock is retracted by turning fully counter-clockwise before installing. Attach the charging gauge assembly to the gas valve stem by turning the gas cock nut clockwise by hand till tight.

Accumulator Lock Up Valve (Shown In OPEN Position)

System Pressure Port


Section H-38 JULY/2013 (4945-3100)

Accumulator Pre-Charge Checking Page 2 of 2

ACCUMULATOR

Using a wrench turn the gas cock nut ONE flat clockwise (DO NOT OVER TORGUE). Insure the bleed off valve on the gauge assembly is closed (Turn in clock wise fully). Depress (OPEN) the gas valve core by turning the T-handle of the gas cock clockwise to depress the valve core in the accumulator gas valve. If the gas pre charge pressure on the gauge reads above 1100 psi open the bleed valve allowing the nitrogen gas to escape until 1100 psi is reached then close the bleed valve. Close the valve core by turning the T-handle counterclockwise fully. If the gas pre charge pressure on the gauge reads below 1100 psi retract the valve core by turning the gas cock fully counter-clockwise. Obtain an adequate supply of pressurized dry nitrogen (normally a compressed gas bottle with regulator) and connect the accumulator charge gauge using a nitrogen hose assembly adapter. . Open the valve on the nitrogen bottle and then depress the gas valve core by turning the T-handle of the gas cock clockwise to depress the valve core in the accumulator gas valve. Read the pressure on the accumulator charge gauge and when above 1100 psi close the nitrogen bottle shut off valve. Open the bleed valve by turning counterclockwise allowing the nitrogen gas to escape until 1100 psi is reached then close the bleed valve. CLOSE the valve core by turning the T-handle counterclockwise fully. Allow the accumulator to rest approx. 10-15 minutes after adding nitrogen gas pre-charge. This will allow the nitrogen gas temperature to adjust, and to check for leaks in the bladder and then check the pressure. Close the valve core by turning the T –handle counterclockwise fully. Check the accumulator valve stem for leak with soapy water…if none observed, complete disconnection procedure and reassemble by re-installing the gas valve cap and protective gas guard.

Valve Stem


JULY/2013 (4945-3100) Section H-39

Accumulator Disassembly Page 1 of 2


Turn the ignition switch to the OFF position. Turn the battery disconnect switch to the OFF position found in battery box. Close the cover to the battery disconnect switch and place a LOCKOUT lock on the box. Open the accumulator ball valve shows the valve in the open position. Handle will be parallel to the hydraulic flow through the valve. Install a pressure gauge the pressure port on the propulsion manifold. Check that the pressure gauge reads zero psi before proceeding.

Hydraulic pressure on fluid end of the accumulator must be reduced to ZERO PSI. Remove the protective guard for the gas valve from bottom of accumulator. Remove the cap from the gas valve. Verify that the T-handle of the gas cock is retracted by turning fully counter-clockwise before installing. Attach the charging gauge assembly to the gas valve stem by turning the gas cock nut clockwise by hand till tight. Using a wrench turn the gas cock nut ONE flat clockwise (DO NOT OVER TORGUE). Insure the bleed off valve on the gauge assembly is closed (Turn in clock wise fully). Depress (OPEN) the gas valve core by turning the T-handle of the gas cock clockwise to depress the valve core in the accumulator gas valve. Open the bleed valve to allow the any nitrogen gas in the bladder to escape. Turn the T-handle fully counter-clockwise so that the gas cock is retracted. It is good practice to disassemble and assemble accumulators in a clean area to keep all parts free of foreign matter.

Accumulator Lock Up Valve (Shown In OPEN Position)


Section H-40 JULY/2013 (4945-3100)

Accumulator Disassembly Page 2 of 2

ACCUMULATOR

Remove the charging valve and gauge assembly. Remove the hose connected to accumulator and drain balance of hydraulic fluid that may be remaining in accumulator when it is disconnected from system. Remove bladder stem lock nut and the remove the valve stem from inside the gas valve from the top of the accumulator. Remove the bleeder plug. Remove the lock nut from the fluid port body at the bottom of the accumulator using a spanner wrench. Next remove metal spacer ring. Note that the lip of the spacer faces into the shell opening to center the fluid port body. Push the poppet valve body into accumulator shell. Insert hand into accumulator opening; remove back up washer, o-ring and metal backup ring from the fluid port and poppet valve body. Remove anti-extrusion ring from the fluid port and poppet valve body, then fold in half and slide through accumulator shell opening. Remove poppet valve/port body from shell. Insert hand into the bottom of the accumulator shell opening and compress bladder by hand. Pull the bladder out of the bottom of the accumulator shell. Examine the interior of the shell for possible contaminants, and then clean/flush thoroughly.

