nifty HYBRID DC HR15N Series Page 4 Service Manual Download

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Service Manual

HR15/17N HYBRID DC

English 07/16

-3

3.3 Batteries............................................................................................................................................. 26

3.3.1 Condition Check (Daily) .............................................................................................................. 26

3.3.2 Condition Check (Weekly) - Excludes AGM Batteries ................................................................... 26

3.4 Hydraulic Oil....................................................................................................................................... 27

3.4.1 Level Check (Weekly) ................................................................................................................. 27

3.4.2 Return Filter Check (Monthly) ..................................................................................................... 27

3.4.3 Pressure Filter Check (Weekly) ................................................................................................... 27

3.4.4 Hydraulic Oil And Filters Replace ................................................................................................ 27

3.5 Telescopic Boom................................................................................................................................ 29

3.5.1 Wear Pad Check (Monthly) ......................................................................................................... 29

3.5.2 Hose Trunking and Energy Chain Check (Weekly) ....................................................................... 29

3.5.3 Lubricate Boom Pivot Bushes (Yearly) ........................................................................................ 30

3.5.4 Boom Pivot Pin Check (Daily) ..................................................................................................... 30

3.6 Boom Rotation Gear ........................................................................................................................... 30

3.6.1 Slew Gear Engagement Check (Monthly) .................................................................................... 30

3.6.2 Slew Ring Lubrication (Monthly)................................................................................................. 31

3.6.3 Slew Ring Bolts Check (Yearly)................................................................................................... 32

3.7 Front Axle........................................................................................................................................... 32

3.7.1 Steer Pin Lubrication (Daily) ....................................................................................................... 32

4 REPAIR PROCEDURES.................................................................................................................33

4.1 General .............................................................................................................................................. 33

4.1.1 Fuses......................................................................................................................................... 33

4.2 Platform/Cage .................................................................................................................................... 35

4.2.1 Footswitch - Contact Switch replace ........................................................................................... 35

4.3 Booms ............................................................................................................................................... 36

4.3.1 Energy Chain Link....................................................................................................................... 36

4.4 Power Tray......................................................................................................................................... 37

4.4.1 Exhaust...................................................................................................................................... 37

4.4.2 Fan Belt...................................................................................................................................... 38

4.5 Base Assembly................................................................................................................................... 39

4.5.1 Steer Cylinder............................................................................................................................. 39

5 SYSTEM OVERVIEW ....................................................................................................................41

5.1 Introduction........................................................................................................................................ 41

5.1.1 Hybrid System............................................................................................................................ 41

5.1.2 DC Electric System..................................................................................................................... 42

5.2 Hybrid Operation................................................................................................................................. 43

5.3 Boom System..................................................................................................................................... 44

5.4 Drive System...................................................................................................................................... 44

5.4.1 Hybrid........................................................................................................................................ 44

5.4.2 DC Electric ................................................................................................................................. 45

5.5 Charging System And Batteries........................................................................................................... 45

5.5.1 Charging System - Hybrid........................................................................................................... 45

5.5.2 Charging System - DC Electric.................................................................................................... 46

5.6 Hydraulic System Overview ................................................................................................................ 47

5.7 Load Sensing Pump ........................................................................................................................... 47

5.8 Valve Block Assembly ........................................................................................................................ 48

5.9 Diff Lock ............................................................................................................................................ 48

5.10 Brake Release .................................................................................................................................. 48

Summary of Contents for HYBRID DC HR15N Series

Page 1: ...htrider Service Manual MODEL HR15N 17N SERIES MkIII www niftylift com e mail info niftylift com Tel 44 0 1908 223456 Fax 44 0 1908 312733 M50602 02 Manufactured by Niftylift Limited Chalkdell Drive Sh...

Page 2: ......

Page 3: ...l Specifications 10 2 4 4 Hydraulic Oil Specifications 10 2 4 5 Engine Coolant Specifications 11 2 4 6 Hydraulic Pressure Settings 11 2 5 Tyre specifications 11 2 6 Torque Settings 12 2 7 Hydraulic Ho...

