306756-000 RRX/RSX/RDX Master Service Manual 2002_February
Contents
1. Main Components of Truck 44 Master Service Manual 2000 08 04 F code Section C code M1 1 Inch SAE and Metric Fasteners Kalmar AC oe Inch SAE and Metric Fasteners 222 E EN O OO 1 Introduction Threaded fasteners such as bolts nuts cap screws and studs are made to specifications that describe the mechanical strength and hardness of the fastener A fastener used in a design application is selected in accordance with its specifications Parts used on this truck are purchased from many countries Many of these fasteners are similar but cannot be used as direct replacements Service persons must use replacement fasteners that have the same specifications Fasteners made to each specification have identification marks for that specification This specification is commonly called grade for SAE standards and property for metric standards This section describes the identification of some common fasteners The metric system used is described as SI International System of Units also called SI in all languages The SI system of measurement is described in ISO Standard 1000 1973 O Kalmar AC Inc Master Service Manual 2002 01 16 45 F code Section M1 1 Inch SAE and Metric Fasteners T code C code Version no 002 ca THREAD d Wann 2 Nomenclature Threads The thread design is specified by a series of nu2. Height 16 4 416 mm 60 0 127 mm 231 mm 1524mm 10 Gradient Performance Loaded Kalmar AC Inc Master Service Manual 2000 08 04 37 F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 1 8 ND30B Dimensions The following diagram shows external dimensions for the ND30B truck in its standard design 8 5 215 mm to E 29 5 749 mm EE y BE GENI icm GE 5 5 139 mm EL Y a gt 31 0 U x40 101 mm o 787 mm LH Foke 30 48 50 0 1270 mm H DH DH E d E a LI 5 5 139 mm 74 6 1894 mm 53 4 1356 mm Max Reach 46 0 gt 1168 mm A gt gt 13 3 337 mm B 39 7 1008 mm 95 0 2413 mm 11 5 292 mm Step 7 0 Height 177 mm Battery Roller n Height al Max Stroke 16 44 tell 116 mm 2 0 50 mm 5 0 127 mm 76 mm 9 4 60 0 JM 231 mm 1524 mm 1096 Gradient Performance Loaded 38 Master Service Manual 2000 08 04 F code Section C code M1 0 General Product Information amp kaimarac ze 001 395 396 397 398 399 1 9 NS40B Dimensions The following diagram shows ext
3. Inch SAE and Metric Fasteners Version no T code 002 Table 4 Torque Nut with Nylon Insert Designations Inch Fasteners Strength Levels SAE Grades Metric Fasteners Strength Levels Property Classes TI Nylon Insert Pre vailing Torque Nuts Markings Not Required Kalmar AC Inc m Nylon Insert Pre vailing Torque Flange Nuts Markings Not Required Master Service Manual 2002 01 16 51 F code Section M1 1 C code Inch SAE and Metric Fasteners Vers 002 ion no T code Table 5 Fastener Torque Values Property Class Property Class Property Class Size and Pitch 8 8 10 9 12 9 Nem in Ib Nem in Ib Nem in Ib M5 x 0 8 5 6 44 53 7 8 62 71 8 10 71 88 M6 x 1 8 10 71 88 12 14 106 124 14 16 124 142 M8 x 1 25 20 25 177 221 30 35 Nem ft Ib Nem ft Ib Nem ft Ib M8x1 25 een 22 26 34 40 26 30 M10 x 1 5 40 45 30 33 60 65 44 48 70 75 52 55 M12 x 1 75 70 80 30 33 100 110 74 81 115 130 85 96 M14 x2 110 125 52 59 155 180 114 133 180 210 133 155 M16 x 2 170 190 125 140 240 270 177 199 280 320 207 236 M20 x 2 5 340 380 251 280 450 500 332 369 550 600 406 443 M24 x 3 580 650 428 479 800 900 590 664 900 1050 664 774 M30 x 3 5 1150 1300 848 959 1600 1800 1180 1328 1850 2100 1364 1549 M36 x4 2000 2250 1479 1660 2800 3150 2065 23
4. Property classes less then 8 8 are often not marked Grades for inch bolts go from 2 to 8 Grade 2 fasteners normally do not have marks The following tables show the marks that identify the grades and property classes for different fasteners A WARNING When fasteners must be replaced the new fasteners must be of the same strength or greater than the original fasteners The new fasteners must also be the correct size NOTE Identification marks are according to bolt strength The higher the number or the increase in the number of marks indicates increased bolt strength O Kalmar AC Inc Master Service Manual 2002 01 16 47 Section C code M1 1 Inch SAE and Metric Fasteners T code F code Version no 002 Types of Fasteners Table 1 Bolt and Screw Designations Inch Fasteners Strength Levels SAE Grades Metric Fasteners Strength Levels Property Classes Markings Not Required Hex Head Bolts amp Cap Screws 2 5 52 7 8 66666 4 6 4 8 5 8 10 9 Markings for size M5 and Larger 7 Hex Head Flange Screws 12 Point Flange Screws Same As Above Lo Hex Socket Head Cap Screws Markings Not
5. Speed of the truck is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving The forks and auxiliary functions are controlled by means of a transistor controller Control of the lift and auxiliary functions are done electrically with the levers on the control pod Control of the speed and positioning of the forks when stacking is done by the position of the levers The trucks can be fitted with different accessories including sideshifter warning light lights fan package travel alarm and adjustable driving lights The trucks can be specially equipped to work in cold conditions 1 1 Truck Side Views The terms rearward and forward used indicate the front and back side of the truck as viewed from the operator s line of sight for proper operation of truck The terms right hand and left hand used indicate the right and left side of the truck as viewed from the operator s line of sight for proper operation of truck Left Side Rearward Forward Right Side Kalmar AC Inc Master Service Manual 2000 08 04 33 F code Section C code M1 0 General Product Information Version no 001 T code 395 396 397 398 399 1 2 Open Back Compartment The truck compartment has an open back design The United States Department of Labor Occupational Safety and Health Administration OSHA has determined that when a stan
6. 2439 Drive tire lug nut 95 ft lb 129 Nem Transmission axle bearing preload 9 14 in Ib 1 01 1 58 Nem Transmission bevel gear nut 90 ft lb 122 Nem Transmission pinion nut 110 120 ft lb 149 162 Nem Transmission pinion bearing preload 5 8 in Ib 0 56 0 90 Nem Transmission cover bolts 18 ft lb 24 Nem Transmission case Loctite 515 Hydraulic collar mounting bolts 44 4 in Ib 5 01 Nem Tilt cylinder piston nut NR45B ND30B 60 65 ft lb 81 88 Nem Lift chain adjusting nuts and locknuts 200 ft lb 271 Nem Control valve assembly hose fastener nut Control valve double solenoid screw and mounting screw Control vale plug Control valve block screw Control valve spring ball screw 480 25 in Ib 54 Nem 14 75 ft lb 20 Nem 11 06 ft lb 15 Nem 5 9 ft lb 8 Nem 8 85 ft lb 12 Nem Kalmar AC Inc Master Service Manual 2002 01 16 53 F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Truck Torque Specifications Description Torque Specification Lower mast mounting bolts 400 ft lb 543 Nem Overhead guard post base bolts 25 ft lb 34 Nem Reach cylinder piston locknut NR35B NR45B ND30B 47 94 ft lb 65 Nem Mast mounting plate bolts 85 ft lb 115 Nem Sideshifter lower hook bolts 55 ft lb 74 Nem Sideshifter lower hook set screw 42 ft lb 57 Nem NR35B S
