Jungheinrich Electric Reach Truck ETB230/340, ETR225/230/230D/230DP/235/340/340P/345/345P Workshop Service Manual

ETR225d, ETR230dp, ETR230-ETR345p, ETB230, ETB340 Service Manual 99759-J6100 01.10 C/ 10 a tUNGHEINRICH

TABLE OF CONTENTS MAST INSTALLATION INSTRUCTIONS Truck How the Truck is Shipped 1-1 Uprighting a Cradled Truck 1-1 Option 1: Uprighting with Two Chain Hoist 1-2 Option 2: Uprighting with One Chain Hoist and a Lift Truck 1-3 Mast Installation Instructions Truck System Requirements 1-3 Mast Inspection 1-3 Chain Lubrication 1-3 Upright and Carriage Position, Chain Tension 1-3 Channel Lubrication 1-4 Mast Mounting Bolts and Torque Specifications 1-5 Overhead Guard Mounting Bolts and Torque Specifications 1-6 Hydraulic Fluid Level 1-7 Hydraulic Functions 1-7 Pump Intake Coupling (Bleed Points) 1-7 GENERAL INFORMATION FEATURES Glossary 2-1 Reach Truck Serial Number Definition 2-3 General Overview 2-4 Jacking Truck 2-8 Load Wheel Replacement Guide 2-9 Caster Adjustment 2-10 Brake Assembly Inspection and Adjustment 2-1 1 Adjustment of Air Gap with Brake Applied 2-1 1 Friction Disc Replacement 2-11 Transmission 2-13 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 i

TABLE OF CONTENTS THEORY OF OPERATIONS (continued) Stepping on the Operator Presence Pedal 3-3 Steer Request 3-3 Electric Steer Controller "APS" 3-4 Travel Request 3-4 Plugging Request 3-6 Regenerative Braking 3-6 Lift / Lower Request 3-6 Lift Activation 3-7 Lower Activation 3-7 Auxiliary Functions 3-7 Tilt Request 3-8 Tilt Activation 3-8 Reach / Retract Request 3-8 Sideshift Request 3-8 Reach / Retract and Sideshift Activation 3-8 Reach / Retract Activation 3-8 Sideshift Activation 3-8 Lift Pressure Adjustment 3-9 Max. Lowering Speed Adjustment (Mechanical) 3-9 Emergency Lowering 3-10 Electrical Lowering Speed Adjustment 3-10 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 ii

TABLE OF CONTENTS OPERATOR DISPLAY (continued) Shelf Height (Option) 4-5 To Change Self Height Option 4-6 Mode of Operation (Performance Modes I, II, III and IV) 4-6 Thermal Monitoring 4-7 SelfTest 4-7 Operation Hours 4-7 Battery State of Charge 4-7 OPERATOR DISPLAY INFORMATION & PROGRAMMING Password Protected Mode Management Mode 5-1 How to Enter "Management" Mode 5-1 Service Mode 5-1 How to Enter "Service Mode" 5-1 Display Enabled Functions General Settings 5-2 History Folder 5-2 Password Manage 5-2 Parameters 5-2 Display Parameters 5-2 Configuration Settings 5-2 Display Parameters Pre-Height Selection 5-3 How to Activate the "Pre-select Shelf Height Setting" Function 5-3 Mode Change 5-4 How to Change the "Mode Change" Function 5-4 Height Display *Service Mode Only* 5-5 How to Activate the "Height Display" Function 5-5 Weight Display *Service Mode Only* 5-6 How to Activate the "Weight Display" Function 5-6 LCD Contrast 5-7 How to Change "LCD Contrast" 5-7 LCD Heater 5-8 How to Activate the "LCD Heater Control" Function 5-8 Keyless Entry "Pin Code" *Service Mode Only* 5-9 How to Activate the "Keyless Entry" Function 5-9 Truck Parameters *Service Mode Only* 5-10 How to Access "Truck Parameters 5-10 BDI Curve 5-11 BDI Timer 5-11 BDI Reset 5-1 1 iii

TABLE OF CONTENTS OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued) Low Batt 5-11 Maintenance Warning 5-1 1 Stand-by-Timer 5-11 Travel Alarm 5-11 Max Speed Fwd 5-11 Max Speed Bwd 5-12 Release Braking 5-12 Inverse Braking 5-12 Steer Sensitivity 5-12 Forward Steering 5-12 Lower Stop / Batt Lock 5-12 Cutback Linear 5-12 Cutback 1 Speed 5-12 Cutback 2 Height / Cutback 2 Speed 5-12 Cutback 3 Height / Cutback 3 Speed 5-12 PreSensor Low 5-13 PreSensor Low 5-13 Real Load Weight 5-13 Max Lift 5-13 FreeLift 5-13 LiftLimit 5-13 Reach 2 5-14 Retract 2 5-14 Reach2 / Retr2 5-14 2nd Pump 5-14 E Cushion 5-14 Wheel Centering 5-14 Diagnostics Diagnostics * Service Mode Only* 5-15 How to Access "Onboard Diagnostics" 5-15 Digital Inputs 5-15 Analog Inputs 5-16 Outputs 5-16 Temperatures 5-17 Motor Controls 5-17 Service Service *Service Mode Only* 5-18 How to Access "Service" 5-18 Set Maintenace Intervals 5-18 Clear History Folder 5-18 Reset Pre-Height Select 5-19 Restore Truck Param 5-19 Restore Perf Mode 5-19 Restore Passwords 5-19 iv

TABLE OF CONTENTS OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued) Height Detection (Option) Height Detection Overview 5-20 Height Detection Installation 5-21 Pre_Selected Shelf Height Option 5-22 To Change the Shelf Height 5-22 Cold Storage Option 5-24 Operator Mode Entering Chart 5-25 Management Mode Entering Chart 5-27 Service Mode Entering Chart 5-29 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 V

TABLE OF CONTENTS MAST (continued) Piston Rod and Piston 6-10 Retainer / Retainer Assembly 6-10 Mast Uprights Upright Desciption 6-1 1 Outer Upright Assembly 6-11 Intermediate Upright Assembly 6-1 1 Inner Upright Assembly 6-1 1 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 vi

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 vii

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 viii

Jungheinrich Electric Reach Truck ETB230/340, ETR225/230/230D/230DP/235/340/340P/345/345P Workshop Service Manual

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