Nor30p Serv Man

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MODEL NOR30/30P: MAINTENANCE

MAINTENANCE Before performing any scheduled maintenance, perform the following checks which OPERATION take only a short time, but can save a lot of unnecessary repairs.

CHECKS

General Truck Operate all functions of the truck and check for any abnormal operation. 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 Check the oil level in the reservoir for the proper amount. If the reser-voir 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 Grease/lubricate all identified lubrication points. Points (See Figure Replace any broken grease fittings.

5.1) Look for any excessive wear in these areas.

Electrical Check for loose connections. This is very important because in DC wir-Connections ing 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.

Electrical Grounds Using a voltmeter, check for any voltage leaks: positive battery terminal to truck frame negative ba1tery terminal to truck frame

An open circuit should be indicated in both cases. If any voltage is read, clean the battery and check if for leaks, cracks, etc.

Using a voltmeter, check for any voltage leaks: FU1-1 (+) to truck frame

M-2 (-) to truck frame

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. MAINTENANCE OPERATION CHECKS

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MAINTENANCE OPERATION CHECKS

Wiring Harness Check to make sure the harnesses are not oil soaked and that they are in good con-Check dition.

Switches and 1. Make sure that the contacdor tips are not burned or pitted.

Contactors 2. Make sure that all switches are operating and providing their designated tion.

Motor Brush Wear Check every brush in every motor for the proper length. Check the spring on the bnushes. Check the commutator on the armature for wear.

Hydraulic Cylinder Check lift cylinder for leaks, air in the hydraulic system and/or damage to chrome plating on cylinder piston.

Hydraulic Lines 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.

Brake & Linkage 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.

Wheels Check to make sure there is enough material left on the wheels. Check to make sure the bearings are still good and shimmed properly. Check and remove all foreign matter between wheels and housings. Accessories Check these items for their proper functions.

Battery Check for correct battery water level.

Check the battery leads for excessive wear and corrosion. Check for corrosion coming from the case.

Check the connectors for breakage or excessive wear. Check the charger connector for breakage.

Check the crimp and soldered connections. These checks are very im-portant because the only way the battery can get charaged is through these connectors.

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).

Chain Condition 1. Check for excessive wear and/or stiff spots in chain. 2. Check for proper adjustments and alignment.

Steering Assembly Check torque generator for proper operation. Check for oil leaks or air in system. l l l l l l l l l l

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SCHEDULED MAIN-TENANCE

Introduction The reasons for a regularly scheduled maintenance program are: maximize truck performance

maximize truck life

reduction of costly downtime

avoidance of many expensive repairs Scheduled maintenance includes:

lubrication repair inspection 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. SCHEDULED MAINTENANCE l l l l l l l l

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Weekly or every 40 operating hours, whichever occurs first

NOTE: 1W, 2W, etc.- refer to Figure 5.1, (W stands for maintenance that should be done weekly; M stands for monthly and S indicates semi-annual maintenance).

Initial Maintenance After the first 50-150 hours of operation:

Change the fluid in gearbox (and seals on plugs; see CAUTION below. Retorque 6 screws holding pivot bearing to truck (62 ft. lbs.)

Retorque wheel nuts (107 ft. lbs.)

WHEN ADDING OIL TO THE DRIVE UNIT, DO NOT REINSTALL FILL LEVEL PLUG FOR A COUPLE OF MINUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT. DO NODO NODO NODO NODO NOT OT OT OT OT OVERFILL DRIVE UNIT!VERFILL DRIVE UNIT!VERFILL DRIVE UNIT!VERFILL DRIVE UNIT!VERFILL DRIVE UNIT!

CAUTION

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MODEL NOR30/30P: MAINTENANCE Monthly or every 175 operating hours, whichever occurs first. SCHEDULED MAINTENANCE

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MODEL NOR30/30P: MAINTENANCE Semi-Annually or 1 000 operating hours, whichever occurs first. SCHEDULED MAINTENANCE

WHEN ADDING OIL TO THE DRIVE UNIT, DO NOT REINSTALL FILL LEVEL PLUG FOR A COUPLE OF MINUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT. DO NODO NODO NODO NODO NOT OT OT OT OT OVERFILL DRIVE UNITVERFILL DRIVE UNITVERFILL DRIVE UNITVERFILL DRIVE UNITVERFILL DRIVE UNIT

CAUTION

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COLD STORAGE If the vehicle is to be used in a cold storage application, it will be equipped with APPLICATIONS Class I or Class II cold storage options components when delivered, EXCEPT for the

oiI oiI oiI oiI

oiI in the hydraulic reservoir and the drive unit.

Class I - Applies to trucks operating in an environment where temperatures fluctu-ate from 20°F (-7°C) to 70°F (21 °C) warehouse temperature, in a continuous duty cycle and/or in applications where the truck goes in a freezer for a short period of time.

Class II - Applies to trucks operating in an environment where temperatures fluctu-ate from +40°F (4°C) to -40°F (-40°C)or for continuous operation at -20°F (-29°C). AT SUCH TIME AS THE CUSTOMER IS READY TO START USING THE TRUCK IN A

CAUTION COLD STORAGE APPLICATION, THE OIL IN THE HYDRAULIC SYSTEM AND THE DRIVE UNITS MUST BE CHANGED IN ACCORDANCE WITH THE FOLLOWING

INFORMATION.

INCORRECT SELECTION OF OIL, FOR A PARTICULAR APPLICATION, MAY CAUSE CHATTER IN THE LIFT RAMS OR SLOW AUXILIARY FUNCTIONS. NO WARRANTY WILL BE PAID ON COMPONENT DAMAGE RESULTING FROM INCORRECT OIL SELECTION. Class I Vehicles

CAUTION

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Class II Vehicles

Perform all of the class I procedures from previous page, and the following.

Hydraulic System Be sure the vehicle is in a clean area, away from any possible contaminating ele-Oil Change ments that could enter the hydraulic system during the changing process.

Drain the hydraulic reservoir completely. Also, drain as much oil as possible from the hydraulic lines and cylinders.

Drain as much oil from the auxiliary system (pump, lines, etc.) as possible. Fill the hydraulic reservoir with the proper oil in accordance with Figure 5.2 and the lubrication equivalency chart on page 7.1.

Operate all truck functions and check for possible hydraulic leaks. Bleed the hydraulic system before placing the truck into service. Check reservoir oil level.

The remainder of the original hydraulic oil left in the system, (approximately 5%), should not be detrimental to the operation of the vehicle.

Drive Unit Remove the drain plug from the drive unit and drain all the oil. Reinstall drain plug.

Refill with the proper oil in accordance with the Lubrication Equivalency Chart on page 7.1.

COLD STORAGE APPLICATIONS

Figure 5.2 Recommended Oils by Temperature (Class I II)

Procedures (Clase II)

1. 2. 3. 4. 5. 6. 7. 1. 2. 3.

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MECHANICAL

Brake Adjustment Brake adjustment should be checked regularly. When the truck is carrying its rated load and traveling at full speed on a level floor, the brake should stop the truck within 6 to 10 feet. Do not adjust the broke to stop the vehicle in less than 6 feet.

Brake Adjustment Loosen the set screw (28, Figure 5.5). Procedure

Turn the plug (29) clockwise for quicker stopping and counterclockwise to increase the stopping distance.

