Caterpillar NPV20N3D to NSF16N3SS Service Manual SM23GB1DHSC3

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Caterpillar NPV20N3D to NSF16N3SS Service Manual SM23GB1DHSC3

$50.00

Type Of Manual: Service Manual
Manual ID: SM23GB1DHSC3
Number of Pages: 286
Size: 14.0MB
Format: PDF

Category: Caterpillar Service Manual PDF

Model List:
- NPV20N3D, NPF20N3DR, NPF20N3DS, NSV12N3, NSF12N3R, NSF12N3S, NSV12N3I, NSF12N3IR, NSF12N3IS, NSV16N3, NSF16N3R, NSF16N3S, NSV16N3I, NSF16N3IR, NSF16N3IS, NSV16N3S, NSF16N3SR, NSF16N3SS

1. GENERAL INFORMATION AND TECHNICAL DATA
1.1. Introduction
1.1.1. General
1.1.2. The trucks
1.1.3. Authorised service personnel
1.1.4. Symbol key
1.2. Safety
1.2.1. General
1.2.2. Safety instructions
1.2.3. Truck modification
1.2.4. Lifting the truck
1.2.5. Welding on truck
1.2.6. Gas spring
1.3. Environmental considerations
1.3.1. We respect the environment
1.4. Preparations
1.4.1. Service
1.4.2. Troubleshooting
1.5. Truck data
1.5.1. Machine plates
1.5.2. Safety and warning signs
1.5.3. Type designation
1.5.4. Truck types
1.5.5. Weights, double stacker
1.5.6. Weights, high lift stacker
1.5.7. Dimensions double stacker – Duplex (T)
1.5.8. Dimensions high lift stacker, load capacity 1250 kg – Duplex (TV/TFV)
1.5.9. Dimensions high lift stacker, load capacity 1600 kg – Duplex (TFV)
1.5.10. Dimensions high lift stacker, load capacity 1600 kg – Triplex (DTFV)
1.5.11. Miscellaneous
1.6. Component placement
1.7. Component specification
1.8. Recommended consumable materials
1.8.1. Oil and grease types
1.9. Code explanations
1.9.1. Colour codes for wiring diagrams
1.9.2. Designations for electrical components in electrical diagram
1.9.3. Standard abbreviations and units
1.9.4. Acronyms and abbreviations
2. SPECIAL TOOLS
2.1. List of tools
3. SERVICE
3.1. Service schedule / inspection
3.1.1. Introduction
3.1.2. Safety
3.1.3. Service schedule explanation
3.1.4. Inspection daily / monthly / PDI and commissioning
3.1.5. First service (200 hours)
3.1.6. Main service
3.1.7. Extra service inspections
3.1.8. Service inspection
3.1.9. Dye penetration inspection instruction
3.2. Service Schedule
3.3. Lubrication
3.3.1. Recommended lubricants
3.3.2. Symbol key, lubrication chart
3.3.3. Lubrication chart
3.4. Specific instructions
3.4.1. Traction motor
3.4.2. Gearbox
3.5. Maintaining the battery (not for Li-ION)
3.6. Battery servicing
4. CHASSIS
4.1. Design and function
4.1.1. Machine housing
4.1.2. Covers and panels
4.1.3. Wheel system
4.1.4. Wheels
4.1.5. Friction force system, double stacker
4.1.6. Adjustable damped floor (option for fixed platform truck variants)
4.2. Repair and maintenance instructions
4.2.1. Before work is performed
4.2.2. Remove and install panels and covers
4.2.3. Remove and install the side protection gates
4.2.4. Remove and install the platform damper (option)
4.2.5. Wheels
4.2.6. Friction force system, double stacker
5. DRIVE UNIT
5.1. Design and function
5.1.1. Description
5.1.2. Traction Motor
5.1.3. Gearbox
5.1.4. Drive wheel
5.2. Repair and maintenance instructions
5.2.1. Before work is performed
5.2.2. Servicing and maintenance
5.2.3. Traction motor
5.2.4. Gearbox
5.2.5. Drive wheel
5.3. Diagnostics and troubleshooting
5.3.1. Troubleshooting chart
6. MAST SYSTEM
6.1. Design and function
6.1.1. Mast systems
6.1.2. Initial lift (option for high lift stacker)
6.1.3. Fork carriage
6.1.4. Link system
6.2. Repair and maintenance instructions
6.2.1. Before work is performed
6.2.2. Leaning angle of truck, adjustment
6.2.3. Initial lift
6.2.4. Fork carriage
6.2.5. Inspection of welded fork carriages
6.2.6. Inspection of forged forks
6.2.7. Lift chains
6.2.8. Link system
6.2.9. Wheels
6.2.10. Closed pallet entry and exit (option for double stacker)
6.3. Diagnostics and troubleshooting
