CATERPILLAR® Reach Service Manual Description

Truck Overview

Description 1:

Truck Figure 1-1 provides an overview of the Caterpillar Reach Truck.

Detailed descriptions of major components, supported by photographs
Overview and drawings, are contained herein.
This section describes the general characteristics of the truck.

Figure 1-1: Caterpillar Reach Truck

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Description CATERPILLAR® Reach Service Manual

Truck Overview

Use The reach truck is designed for indoor narrow aisle warehouse use
only.

Type The truck is a stand up, rider type that is designed for narrow aisle
installations where the operator must store and retrieve items up to
two pallets deep from storage racks. The truck is manually operated.

Power The battery is a 24- or 36-volt industrial battery.

Capacity
Category Specification
Maximum Load Capacity 3,000 lb
Upright Lowered Height Two Heights:
74 in.
86 in.
Lift Height, Maximum Two Heights:
153 in.
189 in.
Extended Height w/48 in. LBR Two Heights:
201 in.
237 in.
Lift Speed Loaded: 30 fpm
Empty: 45 fpm
Lowering Speed Loaded: 50 fpm
Empty: 50 fpm
Travel Speed Loaded: 2.9 mph
Empty: 3.3 mph
Stopping Distance Loaded: 3.85 ft
Empty: 3.19 ft
Overall Length Without Tilt: 90.7 in.
With Tilt: 92.5 in.
Base Leg Width (outside) 42.5 in. - 58.5 in.
Base Leg Opening (inside) 33.0 in. - 49.0 in.
Reach Distance 24.0 in.
Battery Compartment 31.87 in. x 13.55 in.
Battery Voltage 24 volts
Minimum Battery Weight 975 lb
Truck Weight w/o Battery 3,600 lb

Table 1-1: Truck Specifications

Specification The specification plate on the truck lists maximum load information
Plate for safety reasons. The following figure shows the specification plate:

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Truck Overview

Model Number
Serial number
assigned by the
factory for this
Truck Weight (with truck
battery, without Nominal Battery
operator and load) Voltage
Power Rating of
Truck Weight Battery
without Battery
Battery Weight
Truck Weight with (minimum and
Maximum Battery maximum)

Maximum Load
Capacity of
Truck
(Exceeding
maximum might
damage truck or
affect stability)

Figure 1-2: Specification Plate

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Truck Overview

Mast The mast is a two (simplex) and three (triplex) stage hydraulic lift with
a variety of Overall Lowered Heights (OALH) and Elevated Heights
(EH).

Controls The operator controls consist of:

• Lockable key switch
• Emergency disconnect switch
• Steering wheel
• Hydraulic assisted steering
• Travel, lift, and lower controller
• Brake
• Horn button.
Additional options, such as fans and working lights are available by
customer request.

Indicators Indicators include:

• System display
• Audible alarm that sounds to communicate with the operator of
certain system conditions
• Strobe light that gives the truck high visibility

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Mechnical

Mechnical This figure shows the mechanical components of the truck. The main
components are the following:
• Chassis
• Mast assembly
• Operator’s compartment
• Steering system
• Drive unit

Overhead
Guard
Mast

Main Cover

Reach Carriage

Battery
Compartment
Sideshift
Hydraulic
Cylinder

Outrigger

Load Wheels

Forks

Figure 1-3: Component Identification

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Mechnical

Chassis The chassis is constructed of the following parts:

• Power section frame
• Battery compartment
• Battery connector
• Outriggers
• Covers

Power Section The power section frame is constructed of formed sheet and plate steel
Frame welded together to form a strong integral unit.
The power section is bolted to the outriggers and mast.

Battery The battery compartment will accept a battery with the following
Compartment dimensions:

24 Volt 36 Volt
Width (max) 14.00 in. 355.6 13.69 in. 347.7
mm mm
Height 30.88 in. 784.4 30.88 in. 784.4
(max) mm mm
Length 36.38 in. 924.0 38.38 in. 974.9
(max) mm mm

The battery can be removed or installed from either side. Steel rollers
support the battery and make it easy to remove and install.

Battery Connector The battery connector is located on the right side of the truck and is
mounted on the power section frame.

Outriggers Each outrigger has one or two load wheels, depending on the truck
configuration.

Covers Two covers constructed of formed plastic enclose components on the

power section. Screws allow both covers to be removed from the truck.