Brake Inspection If the brakes cannot be adjusted by the adjustment procedure, inspect the brake shoes (8). Use the following procedure:

Procedure 1. Disconnect the battery. 2. Remove nut (1).

3. Hold the deadman pedal in the down position to release pressure on the brake drum (2).

4. Lift the brake drum (2) off. Inspect the brake shoes (8).

5. Loosen the nut (12). Lift brake control lever (11) off and reposition one or two serrations to the left. Retighten nut (12).

6. Reassemble the brake drum.

7. Readjust plug (29) to give a stopping distance of 6 to 10 feet.

8. After adjusting the stopping distance (Step 7), ensure the brake does not drag when the deadman pedal is fully depressed.

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Lower carriage. Disconnect battery.

Remove both console covers.

Disconnect and plug lines to master cylinder. Remove pin (6).

Remove screws holding master cylinder. Repair/replace defective parts.

For reassembly, reverse Steps 3-6. Bleed brake system. See next page. Refill brake reservoir.

Test. MECHANICAL

Brake Master Cylinder Replacement

Figure 5.3 Deadman Pedal/Master Cylinder 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. DEADMAN.PCX

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Disconnect battery.

Loosen and remove the nut (1 ) holding the brake drum (2). Refer to Figure 5.5. Depress and hold the deadman pedal down; remove the brake drum; release the deadman pedal.

Remove clamps holding the drive motor power wires to the brake assembly. Disconnect and plug hydraulic line to the slave cylinder (23).

Remove 4 screws (14) holding brake assembly to motor. Remove brake assembly.

For reassembly, reverse steps 1-7. Bleed the brake system.

If the brake drags when the pedal is fully depressed, bleed the air from the brake line and slave cylinder using a pressure bleeding tank as shown below.

Brake Assembly Removal Brake Bleeding 1. 2. 3. 4. 5. 6. 7. 8. 9.

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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 MECHANICAL 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

Figure 5.5 Exploded Vew of Brake Assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. BRAKE.PCX

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If the brake still drags after doing the brake bleed procedure, or if a new master cyl-inder is installed, adjust the deadman pedal using the following procedure:

Adjust the yoke on the mastercylinder so the heel of the pedal travels ap-proximately 2-1/2" to 3-1/2" from the fully depressed position to the nor-mal (full up) position.

Adjust the deadman switch, on the brake assembly, to remain on until the deadman pedal has been released at least 60%, but never over 80%, of full travel height.

Deadman Switch Adjustment

Figure 5.6 Deadman Switch (S2) Adjustment

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Anytime the truck is jacked up for any reason, 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.

The following diagram illustrates the correct jacking points on the truck frame. Whenever the truck is jacked up, there should not be any load on the forks. The forks should be lowered all the way to the lowest possible point. Disconnect the bat-tery and remove the key. Always use solid blocks to support the vehicle. Never rely on jacks or chains to support the vehicle. Attach a chain to the top of the mast from an overhead hoist to stabilize the mast.

When the orderpicker is jacked up at the tractor end, the truck should not be lifted more than one-half (1/2") off the floor.

When jacking from the side of the truck, the load wheels should not be lifted off the floor more than one-half inch (1/2").

MECHANICAL Jacking Truck

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Open pivoting cover and lift off door.

Turn the drive unit so the lug nuts on the wheel can be loosened. Disconnect battery.

Remove center section of bumper. Loosen lug nuts on drive wheel.

Jack up front of truck and block and remove the drive tire. 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.

With the drive tire removed, a new tread surface can be installed. Press the old tread off and the new tread on the hub.

If the pressure required to press the new tire on the hub is less than five (5) tons, re-place the wheel hub.

Reinstall drive wheel on the truck. Torque the lug nuts to 107 ft. lbs. Remove blocking and lower truck to floor.

Reinstall bumper, test.

Remove brake. See page 5.12.

Jack and block the tractor end so that drive tire is 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.

Remove screws holding motor to drive unit. See NOTE.

The drive motor can be removed without removing the drive tire. If for some reason the screws securing the drive motor to the drive unit must be taken completely out, the drive tire must then be taken off.

The drive motor may now be removed. For reassembly, reverse Steps 1, 2, and 3. Drive Tire Replacement NOTE: Drive Motor Removal NOTE: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1. 2. 3. 4. 5.

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Before performing any maintenance on the drive unit take note that metric tools, special “assistant tools” and metric hardware are required. Review this procedure and page 5.23 for tools needed before starting. Also, ensure that any maintenance performed does not void warranty.

Metric Tools required: 6mm Allen Wrench 8mm Allen Wrench 1Omm Allen Wrench 10mm Socket 13mm Socket 19 mm Socket

During disassembly, the outer wheel shaft bearing may be damaged. In this case, the bearing must be replaced and the drive unit assembly shimmed. This requires the use of special tool “Q” and a dial indicator. To avoid delays, the service techni-cian should have a replacement bearing (1036370) and shims (1036371 through 103674 and 1036417 through 1036421) along with tool “Q” (see page 5.23) available in case they are needed.

Remove covers on tractor.

Turn the drive unit so the lug nuts on the wheel can be loosened. Disconnect battery.

Remove center section of bumper. Loosen lug nuts on drive wheel.

Jack up tractor enough (and block) to remove the drive tire. 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.

Drain any oil remaining in drive unit.

Turn drive unit and remove cover (134). Refer to the Figure on the next page. Remove axle retaining nut (129) along with shims (130, 131, 132, 133). Drive the wheel shaft (119) out of the housing using a 5/16" diameter copper drift.

USE CAUTION NOT TO DAMAGE THE WHEEL SHAFT.

Using a bearing puller, remove the tapered roller bearing (122) inner race with rollers and cage from wheel shaft. If the bearing is damaged, discard it. To pre-vent damage to the bearing, use tool “M”.

Remove and discard the sealing ring (121). MECHANICAL

Drive Unit Axle Seal Replacement (Drive Unit S/N 6000 & Up) NOTE: Disassembly Procedure

CAUTION

! 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

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After thoroughly cleaning wheel shaft (119): (See Figure on Previous Page)

Apply grease to the new seal (121) in the area between the dust and sealing lip. Slide ring onto the wheel shaft (119).

Press the tapered roller bearing (122) inner race with rollers and cage onto the wheel shaft using Assistant Tool “H” or equivalent.

Apply Loctite 245 to the splines of the crown gear (104) and the wheel shaft (119). Assemble the wheel shaft assembly into the drive unit housing. Align the wheel shaft splines with the ring gear. As the assembly is inserted, be careful to properly engage the sealing ring with the drive unit housing. Slight tapping of the wheel shaft with a soft mallet will help to engage the seal.

Install tool “Q” as shown in Figure 5.38. Tighten tool “Q” until there is no bearing clearance in the wheel shaft.

To measure the backlash between the pinion and the crown gear, prevent the pinion from turning. Place a dial indicator as close as possible to a tooth flank. Refer to Figure 5.39.

Turn the wheel shaft in both directions to determine the total amount of back-lash. Maximum permissible backlash is 0.005 - 0.007 in. (0.13 - 0.18 mm). To change the backlash, add or remove shims under the wheel shaft bearing. Items 124 - 127 in Figure 5.8.

