TM5787 OP30B Service Manual 2004_April
Contents
1. Platform Side Gates Optional 482 Master Service Manual 2004 03 15 F code Section C code PT S7 1 7130 Kalmar AC Platform Version no T code 000 Item m Item vide Item whe No Description No Description No Description 1 Screw Nyloc 6 Screw 11 Switch 2 Bracket left 7 Handle right 12 Housing cover 3 Bushing 8 Bracket right 13 Screw machine 4 Bushing flat 9 Lever 14 Harness gate 5 Handle left 10 Housing base 15 Tie wire Side Gates Installation 1 Install gate harness 14 on platform and secure with wire ties 15 2 Install switch 11 housing base 10 and housing cover 12 on right bracket 8 and secure with screw 13 Install right bracket 8 on platform and secure with screws 6 Install right handle 7 on right bracket 8 and secure with bushings 3 and 4 and nyloc screws 1 3 Install switch 11 housing base 10 and housing cover 12 on left bracket 2 and secure with screw 13 Install left bracket 2 on platform and secure with screws 6 Install left handle 5 on left bracket 2 and secure with bushings 3 and 4 and nyloc screws 1 Kalmar AC Master Service Manual 2004 03 15 483 F code Section C code PT S7 1 7130 Platform Version no T code 000 This page is intentionally left blank 484 Master Service Manual 2004 03 15 F code Section C code K PT 7 2 7170 Kalmar AC Lifting2. C Kaimarac Master Service Manual OP30B Electric Order Picker Effective Serial Number OP30B04075001 UP A Warning Read and observe all warnings on this unit before operating it A Warning DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place Part no TM5787 Date April 15 2004 F code Section C code PT S Kalmar AC Contents Section S Version no T code 000 Contents Section S 1 Service Instructions NO FUNCTION GROUP C CODE GHASSIS 0000 MOTORS 1000 DRIVE GEAR TRANSMISSION 2000 o N on RS WH Oo LIFTING MAST 7000 PERIPHERAL INSTALLATION EQUIPMENT 8000 9 OPTIONS ATTACHMENTS 9000 Kalmar AC Master Service Manual 2004 03 15 85 F code Section C code PT S7 1 7130 KalmarAc Platform Version no T code 000 Platform Item eee Item Ee No Description No Description 1 Platform 4 Pin cotter assembly 2 Chain 5 Shim Pin 6 Bearing a 4 ri 3 3 Kalmar AC Master Service Manual 2004 03 15 473 F code Section C code PT S7 1 7130 Platform Version no T code 000 Electrical Heater Platform 474 Master Service Manual 2004 03 15 K Kalmar AC F code Section C code PT S7 1 7130 Platform Version no T cod
3. Install the pedal assembly to the platform main support plate Secure with screws and torque to 15 ft lbs 20 Nem Tension Spring Pivot Bracket Hook the tension spring into the 0 25 inch 6 mm holes in the pivot bracket and pedal weld in the pedal assembly Extend the spring to connect the cable assembly by sliding a 2 inch 51 mm wide block between the left hand pallet support and pallet clamp on pallet clamp assembly Install the cable bracket on the pedal assembly Secure with bolt and hex nut and torque to 15 ft lbs 20 Nem 492 Master Service Manual 2004 03 15 K Kalmar AC F code Section C code PT S7 3 7410 Fork Assembly Version no T code 000 6 Place the cable assembly in the cable bracket and secure with hex nuts Finger tighten the hex nut closest to the pedal mounting and leave other nut 8 loose Remove the 2 inch 51 mm block used in step 4 Adjust the hex nut closest to the pedal mounting until there is a 90 angle between the pallet clamp and the left hand pallet support Torque the remaining hex nut to 21 ft lbs 29 Nem Fork Extensions Item No Description Item No Description 1 Platform 3 Screw cap 2 Nameplate 4 Nameplate Kalmar AC Master Service Manual 2004 03 15 493 F code Section PT S7 3 Fork Assembly Version no T code 000 C code 7410 This page is intentionally left blank 494 Master Servic
4. Gear Crosshead Three Stage Mast Version no T code Lifting Gear Crosshead Three Stage Mast Kalmar AC Master Service Manual 2004 03 15 485 F code Section C code PT S7 2 7170 Lifting Gear Crosshead Three Stage Mast GOU no T code Item No Description Item No Description 1 Bolt shoulder 10 Washer 2 Washer flat 11 Screw set 3 Sheave cable 12 Shaft 4 Screw flathead 13 Nut flanged 5 Plate sheave 14 Cylinder assembly 6 Spacer 15 Nut 7 Sheave chain 16 Anchor 8 Screw flathead 17 Link 9 Bumper 18 Chain lift 486 Master Service Manual 2004 03 15 F code Section C code PT S7 2 7170 KalmarAC Lifting Gear Crosshead Three Stage Mast Version no T code 000 1 Theory of Operation The lifting gear is located at the top of the freelift cylinder and mounts to the inner column 2 Maintenance See Wear on page 438 3 Troubleshooting Make sure lift chains are clean 4 Repair and Rebuild Replace chain as necessary The lifting gear can not be rebuilt Replace lifting gear with new as necessary NOTE Call outs in the following procedures refer to illustration on page 485 Removal 1 Park truck on a level surface and apply brake A DANGER When blocking mast columns to reduce risk of lowering when working on or near mast always block both sides of column If both sides are