Poppet Valve Body

Poppet Valve Body Lock Nut


JULY/2013 (4945-3100) Section H-41

Accumulator Assembly Page 1 of 2

ACCUMULATOR


Lubricate the inside of the shell and the outside of the bladder with clean hydraulic oil. Add a cup of clean hydraulic oil inside the shell to act as a cushion. Remove valve core from new bladder and if available attach a bladder pull rod to the bladder bag. Pull the rod and bladder through the shell fluid port and continue pulling the bladder stem out through the valve stem opening on the opposite end of the shell. Slide the lock nut over pull rod and thread onto bladder stem. Using two wrenches, in order to prevent the bladder bag from rotating inside the shell, tighten lock nut. If installed remove the bladder pull rod. Install valve core into bladder stem. Attach the charging gauge assembly to the valve stem by turning the gas cock nut clockwise by hand till tight. Using a wrench turn the gas cock nut ONE flat clockwise (DO NOT OVER TORGUE). Insure the bleed off valve on the gauge assembly is closed (Turn in clock wise fully). Slide the fluid port body/poppet valve assembly (poppet first) into the accumulator shell.

Fold the anti-extrusion ring in half and slide it through the oil port opening.

Place the anti-extrusion ring on the port body/poppet valve assembly with the stainless steel ring facing toward the shell opening.

Pull plug through accumulator shell opening. Using both hands, pull plug hard until it seats into position on shell opening.

Obtain an adequate supply of pressurized dry nitrogen (normally a compressed gas bottle with regulator) and connect the accumulator charge gauge using a nitrogen hose assembly adapter.

Depress the gas valve core by turning the T-handle of the gas cock clockwise to depress the valve core in the accumulator gas valve.


Section H-42 JULY/2013 (4945-3100)

Accumulator Assembly Page 2 of 2

SLOWLY open valve on nitrogen bottle to inflate the bladder bag with 5-10 psig of pressure to set and hold fluid port body/poppet assembly in place.

Install metal washer onto fluid port body/poppet assembly. Push the metal washer into shell opening until bottomed out.

Lubricate o-ring with clean hydraulic oil, install o-ring over fluid port body/poppet assembly and push into shell opening until bottomed out.

DO NOT ROLL OR TWIST O-RING WHEN INSTALLING!

Install plastic backup ring.

Install metal spacer with small shoulder towards the accumulator shell. Note the lip of the spacer faces into the shell opening to center the fluid port body.

Install lock nut on plug and poppet assembly and tighten securely with spanner wrench.

Install the bleeder plug in fluid port body/poppet assembly.

Install hydraulic hose to fluid port.

Proceed to Pre-Charge Procedures to charge accumulator to 1100 psi.


JULY/2013 (4945-3100) Section H-43

High Speed Check Valves (Lewis Bolt – Option)

Two pilot operated check valves are installed to increase the speed of the Lewis Bolt pull cylinder on the SP2R when extending or retracted. Pilot pressure during Lewis Bolt removal (retracting the pull cylinder): Pushes the check valve off its seat, allowing hydraulic oil to flow from the bind side of the pull cylinder, through the pilot operated check valve to the oil cooler, then back to the hydraulic reservoir instead of the pull cylinder flow control valve. Pilot pressure during extending the pull cylinder: Pushes the check valve off its seat, allowing hydraulic oil to flow from the rod side of the pull cylinder, through the pilot operated check valve to the rod side of the cylinder. The additional flow of oil increases the speed of the Lewis Bolt pull cylinder as it extends downward.

Pilot Operated Check Valve For Lewis Bolt (RETRACT)

Pilot Operated Check Valve For Lewis Bolt (EXTEND)


Section H-44 JULY/2013 (4945-3100)