Screw the inside of tool “Q” against the wheel shaft. Using a torque wrench, torque to 55 ft Ibs (75 Nm). Turn the shaft in both directions several times. Refer to Figure 5.42. Determine the “Y” dimension using a dial indicator, (from the outer edge of tool “Q” to the inner surface of tool “Q” as shown).

Determine dimension Z at the damping nut (item 1)

Determine the thickness of spacers required by using the following formula: Shim thickness = Y - Z

Remove tool “Q”.

Place the shims determined onto the wheel shaft. The tolerance on the actual thickness of the shims used can vary from the calculated thickness by +/- 0.002 (0.05 mm).

Install clamping nut. Using tool “L”, torque nut to 148 h. lbs (200 Nm). After tightening clamping nut, stake nut to wheel shaft.

Refer to Figure 5.44. Apply a thin unifomm coat of Loctite 574 to the sealing sur-face of the cover.

Apply one drop of Loctite 242 on the threads of each cover screw (item 2). Torque cover screws to 7 ft Ibs (9.5 Nm).

Continued next page. Drive Unit Axle

Seal Replacement (Drive Unit S/N 6000 & Up)(Cont’d) Reassembly Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 12. 13. 14. 15. 16. 17.

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Refill the drive unit with proper grade lubricant. The capacity of the drive unit is 2.64 quarts (2.5 L). Check for leaks.

WHEN ADDING OIL TO THE DRIVE UNIT, DO NOT REINSTALL FILL LEVEL PLUG FOR A COUPLE OF MINUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT. DO NODO NODO NODO NODO NOT OT OT OT OVERFILL DRIVE UNIT!T OVERFILL DRIVE UNIT!VERFILL DRIVE UNIT!VERFILL DRIVE UNIT!VERFILL DRIVE UNIT!

Reinstall drive tire and torque nuts to 107 ft. Ibs. (150 Nm). Reinstall bumper.

Remove blocking and lower truck to floor. Reinstall covers.

Test truck/check for leaks. End of procedure.

Drive Unit Axle 18. Seal Replacement (Drive Unit S/N 6000 & Up)(Cont’d) 18. 19. 20. 21. 22. 23.

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Remove four 1/2-13 HHCS (1) and bumper plate (2).

If drive tire is to be removed, loosen the 5 lug nuts, using a 19 mm socket. Remove drive motor. See page 5.16. See NOTE.

If the drive unit is the only item requiring service, separating the brake assembly from the drive motor is not necessary.

Drain oil from drive unit.

Disconnect brake hose (plug openings) and power cables.

Loosen and remove the roller chain from the steer plate (3). Remove steer plate. Remove cap screws (4) holding the drive unit assembly to the tractor. For reas-sembly, apply Loctite 242 to mounting screws and torque to 60 ft.lbs. Slide drive unit toward front of tractor (direction of arrow).

For reassembly, reverse Steps 1 through 5 ensuring bearing plates (5) are posi-tioned between drive unit and power section frame.

Torque wheel nuts to 107 ft. lbs. Refill gearbox with proper lubricant.

Tighten steer chain assembly to allow 1/4" to 3/8" deflection at midspan, using approximately 5 lbs. pressure. Check both sides of chain.

MECHANICAL Removing Drive Unit Assembly

NOTE:

Figure 5.9 Removing Drive Unit 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

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Before performing any maintenance on the drive unit take note that the metric tools, special “assistant tools” and metric hardware are required. Review this procedure and page 5.23 for tools and hardware needed before start-ing. Also, ensure that any maintenance performed does not void warranty.

The next page shows the special tools which assist the technician in servicing the drive unit. All the tools pictured are available through Raymond Parts Division.

Remove drive motor. See page 5.16.

Remove drive unit assembly from vehicle. See page 5.21. Drive Unit

Disassembly

1. 2.

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Drive Unit Disassembly (Cont’d)

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Clean the outside of the drive unit thoroughly before disassembly.

Drain the oil from the drive unit by removing the drain plug (6mm Allen wrench) as shown in Figure 5.10.

Figure 5.10 Draining Oil from Drive Unit

3. Remove the Allen screws (items 1 and 2) as shown in Figure 5.11.

Figure 5.11 Removing Allen Screws Securing Bearing Trunion to Housing

Continued next page. Drive Unit

Disassembly (Cont’d)

DRAIN.PCX

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MODEL NOR30/NOR30P:MAINTENANCE MECHANICAL

Using a plastic-faced hammer, separate the upper part of the drive unit from the rest of the assembly.

Drive

UnitDisassembly (Cont’d)

4

Figure 5.12 Removing Upper Portion of the Drive Unit

5. Remove the screws (item 1, Figure 5.13) holding the lower cover.

6. Loosen the cover by knocking the side of the cover (item 2) using a plastic-faced hammer.

Figure 5.14 Removing Crown Gear Retaining Nut

7. Refer to Figure 5.14. Prevent the wheel staft from turning as shown. Place 2 lug nuts on the studs to prevent damaging the threads. Using Tool “L”, loosen then re-move the nut securing the crown gear to the wheel shaft.

Figure 5.13 Removal of the Lower Cover

UPPER3.PCX

CVR-OFF.PCX

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The crown gear is secured to the wheel shaft with Loctite 245. By heating gear to 212° to 248° F (l00° to 120°c) the wheel shaft can be removed Using a 1/2" dia. (15mm) copper drift, drive the wheel shaft (item 1,) out of the

housing. Remember to replace the radial shaft sealing ring (item 2) before reas-sembly. See NOTE.

Drive

Figure 5.15 Removing Wheel Shaft 8.

NOTE :

9. Remove the crown gear (Item 3) from the housing carefully.

If the tapered roller bearings on the axle are to be reused, proceed with steps 10 through 13. If the tapered roller bearings are to be reused, it is strongly recommended that tool “M” be used to remove the bearing. If the bearings are to be replaced, go to step 16.

1O. Refer to Figure 5.16. Using tool “M”, place the collet of the extractor onto the roller bearings.

11. Tighten the collet against the rollers by turning the cap nut.

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17. If the wheel bolts are to be removed, use tool “O” and press the wheel bolts out. 12. Screw spindle against wheel shaft to remove the bearing evenly.

13. Remove the shaft seal (item 1). See Caution Drive

Refer to Figure 5.16. When removing the wheel shaft, the axle seal may be

dam-aged. When the axle is removed for any reason, it is recommended that the seal al-ways be replaced.

CAUTION

14. Carefully, take the crown gear out of the housing.

15.When removing the bearing inner race off the crown gear, repeat steps 10 through 12.

16. If replacing the bearings, cut the bearing cage (item 1 in Figure 5.17) open and

Figure 5.17 Removing Axle Bearing (Alternate Method)

Figure 5.18 Setup To Remove Wheel Bolts BOLT.PCX BRGS-OFF.PCX

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The gear is secured to the pinion shaft with Loctite 245. By heating the crown gear to 212° to 248° F (100° to 120°c) the gear can be removed more easily.

18.The pinion can only be removed after the crown gear. Holding the spur gear from turning (using strap wrench “P”), remove Hex nut (item 1 Figure 5.19). 19. Pull the gear off the pinion shaft using a gear puller.