5. ach bottom of forks 2 Block platform with 4 inch x 4 inch 10 x 10 cm upright block 3 Secure fork to hoist using a suitable strap or chain 490 Master Service Manual 2004 03 15 C kalmarac F code PT Section C code 7 3 7410 Fork Assembly Version no 000 T code Remove one socket head cap screw from underneath fork at chassis end Remove snap ring from pivot pin in mounting block of fork AN CAUTION The fork weighs approximately 150 pounds 68 kg use caution when it drops 6 7 Install 1 2 Drive out pivot pin The fork washer s or shim s will drop Replace damaged fork Hold new fork in place underneath platform Install pivot pin through fork NOTE Always use new snap when assembling components rings 3 Install new snap ring in pivot pin Kalmar AC Master Service Manual 2004 03 15 491 F code Section PT S7 3 Fork Assembly Version no T code 000 C code 7410 Install correct amount of washers or shim at back side of fork to maintain a level fork Install socket head cap screw at chassis end of fork 6 Remove block from platform 7 Lower platform to floor and make sure forks are level If forks are not level add more shim to fork 4 2 Pallet Clamp Install the pallet clamp assembly on the platform front plate Secure with screws and torque to 30 ft lbs 41 Nem
6. and lowering of the mast assembly Remove forks from platform see page 490 Remove console panel see page 93 Remove the mast cable harness connectors from pin locations JPC8 and JPC9 on the carriage platform manager card located behind the console panel on the platform a e CARRIAGE HANAGER L Li CE A WRK 2 ki am Carriage Platform Manager Card 478 Master Service Manual 2004 03 15 K Kalmar AC F code Section C code PT S7 1 7130 Platform Version no T code 000 6 Remove wire ties holding the mast cable harness to the platform Raise the mast assembly until the cable clamp can be accessed at the base of the platform holding the mast cable harness to the platform Block mast assembly Loosen the clamp and remove the harness Freelift Cylinder Cable y Mast Braid Assembly e gi Main Chassis Nut Ed a h m get Harness Kalmar AC Master Service Manual 2004 03 15 479 F code Section C code PT S7 1 7130 Platform Version no T code 000 7 Remove mast cable harness from the freelift sheave and pull back towards the truck frame Cable Sheave y O N Anchor Bolts Freelift Cylinder 8 Ea Hoist e Fernand 8 Remove blocks from mast assembly Fully lower Guard mast assembly being careful not to pinch the recently removed mast cable harness 9 Attach a hoist to the platform overhead guard Hoist platform up far enough to rel
7. c cable sheaves 3 washer 2 and bolt 1 Remove chains and electric cables from lifting gear sheaves 3 and 7 Reconnect battery connector to the truck Energize EPO switch and turn key switch ON Test truck for proper operation before returning to service 488 Master Service Manual 2004 03 15 K Kalmar AC F code Section C code PT S7 3 7410 Fork Assembly Version no T code 000 Fork Assembly Item No Description Item No Description 1 Nut 6 Ring retaining 2 Lockwasher 7 Shaft fork 3 Washer flat 8 Fork 4 Spacer 9 Platform assembly 5 Screw Kalmar AC Master Service Manual 2004 03 15 489 F code Section C code PT S7 3 7410 Fork Assembly Version no T code 000 1 Theory of Operation The forks are raised by means of an electric powered hydraulic pump unit The lift and lower forks thumb knob is on the end of the control handle Rotating the thumb knob up will lift the forks and rotating the thumb knob down will lower the forks Fork extensions can be installed on truck as an option in either 48 X 96 inch 1219 X 2438 mm or 50 X 96 inch 1270 X 2438 mm size platform 2 Maintenance See Planned Maintenance Schedule on page 69 3 Troubleshooting Make sure forks are in good condition 4 Repair and Rebuild The forks and pallet can not be rebuilt Replace forks and pallet as necessary 4 1 Forks Removal 1 Raise platform high enough to re
8. e 000 o Description Ea Description 1 Screw 9 Screw 2 Switch thermal 10 Spring 3 Relay 11 Washer flat 4 Tie wire 12 Resistor 25 watt 5 Bracket 13 Spring 6 Nut clip 14 Nut 7 Screw 15 Harness 8 Heat 100 watt 16 Fuse 7 Amp 1 Theory of Operation The operator platform attaches to the mast columns and chains The platform side gates can be added to the truck as an optional feature Kalmar AC Master Service Manual 2004 03 15 475 F code Section C code PT S7 1 7130 Platform Version no T code 000 2 Maintenance 2 1 Platform Shimming A WARNING When blocking mast columns to reduce the risk of lowering or when working on or near mast always block both sides of the column Otherwise the truck could tip over on its side 1 Reconnect battery connector to truck Energize EPO switch and turn key switch ON 2 Attach pendant to steer tractor manager card at pin location JPT1 to ease the raising and lowering of the mast assembly see page 478 Lift Lower Pendant 476 Master Service Manual 2004 03 15 K Kalmar AC F code Section C code PT S7 1 7130 Platform Version no T code 000 CON O Gi Raise platform up inner column as far as it will go under normal operation Check bearing shimming as the platform is lowered in six inch increments With a 0 030 inch 0 762 mm feeler gauge a shim works well check bearing clearance between bearings and the
