If items 15 and 16 were separated, clean threads on piston plug (16) using Loctite primer (6V1541). Then apply Loctite (1056016)to threads.
Tighten using a strap wrench only.
Pressure test cylinder in less than fully extended position at 4500 psi.
Plug fitting opening to prevent foreign matter from entering cylinder.
l l l l l
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Center Lift Cylinder 1. Disconnect battery.
Removal (3-Stage)
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.
Center Lift 1. Remove snap ring (1) and oil seal (2).
Cylinder Service
(3-Stage) 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)
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Center Lift 10. Do not separate piston (13) from piston plug (14) unless absolutely necessary. If Cylinder Service disassembly is required, use a strap wrench only. Do not mar piston surface.
(3-Stage)(Cont’d.)
NOTE: 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 re-moved using fine emery cloth.
3. Inspect all parts; replace as required.
Center Lift 1. All packings and O-rings (except O-ring, item 15) to be dipped in new, crean sys-Cylinder (3-Stage) tem hydraulic fluid before assembly. (See Figure 5.72 & Figure 5.73)
Reassembly
2. Lubricate inside of cylinder housing using clean, system hydraulic fluid.
3. Reassemble cylinder by reversing disassembly procedure, noting the following:
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.
l
l
l l
Lift/Lower Valve The following a adjustment procedure is for trucks equipped with variable Lift/Lower
Adjustment manifold,
2-Stage Mast (P/N )
1. Install a calibrated pressure gauge (3000 psi) in test port G1.
2. Back-out high pressure relief (2).
3. Check to see that the manual lower valve (3) is closed (hand tight only).
4. Chain the mast telescopic sections together in the collapsed position.
5. Adjust the high pressure relief (2) to 100 psi over lifting pressure during lift with a capacity Ioad.
2STG-VLV.GEM
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Lift/Lower Valve The following adjustment procedure is for trucks equipped with a 3-stage mast.
Adjustment 3 Stage Mast
1. Install a calibrated pressure gauge (3000 psi) in test port G1.
2. Back-out high pressure relief (2).
3. Check to see that the manual lower valve (3) is closed (hand tight only).
4. Chain the mast telescopic sections together in the collapsed position.
Figure 5.75 Lift/Lower Valve Assembly (3 Stage Mast)
5. While someone is holding the lift controller in the Lift position, slowly increase the relief pressure (2) until the carriage starts to lift. While observing the pressure gauge, increase the pressure to 2300 psi.
6. Remove chain installed in step 5.
7. Readjust the high pressure relief (2) to 100 psi over lifting pressure during lift with a capacity load, in the upper stage of lift.
3STG-VLV.GEM
Replacement of If the proportional lift/lower valve must be replaced or removed, use the following Proportional Valve procedure (refer to Figure 5.76):
Cartridge on
Manifold 1. Cleanliness around the valve which is going to bee removed cannot be over em-phasized.
2. After the valve is removed, inspect the sealing surface for contaminants. Clean the surface as needed, ensuring foreign material does not go into the valve body.
3. Lubricate the o-ring using clean hydraulic fluid.
4. Thread the valve into the valve body.
5. Tighten the valve cartridge 1/2 turn, then loosen 1/4 turn. Continue with se-quence until a torque value of 120 - 150 inch Ibs. is achieved. Tightening the valve in this manner reduces the chance of damaging the seal.
6. This valve requires no bleeding.
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Bleeding Lift The lift cylinder should be bled after maintenance has been performed on the lift hy-Cylinder draulic system or when operation indicates that air has entered the system. A
bounc-ing carriage is one indication that bleedbounc-ing may be necessary.
Procedure 1. Raise the carriage approximately 6" then loosen the bleed screw on top of the inder. See NOTE.
NOTE: On short vehicle, remove button plugs on each side of mast guard to gain access to bleed screws.
CAUTION
THE BLEED SCREW SHOULD ONLY BE LOOSENED ENOUGH TO ALLOW THE AIR TO ESCAPE.2. When only oil flows from the cylinder, tighten the bleed screw.
Figure 5.77 Lift Cylinder Bleed Screws
Steering Torque Before disassembling the torque generator, note location of the mounting holes.
Generator Removal This is important for correct reassembly. Cleanliness is extremely important in repair (Mechanical Power work. Seal all open ports and thoroughly clean the torque generator before begin-Steering) ning any repair work.