7. Manual Battery Safety O Kalmar AC Inc Master Service Manual 2000 08 04 25 F code PS Static Safety Version no 001 Section T code C code Static Safety Electronic circuit board and devices used on truck can be damaged by the discharge of static electricity called electrostatic discharge Static charges can accumulate from normal operation of truck as well as movement or contact between non conductive materials such as plastic bags synthetic clothing synthetic soles on shoes styrofoam coffee cups etc Accumulated static can be discharged through human skin to a circuit board or component by touching the parts Static discharge is also possible through the air when a charged object is placed close to another surface at a different electrical potential Static discharge can occur without seeing or feeling it Whenever working on or near static sensitive electronics always use static discharge precautions 1 Place a static discharge wrist strap around the wrist Connect the ground lead to the wrist strap connector 2 Connect the ground clamp to an unpainted ground surface on truck frame 3 If removing or installing static sensitive components place them on a properly grounded static mat 4 To transport static sensitive components including failed components being returned place the components in an antistatic bag or box The wrist strap and associated accessories should be test
8. S 583 PUISE SENSOR sospira tungen Und MAC a ERA DOMIN IER 585 Height Indicator and Preset Selector eese 587 Generali criniera Ct RR T EDS 588 Operation ves 588 Preset Beete eebe 589 Leet Eat Eege 590 Display Symbols Description sss sse 591 Master Service Manual 2001 10 12 Table of Contents Programming artista 592 Load Backrest ida 601 Removal A ata 604 mstallation EEN 604 O Kalmar AC Inc Master Service Manual 2001 10 12 13 Table of Contents 14 Master Service Manual 2001 10 12 amp kaimarac F code Section C code PS Warning Symbols Version no T code 001 Warning Symbols Always follow the warnings given in this Service Manual and on the truck to avoid accidents and incidents from occurring 1 Warning Levels Warning levels Warning texts are given in four levels and provide information on the risks describe the consequences and instruct how to avoid accidents A DANGER Warns that an accident will occur if the instructions are not followed The consequences are serious personal injury or possibly death and or extremely large material damage A WARNING Warns that an accident can occur if the instructions are not followed The consequences are serious personal injury or possibly death and or large material damage AN CAUTION Warns that an accident can occur if the instructions are not followed The conseq
9. Standard eee ER 1 Warning Symbols aii ea 15 Warning Levels urinarie A A 15 Prohibrtory Symbols eene dia 16 Ordinance Symbols susi a ila 16 Ip Ac EE 17 General RE 17 Baltery Safe cosacos 21 Statie Safety Mee M 26 Welding Safety alleluia 27 Introduction Service Manual iii 29 Contents Section M ad 31 Machine Information eii A lele 31 General Product Information iii 33 Presentation of the Rider Trucks 33 Main ee ee IEN 42 Inch SAE and Metric Fasteners ooocccccccncnccnnncnnnnnnnnnnnananannnnn cnn nn nnnnnnnnnnnnes 45 Jee el erte NEE 45 Nomenclature Threads Iar tedio e Dt ee dcr eee Done 46 Strength Identification NEE 47 Conversion of Metric and English Units sese e 55 Technical Service Data 57 Ordering Spare Parts lil liacle ui di Basi ian 61 Contents Section GE 63 Planned Malntenarte ae EES 63 Introduction Maintenance iii 65 Jacking Truck Off The Floor sse eee eee etae nia 66 Lubricants ses Dac Sales bte oni EA 68 Service Schedule aida 71 Planned Maintenance Schedule sese 71 Kalmar AC Inc Master Service Manual 2001 10 12 Table of Contents Planned Maintenance Procedures AE 76 Lubrication Chart qc 83 Oil and Grease Specifications i 84 Approved Oils and Grease E 84 Grease Location POINTS clin 85 MastAdjusiment PONS cad
10. as possible Disconnect all electrical cards before any type of electric resistance welding is done Do not perform any welding operations near the electrical components If welding must be done near the battery compartment remove the battery from truck e When welding is completed perform all ground tests and electrical inspections before the vehicle is operated 28 Master Service Manual 2000 08 04 amp kaimarac F code Section C code M Introduction Service Manual Version no T code 001 395 396 397 398 399 Introduction Service Manual The information in this Service Manual covers models NR35B NR45B ND30B NS40B and NS50B Federal and State laws require that operators be completely trained in the safe operation of trucks in accordance with OSHA regulation 1910 178 An Operator s Manual is sent with every Kalmar AC Inc lift truck when it is manufactured If the Operators Manual is missing from the truck a new manual may be obtained by contacting Kalmar AC Inc 14481 Lochridge Blvd Bldg 2 Covington Georgia 30014 770 788 3612 This Service Manual is not a training manual The information contained in this service manual is intended as a guide to help trained qualified and authorized technicians safely service the truck The Service Manual is divided into four separate sections which cover needed information for servicing the truck types The main subject for each of the sec
11. eli alianti 86 A e a 87 Service Instructions oio e citet ren Sues AA AN AAA 87 Troubleshooting Guidelines esee 89 General TL 89 Electical arredati 91 s Mis rz qu eer EE EE 96 B inilio n EE 97 CASSIS alal 99 General ni E 99 Delle 100 Motor Compartment Door EEN 101 Left Hand Side Panel EEN 102 Operator Compartment Panel 103 Mam Card Access Panel iniecta risp a erae e ease 103 Battery Compartment neon iaia 105 Battery Retainer Plates ri 106 Battery ROES ura e ede dedi eet aet nd i boia 106 Driver Controls a Ss 107 Brake Pedal NS40B NR35B socia a cada RR n Rasa acne 109 Pedal Removal aa eR ca 110 Pedal Bearing Replacement i 111 Pedal Adjustment i enee cds 111 Brake Pedal NS50B NR45B ND30B REENEN 112 Pedal Removal nidad IR A A ind Amit ila 113 Pedal Bearing Replacement nn nn nnnnnnnnnos 114 GEET EE 114 E UG u E Guardi T spree eee see 115 We 117 Master Service Manual 2001 10 12 Table of Contents Decal with Protective Sheet ici 117 Decal without Protective Sheet AAA 117 Steering Motor siete hs toe baise li ee 121 Removal sase licia end onda sus rt ait abe b i 121 ESMAS Rot p e i ARI 121 Steering Motor Gear Replacement n 122 Fan Motor fec TR 123 Upper Electrical Compartment Fan sss eee 123 Operator Fai carriera ei ce Fu Peta ben z 124 Motor Ma