9. e Manual 2004 03 15
10. ease pressure on the freelift chains 10 Remove freelift chains from chain anchor bolts located on either side of the freelift cylinder 11 Carefully raise mast assembly to clear the upper bearings on the platform 12 Remove platform from mast assembly 13 Fully lower mast assembly 480 Master Service Manual 2004 03 15 K Kalmar AC F code Section C code PT S7 1 7130 Platform Version no T code 000 Assembly L Carefully raise mast assembly far enough to clear the upper bearings on the platform Install platform into mast assembly Install freelift chains on chain anchor bolts located on either side of the freelift cylinder see page 480 Adjust freelift chains see page 444 Install mast cable harness Attach the harness cable clamp to the platform see page 479 Install the mast cable harness connectors into pin locations JPC8 and JPC9 on the carriage platform manager card see page 478 Lower platform until hoist chain is slack Remove the hoist chain 7 Install console panel see page 93 8 Install forks on platform see page 491 9 Test truck for proper operation before returning to service 10 Reconnect battery connector to truck Energize EPO switch and turn key switch ON Test truck for proper operation before returning to service Kalmar AC Master Service Manual 2004 03 15 481 F code Section C code PT S7 1 7130 Platform Version no T code 000
11. not blocked unexpected movement could occur resulting in personal injury or death 2 Lift platform approximately 6 inches 152 mm Securely block platform to reduce risk of lowering 3 Lower freelift cylinder so chains and electric cables are loose 4 Turn key switch OFF and depress Emergency Power OFF EPO switch Disconnect battery connector from truck 5 Remove chains and electric cables from lifting gear sheaves 3 and 7 Kalmar AC Master Service Manual 2004 03 15 487 F code Section C code PT S7 2 7170 Lifting Gear Crosshead Three Stage Mast Version no T code 000 Remove bolt 1 washer 2 and electric cable sheaves 3 7 Remove nut 13 and sheave 7 from shaft 12 8 Remove bolt 8 bumper 9 washer 10 and screw set 11 from end of freelift cylinder rod Remove shaft 12 sheave 7 spacer 6 and sheave plate 5 from the freelift cylinder rod A WARNING When using compressed air wear effective chip guarding and personal protective equipment Compressed air used for cleaning MUST be reduced to less than 30 psi 207 kPa 10 Clean and inspect parts Replace as needed Assembly 1 Install shaft 12 sheave 7 spacer 6 and sheave plate 5 into the freelift cylinder rod Install bolt 8 bumper 9 washer 10 and screw set 11 into end of freelift cylinder rod 3 Install nut 13 and sheave 7 onto shaft 12 4 Install electri
12. web of the column as a pry bar is used to pry the bearings plates of the platform side to side Maximum clearance must not exceed 0 030 inch 0 762 mm Once the number of shims have been determined divide the shims equally as possible between the upper bearings or the lower bearings as needed to keep the platform centered in the mast Remove the platform see page 478 nstall shims behind bearings as needed Install platform into mast see page 481 Remove hoist from platform and test operation of platform in the mast Check operation first with no load by checking the bearing clearance for tight spots If tight spots are encountered shims will need to be removed as reguired If shimming is correct test operation of platform in the mast with a capacity rated load Test truck for proper operation before returning to service Kalmar AC Master Service Manual 2004 03 15 477 F code Section C code PT S7 1 7130 Platform Version no T code 000 3 Troubleshooting Check fork frame mounting and inspect platform for damage and crack formation every six months 4 Repair and Rebuild Replace bearings and chains on platform as necessary The platform can not be rebuilt Replace platform with new as necessary Removal 1 Reconnect battery connector to truck Energize EPO switch and turn key switch ON 2 Attach pendant to steer tractor manager card at pin location JPT1 to ease the raising
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