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Caterpillar NRM20K NRM25K Multiway Reach Truck Service Manual – PDF DOWNLOAD
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Caterpillar NRM20K NRM25K Multiway Reach Truck Service Manual – PDF DOWNLOAD
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Description
Caterpillar NRM20K NRM25K Multiway Reach Truck Service Manual – PDF DOWNLOAD
DESCRIPTION:
Caterpillar NRM20K NRM25K Multiway Reach Truck Service Manual – PDF DOWNLOAD
Foreword :
This service manual is a guide for servicing lift trucks. The long productive life of your lift truck depends on regular and proper servicing, consistent with the instructions provided in this service manual. Before starting to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and familiarize yourself with all of the components.
- The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing.
- The manufacturer reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience, the instructions are grouped by systems as an easy reference. Unauthorized copying and lending of this material is strictly prohibited.
TABLE OF CONTENTS:
Caterpillar NRM20K NRM25K Multiway Reach Truck Service Manual – PDF DOWNLOAD
631058_A-01_FOREWORD......................................................... 1 631058_A-02_HOW_TO_READ_THIS_MANUAL.......................................... 6 631058_A-03_SAFETY_INSTRUCTIONS.............................................. 10 631058_A-04_GENERAL_INFORMATION.............................................. 14 631058_A-05_FORKS............................................................ 16 631058_A-06_ELECTRICAL_OPERATION............................................. 31 631058_A-07_BATTERY_MAINTENANCE.............................................. 37 631058_A-08_ELECTRIC_SYSTEM_MAINTENANCE...................................... 45 631058_A-09_PARAMETER_LISTS.................................................. 70 631058_A-10_FAULT_AND_STATE_REPORTS.......................................... 86 631058_A-11_TECHNICAL_DATA................................................... 89 631058_A-12_ANNEX............................................................ 92 AC_SUPERDRIVE_USERS_MANUAL................................................... 96 Table of Contents........................................................ 97 Scope of this Manual.....................................................101 Related Documents........................................................101 Intended Use of the AC SuperDrive........................................102 Product Identification...................................................102 Technical Support........................................................103 Product Warranty.........................................................104 Introduction.............................................................105 Tools and Equipment Required.............................................105 Orientation..............................................................105 Clearances for Access and Air Circulation................................105 Procedure................................................................106 Introduction.............................................................107 Tools and Equipment Required.............................................107 Motor and Battery Connections............................................107 General..............................................................107 Making Connections to Terminal Posts.................................109 Fuses................................................................109 Inrush Current Limiting Resistance...................................109 Main Contactor.......................................................109 Key Start Input......................................................109 Control and I/O Connections..............................................110 General..............................................................110 ID0 and ID1 Inputs...................................................113 Encoder Signals......................................................113 Temperature Sensor...................................................113 CAN Bus Signals......................................................114 Crimping Contacts onto Signal Conductors.............................114 Installing Crimped Contacts in Connector Housing.....................114 General..................................................................117 Checks Prior to Initial Powerup..........................................117 Verifying AC SuperDrive Readiness for Operation..........................118 Configuring the AC SuperDrive for the Application........................118 Final Operational Checks in Vehicle......................................119 Introduction.............................................................121 Periodic Preventive Maintenance..........................................121 AC SuperDrive Replacement Procedure......................................122 Drive Removal........................................................122 Drive Installation...................................................122 Scope of the Troubleshooting Guide.......................................123 Using the Troubleshooting Guide..........................................123 Organization of Troubleshooting Guide................................123 About Errors and Warnings............................................123 Error Logging........................................................124 Using the Troubleshooting Charts.....................................124 Information for OEMs Preparing User Documentation........................125 Symptom: Main Contactor doesn’t close after switching on Key Switch....126 Symptom: Fuse to Power Stage is blown..................................127 Symptom: AC SuperDrive Status Indicator is blinking or off.............128 Symptom: Motor runs only at low speed and with a ticking sound.........129 Error Code 1: Pulse Sensor Error.......................................130 Error Code 2: Motor Temperature High...................................131 Warning Code 16: Power limited due to Motor Overtemp...................131 Error Code 4: Heatsink Temperature high................................133 Warning Code 1: Power Limited due to Heatsink Overtemp.................133 Error Code 8: Overcurrent..............................................135 Error Code 16: DC Bus High - hardware detected.........................136 Error Code 32: DC Bus High - software detected.........................136 Error Code 64: DC Bus Low..............................................137 Error Code 128: No Charging DC Bus.....................................137 Error Code 256: CAN - too many Errors..................................138 Error Code 512: CAN Watchdog Time-out..................................139 