NOTE:

Figure 5.19 Removing Helical Pinion Gear

20. Using a plastc-faced hammer, drive the pinion (item 1) shaft out. (Refer to Figure 5.20) The pinion must not be damaged!

21. Remove the spur bushing (item 2).

22. Remove the tapered roller bearing inner race (item 3) out of the housing (item 4).

Figure 5.20 Removing Pinion Shaft _PINION.PCX SPLURS.PCX

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23. Remove the tapered roller bearing inner race (item 1, Figure 5.21) of pinion shaft (2) using Bush “B”.

Figure 5.21 Removal of Pinion Tapered Bearing. Drive

24. Remove the bearing outer races (items 1 through 4 in Figure 5.22). Use a cop-per mandrel and a hammer. When driving the races out, make sure not to dam-age the spacers. Always keep the shims with the race they were installed with.

Figure 5.22 Removing Bearing Races

PRESS.PCX

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25. To remove the plastic protective shield, drive the shield off using a hammer. 26. Separate the protective shield using a screwdriver at the separating point

pro-vided.

Figure 5.23 Removing the Protective Shield Drive

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Pre-Assembly Checks

Inspect all components for excessive wear, damage, and cracks. Replace any de-fective parts found.

If a gear requires replacement, the entire gear set must be replaced. New gear sets require new bearings.

If the roller bearings are damaged, remember to replace BOTH the inner and outer races.

Smooth sealing surfaces using an oil stone or fine finishing file.

Lubricate the roller bearing with new transmission oil prior to assembly.

Clean all components thoroughly. Remove any traces of Loctite from all surfaces.

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 1. 2. 3. 4. 5. 6. 7. New Parts

•

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Insert measuring bush “D” into bearing borehole in the housing and measure dimen-sion F.

The housing dimension E is determinad according to the following formula: E = L - F + 1.750 (44.45 mm) (for HFK300 drive units)

E = L - F + 1.7716 (45.00 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), use the following formula:

X= E- B-T E = Housing Dimension

B = Assembly dimension of pinion shaft (marked) T = Bearing width (item 2)

Drive Unit Assembly

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Once the thickness of shims is determined, insert the shims into the seat of the bearing (item 1 in Figure 5.25).

Drive the bearing outer race (item 2) into the bearing seat in the housing. Toler-ance for installation of the bearing is +/-.002" (0.05 mm) from the measured value.

DriveUnit Assem bly (Cont’d)

Install the shims previously removed into the wheel bearing (item 2 in Figure 5.26).

Press the bearing outer race (item 3) into the wheel shaft bearing seat (item 1). 1.

2.

Figure 5.26 Installing Wheel Shaft Outer Race Figure 5.25 Istalling Lower Pinion Bearing Race

3.

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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.

Drive Unit Assem-bly (Cont’d)

Figure 5.28 Installing Dust Seal and Wheel Outer Race 5.

Figure 5.27 Axle Stud Installation

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).

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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

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

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 pin-ion shaft. (Note that HFK400 transmisspin-ions do not have spacer bush).

Figure 5.31 Installing Pinion Into Housing Drive Unit

Assem-bly (Cont’d)

7.

8.

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Determine the thickness of shims to be installed at the top of the pinion shaft as follows:

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)

Use the result from step 10c in selecting the thickness of the shims to be used. Drive Unit

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.

a. 10.

Figure 5.32 Measuring Gap for Pinion Bearing Spacers

Determine dimension S. Dimension S is the distance between the plane sur-face of the bearing outer race and the plane sursur-face of the inner race. Refer to Figure 5.33.

Figure 5.33 Determining Dimension S b.

c.

d.

•

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14. Refer to Figure 5.35. Install the helical gear onto the pinion shaft. Install a new hex nut. Hold the helical gear using strap wrench “P”. Torque the hex nut to 40 - 48 ft. lbs (55 - 65 Nm).

11 .Refer to Figure 5.34. Install the required shims (item 1) into the housing. 12. Press the tapered roller bearing outer race (item 2) into the housing.

13. Using tool “G”, press the tapered roller bearing inner race (item 3) onto the pin-ion shaft up to the stop.

Figure 5.34 Installing Upper Pinion Shaft Bearing

Figure 5.35 Installing Helical Hex Nut Drive Unit

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Lift helical gear carefully as shown using two screwdrivers or tire irons. Read the values on the dial indicator. The value shown indicates the bearing clearance. This step should be repeated several times. Permissible bearing clearance is 0 - 0.002 in (0 - 0.05 mm).

If the clearance exceeds permissible tolerance, the helical gear and upper bear-ing must be removed. Shims must then be added under the outer race of the upper bearing.

Once the proper clearance is obtained, apply Loctite 245 to the helical gear hex nut and torque to 40 - 48 ft. lbs (55 - 65 Nm).

Remove tool “F” which was previously installed.

Push down on the pinion and turn it at the same time for several complete rota-tions. This aligns the rollers in the bearings.

Refer to Figure 5.36. Place a dial indicator as shown. Mark the measuring point using a colorea pencil.

Figure 5.36 Checking Bearing Clearance 15.

16.

17. Drive Unit Assem-bly (Cont’d)

18.

19.

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Refer to Figure 5.37. Insert the crown gear into the housing. Fit tool “K” around the wheel shaft. Insert the splines of the wheel shaft into the crown gear. Remove excess Loctite.

To seat the shaft sealing rim, (item 2 in Figure 5.38), apply light strokes against the wheel shaft (item 1 ) using a plastic-faced hammer.

Refer to Figure 5.38. Install tool “Q” onto the wheel shaft. Tighten tool “Q” until all bearing clearance in the wheel shaft is removed.

Apply a thin, uniform coat of Loctite surface seal 574 to the outside diameter of the shaft seal (item 1 in Figure 5.37).

Apply a thin, uniform coat of Loctite 245 to the splines of the crown gear. Drive Unit

Figure 5.37 Installing Wheel Shaft and Crown Gear 21.

22.

23.

24.

25.

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Turn the wheel shaft in both directions to determine the total amount of back-lash. Maximum permissible backlash is 0.005 - 0.007 in. (0.13 - 0.18 mm). To change the backlash, add or remove shims under the wheel shaft bearing. The next step is to check the gear mesh tooth pattern. Refer to Figure 5.40.

Coat 3 to 4 tooth flanks of the crown gear with ink.

Mesh the ink coated teeth with the pinion. The contact pattern will be more visible if the pinion is prevented from turning easily.

Compare the actual pattern with Figure 5.40. Slight variations from the de-sired pattern are permissible. Variations are primarily due to different con-tact pressures while creating the pattern.

If significant differences are found, it will be necessary to shim the pinion or the crown gear to obtain the proper pattern.

Once the correct pattern is achieved, secure the hex nut by staking. Refer to Figure 5.35.

To measure the backlash between the pinion and the crown gear, prevent the pinion from turning by placing a wooden wedge between the helical gear and the housing. Refer to Figure 5.39.

Place a dial indicator as close as possible to a tooth flank. 26.

27.

Figure 5.39 Adjusting Crown Gear Backlash

28. 29. 30. 31. a. b. c. d.

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Drive Unit

Assembly (cont’d)

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Screw 2 wheel nuts onto the wheel studs. Prevent the wheel from turning as shown. Refer to Figure 4.21.

