• Author / Uploaded
• Christian Bedoya

Citation preview

®

Lift Trucks

Service Manual Chassis, Mast & Options NR3000-36V NR3500-36V NR4000-36V NR4000P-36V NR4500-36V NR4500P-36V ND2500-36V ND3000-36V ND3000P-36V NS3000-36V NS4000-36V

2NR3800900-up 4NR3800900-up 5NR3800900-up 6NR3800900-up 7NR3800900-up 8NR3800900-up 1ND3800900-up 2ND3800900-up 3ND3800900-up 2NS3800900-up 5NS3800900-up

99759-8D100

TABLE OF CONTENTS

MAST INSTALLATION INSTRUCTIONS Truck How the Truck is Shipped ........................................................................... Uprighting a Cradled Truck ......................................................................... Option 1: Uprighting with Two Chain Hoist.................................................. Option 2: Uprighting with One Chain Hoist and a Lift Truck ........................

1-1 1-1 1-2 1-3

Mast Installation Instructions Truck System Requirements ....................................................................... Mast Inspection........................................................................................... Chain Lubrication........................................................................................ Upright and Carriage Position, Chain Tension ............................................ Channel Lubrication.................................................................................... Mast Mounting Bolts and Torque Specifications.......................................... Overhead Guard Mounting Bolts and Torque Specifications ....................... Hydraulic Fluid Level................................................................................... Hydraulic Functions .................................................................................... Pump Intake Coupling (Bleed Points) .........................................................

1-3 1-3 1-3 1-3 1-4 1-5 1-6 1-7 1-7 1-7

GENERAL INFORMATION FEATURES Glossary ........................................................................................................

2-1

Reach Truck Serial Number Definition ........................................................

2-3

General Overview..........................................................................................

2-4

Jacking Truck ................................................................................................

2-8

Load Wheel Replacement Guide..................................................................

2-9

Caster Adjustment ........................................................................................ 2-10 Brake Assembly Inspection and Adjustment ............................................. 2-11 Adjustment of Air Gap with Brake Applied................................................. 2-11 Friction Disc Replacement ........................................................................... 2-11 Transmission................................................................................................. 2-13 THEORY OF OPERATIONS Solenoid Activation Chart ............................................................................

3-1

Main Hydraulic Manifold...............................................................................

3-1

Theory of Operation ..................................................................................... Plugging in the Battery ............................................................................... B+ Feed to .................................................................................................. B-Feed to .................................................................................................... Additional Safety Circuit (Emergency Power Off)........................................ Turning Key Switch (S2) On........................................................................ Can Bus Communication ............................................................................

3-2 3-2 3-2 3-2 3-2 3-2 3-3

i

TABLE OF CONTENTS

THEORY OF OPERATIONS (continued) Stepping on the Operator Presence Pedal ................................................. 3-3 Steer Request............................................................................................. 3-3 Electric Steer Controller “APS” ................................................................... 3-4 Travel Request ............................................................................................ 3-4 Plugging Request ....................................................................................... 3-6 Regenerative Braking ................................................................................. 3-6 Lift / Lower Request.................................................................................... 3-6 Lift Activation .............................................................................................. 3-7 Lower Activation.......................................................................................... 3-7 Auxiliary Functions...................................................................................... 3-7 Tilt Request ................................................................................................ 3-8 Tilt Activation .............................................................................................. 3-8 Reach / Retract Request ............................................................................ 3-8 Sideshift Request........................................................................................ 3-8 Reach / Retract and Sideshift Activation..................................................... 3-8 Reach / Retract Activation .......................................................................... 3-8 Sideshift Activation ..................................................................................... 3-8 Lift Pressure Adjustment............................................................................. 3-9 Max. Lowering Speed Adjustment (Mechanical) ......................................... 3-9 Emergency Lowering .................................................................................. 3-10 Electrical Lowering Speed Adjustment ....................................................... 3-10 OPERATOR DISPLAY Operator Display ...........................................................................................

