Professional Documents
Culture Documents
Lift
Trucks
Service Manual
Chassis, Mast & Options
NR3000-36V 2NR3800900-up
NR3500-36V 4NR3800900-up
NR4000-36V 5NR3800900-up
NR4000P-36V 6NR3800900-up
NR4500-36V 7NR3800900-up
NR4500P-36V 8NR3800900-up
ND2500-36V 1ND3800900-up
ND3000-36V 2ND3800900-up
ND3000P-36V 3ND3800900-up
NS3000-36V 2NS3800900-up
NS4000-36V 5NS3800900-up
99759-8D100
TABLE OF CONTENTS
THEORY OF OPERATIONS
Solenoid Activation Chart ............................................................................ 3-1
Main Hydraulic Manifold............................................................................... 3-1
Theory of Operation ..................................................................................... 3-2
Plugging in the Battery ............................................................................... 3-2
B+ Feed to .................................................................................................. 3-2
B-Feed to .................................................................................................... 3-2
Additional Safety Circuit (Emergency Power Off)........................................ 3-2
Turning Key Switch (S2) On........................................................................ 3-2
Can Bus Communication ............................................................................ 3-3
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TABLE OF CONTENTS
OPERATOR DISPLAY
Operator Display ........................................................................................... 4-1
General Information ...................................................................................... 4-2
ESC (Escape) Button.................................................................................. 4-2
Scroll Left Button ........................................................................................ 4-2
Scroll Up Button.......................................................................................... 4-2
Scroll Down Button ..................................................................................... 4-2
Scroll Right Button ...................................................................................... 4-2
Enter Key .................................................................................................... 4-2
Battery State of Charge .............................................................................. 4-2
Parking Brake ............................................................................................. 4-2
Clock........................................................................................................... 4-2
Mode of Operation (Optional) ..................................................................... 4-2
Travel Direction ........................................................................................... 4-2
Travel Speed Indicator ................................................................................ 4-2
Text Messaging ........................................................................................... 4-3
Shelf Selector (Option) ............................................................................... 4-3
Load Weight Display ................................................................................... 4-3
Turn KEY On.................................................................................................. 4-4
Under General Settings ................................................................................ 4-4
History Folder ............................................................................................... 4-5
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TABLE OF CONTENTS
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 ........................................................................................ 6-4
Description............................................................................................... 6-4
Free Lift Cylinder ........................................................................................ 6-5
Description............................................................................................... 6-5
Cylinder Operation ...................................................................................... 6-6
Cylinder Raising....................................................................................... 6-6
Cylinder Lowering ....................................................................................... 6-6
Main Lift Cylinder Service
Main Lift Cylinder Disassembly................................................................... 6-7
Cleaning and Inspection ............................................................................. 6-7
Main Lift Cylinder Reassembly ................................................................... 6-8
Piston Rod and Piston ............................................................................. 6-8
Retainer / Retainer Assembly .................................................................. 6-8
Free Lift Cylinder Service
Free Lift Cylinder Disassembly ................................................................... 6-9
Cleaning and Inspection ............................................................................. 6-9
Free Lift Cylinder Reassembly .................................................................... 6-10
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TABLE OF CONTENTS
MAST (continued)
Piston Rod and Piston ............................................................................. 6-10
Retainer / Retainer Assembly .................................................................. 6-10
Mast Uprights
Upright Desciption ...................................................................................... 6-11
Outer Upright Assembly........................................................................... 6-11
Intermediate Upright Assembly ................................................................ 6-11
Inner Upright Assembly............................................................................ 6-11
Upright Chain Inspection
Elongation................................................................................................... 6-12
Edge Wear .................................................................................................. 6-12
Turning or Protruding Pins .......................................................................... 6-12
Cracked Plates............................................................................................ 6-13
Fatigue Cracking ...................................................................................... 6-13
Stress-Corrosion Cracking ....................................................................... 6-13
Corrosion Fatigue .................................................................................... 6-13
Ultimate Strength Failure ............................................................................ 6-13
Tight Joints ................................................................................................. 6-13
Chain Length Adjustment............................................................................ 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 ............................................................... 6-18
Removal & Replace Roller Shim................................................................. 6-19
Upright & Lift Bracket Removal ................................................................... 6-23
Upright Removal ...................................................................................... 6-23
Preparation .............................................................................................. 6-23
Disconnect Battery...................................................................................... 6-23
Upright Disassembly
Rail Cylinders ............................................................................................. 6-25
Rollers and Shims.................................................................................... 6-25
Cable, Hose and Chain Sheaves ................................................................ 6-27
Free Lift Cylinder ........................................................................................ 6-27
Cable and Chain Sheaves .......................................................................... 6-28
Lift Bracket Assembly
Shimming.................................................................................................... 6-30
Pantograph Carriage Roller ........................................................................ 6-30
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TABLE OF CONTENTS
MAST (continued)
Checks and Adjustments ............................................................................ 6-30
Roller Clearance Inspection........................................................................ 6-35
Service..................................................................................................... 6-35
Checking Lower Roller Clearance with
Upright 6" from Fully Retracted Position ..................................................... 6-35
When Using a Pry Bar ................................................................................ 6-35
“C” Clamp Method....................................................................................... 6-36
Checking Upper Roller Clearance with
Upright Extended Approx. 1/2 Full Extension ............................................. 6-37
Checking Upper Roller Clearance with
Upright Extended Approx. to Full Extension ............................................... 6-39
Checking Lower Roller clearance with
Upright Extended Approx. Within 6” of Full Extension................................. 6-40
Fork Removal
Lift Bracket Service..................................................................................... 6-43
Fork Carriage Removal ............................................................................ 6-43
Models Equipped with Sideshift Only ................................................... 6-43
Models Equipped with Tilt Only ............................................................ 6-44
Servicing Lift Bracket Arm Rollers ........................................................... 6-45
Tilt Cylinder Overhaul .............................................................................. 6-47
Cylinder Removal ................................................................................. 6-47
ITA Lift Brackets
ITA Lift Bracket with Sidesifter .................................................................... 6-47
ITA Lift Bracket without Sideshifter ............................................................. 6-48
