Caterpillar NRM20K, NRM25K Multiway Reach Truck Service Manual 631058
Caterpillar NRM20K, NRM25K Multiway Reach Truck Service Manual 631058 - Image 2
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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:

Product details

  • 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
  • 13.
  • 14.
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