4-1

General Information ...................................................................................... ESC (Escape) Button.................................................................................. Scroll Left Button ........................................................................................ Scroll Up Button.......................................................................................... Scroll Down Button ..................................................................................... Scroll Right Button ...................................................................................... Enter Key .................................................................................................... Battery State of Charge .............................................................................. Parking Brake ............................................................................................. Clock........................................................................................................... Mode of Operation (Optional) ..................................................................... Travel Direction ........................................................................................... Travel Speed Indicator ................................................................................ Text Messaging ........................................................................................... Shelf Selector (Option) ............................................................................... Load Weight Display ...................................................................................

4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3

Turn KEY On..................................................................................................

4-4

Under General Settings ................................................................................

4-4

History Folder ...............................................................................................

4-5

ii

TABLE OF CONTENTS

OPERATOR DISPLAY (continued) Shelf Height (Option) ....................................................................................

4-5

To Change Self Height Option .....................................................................

4-6

Mode of Operation (Performance Modes I, II, III and IV) ............................

4-6

Thermal Monitoring ......................................................................................

4-7

SelfTest ..........................................................................................................

4-7

Operation Hours............................................................................................

4-7

Battery State of Charge ................................................................................

4-7

OPERATOR DISPLAY INFORMATION & PROGRAMMING Password Protected Mode Management Mode ..................................................................................... How to Enter “Management” Mode .......................................................... Service Mode.............................................................................................. How to Enter “Service Mode”...................................................................

5-1 5-1 5-1 5-1

Display Enabled Functions General Settings ......................................................................................... History Folder ............................................................................................. Password Manage ...................................................................................... Parameters ................................................................................................. Display Parameters .................................................................................. Configuration Settings..............................................................................

5-2 5-2 5-2 5-2 5-2 5-2

Display Parameters Pre-Height Selection ................................................................................... How to Activate the “Pre-select Shelf Height Setting” Function ............... Mode Change ............................................................................................. How to Change the “Mode Change” Function .......................................... Height Display *Service Mode Only*........................................................... How to Activate the “Height Display” Function ......................................... Weight Display *Service Mode Only* .......................................................... How to Activate the “Weight Display” Function ........................................ LCD Contrast .............................................................................................. How to Change “LCD Contrast” ............................................................... LCD Heater................................................................................................. How to Activate the “LCD Heater Control” Function................................. Keyless Entry “Pin Code” *Service Mode Only* .......................................... How to Activate the “Keyless Entry” Function .......................................... Truck Parameters *Service Mode Only*...................................................... How to Access “Truck Parameters ........................................................... BDI Curve............................................................................................. BDI Timer ............................................................................................. BDI Reset .............................................................................................

5-3 5-3 5-4 5-4 5-5 5-5 5-6 5-6 5-7 5-7 5-8 5-8 5-9 5-9 5-10 5-10 5-11 5-11 5-11

iii

TABLE OF CONTENTS

OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued) Low Batt ............................................................................................... Maintenance Warning........................................................................... Stand-by-Timer..................................................................................... Travel Alarm ......................................................................................... Max Speed Fwd ................................................................................... Max Speed Bwd ................................................................................... Release Braking ................................................................................... Inverse Braking..................................................................................... Steer Sensitivity.................................................................................... Forward Steering .................................................................................. Lower Stop / Batt Lock ......................................................................... Cutback Linear ..................................................................................... Cutback 1 Speed .................................................................................. Cutback 2 Height / Cutback 2 Speed ................................................... Cutback 3 Height / Cutback 3 Speed ................................................... PreSensor Low ..................................................................................... PreSensor Low ..................................................................................... Real Load Weight ................................................................................. Max Lift................................................................................................. FreeLift ................................................................................................. LiftLimit ................................................................................................. Reach 2 ................................................................................................ Retract 2............................................................................................... Reach2 / Retr2 ..................................................................................... 2nd Pump ............................................................................................. E Cushion............................................................................................. Wheel Centering...................................................................................

5-11 5-11 5-11 5-11 5-11 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-13 5-13 5-13 5-13 5-13 5-13 5-14 5-14 5-14 5-14 5-14 5-14

Diagnostics Diagnostics * Service Mode Only* .............................................................. How to Access “Onboard Diagnostics”..................................................... Digital Inputs ........................................................................................ Analog Inputs ....................................................................................... Outputs................................................................................................. Temperatures........................................................................................ Motor Controls......................................................................................

