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MAINTENANCE OPERATION CHECKS
Before performing any scheduled maintenance, perform the following checks which take only a short time, but can save a lot of unnecessary repairs.
General Truck Operation
l l l
Operate all functions of the truck and check for any abnormal operation. Talk to the driver to see if he has noficed any problems. Check to see if all the safety and operational decals are in place and legible.
Gearbox Oil Level
Check for leaks at seals, and the condition of the oil to see if it requires changing. Check the drive unit gears for wear. Anything found here that can be fixed can save money on further repairs.
Reservoir Oil Level
l l l
Check the oil level in the reservoir for the proper amount. If the reservoir is too low, hydraulic pumps may be ruined by oil starvation. Check the condition of the oil per pages 5.60 - 5.62. Check the time interval between hydraulic filter replacements; does it need to be changed?
Truck Lubrication Points (See Figure 5.1)
l l l
Grease/lubricate all identified lubrication points. Replace any broken grease fittings. Look for any excessive wear in these areas.
Check for loose connections. This is very important because in DC wiring a loose connection can arc and build up carbon. Carbon will not conduct electricity. If this should happen, all kinds of problems could occur and affect other components, causing costly downtime. Check for wires that are rubbing or ready to break off.
1. Using a voltmeter, check for any voltage leaks: l positive battery terminal to truck frame l negative ba1tery terminal to truck frame 2. An open circuit should be indicated in both cases. If any voltage is read, clean the battery and check if for leaks, cracks, etc. 3. Using a voltmeter, check for any voltage leaks: l FU1-1 (+) to truck frame l M-2 (-) to truck frame 4. An open circuit should be indicated in both cases. If any voltage is read, shorts or grounds exist in the truck wiring and must be located and eliminated. Clean motors and other electrical components thoroughly.
NOTE: VOLTAGE GROUNDS CAUSE THE MAJORITY OF INTERMITTENT PROBLEMS.
MODEL NOR30/30P: MAINTENANCE MAINTENANCE OPERATION CHECKS
MAINTENANCE OPERATION CHECKS Wiring Harness Check to make sure the harnesses are not oil soaked and that they are in good conCheck dition. 1. Make sure that the contacdor tips are not burned or pitted. 2. Make sure that all switches are operating and providing their designated function. Check every brush in every motor for the proper length. Check the spring Check the commutator on the armature for wear. Check lift cylinder for leaks, air in the hydraulic system and/or damage to chrome plating on cylinder piston. Check to see if there are leaks or any improper wear of hoses and that hoses and lines are not crimped, or in danger of being damaged. Check the brake for proper wear and adjustment. Check the linkage to make sure it is not rubbing, and is free and not sticking anywhere.
l Check l Check l Check
Switches and Contactors
Motor Brush Wear on the bnushes. Hydraulic Cylinder
Brake & Linkage
to make sure there is enough material left on the wheels. to make sure the bearings are still good and shimmed properly. and remove all foreign matter between wheels and housings.
Check these items for their proper functions.
l Check l Check l Check l Check l Check l Check
for correct battery water level. the battery leads for excessive wear and corrosion. for corrosion coming from the case. the connectors for breakage or excessive wear. the charger connector for breakage. the crimp and soldered connections. These checks are very important because the only way the battery can get charaged is through these connectors. l Make sure the charger is operating correctly. Many times a circuit breaker will activate and no one notices it. A 3-phase unit with one breaker blown will operate on 1/2 power. Sometimes the ON and OFF knob gets broken or pulled off and no one reports it. The charger does not get turned on to the proper setting (which could cause problems with the battery not lasting its full shift). 1. Check for excessive wear and/or stiff spots in chain. 2. Check for proper adjustments and alignment.
Check torque generator for proper operation. Check for oil leaks or air in system.
MODEL NOR30/30P: MAINTENANCE SCHEDULED MAINTENANCE
SCHEDULED MAINTENANCE Introduction The reasons for a regularly scheduled maintenance program are: l maximize truck performance l maximize truck life l reduction of costly downtime l avoidance of many expensive repairs Scheduled maintenance includes: l lubrication l repair l inspection l replacement Perform all the following scheduled checks and maintenance during the suggested time interval. (See page 7.1 for Lubrication Equivalency Chart.) Daily or every 8 operating hours, whichever occurs first.
DO NOT OVERFILL DRIVE UNIT! NOT OVERFILL 5. etc.4 . M stands for monthly and S indicates semi-annual maintenance).1. Initial Maintenance After the first 50-150 hours of operation: Change the fluid in gearbox (and seals on plugs. DO NOT REINSTALL FILL LEVEL PLUG FOR A COUPLE OF MINUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT.MODEL NOR30/30P: MAINTENANCE SCHEDULED MAINTENANCE Weekly or every 40 operating hours. see CAUTION below. lbs. 2W.refer to Figure 5. Retorque 6 screws holding pivot bearing to truck (62 ft.. lbs. (W stands for maintenance that should be done weekly. whichever occurs first NOTE: 1W.) ! CAUTION WHEN ADDING OIL TO THE DRIVE UNIT.) Retorque wheel nuts (107 ft.
MODEL NOR30/30P: MAINTENANCE SCHEDULED MAINTENANCE Monthly or every 175 operating hours. whichever occurs first. 5.5 .
1 Lubrication/lnspection Points 5.MODEL NOR30/30P: MAINTENANCE SCHEDULED MAINTENANCE Figure 5.6 .
MODEL NOR30/30P: MAINTENANCE SCHEDULED MAINTENANCE Semi-Annually or 1 000 operating hours. ! CAUTION WHEN ADDING OIL TO THE DRIVE UNIT. whichever occurs first. DO NOT REINSTALL FILL LEVEL PLUG FOR A COUPLE OF MINUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT.7 . DO NOT OVERFILL DRIVE UNIT NOT OVERFILL 5.
THE OIL IN THE HYDRAULIC SYSTEM AND THE DRIVE UNITS MUST BE CHANGED IN ACCORDANCE WITH THE FOLLOWING INFORMATION. EXCEPT for the oiI in the hydraulic reservoir and the drive unit. MAY CAUSE CHATTER IN THE LIFT RAMS OR SLOW AUXILIARY FUNCTIONS. ! CAUTION AT SUCH TIME AS THE CUSTOMER IS READY TO START USING THE TRUCK IN A CAUTION COLD STORAGE APPLICATION.Applies to trucks operating in an environment where temperatures fluctuate from 20°F (-7°C) to 70°F (21 °C) warehouse temperature.MODEL NOR30/30P: MAINTENANCE COLD STORAGE APPLICATIONS COLD STORAGE APPLICATIONS If the vehicle is to be used in a cold storage application. in a continuous duty cycle and/or in applications where the truck goes in a freezer for a short period of time. ! CAUTION Class I Vehicles 5. NO WARRANTY WILL BE PAID ON COMPONENT DAMAGE RESULTING FROM INCORRECT OIL SELECTION.Applies to trucks operating in an environment where temperatures fluctuate from +40°F (4°C) to -40°F (-40°C)or for continuous operation at -20°F (-29°C). Class II . Class I . INCORRECT SELECTION OF OIL.8 . FOR A PARTICULAR APPLICATION. it will be equipped with Class I or Class II cold storage options components when delivered.
2 Recommended Oils by Temperature 5. away from any possible contaminating elements that could enter the hydraulic system during the changing process. Drive Unit Procedures (Clase II) 1. Hydraulic System Oil Change (Class I II) 1. drain as much oil as possible from the hydraulic lines and cylinders.1. should not be detrimental to the operation of the vehicle. Figure 5. Drain as much oil from the auxiliary system (pump. lines. The remainder of the original hydraulic oil left in the system. 3.2 and the lubrication equivalency chart on page 7. Check reservoir oil level. etc. and the following. 2. 4. Bleed the hydraulic system before placing the truck into service. 3. (approximately 5%). 7. Be sure the vehicle is in a clean area. 6. Remove the drain plug from the drive unit and drain all the oil.) as possible. 5. Reinstall drain plug.MODEL NOR30/30P: MAINTENANCE COLD STORAGE APPLICATIONS Class II Vehicles Perform all of the class I procedures from previous page.9 . Fill the hydraulic reservoir with the proper oil in accordance with Figure 5. 2. Drain the hydraulic reservoir completely. Refill with the proper oil in accordance with the Lubrication Equivalency Chart on page 7. Operate all truck functions and check for possible hydraulic leaks. Also.1.
When the truck is carrying its rated load and traveling at full speed on a level floor. Lift the brake drum (2) off. Readjust plug (29) to give a stopping distance of 6 to 10 feet. Retighten nut (12). inspect the brake shoes (8).5). Loosen the set screw (28. Loosen the nut (12). 4. 7. Hold the deadman pedal in the down position to release pressure on the brake drum (2). Lift brake control lever (11) off and reposition one or two serrations to the left. Remove nut (1). 2. 6. Figure 5. l Brake Adjustment Procedure Procedure 5. Disconnect the battery. Turn the plug (29) clockwise for quicker stopping and counterclockwise to increase the stopping distance. After adjusting the stopping distance (Step 7). 3.MODEL NOR30/30P: MAINTENANCE MECHANICAL MECHANICAL Brake Adjustment Brake adjustment should be checked regularly.10 . 8. the brake should stop the truck within 6 to 10 feet. Inspect the brake shoes (8). Do not adjust the broke to stop the vehicle in less than 6 feet. Use the following procedure: 1. ensure the brake does not drag when the deadman pedal is fully depressed. Reassemble the brake drum. 5. Brake Inspection If the brakes cannot be adjusted by the adjustment procedure.
2. 8. 7. Remove pin (6). Remove both console covers.PCX Figure 5. Lower carriage. Bleed brake system. 4. See next page. 10. 3.11 . DEADMAN.3 Deadman Pedal/Master Cylinder 5. For reassembly. reverse Steps 3-6. 6. 11. Disconnect battery. Refill brake reservoir.MODEL NOR30/30P: MAINTENANCE MECHANICAL Brake Master Cylinder Replacement 1. Repair/replace defective parts. 5. Disconnect and plug lines to master cylinder. Remove screws holding master cylinder. Test. 9.
Disconnect and plug hydraulic line to the slave cylinder (23). Bleed the brake system. Figure 5.MODEL NOR30/30P: MAINTENANCE MECHANICAL Brake Assembly Removal 1. 5. reverse steps 1-7. 9. Remove clamps holding the drive motor power wires to the brake assembly. Remove 4 screws (14) holding brake assembly to motor.5.12 . For reassembly. 7. remove the brake drum. 8. 3. bleed the air from the brake line and slave cylinder using a pressure bleeding tank as shown below. Refer to Figure 5. Remove brake assembly. Depress and hold the deadman pedal down. 6. 4. Brake Bleeding If the brake drags when the pedal is fully depressed. release the deadman pedal. Disconnect battery. Loosen and remove the nut (1 ) holding the brake drum (2). 2.4 Brake Bleeding Set-up 5.
PCX Figure 5. 3. 20. 10. 6. 9. 11. 25. 22. 14.13 . 27. 2. 12. 23. 18.MODEL NOR30/30P: MAINTENANCE MECHANICAL 1. 7. 5. 29. 13. 15. 19. 4. 8. 26. 31. 28. 30. 16. 24. Washer Mountng Plate Switch Bracket Screw Lockwasher Spring Slave Cylinder Push Rod Brake Clevis Pin Cotter Pin Set Screw Brake Adjustment Screw Spring Woodruff Key BRAKE.5 Exploded Vew of Brake Assembly 5. 21. Lock Nut Brake Drum Brake Drum Spacer Screw Washer Support Plate Shoe to Shoe Spring Brake Shoe Assembly Brake Actuating Cam Shaft Washer Brake Control Lever Nut Bolt Screw Washer Screw 17.
6 Deadman Switch (S2) Adjustment 5. adjust the deadman pedal using the following procedure: l Adjust the yoke on the mastercylinder so the heel of the pedal travels approximately 2-1/2" to 3-1/2" from the fully depressed position to the normal (full up) position.MODEL NOR30/30P: MAINTENANCE MECHANICAL Deadman Switch Adjustment If the brake still drags after doing the brake bleed procedure. but never over 80%. of full travel height. l Figure 5. or if a new master cylinder is installed. on the brake assembly. to remain on until the deadman pedal has been released at least 60%.14 . Adjust the deadman switch.
Always use solid blocks to support the vehicle. The forks should be lowered all the way to the lowest possible point. The following diagram illustrates the correct jacking points on the truck frame.MODEL NOR30/30P: MAINTENANCE MECHANICAL Jacking Truck Anytime the truck is jacked up for any reason. there should not be any load on the forks. When jacking from the side of the truck. Disconnect the battery and remove the key. the service technician should take extra time and caution to ensure that the truck will not tip over or otherwise pose a hazard to himself or others. When the orderpicker is jacked up at the tractor end.7 Truck Jacking Points 5. Figure 5.15 . the load wheels should not be lifted off the floor more than one-half inch (1/2"). Attach a chain to the top of the mast from an overhead hoist to stabilize the mast. the truck should not be lifted more than one-half (1/2") off the floor. Never rely on jacks or chains to support the vehicle. Whenever the truck is jacked up.
USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON. replace the wheel hub. 8. 2. 5. See NOTE. Torque the lug nuts to 107 ft. REFER TO PAGE 5. reverse Steps 1. 6.DO NOT RELY ON JACKS. Remove blocking and lower truck to floor. 3. See page 5. Remove brake. . USE JACK STANDS OR SOLID BLOCKS TO SUPPORT TRUCK . 2. 4. USE A SUITABLE HOIST TO STABILIZE THE MAST. Reinstall drive wheel on the truck. Remove screws holding motor to drive unit. If for some reason the screws securing the drive motor to the drive unit must be taken completely out. NEVER BLOCK THE TRUCK BETWEEN THE TELESCOPIC AND THE FLOOR. lbs. the drive tire must then be taken off. Jack up front of truck and block and remove the drive tire.MODEL NOR30/30P: MAINTENANCE MECHANICAL Drive Tire Replacement 1. Reinstall bumper. Drive Motor Removal 1.15. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT TRUCK . 10. and 3. 3. 4. The drive motor may now be removed.15. a new tread surface can be installed. Remove center section of bumper. Disconnect battery.12. See WARNING. For reassembly. See WARNING. With the drive tire removed. Open pivoting cover and lift off door. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. test. REFER TO PAGE 5. Jack and block the tractor end so that drive tire is off the floor. NEVER BLOCK THE TRUCK BETWEEN THE TELESCOPIC AND THE FLOOR. Turn the drive unit so the lug nuts on the wheel can be loosened.DO NOT RELY ON JACKS. 2. Press the old tread off and the new tread on the hub. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. Loosen lug nuts on drive wheel. USE A SUITABLE HOIST TO STABILIZE THE MAST. 5. NOTE: The drive motor can be removed without removing the drive tire. 9. USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON. NOTE: If the pressure required to press the new tire on the hub is less than five (5) tons. 7.
5. Drain any oil remaining in drive unit. the service technician should have a replacement bearing (1036370) and shims (1036371 through 103674 and 1036417 through 1036421) along with tool “Q” (see page 5. Turn drive unit and remove cover (134). This requires the use of special tool “Q” and a dial indicator. 132.15. the outer wheel shaft bearing may be damaged. USE A SUITABLE HOIST TO STABILIZE THE MAST. Refer to the Figure on the next page. Remove and discard the sealing ring (121). discard it. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING.17 . 9. Turn the drive unit so the lug nuts on the wheel can be loosened. 10. special “assistant tools” and metric hardware are required. 7. See WARNING. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT TRUCK . Using a bearing puller.23) available in case they are needed. Remove center section of bumper. Drive the wheel shaft (119) out of the housing using a 5/16" diameter copper drift. 3. Remove axle retaining nut (129) along with shims (130. To avoid delays. Loosen lug nuts on drive wheel. If the bearing is damaged. Remove covers on tractor. remove the tapered roller bearing (122) inner race with rollers and cage from wheel shaft. Disassembly Procedure ! CAUTION USE CAUTION NOT TO DAMAGE THE WHEEL SHAFT. REFER TO PAGE 5. Review this procedure and page 5. use tool “M”. NEVER BLOCK THE TRUCK BETWEEN THE TELESCOPIC AND THE FLOOR. Jack up tractor enough (and block) to remove the drive tire. 11. 8. Also. the bearing must be replaced and the drive unit assembly shimmed. Disconnect battery. 1. To prevent damage to the bearing. USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON. 131. In this case. 2. 4. 133).MODEL NOR30/30P: MAINTENANCE MECHANICAL Drive Unit Axle Seal Replacement (Drive Unit S/N 6000 & Up) Before performing any maintenance on the drive unit take note that metric tools. 5. 6. 12. Metric Tools required: 6mm Allen Wrench 8mm Allen Wrench 1Omm Allen Wrench 10mm Socket 13mm Socket 19 mm Socket NOTE: During disassembly.DO NOT RELY ON JACKS.23 for tools needed before starting. ensure that any maintenance performed does not void warranty.
MODEL NOR30/30P: MAINTENANCE MECHANICAL Figure 5.Exploded View 5.18 .8 Drive Unit .
3. Slide ring onto the wheel shaft (119).39.42. 15. 10. torque to 55 ft Ibs (75 Nm). To measure the backlash between the pinion and the crown gear. Maximum permissible backlash is 0. Items 124 .007 in. stake nut to wheel shaft. Determine dimension Z at the damping nut (item 1) 12. Continued next page.0.18 mm). Refer to Figure 5. torque nut to 148 h. After tightening clamping nut. 9.127 in Figure 5. Refer to Figure 5. 5. Determine the thickness of spacers required by using the following formula: Shim thickness = Y . Screw the inside of tool “Q” against the wheel shaft.0.MODEL NOR30/30P: MAINTENANCE Drive Unit Axle Seal Replacement (Drive Unit S/N 6000 & Up)(Cont’d) Reassembly Procedure After thoroughly cleaning wheel shaft (119): (See Figure on Previous Page) 1. 6. (from the outer edge of tool “Q” to the inner surface of tool “Q” as shown). 16. 8. To change the backlash.5 Nm). As the assembly is inserted. Refer to Figure 5.19 . Place a dial indicator as close as possible to a tooth flank. Apply one drop of Loctite 242 on the threads of each cover screw (item 2). Determine the “Y” dimension using a dial indicator. Install tool “Q” as shown in Figure 5. Remove tool “Q”.0. Press the tapered roller bearing (122) inner race with rollers and cage onto the wheel shaft using Assistant Tool “H” or equivalent. lbs (200 Nm). Apply Loctite 245 to the splines of the crown gear (104) and the wheel shaft (119). add or remove shims under the wheel shaft bearing.44. Assemble the wheel shaft assembly into the drive unit housing. Slight tapping of the wheel shaft with a soft mallet will help to engage the seal. Apply grease to the new seal (121) in the area between the dust and sealing lip. 7. Using a torque wrench.8.05 mm). 5. 17. Torque cover screws to 7 ft Ibs (9. 4. Turn the shaft in both directions several times. prevent the pinion from turning.Z 13. 14. Tighten tool “Q” until there is no bearing clearance in the wheel shaft. be careful to properly engage the sealing ring with the drive unit housing. Place the shims determined onto the wheel shaft.13 . Align the wheel shaft splines with the ring gear. The tolerance on the actual thickness of the shims used can vary from the calculated thickness by +/. 2. Using tool “L”.002 (0. Install clamping nut. Turn the wheel shaft in both directions to determine the total amount of backlash.38. Apply a thin unifomm coat of Loctite 574 to the sealing surface of the cover. (0.005 .
Remove blocking and lower truck to floor. Ibs.5 L). Check for leaks. DO NOT OVERFILL DRIVE UNIT! NOT OVERFILL 19.20 . (150 Nm). Test truck/check for leaks. Reinstall covers. The capacity of the drive unit is 2.64 quarts (2. 20. 23. WHEN ADDING OIL TO THE DRIVE UNIT. 21. Reinstall drive tire and torque nuts to 107 ft. Refill the drive unit with proper grade lubricant. Seal Replacement (Drive Unit S/N 6000 & Up)(Cont’d) 18.MODEL NOR30/30P: MAINTENANCE MECHANICAL Drive Unit Axle 18. DO NOT REINSTALL FILL LEVEL PLUG FOR A COUPLE OF MINUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT. 5. Reinstall bumper. End of procedure. 22.