Auxiliary Manifold Hydraulic Tools (Option) 10 Gallon Hydraulic Tools

Always turn OFF the flow controls valves when not in use, or when connecting/disconnecting a hydraulic tool to the auxiliary manifold. Check that the flow control valve is OFF (turn counterclockwise) before attempting to connect tool hoses. Always wipe/clean hydraulic tool couplers before connecting to prevent contaminating hydraulic system . A return hose may be connected to either tank return couplers. In cold weather, bring hydraulic oil to above 50 degrees Fahrenheit before applying any load to the tool being used. Procedure for connecting 10 GPM Power Tool to Hydraulic Tool Outlet Manifold: Turn off engine. Verify that the power tool shut off valve is in the OFF position. The power tool shut off valve handle will be perpendicular to hose. Connect the hoses to the 10 GPM and tank tool quick couplers. Start the engine and turn ON the hydraulic pump. Turn the power tool shut off valve to the ON position. The power tool shut off valve handle will be parallel to the hydraulic hose. Turn BOTH 5 GPM flow control valves to the full ON position. The hydraulic tool auxiliary manifold will provide hydraulic oil flow for: 1. One 10 GPM tool 2. One 5 GPM Tool 3. Two 5 GPM tools used at the same time

Hydraulic Tools Manifold Shut Off Valve shown in the OFF position.

10 GPM Tool Connectors

Tank Return Couplers

5 GPM Flow Control Valves


JULY/2013 (4945-3100) Section H-45

Auxiliary Manifold Hydraulic Tools (Option) 5 Gallon Hydraulic Tools

Always turn OFF the flow controls valves when not in use, or when connecting/disconnecting a hydraulic tool to the auxiliary manifold. Check that the flow control valve is OFF (turn counterclockwise) before attempting to connect tool hoses. Always wipe/clean hydraulic tool couplers before connecting to prevent contaminating hydraulic system . A return hose may be connected to either tank return couplers. In cold weather, bring hydraulic oil to above 50 degrees Fahrenheit before applying any load to the tool being used. Procedure for connecting 5 GPM power tool to Hydraulic Tool Outlet Manifold: Turn off engine. Verify that the power tool shut off valve is in the OFF position. The power shut off valve handle will be perpendicular hose. Connect hoses to the 5 GPM and tank tool quick couplers. Start the engine and turn ON the hydraulic pump. Turn the power tool shut off valve to the ON position. The power tool shut off valve handle will be parallel to the hydraulic hose Turn the 5 GPM valve to the full ON Position. The hydraulic tool auxiliary manifold will provide hydraulic oil for: 1. One 10 GPM tool 2. One 5 GPM Tool 3. Two 5 GPM tools used at the same time


10 GPM Tool Connectors

Tank Return Couplers

5 GPM Flow Control Valves


Section H-46 JULY/2013 (4945-3100)

Auxiliary Manifold Hydraulic Tools Pressure Relief Valves

Turn off engine.

Verify that the power tool shut off valve is in the OFF position. The valve handle will be perpendicular to hose.

Install a pressure gage at the 5 GPM tool connector that needs to be tested.

Install a pressure gage at the main system pressure port on main hydraulic pump pressure line.

Turn on pump and open power tool shut off valve.

Check for 2500 psi pressure at the main system pressure port. If not reading 2500 Psi, refer to the Pump Pressure Compensator adjustment procedures.

Check pressure gage at the 5 GPM tool circuit that is being tested.

If hydraulic tools pressure is HIGHER than 2450 psi.

Remove the protective cap from the auxiliary manifold hydraulic pressure relief valve adjusting screw.

Loosen the pressure relief valve adjusting screw lock.

Turn pressure relief valve adjusting screw counterclockwise (CCW) until pressure reads 2450 psi.

Tighten the auxiliary manifold hydraulic pressure relief valve adjusting screw lock.

Install the protective cap from the auxiliary manifold hydraulic pressure relief valve adjusting screw.

Remove the hydraulic gauges.

If hydraulic tools pressure is LOWER than 2450 psi.

Remove the protective cap from the auxiliary manifold hydraulic pressure relief valve adjusting screw.

Loosen the auxiliary manifold hydraulic pressure relief valve adjusting screw lock.

Turn pressure relief valve adjusting screw clockwise (CW) until pressure reads 2450 psi.

Tighten the pressure relief valve adjusting screw lock.

Install the protective cap from the pressure relief valve adjusting screw.

Remove the hydraulic gauges.

5 GPM Tool Circuit Pressure Relief Valves



JULY/2013 (4945-3100) Section H-47

TROUBLESHOOTING - GENERAL Troubleshooting is a matter of quickly and logically isolating the cause of a problem and taking corrective action. Operating experience, a thorough understanding of the information in this manual, and accurate maintenance and operation records are the best troubleshooting tools an operator can have. The SP2R 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. This is intended to give you basic troubleshooting guidelines for the hydraulic systems on this machine. 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 matches the one being experience and, in a step-by-step method, check the causes listed until the correct remedy is found and the problem solved.