5-15 5-15 5-15 5-16 5-16 5-17 5-17

Service Service *Service Mode Only* ..................................................................... How to Access “Service”.......................................................................... Set Maintenace Intervals ...................................................................... Clear History Folder ............................................................................. Reset Pre-Height Select ....................................................................... Restore Truck Param ............................................................................ Restore Perf Mode ............................................................................... Restore Passwords...............................................................................

5-18 5-18 5-18 5-18 5-19 5-19 5-19 5-19

iv

TABLE OF CONTENTS

OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued) Height Detection (Option) Height Detection Overview ......................................................................... Height Detection Installation ....................................................................... Pre_Selected Shelf Height Option .............................................................. To Change the Shelf Height .....................................................................

5-20 5-21 5-22 5-22

Cold Storage Option ..................................................................................... 5-24 Operator Mode Entering Chart .................................................................... 5-25 Management Mode Entering Chart .............................................................. 5-27 Service Mode Entering Chart....................................................................... 5-29 MAST Where to Find Serial Number on Mast ........................................................

6-1

Hydraulic Manifold with Cover.....................................................................

6-1

Hydraulic Manifold with Cover Removed....................................................

6-1

Contents ........................................................................................................

6-2

Periodic Maintenance ...................................................................................

6-2

Inspection......................................................................................................

6-2

500 Hour Inspection .....................................................................................

6-2

Troubleshooting ............................................................................................

6-3

Mast Removal................................................................................................

6-4

Cylinders Main Lift Cylinder ........................................................................................ Description............................................................................................... Free Lift Cylinder ........................................................................................ Description............................................................................................... Cylinder Operation ...................................................................................... Cylinder Raising....................................................................................... Cylinder Lowering .......................................................................................

6-4 6-4 6-5 6-5 6-6 6-6 6-6

Main Lift Cylinder Service Main Lift Cylinder Disassembly................................................................... Cleaning and Inspection ............................................................................. Main Lift Cylinder Reassembly ................................................................... Piston Rod and Piston ............................................................................. Retainer / Retainer Assembly ..................................................................

6-7 6-7 6-8 6-8 6-8

Free Lift Cylinder Service Free Lift Cylinder Disassembly ................................................................... 6-9 Cleaning and Inspection ............................................................................. 6-9 Free Lift Cylinder Reassembly .................................................................... 6-10 v

TABLE OF CONTENTS

MAST (continued) Piston Rod and Piston ............................................................................. 6-10 Retainer / Retainer Assembly .................................................................. 6-10 Mast Uprights Upright Desciption ...................................................................................... Outer Upright Assembly........................................................................... Intermediate Upright Assembly ................................................................ Inner Upright Assembly............................................................................

6-11 6-11 6-11 6-11

Upright Chain Inspection Elongation................................................................................................... Edge Wear .................................................................................................. Turning or Protruding Pins .......................................................................... Cracked Plates............................................................................................ Fatigue Cracking ...................................................................................... Stress-Corrosion Cracking ....................................................................... Corrosion Fatigue .................................................................................... Ultimate Strength Failure ............................................................................ Tight Joints ................................................................................................. Chain Length Adjustment............................................................................

6-12 6-12 6-12 6-13 6-13 6-13 6-13 6-13 6-13 6-14

Periodic Inspection Triple-Stage Upright (TSU) Chain Length Adjustment ................................ 6-14 Chain Lubrication........................................................................................ 6-16 General Guidelines ..................................................................................... 6-16 Chain Removal and Replacement Lift Chains (Standard & TSU) ..................................................................... 6-17 Primary Cylinder / Carriage (TSU’s) ........................................................... 6-17 Other Chain Service Notes ......................................................................... 6-17 Periodic Inspection—Upright & Lift Bracket Removal & Replace Roller Shim Adjustments Lift Bracket Removal Preperation ............................................................... Removal & Replace Roller Shim................................................................. Upright & Lift Bracket Removal ................................................................... Upright Removal ...................................................................................... Preparation .............................................................................................. Disconnect Battery......................................................................................

6-18 6-19 6-23 6-23 6-23 6-23

Upright Disassembly Rail Cylinders ............................................................................................. Rollers and Shims.................................................................................... Cable, Hose and Chain Sheaves ................................................................ Free Lift Cylinder ........................................................................................ Cable and Chain Sheaves ..........................................................................