Remove steer plate.16. lbs. If drive tire is to be removed. 6. loosen the 5 lug nuts. 2. 10. Torque wheel nuts to 107 ft. Drain oil from drive unit. 9. 4.21 . reverse Steps 1 through 5 ensuring bearing plates (5) are positioned between drive unit and power section frame. 5.lbs. See NOTE. Slide drive unit toward front of tractor (direction of arrow). Tighten steer chain assembly to allow 1/4" to 3/8" deflection at midspan. If the drive unit is the only item requiring service. Remove four 1/2-13 HHCS (1) and bumper plate (2). 3. using approximately 5 lbs. apply Loctite 242 to mounting screws and torque to 60 ft. 8. 11. See page 5. pressure. Disconnect brake hose (plug openings) and power cables. NOTE: Figure 5. Loosen and remove the roller chain from the steer plate (3).MODEL NOR30/30P: MAINTENANCE MECHANICAL Removing Drive Unit Assembly 1. Check both sides of chain. separating the brake assembly from the drive motor is not necessary. For reassembly. Remove cap screws (4) holding the drive unit assembly to the tractor. Refill gearbox with proper lubricant. 7. 12. For reassembly. using a 19 mm socket. Remove drive motor.9 Removing Drive Unit 5.
Remove drive unit assembly from vehicle. 1. Remove drive motor.21. See page 5. special “assistant tools” and metric hardware are required.23 for tools and hardware needed before starting.22 . 5. The next page shows the special tools which assist the technician in servicing the drive unit. Also. 2. Review this procedure and page 5. See page 5. ensure that any maintenance performed does not void warranty.16.MODEL NOR30/30P: MAINTENANCE MECHANICAL Drive Unit Disassembly Before performing any maintenance on the drive unit take note that the metric tools. All the tools pictured are available through Raymond Parts Division.
MODEL NOR30/30P: MAINTENANCE MECHANICAL Drive Unit Disassembly (Cont’d) 5.23 .
10. UPPER1. Remove the Allen screws (items 1 and 2) as shown in Figure 5.PCX Figure 5.MODEL NOR30/30P: MAINTENANCE MECHANICAL Drive Unit Disassembly (Cont’d) Clean the outside of the drive unit thoroughly before disassembly.24 .11 Removing Allen Screws Securing Bearing Trunion to Housing Continued next page.11. 5.10 Draining Oil from Drive Unit 3. Drain the oil from the drive unit by removing the drain plug (6mm Allen wrench) as shown in Figure 5. DRAIN.PCX Figure 5.
Refer to Figure 5. Figure 5.14.25 . Figure 5.PCX 5. Figure 5.13 Removal of the Lower Cover CVR-OFF. Figure 5. UPPER3. Remove the screws (item 1. separate the upper part of the drive unit from the rest of the assembly.PCX 7.MECHANICAL Drive UnitDisassembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 4 Using a plastic-faced hammer. Using Tool “L”.12 Removing Upper Portion of the Drive Unit 5.PCX 6. Loosen the cover by knocking the side of the cover (item 2) using a plastic-faced hammer. Place 2 lug nuts on the studs to prevent damaging the threads.13) holding the lower cover. loosen then remove the nut securing the crown gear to the wheel shaft.14 Removing Crown Gear Retaining Nut CROWNOFF. Prevent the wheel staft from turning as shown.
If the tapered roller bearings are to be reused. (15mm) copper drift.PCK 9. drive the wheel shaft (item 1. proceed with steps 10 through 13. By heating to 120°c) the wheel shaft can be removed Figure 5. Figure 5. The crown gear is secured to gear to 212° to 248° F (l00° the wheel shaft with Loctite 245. 11. 1O.15 Removing Wheel Shaft AXLEOUT. See NOTE. Refer to Figure 5.16. Remove the crown gear (Item 3) from the housing carefully. place the collet of the extractor onto the roller bearings. Remember to replace the radial shaft sealing ring (item 2) before reassembly. If the tapered roller bearings on the axle are to be reused. Tighten the collet against the rollers by turning the cap nut. Using a 1/2" dia. If the bearings are to be replaced.MECHANICAL Drive UnitDisassembly (Cont’d) NOTE : MODEL NOR30/NOR30P:MAINTENANCE 8.) out of the housing. go to step 16. it is strongly recommended that tool “M” be used to remove the bearing.26 .PCX 5. Using tool “M”.16 Removing Axle Bearing and Seal BRGS.
17 Removing Axle Bearing (Alternate Method) 17. When removing the wheel shaft.PCX 5. Screw spindle against wheel shaft to remove the bearing evenly. Remove the shaft seal (item 1). it is recommended that the seal always be replaced.When removing the bearing inner race off the crown gear. Figure 5. the axle seal may be damaged. When the axle is removed for any reason. 13.18 Setup To Remove Wheel Bolts BOLT. If replacing the bearings. take the crown gear out of the housing. cut the bearing cage (item 1 in Figure 5. 14.27 . Carefully.PCX Figure 5. 15. use tool “O” and press the wheel bolts out. repeat steps 10 through 12.17) open and BRGS-OFF. See Caution CAUTION Refer to Figure 5. 16.MECHANICAL Drive UnitDisassembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 12. If the wheel bolts are to be removed.16.
MECHANICAL MODEL NOR30/NOR30P:MAINTENANCE 18.PCX 20.19 Removing Helical Pinion Gear SPLURS.20) The pinion must not be damaged! 21. Using a plastc-faced hammer. 19.PCX 5. Remove the tapered roller bearing inner race (item 3) out of the housing (item 4).19).20 Removing Pinion Shaft PINION. Holding the spur gear from turning (using strap wrench “P”).28 . remove Hex nut (item 1 Figure 5. Figure 5. drive the pinion (item 1) shaft out. (Refer to Figure 5. 22. Figure 5. Pull the gear off the pinion shaft using a gear puller.The pinion can only be removed after the crown gear. NOTE: The gear is secured to the pinion shaft with Loctite 245. Remove the spur bushing (item 2). By heating the crown gear to 212° to 248° F (100° to 120°c) the gear can be removed more easily.
Use a copper mandrel and a hammer.PCX 24.MECHANICAL Drive UnitDisassembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 23. When driving the races out. Always keep the shims with the race they were installed with. Figure 5. PRESS.21 Removal of Pinion Tapered Bearing. Figure 5.21) of pinion shaft (2) using Bush “B”. make sure not to damage the spacers.22 Removing Bearing Races HOUSING. Figure 5. Remove the bearing outer races (items 1 through 4 in Figure 5. Remove the tapered roller bearing inner race (item 1.22).PCX 5.29 .
MECHANICAL Drive UnitDisassembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 25.23 Removing the Protective Shield SHIELD. Separate the protective shield using a screwdriver at the separating point provided.PCX 5. To remove the plastic protective shield.30 . Figure 5. drive the shield off using a hammer. 26.
New gear sets require new bearings. New Parts The following are the minimum new parts are requires for assembly • • • • Shaft seal for axle Grooved nut for securing crown gear to axle Hexagon nut for securing gear to pinion sealing rings for the oil fill and drain plugs 5. and cracks. 4. damage. Remove any traces of Loctite from all surfaces. If the roller bearings are damaged. 5. remember to replace BOTH the inner and outer races.31 . Replace any defective parts found. 7. 3. 6. the entire gear set must be replaced.MECHANICAL Pre-Assembly Checks MODEL NOR30/NOR30P:MAINTENANCE 1. If a gear requires replacement. Clean all components thoroughly. Smooth sealing surfaces using an oil stone or fine finishing file. Lubricate the roller bearing with new transmission oil prior to assembly. Inspect all components for excessive wear. 2.
7716 (45.MECHANICAL Drive Unit Assembly MODEL NOR30/NOR30P:MAINTENANCE Insert measuring bush “D” into bearing borehole in the housing and measure dimension F.F + 1.32 .45 mm) (for HFK300 drive units) E = L . use the following formula: • X= E.F + 1.750 (44.00 mm) (for HFK400 drive units) L = Length of measuring Bush “D” (marked) F = Dimension from bearing seat diameter to end face of measuring Bush “D” To calculase the shim thickness (X). The housing dimension E is determinad according to the following formula: • • E = L .B-T E = Housing Dimension B = Assembly dimension of pinion shaft (marked) T = Bearing width (item 2) Figure 5.24 Measuring Housing to Determine Bearing Spacers 5.
25 Istalling Lower Pinion Bearing Race 3.05 mm) from the measured value.MECHANICAL DriveUnit Assem bly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 1.002" (0. 4. 2. Once the thickness of shims is determined. Install the shims previously removed into the wheel bearing (item 2 in Figure 5. Drive the bearing outer race (item 2) into the bearing seat in the housing.25). Tolerance for installation of the bearing is +/-.33 . insert the shims into the seat of the bearing (item 1 in Figure 5. Press the bearing outer race (item 3) into the wheel shaft bearing seat (item 1).26). Figure 5. Figure 5.26 Installing Wheel Shaft Outer Race 5.
Drive Unit Assembly (Cont’d)
5. Using tool “O” and Figure 5.27 as a guide, press the wheel shaft studs in. Note that the flat side on the wheel stud should be towards the center of the wheel shaft.
Figure 5.27 Axle Stud Installation
6. Grease the shaft sealing ring (item 1 in Figure 5.28) in the area between the dust and sealing lip with Shell Alvania R3 grease, then press the seal onto the wheel shaft (item 2).
Figure 5.28 Installing Dust Seal and Wheel Outer Race
Drive Unit Assembly (Cont’d)
7. Press the tapered roller bearing inner race (item 1 in Figure 5.29) carefully onto the crown gear (item 2) to the stop using tool “H”.
Figure 5.29 Installing Crown Gear Outer Race
8. Using tool “C” carefully press the tapered roller bearing inner race (item 1 in Figure 5.30) up to the stop.
Figure 5.30 Installing Inner Race on the Pinion Shaft
9. Lubricate the bearing inner race with new transmission fluid. Insert the pinion shaft in the housing from below. Using tool “F”, apply a slight preload against the bearing outer ring. Place spacer bushing (item 1 in Figure 5.31) onto the pinion shaft. (Note that HFK400 transmissions do not have spacer bush).
Figure 5.31 Installing Pinion Into Housing
Drive Unit Assem- 10. Determine the thickness of shims to be installed at the top of the pinion shaft as follows: bly (Cont’d) a. Determine dimension C. Dimension C is the distance between the top of the spacer bush (HFK300) or top of the collar on the pinion shaft (HFH400) and the bottom of the pinion upper bearing outer race Refer to Figure 5.32.
Figure 5.32 Measuring Gap for Pinion Bearing Spacers b. Determine dimension S. Dimension S is the distance between the plane surface of the bearing outer race and the plane surface of the inner race. Refer to Figure 5.33.
Figure 5.33 Determining Dimension S
c. Using the figure above, determine which condition exists.
If the outer race is higher than the inner race, dimension X is determined as follows: X = C- S - 0.00078 in (0.02 mm) If the outer race is lower than the inner race, dimension X is determinad as follows: X = C + S - 0.00078 in (0.02 mm)
d. Use the result from step 10c in selecting the thickness of the shims to be used.
Figure 5. press the tapered roller bearing inner race (item 3) onto the pinion shaft up to the stop.MECHANICAL Drive Unit Assembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 11 .34. Install the helical gear onto the pinion shaft.48 ft.34 Installing Upper Pinion Shaft Bearing 14. Hold the helical gear using strap wrench “P”.Refer to Figure 5. Press the tapered roller bearing outer race (item 2) into the housing.35. Using tool “G”. 12. 13.65 Nm). Install the required shims (item 1) into the housing. Refer to Figure 5. Install a new hex nut. Torque the hex nut to 40 .35 Installing Helical Hex Nut 5. lbs (55 . Figure 5.37 .
Shims must then be added under the outer race of the upper bearing. 16.36. Mark the measuring point using a colorea pencil.48 ft. 17. apply Loctite 245 to the helical gear hex nut and torque to 40 . The value shown indicates the bearing clearance.0.002 in (0 .MECHANICAL Drive Unit Assembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 15. Push down on the pinion and turn it at the same time for several complete rotations. This step should be repeated several times. the helical gear and upper bearing must be removed. Once the proper clearance is obtained. Place a dial indicator as shown. 5.36 Checking Bearing Clearance 18. 19. Figure 5.38 . lbs (55 . 20. Remove tool “F” which was previously installed. Read the values on the dial indicator. Permissible bearing clearance is 0 . This aligns the rollers in the bearings. If the clearance exceeds permissible tolerance. Refer to Figure 5.0. Lift helical gear carefully as shown using two screwdrivers or tire irons.65 Nm).05 mm).
Apply a thin. 22. Figure 5. Tighten tool “Q” until all bearing clearance in the wheel shaft is removed.38.37 Installing Wheel Shaft and Crown Gear 23. uniform coat of Loctite 245 to the splines of the crown gear. Insert the crown gear into the housing. Fit tool “K” around the wheel shaft. Apply a thin. Insert the splines of the wheel shaft into the crown gear.37. Refer to Figure 5. To seat the shaft sealing rim. (item 2 in Figure 5.MECHANICAL Drive Unit Assembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 21. apply light strokes against the wheel shaft (item 1 ) using a plastic-faced hammer. Remove excess Loctite. Install tool “Q” onto the wheel shaft. 25. Refer to Figure 5.38). uniform coat of Loctite surface seal 574 to the outside diameter of the shaft seal (item 1 in Figure 5.38 Seating Wheel Shaft Seal/Securing Crown Gear 5. 24. Figure 5.39 .37).
MECHANICAL MODEL NOR30/NOR30P:MAINTENANCE 26. To change the backlash.13 . The next step is to check the gear mesh tooth pattern. 31.0.005 .18 mm). Coat 3 to 4 tooth flanks of the crown gear with ink.39. b. c. If significant differences are found. Turn the wheel shaft in both directions to determine the total amount of backlash. d. Place a dial indicator as close as possible to a tooth flank. secure the hex nut by staking. Refer to Figure 5. Refer to Figure 5. Variations are primarily due to different contact pressures while creating the pattern. it will be necessary to shim the pinion or the crown gear to obtain the proper pattern. Mesh the ink coated teeth with the pinion. Figure 5. Once the correct pattern is achieved.40.40. Compare the actual pattern with Figure 5.40 . Refer to Figure 5. prevent the pinion from turning by placing a wooden wedge between the helical gear and the housing. a.39 Adjusting Crown Gear Backlash 28. (0. 27. Maximum permissible backlash is 0. 5. add or remove shims under the wheel shaft bearing.0. 29. The contact pattern will be more visible if the pinion is prevented from turning easily.35. 30. To measure the backlash between the pinion and the crown gear. Slight variations from the desired pattern are permissible.007 in.
MECHANICAL Drive Unit Assembly (cont’d) MODEL NOR30/NOR30P:MAINTENANCE Figure 5.40 Tooth Patterns and Corrective Actions 5.41 .
42.Screw the inside of tool “Q” against the wheel shaft. Turn the shah in both directions several times. Figure 5. 35. 36. torque to 55 ft lbs (75 Nm).Determine the thickness of spacers required by using the following formula: Shim thickness = Y .41 Assembly of Wheel Shaft and Crown Gear 33. Screw 2 wheel nuts onto the wheel studs.42 Determining Shims Required 5. Prevent the wheel from turning as shown. Determine the Y dimension using a dial indicator.42 . Using a torque wrench.MECHANICAL Drive Unit Assembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 32. Refer to Figure 4.21.Refer to Figure 5.Determine dimension Z at the clamping nut (item 1). (from the outer edge of tool “Q” to the inner surface of tool “Q” as shown).Z Figure 5. 34.
After tightening clamping nut. Install clamping nut.MECHANICAL Drive Unit Assembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE 37.44 Installing Cover 5. Figure 5. torque nut to 148 ft Ibs (200 Nm).05 mm). Torque cover screws to 7 ft lbs (9.5 Nm). stake nut to wheel shaft. The tolerance on the actual thickness of the shims used can vary from the calculated thickness by +/.44. Remove tool “Q”. Apply one drop of Loctite 242 on the threads of each cover screw (item 2).43 Installing Clamping Nut 40. Using tool “L”. 39.43 . Apply a thin uniform coat of Loctite 574 to the sealing surface of the cover.0. 38.002 (0. Refer to Figure 5. Place the shims determined onto the wheel shaft. 41. Figure 5.
Figure 5. Refer to Figure 5. The two parts are sufficiently mixed when the color has turned to cream.44 . Spray the surface again and let dry. Allow the cleaner to react then wipe any dirt off using a clean cloth. Apply a thin coat of epoxy to the points indicated in Fioure 5. Mix the two components of the technicoll epoxy in a proportion of 1:1. proceed as follows: 42.46 Applying epoxy to the Protective Shieid 5.46.Spray seat of protective shield on the housing using Loctite fast cleaner 706.45 Preparing Protective Shield Mounting Surface 43.MECHANICAL Drive Unit Assembly (Cont’d) MODEL NOR30/NOR30P:MAINTENANCE If the protective shield for the axle was removed. Figure 5. 44.45. The epoxy should be used within 2 hours. Make sure to read ond observe instructions and warnings on the Loctite cleaner container.
Using pliers. Place a hose clamp around the protective shield (screw casing of the clamp positioned at separating point of the protective shield). Position thread protector on seat of housing.Refer to Figure 5.Allow the epoxy to cure for 12 hours.MECHANICAL MODEL NOR30/NOR30P:MAINTENANCE Drive Unit Assembly 45.Remove the clamp.48. Figure 5.48 Final Assembly of Protective Shield 5. Tighten the clamp until a click is heard indicating the pin has engaged its mating hole.47. 46. NOTE: Due to the long cure time required for the epoxy. a metal protective shield is available for field repairs.47 Installing Protective Shield 46. (Cont’d) press both parts together until the pins are fully engaged in the pin holes.45 .Refer to Figure 5. Press the protective shield against the plane face of the housing 47. See NOTE. Figure 5.
Install the hardware and torque evenly as specified below: • • M8 screws .17 ft Ibs (23 Nm) M10 Screws . 49.5 L).Assemble the subassemblies by aligning the dowel pins in the upper and lower halves of the transmission.46 .34 ft lbs (46 Nm) 51. DO NOT REINSTALL FILL LEVEL PLUG CAUTION FOR A COUPLE OF MlNUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT. CAUTION WHEN ADDING OIL TO THE DRIVE UNIT.MECHANICAL MODEL NOR30/NOR30P:MAINTENANCE Drive Unit Assembly 48. DO NOT OVERFILL DRIVE UNIT! 5. Figure 5.Coat the sealing surface of the transmission with a thin uniform coat of Loctite (Cont’d) 574. The drive unit capacity is 2.64 qts (2.Refill the drive unit with the proper grade of lubricant.49 Assembling Upper ond Lower Halves of Transmission 50.
2. NOTE: Both chains should be replaced when either is defective. Be sure the chains are adjusted to share the load equally. 7. Lubricate a chain in good condition or a new chain before installing it on the truck. 5. 5. Inspect each chain for defects listed in the chart on next page. Use a jack or overhead hoist and raise the carriage enough to slacken the lift chains.MECHANICAL Lift Chains MODEL NOR30/NOR30P:MAINTENANCE Chain maintenance in this manual includes: • chain removal • defect-cause chart • chain lubrication • chain anchor adjustment Figure 5.47 . Secure the carriage with blocks to prevent the carriage from lowering. Thoroughly clean the chain in solvent.50 Lift Chain Lubrication Check the truck lift chains monthly since most unsatisfactory chain performance can be traced directly to inadequate chain maintenance. 4. Also make sure they are not twisted so they will roll flat on the sheaves. Remove each chain and chain anchors by unscrewing the nuts on the carriage and the chain anchors on the main frame. See next page. 3. Remove the chain and inspect it for defects using the following procedure and chart: CAUTION Procedure DO NOT STEAM CLEAN OR DE-GREASE NEW TRUCK CHAINS 1. Reinstall the chains on the truck. 6.
Make sure the exterior surface is covered to prevent rust and that the oil penetrates the chain joints to reduce wear. Defect.48 .MECHANICAL Lift Chain Lubrication MODEL NOR30/NOR30P:MAINTENANCE Liberally apply oil (See Scheduled Maintenance for oil specifics) to the chain using a narrow paint brush.Cause Chart 5.
51 Two Stage Elevating Section. 5.49 .MECHANICAL MODEL NOR30/NOR30P:MAINTENANCE Figure 5.
MECHANICAL MODEL NOR30/NOR30P:MAINTENANCE Figure 5.52 Three Stage Elevating Section 5.50 .
MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Decal Replacement Use the followinga information to correctly position replacement decals or printed plates: A LL TRUCKS Section A-A Section C-C A LL TRUCKS A LL TRUCKS Figure 5.51 .53 Decal Locations (1 of 3) 5.
52 .54 Decal Locations (2 of 3) A LL TRUCKS 5.MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Decal Replacement (Cont’d) A LL TRUCKS View B-B View B-B A LL TRUCKS Figure 5.
53 .55 Decal Locations (3 of 3) 5.MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Decal Replacement (Con’d) E TRUCKS ON L E Y A LL TRUCKS Figure 5.
31 inch.25 inches max. pull midway between the chain sprockets.54 . Ensure that the chain is properly lubricated and that the jam nuts are tight. This can be checked by measuring from the screw head to the edge of the block. Figure 5. The lower chain anchor should be adjusted so the adjusting screw engages its mating block by at least . This should be 1.MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Lower Steering Chain Adjustment Every 6 months or 1000 hours of operation. Refer to Figure 5. Check each side of the chain to ensure proper tension is applied. If the actual dimension does not agree with the figure below.25 to .375 inch with a 5 lb.56. check the tension on the lower steering chain assembly. The chain should deflect . reposition the connecting link.56 Lower Steering Chain Adjustment 5.
Using the Figure below as reference. adjust the turnbuckles in the operator’s compartment so the chain has .62" deflection when 5 Ibs.57 Adjusting Steering Cables 5. force is applied to the chain as shown.55 . use the following procedure to adjust the steering cables which go over the mast. Figure 5.MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Steering Cable Adjustment For vehicles equipped with mechanical power steering. Adjustments should be down with the carriage fully lowered.5" to .
MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Torque Specifications for Tractor The figure below specifies torques required for different arcas of the tractor. Figure 5.56 .58 Torque Specifcations for the Tractor 5.
require service. 2.75" on either side.57 .DO NOT RELY ON JACKS. If the existing skidpads must be replaced. Refer to the next page. If the existing skid pads are not worn to a point where they must be removed. Apply Loctite 242 (p/n 1036909) to threads on screws and install new skid pads on power section (both sides). REFER TO PAGE 5. If the clearance between the skid pad and the floor exceeds 0. refer to the next page. 1. Figure 5. NEVER BLOCK THE TRUCK BETWEEN THE TELESCOPIC AND THE FLOOR. if the material is less than required. located on either side of the tractor. Install service kit P/N 1053014.59 Modifying Existing Worn Skid Pad 5.15.MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Skid Pad Replacement Use the following information to determine if the skid pads. follow the instructions below. the existing skid pad MUST be replaced. NOTE: A minimum of . USE JACK STANDS OR SOLID BLOCKS TO SUPPORT THE TRUCK . USE A SUITABLE HOIST TO STABILIZE THE MAST. 3. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. 25” material MUST remain from the edge of the skid pad to the drilled holes as shown. USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON. modify the existing skid pad as shown below.
Elevate the tractor enough to work on skid pads. Locate new skid pads on tractor frame using dimensions given. Welds to conform to AWS A 5. 6.24" limit switch (2-stage) • JPC8 . Figure 5. REFER TO PAGE 5.60 Skid Pad Replacement 4. 7. Apply Loctite 242 (1036909) to threads of screws. 5.DO NOT RELY ON JACKS.24" limit switch (3-stage) • JPS23 . 3. 2. Clean any weld spatter off and repaint the area. Bolt new skid pad onto support. it is critical that the switches be adjusted so that they are actuated (but not bottomed out) the full length of the switch rails that they are in contact with. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. USE A SUITABLE HOIST TO STABILIZE THE MAST.58 .20 or equivalent low hydrogen process. NEVER BLOCK THE TRUCK BETWEEN THE TELESCOPIC AND THE FLOOR.MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL Skid Pad Removal If the skid pads must be replaced.15. Cut old skid pads off. Carefully lower truck to floor. obtain service kit p/n 1053014. 8. 1. Proper switch actuation can be verified by attaching a meter at the following points: • JPS12 . Weld new skid pads onto tractor. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT THE TRUCK . 24"/150" Limit Switch Adjustment If either switch requires adjustment or replacement.150" limit switch 5. This kit includes parts required when new skid pads must be installed. USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON.
MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC HYDRAULIC General topics covered in this section will be: • • • • Ieakage (external and internal) system contamination general hydraulic “tips” hydraulic oil Specific hydraulic maintenance covered in this section includes: • • • • • • NOTE: Iift cylinder bleeding hydraulic reservoir and filter Iift and auxiliary pump maintenance hydraulic system pressure adjustments solenoids miscellaneous hydraulic components It is important to keep accurate records of all hydraulic inspections and work performed on the truck.59 . Such records are helpful in determining: • • • • repair and maintenance costs reliabilty of components durability of hydraulic fluid scheduling of maintenance 5.
abnormal friction and wear will occur. The resultant stress may cause a leak. Make sure the flare is clean before installation. bouncing carriage and noisy pumps. check the packing inside the cylinder. Examine packings for wear and leakage around the cylinder pistons. PERSONAL INJURY MAY RESULT IF STRUCK BY A HIGH PRESSURE STREAM OF HYDRAULIC FLUID. Leakage Prevention Checks Faulty Flexible Connectors Fitting When installing a flexible connector. Remember. Any leakage inspection should include operating units as well as connections. See that cylinders are securely anchored and that pistons are in alignment. Many situations cause hydraulic leakage. Inspect all tubing before installation. Thoroughly clean and lubricate any O-rings before installation. If the packing gland is too tight. Make sure when making the flare that it is the right size. 5.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Hydraulic Leakage Hydraulic leakage can cause load drop. Worn packings should be replaced since they many times cause internal leakage. Misalignment is a cause of heavy wear of both pistons and packings. Cracked or Bad Tubing Flare Foreign Material in the Flare Defective Threads Dirt Around O-Rings Wrinkled or Flattened Tube Worn Packings Check for leakage around the threads when installing new tubing.60 . If truck operation is sluggish. load drift. USE EXTREME CAUTION WHILE LOOKING FOR HIGH PRESSURE HYDRAULIC LEAKS. Wipe all connections clean when checking for leaks. Use a known-to-be-good tube bender and carefully bend the tube. leaking fluid is likely to run down the underside of pipes and drip at low spots. Do not spring a tube into place before tightening a fitting. avoid twisting it which creates a strain on the joint.
load drift. JOINT COMPOUNDS CAN DISSOLVE. all hoses should be capped or plugged to keep out dirt and moisture-laden air. burrs or dirt present when reassembling the parts. Use a top grade oil with additives.61 . Inspect. etc. Pressure side leaks can be found by wiping connections and observing the accumulations of oil after brief truck operation. clean and/or replace the element whenever contamination is evident. If these are nicked or scratched. they should be resurfaced or replaced. Drive Coupling Alignment Check the alignment of the drive coupling between the motor and pump. NOTE: 5. Wipe all fittings before reconnecting them. nicks. Such leaks are always difficult to find. load drop. make the usual motor checks suggested in the electrical maintenance section. Oxidation can cause internal rusting and sludge. leaking. Also.. be sure to observe both pressure and suction sides. listen for these leaks. Brushing soap solution on joints can be helpful. flush all components and replace the oil and filter. Air leaks on the suction side of various components can cause considerable trouble. packing grit is probably in the hydraulic fluid. inspect the inside of the cylinder housing.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Leakage Prevention (Cont’d. and damage to the valve/pump parts. the bypass valve will allow contaminants into the system. Cylinder and Piston Packing Wear Hydraulic System Oxidation If a hydraulic cylinder is disassembled.) Bad Connections When checking connections to pumps. they may lead to air bubbles in hydraulic oil. Clogged Filter If the filter becomes clogged in less than the recommended change interval. Examine pipe fittings and hoses to be certain there are no seal particles. If the inside cylinder surface is scored. Opening Hydraulic System Whenever a hydraulic system in opened. manifold valves. drain the system. Packing Disintegration Examine rod surfaces which contact the packing. System Contamination System contamination can cause erratic or sluggish operation of lift or auxiliary functions. See the Lubrication Equivalency Chart in the Appendix. but they rate high in importance. clogging. CONTAMINATING THE OIL. Be sure hydraulic fluid from a leak is not seeping onto the field windings and armature. If severe contamination occurs. cylinders. NEVER USE PIPE JOINT COMPOUND ON HYDRAULIC FITTTINGS.
Follow these procedures to avoid future hydraulic problems. WHEN CLAMPING LIFT/LOWER MANIFOLD IN VISE. fill the reservoir bleed the system. DO NOT USE BRAKE FLUID IN THE HYDRAULIC SYSTEM.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Mointenance Tips NOTE: After locating and repairing any leak or other problem.62 . ENSURE VALVE BODY IS NOT CAUTION DAMAGED WHICH MIGHT VOID WARRANTY. 5.
7. Using low air pressure. 6. 4. 3. operate all systems. Flush reservoir using clean hydraulic fluid. the reservoir should be cleaned as follows: 1.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Reservoir and Filter The hydraulic oil in the reservoir should be checked and the return filter replaced periodically as outlined in the Scheduled Maintenance. Flush the filler strainer in clean oil. Remove the six screws securing the breather cap adapter and lift out the adapter. Refill reservoir. Install a new filter (see next page). Lift out the gaskets and filler strainer. Drain the reservoir by removing plug from drain line underneath the reservoir. Reinstall reservoir components in reverse order of disassembly being sure to: • coat gaskets and O-rings with a light coat to hydraulic oil.63 . 5. check for leaks and bleed system if required. Cleaning Procedure Figure 5. 2.61 Reservoir Assembly 5. • run the new oil through a 25 micron rated filter prior to filling the reservoir. Fluid level should be 1/2" below bottom of strainer with the carriage fully lowered and the oil at room temperature. 8. blow out any dust in the breather cap. When excessive contamination has built up.
1. Start hydraulic system and check for leaks. Install new filter. Hydraulic fluid should be within 1/2" of the bottom of the strainer with the carriage lowered and the oil at room temperature. NOTE: Tighten filter cartridge 3/4 turn after gasket makes contact with seat.64 . 6. 5. Apply a film of clean hydraulic oil to the gasket on the new filter. 2. 4. Use only hands to tighten filter cartridge. Check the reservoir level.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Return Filter Replacement The hydraulic return filter should be checked and replaced periodically as outlined in the Scheduled Maintenance. Turn filter cartridge (6) counterclockwise to remove. Clean gasket seat on filter manifold (4). 5. turn filter clockwise to tighten filter. 3. Place a pan under filter cartridge to catch any overflow when removing old filter. 7. See Figure 5.61.
65 . 5. consult the following: NOTE: When assembling the pump to the motor.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Auxiliary and Lift Pumps The pumps should normally require no periodic maintenance or adjustment if you follow a thorough program which includes: • • • • Procedure regular replacement of hydraulic oil and filter checking hoses for leakage cleaning of the oil strainer in the reservoir checking for contamination If you do suspect trouble with a pump. lubricate the shaft ends with a thin coat of Molycote type G lubricant.
DOING SO WILL DAMAGE THE AUXILIARY PUMP. Connect a calibrated pressure gauge to the pressure test port on the auxiliary pump.1600 psi. check the pressure on the gauge. The reading should be 1400 . 3. 4. refer to the figure below for the location of the relief valve on the auxiliary pump.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Auxiliary Pump Relief Valve The auxiliary pump relief valve is set at 1600 psi and normally requires no further adjustment. Adjustment For Power Mechanical Steering Figure 5.If the pressure relief valve requires adjustment refer to the figure below.Turn power on.66 . step on deadman and turn drive unit in either direction all the way to the mechanical stops. 2. While continuing to force drive unit against stop. If for some reason the valve needs adjustment.62 Auxiliory Pump Relief Valve Adjustment 5. 5. Turn Power off. See CAUTION. 1. DO NOT FORCE THE DRIVE UNIT AGAINST THE MECHANICAL STOP FOR MORE THAN 15 SECONDS.
FAILURE TO STOP TEST WILL RUIN THE AUX. Turn off power and put the Solenoid Controller Card on an extender card (P/N 1029620) to access card test points.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Auxiliary Pump Relief Valve (Cont’d) Pressure Adjustment for Electronic Steering The aux. Jumper both TP-2 and TP-43 to DGND (TP-42) using jumper clips to disable the Watchdog circuits. 2. DO NOT ADJUST THE RELIEF VALVE WHILE OPERATING!!! IF THE AUX MOTOR STALLS.Prevent the drive unit from turning by puting a wood block between the drive tire and the frame of the tractor.67 . This prevents the Watchdog circuits from shutting the truck down. USE EXTREME CARE WHILE OPERATING THE TRUCK. Connect a pressure gauge to the aux. 1. 5 Turn on power and steer the drive unit against the wood block. STOP THE TEST IMMEDIATELY BY STEPPING OFF THE DEADMAN PEDAL. This procedure should never be used unless the drive unit refuses to turn when standing still. Continued next page. READJUST THE RELIEF. See NOTE. SINCE ERROR CONDITIONS COULD CAUSE ERRATIC OPERATION OF THE DRIVE UNIT. system relief pressure should never need adjustment under normal circumstances. 5. . NOTE: The pressure gauge used should be calibrated and in good working order. but this procedure can also be used to test the aux. STEP OFF THE DEADMAN PEDAL. system if necessary. SYSTEM FUSE. system pressure port at the Proportional Solenoid manifold. 4. AND RETEST THE PRESSURE. READ THE PRESSURE AS QUICKLY AS POSSIBLE. ONLY FORCE THE AUX SYSTEM INTO RELIEF FOR VERY SHORT PERIODS OF TIME OR DAMAGE WILL RESULT. Figure 5. MOTOR AND/OR BLOW THE AUX.63 Attachment Point for Auxiliary Pressure Test 3. DO NOT LEAVE JUMPER CLIPS ATTACHED AFTER TESTING OR THE WATCHDOG WARNING CIRCUITS WILL NOT FUNCTION.
Turn off power. Read the pressure gauge as the drive unit is trying to rotate. End of Aux System Relief Pressure Adjustment 5. This pressure should be 1600 PSI. remove the wood block. DO NOT WORK ON HYDRAULIC CIRCUITS WITH POWER ON! 7.68 . remove the jumper clips to TP-2 and TP-43. Refer to Figure 5. If the pressure is not as specified.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Auxiliary Pump Relief Valve (Cont’d) Pressure Adjustment for Electronic Steering (Cont’d) 6. adjust the relief valve on the aux pump to achieve the correct pressure. and reinstall the Solenoid Controller Card into the card rack.62 for the location of the relief valve.
5. Remove old shaft seal (2). Lubricate shaft with hydraulic oil and carefully slide front cover (3) over shaft ensuring seal is not damaged by keyway. Be careful not to remove gears from housing. 9. Remove screws (17). 7. Use sharp tool to mark across front plate. Remove front cover (3). Reinstall o-rings and seals on bushings if they come dislodged.Exploded View 5. 3.Driven N/A Body Pin N/A Lock Washer Bolt Rear Cover Qty 1 1 1 2 4 4 1 Figure 5. This will assure proper reassembly. install new seal. Mark made in step 3 should align. 4. 2. Thoroughly clean outside of pump. Reinstall bolts (17) and torque in a diagonal pattern to 29 . Clamp pump in vise.69 . Remove key (9) from drive shaft. body and back plate. Ibs. Item 1 2 3 4 5 6 7 8 9 Description Retaining Ring Shaft Seal Front Cover Seal Seal Seal Bushes Pin Key Qty.64 FCD Lift Pump . 1 1 1 2 1 1 2 1 1 Item 10 11 12 13 14 15 16 17 18 Description Gear Shaft .32 ft. 6. 1. 8.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC FCD Lift Pump Disassembly Repair to this lift pump is limited to replacing the input shaft seal.Input Gear Shaft .
MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Barnes Lift Pump With the exception of shaft seals. this pump cannot be repaired. 5. Ibs.70 . retorque screws to 40/45 ft. If pump is disassembled.
10 11. 6. 4. Remove the two 3/8-16 x 1-1/4 hex screws supporting pump. 7. 3. 1.65 Dowty Lift Pump . 14. Pump can now be removed by pulling away from motor. 4. LOWER THE VERTICAL CYLINDERS AND BLOCK ANY LOAD WHERE MOVEMENT COULD GENERATE SYSTEM PRESSURE. If loss of performance occurs. Disconnect and cap hoses and lines from lift pump. Disconnect supply line to lift pump at reservoir . 3. 9. BEFORE DISCONNECTING ANY HYDRAULIC LINES OR FITTINGS TO THE PUMP.71 .Drain reservoir.Exploded View 5. 8.re-attach. Do not disassemble the pump unnecessarily. Field servicing is restricted to replacing the shaft oil seal and disassembly of the pump for inspection of internal components. 2. ASCERTAIN THAT THE BATTERY IS DISCONNECTED AND HYDRAULIC SYSTEM PRESSURE IS RELEASED. 12. 2. check the entire system before assuming the pump is at fault. 5. 13. Periodic checks of mounting bolts and for oil leakage is recommended.drain . Removal Procedure 1.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Dowty Lift Pump (P/N) (36 volt) Dowly Lift Pump Field Service Routine maintenance is not required. Mounting Flange End Cover Seal End Cover Body Seal Backing Washer Backing Washer Bush Lobe Seals Bush Bush Oil Seal Tie Bolts Body Driven Gear Splined Shaft Figure 5.
4. with garter spring facing inward. mineral-base grease. Cover splined area of shaft (14) with masking or electrical tape. Clamp the mounting flange (1) in a soft-jawed vise. This will prevent the pump from coming apart when the tie bolts are removed. 5. 16. Go to Step 17. Clamp pump in a soft jawed vise so spline is pointed up and the jaws are holding items 3 and 12. Ensure that the seal housing in the mounting flange (1) is clean and free from to burrs. 11. proceed to step 12. Use care not to pull the splined shaft upward while removing mounting flange (1). 21. Pack the space between the lips of the new seal (2) with high melting point. 18. 20. 6. Test/check for leaks. lift mounting flange (1) off pump.72 .65. While holding spline in position. but do not remove. the four tie bolts (11). with the garter spring facing inwards and press to the full depth of the recess. Press the seal into the full depth of the recess. Start the oil seal squarely into the housing. mineralbase grease. Bleed hydraulic system. Lightly grease taped area. The seal can be drifted out using a crank drift. Install the four tie bolts (11). and torque in a diagonal pattern to 34-36 ft. Lightly grease the taped area. start the seal in squarely with the housing. Ensure that the seal housing in the pump mounting flange is clean and free from burrs. 8. 12. Remove tape from spline. 13. 9. Pack the space between the lips of new seal (2) with high melting point. Cover splined area of shaft (14) with masking or electrical tape. See Figure 5. dismantle the pump as follows: 1. Take care not to damage the shaft bore with the drift. 2. 3. 17. 14. over taped area of shaft. it may not be possible to raise sufficient pressure to remove it in this way. 15. 5. 10. lbs. Mounting flange still assembled to pump. Fill reservoir with proper grade of dean hydraulic fluid. If the seal is distorted and leaking badly. Slide mounting flange over splined shaft squarely. Slide the oil seal. Reinstall pump by reversing removal steps 3 and 4 of removal procedure. 7. If seal is removed using hydraulic pressure. In this event. Remove the four tie bolts (11).MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Dowty Lift Pump Replacing Drive Shaft Oil Seal The drive shaft oil seal is best removed by applying hydraulic pressure simultaneously to the pump Inlet and Outlet ports. Loosen. This has the effect of pressurizing the seal cavity and forcing out the seal while ensuring that the pressure on each side of the bush lobe seals is equalized so these are not displaced. 19.
Lightly tap mounting flange (1) clear of the two hollow dowel pins in the pump body. Take note of the pump’s direction of rotaton. 4. Remove the remaining bushes (8. Continued next page. 6). body (12). Lightly mark the end cover (3). 3. the bush lobe seal (7) and body seal (4). Remove the four hex tie bolts (11) which thread into the mounting flange (1). Carefully lift out body seal (4). 6) and lobe seal (7). 9). Cover splined area of shaft (14) with masking or electrical tape.65. 9) from end cover end as previously described. Tap the side of the body (12) with a rubber mallet to dislodge the lower bushes (8. and mounting flange (1) to ensure correct reassembly relationship. Invert the body and lift out the driver (14) and driven (13) gears. 7. With pump body vertical (spline down). Slide the mounting flange squarely off the shaft. 5. Slide bushes out carefully and keep them as a pair with the mounting flange (1). place one hand underneath to support the bushings (8. 6. two backing washers (5. Remove the end cover (3) and carefully lift out the two backing washers (5. 10. 5. 9. 9).73 . See Figure 5.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Dowty Lift Pump Disassembly (36 Volt) 1. 8. Place with end cover (1). Lightly grease taped area. 2.
MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Dowty Lift Pump Disassembly (Cont’d. Keep bushes in pairs and properly oriented with the end of the pump they were removed from.74 . Inspect as follows: 5.) Component inspection Wash all metal parts thoroughly in cleaning fluid.
When fitted correctly the backing washers must be level and flush with the top surface of the bush lobes.75 . Light bruising can be stoned out with a fine-grit hand stone. the bushes should slide in easily. 5. Pick up the body and hold it with the hollow dowels uppermost and with the fingers of one hand inside ready to support the bushes. If the bushes jam in the bore.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Dowty Lift Pump Reassembly (36 Volt) Ensure that all parts are perfectly clean. Prepare the bushes for the mounting flange end of the body for insertion as follows: (See Figure 5. Fit the two backing washers inside the ‘eye-pieces’ of the lobe seal. 1.66 Lobe Seal and Backing Washer Assembly 2. See Figure 5. l The bushes must be entered squarely into the bore and must be kept square to each other.67. Lubricate parts with the oil to be used in hydraulic system. l Place the bushes on the bench with their lopes uppermost and the flats in contact. remove them and examine for bruising. 5. Pack the space between the lips of the oil seal with high melting point mineralbase grease. Lubricate the ‘spectacle’ lobe seal with mineral-base grease and fit it around the bush lobes. Figure 5.66). 3. No force must be used. 4. and slide them down into the body bore with the lobes facing away from the flat. Prepare the bushes for the cover end of the body for insertion in the similar manner. Pick up the mounting flange bushes complete with lobe seal and backing washers.
l Lay the pump body on its side and slide the drive gear (14) through this bore so the spline protrudes from the hollow dowel end of the body. Slide the mounting flange (1) squarely over shaft until the hollow dowel pins engage mounting flange fully.67 Bushes Assembled in Body 5. spline down. Hold the drive gear (14) with one hand. See NOTE. 9. 8. Check the arrow on the body to insure parts are assembled for counterclockwise rotation. Align mark made previously on mountng flange (1) and body (12). NOTE: Ensure that the marked side of the teeth are in contact so the “bedded-in” position is maintained. Insure spline is covered with tape. Refer to Figure 5. 12. Figure 5. Clamp mounting flange (1) in soft-jawed vise.67 to find the position of the drive gear. Remove tape from spline.76 . Check that the bushes (8.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Dowty Pump Reassembly (Cont’d.) 6. 10. 7. 9) are flush against the mounting flange face (1) and that lobe seal (7) and backing washers have not become dislodged. Lubricate the body seal (4) with mineral-base grease and place it in the body recess. Continued next page. 11. Mesh the driven gear (13) with the drive gear already assembled in pump. Lightly oil taped area and shaft.
Assemble hexagon tie bolts through and cover and thread until finger tight. Oil temperature should not exceed 140°-1 50°F. retorque screws to 40 . extend low pressure operation time and/or check entire lift system. During run-in period. Lobes should face outward away from flat. If the temperature exceeds limit. Place end cover (3) on body (12) aligning marks previously made. 19. 17. lbs. If the pump is disassembled. 3. Progressively increase the weight of loads over the first hour. Plug ports to prevent contamination from entering pump. Slide cover end bushes. over the gear journals. 18. 16.77 . Operate the lift system for a period of ten minutes (minimum) unloaded.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Dowty Pump Reassembly (Cont’d. Dowty Lift Pump Run-in If a new lift pump is installed. 14. Torque tie bolts in a diagonal pattern to 34-36 ft. lbs. 2. 5. complete with lobe seal and backing washers. 15. make frequent checks of pump casing temperature.45 ft. this pump can’t be repaired. 1.) 13. the following run-in procedure should be followed carefully. Bushes must be entered squarely and without force. Pour a small amount of clean hydraulic oil into the ports and check for freedom of rotation. Lubricate body seal (4) with clean hydraulic fluid and assemble into its recess. Barnes Lift Pump (36 Volt) With the exception of shaft seals.
5 ft. 6. Figure 5.Barnes Repair on the auxiliary pump is limited to replacing the shaft seal or mylar gasket between the stator (6) and gear housing (2). Clean fittings. 5. lbs. 5. (See Figure 5. 4. See NOTE. 2. twelve point socket. 7. Remove tape from drive shaft. Carefully separate stator (6) and housing.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Auxiliary Pump Removal 1. Lubricate coupling between pump and motor using Molykote grease (1036914). 3. lbs. Remove screws securing auxiliary pump to motor.68 Lubricating Auxiliary Pump/Motor Coupling Auxiliary Pump Repair . Apply dean hydraulic oil to mating surface of pump. See figure below. Disconnect battery. 3. Torque screws (1) to 10-12. remove fittings from old pump. 6. Remove screws (1) using a 1/4". Pull seal (4) from stator. Remove auxiliary pump and motor assembly from vehicle. MAX.69) 1. 5. Use masking or electrical tape to cover end of drive shaft to protect seal lip. 4. New gasket mud be the same color as old. For assembly reverse Steps 1-5. 7. Drain reservoir. If drive shaft (7) stays with stator . 2. Clean seal surface and press new seal in with the lip facing inward. Wrap threads using teflon tape and torque to 10 ft. Dip taped end of drive shaft in clean hydraulic fluid before pushing thru seal.78 . If a new pump is to be installed. NOTE: Gasket (3) is color coded to indicate thickness. Disconnect power wires from auxiliary motor. Disconnect and plug hydraulic lines to auxiliary pump. Use a new mylar gasket (3) between stator and gear housing.remove carefully.
) Item 3 (Mylar Gasket) Figure 5. Exploded View 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Auxiliary Pump Repair.Barnes.69 Auxiliary Pump .Barnes (Cont’d.79 .
Lift the carriage enough to gain access to the chain anchors on the most main frame. 6. Remove the chain anchors from the mast main frame. Disconnect and plug the brake line at the carriage. 7. Bleed hydraulic system after reassembly. See NOTE. or another suitable lifting device. 17. See pages 5. Disconnect all over-the-most electrical cables. 8. Lift cylinder may now be removed. Remove the shoulder bolts securing the upper lift cylinder guide. 16. NOTE: On trucks with an OACH of less than 102". Remove console cover.80 . Disconnect battery. For reassembly reverse Steps 1 -15 and refer to Elevating Section Service Notes for torques and assembly notes. 5. 2. On vehicles equipped with mechanical/hydraulic steering. 10. 12. 11. 9. 15.49 and 5. Disconnect and plug the hydraulic line to the bottom of the lift cylinder.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Lift Cylinder Removal (2-Stage) 1. 18. remove the wire rope from the steering system. the chain anchors are behind the carriage frame. Bleed brake. Remove the nut from the bottom of the lift cylinder housing. Remove the nut at the top of the piston. 4. Check for leaks. 3. Place a sling attached to a hoist around the cylinder to be removed. 5. Lift the carriage out of the telescopic.50. 14. 13. Remove the chain pulleys. raise the carriage to slacken the lift chains. Using a chain hoist.
O-ring (5). NOTE: When repacking the cylinder. use a strap wrench only. Remove seal (14) from plunger. 8. and back-up ring (8) out of housing. Remove spring (13). Refer to the parts section for packing kit part numbers. 9. Remove snap ring (9) from housing. Do not separate piston (16) and piston plug (15) unless absolutely necessary.70 2 Stage Lift Cylinder (Top End) 6. Pull piston out until piston stop forces piston seal (3). Release pressure on plunger (10) and remove. If disassembly is required. Remove wiper ring (2) from housing. replace all packings. Do not mar piston surface. Remove snap ring (11) and retaining ring (12). 5. double gland seal (6). 4. Figure 5. back-up ring (4).MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC 2-Stage Lift Cylinder Service 1.71). Place piston on cushioned stand using care not to damage the piston surface. 3. Push plunger (10) in slightly at base of piston (Figure 5. U cup seal (7).81 . Remove snap ring (1) from housing. 5. 11. 10. 2. Pull piston out of housing. 7.
) Figure 5. Flush inside of housing and wipe piston clean using clean kerosene or suitable industrial solvent. Reassemble cylinder by reversing disassembly procedure.71 2 Stage Lift Cylinder (Bottom End) Cleaning 1. Minor defects may be removed using fine emery cloth.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC 2-Stage Lift Cylinder Service [Con’d. item 17) must be dipped in new. DO NOT MAR CHROME PLATING ON PISTON. Then apply Loctite (1056016)to threads. clean threads on piston plug (16) using Loctite primer (6V1541). 3. 5. 2-Stage Lift Cylinder Reassembly 1. All packings and O-rings (except O-ring. Pressure test cylinder in less than fully extended position at 4500 psi. l l l l If items 15 and 16 were separated. Plug fitting opening to prevent foreign matter from entering cylinder.82 . Tighten using a strap wrench only. Lubricate inside of cylinder housing using clean system hydraulic fluid. clean system hydraulic fluid before assembly. Inspect all parts. 2. 2. 3. Inspect all surfaces for galling or heavy scratches. noting the following: l Tighten piston plug (16) and piston (15) using a strap wrench only. replace as required.
MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC
Center Lift Cylinder Removal (3-Stage) 1. Disconnect battery. 2. Remove console cover. 3. Disconnect all over-the-mast electrical cables. 4. Disconnect and plug the brake line at the carriage. 5. On vehicles equipped with mechanical/hydraulic steering, remove the wire rope from the steering system. 6. Using a chain hoist, or another suitable lifting device, raise the carriage enough to slacken the lift chains. 7. Remove the lift chains from the equalizer on the backside of the center lift cylinder. 8. Disconnect and plug supply hose at bottom of center lift cylinder. 9. Lift end cap off of center cylinder. 10. Remove nut from bottom of center lift cylinder. 11. Support the cylinder with a sling attached to a hoist. 12. Remove clamp supporting center cylinder. 13. Center cylinder may now be removed. NOTE: To remove the outboard lift cylinders, refer to the two-stage lift cylinder removal on page 5.80. For two-stage lift cylinder service, refer to pages 5.74 and 5.75. 14. For reassembly, reverse Steps 1-13 and refer to Elevating Section Service Notes (on pages 5.49 and 5.50) for torques and assembly notes. 15. Bleed hydraulic system after reassembly. Check for leaks. 16. Bleed brake.
MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC
Center Lift Cylinder Service (3-Stage) 1. Remove snap ring (1) and oil seal (2). 2. Remove snap ring (3) in housing. 3. Pull piston out until the piston stop pushes packing ring (4), packing (5), and adapter (6) out. 4. Pull piston out of housing. Place piston on cushioned stand using caution not to damage surface. 5. Push plunger (7) in slightly at base of piston, see figure next page. 6. Remove snap ring (8) and retaining ring (9). 7. Release pressure on plunger and pull out. 8. Remove spring (10). 9. Remove seal (11) from plunger.
Figure 5.72 Center Lift Cylinder, 3-stage (Top End)
MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC
Center Lift Cylinder Service (3-Stage)(Cont’d.) NOTE: 10. Do not separate piston (13) from piston plug (14) unless absolutely necessary. If disassembly is required, use a strap wrench only. Do not mar piston surface.
When repacking the cylinder, replace all packings. See parts pages for packing kits.
Figure 5.73 Center Lift Cylinder, 3-Stage (Bottom End)
Cleaning 1. Flush inside of housing and wipe piston clean using clean kerosene or suitable industrial solvent. 2. Inspect all surfaces for galling or heavy scratches. Minor defects may be removed using fine emery cloth. 3. Inspect all parts; replace as required.
Center Lift Cylinder (3-Stage) Reassembly
1. All packings and O-rings (except O-ring, item 15) to be dipped in new, crean system hydraulic fluid before assembly. (See Figure 5.72 & Figure 5.73) 2. Lubricate inside of cylinder housing using clean, system hydraulic fluid. 3. Reassemble cylinder by reversing disassembly procedure, noting the following: l To prevent damage to packings at the top of the cylinder, use the following tools: Service Driver - P/N 1056017 Service Guide - P/N 1056018
If removed, clean threads on piston plug (16) using Loctite primer (6V1 541). Apply Loctite (1056016) to threads on piston plug. Tighten using a strap wrench only. DO NOT MAR CHROME PLATING ON PISTON. Pressure test cylinder in less than fully extended position at 4500 psi. Plug fitting opening to prevent foreign matter from entering cylinder.
Install a calibrated pressure gauge (3000 psi) in test port G1. 4. Chain the mast telescopic sections together in the collapsed position. Back-out high pressure relief (2). 2STG-VLV. 1. 5. Check to see that the manual lower valve (3) is closed (hand tight only).74 Lift/Lower Valve Assembly (2 Stoge Most) 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Lift/Lower Valve Adjustment 2-Stage Mast (P/N ) The following a adjustment procedure is for trucks equipped with variable Lift/Lower manifold. 3.GEM Figure 5. 2.86 . Adjust the high pressure relief (2) to 100 psi over lifting pressure during lift with a capacity Ioad.
3STG-VLV. 5. increase the pressure to 2300 psi. 2. While observing the pressure gauge. Readjust the high pressure relief (2) to 100 psi over lifting pressure during lift with a capacity load. Chain the mast telescopic sections together in the collapsed position. While someone is holding the lift controller in the Lift position. 1. in the upper stage of lift. Install a calibrated pressure gauge (3000 psi) in test port G1. 6. 4. Check to see that the manual lower valve (3) is closed (hand tight only).MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Lift/Lower Valve Adjustment 3 Stage Mast The following adjustment procedure is for trucks equipped with a 3-stage mast.75 Lift/Lower Valve Assembly (3 Stage Mast) 5.GEM Figure 5. 7. 3.87 . Remove chain installed in step 5. slowly increase the relief pressure (2) until the carriage starts to lift. Back-out high pressure relief (2).
88 . is achieved. Cleanliness around the valve which is going to bee removed cannot be over emphasized. ensuring foreign material does not go into the valve body. Clean the surface as needed. 4. Figure 5. This valve requires no bleeding.76): 1. 6.150 inch Ibs. 2. Tighten the valve cartridge 1/2 turn. Thread the valve into the valve body.76 Proper Installation of Proportional Valve 5. then loosen 1/4 turn. 3. use the following procedure (refer to Figure 5. inspect the sealing surface for contaminants. Lubricate the o-ring using clean hydraulic fluid.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Replacement of Proportional Valve Cartridge on Manifold If the proportional lift/lower valve must be replaced or removed. 5. After the valve is removed. Tightening the valve in this manner reduces the chance of damaging the seal. Continue with sequence until a torque value of 120 .
On short vehicle.89 . THE BLEED SCREW SHOULD ONLY BE LOOSENED ENOUGH TO ALLOW THE AIR TO ESCAPE. A bouncing carriage is one indication that bleeding may be necessary. Raise the carriage approximately 6" then loosen the bleed screw on top of the cylinder. Procedure NOTE: CAUTION Figure 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Bleeding Lift Cylinder The lift cylinder should be bled after maintenance has been performed on the lift hydraulic system or when operation indicates that air has entered the system. When only oil flows from the cylinder. 2. remove button plugs on each side of mast guard to gain access to bleed screws.77 Lift Cylinder Bleed Screws 5. See NOTE. tighten the bleed screw. 1.
l bleed hydraulic system. l adjust steer chain. 5. Disconnect battery.78 Removing Steer Motor (Mechanical Power Steer Vehicles) 5. 13. Remove cover from front of power section. see page 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Removal (Mechanical Power Steering) Before disassembling the torque generator. Figure 5. Remove spirol pin (1). Remove and plug hydraulic lines and ports. Remove console cover in operator’s compartment. 1O. 1.54. Loosen and disconnect lower steer chain.90 . see figure below. note location of the mounting holes. 6. Seal all open ports and thoroughly clean the torque generator before beginning any repair work. Remove screws holding steer motor mounting bracket to tractor frame. see page 5. Loosen turnbuckles. 8. Cleanliness is extremely important in repair work. For reassembly. reverse steps 1 through 12 noting the following: l adiust steer cable. 7. l ensure steering pointer is in correct position. Separate coupling by raising shaft (2). Remove steer motor. 12. 11. 9. 2. This is important for correct reassembly. Remove upper chain from steering shaft in power section.55. 4. Remove cap screws attaching mounting bracket to steer motor. 3.
Loosen and disconnect lower steer chain.54. see page 5. l l bleed hydraulic system. noting the following: adjust steer chain. 6.103 Figure 5. Remove four mounting screws which hold steer motor brackets to tractor. Remove and plug hydraulic lines and ports to steer motor. 7. inspect condition. Remove timing belt. For reassembly. Seal all open ports and thoroughly clean the torque generator before beginning any repair work. 9.79 Removing Steer Motor (Vehicles with Electronic Steering) 5. Disconnect battery. Remove cover from front of power section. 5. l flush hydraulic system. see page 5. 4. 10. replace if required. While belt is removed. 2. Separate steer motor from mounting bracket. 8.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Removal (Electronic Steering) Cleanliness is extremely important in repair work. Disconnect wires from tachometer. Remove sprocket and gear. reverse steps 1-8. 1. 3.91 .
lb.80 Steering Torque Generator Figure 5.81 Steering Torque Generator .92 . capacity) The following tool is not necessary but is extremely helpful for disassembly and reassembly: Spring installation tool .Exploded View 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Disassembly Tools Required 1/4 in. thin wall 12 point socket 5/16 in. Figure 5. thin wall 12 point socket Small screwdriver (1/4 in.Char-Lynn P/N 600057. flat blade) Small breaker bar Torque wrench (150 in.
83 Separating Power End and Housing End 5. Remove seven cap screws. 2.) Before disassembling the torque generator. 5. Do not damage seal cavity. 3.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Disassembly (Cont’d. Use a small screwdriver to remove quad seal from housing.93 . note location of the mounting holes. Remove power end housing assembly.82 Steering Torque Generator Assembly 4. Remove O-ring seal from housing. Figure 5. Figure 5. 1. This is important for correct reassembly. Remove power end shah and wasner from housing.
85 Removing Gerotor 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Disassembly (Cont’d. Remove seal from gerotor. Remove gerotor and seal from control side of geroter.) 6.94 . 7. Figure 5.84 Removing Spacer Plate 8. Remove spacer plate and power end drive. Figure 5.
12 point socket wrench. 11. 16. 10. Remove spacer plate. making sure spool and sleeve assembly remains in housing. Remove washer from control spool. Remove seal from control housing. 5.87 Removing End Cap 14. 15. Remove four cap screws with 1/4 in. Figure 5. Use a small screwdriver to remove quad seal from end cap. Remove control end drive. 13.95 . Figure 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Disassembly (Cont’d.) 9. Remove seal from end cap. Remove end cap from control housing.86 Removing Control End Drive 12. Turn control housing over.
88 Control Housing . Figure 5.96 .Exploded View Inspection/ Preparation for Reassembly Replace all worn or damaged parts and assemblies. Replace all seals when reassembling a torque generator. Remove spool and sleeve assembly from control housing.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Disassembly (Cont’d. Lubricate all finished surfaces to ease assembly and provide start-up lubrication. 19. 18. Remove pin from spool and sleeve assembly. 5. Lubricate all seals with petroleum jelly. Remove spool and centerings springs from sleeve.) 17.
Lubricate the spool. The springs must be flush with the sleeve upper surface. install six centering springs into sleeve and spool.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Assembly 1.90 Removing Spacer Plate 5. Figure 5. Figure 5. Notches in springs must point away from control shaft. Rotate spool while sliding it into sleeve.97 . Using spring installation tool as a guide. (See NOTE next page).89 Spool/Sleeve Assembly (Control End) 2.
92 Removing Spacer Plate 3.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Assembly (Cont’d. 4.) NOTE: If spring installation tool is not available. Install pin into spool and sleeve assembly. Figure 5. Lubricate spool and sleeve assembly. 5.98 .91 Spring Installation (Alternate Method) Figure 5. Rotate assembly into control housing. Add the remaining inner springs as shown below. manually install centering springs by installing the two outside springs first.
ensuring quad seal is not damaged by shaft keyway. as shown below.99 . Install washer over spool shaft with chamfered side toward spool and sleeve assembly. 7. Install quad ring and O-ring seal in control end cap. Install end cap assembly over spool shaft. 6.94 Torque Sequence . lbs. Figure 5.MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Assembly (Cont’d ) 5. Figure 5.93 Control End Assembly . Install control end cap screws.Exploded View 8. Alternately torque to 150 in.Control End 5.