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Mechnical

Mast Assembly The mast assembly is constructed of the following parts:

• Mast main frame
• Telescopic frames
• Mast bearings
• Forks

Mast Main Frame The mast main frame has a ladder type construction. The mast
uprights are made of structural I-sections. The uprights are tied
together using structural steel crossties. The mast uprights are
welded to the outrigger frame forming a strong integral unit.

Telescopic Frame The telescopic frame is also a ladder type construction. It is

constructed of structural I-sections and crossties.

Mast Bearings The mast bearings are roller type construction and lubricated for life.

Forks The forks are constructed of 2 x 4 in. (50.8 x 101.6 mm) rectangular
steel (fork length is optional). The forks are attached to the bottom of
the fork carriage. The overall width of the forks is adjustable from
24 to 28 in. (609.6 to 711.2 mm).

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Mechnical

Operator’s The operator’s compartment has been designed for safety, efficiency,
Compartment and operator comfort. The operator’s compartment is constructed of
the following parts:
• Compartment floor
• Overhead guard
• Operator’s controls

Key Switch and Direction/Speed/

Operator’s Lift/Lower
Emergency
Steering Wheel Display Control Handle
Disconnect

Figure 1-4: Operator’s Console

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Mechnical

Compartment The center section of the floor is plated steel. It is covered by a rubber
Floor cushion.

Overhead Guard The overhead guard (shown in Figure 1-2) is constructed of steel
tubing and bar stock. The overhead guard covers the floor area to
protect the operator and complies with ANSI specification B56.1.

Operator’s The operator’s compartment provides the operator with complete

Controls control of the truck (see Figure 1-3 and Figure 1-4). The controls have
been designed for operator safety, efficiency, and comfort.

Deadman Pedal The deadman pedal is spring loaded. When the pedal is released, the
travel circuit is disabled (turning the power off) and the brake is
applied.

Operator Compartment Additional options, such as fans and work lights, are available by
Options customer request.

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Mechnical

Steering The hydraulic steering system uses the auxiliary pump, which
supplies hydraulic pressure. The steering orbitrol controls the rate
and direction of the hydraulic fluid to the steer motor. The steer motor
in turn rotates the drive unit.

Auxiliary Pump and Motor

(located behind the
steering Orbitrol)

Steer Motor

Orbitrol

Steerable Wheel

Figure 1-5: Hydraulic Steering Components

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Mechnical

Drive Unit The drive unit is a compact, self-contained assembly. It consists of:
• Pivot bearing
• Gear housing
• Gear reduction assembly
• Drive motor
• Brake
• Drive wheel

Pivot Bearing The pivot bearing is the part of the drive unit assembly that provides
support for the drive motor, wheel, and gear housing.

Gear Housing The gear housing is a precision machined casting into which the gear
reduction system is assembled.

Gear Reduction The gear reduction assembly is comprised of:

Assembly • Motor pinion
• Drive gear
• Drive pinion
• Compound gear
• Splined shaft
The gears are continuously bathed in gear oil. The splined axle shaft
turns on two ball bearings.

Drive Motor The drive motor is a series wound motor and uses sealed bearings for
long service life. The drive motor transmits power to the reduction
unit by a motor pinion gear on the motor armature shaft.

Brake The brake is hydraulically activated and mounted to the top of the
drive motor. A brake drum is mounted on the end of the drive motor
armature shaft.

Drive Wheel The drive wheel consists of a polyurethane tire mounted on an inner
hub. The design of the wheel permits replacement of the drive tire.

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Hydraulic

Hydraulic The hydraulic portion of the truck consists of the lift/lower system.
The following figure shows the hydraulic system components.

Reservoir Tank and Control

Filter Handle

Auxiliary Motor and

Pump

DIRA,DIRB
Solenoids

Lift Motor and

Pump

Steer Motor Manifold

Steering
Orbitrol

Deadman
Pedal

Steerable Wheel

Figure 1-6: Hydraulic System Components

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Hydraulic

Lift/Lower The reach truck single- and two-speed systems (reach/retract) are
System controlled manually by the operator using the control handle in the
maximum position for the lift or lower function or using the reach and
retract button in combination. They are located on the directional/
speed controller in the operator’s compartment.
The lift/lower system consists of:
• Lift pump
• Lift motor
• Lift cylinder assembly
• Flow controls
• Reservoir
• Return line filter
• Lift chain
• Lift/lower hydraulic manifold assembly
• Solenoids

Lift Pump A splined, fixed-displacement gear pump is used on both models. The
pump is located under the operator’s console cover and to the right of
the Operator’s Display (OD).

