Nordco TRIPP HD User manual

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

REVISION HISTORY
Release / Rev Date Change Description
Rev A June 2015 Initial manual version for TRIPP-HD
Rev B March 2016 Added information for Cummins Tier 4 engine.

ABOUT THIS MANUAL
This manual contains operation and routine maintenance information for the TRIPP 7610 HD
Tie Replacement machine manufactured by Nordco Inc., Oak Creek, Wisconsin.
This manual covers safety instructions and information, product technical information, as well as
basic operating and maintenance procedures.
It is provided for use by qualified personnel who will supervise, operate or service this machine.
It is imperative that all operators become familiar with all safety instructions, controls and
instruments before operating this machine. Follow all instructions carefully as detailed in
Section 1, “SAFETY INSTRUCTIONS AND INFORMATION”.
Information regarding operation and maintenance of specific OEM parts not manufactured by
Nordco can be found at the back of this manual, behind the tab marked “Component Data”.
This manual is broken down into sections, which have been separated by index tabs:
“Mechanical Tab” has individual parts breakdown drawings and lists for each
assembly.
“Hydraulic Tab” includes adjustment instructions and troubleshooting for the
hydraulic system; and all piping and functional drawings for a standard machine
and optional equipment.
“Electrical Tab” includes electrical schematics, distribution and control boxes,
and cabling drawings for the machine; as well as troubleshooting instructions.
“Cylinders Tab” includes part breakdowns and service instructions for cylinders
installed on the machine.
“Engine Tab” includes the Operation manual and a quick lookup sheet for Fault
Codes.
“Component Data Tab” Original Equipment Manufacture (OEM) parts
information.
If you are in need of any other information, please contact:
Nordco Service Manager
1-800-445-9258 (USA and Canada)

Measurements in this manual are given in both metric (m, cm) and customary U.S. unit (ft, in) equivalents,
where applicable.
Personnel responsible for the operation and maintenance of this equipment should thoroughly study the
manual before starting operation or maintenance procedures.
This manual is to be considered a permanent component of your machine and is to 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 Manuals), at a nominal cost, through the Nordco Part Sales Department.
Additional service information, parts, and application information is also available through the below
Nordco product support resources:
Nordco Sales: Oak Creek, Wisconsin
[phone]
[email protected]
Nordco Parts: Oak Creek, Wisconsin
1-800-647-1724
part[email protected]
Nordco Service: 1-800-445-9258
[email protected]
As a continued service commitment to improve information to our customers please submit any comments
or suggestions about this manual using the comment form at our website:
www.Nordco.com/Parts/Parts-Manual-Feedback.htm
Please direct your comments and inquiries to:
Technical Documentation Department
Nordco Inc.
245 W. Forest Hill Avenue
Oak Creek, WI 53154
[phone]

HAZARDOUS MATERIAL DATA
In an effort to provide information necessary for your employee safety training program and to
meet the requirements of OSHA Hazard Communication Standard 1910.1200, we have OSHA
Form 20 Safety Data Sheets available covering 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:
Facilities Manager
Nordco Inc.
245 W. Forest Hill Avenue
Oak Creek, WI 53154
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer; birth defects, and other reproductive harm.

