Raymond The Raymond ® Transtacker TRT Maintenance Manual SNTRT-03-00100 and up – PDF DOWNLOAD

Description

Raymond The Raymond ® Transtacker TRT Maintenance Manual SNTRT-03-00100 and up – PDF DOWNLOAD

FILE DETAILS:

Raymond The Raymond ® Transtacker TRT Maintenance Manual SNTRT-03-00100 and up – PDF DOWNLOAD

Language : English
Pages :672
Downloadable : Yes
File Type : PDF
Size:35.6 MB

DESCRIPTION:

Raymond The Raymond ® Transtacker TRT Maintenance Manual SNTRT-03-00100 and up – PDF DOWNLOAD

Manual Design

• This manual is designed to give personnel, with an expected level of expertise, the technical information necessary to maintain, troubleshoot, and repair a Raymond product.
• The two-line running page header at the top of each page contains the name of the manual, the title of the current section, and the topic of the current page.

This manual includes the following sections:

TABLE OF CONTENTS:

Raymond The Raymond ® Transtacker TRT Maintenance Manual SNTRT-03-00100 and up – PDF DOWNLOAD

How to Use This Manual 1-1
Map of the Manual 1-2
Manual Design 1-3
START Page 1-5
Safety 2-1
Definitions 2-2
General Safety 2-3
Battery Safety 2-5
Static Precautions 2-7
Jacking Safety 2-8
Tractor End 2-8
Mast End 2-9
Carriage 2-9
Welding Safety 2-10
AC Electrical Safety 2-11
Systems Overview 3-1
General 3-2
Introduction 3-2
Power Circuit 3-2
Mast Configuration 3-2
Operating Controls 3-2
Vehicle Specifications 3-3
General System Data 3-4
Steering System 3-6
Overview 3-6
Hoist System 3-8
Overview 3-8
Load Handler System 3-11
Fork Load Handler 3-11
Overview 3-11
Reach Assembly 3-11
Rotate Assembly 3-12
Fork Load Handler Controls 3-12
Shuttle Load Handler 3-14
Overview 3-14
Shuttle Platform Assembly 3-14
Shuttle Motor/Brake/Gear Reducer Assembly 3-14
Shuttle Load Handler Controls 3-15
Options 3-16
Traction System 3-17
Overview 3-17
Drive Unit 3-17
Control Devices 3-17
Operator Displays 3-19
Operator Display (OD1) 3-19
Operator Display (OD2) 3-19
General Instructions 3-19
Password Instructions 3-20
Table of Contents The Raymond ® Transtacker Maintenance Manual
iv Publication PDMM-0092 Issued: 30 September 2004
Analog Diagnostics / Learn Procedures 3-20
Learn Neutral Potentiometer Positions 3-20
Learn Travel Fwd 3-21
Learn Travel Rev 3-21
Learn Hoist Up 3-21
Learn Hoist Down 3-21
Learn Load Handler Rt 3-22
Learn Load Handler Lt 3-22
VFI Display Operation 3-23
DC to DC Power Supplies 3-24
Overview 3-24
Battery Charger System 3-25
Overview 3-25
Special Considerations for Cold Storage Operation 3-25
Horns 3-26
Overview 3-26
Special Tools 3-27
Programmable Maintenance Tool 3-27
Programmable Maintenance Tool – Model 1311 3-27
Backwards Compatibility 3-28
Program Parameters 3-28
Changing a Parameter 3-29
Monitor Mode 3-30
Faults and Diagnostic History 3-30
Cloning 3-30
Programmable Maintenance Tool – Model 1307 3-31
Diagnostic Modes 3-31
Diagnostics Mode Access 3-32
Special Diagnostics Mode Access 3-32
Clear 3-32
Test Mode 3-32
Access 3-32
Program Mode 3-35
Special Program Mode 3-36
Access 3-36
Cloning 3-37
Copy Parameters 3-37
Enter Parameters 3-37
Scheduled Maintenance 4-1
Maintenance Guidelines 4-2
Maintenance Schedules 4-2
Daily Checklist 4-3
Every 60 Days or 250 Deadman Hours (HD) 4-5
90 Day Inspection 4-10
Every 180 Days or 1000 Deadman Hours (HD) 4-11
Every 360 Days or 2000 Deadman Hours (HD) 4-13
Scheduled Maintenance Lubrication and Inspection Points 4-14
Troubleshooting 5-1
How to Use This Chapter 5-2
Electrical Troubleshooting Guidelines 5-3