1. Disconnect battery.
2. Remove cover from front of power section.
3. Loosen and disconnect lower steer chain.
4. Remove and plug hydraulic lines and ports.
5. Remove console cover in operator’s compartment.
6. Loosen turnbuckles; see figure below.
7. Remove upper chain from steering shaft in power section.
8. Remove spirol pin (1).
9. Remove screws holding steer motor mounting bracket to tractor frame.
1O. Separate coupling by raising shaft (2).
11. Remove steer motor.
12. Remove cap screws attaching mounting bracket to steer motor.
13. For reassembly, reverse steps 1 through 12 noting the following:
adiust steer cable, see page 5.55.
adjust steer chain, see page 5.54.
ensure steering pointer is in correct position.
bleed hydraulic system.
l l l l
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Steering Torque Cleanliness is extremely important in repair work. Seal all open ports and thor-Generator Removal oughly clean the torque generator before beginning any repair work.
(Electronic Steering)
1. Disconnect battery.
2. Remove cover from front of power section.
3. Loosen and disconnect lower steer chain.
4. Disconnect wires from tachometer.
5. Remove and plug hydraulic lines and ports to steer motor.
6. Remove four mounting screws which hold steer motor brackets to tractor.
7. Remove timing belt. While belt is removed, inspect condition; replace if required.
8. Remove sprocket and gear.
9. Separate steer motor from mounting bracket.
10. For reassembly, reverse steps 1-8, noting the following:
adjust steer chain, see page 5.54.
bleed hydraulic system.
flush hydraulic system, see page 5.103
Figure 5.79 Removing Steer Motor (Vehicles with Electronic Steering)
ll l
Steering Torque Generator Disassembly
Tools Required 1/4 in. thin wall 12 point socket 5/16 in. thin wall 12 point socket Small screwdriver (1/4 in. flat blade) Small breaker bar
Torque wrench (150 in. lb. capacity)
The following tool is not necessary but is extremely helpful for disassembly and reas-sembly: Spring installation tool - Char-Lynn P/N 600057.
Figure 5.80 Steering Torque Generator
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Steering Torque Before disassembling the torque generator, note location of the mounting holes.
Generator This is important for correct reassembly.
Disassembly (Cont’d.)
1. Remove seven cap screws.
2. Remove power end housing assembly.
3. Remove O-ring seal from housing.
Figure 5.82 Steering Torque Generator Assembly 4. Remove power end shah and wasner from housing.
5. Use a small screwdriver to remove quad seal from housing. Do not damage seal cavity.
Figure 5.83 Separating Power End and Housing End
Steering Torque 6. Remove spacer plate and power end drive.
Generator
Disassembly 7. Remove seal from gerotor.
(Cont’d.)
Figure 5.84 Removing Spacer Plate
8. Remove gerotor and seal from control side of geroter.
Figure 5.85 Removing Gerotor
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Steering Torque 9. Remove control end drive.
Generator
Disassembly 10. Remove spacer plate.
(Cont’d.)
11. Remove seal from control housing.
Figure 5.86 Removing Control End Drive
12. Turn control housing over, making sure spool and sleeve assembly remains in housing. Remove four cap screws with 1/4 in. 12 point socket wrench.
13. Remove end cap from control housing.
Figure 5.87 Removing End Cap 14. Remove seal from end cap.
15. Use a small screwdriver to remove quad seal from end cap.
16. Remove washer from control spool.
Steering Torque 17. Remove spool and sleeve assembly from control housing.
Generator
Disassembly 18. Remove pin from spool and sleeve assembly.
(Cont’d.)
19. Remove spool and centerings springs from sleeve.
Figure 5.88 Control Housing - Exploded View
Inspection/ Replace all worn or damaged parts and assemblies. Replace all seals when reas-Preparation for Re- sembling a torque generator. Lubricate all seals with petroleum jelly. Lubricate all assembly finished surfaces to ease assembly and provide start-up lubrication.
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Steering Torque 1. Lubricate the spool. Rotate spool while sliding it into sleeve.
Generator Assembly
Figure 5.89 Spool/Sleeve Assembly (Control End)
2. Using spring installation tool as a guide, install six centering springs into sleeve and spool. The springs must be flush with the sleeve upper surface. Notches in springs must point away from control shaft. (See NOTE next page).
Figure 5.90 Removing Spacer Plate
Steering Torque Generator
Assembly (Cont’d.)
NOTE: If spring installation tool is not available, manually install centering springs by installing the two outside springs first. Add the remaining inner springs as shown below.