12. or article number cannot be found call your local Komatsu Forklift Dealer for assistance Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 61 F code Section PS M3 0 Ordering Spare Parts Version no T code 001 C code 62 Master Service Manual 2000 08 04
13. 197 Non Braking Caster Assembly NR35B NS40B 199 A sake elei Gr aaa 200 IriStellati ht sale Eb A c da Es LU PLE bade iD EE 200 Braking Caster Wheel NR45B ND30B NS50B 201 Removal otia dU pe cdi S ce a Dk da upra di ae oig fou Mito da d aay 203 Braking Caster Assembly NR45B ND30B NS50B 205 REMOVAL T 207 A O ei 208 Load Wheels Sizes 4 X 3 5 X 4 and 5X3 ccce 209 Ee EE 211 INSTANT ia 212 Load Wheels Size 10 5 X 3 5 iii 213 Removal daa 214 Iristall duo oa one E ded bum ouo ibus siot IS bu ido 214 Steering Arm Wheel Lever eese 215 Control Pod icut ero mure t pA A LA Cad A LR EE 217 steering Wheel EE 218 es ccc urd ead 219 Steering Tal L ail 221 Removal 222 Installation varate ari baila eat e au nre tego cena dle ile ia i 222 Electrical EHNEN 223 Gone a 223 A A 227 Steering Components pitt lA terrd bdo 231 Master Service Manual 2001 10 12 Table of Contents Brake Release iio O aa 237 Direction Selection crac a 239 Travel Request FORKS EEN 241 Travel Request Forks Trailing EN 245 lt Ne Tt DEE 250 12 Volt Power Supply d eei i a ctia nee i nd Aa 254 7 35 Volt Power Supplies iter 255 tee 258 Height Indica ls 262 Drive Motor Brush Wear Indicator Switches 2
14. 23 3250 3700 2397 2729 Property class 8 8 Protective Treatment CMHC Specification H zinc phosphate applies also to internally threaded fasteners made of property class 8 material Property class 10 9 Protective Treatment CMHC Specification H zinc phosphate applies also to internally threaded fasteners made of property class 10 material Property class 12 9 Protective Treatment CMHC Specification H zinc phosphate applies also to internally threaded fasteners of property class 12 material 52 Master Service Manual 2002 01 16 amp kaimarac F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Truck Torque Specifications Description Torque Specification Steering motor gear mounting bolt 88 in Ib 10 Nem Motor terminals 140 in Ib 15 82 Nem Motor pole piece screws 250 300 in Ib 28 33 Nem Pump motor mounting bolts 14 18 ft Ib 19 24 N m Pump motor electrical power cable nuts 100 120 in Ib 11 3 13 6 Nem Drive motor mounting bolts 20 25 ft lb 30 35 Nem Transmission mounting bolts 50 59 ft Ib 68 80 N m Drive wheel nuts 65 ft lb 88 Nem Overhead guard mounting bolts 200 ft Ib 271 N m Drive axle retaining bolts 81 ft lb 109 Nem Steering gear ring bolts 50 59 ft Ib 68 80 Nem Steer motor shaft Loctite
15. 270 210 402 inches mm 4876 6858 5334 10210 5334 10210 4876 6858 5334 10210 Operating 24 Volt 24 Volt speed without 9 9 mph 36 Volt 36 Volt o pn 36 Volt load mph E 6 5 mph 6 5 mph SOON 6 5 mph i 6 5 mph i 6 5 mph i Operating 24 Volt 24 Volt speed with 9 3 mph 36 Volt 36 Volt 3 9 mph 36 Volt load mph 26 VOI 6 0 mph 6 0 mph 20 yol 6 0 mph i 6 0 mph i 6 0 mph Service weight 240 Mast 210 Mast 330 Mast 210 Mast 210 Mast without battery 5595 5915 6945 4645 5530 Ib kg 2537 2682 3150 2106 2508 Service weight Above Above Above Above Above including battery battesvcwelalt battery weight battery weight battery weight battery Ib kg weight ry Welg 2600 min 2400 min 2400 min The lifting capacity lifting height and weight of the truck can be found on the truck data plate O Kalmar AC Inc Master Service Manual 2000 08 04 35 F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 1 6 NR35B Dimensions The following diagram shows external dimensions for the NR35B truck in its standard design i IL 5 5 139 mm gt 16 0 KS l 32 0 812 40 4 75 44 mm ae o i 4 07007 r 1028 Eat A A 48 295 50 0 1270 mm E 749 mm Y ad EE 5 5 139 mm sg 7222 A 1833 m
16. 64 Pump Motor Brush Indicator Switch 265 Salely Check suit iii uw me fec b n enis lalla 266 Shunt Power ee 268 Electrical Symbols iii ips lai 275 Electrical Schematics Serial numbers 27163000 28105000 277 Circuit Diagram TOL T es asd ner tener eta cto ecce coe 277 Circuit Diagram 2l T corr 278 Circuit Diagram 1 R D aio 279 Circuit Diagram ATT corto oe Og petia totes 280 Circuit Diagram SOU 5i eden dq uid imitar acie fid esce nos ace edet 281 Circuit Diagram O 11 iui iu penetrar rane cee eee ee 282 Circuit Diagram uus CR 283 AA t um P 284 Circuit Diagram 9CUD anatre ilc las ee ete 285 Circuit Diagram C 286 Circuit Diagram DIU B ere rn le ti lodo retento 287 Electrical Schematics Serial numbers 28105001 28126000 289 Creu Diagram 12 duo dtp UP eeu lem am aleam Eos 289 Circuit Diagram pM ES ER LE 290 Circuit Diagram KEE 291 Circuit Diagram RAP 292 Circuit Diagram 9 12 zs sze A eoe 293 Circuit Diagram 6 12 li 294 Circuit Diagrami Ee ee ee doeet eie leere of etur euntem ios 295 Circuit Diagram 8 12 tee Un een tentus iai as 296 Circuit Diagram 9 T2 d dq uit nitet det e pesi do aa ctia 297 Circuit Diagram 10 12 5 eene iii 298 Circuit Diagram 11 12 EE 299 Circuit Diagram S G EE 300 Electrical Schematics Serial numbers 28126001 31285000 301 Circuit Diagram TUE ii 301 O Kalmar AC Inc Master Ser
17. 82 RV2 Adjustment Procedure cetonas 382 Adjustment Procedures for Setting Brake Switch and Brake Transducer 383 Kalmar AC Inc Master Service Manual 2001 10 12 Table of Contents Battery Discharge Indicator Parameter Adjustment 384 A5 Jumper Harness Kit Installation Serial numbers 28126000 below 390 Warning aullom Odes tercios ideada 393 ErrorGOdes pio ina ovr e ee ds tomo o rea 395 Programming Parameter sti o ndo ardet 401 Switches KE E 411 Generale iti 411 Platform Right Foot Switch S108 23 3 5 ceeds ate ens plo ette e 411 Staging Switch 845 RE 413 Wheel Direction Sensor 415 Steer Proximity Sensors A and B S66 and S67 417 Drive Motor Speed S64 Direction Sensors S125 419 Hydraulic SySIGITI aui oet nes a taies Sese pau atu leali ceri 421 OPTA MON Bee 421 NR35B Hydraulic Schematic nn nononononoos 442 NR45B Hydraulic Schematic ono nnnnnnnnnos 443 ND30B Hydraulic eu TEE 444 NS40B Hydraulic Schematic spin deutet tecto tete peii de 445 NS50B Hydraulic arbeiten 446 Hydraulic FIUIQ ad o 447 Hydraulic Fluid Selection AE 447 Changing Hydraulic System Fluid i 447 System Draining ta qe ee AE 448 Refilling SY SlOIN pe A A eli LI alata 449 Bleeding Hydraulic System ii 450 Hydraulic Tank na e aa c 452 Removal e 453