6-25 6-25 6-27 6-27 6-28

Lift Bracket Assembly Shimming.................................................................................................... 6-30 Pantograph Carriage Roller ........................................................................ 6-30 vi

TABLE OF CONTENTS

MAST (continued) Checks and Adjustments ............................................................................ Roller Clearance Inspection........................................................................ Service..................................................................................................... Checking Lower Roller Clearance with Upright 6" from Fully Retracted Position ..................................................... When Using a Pry Bar ................................................................................ “C” Clamp Method....................................................................................... Checking Upper Roller Clearance with Upright Extended Approx. 1/2 Full Extension ............................................. Checking Upper Roller Clearance with Upright Extended Approx. to Full Extension ............................................... Checking Lower Roller clearance with Upright Extended Approx. Within 6” of Full Extension.................................

6-30 6-35 6-35 6-35 6-35 6-36 6-37 6-39 6-40

Fork Removal Lift Bracket Service..................................................................................... Fork Carriage Removal ............................................................................ Models Equipped with Sideshift Only ................................................... Models Equipped with Tilt Only ............................................................ Servicing Lift Bracket Arm Rollers ........................................................... Tilt Cylinder Overhaul .............................................................................. Cylinder Removal .................................................................................

6-43 6-43 6-43 6-44 6-45 6-47 6-47

ITA Lift Brackets ITA Lift Bracket with Sidesifter .................................................................... ITA Lift Bracket without Sideshifter ............................................................. Cylinder Removal..................................................................................... Preparation and Cleaning ........................................................................ Disassembly............................................................................................. Retainer Assembly ............................................................................... Piston Rod and Assembly .................................................................... Cleaning and Inspection ....................................................................... Reassembly ............................................................................................. Retainer Assembly ...............................................................................

6-47 6-48 6-48 6-48 6-49 6-49 6-49 6-50 6-50 6-50

Reach Cylinder Overhaul Cylinder Removal........................................................................................ Remove Forks.......................................................................................... Remove the Fork Carriage....................................................................... Preparation, Cleaning and Inspection ......................................................... Disassembly ............................................................................................... Retainer Assembly ................................................................................... Piston Rod and Piston ............................................................................. Cleaning and Inspection .......................................................................... Reassembly ................................................................................................ Retainer Assembly......................................................................................

6-50 6-50 6-51 6-51 6-53 6-53 6-53 6-53 6-54 6-54

vii

TABLE OF CONTENTS

MAST (continued) Sideshift Cylinder Overhaul Cylinder Removal—Lift Bracket .................................................................. Remove Forks.......................................................................................... Preparation Cleaning and Inspection .......................................................... Disassembly ............................................................................................... Retainer Assembly ...................................................................................

6-55 6-55 6-55 6-55 6-55

Lift Bracket Service Cleaning and Inspection ............................................................................. 6-57 Reassembly ................................................................................................ 6-57 Reach and Sideshift Selector Valve Preparation ................................................................................................. 6-57 Mast Hydraulic Schematic............................................................................ 6-59 Reach and Tilt Selector Valve Removal...................................................................................................... Disassembly ............................................................................................... Mounting Selector Valve ............................................................................. Connecting Hydraulic Plumbing ..................................................................

6-60 6-60 6-60 6-61

Sideshifter Solenoid Control Valve Removal...................................................................................................... Installation .................................................................................................. Mount Selector Valve ............................................................................... Install Hoses ............................................................................................ Connect Coils ..........................................................................................

6-62 6-63 6-63 6-63 6-63

Servicing a Double Reach Lift Bracket ....................................................... 6-64 Installing Reach Cylinders ........................................................................... 6-66 Reach and Tilt Selector Valve Service Disassembly ............................................................................................... Cleaning ..................................................................................................... Reassembly—Solenoid Valves.................................................................... Reassembly—Counterbalance Valves ........................................................ Installation ..................................................................................................

6-67 6-68 6-69 6-71 6-71

Sideshifter Selector Valve Disassembly ............................................................................................... 6-72 Cleaning ..................................................................................................... 6-72 Reassembly ................................................................................................ 6-73 Mast Triline Hose / Cable Routing ............................................................... 6-74 Field Replacement of Mast Triline Harness ................................................ 6-75 Mast “Auxiliary” Hydraulic Flushing Procedure ......................................... 6-77

viii

TABLE OF CONTENTS

HYDRAULIC SCHEMATICS Legend ...........................................................................................................