Figure 5.91 Spring Installation (Alternate Method)
Figure 5.92 Removing Spacer Plate
3. Install pin into spool and sleeve assembly.
4. Lubricate spool and sleeve assembly. Rotate assembly into control housing.
HYDRAULIC
MODEL NOR30/NOR30P: MAINTENACE
Steering Torque 5. Install washer over spool shaft with chamfered side toward spool and sleeve as-Generator sembly.
Assembly (Cont’d )
6. Install quad ring and O-ring seal in control end cap.
7. Install end cap assembly over spool shaft, ensuring quad seal is not damaged by shaft keyway.
Figure 5.93 Control End Assembly - Exploded View
8. Install control end cap screws. Alternately torque to 150 in. lbs. as shown below.
Figure 5.94 Torque Sequence - Control End
Steering Torque 9. Turn control housing over, making sure that spool and sleeve assembly remains Generator in housing.
Assembly (Cont’d.)
10. Install seal control housing.
Figure 5.95 Installing Control End Drive
11. Install spacer plate, aligning holes in housing and plate. (Both spacer plates are the same and either of the plate may face the control housing).
Correct Alignment Incorrect Alignment
MODEL NOR30/NOR30P: MAINTENANCE
Steering Torque Generotor
Assembly (Cont’d.)
Figure 5.97 Installing Spacer Plate
Align star valleys with drive mark. Install gerotor, making sure that the seal is in-installed in side facing the control end spacer plate.
Install seal in power end side of gerotor.
Install power end drive in gerotor, smaller splined end first.
Install spacer plate, aligning holes in piate and gerotor. (Either side of spacer plate may face gerotor.)18. Install quad seal in power end housing.
Install washer over power end shaft with chamfered side away from shaft key-way.
HYDRAULIC
To time the Torque Generator, rotate spool and sleeve assembly until pin i5 par-allel with port face. Install control end drive, making sure drive engagases with pin. Mark drive as shown on previous page.
Install seal in gerotor.
12.
Figure 5.98 Installing Power End
Install shaft in power end housing, making sure quad seal is not damaged by shaft keyway.
Install seal in power end housing.
Align control end and power end keyways.Install power end housing, aligning splines in shaft and drive.
20.
21.
22.
Steering Torque Generator
Assembly (Cont’d.)
Install power end cap screws. Aitemately tighten cap screws to 200 in. lbs.
See figure below for torque pattem.
Figure 5.101 Power End Torque Sequence
Figure 5.99 Torque Generator Final Assembly 23.
Flushing Hydraulic System
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.
Whenever oil is added, always filter the oil before adding it to the reservoir.
Steps 1 through 11 provide a method for flushing the lift system without using the proportional lit/lower valve. This is done to prevent contamination SOL1. The re-maining steps are for flushing the auxiliary hydraulic system.
If the truck has just been assembled, if a hydraulic component is changed or if the oil is new perform all the following steps.
If steering components have been worked on, (i.e., auxiliary pump, torque genera tor, proportional solenoid, hoses, hydraulic steer motor), only perforrn steps 12 through 20.
With keyswitch Off, disconnect one of the leadwires to the auxiliary motor.
Turn Keyswitch On and enter Maintenance Mode and select test 06. Depress the horn button to get “Open” on the Operator’s Display. This will close SOL2. See WARNINGS and CAUTION.
Manually push in the lift pump contactor. Hold the contactor in firmly to avoid contactor tip damage.
DO NOT USE REMOTE LIFT/LOWER TOOL AS THIS WILL ALLOW CONTAMINA-TION TO ENTER THE PROPORCONTAMINA-TIONAL VALVE.
THE CARRIAGE WILL LIFT AT FULL SPEED WHEN THE LIFT CONTACTOR IS PUSHED IN.
ENSURE THAT THERE IS ADEQUATE CLEARANCE ABOVE THE TRUCK TO PREVENT DAMAGE TO THE BUILDING AND/OR THE TRUCK.
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.
Lower the carriage by opening the emergency lowering valve located on the lift/lower manifold.
Close the manual lowering valve.
Repeat the lift/lower process 5 times. See NOTE.
BE SURE TO COVER THE LOOSE END TO PREVENT IT FROM COMING IN CONTACT WITH THE TRUCK FRAME.
Continued next page.
MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC
The hydraulic system must be flushed:
1.
Turn the keyswitch Off, reposition Mode toggle switch to RUN, then turn key-switch On.
Lift and lower the carriage normally 3 more times using the lift/lower control.