Error Code 1024: Missing “Okay to Start” from Truck Controller.........140 Error Code 2048: Contradictory Commands from Truck Controller..........141 Error Code 4096: Potentiometer Values Out of Range.....................142 Warning Code 2: Heatsink Temperature Sensor – Open Circuit.............143 Warning Code 4: Heatsink Temperature Sensor – Short Circuit...........143 Warning Code 8: Power limited - temp < -20 deg. C......................144 Warning Code 32: Motor Temperature Sensor - Open Circuit...............145 Warning Code 64: Motor Temperature Sensor - Short Circuit.............145 Warning Code 128: Speed from Truck Controller Out of Range.............146 Warning Code 256: Current Calibration Error............................147 Warning Code 512: Reverted to Default Parameters.......................148 ADJUSTMENT_INSTRUCTIONS60406.................................................149 APS_ADVANCED_POWER_STEERING_USERS_MANUAL.....................................151 Table of Contents........................................................153 Introduction.............................................................157 About APS Documentation..............................................157 Scope of this Manual.............................................157 Intended Use.....................................................157 Related Documents................................................157 About the Advanced Power Steering Unit...............................158 Intended Use.....................................................158 Safety Instructions..............................................158 APS Configurations...........................................158 Product Identification Label.................................159 Technical Support................................................159 Product Warranty.................................................160 APS Installation.........................................................161 Installing APS in Vehicle............................................161 Introduction.....................................................161 Installing the Actuator..........................................161 Installing a Separately mounted Controller.......................161 Installing Steering Feedback Sensors.................................162 Introduction.....................................................162 Potentiometer....................................................162 General Information..........................................162 Mounting.....................................................162 Steering Feedback Potentiometer Coarse Alignment.............163 Home Cam with Center Position Sensor.............................163 General Information..........................................163 Mounting.....................................................163 Home Cam with Combination Center/End Limit Sensor................164 General Information..........................................164 Mounting.....................................................165 Installing Steering Input Sensors....................................166 Introduction.....................................................166 Stepper Motor....................................................166 General Information..........................................166 Mounting.....................................................166 Joystick or Potentiometer........................................166 General Information..........................................166 Mounting.....................................................166 Steering Input Potentiometer Coarse Electrical Alignment.....166 Encoder..........................................................167 General Information..........................................167 Mounting.....................................................167 Wiring the APS.......................................................168 Introduction.....................................................168 Tools and Equipment Required.....................................168 Mating Connector and Contacts................................168 Assembly Tools...............................................168 Wiring the APS Mating Connector..................................169 Wire Size Requirements.......................................169 Crimping Contacts onto Conductors............................169 Installing Crimped Contacts in Connector Housing.............169 Mating Connector Pin Assignments.............................170 APS Mating Connector Latching Mechanism......................171 Battery Power Connections........................................171 General......................................................171 Power Distribution Wiring to Mating Connector...............172 Fuses........................................................172 Inrush Current Limiting Components...........................173 Sensor, Safety and Communications Wiring.........................173 CAN Bus......................................................174 Steering Sensor Wiring Practices.............................175 Actuator to Separately Mounted Controller Cabling................175 Startup and Commissioning................................................177 Initial Startup......................................................177 General Information..............................................177 Checks Prior to Initial Powerup..................................177 Verifying APS Unit Readiness for Operation.......................177 Configuring the APS for the Application..........................178 Operational Checks in Vehicle....................................178 Maintenance..............................................................179 Maintenance Procedures...............................................179 Introduction.....................................................179 Periodic Inspection and Preventive Maintenance...................179 Steering Feedback Calibration....................................179 General Information..........................................179 APS with Potentiometer Steering Feedback.....................179 APS with Cam and Sensor Steering Feedback....................180 APS Replacement Procedures...........................................181 Safety Information...............................................181 APS with Integrated Controller...................................181 APS Removal..................................................181 APS Installation.............................................181 APS with Separately Mounted Controller...........................182 Actuator Removal.............................................182 Actuator Installation........................................182 Controller Removal...........................................182 Controller Installation......................................183 