Shorts to Frame Test 5-4
Troubleshooting Procedure 5-8
The Raymond ® Transtacker Maintenance Manual Table of Contents
Publication PDMM-0092 Issued: 30 September 2004 v
AC Electrical 5-12
General Test Procedures 5-12
Truck Ground Test 5-12
Phase Isolation Test 5-12
Ground Verification Circuitry 5-12
Input Power Collectors and Busses 5-13
Troubleshooting Wiring Problems 5-14
Electrical Connections 5-15
Terminology 5-15
Electrical Connection Locator Chart 5-15
Kollmorgen Steer Amplifier Connection Cross Reference 5-18
Kollmorgen Steer Amplifier 5-18
Fuses/Circuit Breakers 5-19
Test/Inspection 5-19
Fuse Locator Chart 5-19
Fuse Locations 5-21
Circuit Breaker Locator Chart 5-24
Gear Reducer Troubleshooting and Repair (Reach/Shuttle) 5-26
Brake Assembly Troubleshooting and Repair (Reach/Shuttle) 5-28
DC Lowering Troubleshooting 5-29
DC Lower Function Inoperative 5-29
Symptom Tables 5-30
Truck Completely Inoperative 5-30
Rotate 5-32
Erratic/Intermittent Operation 5-32
Noisy Operation 5-34
Slow Operation 5-35
One Direction Only 5-36
None 5-37
Reach/Retract — Fork and Shuttle Load Handlers 5-40
Erratic/Intermittent Operation 5-40
Noisy Operation 5-44
Slow Operation 5-46
No Reach 5-50
No Retract 5-53
Lift/Lower System 5-56
Intermittent Lift and Lower 5-56
Incorrect or No Decels Lift and/or Lower 5-56
Slow Lift or Lower 5-57
None 5-57
VFI Relay Rewiring and Reprogramming 5-59
Travel Problems 5-60
None 5-60
Slow or Sluggish Acceleration 5-61
Slow or Uneven Travel Speeds 5-62
Table of Contents The Raymond ® Transtacker Maintenance Manual
vi Publication PDMM-0092 Issued: 30 September 2004
Electrical Problems 5-63
Traction (Drive) Motor Brushes Arching 5-63
ODI Problems (OD1 and OD2) 5-63
Fuses Blowing 5-63
Messages Codes and Tests 6-1
List of Codes 6-3
List of Tests Checks and Adjustments 6-4
Code 1—Hoist System Fault 6-5
VFI Fault Codes and Tests 6-6
Dynamic Braking Resistor Assembly Tests 6-10
Code 2—Traction System Fault 6-11
Code 3—Steer System Fault (Danaher System) 6-22
Code 3—Steer System Fault (Kollmorgen System) 6-27
Code 4—Traction Control Potentiometer (VR2) Out-of-Range 6-34
Code 4 Tests and Adjustments 6-35
Code 5—Hoist Control Potentiometer (VR3) Out-of-Range 6-36
Code 5 Tests and Adjustments 6-37
Code 6—Load Handler Potentiometer (VR4) Out-of-Range 6-38
Code 6 Tests and Adjustments 6-39
Code 7—Rotate Feedback Potentiometer (VR5) Out-of-Range
(Fork Load Handler Only) 6-40
Code 7 Tests and Adjustments (Fork Load Handler Only) 6-41
Code 8—Reach Feedback Potentiometer (VR6) Out-of-Range
(Fork Load Handler Only) 6-42
Code 8 Tests and Adjustments (Fork Load Handler Only) 6-43
Code 9—Hoist Enable Switch (S10) Closed on Start-up 6-44
Code 9 Tests and Adjustments 6-45
Code 10—Travel Enable Switch (S11) Closed on Start-up 6-46
Code 10 Tests and Adjustments 6-47
Code 11—Load Handler Enable Switch (S9) Closed on Start-up 6-48
Code 11 Tests and Adjustments 6-49
Code 12—Deadman Switch(es) (S2 and/or S3) Closed on Start-up 6-50
Code 12 Tests and Adjustments 6-51
Code 13—Loss of Communication Between PLCs 6-52
Code 13 Checks and Tests 6-53
Code 15—Drive Wheel Not Centered on AC Power 6-54
Code 15 Checks and Tests 6-55
Code 16—Steer Position Feedback Potentiometer (VR1)
Out-of-Range 6-56
Code 16 Checks and Tests 6-57
Code 17—Travel Limit Switch (S24) and the Down Limit
Switch (S16) Do Not Agree 6-58
Code 17 Checks Tests and Adjustments 6-59
Code 18—AC Sense Inputs to the Tractor PLC (NA) Do Not Agree 6-61