Figure 5.41 Assembly of Wheel Shaft and Crown Gear

Screw the inside of tool “Q” against the wheel shaft. Using a torque wrench, torque to 55 ft lbs (75 Nm). Turn the shah in both directions several times. Refer to Figure 5.42. Determine the Y dimension using a dial indicator, (from the outer edge of tool “Q” to the inner surface of tool “Q” as shown).

Determine dimension Z at the clamping nut (item 1).

Determine the thickness of spacers required by using the following formula: Shim thickness = Y - Z

Figure 5.42 Determining Shims Required Drive Unit

Assem-bly (Cont’d) 32. 33. 34. 35. 36.

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Remove tool “Q”.

Place the shims determined onto the wheel shaft. The tolerance on the actual thickness of the shims used can vary from the calculated thickness by +/- 0.002 (0.05 mm).

Install clamping nut. Using tool “L”, torque nut to 148 ft Ibs (200 Nm). After tightening clamping nut, stake nut to wheel shaft.

Refer to Figure 5.44. Apply a thin uniform coat of Loctite 574 to the sealing sur-face of the cover.

Apply one drop of Loctite 242 on the threads of each cover screw (item 2). Torque cover screws to 7 ft lbs (9.5 Nm).

Drive Unit

Assembly (Cont’d) 37. 38.

39.

Figure 5.43 Installing Clamping Nut

Figure 5.44 Installing Cover 40.

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Figure 5.45 Preparing Protective Shield Mounting Surface

If the protective shield for the axle was removed, proceed as follows:

Spray seat of protective shield on the housing using Loctite fast cleaner 706. Allow the cleaner to react then wipe any dirt off using a clean cloth. Spray the surface again and let dry. Refer to Figure 5.45. Make sure to read ond ob-serve instructions and warnings on the Loctite cleaner container. Drive Unit Assembly

(Cont’d)

42.

Mix the two components of the technicoll epoxy in a proportion of 1:1. The two parts are sufficiently mixed when the color has turned to cream. The epoxy should be used within 2 hours.

Apply a thin coat of epoxy to the points indicated in Fioure 5.46. 43.

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Refer to Figure 5.47. Position thread protector on seat of housing. Using pliers, press both parts together until the pins are fully engaged in the pin holes.

Refer to Figure 5.48. Place a hose clamp around the protective shield (screw cas-ing of the clamp positioned at separatcas-ing point of the protective shield). Tighten the clamp until a click is heard indicating the pin has engaged its mating hole.

Remove the clamp. Press the protective shield against the plane face of the hous-ing

Allow the epoxy to cure for 12 hours. See NOTE.

Due to the long cure time required for the epoxy, a metal protective shield is avail-able for field repairs.

Drive Unit Assembly (Cont’d)

45.

46.

Figure 5.47 Installing Protective Shield

NOTE:

Figure 5.48 Final Assembly of Protective Shield 46.

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Coat the sealing surface of the transmission with a thin uniform coat of Loctite 574.

Assemble the subassemblies by aligning the dowel pins in the upper and lower halves of the transmission.

Figure 5.49 Assembling Upper ond Lower Halves of Transmission 48.

49. Drive Unit Assembly (Cont’d)

Install the hardware and torque evenly as specified below: M8 screws - 17 ft Ibs (23 Nm)

M10 Screws - 34 ft lbs (46 Nm)

Refill the drive unit with the proper grade of lubricant. The drive unit capacity is 2.64 qts (2.5 L).

WHEN ADDING OIL TO THE DRIVE UNIT, DO NOT REINSTALL FILL LEVEL PLUG

CAUTION FOR A COUPLE OF MlNUTES TO ALLOW ANY EXCESS OIL TO DRAIN FROM THE DRIVE UNIT. DO NOT OVERFILL DRIVE UNIT!

50.

51.

CAUTION

•

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Use a jack or overhead hoist and raise the carriage enough to slacken the lift chains.

Secure the carriage with blocks to prevent the carriage from lowering.

Remove each chain and chain anchors by unscrewing the nuts on the carriage and the chain anchors on the main frame.

Thoroughly clean the chain in solvent.

Inspect each chain for defects listed in the chart on next page.

Lubricate a chain in good condition or a new chain before installing it on the truck. See next page.

Reinstall the chains on the truck. Be sure the chains are adjusted to share the load equally. Also make sure they are not twisted so they will roll flat on the sheaves.

Lift Chains Chain maintenance in this manual includes: chain removal

defect-cause chart chain lubrication

chain anchor adjustment

•

Figure 5.50 Lift Chain Lubrication

Check the truck lift chains monthly since most unsatisfactory chain performance can be traced directly to inadequate chain maintenance. Remove the chain and inspect it for defects using the following procedure and chart:

DO NOT STEAM CLEAN OR DE-GREASE NEW TRUCK CHAINS

CAUTION

Procedure 1. 2. 3. 4. 5. 6. 7.

Both chains should be replaced when either is defective. NOTE:

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Liberally apply oil (See Scheduled Maintenance for oil specifics) to the chain using a narrow paint brush.

Make sure the exterior surface is covered to prevent rust and that the oil pene-trates the chain joints to reduce wear.

Lift Chain Lubrication

Defect- Cause Chart

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MODEL NOR30/NOR30P: MAINTENANCE MECHANICAL

Decal Replacement Use the followinga information to correctly position replacement decals or printed plates:

Figure 5.53 Decal Locations (1 of 3)

MODEL NOR30/NOR30P: MAINTENANCE

A LL TRUCKS

Section A-A

A LL TRUCKS

Section C-C

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MECHANICAL Decal Replacement (Cont’d)

A LL TRUCKS

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Decal Replacement (Con’d)

Figure 5.55 Decal Locations (3 of 3)

A LL TRUCKS

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MECHANICAL

Lower Steering Every 6 months or 1000 hours of operation, check the tension on the lower steering Chain Adjustment chain assembly. The chain should deflect .25 to .375 inch with a 5 lb. pull midway

between the chain sprockets.

Check each side of the chain to ensure proper tension is applied. Ensure that the chain is properly lubricated and that the jam nuts are tight.

The lower chain anchor should be adjusted so the adjusting screw engages its mat-ing block by at least .31 inch. This can be checked by measurmat-ing from the screw head to the edge of the block. This should be 1.25 inches max. Refer to Figure 5.56.

If the actual dimension does not agree with the figure below, reposition the connect-ing link.

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Steering Cable For vehicles equipped with mechanical power steering, use the following procedure Adjustment to adjust the steering cables which go over the mast.

Using the Figure below as reference, adjust the turnbuckles in the operator’s com-partment so the chain has .5" to .62" deflection when 5 Ibs. force is applied to the chain as shown. Adjustments should be down with the carriage fully lowered.

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MECHANICAL

Torque Specifica- The figure below specifies torques required for different arcas of the tractor. tions for Tractor

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Skid Pad Use the following information to determine if the skid pads, located on either side of Replacement the tractor, require service. If the existing skid pads are not worn to a point where

they must be removed, follow the instructions below. If the existing skidpads must be replaced, refer to the next page.

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 THE TRUCK - DO NOT RELY ON JACKS. REFER TO PAGE 5.15.

If the clearance between the skid pad and the floor exceeds 0.75" on either side, modify the existing skid pad as shown below.