Page 4: ...Lubrication Monthly 31 3 6 3 Slew Ring Bolts Check Yearly 32 3 7 Front Axle 32 3 7 1 Steer Pin Lubrication Daily 32 4 REPAIR PROCEDURES 33 4 1 General 33 4 1 1 Fuses 33 4 2 Platform Cage 35 4 2 1 Foot...

Page 5: ...rview 50 5 14 Control Logic 50 5 15 Motor Generator 50 5 16 Controller 51 5 17 Niftylift Diagnostic Unit 52 6 TROUBLESHOOTING GUIDE 54 6 1 Trouble Shooting Information 54 6 2 Platform Function Fault F...

Page 6: ...Service Manual HR15 17N HYBRID DC English 07 16 1 Notes...

Page 7: ...ANGER WARNING CAUTION IMPORTANT INSTRUCTIONS AND NOTICE Any place these topics may appear either in this manual or on the Niftylift are defined as follows DANGER If not correctly followed there is a h...

Page 8: ...nd to be either incorrect or missing Niftylift encourage you to send in suggestions which will aid our continuous product improvement If after reading this manual you require further information pleas...

Page 9: ...Y RESULT IN A NIFTYLIFT THAT IS NOT SAFE TO USE WHICH COULD CAUSE INJURY OR POSSIBLE DEATH Regular inspections and appropriate maintenance will ensure the Niftylift performs efficiently and economical...

Page 10: ...t inspection is carried out in accordance with the manufacturer s instructions on a Niftylift 1 That was purchased used This inspection shall be accomplished unless it is determined that the frequent...

Page 11: ...on parts of the Niftylift which are not intended for this Use caution when checking hot pressurised systems such as hydraulic and engine coolant Use correct tools and equipment broken or damaged tool...

Page 12: ...Electric machines See lower diagram Note for clarity the diagram shows battery tray removed Ensure sparks flames or lighted tobacco are kept away from batteries as they emit explosive gases Keep metal...

Page 13: ...idual pressure If pressure is detected allow it to be released slowly before completely removing hose Fluid leaks may not be visible to the naked eye Use a piece of cardboard to check for leaks not yo...

Page 14: ...ycle 3 cylinder diesel engine Fuel Diesel fuel No 2 D Engine oil See section 2 4 2 Mass Dry weight 63 1kg 139 lbs Displacement 719cm3 Net power 14kW 18 8hp 3600rpm Net torque N A Oil capacity 3 8 L 0...

Page 15: ...R17 HR15 HR17 Slew 180 Tele in 50 5 40 5 Slew 180 Tele out 50 5 47 5 Links 18 2 26 5 20 4 26 5 Luffing Boom rest to full height Tele in 24 5 24 5 Luffing Boom rest to full height Tele out 35 5 26 5 Fl...

Page 16: ...ons please contact your nearest Niftylift approved dealer Fluid Volumes Hydraulic oil tank 35 L 7 7 gal Fuel tank 20 L 4 4 gal Engine oil 3 8 L 0 84 gal Coolant 3 1 L 0 68 gal Ambient temperature Oil...

Page 17: ...elow 2 4 6 Hydraulic Pressure Settings Refer to hydraulic schematic as supplied with the machine noting the serial number of the Niftylift 2 5 Tyre specifications Standard tyre fitment Solideal Safety...

Page 18: ...n the following assumptions Bolts to ISO 898 1 Mechanical properties of fasteners made of carbon steel and alloy steel For unplated bolts all grades Hex head bolts Black oxide steel bolt with a rolled...

Page 19: ...74 10 5 8 14 65 48 10 5 8 14 130 96 12 3 4 14 100 70 12 3 4 14 190 140 16 1 11 125 92 16 1 11 300 221 20 1 1 4 11 190 140 20 1 1 4 11 330 243 24 1 1 2 11 250 184 24 1 1 2 11 460 339 32 2 11 400 295 3...

Page 20: ...5 55 41 M16 X 1 5 80 59 40 30 M18 X 1 5 70 52 M18 X 1 5 95 70 45 33 M20 X 1 5 80 59 M20 X 1 5 140 103 70 52 M22 X 1 5 100 74 M22 X 1 5 150 111 75 55 M27 X 2 0 180 133 M27 X 2 0 200 148 100 74 M30 X 2...