Always turn off the SP2R 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.

To avoid possible personal injury and/or engine damage from accidental engine startup, always disconnect the battery before servicing this machine.

INSPECTION Inspect the hydraulic system for clues to the malfunction. Check to see if the unit can be operated without further damage. If not, shut down machine immediately. Always check these items before starting the machine: 1. Check hydraulic oil level. 2. Look for loose or disconnected hoses. An oil spot below the machine is a good indication of a loose hose or hydraulic component. 3. Make certain shut-off valve on suction strainer is OPEN. Opening valve can often correct what appears to be a malfunction. 4. Inspect all vital hose connections, especially at main pump and the main pump hose connection at the manifold.

Loosen fittings only when system is not pressurized. High pressure leaks can cause personal injury. 5. Look for cover damage and/or indications of twisted, worn, crimped, brittle, cracked, or leaking hoses. Hoses with their outer cover worn through or otherwise damages should be considered unfit for further service. 6. While the SP2R is running, and before going to work, inspect machine for leaks.


Section H-48 JULY/2013 (4945-3100)

FLUID CONTAMINATION The SP2R utilizes high pressures up to 2500 psi and 2500 RPM’s engine speed, Contamination is an extreme issue that must always be addressed. Contamination comes in many forms. It may be air, water and cutting oils, rust, chips and grit. It is usually easier to keep contaminants out of a system rather than remove them after they are in the system. Bulk handling and the re-use of oil containers almost guarantees you that "new" oil will be dirty. Make it a practice to filter all "new" oil before adding it to your system. Make it another practice to change filters on a regular basis before they become clogged. Use a Beta 3 Micron 1000 Filter when adding oil to the reservoir (Refer to Service Parts Listing)

FILTERS The right combination of filters (tank breather, suction, pressure, return, and case) will keep the oil in the hydraulic circuit clean and within the contamination code. When replacing a hydraulic filter use a filter that is equal in quality to and has the same BETA RATING as the one Nordco installed on the SP2R (Refer to Service Parts Listing). For a hydraulic filter to work in cleaning hydraulic oil, multiple passes are needed to remove all the contaminates to within contamination code.

LOCATING LEAK SOURCES Petroleum oils are used in most hydraulic application to lubricate parts as well as transmit power. As oil temperature increases and as the hydraulic pressure rises, the lubricating film thins out. The result is rubbing parts supported by the oil film move closer together; friction and wear increase; seal materials age more quickly, become stiff and hard, and may readily permit leakage. The first step in locating leaks is to eliminate the possibility that an over-filled reservoir or spill created the "suspected" leak. The next step would be to clean the suspected area and watch. Leaks usually occur in fittings, hoses, O-rings, and other seals. Most leaks occur at fittings, but too often, finding the fitting that is leaking is difficult because the fluid runs along the hose and drips off at some other point. Leaks in high pressure lines sometimes are difficult to pin-point because the fluid comes out as a mist. 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 for pressure spikes or surge. If bulges or bubbles occur on a flexible hose, a leak is taking place within the layers. The hose should be replaced. High oil temperatures (over 200 degrees Fahrenheit, 93 degrees Celsius) quickly harden or stiffen a rubber hose. 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. If a hose is installed with a twist in it, high operating pressures tend to force it straight. This can loosen the fitting or even burst the hose at the point of the strain. The number one cause of hose failure is abrasion due to lack of protection, and/or hoses not secured where possible.


JULY/2013 (4945-3100) Section H-49

HYDRAULIC SYSTEM TROUBLESHOOTING GUIDE

PROBLEM

POSSIBLE CAUSE

SOLUTION

Hydraulic pump does not develop pressure

No hydraulic oil in tank (NOTE: if pump is run without oil in tank, pump damage will occur.) Shut-off valve closed. (NOTE: if pump is run with valve closed, pump damage will occur.) Main relief valve bypassing. (NOTE: oil blowing past any relief valve can cause oil to overheat.) Main pump compensator setting is too low. Pump is defective. Destroke valve stuck. Pump valve turned off.

Check oil level. Refill tank. Open valve completely. Increase pressure setting on relief valve. (See Pressure checks) Adjust compensator setting. 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". Increase pressure setting on relief valve Inspect and repair. See pump manual, repair or replace pump.

Hydraulic Oil Overheats

Oil viscosity too high (oil too thick) System relief valve set too low. Oil lines damaged causing excessive internal restriction Propulsion crossover relief setting too low.