Lift Motor Power to drive the lift pump is a series wound, fan-cooled,
intermittent duty motor. The lift motor is located under the operator
console cover and to the right of the display (OD).

Lift Cylinder The lift cylinder is composed of the following:

Assembly • Cylinder housing
• Piston
• Flow controls

Cylinder Housing The cylinder housing is constructed of welded steel tubing. The
cylinder housing is attached to the mast main frame.

Piston The piston is encased within the cylinder housing and lifts the
telescopic section of the mast assembly. The piston is constructed
from chrome-plated tubing.

Flow Controls Flow controls are used to limit the rate that fluid leaves the cylinder
when there is a broken hose.

Reservoir The welded steel reservoir has a capacity of approximately 5.5 gal.
(20.8 L). The reservoir is located in the upper-left corner of the
operators console and is vented to the atmosphere through the filler
cap.

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Hydraulic

Return Line Filter The return line filter consists of a 10-micron filter element and bypass
valve set at 15 psi (103.4 KPa) cracking pressure. The unit has a
replaceable spin-on-type canister. The filter is directly screwed onto
the reservoir tank.

Lift Chains The heavy duty lift chain is constructed of 3/4 inch pitch, 4x4 laced-
leaf chain. The lift chains comply with ANSI 829.8 requirements.

Lift/Lower The lift/lower hydraulic manifold assembly controls hydraulic flow

Hydraulic rate and direction in the lift/lower system. The manifold assembly is
controlled electrically by the interface card. The assembly is located
Manifold Assembly under the operator’s console cover and to the front and slightly left of
the steering orbitrol.
The lift/lower hydraulic manifold assembly consists of:
• Manifold housing
• Lift pump check valve (5 psi)
• High pressure relief valve
• Output check valve

Manifold Housing The manifold housing is machined from aluminum.

Lift Pump Check Valve The check valve prevents hydraulic oil from flowing back through the
(5 PSI) lift pump.

High Pressure Relief The high pressure relief valve is set to prevent lifting a load which
Valve exceeds the maximum load capacity of the truck.

Output Check Valve The check valve provides for smooth stopping during lift.
(100 PSI)

Solenoids The following list describes the solenoids used in the Caterpillar Reach
truck:

Solenoid Description

Load/holding prevents hydraulic fluid from leav-

Sol L/H ing the lift cylinder when the carriage is elevated
and the lift/lower control is in neutral.
Enables the carriage to reach or retract; it works
Sol REACH in conjunction with the DIRA and DIRB Sole-
noids.

Enables the carriage to extend or reach; it works

Sol DIRB
in conjunction with the Reach Solenoid.

Table 1-2: Solenoids

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Hydraulic

Solenoid Description

Enables the carriage to retract and move the forks

Sol DIRA back toward the mast; it works in conjunction
with the Reach Solenoid.

Enables the forks to tilt up or down. It works in

conjunction with the DIRA and DIRB solenoids.
Sol TILT The direction of tilt depends on the input received
from the control handle in the operator’s compart-
ment.

Enables the fork carriage to move left or right. It

works in conjunction with the DIRA and DIRB
Sol SIDESHIFT solenoids. The left or right movement of the car-
riage depends on the input received from the con-
trol handle in the operator’s compartment.

The Equalizing solenoid function is to stop or

inhibit the return flow of hydraulic fluid during
Sol EQ
select operations. This ensures smooth controlled
motion of the truck functions.

Enables the system to utilize the high speed lift

2nd Solenoid
function.