Troubleshooting..........................................................185 Introduction.........................................................185 Terms and Definitions............................................185 General......................................................185 Errors.......................................................185 Emergency Messages...........................................185 Warnings.....................................................185 Troubleshooting Data Available from APS..........................185 Error Codes..................................................185 The Error Log................................................185 LED Status Indicator.........................................186 The Troubleshooting Guide............................................187 General..........................................................187 Using the Troubleshooting Guide..................................187 General Troubleshooting Procedure................................187 Information for OEMs Preparing User Documentation................188 LED status Indicator is Off......................................189 2301 High Current Error........................................191 3101 Voltage Error.............................................192 4201 High Temp Error...........................................193 5001 Watchdog Reset............................................194 5004 Hardware Power Protection Trip............................195 5007 Safety Out Error..........................................196 5010 Steer Sensor Error........................................197 5015 Switch Error..............................................198 501A Feedback Sensor Error.....................................200 5020 EEPROM Error..............................................201 5021 Motor Error................................................202 Position Error...................................................203 8101 Communications Timeout Error..............................205 CANION_USERS_MANUAL..........................................................206 Table of Contents........................................................208 Introduction.............................................................210 About CANION Documentation...........................................212 Scope of this Manual.............................................210 Product Identification Label.................................211 Technical Description....................................................214 Principles of Operation..............................................214 Introduction.....................................................216 General Description..........................................214 Introduction.....................................................217 CANION Software..................................................218 Error Detection..............................................217 Applications.............................................................220 Order Picker.........................................................222 Order Picker.........................................................223 Reach Truck......................................................224 Interfacing to CANION....................................................224 Interfacing Input Devices............................................228 General..........................................................224 General......................................................224 Interfacing Input Devices............................................231 PWM Outputs......................................................228 General Hardware Description.................................228 Interfacing Output Devices...........................................233 Interfacing CANION in a Truck Can Network........................231 Can Bus Communications...............................................234 General Configuration............................................233 Installation and Wiring..................................................236 CANION Installation..................................................238 Mounting CANION in a Vehicle.....................................236 CANION Installation..................................................240 Introduction.....................................................238 Mating Connector and Contacts................................238 Specifications...........................................................242 Electrical Power Inputs & Outputs....................................243 DACI2_ENGLISH................................................................244 MULTIWAY_CONTROLLER_ERRORS...................................................271 NRM20K,NRM25K................................................................272 STEERING_INVERTER_ERRORS.....................................................279 TH51_1005....................................................................280 TS761104.....................................................................281 TS761104.................................................................281 3-6867: AC-NRM 20K/25K...............................................281 1: POWERSUPPLY 48V...............................................281 2: POWERSUPPLY 12/24V............................................282 3: MAINCIRCUITS..................................................283 4: DRIVECIRCUIT 1................................................284 5: DRIVECIRCUIT 2................................................285 6: STEERING CIRCUIT..............................................286 7: STEERING CIRCUIT 2............................................287 8: STEERING CIRCUIT 3............................................288 9: HYDRAULIC CONTROL CIRCUIT 1...................................289 10: HYDRAULIC CONTROL CIRCUIT 2..................................290 11: CONTROL CIRCUIT 1............................................291 12: CONTROL CIRCUIT 2............................................292 13: SIGNAL- /LIGHTCIRCUIT........................................293 14: FANS, AUX.DEVICES............................................294 15: AUX.DEVICES..................................................295 16: LAYOUT.......................................................296 17: LAYOUT.......................................................297 18: WIRE HARNESS W3: RL468152....................................298 TS1050508_REV_I..............................................................299 WHOMM0001....................................................................318 ENG-MANUAL TEM...........................................................319 TEM CAT-kannet...........................................................318
CATERPILLAR NRM20K NRM25K MULTIWAY REACH TRUCK SERVICE MANUAL – PDF DOWNLOAD:
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