Drain and add correct oil as specified under "RECOMMENDED LUBRICANTS". Increase pressure setting on relief valve Inspect and repair. Check and reset


Section H-50 JULY/2013 (4945-3100)

PROBLEM

POSSIBLE CAUSE

SOLUTION

Hydraulic Oil Foams

Water in oil Using wrong oil Low hydraulic level Damaged hydraulic oil lines Air leak in suction line to hydraulic 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) Note: Hydraulic oil must be close to operating temperature (not cold) otherwise indicator may light up

Restricted (dirty) oil filter Hydraulic Oil Filter Restriction Indicator switch defective

Replace filter Replace switch

Machine will not propel

Brakes on/not releasing Hydraulic pump not developing pressure Main relief is defective – debris in valve allowing fluid back to tank

One or both counterbalance valves is defective – debris in valve allowing fluid back to tank

Defective hydraulic motor

Propel directional control valve spool will not shift

See brake section below. Inspect, repair, or replace hydraulic motor. Inspect, repair, or replace main relief valve. Debris in valve, disassemble, inspect, clean, repair, or replace valve. Disassemble, inspect, clean, repair, or replace motor.

Disassemble, inspect, clean, repair, or replace motor. .


JULY/2013 (4945-3100) Section H-51

PROBLEM

POSSIBLE CAUSE

SOLUTION

Brakes will not release

Brake lock valve closed.

Brake directional control valve Deadman/Service Switch in Deadman Position

Open lock valve. Check spool for free motion and that solenoid is being energized. Brakes are applied in deadman position and are released when either foot pedal (forward/reverse) propel is pushed down.

Brakes will not apply.

Brake valve not shifting.

Broken brake spring.

Brake shoes worn.

Deadman/Service Switch in Service Position

Brake pedal is not working in travel mode

Check valve spool for free motion and that solenoid is being energized. Inspect spring and replace if necessary. Inspect shoes, and replace if necessary.

Brakes are released in service mode to allow track travel and coasting. Use brake pedal to engage brakes.

Check the normally closed switch in brake pedal to the brake directional valve electrical circuit for problem.

Multiple work head functions -- response is sluggish

Check system relief valve

Check pump pressure compensator setting

Internal system leaks

Hydraulic fluid viscosity above acceptable limits

Check for problems in the valve’s manifold

See Hydraulic Instructions

See Hydraulic Instructions

Worn internal parts – bad o-rings – Inspect and repair Allow hydraulic oil to reach operating range.

Disassemble, inspect, and repair


Section H-52 JULY/2013 (4945-3100)

PROBLEM

POSSIBLE CAUSE

SOLUTION

An individual work head (operation) function is slow or does not work

Check pressure reducing setting for that operation Directional control valve spool not shifting

See Hydraulic Instructions Disassemble, inspect, repair or replace valve.

A Lock Up does not disengage

Check that lock up switch is in the unlock position Lock up solenoid valve not shifting Check that cylinder is fully retracted to allow lock up mechanism move Flow control valve in manifold needs adjusting or debris blocking flow With RPI in WORK MODE & when ELECTRICAL INTERLOCK BUTTON is pulled out the work head assembly should raise slightly first to allow lock ups to disengage.

Put switch in unlock position Check that coil is energized. If valve spool does not shift - disassemble, inspect, repair or replace valve. Retract cylinder and try lock up again Disassemble, inspect, repair, adjust or replace. Diagnose, inspect, & repair.

Emergency pump (electric/manual) Not developing pressure

Main pump ball valve not in closed position Check emergency pump pressure relief setting (electric)

Turn valve to closed position Caution return valve to open position when done and before starting engine. See Hydraulic Instructions


JULY/2013 (4945-3100) Section H-53

Post-Troubleshooting

After troubleshooting and eliminating the problems, be sure to follow correct procedures in restarting the machine. The items to be checked include the following:

check to ensure replaced components are the correct units, ensure hydraulic connections are correct and tightened, ensure electrical connections are correct and tight, be sure pump and hydraulic motor housing cases are filled with clean oil (if required), properly set adjustable components, remove electrical interlocks, alert personnel to stand clear before starting the machine, and after the system is running, bleed the air and set the pressures to the proper settings.

Effective hydraulic system maintenance and troubleshooting is critical to reducing your hydraulic system downtime. While these guidelines do not address every possible problem, they offer a basic day-to-day approach to troubleshooting your hydraulic system.

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