TABLE OF CONTENTS
Contents-1 MAR 2016 49457607 TRIPP HD RevB
SECTION PAGE
1 SAFETY INSTRUCTIONS AND INFORMATION
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SAFETY ALERT SYMBOLS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FOLLOW SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
GENERAL SAFETY TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
OPERATIONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SAFETY PRIOR TO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SAFETY WHILE STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SAFETY WHILE OPERATING AND TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
NON-OPERATIONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SAFETY WHILE PARKED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SAFETY DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MACHINE SAFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
ENGINE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
LOCKUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SPRING PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
STEPS, PLATFORMS, AND HAND RAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SAFETY DECALS ON THIS MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2 LOGOUT/TAGOUT
ENGINE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
WELDING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SAFETY SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Lockout/Tagout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
MAINTAINING INACCESSIBLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
3LOCKUPS
MACHINE LOCKUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
LOCKUP CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
TRAVEL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4 GENERAL MACHINE SPECIFICATIONS
TRIPP MODEL HD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
OVERALL MACHINE PHYSICAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
RAILWAY LINE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
5 OPERATOR SYSTEM FAMILIARIZATION
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ABOUT THIS MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Contents-2 MAR 2016 49457607 HD TRIPP RevB
TABLE OF CONTENTS
OPERATORS CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
UPPER CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
LOWER CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
POWERVIEW GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
ENGINE EXHAUST REGEN CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
OVERHEAD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
UPPER CONTROL CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
HYDRAULIC FILTERS STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
OPERATOR HAND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
RIGHT HAND JOYSTICK CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
LEFT HAND CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
6 MACHINE OPERATION
STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
PRE START-UP CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TRAVEL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
FORWARD RAILWAY TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
REVERSE RAILWAY TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
WORK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
RAIL LIFT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
TIE EXCHANGER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
RAILWAY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
TOWING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
DEADMAN/SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
PARKING BRAKE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
MACHINE SHUT-DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
EMERGENCY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
EMERGENCY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
7 ROUTINE MAINTENANCE
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SAFETY DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
REQUESTING ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

TABLE OF CONTENTS
Contents-3 MAR 2016 49457607 TRIPP HD RevB
SECTION PAGE
MACHINE MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DAILY SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DETAILED DAILY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
WEEKLY SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
DETAILED WEEKLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
MONTHLY SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
DETAILED MONTHLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
QUARTERLY SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
DETAILED QUARTERLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
YEARLY SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
DETAILED YEARLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
GENERAL ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
ENGINE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
FUELS, LUBRICANTS & COOLANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
CUMMINS ENGINES ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
CATERPILLAR ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Contents-4 MAR 2016 49457607 HD TRIPP RevB
TABLE OF CONTENTS

MAR 2016 49457607 TRIPP HD RevB 1-1
Section 1
SAFETY INSTRUCTIONS AND INFORMATION
GENERAL
Please read and comply with all of the safety
precautions in this manual BEFORE operating this
machine.
• Operate this machine only for which it is intended.
• Nordco is not responsible for any modifications
made without authorization or written approval.
Replace all Nordco and OEM parts with genuine
Nordco or OEM parts. Use of Non-OEM parts could
compromise the safety of your machine.
• Federal Road Administration (FRA) regulations
require that a copy of this Operation Manual be
kept on the machine at all times. Additional copies
of this Operation Manual only can be ordered from
Nordco Parts Sales, please contact, 800-647-1724.
SAFETY ALERT SYMBOLS!
Shown below are safety-alert symbols used throughout
this manual. These symbols require your attention!.
Your safety is at risk!

DANGER
DANGER is used to indicate a definite
hazardous situation which, if not avoided,
WILL result in death or serious injury.

WARNING
WARNING indicates a potentially
hazardous situation which, if not avoided,
COULD result in death or serious injury

CAUTION
CAUTION indicates a potentially
hazardous situation which, if not avoided,
MAY result in minor or moderate injury
and/or property damage. It may also be
used to alert against unsafe practices.
NOTICE
NOTICE indicates special attention should be given to
these specific instructions.
IMPORTANT
IMPORTANT tags indicate the following points are
instructions for safely operating the machine or specific
components of the machine, and should not be
ignored.
NOTE
NOTE tags are points of attention, as reference
information to be remembered.
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual.
Learn how to operate the machine and all controls
properly. DO NOT allow anyone to operate this
machine without proper instruction.

DANGER
Failure to fully understand the contents of
this manual could result in serious
personal injury or death.
IMPORTANT
Throughout this manual references made to the right
and left sides of the machine are set from within the
operators control cab while looking toward the Tie
Exchange workheads. Also reference to the front of
the machine refers to the opposite end of the machine
from the TRIPP engine.

1-2 MAR 2016 49457607 TRIPP HD RevB
SAFETY INSTRUCTIONS AND INFORMATION
GENERAL SAFETY TIPS
Only trained and authorized personnel should be
allowed to operate this machine. All personnel at the
work site (gang) should be aware of the safety
concerns and their individual responsibilities prior to
working this machine.