18. Insiallalio ali I ii 454 Hydraulic Filter Assembly iii 456 Hydraulic Per a paola ao det ert atc titers 457 Hydraulic Filter Adapter ii 458 Hydraulic Pump iioii o Etc einer an 460 Removal orologio Danis aea ded nere nA erae 460 Repair rali EE 460 Ve 461 Removal LL EE 461 Installation bru Rx c 461 Master Service Manual 2001 10 12 Table of Contents Control Valve Assembly sssssssss ereer ee sees sees essere ennenen ennn 466 A o eee 468 Staging Cylinder Three Stage Mast ecce 473 Bearing Removal aii Mam 474 Disdssembly A lla 475 Ln s EE 475 MS EAU ALLO asst eho OECD D TA EUN 475 Freelift Cylinder Three Stage Mast eene 477 REMOVAL pra Dn 479 Disassembly seat recientes IAEA DT pa 480 el 480 a Lo 480 Reach Cylinder Assembly iiiiiiii iii iii iene 481 Removal ira AREA A 483 ASAS EMI a deelen einer leo set zat E 484 INSPECUON verano 485 Lane toot exec Out coerced eek cates poe lessen cosines tone EErEE aiae 486 Instala ron ds 487 Tilt Cylinder Assembly NR35B NS40B NS50B 489 Removal nasan eii a EE 490 SIS EMI a 491 ee ee 492 ASSEMDIN sr EE 493 Installation eco A A A dates eo cod Fi O bios 494 Tilt Cylinder Assembly NR45B ND30B esse sees eee essere reenn 495 Removal sist da n 497 DISASSEMBLY a 498
19. K Kalmar AC Master Service Manual Book TM5749 2 NR35B 45B ND30B NS40B 50B Electric Stand Up Rider Truck Effective Serial Number 27163001 and Up Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place Date February 07 2002 2002 Kalmar AC Inc Covington Georgia All Rights Reserved D kaimarac F code Section C code Standard Codes Version no T code 000 Standard Codes B Code Business area F Code Product family T Code Product type C Code Component function Worksheet standard W Code Working code R Code Reason code SO Code Assortment F Code List PS Powered Pallet Stacker T Code List Code Model 395 NR35B 396 NR45B 397 ND30B 398 NS40B 399 NS50B C Code List No Function Group C Code O Chassis 0000 1 Motors 1000 2 Drive Gear Transmission 2000 3 Brake Wheel System 3000 4 Steering System 4000 5 Electrical System 5000 O Kalmar AC Inc Master Service Manual 2000 08 04 1 F code Section C code Standard Codes Version no T code 000 6 Hydraulic Pneumatic System 6000 7 Operating Function lifting Mast Cylinders 7000 8 Peripheral Installation Equipment 8000 9 Options Attachments 9000 2 Master Service Manual 2000 08 04 Table of Contents
20. N 27091 000 28075000 NR45B S N 27091000 28266000 ND30B S N 27091000 28266000 Sideshifter lower hook bolts 65 ft lb 88 Nem Sideshifter lower hook set screw 21 ft lb 28 Nem Sideshifter safety screw 70 ft lb 95 Nem Sideshifter cylinder hydraulic fittings 56 ft lb 76 Nem NR35B S N 28075001 UP NR45B S N 28266001 UP ND30B S N 28266001 UP NS40B S N 2830800 UP NS50B S N 28308000 UP Reach outer arm jam nut NR35B 34 36 ft lb 47 Nem Loctite 243 Reach outer arm jam nut NR35B 45B ND30B Loctite 243 54 Master Service Manual 2002 01 16 F code Section C code M1 1 Inch SAE and Metric Fasteners K Kalmar AC e 4 Conversion of Metric and English Units AREA Multiply By To Get Multiply By To Get inches 6 451 centimeters cm centimeters 0 155 inches in feet 0 093 meters m meters 10 764 feet ft LINEAR Multiply By To Get Multiply By To Get inches 25 4 millimeters mm millimeter 0 039 inches in feet 0 305 meters m meter 3 280 feet ft yards 0 914 meters m meter 1 094 yards yd miles 1 609 kilometers km kilometer 0 621 miles mi MASS Multiply By To Get Multiply By To Get ounces oz 28 49 grams g grams 0 035 ounces oz pounds Ib 0 454 kilograms kg kilograms 2 205 pounds Ib tons 2000 Ib 907 18 kilog
21. N 27135001 UP Steering circuit 30A S N 27135001 UP part number 25275 13 30A S N 27091000 27135000 part number 122308 300 BATTERIES Dimension W x L x H 14 4 x 38 8 x 32 0 355 x 985 x 812 16 4 x 38 8 x 32 0 416 x 985 x 812 16 4 x 38 8 x 32 0 416 x 985 x 812 Weight Minimum 1600 Ib 726 mm 2300 Ib 1043 mm 2000 Ib 907 mm 2300 Ib 1043 mm inches mm 16 4 x 38 8 x 32 0 21 0x 38 8 x 32 0 21 0x 38 8 x 32 0 416 x 985 x 812 533 x 985 x 812 533 x 985 x 812 Capacity Max 24 V 1395 7 l Amp hrs 36 V 1240 36 V 1240 36 V 1240 14 5 inch 16 5 inch 16 5 inch 2000 Ib 907 mm 2300 Ib 1043 mm Maximum 16 5 inch 21 0 inch 21 0 inch 2000 Ib 907 mm 2600 Ib 1179 mm 2400 Ib 1089 mm 2300 Ib 1043 mm 2900 Ib 1315 mm 2900 Ib 1315 mm DRIVING SPEEDS 24 V 6 0 mph Without load 36 V 6 5 mph 36 V 6 5 mph 36 V 6 5 mph f 24 V 5 5 mph With rated load 36 V 6 0 mph 36 V 6 0 mph 36 V 6 0 mph Kalmar AC Inc Master Service Manual 2001 09 18 59 F code Section C code PS M2 0 Technical Service Data Version no T code 003 395 396 397 398 399 MODEL NR35B NS40B ND30B NR45B NS50B LIFTING LOWERING TIME TON 24 V 60 fpm Lift without load 36 V 80 fpm 36 V 94 fpm 36 V 94 fpm VES 24 V 40 fpm Lift with rated load 36 V 60 fpm 36 V 60 fpm 36 V 60 fpm L
22. Required 48 Master Service Manual 2002 01 16 F code Section C code M1 1 Inch SAE and Metric Fasteners Kalmar AC S Table 2 Stud and Nut Designations T f Inch Fasteners Metric Fasteners ypes o Strength Levels SAE Grades Strength Levels Property Classes Fasteners Markings Not Required Markings Not Required 6 4 87 5 87 8 8 8 10 9 12 9 Markings O SE an 8 1 Larger 000 Optional Geometric Symbols for Size M5 through M11 ONLY 8 E E den m 99090 eo ei Hex Nuts d Us D Ce OSD Det Ced Markings Not Required 8 9 10 12 Hex Slotted Nuts 2 8 9 10 12 SEN Hex Flange Nuts Markings Not Required ci at ar ET NEE O Kalmar AC Inc Master Service Manual 2002 01 16 49 F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Table 3 Torque Nut Designations Types of Inch Fasteners Metric Fasteners Fasteners Strength Levels SAE Grades Strength Levels Property Classes B C C A 1D TD 8D ded ES g All Metal Prevailing O Torque Nuts 2 Z 3 F G GS YA om V 2 or All Metal Pre O vailing Torque S or Flange Nuts ILL JE Master Service Manual 2002 01 16 50 amp kaimarac Types of Fasteners F code Section C code M1 1