Table 1-2: Solenoids

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Electrical

Electrical This section is primarily descriptive. For detailed operation, see

"Theory of Operation" on page 4-1, or "Operating Instructions" on page
3-1.
The descriptions for the 24- or 36-volt electrical system include:
• System Displays
• Electronic Control System/Vehicle Manager
• Travel System
• Reach/Sideshift/Tilt Components
• Lift/Lower Components
• Miscellaneous Circuits

System Displays The system displays consist of:

• Operator’s Display (OD)
• Maintenance Displays

Operator’s Display The Operator’s Display (OD) is a visual communication device that
(OD) shows the operator specific conditions at any given moment. See
Figure 1-7. There are two message formats used on the display:
• Static
• Scrolling
The OD is mounted on the operator’s console adjacent to the control
handle and is visible to the operator. The OD shows:
• SelfTest
• Total Hours on Deadman (HD)
• Weight of Load on Forks (36-volt vehicles)
• Status Messages
• Display System Messages and Fault Codes
• Service Required
• Lift Bypass
• Over Temperature
• Truck Speed

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Electrical

The OD shows information using an alphanumeric digital display and

a series of icons. Information is displayed in a static or scrolling
format. Scrolling messages move from right to left.

Over-Temp
Icon
key switch Service Required
Tool

Truck
Speed
Lift Inhibit Icon
Icon

Battery State of Static & Scrolling

Charge Icon Display

Figure 1-7: Operator’s Display

Maintenance An additional maintenance display is provided for Service Technician

Displays use: all trucks have a display mounted on the Vehicle Manager
assembly.

Electronic The electronic control system consists of:

Control System • Vehicle Manager
• Power Panel Driver Assembly
• Hydraulic Driver Assembly (HDA)
• Distribution Board

Vehicle Manager The Vehicle Manager (VM) consists of the following:

• Vehicle Function Controller (VFC)
• Power Supply
• Distribution Board
The VM is the brains of the MicroCommandNA Control System. The
VM is located on the right side wall of the operators compartment
behind the access panel. Virtually all vehicle inputs and outputs pass
through and are monitored by the VM. The VM controls the traction
and lift/lower systems. The flexibility of the VM allows a variety of
programmable operating parameters (i.e., lift/lower, accel/decel, etc.).

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Electrical

Two-Digit
Display

Figure 1-8: Vehicle Manager - Installed View

Power Supply The power supply is located within the Vehicle Manager enclosure.
The power supply delivers clean, stabilized power to the distribution
board. Voltages generated by the power supply are:
• +12 volts
• +5.3 volts (for Vehicle Function Controller [VFC])
• +5 volts (used by Encoder)

Power
Supply

Figure 1-9: Vehicle Manager - Internal View

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Electrical

Two-Digit Display The two-digit alphanumeric display is located on the VFC and
provides status and error codes to the service technician.

Two-Digit
Display

Firmware

Figure 1-10: Vehicle Function Controller (VFC)

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Electrical

Power Panel The power panel driver assembly is mounted on the top of the power
Driver Assembly contactor control panel. It is an interconnection point for several truck
systems. It consists of three coil drivers that control the lift (P),
plugging (IS), and power disconnect (PC) contactors on the power
panel mounted directly below. It also contains four 15-amp control
fuses.

Power Panel Driver

Assembly

Coil Drivers (3)

Contactor Panel
Assembly

Figure 1-11: Power Panel Driver Assembly Location

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Electrical

Hydraulic Driver The Hydraulic Driver Assembly Board (HDA) is mounted to the
Assembly (HDA) hydraulic reservoir. The HDA is an interconnection point for several
truck systems. It also contains the horn relay and 8 of the 12-coil
drivers and is controlled by the Vehicle Manager.

Coil Drivers A total of eight coil drivers can be connected into the vehicle manager
via the hydraulic drive assembly card. Coil drivers have built-in diode
assemblies, with the advantage of not having to use unique
components between 24- and 36-volt trucks. Coil drivers are used to
allow 24-volt coils to be used on all vehicles. The coil drivers are
plugged into the hydraulic drive card assembly which is located under
the operator console cover, (left and forward of the control handle),
next to the hydraulic fluid reservoir tank.

Coil Drivers

Hydraulic Driver
Assembly Board

Figure 1-12: Hydraulic Driver Assembly Board Location

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Electrical

Distribution Board The distribution board is the main interface between the Vehicle
Function Controller (VFC) and the remainder of the system. All inputs
to and outputs from the VFC pass through the distribution board. The
distribution board features input and output buffers which boost the
signal to the device being controlled. The board also:
• Provides for termination of all cables
• Eliminates all terminal strips
• Uses Opto-Isolators to protect the VFC from electrical input
disturbances
The distribution board is a wiring harness in the form of a printed
circuit board.

Mode Select Switch The mode select switch is located on the Vehicle Manager distribution
board and is used to select Run or Program mode of the system.