7-1

Standard Performance with Tilt ...................................................................

7-2

Standard Performance with Tilt and Sideshift ............................................

7-3

High Performance with Tilt ...........................................................................

7-4

High Performance with Tilt and Sideshift ...................................................

7-5

CONTROLLER System Configuration and Outline .............................................................. 8-1 System Configuration.................................................................................. 8-1 Outline ........................................................................................................ 8-2 Logic Unit................................................................................................. 8-2 Inverter..................................................................................................... 8-2 Output Unit (RIO)..................................................................................... 8-3 Display Unit.............................................................................................. 8-3 APS (Advanced Power Steering) Unit ...................................................... 8-3 External Logic............................................................................................. 8-4 Logic Unit................................................................................................. 8-4 Inverter..................................................................................................... 8-5 Output Unit............................................................................................... 8-6 Display Unit.............................................................................................. 8-7 Controller Area Network (CAN)................................................................... 8-8 AC Motor System Basics ............................................................................ 8-9 Feature of AC Motor ................................................................................ 8-9 Speed Control of Induction Motor ............................................................ 8-9 Inverter..................................................................................................... 8-10 Function......................................................................................................... Traction Control Function ............................................................................ Powering .................................................................................................. Limitation of Maximum Travel Speed........................................................ Regeneration ........................................................................................... Controlled Roll Back ................................................................................ Steering ................................................................................................... Stall Timer................................................................................................ Free Lift.................................................................................................... Hydraulic Control Function.......................................................................... Hydraulic Controller ................................................................................. Priority ..................................................................................................... Inhibition of Simultaneous Operation ....................................................... Attachments 2 and 3................................................................................ Steering Control Function ........................................................................... OPP (Operator Presence Pedal) Function .................................................. Preventing Operator’s Absence................................................................ Other Functions .......................................................................................... ix

8-11 8-11 8-11 8-12 8-13 8-13 8-14 8-14 8-14 8-16 8-16 8-17 8-17 8-17 8-18 8-19 8-19 8-20

TABLE OF CONTENTS

CONTROLLER (continued) BDI (Battery Discharge Indicator) ............................................................ Service Indicator ...................................................................................... Hour Meter Function ................................................................................ Chime Control Function ........................................................................... Battery Voltage Monitor............................................................................ Display Function (See Display Section) ...................................................... Normal Operation Display ........................................................................ Error Display ............................................................................................ Password Display.....................................................................................

8-20 8-20 8-20 8-21 8-21 8-22 8-22 8-23 8-23

Removal and Installation.............................................................................. Inspecting Before Replacing Controllers..................................................... Checking Inverter and DSP Card............................................................. Checking Logic Card................................................................................ Checking Power Supply Card .................................................................. Checking Output Unit............................................................................... Checking Display Unit .............................................................................. Discharging Electric Charges from Inverters and APS Unit ........................ Replacing Inverter....................................................................................... Replacing DSP (Digital Signal Processor) Card ......................................... Replacing Logic Unit................................................................................... Replacing Logic Card ................................................................................. Replacing Power Supply Card .................................................................... Replacing Output Unit................................................................................. Replacing APS (Advanced Power Steering) Unit ........................................

8-24 8-24 8-24 8-25 8-26 8-27 8-28 8-29 8-30 8-32 8-34 8-35 8-36 8-37 8-38

Basic .............................................................................................................. Basic Items ................................................................................................. Testing Tools ............................................................................................... Pin by Pin Voltage Measurement ................................................................ Pin by Pin Measurement Chart................................................................... Coil Resistances .........................................................................................