23. Tuez EE 499 ISSO EA A 500 ele WEE 501 Mast J AA a E E 503 Shimming Carriage with Mast on Truck eee 507 Three Stage Masl a szek EKE mesi ed el 509 MECO A ili 514 Lifting Gear Crosshead cisco lied 523 Lifting Gear Repair micrones 525 Sideshifter NR35B 45B ND3OB sse essen 527 O Kalmar AC Inc Master Service Manual 2001 10 12 11 Table of Contents MOUNING Insiruclionsizia rie TN 529 Operation and Maintenance EEN 530 Sideshifter NR35B 45B NS40B 50B ND30B 533 Mounting Instructions a urit rq dmt rient mulie e urere quus 535 OPM oos vexit tut ad ev Rod area A Ra 536 Mainienante ru err Tcp 536 Troubleshooting oor etie ld atra o 540 Single Reach NR35B ilaria 541 Maint naN e PRU 547 ROTO REPAIR A AA A AA 552 Carnage Bumpers aida 556 Fork Carriage Pivot Pins ce idos 558 Carriage Roller Bearings pesce 558 Single Reach NR45B li ai rail 559 Mailif nalleg atei aiar i Du eld Laus mo 559 Reach Reparar 567 Fork tGarndge PIVOE PINS ucc ero roc eo often ferie ae iris 571 Carriage Roller Bearings eee eee eee 572 Double Reach Mechanism ND30B eene nennen nnns 573 Theory of Operation td eMe oe uar qu ad su kei pae Fed tai 575 Enn TEE 575 Troubleshootng enin ertet Do lab ail ea 575 Repar A ee elez Mu Dea dut 575 A A rara 575 Le AAA id ii ie o ABE RES 577 Removal ss EP 579 INSPECIOR cata 579 SMN a a da 580 Coad IICA E 581 LOT M Ts 1 eT ii
24. U S gal gallons U S 0 83 gallons Imp gal gallons Imp 1 205 gallons U S gal ounces 29 57 milliliters ml milliliters 0 034 ounces oz 56 Master Service Manual 2002 01 16 Kalmar AC F code PS Section C code M2 0 Technical Service Data Version no 003 T code 395 396 397 398 399 Technical Service Data AA WARNING When the battery tolerance is fully charged performance may vary due to motor and system efficiency service data represents nominal values obtained under typical operating conditions Specifications are subject without notice Technical to change MODEL NR35B NS40B ND30B NR45B NS50B DRIVE MOTOR Type Series DC Series DC Series DC Power Duty factor 1 Hour Continuous 1 Hour Continuous 1 Hour Continuous Minimum brush length 0 8 inch 20 mm 0 8 inch 20 mm 0 8 inch 20 mm Minimum commutator diameter 2 90 inches 74 mm 2 90 inches 74 mm 2 90 inches 74 mm Minimum brush spring tension 6 4 oz 180 grams 6 4 oz 180 grams 6 4 oz 180 grams TRANSMISSION GEAR Vertical motor spiral Vertical motor spiral Vertical motor spiral Type bevel output bevel output bevel output Gear ratio 17 57 17 57 17 57 Oil volume 1 gal 4 liters 1 gal 4 liters 1 gal 4 liters TRANSMISSION GEAR AMBIENT TEMPERATURES Stan
25. ay error codes travel direction parking brake steering angle and battery status 12 Mast The mast is a clear view model 1 42 Master Service Manual 2000 08 04 D kaimarac F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 13 Electronics The electronics are in a protected compartment 14 Control circuit fuse for fuse size and part number see page 59 15 Steering circuit fuse for fuse size and part number see page 59 16 Drive motor fuse for fuse size and part number see page 59 17 Pump motor fuse for fuse size and part number see page 59 18 Right foot pedal An operator must keep all of his or her body in the operators compartment at all times The area of the operator s compartment in the truck is designed so that an operator can do so A red triangle reminder light will be displayed on the instrument panel if the right foot pedal is not depressed This feature reinforces that the operator must take advantage of the area of the operator s compartment and keep all of his or her body in the compartment 19 Emergency stop The emergency stop switch will stop all control and power functions Kalmar AC Inc Master Service Manual 2000 08 04 43 F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 ra 7 NO N N n
26. ch 16 mm Minimum commutator diameter 2 90 inches 74 mm 2 80 inches 71 mm 2 80 inches 71 mm Minimum brush spring tension 6 4 oz 180 g 40 oz 1120 g 40 oz 1120 g Pressure at rated load 2450 psi 2400 psi 2450 psi 24 V 13cc Pump displacement 36 V 19 cc 36 V 27 cc 36 V 27 cc Tank volume 5 gal 19 liters 5 gal 19 liters 5 gal 19 liters HYDRAULIC UNIT AMBIENT TEMPERATURES Standard and corrosion continuous operation see page 68 above 23 F 5 C Sunoco TH 58 Master Service Manual 2001 09 18 F code Section C code PS M2 0 Kalmar AC Technical Service Data Version no T code 003 395 396 397 398 399 MODEL NR35B NS40B ND30B NR45B NS50B Cold Storage see page 68 Continuous operation 5 F 15 C ATF Intermittent operation 13 F 25 C Freezer continuous operation Texaco 15 To 31 F 35 C see page 70 FUSES Drive motor circuit 250A fuses part number 305656 000 425A 24V part number 2 250A fuses F3 amp 2 250A fuses F3 amp part number 25275 12 S N 27135001 UP Pump motor circuit 355A ia F4 part number F4 part number 305656 001 305656 000 305656 000 15A NR35B part 15A NR45B part number 122308 150 number 122308 150 SIN 27091000 40A S N 27091000 Control circuit 27135000 27135000 40A part number 25275 12 40A part number 25275 12 S
27. d up narrow aisle lift truck tips over the operator should be trained to step off the truck The open back design allows the operator to make the quickest exit from the truck should the truck begin to tip over or fall from an elevated height such as a loading dock or ramp The ease of entering and exiting the open back design also minimizes operator fatigue Open back compartment 1 3 Intended Truck Application The trucks are solely designed and manufactured to handle goods The trucks should be fitted with the appropriate accessories relevant to the application 34 Master Service Manual 2000 08 04 Section C code M1 0 General Product Information Kalmar AC Sch 1 4 Prohibited Truck Application F code T code 395 396 397 398 399 The trucks are designed for handling goods indoors It is not permitted to use the trucks for other purposes including the following Asatowing tractor for trailers e To tow other trucks e To transport lift passengers To drive on gravel or grass 1 5 Truck Data The following table provides information regarding some technical data which is of value with daily use of the trucks pod NR35B NR45B ND30B NS40B NS50B Lifting capacity rated load 3500 4500 3000 4000 4000 Ib kg 1587 2041 1360 1814 2267 Lift height 192 270 210 402 210 402 192
28. dard and corrosion continuous operation see page 68 above 23 F 5 C SAE 80W90 Cold Storage see page 68 Continuous operation 5 F 15 C Intermittent operation 13 F 25 C SAE 80W 90 Freezer continuous operation To 31 F 35 C see page 70 ATF Kalmar AC Inc Master Service Manual 2001 09 18 57 F code Section C code PS M2 0 Technical Service Data Version no T code 003 395 396 397 398 399 MODEL NR35B NS40B ND30B NR45B NS50B WHEELS Drive wheel 13 5 x 5 5 x 10 0 13 5 x 5 5 x 10 0 13 5 x 5 5 x 10 0 inch mm 342 9 x 139 7x 254 342 9 x 139 7x 254 342 9 x 139 7x 254 Drive wheel weight without 240 Mast 330 Mast 402 Mast load with battery 3175 Ib 1440 kg 3595 Ib 1630 kg 3875 1757 mm Drive wheel weight with rated load 240 Mast 330 Mast 402 Mast and battery 2385 lb 1081 mm 2670 Ib 1211 mm 3184 Ib 1444 mm Torque drive tire lug nut 95 ft Ib 129 Nem Load wheel 5 0 x 3 6 inches 127 x 91 mm 5 0 x 3 6 inches 5 0 x 3 6 inches 127 x 91 mm 127 x 91 mm Load wheel weight 6975 lbs with rated load 3163807 g HYDRAULIC UNIT 24 V Power 36 V 9 8 Kw 36 V 36 V 13 1 hp Ie 2200 rpm 2550 rpm 2550 rpm at work pressure Duty factor Minimum brush 20 on 5 min cycles 20 on 5 min cycles 20 on 5 min cycles length 0 8 inch 20 mm 0 62 inch 16 mm 0 62 in
