Caterpillar NRM20K, NRM25K Multiway Reach Truck Service Manual 631058

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Caterpillar NRM20K, NRM25K Multiway Reach Truck Service Manual 631058

$50.00

Type Of Manual: Service Manual
Manual ID: 631058
Number of Pages: 325
Size: 6.1MB
Format: PDF

Category: Caterpillar Service Manual PDF

Model List:
- NRM20K, NRM25K Multiway Reach Truck

1.
2.
3.
4.
5.
6.
7.
7.1. Table of Contents
7.2. Scope of this Manual
7.3. Related Documents
7.4. Intended Use of the AC SuperDrive
7.5. Product Identification
7.6. Technical Support
7.7. Product Warranty
7.8. Introduction
7.9. Tools and Equipment Required
7.10. Orientation
7.11. Clearances for Access and Air Circulation
7.12. Procedure
7.13. Introduction
7.14. Tools and Equipment Required
7.15. Motor and Battery Connections
7.15.1. General
7.15.2. Making Connections to Terminal Posts
7.15.3. Inrush Current Limiting Resistance
7.15.4. Main Contactor
7.15.5. Key Start Input
7.16. Control and I/O Connections
7.16.1. General
7.16.2. ID0 and ID1 Inputs
7.16.3. Encoder Signals
7.16.4. Temperature Sensor
7.16.5. CAN Bus Signals
7.16.6. Crimping Contacts onto Signal Conductors
7.16.7. Installing Crimped Contacts in Connector Housing
7.17. General
7.18. Checks Prior to Initial Powerup
7.19. Verifying AC SuperDrive Readiness for Operation
7.20. Configuring the AC SuperDrive for the Application
7.21. Final Operational Checks in Vehicle
7.22. Introduction
7.23. Periodic Preventive Maintenance
7.24. AC SuperDrive Replacement Procedure
7.24.1. Drive Removal
7.24.2. Drive Installation
7.25. Scope of the Troubleshooting Guide
7.26. Using the Troubleshooting Guide
7.26.1. Organization of Troubleshooting Guide
7.26.2. About Errors and Warnings
7.26.3. Error Logging
7.26.4. Using the Troubleshooting Charts
7.27. Information for OEMs Preparing User Documentation
7.28. Symptom Main Contactor doesnt close after switching on Key Switch
7.29. Symptom Fuse to Power Stage is blown
7.30. Symptom AC SuperDrive Status Indicator is blinking or off
7.31. Symptom Motor runs only at low speed and with a ticking sound
7.32. Error Code 1 Pulse Sensor Error
7.33. Error Code 2 Motor Temperature High
7.34. Warning Code 16 Power limited due to Motor Overtemp.
7.35. Error Code 4 Heatsink Temperature high
7.36. Warning Code 1 Power Limited due to Heatsink Overtemp.
7.37. Error Code 8 Overcurrent
7.38. Error Code 16 DC Bus High – hardware detected
7.39. Error Code 32 DC Bus High – software detected
7.40. Error Code 64 DC Bus Low
7.41. Error Code 128 No Charging DC Bus
7.42. Error Code 256 CAN – too many Errors
7.43. Error Code 512 CAN Watchdog Time-out
7.44. Error Code 1024 Missing Okay to Start from Truck Controller
7.45. Error Code 2048 Contradictory Commands from Truck Controller
7.46. Error Code 4096 Potentiometer Values Out of Range
7.47. Warning Code 2 Heatsink Temperature Sensor Open Circuit
7.48. Warning Code 4 Heatsink Temperature Sensor Short Circuit
7.49. Warning Code 8 Power limited – temp < -20 deg. C
7.50. Warning Code 32 Motor Temperature Sensor – Open Circuit
7.51. Warning Code 64 Motor Temperature Sensor – Short Circuit
7.52. Warning Code 128 Speed from Truck Controller Out of Range
7.53. Warning Code 256 Current Calibration Error
7.54. Warning Code 512 Reverted to Default Parameters
7.55. _UM.pdf
7.55.1. Scope of this Manual
7.55.2. Related Documents
7.55.3. Intended Use of the AC SuperDrive
7.55.4. Product Identification
7.55.5. Technical Support
7.55.6. Product Warranty
7.55.7. Introduction
7.55.8. Tools and Equipment Required
7.55.9. Orientation
7.55.10. Clearances for Access and Air Circulation
7.55.11. Procedure