MODEL NOR30/NOR30P: MAINTENACE HYDRAULIC Steering Torque Generator Assembly (Cont’d. Install spacer plate. making sure that spool and sleeve assembly remains in housing. Correct Alignment Incorrect Alignment Figure 5.) 9. Install seal control housing. 10.100 . Figure 5. aligning holes in housing and plate.95 Installing Control End Drive 11. Turn control housing over.96 Timing Torque Generator 5. (Both spacer plates are the same and either of the plate may face the control housing).
Install seal in power end housing. smaller splined end first. Align control end and power end keyways. 16. Figure 5. Install spacer plate. Install quad seal in power end housing. Align star valleys with drive mark.) 12.98 Installing Power End 20. Install washer over power end shaft with chamfered side away from shaft keyway. aligning splines in shaft and drive. 17. making sure drive engagases with pin.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Steering Torque Generotor Assembly (Cont’d.97 Installing Spacer Plate 14.Install power end housing. To time the Torque Generator. Install control end drive.)18. making sure that the seal is ininstalled in side facing the control end spacer plate. 5. 13. aligning holes in piate and gerotor. Install seal in gerotor.101 . (Either side of spacer plate may face gerotor. Install seal in power end side of gerotor. rotate spool and sleeve assembly until pin i5 parallel with port face. making sure quad seal is not damaged by shaft keyway. Figure 5. Install shaft in power end housing. Mark drive as shown on previous page. 22. Install gerotor. 21. 15. Install power end drive in gerotor. 18.
99 Torque Generator Final Assembly Figure 5.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Steering Torque Generator Assembly (Cont’d. Install power end cap screws.102 .) 23.101 Power End Torque Sequence Figure 5. Aitemately tighten cap screws to 200 in. lbs.100 Torque Generator Cross section 5. Figure 5. See figure below for torque pattem.
MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Flushing Hydraulic System The hydraulic system must be flushed: • after the truck is first assembled • after any maintenance an the eletronic steering or wire guidance hydraulic components • after any hydraulic components are changed • when the hydraulic oil is changed. Manually push in the lift pump contactor. hydraulic steer motor). Repeat the lift/lower process 5 times. Turn Keyswitch On and enter Maintenance Mode and select test 06. Lower the carriage by opening the emergency lowering valve located on the lift/lower manifold. ENSURE THAT THERE IS ADEQUATE CLEARANCE ABOVE THE TRUCK TO PREVENT DAMAGE TO THE BUILDING AND/OR THE TRUCK. This is done to prevent contamination SOL1. With keyswitch Off. 1. If the truck has just been assembled. auxiliary pump. 7. Close the manual lowering valve.. Continued next page. The remaining steps are for flushing the auxiliary hydraulic system. disconnect one of the leadwires to the auxiliary motor. 3. 4. only perforrn steps 12 through 20. NOTE: Whenever oil is added. 5. (i. NOTE: If steering components have been worked on. See NOTE. This will close SOL2. if a hydraulic component is changed or if the oil is new perform all the following steps. Hold the contactor in firmly to avoid contactor tip damage. proportional solenoid. 5. Depress the horn button to get “Open” on the Operator’s Display. BE SURE TO COVER THE LOOSE END TO PREVENT IT FROM COMING IN CONTACT WITH THE TRUCK FRAME. 2. hoses. Steps 1 through 11 provide a method for flushing the lift system without using the proportional lit/lower valve. torque genera tor. DO NOT USE REMOTE LIFT/LOWER TOOL AS THIS WILL ALLOW CONTAMINATION TO ENTER THE PROPORTIONAL VALVE.103 . The carriage should be raised until the side lift cylinders are extended at least one-half of their fully extended length then release the contactor. always filter the oil before adding it to the reservoir. See WARNINGS and CAUTION. THE CARRIAGE WILL LIFT AT FULL SPEED WHEN THE LIFT CONTACTOR IS PUSHED IN.e. 6.
17. 19. 15. STAY CLEAR OF THE DRIVE UNIT AS IT MAY TURN AS SOON AS THE KEYSWITCH IS TURNED ON. End of procedure. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. 5. USE A SUITABLE HOIST TO STABILIZE THE MAST. See WARNING. After 10 minutes.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Flushing Procedure (Cont’d) 8. 12. 20. Tum the keyswitch off. USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON. 15. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT TRUCK . 9. Manually turn the drive unit until it is centered.104 . NEVER BLOCK THE TRUCK BETWEEN THE TELESCOPIC AND THE FLOOR. 14. Turn the keyswitch to the off position. Depress the deadman pedal and let the auxiliary motor run for approximately 10 minutes. REFER TO PAGE 5.DO NOT RELY ON JACKS. reposition Mode toggle switch to RUN. 18. Check the fluid level in the reservoir. 13. Lift and lower the carriage normally 3 more times using the lift/lower control. turn the drive unit from stop to stop at least ten times. Ensure that the carriage is elevated until the side lift cylinders are extended at least one-half of their fully extended length. 16. Turn the keyswitch Off. Lower the truck to the floor. then turn keyswitch On. Reconnect the lead to the auxiliary motor. Jack the drive tire off the floor. 11. Turn the keyswitch to the on position. Replace the return-line filter. 10. See WARNING.
perform the following: 1. 5. Wipe all tools and place them on a clean surface. have all fittings and hardware stationed near to the vehicle on a clean work surface. with a plastic bag. When a new component is installed. When assembling a new or cleaned component. securing it with a rubber band or twist tie. Clean around all areas to be disconnected. 6. 4. disconnect the component or hose. 3. Cover the end of hose.105 . When removing a component. thoroughly wash the component and any fittings and hardware using clean kerosine or an industrial solvent and place them onto a clean work surface. capping the ends or ports with pressure fittings. Pressure solvent (kerosine or an industrial solvent) and wiping with a line free towel are suggested. which will be reused.MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC Clean Procedure WHENEVER THE AUXILIARY OR STEERING HYDRAULIC COMPONENTS ON A WIRE GUIDED SYSTEM ARE REPAIRED OR REPLACED. Have a clean surface prepared for holding tools and components. 5. Before performing maintenance on wire guidance or steering hydraulics. 2. THE CLEAN PROCEDURE AND FLUSHING PROCEDURE SHOULD BE FOLLOWED.
make a connection between the control side terminal and the truck frame with the ohmmeter. wire connections. BATTERY CURRENT CAN DAMAGE THE METER. 5. See to Appendix. Shorts To Frame Another common cause of truck electrical problems is shorting to the truck frame which can be caused by: • accumulation of dirt • breakdown in insulation • bare wires Shorts to frame can occur at numerous locations including: • battery • motors • cables • buss bars • heat sinks Check for shorts to frame using the following procedure: UNPLUG THE BATTERY. 10. use the following procedure to check out the wiring harness: 1. If the ohmmeter registers less than one megohm. Any reading below 2 megohms indicates unacceptable shorts somewhere in the system.i.106 . 8. Connect one lead to the truck frame and the other to different points in the electrical system . For each fuse. When truck problems exist. Visually inspect problem areas for: • loose connections • faulty terminals • broken wires • worn insulation 2. 3. 9. The meter should register no less than one megohm. make a connection between the battery side terminal and the truck frame with the ohmmeter. and FU3). 4. the meter needle will noticeably move. For each fuse. contactors. Procedure 1. Use an ohmmeter set on the R x 10. 7. Check for continuity in the wiring harness using an ohmmeter and referring to Electrical Schematic. Reverse the leads and repeat steps 3 through 5. 2. etc. FU2.. 6. Remove 15 amp control fuses (FU1. Any reading registering on the meter indicates unacceptable shorts in the systems.000 scale. If there is a short.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL ELECTRICAL Wiring Harness Truck problems are often caused by defects in the wiring. \ 5. the short within the particular circuit must be located. terminal strips.e.
4. • Remove battery from truck. If voltage drops. Voltage to frame leakage is a result of dirt accumulation and can occur at: • Motors • Heatsinks • Battery • Switches • Contactor Panel • Cables/Wiring Check for voltage to frame using the following procedure: 1. • Disconnect motor leads (one at a time). Reconnect battery to receptacle. If battery checks good. motor needs cleaning or repair. battery needs cleaning or resealing. 3. If voltage drops when fuse is removed the defective circuit is isolated.HYDRAULIC Voltage To Frame MODEL NOR30/NOR30P: MAINTENANCE Voltage grounds are the most common causes for system intermittent “overloads”. If voltage drops. Use the following procedure: • Connect voltmeter leads as in Step 2 above. Use a voltmeter set on 50 VDC scale (some voltage above truck system). 5. negative lead to truck frame • Positive lead to truck frame.107 . Eliminating voltage to frame can be accomplished by isolating a particular area of the truck electrical system. reinstall in truck and: • Remove fuses (one at a time). 2. Connect voltmeter leads as follows: • Positive lead to PC1-1. negative lead to TP4 Voltage readings of 2-3 volts in either test should be eliminated.
174. See Page 5. Attach the positive lead of the ohmmeter to the heat sink and negative lead to the Power Transistor panel base. The resistance should register at least one megohm. 3. 4. REC2 • 2 cables at TP6 • unplug JPT1 • 2 lines at TP5 2. If the resistance is still Iow. 5.000 scale. clean around the heat sink.108 . • REC1. Remove all electrical connections from the heat sink. Use the following procedure to check the heat sink insulation for shorts to the frame: 1. replace the insulation between the heat sink and the truck frame. Set the ohmmeter on the R x 100. If the resistance is lower than one megohm.ELECTRICAL Heat Sink Insulation MODEL NOR30/NOR30P: MAINTENANCE Heat sink insulation may become faulty for several reasons: • poorly insulated screws which secure the component to the heat sink • carbon build-up which allows current to bypass heat sink insulation • cracks in the heat sink insulator.
The acid also causes corrosion of cell posts. Leave the solution there until all “fizzing” stops. Tighten the battery vent caps. 3. Electrolyte Process Battery Cleaning Procedure 1. Mix 1 lb. Use a voltmeter set on the 50 volt scale. 1. 5. the following process occurs: 1. If cells are overfilled and electrolyte collects on the covers. 4. Battery Electrical Leakage To Frame Test 5. If there is more than a 2 to 3 volt reading in Steps 3 and 5. positive to battery positive. The voltmeter should show no voltage or at most a 2-3 volt reading. Attach meter leads: negative to truck frame. clean the battery rollers. This affects battery performance and truck operation. 2. NOTE: Wet covers can be an indication of overfilling. 5. 4. Battery Cleaning Batteries in industrial trucks pick up various kinds of dirt and dust depending on their surroundings and the types of material handled. This moist surface. the cause should be determined and the adverse conditions corrected. Attach meter leads: negative to battery negative. leaky seals at posts or excessive gassing during charge. Most industrial batteries can be expected to function properly for more than five years. since the acid in the electrolyte does not evaporate. nuts. in combinahon with certain kinds of dirt.109 . connectors and the steel battery case. 2. Rinse thoroughly with clean water. 6. The voltmeter should show no voltage or at most a 2-3 volt reading. When observed. 3. indicating that the acid has been neutralized. The following section contains essential battery maintenance information: • cleaning • leak test • charging • hydrometer check • voltage check • record keeping This information should extend battery life and increase truck efficiency.ELECTRICAL Batteries MODEL NOR30/NOR30P: MAINTENANCE The lead acid batteries furnish all power requirements of the truck. 2. baking soda and 1/2 gallon of hot water. The top of the battery becomes wet and stays wet. becomes electrically conductive and permits stray currents to flow externally over the top of the battery. Use a brush with flexible bristles and apply the soda solution over the top of the battery. Blow battery case dry using compressed air. positive to truck frame. 3. WEAR EYE PROTECTION.
110 . 1. DO NOT routinely recharge batteries when they are only partially discharged. become familiar with the following: • Charging rate. • WEAR PROTECTIVE CLOTHING AND EYE PROTECTION WHEN HANDLING. starting rate. NOTE: Get the maximum use out of each battery by recharging the batteries only when they are effechvely discharged. CORROSION CAUSES GROUNDS AND THE POSSIBILITY OF SPARKS. this will decrease battery life. • CHARGE IN A WELL-VENTILATED AREA TO AVOID HYDROGEN GAS CONCENTRATION. OR SPARK PRODUCING DEVICES NEAR THE BATTERIES. • Time available for charge. CHECKING OR FILLING BATTERIES. Charging time is 5-20% longer than that of discharge. • CHARGE BATTERIES AT THE INDICATED RATES. • KEEP BATTERIES CLEAN. At maximum recommended discharge. direct current is passed through the battery cells in the direction opposite to that of discharge. • Variations in cell voltage • Avoiding overheating. Charging Process 5.150 or less. OBSERVE THE FOLLOWING PRECAUTIONS: • DO NOT SMOKE. • NEVER LAY TOOLS ON TOP OF THE BATTERIES. the specific gravity should read 1. • KEEP PLUGS. CABLES. USE OPEN FLAME. To charge a battery.ELECTRICAL Battery Charging MODEL NOR30/NOR30P: MAINTENANCE WHEN CHARGING BATTERIES. Consult your battery manual for specific charging procedures. excessive gassing or overcharging 2. AND RECEPTACLES IN GOOD CONDITION TO AVOID SHORTS AND SPARKS. First. and finish rate. TERMINALS.
ELECTRICAL Hydrometer Use
MODEL NOR30/NOR30P: MAINTENANCE
The hydrometer measures the specific gravity of the electrolyte. The specific gravity varies directly with the state-of-charge of a lead acid battery as follows:
1. Insert the nozzle of the hydrometer into the battery cell and draw enough electrolyte into the tube to permit the float to ride free. 2. Bring the hydrometer to eye level and determine the specific gravity of the cell. See Chart above. 3. If there is insufficient electrolyte to obtain a hydrometer reading: • add just enough water to cover the battery plate. • Now charge the battery and take additional readings. 4. The specific gravity reading for each cell should be taken and recorded on the battery chart. NOTE: No amount of charging will increase battery capacity or raise the specific gravity above its fully charged level (1.280 to 1.300). Water is added to the cell after the charging process is completed. Consult your battery manual for further information. Take a voltage check on each cell after performing the hydrometer check above. Connect the leads of a Simpson Volt/Ohmmeter (VOM) or equivalent to the positive and negative terminals of each cell. VOM readings will vary with the state of charge:
1. Touch the voltmeter leads to the positive and negative terminals of each cell. There should be a reading of two volts for each fully charged cell and a variance of no more than .2 volts between cells. 2. Record the voltage reading for each cell on the battery maintenance chart.
MODEL NOR30/NOR30P: MAINTENANCE
Adding Water To Battery Guidelines
Water must be added to battery cells periodically. Frequency and quantity depend on the water level above the plates and the amount of gassing during charge.
• • • • •
Use only approved or distilled water. Add water after hydrometer and voltmeter readings are taken. Add water after charging to minimize overfilling. Always have plates entirely covered. Keep outside of battery case clean and dry.
Battery History Record
A battery record system is essential because battery failure can cause production slowdowns and increased battery operating costs. A properly supervised record system can detect and call attention to such operating irregularities as: Overcharging • Undercharging • Over discharging • Excessive water consumption • Excessive dirt and corrosion • Worn out batteries • Excessive current consumption of trucks • Records should be kept for each battery. Your battery supplier should be able to provide maintenance record sheets. Each report should contain: Battery number, type, serial number, and service data • Specific gravity and voltage readings for each cell • Temperature of the air and eletrolyte • Electrolyte • Amperes • Condition of connectors, cover, sealing compound and tray • General cleanliness • Number of total cycles • Average specific gravity drop • Watering frequency • User comments and observations •
MODEL NOR30/NOR30P: MAINTENANCE
ELECTRICAL Motors All motors are designed to operate with a minimum of maintenance. Sealed bearings are used in all motors thereby eliminating lubrication. Included in the motor section are the following maintenance procedures: • motor cleaning • brush care • commutator care • prevention of motor overheating • open circuit test • short circuit test These procedures, along with periodic inspection help to provide trouble-free motor performance. Motor Cleaning Periodic motor deaning is essential to prevent overheating and electrical grounds. To clean the motor properly, use the following procedure: 1. Wear safety glasses. Use crean, dry, low pressure air (30 psi), to blow carbon dust and other foreign materials from: • the motor housing • brush holders • commutator • field and armature windings (if accessible)
Figure 5.102 Example of Cleaning Motor
NEVER USE A CHEMICAL SOLVENT TO CLEAN THE MOTOR AS IT WILL CARRY CARBON DUST TO HARD TO CLEAN AREAS AND CAUSE SHORTS WITHIN THE MOTOR. WASHING WITH DETERGENTS REQUIRES COMPLETE DISASSEMBLY AND DRYING. THIS SHOULD ONLY BE ATTEMPTED BY AN AUTHORIZED MOTOR REPAIR SHOP.
Since the operating environment of lift truck motors varies widely. the following recommendations should be applied as actual conditions dicdate: Several conditions to define before considering the following Maintenance Inspection Chart are: Maintenance Schedule Maintenance Inspection Chart 5.114 .ELECTRICAL MODEL NOR30/NOR30P: MAINTENANCE Brush Care Brushes should be inspected for: Proper wear Signs of overheating Physical damage to brush holders Proper spring pressure/alignment Freedom of movement within brush holders.
Insufficient spring pressure will cause excessive arcing and reduced • motor performance.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Brush Care (Cont’d) 1. Be certain connections are clean and tight and that brush wires do not ground on motor frame or armature. Figure 5. Excessive spring pressure will result in premature wear of the commutator.Check for correct clearance and freedom of brush movement within the holder.103 Measuring Brush Spring Tension 5. • Physical Damage . Inspect the brushes in all motors for: • Proper Wear . Freedom of Movement .check spring pressure as shown below. Position motors to provide easiest access to brushes. • Overheating .overheating will be indicated if the brush shunts or brush springs are discolored. Make sure the holders are not loose on the end head or brush holder plate.the brush surface should be polished and show even wear. • Spring Pressure/Alignment . • A brush spring that does not apply even pressure on the center of the brush will cause the brush to wear unevenly. 2.Inspect the brush holders for damage.115 .
Refer to the figure below for minimum brush lengths. Do not replace just one or two brushes. *Measurement of brush length refers to the “short” side dimension. 1 Measured from the long end. Figure 5. Continued next page.116 . When ordering replacements refer to the motor serial number on the motor nameplate.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Brush Replacement If any of the brushes require replacement.104 Minimum Brush Lengths 5. the complete brush set should be replaced. *Measurement of brush length refers to the “short” side dimension. 1 Measured from the long end. When ordering replacements refer to the motor serial number on the motor nameplate.
DO NOT use emery cloth to seat brushes. The brushes are matched to the motor type and application to provide the best service. 5. the dust should be blown out of the motor with dry compressed air (30 psi). This can be accomplished by wrapping a piece of 00 sandpaper around the commutator. On smaller motors where space is limited. a brush seating stone may be used. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear. new brushes should be seated to the commutator curvature.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Brush Replacement (Cont’d) When ordering replacements refer to the motor serial number on the motor nameplate. and turning the armature. After the brushes are seated. seating the brush in the brush holder.117 . Do not substitute brushes. Where accessible.