29. ed monthly to verify they are working properly A defective static discharge wrist band will not alert that it is bad 26 Master Service Manual 2000 08 04 amp kaimarac F code Section C code PS Welding Safety Version no T code 001 Welding Safety A WARNING Flame cutting or welding on painted surfaces may produce potentially harmful fumes smoke and vapors Prior to performing flame cutting or welding operations it is recommended that the coating be removed in the vicinity where the operation s will be performed A WARNING Coating removal may be by mechanical methods chemical methods or a combination of methods Flame cutting and or welding operations should be carried out only in well ventilated areas using local exhaust if necessary Before working on truck make sure of the following Fire protection equipment is nearby Know where the nearest eyewash station is located A CAUTION Disconnect battery before attempting to inspect service or repair truck Check for shorts to frame If any shorts are detected remove before proceeding with the welding operation Clean the area to be welded Protect all truck components from heat weld spatter and debris Kalmar AC Inc Master Service Manual 2000 08 04 27 F code Section C code PS Welding Safety Version no T code 001 Attach the ground cable as close to the weld area
30. ernal dimensions for the NS40B truck in its standard design TO CO N T T E En I D Alo 3 1 M CO dl A elo de Al Se La 3100 anso M O iu 1028 7 o lo Er NIN Sle 1 N N qa CL I 1 1 C ncs rmm m gt L US y 67 05 R 1703 0 5 50 139 7 s 48 75 1238 2 lu 3 25 11 82 5 SS 2 7 T ba 95 00 2413 0 m C 48 00 1219 2 53 50 Fork length Geen 11 00 279 4 KE M L 16 44 5 00 2 00 As 3 00 2 00 127 0 50 8 34 78 76 2 50 8 zm 882 4 x 9 15 232 5 57 45 R 1459 3 S 72 14 3 1832 3 S Kalmar AC Inc Master Service Manual 2000 08 04 39 F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 1 10 NS50B Dimensions The following diagram shows external dimensions for the NS50B truck in its standard design SE I _ ELE 1 I J M Dr d a oj Ro 8 g 31 00 40 50 D n SS RS 787 4 1028 7
31. intenance Schedule Troubleshooting cceeseseeceececeeeeeeeeeeeeseeeeeesneeseeseeeseeeeeeees 125 General mormallon scale diari 125 Operating Conditions sese eee eee eee eee 125 ro bleshootirig ci A een et B To 126 Motor Re pal ai 133 DISASSEMDIV cdi t 133 MOtOr IriSDe OT sr si 135 Pump Motor cirillico 141 Mounting POINTS tii ET 141 RED aca 145 RI AAA 149 Mounting OURS Las datada rure rete e etti ete cr ed eis 149 Repaire arteria UL ADIRE E EDS Ta dq lei 152 NR ele En TE nm 155 MoGning PoIRS salite bes 155 Ee 159 Disassemble vii NAAA AA AA A 161 ASSIM ee eee 165 Axle Sealing RING sirena edet ee 174 Leakage 5o cates pentose eten een eh e ida 176 Wheel Bolton dl dll iii ione 178 Electromagnetic Brake iaia alii iu 179 A A EI A IO 179 INStalMON iaa 181 Lie 182 Coil Gheck Orr Brake 5t od tton D Cof EE 183 Electromagnetic Brake Armature and Magnetic Coil 183 Kalmar AC Inc Master Service Manual 2001 10 12 Table of Contents Brake FnetioniPiate anti eC eaa oH uinea on UM io obe cou 184 Drive WGN iaia irta eat dea 185 te EE 186 lafe UE e sein treno necu EA Ned EEG dad 186 Tire Pressing Procedure iii 187 Non Braking Caster Wheel NR35B NS40B sese 189 Caster PIVOL xen esos B o dalia 191 EMMIS BS Le NR EE Y 193 G ster Springs uta Dan conti etn ri iii 195 E Ee EE
32. k only from the position of the Operator Before working on this truck always turn key switch to OFF and disconnect battery connector on truck unless this manual states otherwise Do NOT wear watches rings or jewelry when working on truck Follow the scheduled lubrication maintenance and inspection steps 18 Master Service Manual 2000 08 04 F code Section C code PS Kalmar AC m Ss Follow exactly the safety and repair instructions in this manual Do NOT take shortcuts Safety Do NOT Use an open flame near the truck Do NOT use gasoline or other flammable liquids for cleaning parts Clean up any hydraulic fluid oil or grease that has leaked or spilled on the floor O Kalmar AC Inc Master Service Manual 2000 08 04 19 F code PS Safety Version no 001 Section T code C code Always operate and park truck indoors AA A 016 6 54 0 0 8 060 oo 00 9 0 RAT Do NOT add to or modify truck without written approval from Kalmar AC Inc 20 Master Service Manual 2000 08 04 D kaimarac F code Section C code PS Battery Safety Version no T code 001 Battery Safety A WARNING As a battery is being charged an explosive gas mixture forms within and around each cell If the area is not properly ventilated this explosive gas can remain in or around the battery for several hours after charging Be sure there are no open flames o
33. m B 5 7 144 mm A Ade ra bas Mss mri gt 23 0 584 mm 95 0 2413 mm 11 5 292 mm Step Height 3 0 Battery Y 76 mm Y Roller 7 0 177 mm 48 0 1219 mm Height 16 4 416 mm 9 1 4848 57 45 31 mm 1459 mm Lal 10 Gradient Performance Loa 5 0 127 mm ded 36 Master Service Manual 2000 08 04 F code Section C code M1 0 General Product Information C kaimarac a um 001 395 396 397 398 399 1 7 NR45B Dimensions The following diagram shows external dimensions for the NR45B truck in its standard design Ng 85 v T 7 d m 5 5 139 mm 40 5 T E 8 0 32 0 1028 mm S 77 4 75 44 mm Ge mm I 1 A nn o 787 mm EA Forks 30 46 42 44 48 2 i SE po ML Y 4 AZ LIU 5 5 139 mm de 7227 pe 1833 mm B 7 6 193 mm A qa 45 5 1455 mm JM 22 0 558 mm A i A 48 0 1219 mm 95 0 2413 mm ud 11 5 292 mm Step Height 3 0 76 ii Battery Y y Roller 7 0 177 mm
34. mbers and letters for inch and metric fasteners see figure below The diameter of the shank of the fastener is shown first in the series e g M12 12 mm M20 20 mm 1 2 1 2 inch 3 4 3 4 inch 1 0 inch Y x 13 UNC THREAD DIA x NO OF THREADS PER INCH DIA METRIC M12 x 1 75 mm THREAD mm DIA x THREAD PITCH mm E 75 im I The number of threads per inch is normally not shown for inch nomenclature and only the UNC Unified National Coarse or UNF Unified National Fine is shown This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter The length of a shank is often indicated as part of the description of a fastener This length is shown in inches for inch fasteners and in millimeters for metric fasteners A cap screw will have the following description Inch Metric 1 2 x 13 UNC x 1 1 2 A B C M12 x 1 75 x 50 D A B C Shank diameter Type of thread Shank length B Number of threads per unit of length A B C Thread size Pitch Length 46 Master Service Manual 2002 01 16 F code Section C code M1 1 Inch SAE and Metric Fasteners Kalmar AC Bee 3 Strength Identification The most common property classes for metric fasteners are 8 8 and 10 9 The property class is marked with a number on the head of the cap screw or on a nut