7.55.12. Introduction
7.55.13. Tools and Equipment Required
7.55.14. Motor and Battery Connections
7.55.14.1. General
7.55.14.2. Making Connections to Terminal Posts
7.55.14.3. Inrush Current Limiting Resistance
7.55.14.4. Main Contactor
7.55.14.5. Key Start Input
7.55.15. Control and I/O Connections
7.55.15.1. General
7.55.15.2. ID0 and ID1 Inputs
7.55.15.3. Encoder Signals
7.55.15.4. Temperature Sensor
7.55.15.5. CAN Bus Signals
7.55.15.6. Crimping Contacts onto Signal Conductors
7.55.15.7. Installing Crimped Contacts in Connector Housing
7.55.16. General
7.55.17. Checks Prior to Initial Powerup
7.55.18. Verifying AC SuperDrive Readiness for Operation
7.55.19. Configuring the AC SuperDrive for the Application
7.55.20. Final Operational Checks in Vehicle
7.55.21. Introduction
7.55.22. Periodic Preventive Maintenance
7.55.23. AC SuperDrive Replacement Procedure
7.55.23.1. Drive Removal
7.55.23.2. Drive Installation
7.55.24. Obtaining Factory Repair
7.55.25. Scope of the Troubleshooting Guide
7.55.26. Using the Troubleshooting Guide
7.55.26.1. Organization of Troubleshooting Guide
7.55.26.2. About Errors and Warnings
7.55.26.3. Error Logging
7.55.26.4. Using the Troubleshooting Charts
7.55.27. Information for OEMs Preparing User Documentation
7.55.28. Symptom Main Contactor doesnt close after switching on Key Switch
7.55.29. Symptom Fuse to Power Stage is blown
7.55.30. Symptom AC SuperDrive Status Indicator is blinking or off
7.55.31. Symptom Motor runs only at low speed and with a ticking sound
7.55.32. Error Code 1 Pulse Sensor Error
7.55.33. Error Code 2 Motor Temperature High
7.55.34. Warning Code 16 Power limited due to Motor Overtemp.
7.55.35. Error Code 4 Heatsink Temperature high
7.55.36. Warning Code 1 Power Limited due to Heatsink Overtemp.
7.55.37. Error Code 8 Overcurrent
7.55.38. Error Code 16 DC Bus High – hardware detected
7.55.39. Error Code 32 DC Bus High – software detected
7.55.40. Error Code 64 DC Bus Low
7.55.41. Error Code 128 No Charging DC Bus
7.55.42. Error Code 256 CAN – too many Errors
7.55.43. Error Code 512 CAN Watchdog Time-out
7.55.44. Error Code 1024 Missing Okay to Start from Truck Controller
7.55.45. Error Code 2048 Contradictory Commands from Truck Controller
7.55.46. Error Code 4096 Potentiometer Values Out of Range
7.55.47. Warning Code 2 Heatsink Temperature Sensor Open Circuit
7.55.48. Warning Code 4 Heatsink Temperature Sensor Short Circuit
7.55.49. Warning Code 8 Power limited – temp < -20 deg. C
7.55.50. Warning Code 32 Motor Temperature Sensor – Open Circuit
7.55.51. Warning Code 64 Motor Temperature Sensor – Short Circuit
7.55.52. Warning Code 128 Speed from Truck Controller Out of Range
7.55.53. Warning Code 256 Current Calibration Error
7.55.54. Warning Code 512 Reverted to Default Parameters
7.55.54.1. Table of Contents
8.
8.1. Table of Contents
8.2. Introduction
8.2.1. About APS Documentation
8.2.1.1. Scope of this Manual
8.2.1.2. Intended Use
8.2.1.3. Related Documents
8.2.2. About the Advanced Power Steering Unit
8.2.2.1. Intended Use
8.2.2.2. Safety Instructions
8.2.2.3. Technical Support
8.2.2.4. Product Warranty
8.3. APS Installation
8.3.1. Installing APS in Vehicle
8.3.1.1. Introduction
8.3.1.2. Installing the Actuator
8.3.1.3. Installing a Separately mounted Controller
8.3.2. Installing Steering Feedback Sensors
8.3.2.1. Introduction
8.3.2.2. Potentiometer
8.3.2.3. Home Cam with Center Position Sensor
8.3.2.4. Home Cam with Combination Center/End Limit Sensor
8.3.3. Installing Steering Input Sensors
8.3.3.1. Introduction
8.3.3.2. Stepper Motor
8.3.3.3. Joystick or Potentiometer
8.3.3.4. Encoder
8.3.4. Wiring the APS