6.3.1. Troubleshooting chart
7. STEERING
7.1. Design and function
7.1.1. General
7.1.2. Mechanical steering
7.1.3. Electrical power steering
7.1.4. Feedback sensors
7.1.5. Communication between the servo components
7.2. Repair and maintenance instructions
7.2.1. Before work is performed
7.2.2. Cleaning
7.2.3. Tiller arm
7.2.4. Mechanical steering
7.2.5. Power steering
8. HYDRAULIC SYSTEM
8.1. Design and function
8.1.1. Overview
8.1.2. Description
8.1.3. Lifting and lowering
8.1.4. Hydraulic diagram
8.1.5. Hydraulic unit
8.1.6. Hydraulic unit valves
8.1.7. Hydraulic oil
8.2. Repair and maintenance instructions
8.2.1. Before work is performed
8.2.2. General instructions
8.2.3. Installation
8.2.4. Connections
8.2.5. Hydraulic hoses
8.2.6. Start-up
8.2.7. Remove and install the hydraulic unit
8.2.8. Raise the hydraulic unit, double stacker
8.2.9. Hydraulic oil, changing/draining
8.2.10. Replace the air filter
8.2.11. Hydraulic motor
8.2.12. Hydraulic control valves
8.2.13. Installation instruction for pipe couplings
8.3. Diagnostics and troubleshooting
8.3.1. Symptoms and Actions
9. CYLINDERS
9.1. Design and function
9.1.1. Description
9.1.2. Hose break valve
9.2. Repair and maintenance instructions
9.2.1. Before work is performed
9.2.2. Bleeding of the hydraulic cylinders with an air bleed screw
9.2.3. Bleeding of the hydraulic cylinders without a bleed air screw
9.2.4. Double stacker
9.2.5. High lift stacker
10. ELECTRICAL SYSTEM
10.1. Introduction
10.1.1. Overview of components
10.1.2. CAN bus communication
10.2. Safety
10.2.1. Safety instructions
10.2.2. Electronic controllers
10.2.3. Safety checks
10.2.4. Servo steering system
10.2.5. Hydraulic system
10.2.6. Hydraulic pressure sensors for initial lift and main lift (S26, S30)
10.2.7. Brake system
10.2.8. Traction system
10.2.9. Sensors
10.2.10. Maximum drive speed and drive stop
10.3. Design and function
10.3.1. Battery capacity
10.3.2. VCM (Vehicle Control Module) (truck computer)
10.3.3. Display
10.3.4. CMC (Combi Motor Controller)
10.3.5. EPS (Electrical Power Steering) controller
10.3.6. Connector specifications
10.4. Repair and maintenance instructions
10.4.1. Before work is performed
10.4.2. Wiring diagram
10.4.3. Insulation resistance test
10.4.4. Remove and install the battery lock
10.4.5. Battery replacement (with rollers)
10.4.6. Battery replacement (without rollers)
10.4.7. Battery replacement (Lithium-ion)
10.4.8. Replacing the Electric panel components
10.4.9. Remove and install the VCM
10.4.10. Remove and install the emergency stop
10.4.11. Remove and install the standard display (HMI-10)
10.4.12. Remove and install the multi function display (HMI-20)
10.4.13. Replace the Foot protection sensor (S1) Reflector, Fixed rear platform
10.4.14. Remove and install the safety sensors
10.4.15. TruckTool
10.5. Diagnostics and troubleshooting
11. SPEED CONTROL AND BRAKE SYSTEMS
11.1. Design and function
11.1.1. Speed and brake control
11.1.2. Electric brake
11.2. Repair and maintenance instructions
11.2.1. Before work is performed
11.2.2. Electric brake
11.3. Diagnostics and troubleshooting
11.3.1. Troubleshoot the speed controller
11.3.2. Troubleshoot the brake
12. MISCELLANEOUS
12.1. Options
12.1.1. Additional equipment
12.1.2. Additional equipment overview
12.1.3. Battery lock, quick lock (option)
12.1.4. Adjustable damped floor (option)
12.1.5. Load backrest (option)
12.1.6. power supply socket (option)
12.1.7. USB-power supply socket (option)
12.1.8. Equipment bar installation (option)
12.1.9. Work light (only with overhead guard)
12.1.10. Floor spot (option)
12.1.11. Writing surface installation
12.1.12. Foot protection (option)
12.1.13. Closed Pallet Entry and Exit (option)

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