Ensure that the carriage is elevated until the side lift cylinders are extended at least one-half of their fully extended length.
Tum the keyswitch off.
Reconnect the lead to the auxiliary motor.
Jack the drive tire off the floor. See WARNING.
USE EXTREME CARE WHENEVER THE TRUCK IS JACKED UP FOR ANY REASON.
NEVER BLOCK THE TRUCK BETWEEN THE TELESCOPIC AND THE FLOOR. USE A SUITABLE HOIST TO STABILIZE THE MAST. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT TRUCK - DO NOT RELY ON JACKS. REFER TO PAGE 5. 15.
Manually turn the drive unit until it is centered.
Turn the keyswitch to the on position. See WARNING.
STAY CLEAR OF THE DRIVE UNIT AS IT MAY TURN AS SOON AS THE KEYSWITCH IS TURNED ON.
Depress the deadman pedal and let the auxiliary motor run for approximately 10 minutes.
After 10 minutes, turn the drive unit from stop to stop at least ten times.
Turn the keyswitch to the off position.
Replace the return-line filter.
Lower the truck to the floor.
Check the fluid level in the reservoir.
End of procedure.
WHENEVER THE AUXILIARY OR STEERING HYDRAULIC COMPONENTS ON A WIRE GUIDED SYSTEM ARE REPAIRED OR REPLACED, THE CLEAN PROCE-DURE AND FLUSHING PROCEPROCE-DURE SHOULD BE FOLLOWED.
Before performing maintenance on wire guidance or steering hydraulics, perform the following:
Clean around all areas to be disconnected. Pressure solvent (kerosine or an in-dustrial solvent) and wiping with a line free towel are suggested.
Have a clean surface prepared for holding tools and components.
Wipe all tools and place them on a clean surface.
When a new component is installed, thoroughly wash the component and any fit-tings and hardware using clean kerosine or an industrial solvent and place them onto a clean work surface.
When removing a component, disconnect the component or hose, capping the ends or ports with pressure fittings. Cover the end of hose, which will be re-used, with a plastic bag, securing it with a rubber band or twist tie.
When assembling a new or cleaned component, have all fittings and hardware stationed near to the vehicle on a clean work surface.
MODEL NOR30/NOR30P: MAINTENANCE HYDRAULIC
Clean Procedure
1.
2.
3.
4.
5.
6.
Truck problems are often caused by defects in the wiring. When truck problems exist, use the following procedure to check out the wiring harness:
Visually inspect problem areas for:
loose connections faulty terminals broken wires worn insulation
Check for continuity in the wiring harness using an ohmmeter and referring to Electrical Schematic. See to Appendix.
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; BATTERY CURRENT CAN DAMAGE THE METER.
Use an ohmmeter set on the R x 10,000 scale.
Connect one lead to the truck frame and the other to different points in the elec-trical system - i.e., terminal strips, contactors, wire connections, etc.
If there is a short, the meter needle will noticeably move. The meter should regis-ter no less than one megohm.
If the ohmmeter registers less than one megohm, the short within the particular circuit must be located.
Reverse the leads and repeat steps 3 through 5.
Remove 15 amp control fuses (FU1, FU2, and FU3).
For each fuse, make a connection between the battery side terminal and the truck frame with the ohmmeter.
Any reading below 2 megohms indicates unacceptable shorts somewhere in the system.
Voltage grounds are the most common causes for system intermittent “overloads”.
Voltage to frame leakage is a result of dirt accumulation and can occur at:
Motors
Check for voltage to frame using the following procedure:
Use a voltmeter set on 50 VDC scale (some voltage above truck system).
Connect voltmeter leads as follows:
Positive lead to PC1-1, negative lead to truck frame Positive lead to truck frame, negative lead to TP4 Voltage readings of 2-3 volts in either test should be eliminated.
Eliminating voltage to frame can be accomplished by isolating a particular area of the truck electrical system. Use the following procedure:
Connect voltmeter leads as in Step 2 above.
Remove battery from truck. Reconnect battery to receptacle. If voltage drops, battery needs cleaning or resealing.
If battery checks good, reinstall in truck and:
Remove fuses (one at a time). If voltage drops when fuse is removed the defective circuit is isolated.
Disconnect motor leads (one at a time). If voltage drops, motor needs cleaning or repair.
Heat sink insulation may become faulty for several reasons:
poorly insulated screws which secure the component to the heat sink
poorly insulated screws which secure the component to the heat sink