8.3.4.1. Introduction
8.3.4.2. Tools and Equipment Required
8.3.4.3. Wiring the APS Mating Connector
8.3.4.4. Battery Power Connections
8.3.4.5. Sensor, Safety and Communications Wiring
8.3.4.6. Actuator to Separately Mounted Controller Cabling
8.4. Startup and Commissioning
8.4.1. Initial Startup
8.4.1.1. General Information
8.4.1.2. Checks Prior to Initial Powerup
8.4.1.3. Verifying APS Unit Readiness for Operation
8.4.1.4. Configuring the APS for the Application
8.4.1.5. Operational Checks in Vehicle
8.5. Maintenance
8.5.1. Maintenance Procedures
8.5.1.1. Introduction
8.5.1.2. Periodic Inspection and Preventive Maintenance
8.5.1.3. Steering Feedback Calibration
8.5.2. APS Replacement Procedures
8.5.2.1. Safety Information
8.5.2.2. APS with Integrated Controller
8.5.2.3. APS with Separately Mounted Controller
8.6. Troubleshooting
8.6.1. Introduction
8.6.1.1. Terms and Definitions
8.6.1.2. Troubleshooting Data Available from APS
8.6.2. The Troubleshooting Guide
8.6.2.1. General
8.6.2.2. Using the Troubleshooting Guide
8.6.2.3. General Troubleshooting Procedure
8.6.2.4. Information for OEMs Preparing User Documentation
8.6.2.5. LED status Indicator is Off
8.6.2.6. High Current Error
8.6.2.7. Voltage Error
8.6.2.8. High Temp Error
8.6.2.9. Watchdog Reset
8.6.2.10. Hardware Power Protection Trip
8.6.2.11. Safety Out Error
8.6.2.12. Steer Sensor Error
8.6.2.13. Switch Error
8.6.2.14. Feedback Sensor Error
8.6.2.15. EEPROM Error
8.6.2.16. Motor Error
8.6.2.17. Position Error
8.6.2.18. Communications Timeout Error
9.
9.1. Table of Contents
9.2. Introduction
9.2.1. About CANION Documentation
9.2.1.1. Scope of this Manual
9.3. Technical Description
9.3.1. Principles of Operation
9.3.1.1. Introduction
9.3.1.2. Introduction
9.3.1.3. CANION Software
9.4. Applications
9.4.1. Order Picker
9.4.2. Order Picker
9.4.2.1. Reach Truck
9.5. Interfacing to CANION
9.5.1. Interfacing Input Devices
9.5.1.1. General
9.5.2. Interfacing Input Devices
9.5.2.1. PWM Outputs
9.5.3. Interfacing Output Devices
9.5.3.1. Interfacing CANION in a Truck Can Network
9.5.4. Can Bus Communications
9.5.4.1. General Configuration
9.6. Installation and Wiring
9.6.1. CANION Installation
9.6.1.1. Mounting CANION in a Vehicle
9.6.2. CANION Installation
9.6.2.1. Introduction
9.7. Specifications
9.7.1. Electrical Power Inputs Outputs
10.
11.
11.1. TS761104
11.1.1. AC-NRM 20K/25K
11.1.1.1. POWERSUPPLY 48V
11.1.1.2. POWERSUPPLY 12/24V
11.1.1.3. MAINCIRCUITS
11.1.1.4. DRIVECIRCUIT 1
11.1.1.5. DRIVECIRCUIT 2
11.1.1.6. STEERING CIRCUIT
11.1.1.7. STEERING CIRCUIT 2
11.1.1.8. STEERING CIRCUIT 3
11.1.1.9. HYDRAULIC CONTROL CIRCUIT 1
11.1.1.10. HYDRAULIC CONTROL CIRCUIT 2
11.1.1.11. CONTROL CIRCUIT 1
11.1.1.12. CONTROL CIRCUIT 2
11.1.1.13. SIGNAL- /LIGHTCIRCUIT
11.1.1.14. FANS, AUX.DEVICES
11.1.1.15. AUX.DEVICES
11.1.1.16. LAYOUT
11.1.1.17. LAYOUT
11.1.1.18. WIRE HARNESS W3 RL468152
12.
12.1. TS1050000
12.1.1. TEM AC SAUER DANFOSS
12.1.1.1. POWER SUPPLY 48V
12.1.1.2. MAIN CIRCUITS
12.1.1.3. DRIVE CIRCUIT
12.1.1.4. DRIVE CIRCUIT 2
12.1.1.5. STEERING CIRCUIT 1
12.1.1.6. HYDRAULIC CONTROL CIRCUIT
12.1.1.7. AUX DEVICES
12.1.1.8. STEERING CIRCUIT
12.1.1.9. CONTROL CIRCUIT
12.1.1.10. SIGNAL/LIGHT CIRCUITS
12.1.1.11. CSM FLASH LIGHTS WITH RUBBER BODY
12.1.1.12. 24V POWER SUPPLY/AUX DEVICES
12.1.1.13. MAIN WIRE HARNESS 479690
12.1.1.14. MAIN WIRE HARNESS 479690
12.1.1.15. PUSH WIRE HARNESS 480917
12.1.1.16. SUPPLY AND MOTOR CABLES 479691
12.1.1.17. INSTRUMENT PANEL WIRE HARNESS 479692
12.1.1.18. PIN CODE LOCK 480016
12.1.1.19. PEDALS 482458
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14.

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