118 . Determine the minimum commutator diameter. After the commutator has been undercut. if the armature does not have the mica undercut. The decision to undercut or not is determined by the type and grade of brush used in that particular motor. this operation should not be done. (refer to the next section on commutator resurfacing). the armature should be placed in a lathe Figure 5. However. See Figure 5. The mica should be undercut to a depth equal to the width of the mica.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Commutator Servicing High Mica If the commutator requires service. NOTE: ALL DIMENSIONS GIVEN ARE IN INCHES Figure 5. To do so will impede the operation of the motor and possibly result in motor component damage. the commutator must not be turned below this diameter. Review the following information before servicing a motor commutator. but may vary in some motors. Most modern armatures have the mica undercut between the commutator segments.106 Commutator Cutting Tool 5. the segments on the commutator should be chamfered and the armature should balanced. After the commutator has been polished. the armature will have to be removed from the motor.105. Commutator Resurfacing Light pitting and wear can be removed using a abrasive rubber polisher. This is usually 1/32 inch. These last two steps (chamfering and balancing) are normally neglected and can contribute to an early failure of the motor brushes.105 Mica Undercut and the commutator lightly polished using an abrasive rubber polisher.Excessive pitting or wear will have to be removed by resurfacing the commutator.
if not done properly. creates additional problems. Stoning of Motor Commutators Figure 5.107 Commutator Mica Undercut and Chamfering 5. Using a stone to correct commutator problems is an old and improper technique that has been used for a long time.002 inch. they become oxidized by sparking as the trailing edge of the brush passes over them. This can best be accomplished by using the proper slotting file. Instead of using the traditional stone. This converts copper to copper oxide. it is critical to remove the copper burrs on the commutator segment edges. taking only light cuts each time. Always make sure the cutting tool is sharp before resurfacing the commutator. Ensure that the tool is retracted from the commutator surface before repositioning the tool to prevent damage to the surface of the commutator.005 inch should be removed during any one cut and the final cut should not be more than 0. If the burrs on the commutator segments are not removed after stoning. a hard abrasive. Refer to the figure below and on the following page. Usually. The commutator should then be polished using the abrasive rubber polisher.119 . stoning a commutator does not correct the problem and. If stoning is the only alternative to polishing or to even-out high/low spots on the commutator. Refer to High Mica after machining is complete. use a suitable abrasive rubber polisher. Resurface the cammutator at 800 rpm. No more than 0.106 shows the dimensions for sharpening the commutator cutting tool. Position the cutting tool so the point of the tool is approximately 1/32" below the center line of the armature. which will cause accelerated brush wear. Rubber abrasive polishers may be purchased from Martindale or Ideal. These suppliers specialize in commutator maintenance items. The polishers are available in various sizes.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Commutator Resurfacing (cont’d) Figure 5.
which reduces the likelihood of flashover. 108 Chamfering Segment Bar Edges on the Commutator 5. It also reduces the possibili1y of copper burrs on the bars which will cause premature wearing of the brushes. Figure 5. the life of the brushes will be shortened. Chamfering increases the distance between two successive bars.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Commutator Segment Trueness Chamfering Commutator Bar Edges After any machining. Polish each chamfer using an abrasive rubber polisher.120 . Below are diagrams which show proper and improper chamfering techniques. If they are not true. the edges of the segment bars should be chamfered. inspect the commutator. After machining is complete. Ensure that the segment bars are parallel and true with each other.
PERSONNEL SHOULD NOT BREATHE THE FUMES WHICH HAVE BEEN GENERATED INSIDE THE MACHINE. IF POSSIBLE. ESPECIALLY IN A TOTALLY ENCLOSED MOTOR.ELECTRICAL Motor Overheating MODEL NOR30/NOR30P: MAINTENANCE Most motor overheating can be prevented by understanding the causes and preventions listed below: IF AN ELECTRICAL FAILURE OR AN EXTREME OVERLOAD OCCURS. ALL POWER SHOULD BE DISCONNECTED FROM THE MOTOR BEFORE ANY INVESTIGATION OF THE FAILURE IS ATTEMPTED. PERSONNEL SHOULD NOT BREATHE THE TOXIC FUMES PRODUCED BY THE FAILURE. THE AREA AROUND THE MOTOR SHOULD BE WELL VENTILATED.121 . THE HEAT OF THE FAILURE ARC OR OVERLOAD MAY GENERATE NOXIOUS FUMES BY PYROLYSIS OF THE INSULATION MATERIALS. TIME SHOULD BE ALLOWED FOR THE 5.
Connect the leads of an ohmmeter between the individual circuits. these motors must be disassembled to check the field and armature circuits for continuity. 5. The above continuity check may be made between the two external terminals. If the meter indicates an open circuit in the armature.122 . The meter should register more than 100. (The drive motor has four external connections . There should be continuity within each circuit and the meter reading should be zero.) 3. 2.two armature and two field.000 ohms. Figure 5. check condition of the brushes before rejecting the motor.109 Drive Motor Terminals and Circuits 5. See below. 4. There should be NO continuity between the armature and the field terminals. NOTE: The auxiliary and lift motors have only two external connections because the armature and field windings are connected intenally. This can be caused by: • bad brushes or brush springs Motor Open Circuit Test Procedure • • a broken wire in the field winding a loose or bad connection 1. If an open circuit is found. Disconnect the motor from the truck circuit.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor Test for Open Circuit An open circuit is one in which the electrical circuit within the motor has been broken.
A shorted motor may be indicaded by: • slow or sluggish operation • running faster than nommal • overheating • blowing a power fuse Short Circuit Test 1. Refer to the inspection report showing the motor current when the motor was new. Duplicate the same truck conditions (loaded or unloaded) and measure the present current. 3. 5. The breakdown creates a low resistance current path.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Short Circuit Test . Armature Shorts A short circuit in the armature will cause heating which will probably resuh in burning of: • the armature coil • banding wires • commutator segments Visual inspection should show this condition. allowing current to flow from one turn of the coil to another adjacent coil turn. The result is a decrease in total resistance of the motor winding and an increase in the current flow. If the present current reading is 25% more than the original current value. a short circuit probably exists. 2. without octually flowing through the coil wire.123 . Location of the short determines its severity.Motors A short circuited motor is one in which the insulation on the field or armature windings has broken down at two or more points.
Connect the other ohmmeter lead to each of the following points individually: • FU 1-2 • FU3-2 • TP4 4.000.124 . repair or replace the motor as necessary.000 ohms.General Another common cause of truck electrical problems is other grounding. 1. 3.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor Grounds Test In a grounded motor. Be sure paint does not interfere with connections. 5. This can be caused either by direct contact or through conductive foreign material. Grounds can be caused by: • accumulation of dirt • breakdown of insulation • bare wires Grounds can occur at numerous locations including: • batteries • motors • contactors • solenoid coils • terminal strips • switches Procedure 1. 2. Inspect circuit carefully to find the cause of the ground. Isolate the motor from the truck circuit. or an ohmmeter set to the highest resistance scale. Disconnect battery connector. an electrical circuit exists between the current-carrying conductors and the motor housing. Clean. Attach one lead of a megohmmeter (preferably). If the megohmmeter indicates a resistance of less than 100. The ground may be caused by: • insulation breakdown • brush leads touching the motor housing • build-up of carbon dust or other materials. 5. Use R x 100 scale. A reading of less than 1. Connect one ohmmeter lead of a Simpson Model 260 (or equivalent) to the truck frame making sure of good contact with bare metal.000 ohms between any of the connections indicates that a ground exists. 3. Grounds . to a motor terminal and the other lead to the motor housing. 2. the motor is grounded.
Foot Mount Base Figure 5. Remove nuts from the tie bolts.110 Pacific Scientific Motor . If motor is left on truck. 2.125 .MODEL NOR30/NOR30P: MAINTENANCE MODEL NOR30/NOR30P:MAINTENANCE ELECTRICAL Auxiliary Motor Pacific Scientific Specifications Brush Replacement 1. pump from motor. place tape over the bolt heads to hold in place once the nuts are removed. this will aid in reassembly. Lift off rear end bell assembly. 3. Continued next page.Exploded View 5. remove foot mounting screws and separate aux. If motor is to be removed. 4. Tag and remove power cables. 5. Disconnect battery.
Figure 5. Continued next page. install new brush. Using small screwdriver align tie bolts with holes. See Figure 5. Repeat for other brush. 9. Position brush as shown below. 7. Orient end bell key to line up with mating notch in shell. 14.) 6. put lug under terminal and tighten. Push end bell assembly back into its original position. See CAUTION TO PREVENT SHORTING ENSURE THAT INSULATOR IS IN POSITION AND HAS NOT BEEN DAMAGED. Remove old brush.126 . Tuck insulators back into position between brush leads and shell.112 Brush Spring in Proper Position 13. Figure 5.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Brush Replacement (Cont’d. Hold the washer in place using finger through hole in end bell during assembly. Partially insert bell and ‘uncock’ brush springs by pushing brush toward commutator until the spring snaps over the brush.112. Ensure that the wave washer is in the bearing bore. 15. 5. pull brush lug from under nut. Lift spring off brush. 12.111 Brush Spring ‘Cocked’ For Insertion 10. Loosen terminal stud. 8. 11.
10. 19. CAUTION WHEN DISASSEMBLING MOTOR. Commutator Care See Page 5. Disconnect the battery. To assemble. INSERT COMMUTATOR END FIRST. 8. AVOID SCARRING COMMUTATOR WIRES.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Brush Replacement (Cont’ d. Remove rear end bell assembly and wave washer. See Brush Replacement for rear end bell installation. reverse Steps 1-10 observing the following NOTE and CAUTION. Remove screws holding pump/motor assembly to the tractor. 5. Reconnect battery and test motor. 4. re-attach auxiliary pump to motor (apply Molycote grease to tang) and remount motor in vehicle. Press the bearing out of the front end bell. Hold shell assembly securely (do not squeeze excessively in vise). Remove rear bearing. 17. 7. 3. USE A CLEAN BENCH. 18. Grasp shaft and/or front bell and withdraw briskly. NOTE: After pressing new front bearing onto shaft use Loctite 242 (1036909) on outer race in front end bell. 6. Reconnect power cables. WHEN INSERTING ARMATURE IN SHELL. disconnect power leads from auxiliary motor. 9. Remove tape if used in Step 3. Pacific Scientific Bearing/Armature 1. Separate auxiliary pump from motor. The bearing in the front end bell is held in place with Loctite. Use a puller to remove front end bell and bearing from shaft. See NOTE.) 16.127 . Replace tie bolt nuts. 11. replace both bearing and end bell. 2. NOTE: If the bearing cannot be properly removed. Remove tie bolts and nuts. CAUTION 5. Use caution not to distort end bell. FREE OF STEEL PARTS OR CHIPS AS THE PERMANENT MAGNET FIELD WILL ATTRACT LOOSE PARTICLES.118. If motor was removed from vehicle.
Scribe or center punch locating marks in the end heads and the frame. Use a brush hook to reach into the motor and lift the brush springs.Prestolite The service procedures for Prestolite motors are basically the same regardless of size.113 Typical Prestolite Motor 1. Remove the cover band from the commutator end of the motor (if so equipped). Pull the brushes out of the brush holders. Although locating marks are not always necessary because of locating pins in some motors. Figure 5.114 Lifting Brush Springs . Figure 5. the marks can save a lot of time when the motor does not have locating pins.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor Disassembly . Figure 5.Brush Removal 2.115 Removing Brush Retaining Screws 5. Either position the brushes outside the motor or remove the brush retaining screws and remove the brushes from the motor.128 .
Remove the drive end head retaining bolts or screws.Prestolite Disassembly (Cont’d.117 Commutator End Removed 4. if necessary. Figure 5. Figure 5. and the end head can be removed with very little trouble. Some of the smaller pump motors retain the drive end head with the motor through-bolts.118 Removing Drive End Retaining Screws 5.116 Removing Commutator End Retaining Screws NOTE: On motors that have a shaft extension on both ends of the armature. the attachment on the commutator end of the shaft must be removed before the end head can be separated from the motor.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor .) 3. Most motors have a slip fit bearing at the commutator end.129 . Remove the commutator end head retaining screws or bolts. Figure 5.
the armature or the drive spline usually has to be replaced. Separate the armature and drive end head. the end head and bearing will have to be removed with a puller. as an assembly. This operation is usually accomplished by pressing the armature out of the drive end bearing.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor . Figure 5. NOTE: When a puller is used. Figure 5.Prestolite Disassembly (Cont’d. from frame and field coil. On larger motors the bearing is retained with a snap ring.119 Removing Drive End Head and Armature 6. On some of the larger motors. protect the end of the armature shaft with a nut or a thick flat washer. coupling. If the shaft. then press the bearing out of the end head.130 .120 Removing Drive End Head With Puller 5. Separate the bearing from the end head. 7. Separate the armature from the drive end head. Se the figure on the next page. or spline is damaged when removing the end head. Use caution and do not damage the armature. Remove the snap ring.) 5.
122 Removing Fan 5. Figure 5.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor . Use a small propane torch to heat the area of the fan around the shaft. cast iron or cast aluminum.121 Removing Bearing Retainer 8. for the most part. There will be occasions when it will be necessary to remove ventilating fan and/or drive splines from armature shafts. Once these fans have been pressed onto the armature. A puller is installed and a slight pressure exerted against the fan. as evidenced by the puller becoming loose. When the fan becomes loose on the shaft. The ventilating fans are.Prestolite Disassembly (Cont’d) Figure 5.131 . they must be heated to be removed without damage. remove it as quickly as possible.
Submerging bearings in a solvent will deteriorate internal lubrication which cannot be replaced. 11. The armature should be blown off with compressed air to remove brush dust and dirt from around the commutator and windings.) 9.124 Removing Spline Cleaning Before any testing or inspection. Figure 5.123 Removing Spline Retaining Pin Figure 5.132 . the armature shaft must be cleaned to remove all of the old grease and any metal chips or filings. except bearings and armature. Press or drive the spline retaining pins out of the shaft and spline. 5.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor . Use a hammer and chisel or drift punch to drive the spline out of the shaft. 10. should be thoroughly cleaned with a good grade petroleum base cleaning solvent and dried with compressed air. Once the spline is removed. motor components. Bearings should be wiped clean with a cloth and never submerged in a solvent.Prestolite Disassembly (Cont’d.
Inspection After the motor components have been thoroughly cleaned and dried.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor . they should be inspected for the following: 5.Prestolite.133 .
MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Testing Motor Prestolite After thorough inspection. Most commercial growlers incorporate a test light.134 . open or shorted circuit. Test the Frame and Field Assembly as follows: Figure 5. Grounded and open circuits can be checked using a test light. the Frame and Field Assembly should be checked for grounded.126 Checking for Open Circuit 5.125 Checking for Grounds Figure 5.
we recommend using a Class F. pole shoe faces and end head seats to keep varnish off.135 .MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Prestolite Frame and Field Service Notes If the inside of the motor is exceptionally dirty and there is evidence of a grounding condition caused by the dirt. The connections should then be tinned with a soldering iron. Protect brush rigging. After field coil installation. Red glyptol can be used if a better material is not available. the inside of the motor can be given an additional coat of insulating varnish. Polyurethane air drying insulating varnish. connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint. Field Coil lnstallation Good solder connections are important due to the vibration characteristics encountered by these motors which can cause cold or poorly soldered connections to break. the connections which require soldering should be buffed or wire brushed clean to remove any oxidation. This method facilitates soldering and results in a stronger connection for added vibration protection. After the connection has been made. Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation. Before spraying field coils. NOTE: We do not recommend using a soldering gun or torch. align the coil straps and drill an 11/64" hole (#18 drill) through both straps. After tinning and installing the field coils in the frame. 5. however. Insert a #8-32 brass screw and nut or a brass pop rivet and solder the connection. This is readily available under various brand names from electrical repair or parts houses in aerosol type dispensers. NOTE: There is an optional method of connecting field coils which provides a mechanical connection before soldering. Continued next page. make sure they are absolutely clean and dry. Use a heavy soldering iron. check the clearance between it and the end head to prevent grounding the connection when the end head is installed. Before installing the field coils.
If the armature has been turned and undercut prior to testing.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Prestolite Frame and Field Service Notes (Cont’d. If the test light lights. This condition will cause an armature to check shorted and is usually caused from a dull undercutting tool. repaired or replaced. assemble the unit. Reassembly After the motor components have been thoroughly cleaned. NOTE: Figure 5. If a winding is shorted. Rotate the armature in the growler while holding the strip or blade over the armature so it passes over each armature core slot. check for and remove any copper buildup or fillings between commutator bars and at the commutator riser. the strip or blade will vibrate. tested.136 . the armature is grounded.127 Testing Armature Standard Wiring Connections These armatures are tested on a growler using a steel strip or hacksaw blade to locate any shorted windings. 5.) Armature Testing Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft.
137 . lockshft.gem Figure 5. Figure 5. Use “Loctite Retaining Compound 40" or equivalent on the inside of the fan hub when reassembling fan.128 Drilling Spline New splines have instructions calling out a dimension for spline installation. After the hole has been drilled through the spline.Prestolite Assembly If the spline has been removed a new one must be installed. Once the spline is removed. make sure it is a tight fit.MODEL NOR30/NOR30P: MAINTENANCE Motor . the armature shaft must be cleaned to remove all old grease and metal chips or filings. The new spline is pressed into the shaft and the retaininq pin hole is drilled through the new spline. When the fan is reassembled on the shaft. the armature and spline should be blown out using dry compressed air to remove all metal chips and filings.129 Fan Installation 5.
This is done to avoid excessive current draw and/or excessive free running RPM.End Head Installation Reassembly Reverse Disassembly Instructions to Reassemble.130 Typical Bearing . Testing NOTE: After assembly.Prestolite Assembly (Cont’d) Bearing Installation Whenever ball bearings are pressed into an end head or onto a shaft. Press on the outer race when installing into end heads and against the inner race when installing onto a shaft. the motor should be connected and tested as specified.138 . 5. When testing motors.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Motor . the voltmeter connections must be made at the motor terminals. Figure 5. always press against the race that is absorbing the pressure. Some motors are tested at voltage lower than (1/2 to 2/3) rated voltage of the motor.
139 .MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL ELECTRICAL Drive Motor Prestolite (24 Volt) Test Connections Test Specifications (@ 77°F/25°C) Test in both directions of rotation Viewed from Commutator End 5.
MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Lift Pump Motor Test (24 Volt) Test Specifications @ 77°F/25°C Lift Pump Motor Test Viewed from Commutator End (36 Volt) Test Specifications @ 77°F/25°C Viewed from Commutator End 5.140 .
MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER STEERING ENCODER The steering encoder is mounted behind the steering wheel. Figure 5.131 Electronic Steering Wheel Assembly 5. The figure below shows a cross section of the steering assembly and applicable service notes.141 .
MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER
Handling Printed Circuit Cards Observe the following when performing any adjustments or replacing a printed circuit card:
l l l l
DO NOT touch the gold fingers on the edge connector on any printed circuit card. The oil from your fingers can cause intermittent contact. If required, clean the edge connector using a soft pink pencil eraser. Wipe off any excess eraser particles using a soft, clean cloth. Connect the harness to the card before inserting card into the card cage. DO NOT push on the connector when inserting the card; the connector may be damaged. Push on the card ejector only. Turn truck power off before removing or installing circuit cards. Circuit cards containing CMOS devices SHOULD NOT be exposed to static electricity.
MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER
If the horn button requires replacement, removing the grip portion of the controller will save you time as you will not need to perform LEARN again. If the lift/lower thumb lever is removed for any reason, you MUST perform LEARN again before returning the truck to service.
Directional/speed Controller Removal From Vehicle
With power disconnected and console cover in operator’s compartment removed: 1. Remove connector JPC9 from the carriage wiring board. 2. Remove screws holding controller assembly to vehicle. Remove controller from truck.
Potentiometer Removal (VR1)
3. Remove screws holding cover (2). 4. Remove screws holding bracket (3). 5. Lift out VR1 along with bracket (3). The cable clamp on the outside of the housing (1) may need to be removed. 6. Remove old shrink sleeve from pot (VR1) terminals. Identify wires for reassembly. 7. Unsolder wires. 8. Remove gear (9). 9. Remove nut holding potentiometer to bracket (3).
If potentiometer is the only item being replaced, proceed to Step 4 of Assembly Procedure on the next page. 10. Remove cap screw securing gear (8) to shaft (5). 11. Support gear (8) with one hand and pull shaft (5) out with the other. 12. Shaft (5) and spring (7) may now be removed. Note quantity and position of any spocers. 13. If spring (7) needs replacement it may now be removed/replaced.
If spring is replaced, apply a light coat of lubricate (P/N 1056019) to new spring before assembling onto gear (8).
DO NOT BEND SPRING EARS - FATIGUE FAILURE MAY RESULT. 14. If oilite bearings (6) require replacement, press old bearings out and new ones in.
Bearings to be flush with inside of housing. Use gear (8) as a gauge to ensure proper distance between bearings.
MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER
Directional/Speed Controller Assembly 1. Install gear (8) and spring (7) into housing (along with any spacers previously removed). Position ears of spring (7) correctly around spirol pin in housing. (See Figure 5.132 and Figure 5.133) 2. Line up holes in housing (1) and gear (8) and slide shaft (5) into housing and gear. 3. Install cap screw to secure gear (8) to shaft (5). Turn shaft 90° in both direction to insure free movement. Push and pull on shaft (5), if excessive play is found, correct NOW. 4. Bend locating tab of potentiometer (VR1) down so it does not engage bracket (3). 5. Place potentiometer (10) into bracket (3). 6. Replace washer/nut on potentiometer and tighten only finger tight. 7. Slide new shrink sleeving (3/8" long) over individual wires. 8. Solder wires onto new potentiometer. 9. Shrink sleeving over terminals and solder joint. 10. Bend terminals over as shown. 11. Install gear (9) on potentiometer shaft. Set screw in aear should be away from potentiometer. Potentiometer shaft should be flush with end of gear (9). 12. Carefully place bracket and potentiometer back into housing. Specially formed teeth assure proper alignment of the gears. 13. Install screws into bracket (3). NOTE: Do not lubricate gears in controller assembly. 14. Connect a VOM to the wires between JPC9-7 and JPC9-8. 15. Wth the travel control handle in the neutral position, rotate the bocdy of VR1 until a reading of 650 +/-20 ohms is obhined. This is course adjustment. 16. Disconnect meter and reconnect wires back onto Carriage Wiring Board at JPC9. 17. Power up truck and enter test A3. 18. Rotate the body of VR1 until a reading of 2.50 +/-0.1 volts is on the Operator’s Display. This is the fine adjustment. 19. Tighten nut securing VR1 in bracket (3). 20. Ensure voltage measured in step 18 is still within tolerance; adjust if required. 21. Replace cover (2). 22. Reverse removal from vehicle instructions Steps 1-4 to install controller assembly back into vehicle. 23. Perform LEARN before returning truck to service.
145 . 132 Directional/Speed Control Assembly 5.MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER Figure 5.
Exploded View 5.133 Directional/Speed Control .146 .MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER Figure 5.
Remove set screws (1). 4. Perform LEARN mode. 5. See NOTE. Figure 5. Carefully slide thumb lever onto pot shaft. 8. ensuring that shaft is not turned from original position. If the potentiometer shaft is moved perform Test A4 to ensure that the voltage is correct. 6. Install new spring. NOTE: DO NOT rotate potentiometer shaft while thumb lever is removed.MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER Lift/Lower Return Spring Replacement 1.147 . Carefully pull thumb lever (2) straight off of assembly. 3.134 Lift/Lower Return Spring Replacement 5. Disconnect battery. Remove old spring. 2. carefully positioning spring ears around pin. 7. See CAUTION. CAUTION DO NOT BEND SPRING EARS. Tighten set screws (1 ) securely.
Slide shrink sleeving (3/8" long) over wires. 3. Continued next page. Loosen set screws from backside of thumb lever.148 . 7. Separate control handle halves. 2. Pull thumb lever off. Figure 5. Remove screws holding handle halves together. 5. Shrink sleeving over terminals.136 Lift/Lower Control Section 5. Unsolder wires from potentiometer. Remove pot from housing. Bend terminals over as close to pot body as possible. Solder wires to pot as shown below.135 Lift/Lower Control Assembly. 4. Potentiometer Wiring Figure 5.MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER VR2 Replacement 1. Disconnect battery. 6. 8.
locking pot tab into molded recess in housing 10. 11. Slide pot into housing.149 . Reassembly halves of controller handle. Perform LEARN mode.MODEL NOR30/NOR30P: MAINTENANCE STEERING ENCODER VR2 Replacement (Cont’d) 9. 5.
6. For best results. The beh tension does not need adjustment as it is preset by a spring. 1. Be sure the protective rubber boot is installed which prevents oil from entering and damaging the tachometer.137 Steering Feedback Tachometer 5. 2. If the tachometer support is disassembled. should not need any maintenance over the life of the truck. although belt tension could be adversely affected if the mounting brackets are bent. However. Replace the belt if there are any cracks or frayed sections. Stiffness of the cable jacket is enough to upset the operation of the tachometer. Figure 5. Do not secure the cable between the tachometer and the free-hanging quick disconnect terminals. 4.150 . This also prevents over-tightening of the belt which can damage the tachometer. replace the tachometer as a complete unit rather than trying to service it. 7. be sure to reassemble the spacer associated with the pivoting bracket and that the bracket moves freely. 3. care should be taken to ensure its proper operation.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL ELECTRICAL Steering Tachometer Assembly Maintenance The tachometer assembly. which is driven by the hydraulic steer motor. The tachometer brushes should never require service. 5.
care should be taken to ensure its proper operation. which is turned as the drive unit is moved from side to side. 1. 3.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Position Feedback Pot Assembly Maintenance The Position Feedback Pot Assembly. Make sure that the wires soldered on the pot cannot touch one another when installed.138 Position Feedback Potentiometer 5. apply Loctite (1036909) to threads then retighten. however. Figure 5. replace the Position Feedback Pot as a complete unit rather than trying to service it. 2. Be sure to tighten all mounting bracket and coupler hardware whenever the Position Feedback Pot Assembly is worked on. should not need any maintenance over the life of the truck.151 . If set screws are loosened. For best results.
Turn the drive unit so it is straight ahead. 5. Tighten coupler. NOTE: If Code 76 appears intermittently during normal operation. NOTE: If a new VR9 is being installed. Figure 5. Rotate coupler until Operator’s Display shows 4. set the pot initially to a rough setting of 6. End of Procedure. Refer to Figure 5. 6. See NOTE.152 . Check voltages as per Test A0: 7.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Potentiometer VR9 Adjustment Potentiometer VR9 is used on trucks with power steering. 8. It is important that the drive unit be as straight ahead as practical! 2. 3. (Turn coupler clockwise to increase voltage).1 volts.139 Adjusting Potentiometer VR9 (Power Steer Trucks Only) 5. See NOTE.139. 4. Run Learn.000 ohms.3volts. Enter Test A0. Loosen the coupler.4 +/-0. To adjust the voltage output from VR9: 1. 9. Exit test. set the voltage of VR9 more towards 4.
4. 2. This and all other instructions are written for using either a voltmeter or the wireguidance test/alignment box P/N 1056002 to do the adjustments.12 volts DC Figure 5. Figure 5.90 to 5. 1. the corresponding switch position is also given in brackets [ ]. An extender card P/N 1029620 is also available to make access to testpoints easier. the cards are arranged in the card rack in the following manner: Continued next page. or pot VR1 (WHEEL TRIM) cannot be adjusted enough when aligning wireguidance.153 . Turn keyswitch on and verify that all three Leds on the Power Supply Card are lit. This inclades vehicles with or without wire guidance.88 to 12. Connect a meter to each of the listed test points on the Power Supply card with respect to TP4 (GRD) and verify supply voltages: • TP1 . Proportional solenoid must be properly installed. the testpoints for connecting it are listed. the Position Feedback pot is replaced. An adapter P/N 1056001 is necessary in order to use the wireguidance alignment box with this system.141 Card Cage Layout 5.88 to 6.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Electronic Steering Test Procedure Initial Checks for All Vehicles The following information is applicable to all vehicles equipped with electronic steering. If the alignment box is used.140 Power Supply Card (Electronic Steer & W/G Vehicles) Initial Adjustments All vehicles must initially have the Position Feedback pot adjusted.10 volts DC • TP2 . As a reference. If a voltmeter is used.12 volts DC • TP3 . This procedure should only need to be done when the truck is first put together.11.5.
NOTE: Turning the drive unit while standing shil creates tension between the surface of the tire and the floor. This situation will cause degraded steering performance. Position the drive unit so that the truck travels straight while driving in manual. 1. Adjust the Position Feed back Potentiometer mounhng bracket so that the pot is concentric within 1/8" of the drive unit centerline. 5. or TP-3 on the Power Supply). This tension can rotate the drive unit when the auxiliary system is turned off. it can cause the output of the feedback pot to incorrectly indicate position if the drive unit should tilt. or an error condition of “Drive Unit Out of Range” when in wire guided mode. See NOTES. NOTE: If this adjustment is not done correctly. This would throw the drive unit out of position. Slight tilt of the drive unit will occur when accelerating/decelerating or when traveling over uneven floors. Improper adjustment can result in: • • • improper auto-centering during power-up the drive unit hitting a physical stop when turned. Connect a DVM (Digital Voh Meter) to TP-5 WRT (with respect to) Vr (TP-4 on the Solenoid Control card. Ensure that all hardware is tight when done. NOTE: Position Feedback Potentiometer Figure 5.142 Adjusting Feedback Potentiometer 2. See NOTE. This procedure should be done every 6 months or 1000 hours of operation or whenever the pot mounting bracket or flexible coupler are removed. This will assure that the drive unit is positioned correctly and it also releases any tension between the tire surface and the floor. 3.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Setting Position Feedback Potentiometer VR8 Adjusting the position feedback potentiometer is required so the steering system knows when the drive wheel is straight ahead. Attempting to positon the drive unit by sight will give in poor results. Continued next page.154 .
143 Solenoid Control Card 5. Loosen. 6. 5. full scale. NOTE: VR1 will not change the voltage that represents drive unit position at TP-3 or test/alignment unit switch position [WHEEL POSITION]. Figure 5. Set the DVM to a scale of approximately 2 volts.100 millivolts of zero (one minor division of the alignment box scale).155 . The voltage at TP-3 [WHEEL POSITION] should still be within +/.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Setting Feedback Potentiometer VR8 (Cont’d) 4. Adjust VR1 on the Solenoid Control card (WHEEL TRIM) until a reading of zero volts is obtained. See NOTE. but do not remove. Perform Learn mode. Connect a voltmeter to TP-3 [WHEEL POSITION] on the Solenoid Controller Card WRT to Vr (TP-4). 8. End of procedure. the Feedback Potentiometer hold down screws and rotate the pot until the meter reads as close to zero as possible. 7. Tighten the pot hold down screws.
See Figure below for an easy way to measure this. Turn power back on. and then step on the deadman pedal. When using the Digital Tester. Turn the drive unit fully left. Figure 5. and an LED OFF is equivalent to a “0” ( zero ). 4.156 . Read the Status Message in the Status Message Register of the Digital Tester. Continued next page. 5. Drive the truck at least ten feet without turning the steering wheel to release tire friction. The drive unit should be within 3 degrees of centered. It should read one of the following messages depending on the angular position of the drive unit: 3.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Operational Checks (For All Vehicles With Electronic Steering) NOTE: 1.144 Measuring Drive Angle 5. 2. shut off power for at least 5 seconds. Repeat steps 3 through 5 with the drive unit initially turned full right. an LED ON is equivalent to a “1” ( one ). The drive unit should turn to approximately straight (autocenter) within 1.5 seconds of stepping on the deadman pedal. Connect the Wireguidance Digital Tester P/N 1056020 to PW4 on Logic Card and turn the AUTO/MAN switch (if equipped) to manual.
The mechanical stop on the drive unit should be within 16°. Repeat this test for the drive unit turned fully right. 7. Verify that the audible alarm comes on. that the PC contactor drops out. The Status message should change to the following: 8. Verify the audible alarm comes on. Reconnect the harness to JPW3. The status message should change to the following: 10. Remove the short from the Power Supply. or JPS28 on the Vehicle Manager. 9. NOTE: END OF TEST FOR NON-WIREGUIDED VEHICLES. and that the brake is applied. 5. Continue to next page for vehicles equipped with wire guidance.0") of hitting the frame stop without hitting it. drive the truck a short distance without turning the steering wheel back. Disconnect the harness connected to the Solenoid Control Card at JPW3. Verify that the audible alarm comes on. Reconnect harness.157 .MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Operational Checks (For All Vehicles With Electronic Steering) (Cont’d) 6. Short circuit TP3 to TP4 on the Power Supply card with a jumper clip. With drive unit turned full left. 11. and turn power off and then back on to clear the error condition. (2. Turn power off and then back on to clear the error condition. Disconnect the cable marked JPC12 on the carriage wiring board. The Status message should change to the following: 12.
The Status message should change to the following: Verify that the: audible alarm comes on truck will still steer in manual mode truck speed is limited to slow speed. When the sensor gets close to the wire. the truck should attempt to align itself over the guidewire. 2. When all of the lights in the Deviation register go out. At this point.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Complete the Operational Checks on the previous pages before proceeding. Drive the truck toward a guidewire at approximately 15°. the: audible alarm goes off truck will no longer steer manually. Drive the truck to a position away from any guidewire and switch the AUTO/MAN switch to automatic.158 . Operational Checks Wireguided Vehicles Only 1. and Status Message should change to the following: 3. the Locked-On-Wire light should come on and the Status Message should change to one of the following messages depending on the frequency being used: Continued next page 5.
The Status Message shouid change to the following: 5. 8. 7. 6. shut the Line Driver off. with the first coming on at approximately 1-1/4 inch and the second at about 2 inches. 9. Turn the drive unit completely to one side and rotate the truck over the wire while observing the Leds in the deviation register of the Digital Tester. 5. Drive the truck along the wire so that it gradually moves away from the wire. The Leds in the Heading Limit side shouid come on in sequence with the first LED coming on at approximately 1.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Operational Checks Wireguided Vehicles Only (Cont’d) 4. Return truck to approximately parallel to the wire and turn the drive unit so that it is straight.159 . The audible alarm shouid turn off whenever the second LED in either the Heading or Displacement Limit section of the Deviation register turns on. Observe the Leds in the Displacement Limit side of the deviation register. switch the AUTO/MAN switch to manual. Verify that the audible alarm comes on. Reconnect the Line Driver.5° to the wire and the second LED coming on at approximately 3°. End of procedure. the audible alarm should come on. With the truck locked on wire. With the truck locked on wire. These Leds should also come on in sequence.
2.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Wire Guidance Test Procedure Initial Checks Before making any adjustments to the vehicle wire guidance system. This can be verified through Configure mode. Note that if the wire frequency is changed. perform the following: 1.160 . Verify that guidewire frequency is correct and that the guidewire current is adjusted correctly. Continued next page 5. 3. Ensure that the correct wire guidance frequency has been selected. the preamp in the wire guidance sensor must be changed to match the new frequency. Check that the proportional valve and guidance sensor are installed and functioning properly.
Connect a meter to each of the test points on the Power Supply card with respect to TP4 (grd) and verify supply voltages.) 4. Figure 5.146 Power Supply Card 5.161 . Verify that all three Leds on the Power Supply card are lit.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Wire Guidance Test Procedure (Cont’d. Turn the keyswitch on.
An Extender card (1029620) is available to make the listed test points more accessible. Refer to page 5. whenever any component of the guidance system is changed (Filter card. care must be taken to prevent damage to it because the voltages to be measured can be of either polarity. The truck dynamic adjustment is the fine-tuning procedure. Static Adjustment The truck static adjustment is the initial set-up procedure of the guidance system. Adjusiments are done by observing the truck moving back and forth over a guidewire. 5. but it should be a quality unit in proper working order.162 . This section is also written two different ways depending on whether an alignment track is available or not. An adapter P/N 1056001 is necessary in order to use the wire guidance alignment box with this system. See CAUTION. the corresponding switch position is also given in brackets.154. [ ]. and the adjustments are done with the truck standing still. All procedures are written for using either a voltmeter or the wire guidance alignment box P/N 1056002.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Wire Guidance Alignment The wire guidance alignment procedure is divided into the following sections: • vehicle static adjustments • vehicle dynamic adjusiments • optimizing wire guidance performance Adjustments to the feedback potentiometer are only required when the feedback po tentiometer is replaced or VR1 on the Solenoid Controller card cannot be adjusted enough. See Figure 5. Preamp. Dynamic Adjustment CAUTION DO NOT REMOVE OR INSTALL CARDS WITH THE POWER ON AS THE CARDS MAY BE DAMAGED. every 6 months or 1000 hours of operation or whenever necessary to improve the tracking accuracy of the vehicle. This procedure should always be done following the static adjustment procedure. It is highly recommended that an alignment track be used as it makes the adjustments easier and more effective. where the guidance system is adjusted to meet the needs of the vehicle. Processing card.147. or whenever the dynamic adjustments are not sufficient to get the truck to guide adequately. If an analog meter is used. Any good voltmeter can be used. This procedure shouid be done when the truck is first put together. or Wire Guidance sensor). If the alignment box is used.
MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Wire Guidance Cards NOTE: The wire guidance cards are arranged in the card rack as follows: The Filter Card and Processing Card are used strictly for wire guidance.148 Wire Guidance Circuit Cards Figure 5.163 . Figure 5.147 Wire Guidance Alignment Box w/Adapter 5.
and all measurements are with respect to TP14 when using a voltmeter. and is within 1/8" of being centered between the baselegs or load wheels. End of Static Adjustment Procedure without an Alignment Track. Read the voltage at TP-5 and the readjust R120 ( LOAD AGAIN ) until the meter reads one-half this value.164 . DO NOT readjust R120 ( LOAD GAIN ) for any reason. USE A CHAIN HOIST ATTACHED TO THE OVERHEAD GUARD OR OTHER ADEQUATE MEANS TO SUPPORT CARRIAGE WHILE WORKING UNDERNEATH. Connect meter to TP-5 [ HEADING ANGLE ] and adjust R124 ( TRACTOR OFFSET ) until the meter reads zero. but in all cases the sensor must be kept os parallel to the wire as possible. Be sure to observe the polarity of the voltage! The static pot adjustments are now complete. All pots mentioned in this section can be found on the Processing Card. See NOTE. 3. Adjust the sensor so that it is level within 1/8". Position the sensor so that it is approximately 3-1/2" to one side of the guidewire and as parallel to it as possible. Either the wire or the sensor can be moved to get the desired relationship. Truck Static Adjustments W/O Alignment Track 5. Read the voltage at TP-5 [ HEADING ANGLE ] and adjust R120 ( LOAD GAIN ) until the meter reads zero. 1. between 1-1/4" to 1-3/4" above the floor. 4. 2. Position the sensor so that it is directly over the guidewire and as parallel to it as possible. Position the sensor so that it is approximately 3-1/2" to the opposite side of the guidewire and as parallel it is possible.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Truck Static Adjustments The static adjustment consist of moving the sensor position relative to the guidewire so that various parts of the wire guidance system can be matched. NOTE: If either potentiometer runs out of adjustment. try rotating the sensor SLIGHTLY over the guide wire and repeat stops 2 through 4.
165 . The static pot adjustments are now complete. 4. DO NOT readjust R120 (LOAD GAIN) for any reason.3/8") and is as parallel to it as possible. Set the track to the center wire and adjust R124 (TRACTOR OFFSET) so that TP5 [HEADING ANGLE] is zero volts. Set the track to the center wire and readjust R124 (TRACTOR OFFSET) so that TP5 [HEADING ANGLE] is zero volts. 5. End of Static Adjustment Procedure using alignment Track. Be sure to observe the polarity of the voltage! 6. Set the track to either outside wire and adjust R120 (LOAD GAIN) so that TP5 [HEADING ANGLE] is zero volts. Position the truck so that it is centered over the alignment track (+/. between 1-1/4" to 1-3/4" above the floor. USE A CHAIN HOIST ATTACHED TO THE OVERHEAD GUARD OR OTHER ADEQUATE MEANS TO SUPPORT CARRIAGE WHILE WORKING UNDERNEATH. Adjust the sensor so that it is level within 1/8". try rotating the sensor SLIGHTLY over the guide wire and repeat steps 2 through 6. 3.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Truck Static Adjustments WITH Alignment Track 1. Set the track to the opposite outside wire and readjust R120 (LOAD GAIN) so that TP5 [HEADiNG ANGLE] is one-half its value.149 Example of an Alignment Track 5. See NOTE: NOTE: If either potentiometer runs out of adjustment. of being centered between the baselegs or load wheels. and is within 1/8". 2. Figure 5.
BE SURE THE VEHICLE’S PATH IS CLEAR! NOTE: Best results can be obtained by accelerating up to at least half speed and allowing the truck to coast to a stop in each direction. NOTE: 4. 3. If sensor tracks offset to the guidewire at the same point in each direction. DO NOT attempt to adjust R120 (LOAD GAIN) when using this procedure. Read the following notes. If the vehicle moves to the RIGHT when traveling tractor end first and to the LEFT when traveling load end first. Observe the tracking of the vehicle at the sensor as the truck is driven up and down the wire. adjust pot R124 (TRACTOR OFFSET) until the sensor tracks at the same point relative to the wire in each direction. This can be done by observing the sensor directly or by measuring the signal at TP-12 [DISTANCE FROM WIRE] with respect to TP-14 on the Processing Card. If the sensor moves to different lateral(side-to-side) positions relative to the wire when driven forward verses reverse. and/or braking to a stop can give misleading indications of adjustment. NOTE: RIGHT and LEFT does not necessarily mean that the truck is actually to the right or left of the wire. which can be found on the Solenoid Controller Card. Plugging. 1. The drive tire cannot be used as an indication of adjustment. Ensure the wire current is properly adjusted. End of Wire Guidance Dynamic Adjustments 5. Turn VR1 IN (clockwise) to make the vehicle move to the RIGHT relative to the wire. All pots can be found on the Processing Card except VR1 (WHEELPOS) pot. Acquire a straight section of guidewire. hard accelerations. turn R124 OUT (counter-clockwise). 2.166 . This procedure should be done every 6 months or every 1000 hours of operation.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Truck Dynamic Adjustments The dynamic adjustment procedure is a fine tuning of the adjustments done in the static procedure. The truck should be driven at least 20 feet in each direction to give it time to settle into its new position relative to the wire. just that it moves right verses left for the direction indicated. If the sensor cannot be centered. adjust VR1 (WHEELPOS) on the Solenoid Controller Card until the sensor tracks directly over wire. recheck the Position Feedback Pot adjustment or the sensor position. Sensor position is what is important.