Install service kit P/N 1053014.

Apply Loctite 242 (p/n 1036909) to threads on screws and install new skid pads on power section (both sides).

Figure 5.59 Modifying Existing Worn Skid Pad 1.

2. 3.

NOTE:

A minimum of . 25” material MUST remain from the edge of the skid pad to the drilled holes as shown. if the material is less than required, the existing skid pad MUST be replaced. Refer to the next page.

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MECHANICAL

Skid Pad Removal If the skid pads must be replaced, obtain service kit p/n 1053014. This kit includes parts required when new skid pads must be installed.

1. Elevate the tractor enough to work on skid pads.

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 THE TRUCK - DO NOT RELY ON JACKS. REFER TO PAGE 5.15. 2. Cut old skid pads off.

3. Locate new skid pads on tractor frame using dimensions given.

Figure 5.60 Skid Pad Replacement

Weld new skid pads onto tractor. Welds to conform to AWS A 5.20 or equivalent low hydrogen process.

Clean any weld spatter off and repaint the area. Apply Loctite 242 (1036909) to threads of screws. Bolt new skid pad onto support.

Carefully lower truck to floor.

24"/150" Limit If either switch requires adjustment or replacement, it is critical that the switches be Switch Adjustment adjusted so that they are actuated (but not bottomed out) the full length of the switch

rails that they are in contact with. Proper switch actuation can be verified by attach-ing a meter at the followattach-ing points:

4.

5. 6. 7. 8.

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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: Iift cylinder bleeding

hydraulic reservoir and filter

Iift and auxiliary pump maintenance hydraulic system pressure adjustments solenoids

miscellaneous hydraulic components

NOTE: It is important to keep accurate records of all hydraulic inspections and work per-formed on the truck. Such records are helpful in determining:

repair and maintenance costs reliabilty of components durability of hydraulic fluid scheduling of maintenance • • • • • • • • • • • • • •

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HYDRAULIC

Hydraulic Leakage Hydraulic leakage can cause load drop, load drift, bouncing carriage and noisy pumps.

Wipe all connections clean when checking for leaks. Remember, leaking fluid is likely to run down the underside of pipes and drip at low spots. Many situations cause hydraulic leakage. Any leakage inspection should include operating units as well as connections.

USE EXTREME CAUTION WHILE LOOKING FOR HIGH PRESSURE HYDRAULIC

LEAKS. PERSONAL INJURY MAY RESULT IF STRUCK BY A HIGH PRESSURE STREAM OF HYDRAULIC FLUID.

Leakage

Prevention Checks

Faulty Flexible When installing a flexible connector, avoid twisting it which creates a strain on the Connectors joint.

Fitting Do not spring a tube into place before tightening a fitting. The resultant stress may cause a leak.

Cracked or Bad Inspect all tubing before installation. Make sure when making the flare that it is the Tubing Flare right size.

Foreign Material Make sure the flare is clean before installation. in the Flare

Defective Threads Check for leakage around the threads when installing new tubing. Dirt Around Thoroughly clean and lubricate any O-rings before installation. O-Rings

Wrinkled or Use a known-to-be-good tube bender and carefully bend the tube. Flattened Tube

Worn Packings Examine packings for wear and leakage around the cylinder pistons. If the packing gland is too tight, abnormal friction and wear will occur. See that cylinders are se-curely anchored and that pistons are in alignment. Misalignment is a cause of heavy wear of both pistons and packings. Worn packings should be replaced since they many times cause internal leakage. If truck operation is sluggish, check the packing inside the cylinder.

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Leakage Prevention (Cont’d.)

Bad Connections When checking connections to pumps, cylinders, manifold valves, etc., be sure to ob-serve both pressure and suction sides. Pressure side leaks can be found by wiping connections and observing the accumulations of oil after brief truck operation. Brushing soap solution on joints can be helpful. Air leaks on the suction side of vari-ous components can cause considerable trouble; listen for these leaks; they may lead to air bubbles in hydraulic oil. Such leaks are always difficult to find, but they rate high in importance.

Drive Coupling Check the alignment of the drive coupling between the motor and pump. Also, Alignment make the usual motor checks suggested in the electrical maintenance section. Be

sure hydraulic fluid from a leak is not seeping onto the field windings and armature.

System System contamination can cause erratic or sluggish operation of lift or auxiliary func-Contamination tions, load drift, load drop, clogging, leaking, and damage to the valve/pump

parts.

Packing Examine rod surfaces which contact the packing. If these are nicked or scratched, Disintegration they should be resurfaced or replaced.

Cylinder and If a hydraulic cylinder is disassembled, inspect the inside of the cylinder housing. If Piston Packing the inside cylinder surface is scored, packing grit is probably in the hydraulic fluid. Wear

Hydraulic Oxidation can cause internal rusting and sludge. Use a top grade oil with additives. System Oxidation See the Lubrication Equivalency Chart in the Appendix.

Opening Hydraulic Whenever a hydraulic system in opened, all hoses should be capped or plugged to System keep out dirt and moisture-laden air. Examine pipe fittings and hoses to be certain

there are no seal particles, nicks, burrs or dirt present when reassembling the parts. Wipe all fittings before reconnecting them.

Clogged Filter If the filter becomes clogged in less than the recommended change interval, the by-pass valve will allow contaminants into the system. Inspect, clean and/or replace the element whenever contamination is evident.

NOTE: If severe contamination occurs, drain the system, flush all components and replace the oil and filter.

NEVER USE PIPE JOINT COMPOUND ON HYDRAULIC FITTTINGS. JOINT COMPOUNDS CAN DISSOLVE, CONTAMINATING THE OIL.

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HYDRAULIC Mointenance Tips

NOTE: After locating and repairing any leak or other problem, fill the reservoir bleed the system.

WHEN CLAMPING LIFT/LOWER MANIFOLD IN VISE, ENSURE VALVE BODY IS NOT CAUTION DAMAGED WHICH MIGHT VOID WARRANTY.

Follow these procedures to avoid future hydraulic problems.

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Reservoir and Filter The hydraulic oil in the reservoir should be checked and the return filter replaced pe-riodically as outlined in the Scheduled Maintenance. When excessive contamination has built up, the reservoir should be cleaned as follows:

Cleaning Procedure 1. Drain the reservoir by removing plug from drain line underneath the reservoir. 2. Remove the six screws securing the breather cap adapter and lift out the adapter. 3. Using low air pressure, blow out any dust in the breather cap.

4. Lift out the gaskets and filler strainer. Flush the filler strainer in clean oil. 5. Flush reservoir using clean hydraulic fluid.

6. Reinstall reservoir components in reverse order of disassembly being sure to: coat gaskets and O-rings with a light coat to hydraulic oil.

run the new oil through a 25 micron rated filter prior to filling the reservoir.

7. Install a new filter (see next page).

8. Refill reservoir, operate all systems, check for leaks and bleed system if required. Fluid level should be 1/2" below bottom of strainer with the carriage fully low-ered and the oil at room temperature.

Figure 5.61 Reservoir Assembly •

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HYDRAULIC

Return Filter The hydraulic return filter should be checked and replaced periodically as outlined Replacement in the Scheduled Maintenance.

Place a pan under filter cartridge to catch any overflow when removing old filter. Turn filter cartridge (6) counterclockwise to remove. See Figure 5.61.

