Caterpillar NSP10N2R Lift Trucks Service, Operation & Maintenance Manual – PDF DOWNLOAD

Description

Caterpillar NSP10N2R Lift Trucks Service, Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Caterpillar NSP10N2R Lift Trucks Service, Operation & Maintenance Manual – PDF DOWNLOAD

Foreword :

This service manual is a guide for servicing lift trucks.

• The long productive life of your lift truck depends on regular and proper servicing, consistent with the instructions provided in this service manual.
• Before starting to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and familiarize yourself with all of the components.
• The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing.
• The manufacturer reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience, the instructions are grouped by systems as an easy reference.
• Unauthorized copying and lending of this material is strictly prohibited.

TABLE OF CONTENTS:

Caterpillar NSP10N2R Lift Trucks Service, Operation & Maintenance Manual – PDF DOWNLOAD

Contents 3
1 Foreword 8
2 How to read this manual 9
2 1 Safety-related signs 9
2 2 Symbols and abbreviations 9
2 2 1 Safety symbols 9
2 2 2 Other symbols and abbreviations 11
2 3 Units 11
3 Safety instructions 12
3 1 Service area safety 12
3 2 Personal safety 13
3 3 Work safety 13
4 General information 16
4 1 Truck model covered by this manual 16
4 2 Identification plates on the truck 16
4 3 Overview of the truck 18
4 3 1 Operating devices 18
4 3 2 Tiller arm 19
4 3 3 Front cover with controls 22
4 3 4 Driving position 27
4 3 5 Driving direction 29
4 3 6 Motor and electrical system 30
4 3 7 Sensors 34
4 3 8 Mast unit 35
5 Mechanical maintenance 38
5 1 Lifting points 38
5 1 1 Jack points 38
5 1 2 Hoist points 39
5 2 Transportation 39
5 3 Ordering spare parts 40
5 4 Opening the covers 41
5 4 1 Front cover with controls 42
5 4 2 Battery cover 44
5 5 Removing the operator’s platform 45
5 5 1 Removing the operator’s platform rubber absorbers 48
5 5 2 Replacing the operator’s platform gas spring 49
5 5 3 Removing the operator’s platform slide bearing 51
5 6 Transmission gear 52
5 7 Bogie bearing 53
5 8 Traction wheel 53
5 8 1 Disassembly of the traction wheel 54
Copyright© 2013 by MCFE All rights reserved Revision: B Document ID: 616843 4 (338)
NSP_R Service Manual
5 8 2 Assembly of the traction wheel 56
5 9 Castor wheel 57
5 9 1 Adjusting the castor wheel 57
5 9 2 Disassembly of the castor wheel unit 59
5 9 3 Disassembly of the castor wheel 60
5 9 4 Assembly of the castor wheel 60
5 10 Tiller arm 61
5 10 1 Disassembly of the center steering assembly 62
5 11 Tiller arm joint 63
5 12 Mast unit 68
5 12 1 Detailed construction 68
5 12 2 Mast unit maintenance 80
5 12 3 Lubricant and fluid recommendations 81
5 12 4 Removing the mast unit 81
5 12 5 Disassembly of the mast unit 96
5 12 6 Triplex mast with free lift 123
5 12 7 Inspecting the forks 134
5 12 8 Load wheels 140
5 12 9 Mast chains 141
5 12 10 Chain yoke 150
5 12 11 Guidance rollers 152
5 12 12 Main rollers 154
5 12 13 Free lift cylinder 156
5 12 14 Side cylinders 163
5 12 15 Initial lift cylinder 173
6 Electrical operation 176
6 1 Using the schematic diagram 176
6 2 Power source 179
6 3 Safety circuit (emergency stop button) 179
6 4 Key switch 179
6 5 Traction 180
6 6 AC motor operation 180
6 7 Sensorless operation 181
7 Battery maintenance 182
7 1 Safety regulations concerning the handling of lead-acid batteries 183
7 2 Battery maintenance 184
7 2 1 Daily maintenance 184
7 2 2 Weekly maintenance 184
7 2 3 Monthly maintenance 184
7 2 4 Annual maintenance 185
7 3 Recharging the battery 185
7 4 Measuring the battery’s specific gravity 188
7 5 Replacing the battery 188
8 Electric system maintenance 191
8 1 Tiller arm 191
8 1 1 Removing the tiller head 192
Copyright© 2013 by MCFE All rights reserved Revision: B Document ID: 616843 5 (338)
NSP_R Service Manual