35. na YE N S P nm ge Y e TT 1 1 OU SN 69 48 R 1764 8 5 50 139 7 sa 51 64 ses ASL 11 143 6 2 7 T n T i 2413 0 AN X LO 44 0 1117 9 Fork length 53 50 1358 9 r1 11 00 1 279 4 eg 1 eee DER T ojo 11 6199 el e i gt i l I I E 200 _ 15 44 3 00 2 00 sui 50 8 417 4 76 2 50 8 L 34 78 883 4 9 15 232 5 59 95 9 1522 8 S 198 74 54 1895 8 40 Master Service Manual 2000 08 04 amp kaimarac F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 1 11 Data Plate The illustration below shows the data plate used on the truck Model inches Serial Number Cop Lbs A B C Truck Wt Less Batt Lbs 3 Battory Wt Max Lbs Battory Wt Aia Lbs DC Voltage IL Use UL Class Battery Typo Max Amp Hours Type Max Back Tit Most Serial Number Attachment Truck as rated at factory conforms to requirements of Part Il of ASME B561 1993 3066040 005 i pec scie um 1 2 di Legend OOnN O GQ E GKM O Kalmar AC Inc Master Service Manual Truck model number Truck serial number Weight less battery Maximum battery weight Minimum battery weight Truck voltage DC Battery type UL class Battery maximum AMP hours Truck type Mast serial number Attachment Maxim
36. ower without load 75 fom 90 fom 90 fom electrical valve Lower with rated load 80 fom 95 fom 95 fom electrical valve CURRENT READINGS Driving without 24 V 140 amp load 36 V 140 amp 36 V 150 amp 36 V 150 amp Driving with rated 24 V 160 amp _ load 36 V 165 amp 36 V 170 amp 36 V 170 amp Lifting without 24 V load 36 V 240 amp 36 V 320 amp 36 V 320 amp Lifting with rated 24V load 36 V 415 amp 36 V 570 amp 36 V 570 amp 60 Master Service Manual 2001 09 18 F code Section C code PS M3 0 Ordering Spare Parts amp kaimarac u SZ Ordering Spare Parts 1 Locate fault on truck 2 Identify truck model serial number and battery voltage 3 Locate page with the exploded diagram and find the item number for the part required 4 Locate item number in table Select the column for actual truck model and serial number The following is an explanation of a serial number ND 30 3 1 265 001 Number of unit for that day Day of year 265 Year 2001 Decade 2000 Capacity Ib Model 30 3000 35 3500 45 4500 40 4000 50 5000 ND NR NS A CAUTION Although some trucks appear to be similar component parts may not be interchangeable If an incorrect part is used the truck may malfunction 5 Note part number 6 Call your local Komatsu Forklift Dealer and state the part number T If truck model serial number
37. r sparks in the charging area An open flame or spark can ignite this gas resulting in serious damage or injury AA WARNING Battery electrolyte is a solution of sulfuric acid and water Battery acid causes burns Should any electrolyte come in contact with clothing or skin flush the area immediately with cold water Should the solution get on the face or in the eyes flush the area with cold water and receive medical attention immediately Read understand and follow procedures recommendations and specifications in the battery and battery charger manuals from the manufacturer O Kalmar AC Inc Master Service Manual 2000 08 04 21 F code PS Section Battery Safety Version no 001 T code C code Wear personal protective equipment to protect eyes face and skin when checking handling or filling batteries This equipment includes goggles or face shield rubber gloves with or without arm shields and a rubber apron Make sure a shower and eyewash station are nearby in case there is an accident A battery gives off explosive gases Never smoke use an open flame or use anything that gives off sparks near a battery Keep the charger area well ventilated to avoid hydrogen gas concentration 22 Master Service Manual 2000 08 04 F code Section C code PS Ka Imar AC Dd T code Turn the key switch off before disconnecting the battery from the truck at
38. rams kg kilograms 0 001 tons 2000 Ib tons 2000 Ib 0 907 metric ton t metric ton 1 102 tons 2000 Ib POWER Multiply By To Get Multiply By To Get horsepower 0 746 kilowatts KW kilowatts 1 34 horse power hp PRESSURE Multiply By To Get Multiply By To Get pounds in 6 895 kilopascal kPa kilopascals 0 145 pounds in psi pounds in 0 007 megapascal MPa megapascals 145 04 pounds in psi O Kalmar AC Inc Master Service Manual 2002 01 16 55 F code Section C code Inch SAE si Ml Fasteners Version no T code 002 TEMPERATURE Multiply By To Get Multiply By To Get Fahrenheit 0 56 Celsius C Celsius x 32 Fahrenheit 32 1 8 F TORQUE Multiply By To Get Multiply By To Get inch pound 0 113 Newton meter Newton 8 851 inch pounds Nem meter in Ib feet pound 1 356 Newton meter Newton 0 738 foot pounds Nem meter ft Ib VELOCITY Multiply By To Get Multiply By To Get miles hour 1 609 kilometer hour kilometer 0 621 miles hour km h hour mph VOLUME Multiply By To Get Multiply By To Get inches 16 387 centimeters cm centimeters 0 061 inches in inches 0 016 liters liters 61 024 inches in quarts U S 0 946 liters liters 1 057 quarts U S at quarts U S 0 83 quarts Imp qt quarts Imp 1 205 quarts U S at gallons U S 3 785 liters liters 0 264 gallons
39. ssa 332 Operator Fam CODO aig salsa a e A S eir 333 APA ita 335 REMOVA EE 335 liz TEE 335 Start Stop Switches ci 337 Master Service Manual 2001 10 12 Table of Contents General A Es SOPH ie A A DI pre logan 337 KEV Mic tense tando ille 337 Emergency Disconnect Switch 521 339 Battery COMNECION csi 341 LOG ATION AAA dee 341 INspeclion ete TS 341 Jet UE e e EE 342 ER CC A BEE 343 A nettes reor ratus ue a a ia AH 343 Control Cable and Harness sss sese sec esse eee eee 347 PUSO dato Os 347 UTs Te O lille 348 COntactors due a ai na 351 AA rire 351 Direction Contactors lt a e ode o Dt a t efe sai 352 Lift Bypass Contactor NBABB NSSOBINDOSDB ii ba 354 Mal De ue WEE 356 Transistor Panel Drive 2 52a ii 359 MotorConnections ideo Ee pr e tit e itus 360 Transistor Panel Lift inier ia 361 Circuit Check Drive Only insidiae retine on coca oz d a 363 MicroSWITGhes ara i eege ERI PSA T 365 Cenere A EIL AMEN MOL 365 Lift Limit Override Switch S33 Optional sss esse eee ee 366 Optional Light and Fan Switches S96 S97 and S99 367 Main Electronic Card ee reed ennenen nenen en 369 Connectivity to TrUCK cranio 369 Transistor Controller Replacement zzz 370 FREIMOVAL RE 374 GA A A IE 374 A ilaele la lei lana ara rea de 380 LACIE IATA AAA AIA 381 MOGI ON Tuca S RD ees 381 m ipae tds 3