Clean gasket seat on filter manifold (4).

Apply a film of clean hydraulic oil to the gasket on the new filter. Install new filter; turn filter clockwise to tighten filter.

NOTE: Tighten filter cartridge 3/4 turn after gasket makes contact with seat. Use only hands to tighten filter cartridge.

Start hydraulic system and check for leaks.

Check the reservoir level. Hydraulic fluid should be within 1/2" of the bottom of the strainer with the carriage lowered and the oil at room temperature.

1. 2. 3. 4. 5. 6. 7.

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Auxiliary and Lift The pumps should normally require no periodic maintenance or adjustment if you Pumps follow a thorough program which includes:

regular replacement of hydraulic oil and filter checking hoses for leakage

cleaning of the oil strainer in the reservoir checking for contamination

Procedure If you do suspect trouble with a pump, consult the following:

NOTE: When assembling the pump to the motor, lubricate the shaft ends with a thin coat of Molycote type G lubricant.

• • • •

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HYDRAULIC

Auxiliary Pump The auxiliary pump relief valve is set at 1600 psi and normally requires no further Relief Valve adjustment. If for some reason the valve needs adjustment, refer to the figure below

for the location of the relief valve on the auxiliary pump. Adjustment For Turn Power off.

Power Mechanical

Steering Connect a calibrated pressure gauge to the pressure test port on the auxiliary pump.

Turn power on, step on deadman and turn drive unit in either direction all the way to the mechanical stops.

While continuing to force drive unit against stop, check the pressure on the gauge. The reading should be 1400 - 1600 psi. See CAUTION.

DO NOT FORCE THE DRIVE UNIT AGAINST THE MECHANICAL STOP FOR MORE THAN 15 SECONDS. DOING SO WILL DAMAGE THE AUXILIARY PUMP.

If the pressure relief valve requires adjustment refer to the figure below.

Figure 5.62 Auxiliory Pump Relief Valve Adjustment 1.

2.

3.

4.

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Auxiliary Pump Relief Valve (Cont’d)

Pressure Adjust- The aux. system relief pressure should never need adjustment under normal circum-ment for Electronic stances, but this procedure can also be used to test the aux. system if necessary. This Steering procedure should never be used unless the drive unit refuses to turn when standing

still.

Turn off power and put the Solenoid Controller Card on an extender card (P/N 1029620) to access card test points.

Jumper both TP-2 and TP-43 to DGND (TP-42) using jumper clips to disable the Watchdog circuits. This prevents the Watchdog circuits from shutting the truck down.

Figure 5.63 Attachment Point for Auxiliary Pressure Test

Connect a pressure gauge to the aux. system pressure port at the Proportional Solenoid manifold. See NOTE.

NOTE: The pressure gauge used should be calibrated and in good working order.

DO NOT LEAVE JUMPER CLIPS ATTACHED AFTER TESTING OR THE WATCHDOG WARNING CIRCUITS WILL NOT FUNCTION. USE EXTREME CARE WHILE OPERATING THE TRUCK, SINCE ERROR CONDITIONS COULD CAUSE ERRATIC OPERATION OF THE DRIVE UNIT.

Prevent the drive unit from turning by puting a wood block between the drive tire and the frame of the tractor.

Turn on power and steer the drive unit against the wood block.

ONLY FORCE THE AUX SYSTEM INTO RELIEF FOR VERY SHORT PERIODS OF TIME OR DAMAGE WILL RESULT. READ THE PRESSURE AS QUICKLY AS POSSIBLE, STEP OFF THE DEADMAN PEDAL, READJUST THE RELIEF, AND RETEST THE PRESSURE. DO NOT ADJUST THE RELIEF VALVE WHILE OPERATING!!! IF THE AUX MOTOR STALLS, STOP THE TEST IMMEDIATELY BY STEPPING OFF THE DEADMAN PEDAL. FAILURE TO STOP TEST WILL RUIN THE AUX. MOTOR AND/OR BLOW THE AUX. SYSTEM FUSE.

Continued next page. 1.

2.

3.

4.

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HYDRAULIC Auxiliary Pump Relief Valve (Cont’d)

Pressure Adjust- Read the pressure gauge as the drive unit is trying to rotate. This pressure should ment for Electronic be 1600 PSI. If the pressure is not as specified, adjust the relief valve on the aux Steering (Cont’d) pump to achieve the correct pressure. Refer to Figure 5.62 for the location of the

relief valve.

DO NOT WORK ON HYDRAULIC CIRCUITS WITH POWER ON!

Turn off power, remove the jumper clips to TP-2 and TP-43, remove the wood block, and reinstall the Solenoid Controller Card into the card rack.

End of Aux System Relief Pressure Adjustment 6.

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FCD Lift Pump Repair to this lift pump is limited to replacing the input shaft seal. Disassembly

1. Remove key (9) from drive shaft. 2. Thoroughly clean outside of pump.

3. Use sharp tool to mark across front plate, body and back plate. This will assure proper reassembly.

4. Clamp pump in vise. 5. Remove screws (17).

6. Remove front cover (3). Be careful not to remove gears from housing. Reinstall o-rings and seals on bushings if they come dislodged.

7. Remove old shaft seal (2); install new seal.

8. Lubricate shaft with hydraulic oil and carefully slide front cover (3) over shaft ensuring seal is not damaged by keyway. Mark made in step 3 should align. 9. Reinstall bolts (17) and torque in a diagonal pattern to 29 - 32 ft. Ibs.

Figure 5.64 FCD Lift Pump - Exploded View Item 1 2 3 4 5 6 7 8 9 Description Retaining Ring Shaft Seal Front Cover Seal Seal Seal Bushes Pin Key Qty. 1 1 1 2 1 1 2 1 1 Item 10 11 12 13 14 15 16 17 18 Description Gear Shaft - Input Gear Shaft - Driven N/A Body Pin N/A Lock Washer Bolt Rear Cover Qty 1 1 -1 2 -4 4 1

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HYDRAULIC

Barnes Lift Pump With the exception of shaft seals, this pump cannot be repaired. If pump is disas-sembled, retorque screws to 40/45 ft. Ibs.

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Dowty Lift Pump Routine maintenance is not required. Periodic checks of mounting bolts and for oil (P/N) leakage is recommended.

(36 volt) Dowly Lift

Pump Field Field servicing is restricted to replacing the shaft oil seal and disassembly of the Service pump for inspection of internal components.

Do not disassemble the pump unnecessarily. If loss of performance occurs, check the entire system before assuming the pump is at fault.

BEFORE DISCONNECTING ANY HYDRAULIC LINES OR FITTINGS TO THE PUMP, ASCERTAIN THAT THE BATTERY IS DISCONNECTED AND HYDRAULIC SYSTEM PRESSURE IS RELEASED. LOWER THE VERTICAL CYLINDERS AND BLOCK ANY LOAD WHERE MOVEMENT COULD GENERATE SYSTEM PRESSURE.

Removal Procedure Drain reservoir.

Disconnect supply line to lift pump at reservoir - drain - re-attach. Disconnect and cap hoses and lines from lift pump.

Remove the two 3/8-16 x 1-1/4 hex screws supporting pump. Pump can now be removed by pulling away from motor.