Page 21: ...very Month Every 500 Hours Every Year Every 2 Years Engine Oil 1 Engine Oil Filter Air Filter Engine Coolant Coolant Hoses and Clamp Bands Fuel Filter In Line Fuel Filter Water Separator Fuel Tank Fue...

Page 22: ...ry 2 Years Gearbox Oil 1 Battery condition a a Excludes optional Absorbent Glass Mat AGM maintenance free batteries Hydraulic oil level Return filter Pressure filter Hydraulic oil and filters 1 Telesc...

Page 23: ...stopping the engine 2 Remove oil level dipstick 2 and wipe clean 3 Insert dipstick and remove to check oil level 4 If low add correct specification oil to the oil filling port 1 until the upper limit...

Page 24: ...found in the oil specification table See section 2 4 2 5 Re check oil level at least 5 minutes after filling engine 3 1 4 Engine Oil Filter Replace ENSURE ENGINE IS OFF BEFORE REPLACING THE ENGINE OIL...

Page 25: ...supply port 2 Ensure coolant level is sufficient on the reserve tank The level should be between the full and low marks 3 Ensure both drain plugs are installed one to the lower part of the radiator 2...

Page 26: ...ator cap This must be removed to allow a full coolant drain 2 Remove the overflow pipe from the radiator pressure cap to drain the reserve tank 3 Ensure both drain plugs are fitted one to the lower pa...

Page 27: ...soak the filter in detergent for 15 minutes 7 Wash it several times in water rinse with clean water and allow to dry naturally 8 After filter is fully dried inspect the inside with a flashlight for d...

Page 28: ...eeding air from the fuel system before attempting to start the engine 3 1 11 Fuel Filter and Water Separator Clean Replace FUEL ESCAPE PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK AREA AND DISPOSE F...

Page 29: ...torage Fuel filter 1 Fill the fuel tank 2 Open the fuel filter tap 1 as shown above 3 Loosen air vent plug 2 by a few turns 4 Tighten plug 2 once air bubbles are no longer present in container 3 5 Car...

Page 30: ...uild up around joints and seams 3 1 14 Fan Belt Check Every 100 hours 1 Ensure engine is switched OFF 2 Apply moderate pressure to belt using your thumb in area shown on diagram If dimension A does no...

Page 31: ...gram Fill gearbox through plug hole 1 until oil level reaches bottom of plug hole 2 See section 2 4 3 and 2 2 for oil specifications and capacities 5 Reinstall plugs and tighten to 33Nm 24 ft lbs 6 Re...

Page 32: ...ccordance with local regulations for acid and lead scrap Use approved respiratory protection rubber gloves and splash proof safety goggles Use rubber boots and acid proof clothing for major spills Rep...

Page 33: ...e the oil has cooled sufficiently 3 4 3 Pressure Filter Check Weekly With the Niftylift running and the oil temperature at 40 C 104 F observe the pressure filter condition indicator located on the val...

Page 34: ...housing cover 16 Tighten 3 bolts to 10 0Nm 7 4ft lbs Pressure filter 17 Locate the pressure filter on the power tray 18 Place a suitable container underneath filter housing 19 Remove the filter bowl...

Page 35: ...elescope boom then tighten the locking nuts 8 Check that the underside of the inner telescope boom section is adequately lubricated and free from scoring or rubbing marks 9 Lubricate if necessary use...

Page 36: ...3 5 4 Boom Pivot Pin Check Daily Check the respective locking device on each boom pivot pin is installed and secure 3 6 Boom Rotation Gear 3 6 1 Slew Gear Engagement Check Monthly 1 Check the play bet...

Page 37: ...1 Open the control left hand canopy 2 Two grease nipples 1 are located on the side of the superstructure 3 Pump the grease gun two to three times as required Use lithium based Ep grease corresponding...

Page 38: ...rque settings 3 7 Front Axle 3 7 1 Steer Pin Lubrication Daily 1 Two grease nipples 1 are located on either side of the front axle 2 Pump the grease gun two to three times as required Use lithium base...