CAUTION
• Handle fuel safely. Fuel is highly
flammable and prolonged breathing of
fumes may cause bodily harm.
• Prepare for emergencies. Keep a first
aid kit and fire extinguisher handy.
• Protect your eyes against flying pieces
of metal and debris by wearing safety
glasses or goggles.
• Wear good-fitting pants and shirt, no
baggy or loose clothing.
• Protect your head and eyes from flying
debris by wearing a hard hat and safety
goggles/glasses.
• Wear leather gloves to protect your
hands from vibration or flying metal
particles.
• Use safety-toed work boots.
OPERATIONAL SAFETY
SAFETY PRIOR TO OPERATION
All personnel at the work site (gang) should be aware
of the safety concerns and their individual
responsibilities prior to operating this machine:

CAUTION
• If you are unsure of any operation,
review the operating instructions.
Know the positions and functions of
ALL controls before attempting to
operate this machine.
• Use the “PRE START-UP CHECKS” on
page 6-1 to check the machine for
obvious faults. Repair and/or replace
components as necessary PRIOR to
operating the machine.
• Before climbing onto the machine,
make certain the area around and
under the machine is clear of
obstructions and personnel.
• Be careful when climbing onto 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, DO NOT
attempt to access that area.
• Make seat and control adjustments
PRIOR to starting the machine and
ALWAYS wear a seatbelt.
• Know the weather forecast and plan
your work speeds accordingly.
• There are guards on this machine.
Guards are to be removed ONLY when
service or maintenance is being
performed on that area of the machine.
Make certain they have been
re-installed PRIOR to operating the
machine.
• Check and service the fire extinguisher
(if so provided) at regular intervals.
Make certain ALL personnel are trained
in its use.
NOTE
Non-use of the fire extinguisher still requires that it
be recharged at the intervals stated on its last
inspection notice.
• Keep the stairs, cab entry platform and
cab interior free and clear of ice, tools
and personal items. Use the
accessories provided on the machine
(tool box, cup holder, coat hook, etc.) to
properly store gear.
• NEVER climb onto the machine while it
is in motion.

SAFETY INSTRUCTIONS AND INFORMATION
MAR 2016 49457607 TRIPP HD RevB 1-3
• There are Lockup controls on this
machine that are used for both work
and travel. Lockup points are those
areas required to be locked up prior to
working, propelling through crossings,
switches or other rail obstructions, or
during high speed travel. These lockup
points should be kept clear and free of
debris, grease, etc. See “MACHINE
LOCKUPS” on page 3-1, for
instructions on use.
• Inspect safety decals and replace when
they become unreadable and/or
damaged. See “SAFETY DECALS ON
THIS MACHINE” on page 1-7.
• Before starting the engine check ALL
fluid levels; engine coolant, hydraulic
oil and diesel fuel levels. Check for any
leaks, damaged or loose components
and/or damaged or worn belts.
• Activate the horn several times before
propelling the machine to alert anyone
around the machine that it will soon be
moving.
• DO NOT make any welding repairs to
the machine until all power is shut off
to the system by turning the battery
switch to the off position, or
disconnect the battery cables.
• Keep ALL equipment and assemblies
clean.
SAFETY WHILE STARTING THE
MACHINE
Nordco recommends the use of a Command position.
This means that the machine is never running unless
someone is at or near the main operator control
station.
To prevent injury to personnel or damage to the
machine:
1. Only start and operate the machine from the
operator’s seat (Command Position).
2. Use the “PRE START-UP CHECKS” on page 6-1
to check the machine controls and instrumentation
to make certain all systems are operating correctly.
SAFETY WHILE OPERATING AND
TRAVELING

CAUTION
• NEVER allow more riders than seats
and seat belts will allow. This machine
was designed to be operated by one
person.
• The machine is to be operated while
seated at the Operator’s seat only. DO
NOT stand and operate this machine.
• Press the EMERGENCY STOP
pushbutton located on the center
console in emergencies and potentially
dangerous situations.
• If personnel or bystanders are near the
machine during operation, give a
warning signal using the air horn. If
they fail to respond to this warning,
stop operation immediately.
• Slow down the work cycle and use
slower travel speeds in congested or
populated areas. Stop work if visibility
is poor. Strong rains, fog, and
extremely dusty conditions can affect
visibility in your work area. Wait for the
weather to improve before continuing
work.