The sensor’s electrical centerline is probably not the same as the sensor’s physical centerline due to component tolerances.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Optimizing Wire Guidance Performance This section details how to reduce the amount of offset used in the adjustment of a Wire Guidance system. You cannot see the truck’s steering centerline. This procedure only needs to be done if the truck will guide properly only in some aisles. The only way to tell if the sensor’s electrical centerline matches the truck’s physical centerline is to watch the truck guide up and down the wire. If the truck tracks at the same point laterally (side-to-side) to the wire in each direction of travel. This is the same as if the signal from the floor was to vary for some reason and can affect the adjustment of the system. the balancing act is upset and the system will go out of adjustment. the centerlines match. Reasons for Optimizing a Wire Guidance System The OFFSET pot adjustment is provided as a convenient method for matching the sensor electrical centerline with the truck steering centerline. Opoimum tracking will be achieved when zero electrical offset is used. If the guidewire current changes. The truck’s steering centerline is probably not the same as the truck’s physical centerline due to manufaduring tolerances. the truck can only be adjusted for certain points on the floor or only for certain aisles. These problems occur because this adjustment is a balancing act between two things: a constant that you input with the offset pot. (Note: This does not necessarily mean centered over the wire. If the floor signals vary. The signals received by the sensor will actually increase as the platform is lowered because the platform will distort the magnetic field. It is important to note the following points: • • • • • You cannot see the sensor’s electrical centerline. or possibly if frequent adjustments are necessary. and the signals received from the floor. the carriage comes down close over the sensor. 5. • • • • Continued next page.) Floor signals tend to vary quite a bit between aisles or even in any given aisle. On orderpickers. It is intended to only be a fine-tune adjustment because using an excessive amount of offset causes the following problems: • • If the floor signals vary.167 . the truck will be out of adjustment. The offset adjustment is roughly equivalent to rotating the sensor’s eledrical centerline.
1.5 volts or less than -1. Continued next page. Measure the voltage at the wiper of the TRACTOR OFFSET pot with respect to Vr: • TRACTOR OFFSET is R124 on Processing Card and • Vr is TP-14 on Processing Card. Adjust the offset pot until this voltage is zero volts. 3. 2. Put truck on wire.150 Adjusting Guidance Sensor Procedure 1. NOTE: The wiper is always the center terminal of the pot. This will align the truck steering centerline with the wire. Ideally this voltage would be zero. Measure Heading Angle TP-5 on Processing Card WRT TP-14 (Vr). complete the following steps: See figure next page. 2. 5. and coast to a stop. Figure 5.168 . If the Offset voitage is greater than + 1. This will be done by adjustment of the sensor in its mounting bracket as shown in the following figure. Electrical OFFSET Reduction Procedure This procedure will physically position the sensor so that the centerline of the sensor and truck match. accelerate to at least half speed. To determine if this is the case.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Optimizing Wire Guidance Performance (Cont’d) Determine How Much OFFSET is Being Used This procedure will only help if a large amount of offset is being used by a vehicle. Do not reverse direction. Measure the voltage at the OFFSET pot (R124) wiper. then this procedure can help improve the performance of the Wire Guidance system. Do a complete static and dynamic adjustment of the vehicle. 3.5 volts.
Pivot bracket to center sensor between baselegs.169 . 10. 7. Loosen mounting bracket bolts holding bracket to truck. 5. Perform dynamic adjustment procedure. 6.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Optimizing Wire Guidance Performance (Cont’d) Electrical OFFSETReduction Procedure (Cont’d) 4. 8. Rotate sensor until Heading Angle indicates zero. End of procedure Figure 5. Tighten the mounting bracket screws. Ensure sensor remains level.151 Card Cage Circuit Cord Arrangement 5. 9. Loosen bolts holding sensor to its mounting bracket. Tighten sensor mounting bolts.
the capacitors were charged to the voltage level of the test meter. This prevents signals appearing at the cathode (-) from feeding back into the anode (+) (control) circuits. replace the assembly. Repeat step 3. If DA6 continues to fail this test.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Diode Assemblies Diode assemblies stop current in one direction and allow it to flow in the other direction. Disconnect one lead from the meter and attach the positive lead to 6 and the negative lead to 1. 2. Watch the needle on the meter carefully. Procedure CAUTION DA6 Note that the following test for DA6 assumes that a Simpson 260 VOM meter is used. Replace any module failing any part of a test. Attach leads from meter so the positive lead is attached to 2 and the negative lead is attached to 4. as described above. DO NOT ATTEMPT TO TEST DIODE ASSEMBLIES WHILE THEY ARE CONNECTED TO THE CIRCUIT. Do not omit any check.170 . the needle will momentarily jump as the capacitor discharges through the meter. perform the following checks. To check the capacitors within the circuit proceed as follows: When the diode portion of the circuit was tested in DA6. Disconnect one test lead at the ohmmeter. If the needle does not move. 1. 3. 4. When the disconnected lead is reattached to the meter. 5. the needle on the meter should jump again. Using a Fluke 8060A volt/ohmmeter or equivalent. complete the entire test once again to ensure that the capacitors were in fact charged.
171 . If a coil is suspected to be bad. swap it for another coil driver in a circuit which functions properly.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Coil Driver Test The coil drivers used on this vehicle are all identical. Revised 12/15/92 5.
If a cone and crater appear. • Burning means loss of contact point material or droplets of molted con• tact material being displaced. compressed air (maximum 30 psi). do not use sandpaper or emery cloth.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Contactors General Cleaning Clean and inspect contactors regularly to help ensure their proper operation. • Do not file contact points to remove discoloration or minor irregularities this is wasteful and produces a surface more susceptible to sticking. and other foreign materials from contactors with dry. in the opinion of the Maintenance department. • Remove dust. THE ONLY REPLACEABLE COMPONENT OF THE CONTACTOR ASSEMBLY ARE THE CONTACTOR TIPS. filtered. See the Scheduled Maintenance in this manual for the suggested service interval. there is not enough contact point material to last until next regular inspection. insulation or contact guards • stripped threads • other obvious damage. remember • Darkening of points does not indicate burning. remove the cone only with a file. • The contact may be used until the material is almost completely gone. dirt. Visually inspect all parts for: • nicks • broken or damaged leads • broken terminals or springs • burned contact tips • cracked or deteriorating bushings. THE ENTIRE CONTACTOR ASSEMBLY MUST BE REPLACED Guidelines When inspecting contactors.172 . Inspection 5. Wear safety glasses. • The silver alloy part of the point is usable contact material. • Replace the contact points if. • Use a cleaning solution on a clean cloth to remove stubborn dirt if necessary. IF ANY OTHER SEGMENT OF THE CONTACTOR IS FOUND TO BE DEFECTIVE. the copper backing is not.
test the coil with an ohmmeter as outlined on Page 5. The contractors used in the orderpicker are all Contact Industries brand contactors. Revised 12/15/92 5. The table below lists and identifies the specific contactors: Coil Test If you suspect a defective contactor coil.176.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Contractors Specific. before you replace the contactor.173 .
If a stud mounted Rectifier is to be mounted.174 . nicks and the plate is flat so that the insulator is not penetrated when the mounting screws are tightened on the heatsink assembly. Immediately after surface is prepared. Scott As sembly . Clean off any pad remnant by using a lint-free tissue (e. Ensure there are no burrs. Assemble heat sink and prepare each semi-conductor mounting surface time. Check to make sure each surface that the Rectifier’s mount is spot-faced and the spot-face is flat or the entire top surface has at least a 63 surface finish. DO NOT GET ANY ON THE THREADED PORTION OF THE SEMI-CONDUCTOR.Wipes). the semi-conductor must be installed. 2. 3. lightly rob the mating shoulder with the Scotchbrite pad and apply a thin coating of P/N 1050492 (Thermal Com pound).g. 7447 or equivalent until oxide is removed. Kimberly Clark KIMWIPES.MODEL NOR30/NOR30P: MAINTENANCE ELECTRICAL Rectifier Torque Ratings and Installation Preparation Procedure of Power Transistor/Rectifier and Heat Sink Block 1. 5. 2. Rub the mounting surface to where the Rectifier is to be installed with 3M Scotchbrite Pad No. 5.
OB. test the Chopper Module BEFORE installing the new Power Transistor! CAUTION Replace REC1 only if it fails any static tests (open or shorted). If the readings are not as specified replace the Power Transistor. Figure 5. A2. See NOTE. If the Power Transistor is found to be defective. connect a DVM to the points specified to test the Power The values shown below were measured using a Fluke 8060A digital voltmeter. ensure that all leads are disconnected and clear from the device. The Power Transistor shouid be at room tempera ture. and OD 5. 16. the Chopper Module is assumed Chopper to be OK. it is safe to assume that the Power Transistor is defective. 17. NOTE: Before testing the Power Transistor.MODEL NOR30/NOR30P:MAINTENANCE ELECTRICAL Power Transistor (Q1) Test Relering to the figure below. higher or lower temperatures will affect the readings.152 Test Points for Power Transistor Q 1 Chopper Module Test If the Chopper Module passes the following tests. If the Power Transistor resistance reading is less than 10 ohms from E to C or C to E.175 . The tests are: A1.
The ohmmeter.MODEL NOR30/NOR30P:MAINTENANCE ELECTRICAL Testing Other Electrical Components The table below gives the recommended test procedures for electrical components not previously covered. will indicated most shorted or open circuited conditions. 3. Connect meter from B to A: • resistance shouid be greater than 1 megohm If the Power Transistor has shorted. Remove device from circuit. 2. CAUTION REC1/REC2 Test The following test should determine if the rectifier in question is good in the static condition. The readings do not absolutely mean components checked will function properly in the system under different current and voltage conditions. however. The checks are all made by the use of an ohmmeter (Fluke 8060A or equivalent). Set meter to diode scale: • Reading should be between . 1.7 volts.5 to . replace REC1 regardless of this test! 5. 4. Connect Digital voltmeter from A to B. DISCONNECT THE COMPONENT FROM THE TRUCK FOR TESTING.176 .
).MODEL NOR30/NOR30P:MAINTENANCE PASSWORD LEVELS PASSWORD LEVELS Two password levels are used with Micro Command NA . see discussion below. If the code is lost or forgotten. Instructions for entering or changing the PASSWORD or SUPERWRD password are also included in this section. PASSAWORD SUPERWRD It is strongly recommeded thot the SUPERWRD be changed from the factory default of CAT2 to something else during installation so access to programming is limited to qualified personnel. Only qualified service technicians should have access to SUPERWRD.. etc.. SUPERWRD allows access to all program levels available. Speed. SUPERWRD. they are: • PASSWORD and . PASSWORD. 5. see discussion below. This would require all the variable settings to be reset (i. it will be necessary for a technician to reset the truck to factory default settings. All trucks leaving the factory will have a PASSWORD of “CAT1”. it is very important to remember the unique SUPERWRD code that has been entered and saved. Specific instructions for the correct procedures are described in Program Mode. Instructions for using CONFIG are outlined in Program Mode. All trucks leaving the fadory will have a SUPERWRD of “CAT2”.. With that in mind. • SUPERWRD PASSWORD allows access to Configure mode only.177 . Drive.e.
SUPERWRD must be used..178 . To access LEARN. To access MAiNT. the SUPERWRD must be used. Configure Mode Configure mode is used to adjust vehicle performance to specific customer requirements. Perform LEARN Mode before attempting to configure the truck. use PASSWORD. Refer to page 5.184.. Learn mode (LEARN) Maintenance mode is used to test and troubleshoot individual circuits related to Micro Command NA. Learn Mode (LEARN) 5. To access CONFIG. Refer to page 5.e.. throttle and lift/lower potentiometers). (i.182.MODEL NOR30/NOR30P:MAINTENANCE PROGRAM MODE PROGRAM MODE Program mode is used by maintenance personnel to access: • • • Maintenance Mode (MAINT) Configure Mode (Config) Maintenance mode (MAINT) Configure mode (CONFIG) and. Learn mode is used to calibrate the operator’s controls and the external sensors.
. move the speed control towards the tractor. 3.179 . Move the lift control to lift and hold. 9. 4. Move the control to lift to scroll throuch the numbers then letters (1. The flashing of the segment indicates that it is active 7. The Operator’s Display will show eight (8) blank spaces 6. . 2. move the speed control towards the forks.. 8. If an invalid Password or Superword was used the Operator’s Display will show: Invalid Code. When the segment you want is active (flashing).. Depress and hold the horn button in. Entering the Password will take you to the Configure menu. 1. The left-most segment is flashing.x. 3. y. 10.Try Again.. NOTE: 5. To move the cusor to the left. The correct Password or Superword MUST be correct before the system will allow you to proceed. 4. z). depress the horn but ton. Only the Superword will allow the use of Learn Configure and Maintenance Modes. When the correct Password or Superword is on the display. To move the cusor to the right. 1).. Turn the keyswitch Off.. Turn the keyswitch On. x. 2. 5.4. Continued next page. See NOTE. 2. y. Repeat steps 7 and 8 until the correct Password or Superword is on the display. move the lift/lower control to lower to scroll through the letters then numbers (z..MODEL NOR30/NOR30P:MAINTENANCE PROGRAM MODE Entering Program Mode Entering Program This procedure details how to enter Program mode. 3.
Figure 5. 5.MODEL NOR30/NOR30P:MAINTENANCE PROGRAM MODE Entering Program Mode (Cont’d) Numbers and letters will be displayed in each segment in the order shown below when the Lift/Lower control is moved to Lift.. then repeats.153 Operator Display for Program Mode (Example Only) Continued next page..180 .153 Operator Display for Program Mode (Example Only) Figure 5. Moving the control to Lower scrolls the information in the opposite direction.
VFC-SU. depress the horn button.GEM Figure 5. If “QUIT” is the desired menu selection. VFC-1.GEM Figure 5. Manager in Configure Mode 5. then depress the horn button. “CG” will be displayed on the VFC. When the correct code for SUPERWRD is entered.154 VFC indicating SUPERWRD has been entered 12. Configure mode submenus are described on pace 5. depress the horn button to enter Maintenance Mode. the Operator’s Display will remind the service technician to jack the drive tire off the floor and to open the emergency lowering valve while in maintenance mode.181 .154. If “CONFIG”. “QUIT” will appear as the first selection. “SU” will be displayed on the VFC until a selection is made from the menu on the Operator’s Display. If “MAINT” is selected. If the correct code for PASSWORD is entered. “Quit Cfg” will be the first selection on the Operator’s Display.184. use the Lift/Lower control to get to that menu.155 Vehicle. “LEARN” or “MAINT~ is wanted. see Figure 5.MODEL NOR30/NOR30P:MAINTENANCE PROGRAM MODE Entering Program Mode (Cont’d) 11. When “READY” appears on the Operator’s Display.
When all Learn instructions have been completed. 5. and steer pot (VR8 or VR9). Instructions will repeat until they have been completed. Scroll (lift/lower) through the menu until “LEARN” is displayed. After entering the SUPERWRD.the alarm will “beep” indicating that you are in LEARN mode. Learn instructions will vary slightly between vehicles with different options.MODEL NOR30/NOR30P:MAINTENANCE LEARN MODE LEARN MODE Review instructions for Program mode (if required) before proceeding. (i. VFC-LEARN.. lift/lower potentiometer (VR2). On the next page is an example of a completed Learn procedure.e.GEM Figure 5. LEARN mode is used to calibrate the operator’s controls and extemal sensors. Review instructions for Program mode (if required) before proceeding. the system will automatically reset and SelfTest will complete.. “QUIT PGM” will be on the Operator’s Display.. throttle (VR1).182 . then depress the horn button firmly.156 Learn ModeFigure 5. This will continue until all required components are “Learned”. The VFC display will appear as shown below. After the VFC is satisfied that the instructions on the Operator’s Display have been followed.156 Learn Mode Follow the instructions as they appeor on the Operator’s Display. the alarm will beep and the next instruction will appear.
MODEL NOR30/NOR30P:MAINTENANCE LEARN MODE Learn Mode Example 5.183 .
Depressing the horn button will select the item currently being displayed and return you to the main menu. To change the access code: 1. To reinstate the factory default settings: 1. When the new code is on the display. Enter the new code using the lift/lower and speed control. Continue moving the lift/lower control until the name of the menu name you want to modify is displayed. After entering the SUPERWRD. Default setting are indicated in the following tables by asterisks (*). Select “Save?” to save the settings. then depress the horn button. The display returns to the main menu. Select SUPERWRD or PASSWORD from the main menu using the lift/lower control. move the Lift/Lower control in either direction. Selecting “Save? Y” saves the changes you have made and exits CONFIG Mode. simply select “Save? N” and depress the horn button. 5. Each time the lift/lower control is moved to lift. 5. 2. Rotate the Lift/Lower control until “CONFIG” is on the Operator’s Display. Changing the Access Code Both the PASSWORD and SUPERWRD may be changed to any combination of letters. depress the horn button. The minimum is one (1 ) character. If your truck does not have one or more of the listed options they will not appear as a selection on the Operator’s Display. the maximum is eight (8). To make another selection or change. this will take you into the sub-menu for the item selected. 6. Depress the horn button. Return the control to neutral when the desired item appears. See NOTE: NOTE: If after modifying CONFIG. “QUIT PGM” will be displayed. Selecting and saving DEFAULT resets all variable values to factory settings. select Quit Cfg from the main menu and depress the horn button.184 . then depress the horn button. To save changes made in CONFIG. the selection advances one item in the menu. you change your mind. Enter Configure mode using current SUPERWORD. Currently selected values appear in the sub-menu first. 3. Select DEFAULT from the main menu and depress the horn button. Save? N exits Configure mode without saving any of the changes made. numbers and/or spaces you decide. then depress the horn button. 4. 2. The table on the next page outlines all menus and sub-menus available in CONFIG. All possible truck configurations and options are listed in these instructions.MODEL NOR30/NOR30P:MAINTENANCE CONFIGURE MODE CONFIGURE MODE Review instructions for Program mode (if required) before proceeding.
SUPERWORD menu only appears if CONFIGURE mode was entered using SUPERWORD 2 *Denotes Factory Default setting.MODEL NOR30/NOR30P:MAINTENANCE CONFIGURE MODE Configure Mode Standard Features Continued next page. Entered through SUPERWRD.185 . Revised 12/15/92 5. 1 XXXXXXXX are password variables entered by the individual using Configure mode.
MODEL NOR30/NOR30P:MAINTENANCE CONFIGURE MODE Configure Mode Optional Features (Cont’d from previous page) *Denotes Factory Defaulting setting 1 Only available through SUPERWORD with CUTOUT option 5.186 .
178 for information on procedures for accessing Maintenance mode. the display will appear as shown below. When “READY?” appears on the Operator’s Display. always jack the drive tire off the floor and open the Emergency Lowering Valve.MODEL NOR30/NOR30P:MAINTENANCE MAINTENANCE MODE MAINTENANCE MODE Maintenance mode allows the service technician a means of testing individual circuits within the Micro CommandNA system. NEVER BLOCK THE TRUCK BETWEEN. REFER TO PAGE 5.157 VFC shown in Maintenanre Mode During Maintenance Mode. Detailed. Figure 5. Maintenance mode is accessed through Program mode after the SUPERWRD is entered.DO NOT RELY ON JACKS. Refer to Program mode on page 5. After selecting MAINT has been selected from the menu. If “MAINT” is selected. THE TELESCOPIC AND THE FLOOR. step-by-step prodedures for each test are in Chapter 6. 5. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT TRUCK . the Operator’s Display will remind the service technician to jack the drive tire off the floor and to open the emergency lowering valve while in maintenance mode.187 . KEEP HANDS AND FEET CLEAR FROM BENEATH THE VEHICLE WHILE JACKING. See WARNING USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON.15. depress the horn button to enter Maintenance Mode. USE A SUITABLE HOIST TO STABILIZE THE MAST.
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