Page 39: ...es blade fuses can be found in the following locations 15A x2 2A Base control box 15A 2A Control panel assembly Prior to the replacement of any fuse determine the cause of the fault Do not replace the...

Page 40: ...Service Manual HR15 17N HYBRID DC English 07 16 34 DC Electric main fuse location Note for clarity diagram shows battery tray removed 325A...

Page 41: ...t Note the longer length of bolt 1 3 Record wiring locations 4 Disconnect wiring from switch terminals 3 5 Remove 2 screws 4 from contact switch and remove Install 6 Replace contact switch and tighten...

Page 42: ...elescopic boom to access the worn or damaged link 2 Insert a small flat screwdriver into chain bridge 1 3 Raise the chain bridge until vertical 4 Carefully prise apart link 2 at the four points arrowe...

Page 43: ...Reinstall heat shield to exhaust assembly and tighten 4 bolts See section 2 6 for torque settings 7 Reinstall exhaust assembly and tighten 2 bolts See section 2 6 for torque settings 8 Reinstall the e...

Page 44: ...HOT ENGINE COMPONENTS Remove 1 Open the engine canopy 2 Remove 4 bolts 1 and remove fan guard 3 Loosen the alternator mounting bolts and remove the fan belt Install 4 Replace fan belt 5 Reinstall fan...

Page 45: ...low pressure to dissipate 6 Insert plugs and cap to prevent oil loss 7 Remove and discard 2 roll pins from the steer rod arms 8 Remove 4 bolts 4 washers and 4 spring washers 9 Remove steer cylinder fr...

Page 46: ...17N HYBRID DC English 07 16 40 19 Check hydraulic oil level and top up with appropriate grade of oil if necessary See section 2 4 4 20 Reinstall cover to front axle and tighten 4 bolts See section 2 6...

Page 47: ...nergy consumption and noise levels as low as possible when performing lower duty operations When in electric only mode the machine enables machine performance with reduced noise and zero emissions Bat...

Page 48: ...warning light will illuminate reinforcing the charge warning At this point sufficient power remains to drive to the nearest power point Immediate charging will then be required Battery Isolation The b...

Page 49: ...motor supports the shaft boost to keep the RPM above the lower limit Figure below explains the working principle During boost the system demand is always monitored such that if boost is not required i...

Page 50: ...nction controller failure motor failure etc the booms can be operated in diesel only mode However this mode is only for low duty functions and for assisting to recover the booms back to the transport...

Page 51: ...of charging it is essential that regular and thorough maintenance of the batteries is performed The engine alternator charges the start battery when the engine is running which keeps the battery at 14...

Page 52: ...occur 5 5 2 Charging System DC Electric As standard all Niftylifts are fitted with a 18A variable input intelligent charger The Niftylift can be left on charge over an infinite period or can be used w...

Page 53: ...isplacement pump open loop load sensing Standby pressure and maximum pressure are set to 17 bar 247 psi and 280 bar 4061 psi The load sense signal is obtained either from the boom control valve or fro...

Page 54: ...ed via the divider combiner valve and flow is free to go to either of the two rear wheels 5 10 Brake Release The rear brakes are released using the Brake Release Valve BRV in the DCV which is energise...

Page 55: ...ed by the spool Where necessary anti shock valves are fitted to the work ports For all main boom functions both manual operation and hydraulic pilot operation is possible For steer and cage level func...

Page 56: ...ed a 48V AC 3 phase motor generator is fitted to the power train The motor is equipped with a temperature and speed sensor which feed information to the controller Current supplied to the motor is con...

Page 57: ...the motor High voltage safety functions are controlled within the motor controller If a fault is detected in the power supply motor controller or motor a main contactor will shut off the power to the...

Page 58: ...g The monitor menu provides useful information for troubleshooting The diagram on page 53 shows the layout of the menus The main menu allows access to the diagnostic units multiple functions Scroll th...

Page 59: ...e I O Machine Enable 1 Coil Machine Enable 1 SW Machine Enable 2 Coil Machine Enable 2 SW Machine Active Auxiliary Descent SW Sounder Horn Menu Back Engine Speed from motor High Speed Enable Glow Star...