1-4 MAR 2016 49457607 TRIPP HD RevB
SAFETY INSTRUCTIONS AND INFORMATION
NON-OPERATIONAL SAFETY
SAFETY WHILE PARKED
When leaving a machine engine running, make sure
that the parking brake is applied.
NEVER stop and park this machine on an incline,
unless the machine wheels have been chocked.
SAFETY DURING MAINTENANCE
NOTICE
Follow these guidelines when performing maintenance:
1. ALWAYS chock the wheels.
2. Alert personnel in the area that service or
maintenance is being performed on this machine.
3. Become familiar with, and use, your company’s
Lockout/Tagout procedures when performing
maintenance on this machine.
4. Reference Section 2, “LOGOUT/TAGOUT” for a
chart on energy sources located on this machine.
5. DO NOT start the engine if repairs or work are
being performed. You should ALWAYS have at
least two people working together if the engine
must be run during service repairs. One person
NEEDS to remain in the command position
(seated at the controls), ready to stop the machine
and shut off the engine if the need arises, while the
second person completes the repair.
6. Collect oil and fuel as needed and dispose of them
properly. Be careful, there is a danger of scalding
when working with engine oils.
7. Use only Nordco supplied repair parts for this
machine. Use of non-OEM designed parts could
comprise the integrity of this machine.
8. There are welding cautions on this machine. Pay
attention to them PRIOR to welding.
9. Kits supplied by Nordco have welding instructions
included. Welding of any components NOT of
Nordco’s manufacture, or failure to follow these
instructions, may affect the stability of the machine.
MACHINE SAFETY ALERTS

DANGER
• Improper use of this machine for any
type of operation, other than for what
is intended, can cause serious injury
or death.
• To avoid serious injury or death, make
certain that the area around and under
the machine is clear of all personnel
and obstructions, BEFORE operating,
propelling or working.
• Serious injury or death can result from
reaching into working components
while the machine is running. Make all
observations from a distance and
SHUT OFF the machine while making
adjustments.
• Shut off the engine when checking
battery electrolyte level. DO NOT
check or fill the battery in the presence
of an open flame, sparks, or when
smoking. Battery fumes are flammable
and/or explosive and if ignited will
result in severe bodily injury or death.
• DO NOT ride on the tow bar between
the machine and the towing vehicle.
Falling from a moving vehicle may
cause serious injury or death.

WARNING
• Failure to engage all lockup devices
before propelling can result in injury to
personnel and/or extensive damage to
the machine.
• Remove hoses and fittings only when
the system is not pressurized. High
pressure hydraulic leaks can pierce
skin and cause personal injury.

SAFETY INSTRUCTIONS AND INFORMATION
MAR 2016 49457607 TRIPP HD RevB 1-5
SAFETY PROCEDURES

CAUTION
1. If you have not already done so,
determine which components require
maintenance. Place all machine
mechanical systems and/or workheads
in the full up and locked positions.
2. When mechanically locking up
equipment is not feasible for
maintenance, lower the component to
the ground prior to working on the
equipment.
3. Chock the wheels to prevent accidental
rolling of the machine on a grade.
4. Turn the IGNITION switch to the OFF
position.
5. Place a TAGOUT card/notice in close
proximity to the ignition switch.
6. Turn the Battery Disconnect Switch
(BDS) to the OFF position. This turns
off the power to the control circuits on
the machine. See Figure 1-1.
Figure 1-1
7. Place a TAGOUT card on the switch
after you have switched the BDS to the
OFF position.
8. Place a LOCKOUT lock on the switch
after you have switched it to the OFF
position.
9. Bleed off the hydraulic pressure.
10.Follow all of your company’s
Lockout/Tagout procedures before
proceeding.
NOTE
When working on the machine components, be aware
that moving components, such as moving a hydraulic
cylinder, during repairs may create static energy.
• ALWAYS turn off the machine when
performing maintenance or
adjustments, unless otherwise
directed. Unintended movement of the
machine could occur. Failure to
comply could result in personal injury
and/or damage to the machine.
• Exhaust emissions caused by the use
of the engine on this machine may
cause cancer, birth defects, or other
reproductive harm if inhaled.
• Disconnect the battery before
servicing this machine. Failure to do
so could result in personal injury from
accidental engine startup.