Figure 5.65 Dowty Lift Pump - Exploded View 1.

2. 3. 4.

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 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 11. 12. 13. 14.

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HYDRAULIC

Dowty Lift Pump The drive shaft oil seal is best removed by applying hydraulic pressure simulta-Replacing Drive neously to the pump Inlet and Outlet ports. This has the effect of pressurizing the Shaft Oil Seal 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. If seal is removed using hydraulic pressure, proceed to step 12. See Figure 5.65.

If the seal is distorted and leaking badly, it may not be possible to raise sufficient pressure to remove it in this way. In this event, dismantle the pump as follows:

Loosen, but do not remove, the four tie bolts (11).

Clamp pump in a soft jawed vise so spline is pointed up and the jaws are hold-ing items 3 and 12. This will prevent the pump from comhold-ing apart when the tie bolts are removed.

Remove the four tie bolts (11).

While holding spline in position, lift mounting flange (1) off pump. Use care not to pull the splined shaft upward while removing mounting flange (1).

Clamp the mounting flange (1) in a soft-jawed vise. The seal can be drifted out using a crank drift. Take care not to damage the shaft bore with the drift.

Ensure that the seal housing in the pump mounting flange is clean and free from burrs.

Pack the space between the lips of the new seal (2) with high melting point, min-eral-base grease.

Start the oil seal squarely into the housing, with the garter spring facing inwards and press to the full depth of the recess.

Cover splined area of shaft (14) with masking or electrical tape. Lightly grease the taped area.

Slide mounting flange over splined shaft squarely.

Install the four tie bolts (11), and torque in a diagonal pattern to 34-36 ft. lbs. Go to Step 17.

Ensure that the seal housing in the mounting flange (1) is clean and free from to burrs.

Cover splined area of shaft (14) with masking or electrical tape. Lightly grease taped area.

Pack the space between the lips of new seal (2) with high melting point, mineral-base grease.

Slide the oil seal, with garter spring facing inward, over taped area of shaft. start the seal in squarely with the housing.

Press the seal into the full depth of the recess. Remove tape from spline.

Reinstall pump by reversing removal steps 3 and 4 of removal procedure. Mounting flange still assembled to pump. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

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Lightly mark the end cover (3), body (12), and mounting flange (1) to ensure cor-rect reassembly relationship. Take note of the pump’s dicor-rection of rotaton. See Figure 5.65.

Remove the four hex tie bolts (11) which thread into the mounting flange (1). Remove the end cover (3) and carefully lift out the two backing washers (5, 6), the bush lobe seal (7) and body seal (4).

Cover splined area of shaft (14) with masking or electrical tape. Lightly grease taped area.

Lightly tap mounting flange (1) clear of the two hollow dowel pins in the pump body. Slide the mounting flange squarely off the shaft.

Carefully lift out body seal (4), two backing washers (5, 6) and lobe seal (7). With pump body vertical (spline down), place one hand underneath to support the bushings (8, 9).

Tap the side of the body (12) with a rubber mallet to dislodge the lower bushes (8, 9). Slide bushes out carefully and keep them as a pair with the mounting flange (1).

Invert the body and lift out the driver (14) and driven (13) gears.

Remove the remaining bushes (8, 9) from end cover end as previously de-scribed. Place with end cover (1).

Continued next page. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Dowty Lift Pump

Disassembly (36 Volt)

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HYDRAULIC Dowty Lift Pump Disassembly (Cont’d.)

Component Wash all metal parts thoroughly in cleaning fluid. Keep bushes in pairs and prop-inspection erly oriented with the end of the pump they were removed from. Inspect as follows:

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HYDRAULIC

MODEL NOR30/NOR30P: MAINTENACE

Dowty Lift Pump Ensure that all parts are perfectly clean. Lubricate parts with the oil to be used in Reassembly hydraulic system.

(36 Volt)

1. Prepare the bushes for the mounting flange end of the body for insertion as fol-lows: (See Figure 5.66).

Place the bushes on the bench with their lopes uppermost and the flats in contact. Lubricate the ‘spectacle’ lobe seal with mineral-base grease and fit it around the bush lobes. Fit the two backing washers inside the ‘eye-pieces’ of the lobe seal. When fitted correctly the backing washers must be level and flush with the top surface of the bush lobes.

Figure 5.66 Lobe Seal and Backing Washer Assembly

2. Prepare the bushes for the cover end of the body for insertion in the similar manner.

3. Pack the space between the lips of the oil seal with high melting point mineral-base grease.

4. Pick up the body and hold it with the hollow dowels uppermost and with the fin-gers of one hand inside ready to support the bushes.

5. Pick up the mounting flange bushes complete with lobe seal and backing wash-ers, and slide them down into the body bore with the lobes facing away from the flat. See Figure 5.67.

The bushes must be entered squarely into the bore and must be kept square to each other. No force must be used; the bushes should slide in easily. If the bushes jam in the bore, remove them and examine for bruising. Light bruising can be stoned out with a fine-grit hand stone.

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Dowty Pump 6. Lubricate the body seal (4) with mineral-base grease and place it in the body re-Reassembly cess.

(Cont’d.)

7. Refer to Figure 5.67 to find the position of the drive gear.

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.

8. Insure spline is covered with tape. Lightly oil taped area and shaft.

9. Align mark made previously on mountng flange (1) and body (12). Hold the drive gear (14) with one hand. Slide the mounting flange (1) squarely over shaft until the hollow dowel pins engage mounting flange fully. Remove tape from spline.

10. Clamp mounting flange (1) in soft-jawed vise, spline down.

11. Check that the bushes (8, 9) are flush against the mounting flange face (1) and that lobe seal (7) and backing washers have not become dislodged. Check the arrow on the body to insure parts are assembled for counterclockwise rotation. 12. Mesh the driven gear (13) with the drive gear already assembled in pump. See

NOTE.

Ensure that the marked side of the teeth are in contact so the “bedded-in” position is maintained.

Continued next page. l

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HYDRAULIC

MODEL NOR30/NOR30P: MAINTENACE

Dowty Pump 13. Slide cover end bushes, complete with lobe seal and backing washers, over the Reassembly gear journals. Lobes should face outward away from flat. Bushes must be en-(Cont’d.) tered squarely and without force.

14. Lubricate body seal (4) with clean hydraulic fluid and assemble into its recess. 15. Place end cover (3) on body (12) aligning marks previously made.

16. Assemble hexagon tie bolts through and cover and thread until finger tight. 17. Torque tie bolts in a diagonal pattern to 34-36 ft. lbs.

18. Pour a small amount of clean hydraulic oil into the ports and check for freedom of rotation.

19. Plug ports to prevent contamination from entering pump.

Dowty Lift Pump If a new lift pump is installed, the following run-in procedure should be followed Run-in carefully.

1. Operate the lift system for a period of ten minutes (minimum) unloaded. 2. Progressively increase the weight of loads over the first hour.

3. During run-in period, make frequent checks of pump casing temperature. Oil temperature should not exceed 140°-1 50°F.

If the temperature exceeds limit, extend low pressure operation time and/or check entire lift system.

Barnes Lift Pump With the exception of shaft seals, this pump can’t be repaired. If the pump is disas-(36 Volt) sembled, retorque screws to 40 - 45 ft. lbs.