Page 60: ...the drive block Replace Drive Enable Relay Check main PCB for signal in from joystick and out to drive block Loose connector Check joystick Replace joystick if faulty No functions but engine operates...

Page 61: ...arbon deposits on orifice of injection nozzle This is caused when water or dirt is mixed in the fuel Clean the nozzle injection piece being careful not to damage the orifice Check to see if nozzle is...

Page 62: ...ement Check clearance of bearings are within factory specifications Check ignition timing Valve clearance is wrong Adjust valve clearance to 0 145 to 0 185mm 0 0057 to 0 0072in when the engine is cold...

Page 63: ...e centre Dented or chipped teeth Contact a Niftylift approved service centre Low oil level Check oil level top up if necessary See section 3 2 1 The brakes fails to disengage Low pressure in the braki...

Page 64: ...06 Machine Enable Relay 2 Error Open circuit or short circuit of the machine enable relay2 coil Check wiring to the machine enable relay2 coil on the PCB 07 Horn Error Open circuit or short circuit of...

Page 65: ...odes Diagnose further using the service tool 19 Base ERROR_ANALOG Error on one of the analogue inputs to the base PLC Check screen for further fault codes Diagnose further using the service tool 20 Ba...

Page 66: ...agnosed an internal fault Diagnose further using the service tool Use the LEDs on the motor controller to ascertain the fault code s Red and Orange LEDs flash alternately 1 red is followed by the firs...

Page 67: ...s The base PLC is not receiving the cage node s present signal Check the power supply to the cage node Check the CANBus connections from the cage panel to the cage node 36 Parameter Error Parameters d...

Page 68: ...LC is 0v 45 Cage Set to Download The base run download switch is set to download Check switch is in RUN position Check that when the switch is in RUN pin 24 of the PLC is 0v 46 Base ERROR_POWER The vo...

Page 69: ...ke ShutdownThrottle FullBrake ShutdownPump 1 See Monitor menu Battery Capacitor Voltage 2 External load on capacitor bank B connection terminal that prevents the capacitor bank from charging Set Prech...

Page 70: ...abled Clear Bring capacitor voltage below Severe Overvoltage limit and then cycle KSI 22 Controller Overtemp Cutback Reduced drive and brake torque 1 See Monitor menu Controller Temperature 2 Controll...

Page 71: ...al load impedance on the 5V supply pin 26 is too low 2 See Monitor menu Outputs 5 Volts and Ext Supply Current Set 5V supply pin 26 outside the 5V 10 range Clear Bring voltage within range 26 Digital...

Page 72: ...Analog2 Set Motorthermistor input pin 8 is at the voltage rail 0 or 10V Clear Bring the motor thermistor input voltage within range 31 Coil1 Driver Open Short ShutdownDriver1 1 Open or short on drive...

Page 73: ...iring Set Proportional driver pin 2 is either open or shorted Clear Correct open or short and cycle driver 36 Encoder Fault ShutdownEMBrake ShutdownThrottle 1 Motor encoder failure 2 Bad crimps or fau...

Page 74: ...Pot 2 Throttle pot wiper voltage too low Set Throttle pot wiper pin16 voltage is lower than the low fault threshold can be changed with the VCL function Setup_Pot_Faults Clear Bring throttle pot wiper...

Page 75: ...ply inputs in correct sequence 47 Emer Rev HPD ShutdownThrottle ShutdownEMBrake 1 Emergency Reverse operation has concluded but the throttle forward and reverse inputs and interlock have not been retu...

Page 76: ...g Menu parameters Ext Supply Max and Ext Supply Min are mis tuned 3 See Monitor menu Outputs Ext Supply Current Set The external supply current combined current used by the 5V supply pin 26 and 12V su...

Page 77: ...r characterization failed during characterization process See Monitor menu Controller Motor Characterization Error for cause 0 none 1 encoder signal seen but step size not determined set Encoder Step...

Page 78: ...coder Fault Code 36 or a Stall Detect Fault Code 73 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Vehicle is stalled Set Encoder Fault Code 36 or a Stall Detect Fault Code 73 was activated a...

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