Cylinder Removal..................................................................................... 6-48
Preparation and Cleaning ........................................................................ 6-48
Disassembly............................................................................................. 6-49
Retainer Assembly ............................................................................... 6-49
Piston Rod and Assembly .................................................................... 6-49
Cleaning and Inspection ....................................................................... 6-50
Reassembly ............................................................................................. 6-50
Retainer Assembly ............................................................................... 6-50
Reach Cylinder Overhaul
Cylinder Removal........................................................................................ 6-50
Remove Forks.......................................................................................... 6-50
Remove the Fork Carriage....................................................................... 6-51
Preparation, Cleaning and Inspection ......................................................... 6-51
Disassembly ............................................................................................... 6-53
Retainer Assembly ................................................................................... 6-53
Piston Rod and Piston ............................................................................. 6-53
Cleaning and Inspection .......................................................................... 6-53
Reassembly ................................................................................................ 6-54
Retainer Assembly...................................................................................... 6-54
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TABLE OF CONTENTS
MAST (continued)
Sideshift Cylinder Overhaul
Cylinder Removal—Lift Bracket .................................................................. 6-55
Remove Forks.......................................................................................... 6-55
Preparation Cleaning and Inspection .......................................................... 6-55
Disassembly ............................................................................................... 6-55
Retainer Assembly ................................................................................... 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...................................................................................................... 6-60
Disassembly ............................................................................................... 6-60
Mounting Selector Valve ............................................................................. 6-60
Connecting Hydraulic Plumbing .................................................................. 6-61
Sideshifter Solenoid Control Valve
Removal...................................................................................................... 6-62
Installation .................................................................................................. 6-63
Mount Selector Valve ............................................................................... 6-63
Install Hoses ............................................................................................ 6-63
Connect Coils .......................................................................................... 6-63
Servicing a Double Reach Lift Bracket ....................................................... 6-64
Installing Reach Cylinders ........................................................................... 6-66
Reach and Tilt Selector Valve Service
Disassembly ............................................................................................... 6-67
Cleaning ..................................................................................................... 6-68
Reassembly—Solenoid Valves.................................................................... 6-69
Reassembly—Counterbalance Valves ........................................................ 6-71
Installation .................................................................................................. 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
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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......................................................................................................... 8-11
Traction Control Function ............................................................................ 8-11
Powering .................................................................................................. 8-11
Limitation of Maximum Travel Speed........................................................ 8-12
Regeneration ........................................................................................... 8-13
Controlled Roll Back ................................................................................ 8-13
Steering ................................................................................................... 8-14
Stall Timer................................................................................................ 8-14
Free Lift.................................................................................................... 8-14
Hydraulic Control Function.......................................................................... 8-16
Hydraulic Controller ................................................................................. 8-16
Priority ..................................................................................................... 8-17
Inhibition of Simultaneous Operation ....................................................... 8-17
Attachments 2 and 3................................................................................ 8-17
Steering Control Function ........................................................................... 8-18
OPP (Operator Presence Pedal) Function .................................................. 8-19
Preventing Operator’s Absence................................................................ 8-19
Other Functions .......................................................................................... 8-20
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TABLE OF CONTENTS
CONTROLLER (continued)
BDI (Battery Discharge Indicator) ............................................................ 8-20
Service Indicator ...................................................................................... 8-20
Hour Meter Function ................................................................................ 8-20
Chime Control Function ........................................................................... 8-21
Battery Voltage Monitor............................................................................ 8-21
Display Function (See Display Section) ...................................................... 8-22
Normal Operation Display ........................................................................ 8-22
Error Display ............................................................................................ 8-23
Password Display..................................................................................... 8-23
Removal and Installation.............................................................................. 8-24
Inspecting Before Replacing Controllers..................................................... 8-24
Checking Inverter and DSP Card............................................................. 8-24
Checking Logic Card................................................................................ 8-25
Checking Power Supply Card .................................................................. 8-26
Checking Output Unit............................................................................... 8-27
Checking Display Unit .............................................................................. 8-28
Discharging Electric Charges from Inverters and APS Unit ........................ 8-29
Replacing Inverter....................................................................................... 8-30
Replacing DSP (Digital Signal Processor) Card ......................................... 8-32
Replacing Logic Unit................................................................................... 8-34
Replacing Logic Card ................................................................................. 8-35
Replacing Power Supply Card .................................................................... 8-36
Replacing Output Unit................................................................................. 8-37
Replacing APS (Advanced Power Steering) Unit ........................................ 8-38
Basic .............................................................................................................. 8-38
Basic Items ................................................................................................. 8-38
Testing Tools ............................................................................................... 8-38
Pin by Pin Voltage Measurement ................................................................ 8-39
Pin by Pin Measurement Chart................................................................... 8-40
Coil Resistances ......................................................................................... 8-50
Checking Contactor ...................................................................................... 8-51
Checking Contactor Coil ............................................................................. 8-51
Checking Contactor Tip .............................................................................. 8-51
Checking Inverter.......................................................................................... 8-52
Regeneration Check ..................................................................................... 8-52
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TABLE OF CONTENTS
PLANNED MAINTENANCE
Maintenance Locations ................................................................................ 10-1
Maintenance Intervals .................................................................................. 10-2
Service Data
Recommended Lubricants .......................................................................... 10-3
Fluid Capacities .......................................................................................... 10-3
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