1-6 MAR 2016 49457607 TRIPP HD RevB
SAFETY INSTRUCTIONS AND INFORMATION
SAFETY FEATURES
ENGINE SAFETY FEATURES
Potential for Machine Damage
Before starting a new or overhauled engine that has
been in storage, consult the engine manufacturer’s
manual for initial start instructions. Failure to follow
those instructions can result in serious engine damage.
IMPORTANT
1. NEVER shut off the Battery Disconnect Switch
(BDS) with the engine running. This could
cause damage to the voltage regulator,
alternator, and/or other components of the
electrical system.
2. This machine has an Electronic Control Unit
(ECU). Failure to correctly isolate it during
welding on this equipment will result in
damage to this machine.
See the decals on the engine for more engine specific
notices that may cause damage to the engine.
Emergency Engine Shutdown
Installed on the front main operator console is a
manual emergency shutdown control. See Figure 1-2.
Figure 1-2
LOCKUPS
There are lockups on this machine that are used for
both work and travel. These should be kept clear and
free of debris, grease, etc.
The bottom of the central control panel contains all the
lockup controls for the workheads. See “MACHINE
LOCKUPS” on page 3-1.
SPRING PARKING BRAKES
The Spring Parking Control Brake (Air Deactivated) will
not release if the air pressure in the braking system is
less than 60 PSI. When released, the Spring Parking
Brake automatically applies if the air pressure in the
braking system drops below 60 PSI.
The spring PARKING BRAKE control is located on the
left side of the operators front console panel. The
spring parking brakes are released when the control
knob is pulled outward (air is applied to the spring
portion of the brake chamber) and applied when the
control knob is pushed inward (air is released from the
spring portion of the brake chamber). See Figure 1-3.
NOTE
Some machines are set up where the brakes are
applied with the knob pulled outward and released with
the knob pushed in. Read the knob to know the
“applied” position.
Figure 1-3

CAUTION
MOVEMENT HAZARD! Machine can move
and cause personal injury. ALWAYS start
and end operation with the PARKING
BRAKE in the “applied” position. Read the
knob to know the “applied” position
(usually push in the push/pull knob).
STEPS, PLATFORMS, AND HAND
RAILS
TRIPP machines are fitted with steps and platforms on
components such as the fuel tank and the frame
assembly. Hand or grab rails have also been added in
some areas. These features provide safer access to
components when servicing or making repairs.

SAFETY INSTRUCTIONS AND INFORMATION
MAR 2016 49457607 TRIPP HD RevB 1-7
SAFETY DECALS ON THIS
MACHINE
Safety decals and plaques placed on this machine are
to be kept clean and legible. Replace any decals or
plaques that have become illegible or are missing.
When repairing or replacing components that had
safety decals on them, it is your responsibility to
replace the safety decals as well. These can be
ordered from the Parts Sales Department.
See Table 1-1 for a list of Decals on this Machine:
Table 1-1: Safety Decals on this Machine
PART NUMBER DESCRIPTION LOCATION
5642 0001 General Machine Cautions Inside Logic Box Cover
5642 0002 Caution! Watch Your Step Frame, by Step
5642 0004 Danger! Pinch Points On Rail Clamps
5642 0005 Warning! Hand Hazard On Rail Clamps
5642 0006 Danger! Before Servicing... Logic Box Sides
5642 4501 Caution! Before Welding... Logic Box Face / Battery Box
5642 0010 Lockout Area Logic Box Face
5642 0011 Lockout Area Battery Box
5642 0012 Lockup Points All areas requiring / Lockups for travel.