40. the battery connector Do NOT break live circuits at the battery terminals A spark often occurs at the point where a live circuit is broken Battery Safety Do NOT lay tools or metal objects on top of battery A short circuit or explosion could result Keep batteries clean Corrosion causes shorts and possibly sparks to the frame Keep plugs terminals cables and receptacles in good condition to avoid shorts and sparks Kalmar AC Inc Master Service Manual 2000 08 04 23 F code PS Section Battery Safety Version no 001 T code C code Keep filler plugs firmly in place at all times except when the electrolyte level is checked when water is added to the cells or when the specific gravity is checked Make sure vent holes in filler plugs are open to allow gas to escape from the cells Vent Plug Do NOT allow cleaning solution dirt or any foreign matter to enter the cell Make sure to install the correct size battery A smaller or lighter weight battery could seriously affect truck stability See the truck s specification data plate for more information Never plug a battery charger into the truck battery connector Plug battery charger ONLY into battery connector from battery 24 Master Service Manual 2000 08 04 F code Section C code PS Kalmar AC go Ze Follow the charging procedures in the Battery Instruction Manual and in the Battery Charger Instruction
41. tions are as described below SECTION SUBJECT M MACHINE INFORMATION P PLANNED MAINTENANCE S SERVICE INSTRUCTIONS O OPTIONS Kalmar AC Inc Master Service Manual 2000 08 04 29 F code Section C code M Introduction Service Manual Version no T code 001 395 396 397 398 399 30 Master Service Manual 2000 08 04 F code Section C code M Contents Section M Kalmar AC i AE Contents Section M 1 Machine Information M1 0 GENERAL PRODUCT INFORMATION M2 0 TECHNICAL SERVICE DATA M3 0 ORDERING SPARE PARTS O Kalmar AC Inc Master Service Manual 2000 08 04 31 F code Section C code M Contents Section M Version no T code 001 32 Master Service Manual 2000 08 04 F code Section C code M1 0 General Product Information amp kaimarac sa 001 395 396 397 398 399 General Product Information 1 Presentation of the Rider Trucks The NR35B 45B are battery powered reach trucks The ND30B is a battery powered deep reach truck The NS40B 50B are battery powered straddle arm trucks These trucks are intended solely to be operated handling pallets or similar load carriers indoors The trucks are equipped with a steering wheel with all the controls for operating within easy access The trucks have various maximum lifting capacities review data plate on the truck to note the maximum lifting capacity and are equipped with a 24V or 36V electrical system
42. uences are personal injury and or material damage NOTE Marks the risk of an accident or breakdown if the instructions are not followed O Kalmar AC Inc Master Service Manual 2000 08 04 15 F code PS Prohibitory Symbols Version no 001 Section T code C code Prohibitory Symbols 6 NO SMOKING If smoking occurs in situations where a restriction against smoking is stated a serious accident can occur D OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited a serious accident can occur O GENERAL PROHIBITION If the prohibition is ignored a serious accident can occur 1 Ordinance Symbols e SAFETY SHOES When the directive for safety shoes is given safety shoes shall always be worn to avoid personal injury PROTECTIVE GLASSES When the directive for protective glasses is given protective glasses shall always be worn to avoid personal injury 16 Master Service Manual 2000 08 04 F code Section C code PS K Kalmar AC cd X Safety Safety 1 General Safety Do NOT operate or work on this truck unless trained qualified and authorized to do so and have read the Operator s Manual Know the controls on the truck and what they do Do NOT operate truck if it needs repair or if it is in any way unsafe O Kalmar AC Inc Master Service Manual 2000 08 04 17 F code PS Safety Version no 001 Operate truc
43. um degree rear tilt Truck capacity 2000 08 04 41 F code Section C code M1 0 General Product Information Version no 001 T code 395 396 397 398 399 2 Main Components 1 Hydraulic valve The valves are located to provide easy access 2 Battery 24 36V with different capacities and weights 3 Battery connector The truck is connected to the battery through the battery connector When charging the battery do not connect the battery charger to the battery connector at the truck chassis 4 Hydraulic unit Pump motor and hydraulic pump are an integrated unit 5 Drive unit with brake Drive motor gears drive wheel and electrical brake combined in the drive unit 6 Electrical steering A servo steer motor drives a gear ring enabling the drive unit to be rotated through 360 degrees in either direction 7 Data plate See Data Plate on page 41 8 Cover Removable to provide access for servicing 9 Pedal Brake pedal 10 Control console The control console can be adjusted to a suitable height and angle to obtain a comfortable working position The steering hydraulic functions horn parking brake preset height travel direction key switch and any extra hydraulic functions are all controlled from this console The position of the console may be set in 1 of 3 positions forward facing 45 degrees or side stance Instrument panel This provides information on the truck s running hours time displ
44. vice Manual 2001 10 12 Table of Contents Circuit Diagrami 2002 DC DA a 302 Circuit Diagram TL eege 303 Circuit Diagrama omms 304 Circuit Diagram AL AA AA ria 305 Circuit Diagrami eege 306 Circuit Diagram 7 12 eee 307 Circuit Diagram 9 12 ito ic bs IE pk Ree Ea 308 Circuit Diagram E 309 Circuit Diagram 10 12 ini ne rola pacte cia Ra Eua elata eda 310 Circuit Diagram WZ A a Sd de Deco cut at aote 311 Circuit Diagram T2 12 sonia tecti reti ern etre o ii 312 Electrical Schematics Serial numbers 31285001 UP 313 Circuit ST 12 le Ta LEE 313 Circuit Diagram PANES uta a ia 314 Circuit Diagram EE 315 Circuit Diagram APP s ta 316 Circuit Diagram e A Si 317 Circuit Diagrama 318 Circuit Diagrami d i RN c eege Een 319 Circuit Diagram 9 12 pio ai egentes gu aiu es 320 Circuit Diagram 9 EZ vade a tl tesi do Ad citatis 321 Circuit Diagram LAAFE 322 Circuit Diagram 11 12 sese 323 Circuit Diagram Er KEE 324 A n 325 ISerhoval A ree fh cM ile rite dio UE 325 Installato lt ii Sd rte ie 325 Battery Maintenance cvoctec dicte tete e Ed cE ck 326 Storage M PD 328 Battery History R G TA Co Lotes ee 328 Light Assemblies e 329 Overhead Guard Lights Option cette eeeeeeeeeeeeeeeeeeeeeeeeeaaaaes 329 Warning Lights Option mens odds 330 Working Lights Option microsite 331 Travel Alarm Option e
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