8 1 2 Removing the tiller head switches 194
8 1 3 Removing the safety button 195
8 1 4 Removing the accelerator 197
8 1 5 Installing the accelerator 199
8 1 6 Removing the controller for lifting and lowering 200
8 1 7 Installing the controller for lifting and lowering 201
8 2 Electric panel 202
8 2 1 Removing the controller cover 203
8 2 2 Traction controller 204
8 2 3 Traction controller connectors 205
8 2 4 Contactors and relays 210
8 2 5 Fuses 211
8 2 6 Accessing the controller fan 212
8 3 Truck connector 214
8 3 1 Replacing the truck connector 214
8 4 Motor compartment 215
8 4 1 Removing the drive unit 216
8 4 2 Disassembly of the drive unit 217
8 4 3 Installation of the traction motor 217
8 4 4 Assembly of the splined shaft-hub connection 218
8 4 5 Temperature sensor check 220
8 4 6 Magnetic brake 221
8 4 7 Motor belt 222
8 5 Pump motor 226
8 5 1 Solenoid valve 227
8 6 Sensors 228
8 6 1 Tiller and operator’s platform sensors 228
8 6 2 Initial lift upper limit sensor 230
8 7 Switches and buttons 231
8 7 1 Emergency stop button 231
8 7 2 Key switch 232
8 7 3 Tiller head microswitch 233
8 8 Horn 234
8 8 1 Diode test with a multimeter 234
8 9 Wiring harnesses and cables 235
8 9 1 Installing the traction motor cables 238
9 Electric system adjustments and measurements 240
9 1 Calibrating the accelerator 240
9 1 1 Acquiring the VACC with TruckTool 240
9 1 2 Acquiring the VACC without Truck Tool 241
9 2 Calibrating the controller for lifting and lowering 241
9 2 1 Acquiring the VACC with TruckTool 241
9 3 Insulation resistance test 242
9 3 1 Test voltage 242
9 3 2 Checking the insulation tester 243
9 3 3 Measuring the insulation resistance 243
10 Hydraulic operation 246
10 1 Hydraulic symbols 249
Copyright© 2013 by MCFE All rights reserved Revision: B Document ID: 616843 6 (338)
NSP_R Service Manual
10 2 Hydraulic oil recommendations 251
10 3 Maintenance points of the hydraulic system 251
10 4 Hydraulic aggregate 252
10 4 1 Setting the lifting pressure 252
10 4 2 Disassembly of the hydraulic aggregate 254
11 TruckTool Diagnostics 255
12 Parameter descriptions 256
12 1 Traction controller 256
13 Alarm codes 264
13 1 Traction controller 264
14 Service data 283
14 1 Special tightening torques 283
14 2 Tightening torque for standard bolts and nuts 284
14 3 Maintenance check list 286
14 4 Lubrication 289
14 4 1 Hydraulic oil 289
14 4 2 Transmission oil 289
14 5 Special tools 289
15 Options 291
15 1 Load support 292
15 1 1 Installation of the load support 292
15 1 2 Installation of the load support (masts with straddle fork) 293
15 2 Accessory rack 293
15 2 1 Installation of the accessory rack 294
15 2 2 Installation of the list bracket 295
15 2 3 Installation of the computer rack 296
15 2 4 Installation of the bottle rack 297
15 2 5 Installation of the pen rack 298
15 3 Voltage converter 299
15 3 1 Installation of the voltage converter 299
15 4 Battery connector 300
15 4 1 Replacing the battery connector 301
15 5 Charger connector 301
15 5 1 Replacing the charger connector 302
15 6 Internal charger and the internal charger connector 302
15 6 1 Installation of the internal charger and the internal charger connector 303
15 7 Abbot 305
15 7 1 Installation of the abbot 306
15 8 Hydraulic block valve 306
15 8 1 Installation of the hydraulic block valve 307
15 9 PIN code unit keyboard 308
15 9 1 Installation of the PIN code unit keyboard 308
15 9 2 Activating the truck with the PIN code 309
15 9 3 Programming a new PIN code 309
Copyright© 2013 by MCFE All rights reserved Revision: B Document ID: 616843 7 (338)
NSP_R Service Manual
15 9 4 Driver Present mode 310
15 10 Driving speed reduction 311
15 10 1 Driving speed reduction sensor 311
16 Technical specification 318
17 Index 328
APPENDIX A: Stickers 332

CATERPILLAR NSP10N2R LIFT TRUCKS SERVICE, OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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