1-8 MAR 2016 49457607 TRIPP HD RevB
SAFETY INSTRUCTIONS AND INFORMATION

MAR 2016 49457610 TRIPP HD RevB 2-1
Section 2
LOGOUT/TAGOUT
ENGINE PRECAUTIONS
WELDING PRECAUTIONS
This machine is equipped with an engine that has an
electronic control unit/module (ECU/ECM).
IMPORTANT
Failure to correctly isolate the ECU during welding on
this machine WILL result in damage to the machine.
Take the following steps to avoid damage to the
ECU/ECM:
1. Remove the ground connection between the
engine and the machine frame.
2. Remove the connectors from the ECU/ECM of the
engine and the engine harness from the control
box or panel.
3. Turn the Battery Disconnect Switch (BDS) to the
OFF position.
a. For machines with the BDS on the left side of
the center (front) control console: Place a
TAGOUT card on the switch after you have
switched it to the OFF position.
b. For machines with a remotely located BDS
(usually next to the battery box itself): Close
the cover to the disconnect switch and place a
LOCKOUT lock on the box after you have
switched it to the OFF position.
4. Connect the welder ground close to a weld point so
that the ECU/ECM and other electronic
components are not in the ground path.
SAFETY PROCEDURES
1. Apply the parking brakes with the yellow PARKING
BRAKE button located on the center control
console.
NOTE
Apply this button to release air pressure that
normally releases the parking brakes. By relieving
this pressure, a high energy spring applies to all
four brakes.
Read the knob to determine whether the brake is
applied by pushing in or pulling out.
2. Chock the wheels to prevent accidental rolling of
the machine on an incline.
3. If you have not already done so, determine which
components are to have maintenance. Place all
machine mechanical systems or workheads in the
full up and locked positions.
4. Refer to this list to determine what procedures are
required, when mechanically locking up of
equipment is not feasible for maintenance. See
“LOCKOUT/TAGOUT – PROCEDURES,
MACHINES WITH POWER LOCKUPS (OPTION)”
on page 2-3.
5. Turn the IGNITION switch to the OFF position. This
turns off the power to the control circuits on the
machine. Place a TAGOUT card in close proximity
to the IGNITION switch.
6. Turn the Battery Disconnect Switch (BDS) to the
OFF position.
a. For machines with the BDS on the left side of
the center (front) control console: Place a
TAGOUT card on the switch after you have
switched it to the OFF position.
b. For machines with a remotely located BDS
(usually next to the battery box itself): Close
the cover to the disconnect switch and place a
LOCKOUT lock on the box after you have
switched it to the OFF position.

2-2 MAR 2016 49457610 TRIPP HD RevB
LOGOUT/TAGOUT
7. Completely bleed down the air system by pulling
on the air drain cords located near the right rear of
the machine. See Figure 2-1.
Figure 2-1
8. Bleed off the hydraulic pressure to the component
system under repair.
9. Follow all of your company’s Lockout/Tagout rules
before proceeding.
SAFETY SECURITY

WARNING
MOVING HAZARD! When working on
machine components, be aware that
moving components during repairs may
create energy (ie., moving a hydraulic
cylinder). Take proper precautions. Follow
your company’s Lockout/Tagout policies.
LOCKOUT/TAGOUT PROCEDURES
Nordco has provided the means to Lockout/Tagout
this machine.
IMPORTANT
Nordco cannot be held responsible for injury caused by
failure to comply with your company’s Lockout/Tagout
Procedures. ONLY qualified and trained personnel are
to install Logout/Tagout devices on this machine.
The following procedures are designed to lead the
operator through the steps required to shut the
machine down and prepare it for performing
mechanical maintenance work. These procedures are
intended to release potentially dangerous stored
energy and make the machine safe to begin repairs.
It is your company’s responsibility to use appropriate
Lockout/Tagout Procedures based on the included
list and train their personnel in proper and safe use,
and also to periodically inspect your work area to verify
that you are complying with the procedures.
IMPORTANT
Lockout/Tagout Procedures must be followed at all
times!