Code 18 Checks Tests and Adjustments 6-62
Code 19—Carriage Drift Proximity Switch Inputs to the Carriage
PLC (NB) Do Not Agree 6-63
Code 19 Checks Tests and Adjustments 6-63
The Raymond ® Transtacker Maintenance Manual Table of Contents
Publication PDMM-0092 Issued: 30 September 2004 vii
Component Procedures 7-1
List of Component Procedures 7-3
Component Locator Photos 7-7
Covers and Finish 7-21
Steering and Controls 7-33
Drive and Brake 7-81
Electrical Components 7-125
Mast Hoist Carriage and Load Handler 7-261
Options 7-311
Theory of Operation 8-1
Fork Load Handler 8-3
System Architecture 8-4
Electronic Components 8-4
Overview 8-4
Tractor PLC (NA) 8-5
Carriage PLC (NB) 8-7
Analog/Digital Input/Output Modules 8-11
Tractor PC Board (BD1) 8-12
Carriage PC Board (BD2) (S/N 00116 and Below) 8-14
Carriage PC Board (BD2) (S/N 00117 and Above) 8-15
Operator Displays (OD1 OD2) 8-17
Load Handler Motor Controllers (MC1 MC2) 8-18
Steer Encoder Card (SEC) (S/N 00116 and Below) 8-19
Steer Encoder (SE) (S/N 00117 and Above) 8-19
Steer Encoder Card (SEC) (S/N 00117 and Above) 8-19
Steering System 8-20
Steer Amplifier (SA) 8-20
Steer Amplifier (SA) (Kollmorgen) 8-21
Steer Actuator 8-22
Steer Actuator (Kollmorgen) 8-22
Filter Module (CA1) 8-22
Traction Power Amplifier (TPA) 8-22
Traction Power Amplifier (TPA) Inputs 8-23
Traction Power Amplifier (TPA) Outputs 8-24
Regenerative Braking 8-25
Line Opto-Isolator Unit (LOU) 8-25
Line Reactor (LR) 8-26
Hoist Motor Controller (VFI) 8-26
Earth Ground Verification Board (EGVB) 8-28
Battery Charger 8-30
Emergency DC Functions 8-31
DC Retract 8-31
DC Rotate 8-31
DC Lower 8-32
Functional Diagram—Fork 8-34
Shuttle Load Handler 8-37
System Architecture 8-38
Electronic Components 8-38
Overview 8-38
Tractor PLC (NA) 8-39
Carriage PLC (NB) 8-41
Analog/Digital Input/Output Modules 8-45
Table of Contents The Raymond ® Transtacker Maintenance Manual
viii Publication PDMM-0092 Issued: 30 September 2004
Tractor PC Board (BD1) 8-46
Carriage PC Board (BD2) (S/N 00116 and Below) 8-47
Carriage PC Board (BD2) (S/N 00117 and Above) 8-49
Operator Displays (OD1 OD2) 8-50
Shuttle Load Handler Motor Controller (MC1) 8-51
Shuttle Load Handler and Proximity Switch Operation 8-52
Steer Encoder Card (SEC) (S/N 00116 and Below) 8-53
Steer Encoder (SE) (S/N 00117 and Above) 8-53
Steer Encoder Card (SEC) (S/N 00117 and Above) 8-53
Steering System 8-54
Steer Amplifier (SA) 8-54
Steer Amplifier (SA) (Kollmorgen) 8-55
Steer Actuator 8-56
Steer Actuator (Kollmorgen) 8-56
Filter Module (CA1) 8-56
Traction Power Amplifier (TPA) 8-56
Traction Power Amplifier (TPA) Inputs 8-57
Traction Power Amplifier (TPA) Outputs 8-58
Regenerative Braking 8-59
Line Opto-Isolator Unit (LOU) 8-59
Line Reactor (LR) 8-60
Hoist Motor Controller (VFI) 8-60
Earth Ground Verification Board (EGVB) 8-63
Battery Charger 8-64
Emergency DC Functions 8-65
DC Shuttle Motor Brake 8-65
DC Shuttle Retraction — Right 8-65
DC Shuttle Retraction — Left 8-65
DC Lowering 8-66
Functional Diagram—Shuttle 8-68
Appendix 9-1
TRT Torque Quick Reference Chart 9-2
Lubrication Specification Chart 9-5
Thread Adhesives Sealants and Lubricants 9-6
Torque Chart – Standard (Ferrous) 9-7
Torque Chart – Standard (Brass) 9-8
Torque Chart – Metric (Ferrous) 9-9
Torque Chart – Metric (Brass) 9-10
Torque Chart – Thread-Forming Screws 9-10
Decimal Equivalent Chart 9-11
Standard/Metric Conversions 9-13
Overspeed Replacement Form 9-15
Index I-1

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