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Electrical

Travel System The travel system consists of:

• Driver Motor
• Travel Contactors
• Control Handle
• Deadman Pedal

Drive Motor The drive motor transmits power to the reduction unit via a pinion
gear on the armature shaft. The drive motor is located inside on the
left side of the operators compartment and behind the swing door.

Drive Motor Encoder The drive motor encoder is mounted on a fixed bracket and belt-driven
from the drive motor. The purpose of the encoder is to determine
vehicle direction and speed. As the armature in the drive motor
rotates, the encoder turns at the same rpm and in the same direction
as the drive motor. As the encoder is turned, a quadrature phase
signal allows MicroCommand/Vehicle Manager to determine the
direction and speed the truck is traveling. Power to the encoder is +5
volts.

Drive Motor
Encoder (DE)

Figure 1-13: Drive Motor Encoder Location

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Electrical

Travel Contactors The contactors used are magnetic type, designed for maximum
interchangeability of parts. Contactor tips are silver alloy and are
replaceable. The following contactors can be found in this truck:

Contactor Description

The 1S Contactor (Shorting) allows a controlled safe

slow down, stop and direction change without abrupt
truck motion. It is used to route excess current gen-
1S
erated during plugging to the plugging resistor
located on the side of the mast. The resistor dissi-
pates the energy as heat.
The P Contactor (Lift Pump) controls the operation of
P the pump motor. When closed, the P Contactor ener-
gizes the pump motor.

The PC Contactor (Power Disconnect) controls the

flow of main power to the various truck systems. The
PC
contactor is energized when the operator depresses
the deadman switch (S2).

Steering System The steering system consists of:

• Auxiliary Motor
• X Contactor
• Control Handle
• Deadman Pedal (Switch S2)
• Emergency Disconnect
• Horn/Horn Button
• Key Switch (S1)

Auxiliary Motor Power to drive the auxiliary pump is a compound-wound,

intermittent-duty motor. The auxiliary motor is located under the
operator’s console cover and to the left of the operator’s control
handle.

X Contactor The X contactor is a single-pole, single-throw design with normally

open tips. Activation of the X contactor energizes the auxiliary motor
circuit, which enables:
• Steering function
• Reach
• Tilt
• Sideshift

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Electrical

Control Handle The travel contactors are located behind the access panel on the right
side wall of the operator’s compartment. The control handle functions
are:

Function Description

VR1 Throttle forward and reverse motion

S3 Horn button

S4 Reach button (high-speed retract)

S5 Retract button (high-speed reach)

S6 Tilt forks UP button

S7 Tilt forks DOWN button

S8 Carriage sideshift left

S9 Carriage sideshift right

S20 Lift

S21 Lower

Deadman Pedal The deadman pedal is switch S2. Switch S2, which is normally open,
(Switch S2) is located on the brake assembly near the drive motor in the power
section. When the deadman pedal is up, switch S2 is open, preventing
travel.

Emergency The emergency disconnect is located on the operator’s control console,

Disconnect to the right of the control handle. The disconnect has two positions:
• UP allows the truck to travel, lift, auxiliary, and steer
• DOWN prevents travel and all other functions from operating

Key Switch (S1) The lockable key switch is located to the left of the operator’s display.
The key switch has two positions; OFF and ON.

Horn/Horn Button The horn button is located on the front side of the directional/speed
(S3) control handle; the horn can be sounded whenever the key switch is
ON. The horn assembly is mounted in the operator’s compartment
behind the swing door, to the right and slightly below the steer motor.

Line Filter The line filter is used to filter the battery positive feed to the coil driver
circuits. It contains a slow-blow fuse mounted in a fuse holder.

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Electrical

Auxiliary Manifold
Pump and
Motor

Steer Motor

Horn
Brake

Drive Motor Deadman

(S2)

Brake
Reservoir

Dip Stick
Filler Tube

Figure 1-14: Platform Components (Hydraulic)

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Electrical

FU1 FU2 FU3 FU4 Power Panel Driver

Assembly Coil Drivers

FU5

PC Contactor

1S Contactor
(36V only)

P Contactor

FU6

FU8 L1

Line Filter CCM

Chopper
Q1 Main Control
Power Module
Transistor

HCM
Bridge
Control
Module
Vehicle
Manager

Figure 1-15: Platform Components (Electrical)

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Electrical

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