8-38 8-38 8-38 8-39 8-40 8-50

Checking Contactor ...................................................................................... 8-51 Checking Contactor Coil ............................................................................. 8-51 Checking Contactor Tip .............................................................................. 8-51 Checking Inverter.......................................................................................... 8-52 Regeneration Check ..................................................................................... 8-52 TROUBLESHOOTING FOR CONTROL CIRCUITS General Information ...................................................................................... Before Replacing Devices........................................................................... Connection of the Service Tool ................................................................... How to Clean Harness Connectors and System Components...................... CAN-BUS Reach Truck AC .........................................................................

x

9-1 9-1 9-1 9-2 9-3

TABLE OF CONTENTS

TROUBLESHOOTING FOR CONTROL CIRCUITS (continued) Troubleshooting ............................................................................................ 9-4 E0 Traction Motor, Overheating.................................................................. 9-4 E2 Pump Motor 1, Overheating ................................................................. 9-8 E3 Pump Motor 2, Overheating ................................................................. 9-11 E4 Steer Motor, Overheating ..................................................................... 9-14 E5 Traction Inverter, Overheating............................................................... 9-17 E7 Pump Inverter 1, Overheating .............................................................. 9-20 E8 Pump Inverter 2, Overheating .............................................................. 9-23 E9 Steer Inverter, Overheating .................................................................. 9-26 A5 Traction Motor, Over-Current ............................................................... 9-29 14 Traction Motor Current Sensor Fault ..................................................... 9-32 15 Traction Motor, Over-Current................................................................. 9-34 16 Traction Motor, Stall Timer Speed Fault ................................................ 9-37 34 Pump Motor 1, Current Sensor Fault .................................................... 9-39 35 Pump Motor 1, Over-Current ................................................................ 9-41 40 Line Contactor Fault ............................................................................. 9-44 45 Traction Motor Open ............................................................................. 9-46 47 Pump Motor 1, Open ............................................................................ 9-49 48 Pump Motor 2, Open ............................................................................ 9-52 49 Steer Motor, Open ................................................................................ 9-55 51 Traction Lever Sensor Fault .................................................................. 9-58 52 Traction Motor Pulse Input Fault ........................................................... 9-61 55 FC Solenoid Fault ................................................................................. 9-64 56 FC Solenoid Current Leak .................................................................... 9-67 57 Pump Motor 1 Pulse Input Fault ........................................................... 9-69 58 Pump Motor 2 Pulse Input Fault ........................................................... 9-72 59 Steer Motor Pulse Input Fault ............................................................... 9-75 60 Display Communication Fault ............................................................... 9-78 61 Parameter Write Fault ........................................................................... 9-81 62 Logics Fault .......................................................................................... 9-82 63 Traction Inverter Fault ........................................................................... 9-83 65 Pump Inverter 1 Fault ........................................................................... 9-86 66 Pump Inverter 2 Fault ........................................................................... 9-89 68 Output Unit Fault .................................................................................. 9-92 71 APS Controller Fault ............................................................................. 9-94 78 Battery Voltage Too Low ....................................................................... 9-96 79 Battery Voltage Too High ...................................................................... 9-98 81 Pressure Sensor Fault .......................................................................... 9-100 82 Steer Stepper Motor Fault .................................................................... 9-103 85 Brake Switch Fault ................................................................................ 9-105 86 Height Sensor Fault .............................................................................. 9-107 88 Logic Fault Multipurpose Output #1, Travel Alarm ................................ 9-110 88 Logic Fault Multipurpose Output #2, Horn ............................................ 9-112 94 Pump Motor 2, Current Sensor Fault .................................................... 9-114 95 Pump Motor 2, Over-Current ............................................................... 9-116 xi

TABLE OF CONTENTS

TROUBLESHOOTING FOR CONTROL CIRCUITS (continued) (E) Incorrect Start ...................................................................................... 9-119 (H1) Lift Lever, Faulty Setting .................................................................... 9-121 (H2) Tilt Switch, Faulty Setting................................................................... 9-123 (H3) Reach Switch, Faulty Setting ............................................................. 9-125 (H4) Sideshift Switch, Faulty Setting.......................................................... 9-127 (Lo) Battery Low ........................................................................................ 9-129 Component Identification............................................................................. 9-131 Electrical Diagrams....................................................................................... 9-135 Wiring Schematic Wiring Diagram PLANNED MAINTENANCE Maintenance Locations ................................................................................ 10-1 Maintenance Intervals .................................................................................. 10-2 Service Data Recommended Lubricants .......................................................................... 10-3 Fluid Capacities .......................................................................................... 10-3

xii