Caterpillar NRM20N2, NRM25N2 Service Manual SM24GBUFW1C4

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Caterpillar NRM20N2, NRM25N2 Service Manual SM24GBUFW1C4

$50.00

Type Of Manual: Service Manual
Manual ID: SM24GBUFW1C4
Number of Pages: 254
Size: 11.8MB
Format: PDF

Category: Caterpillar Service Manual PDF

Model List:
- NRM20N2, NRM25N2

1. GENERAL INFORMATION AND TECHNICAL DATA
1.1. Introduction
1.1.1. General
1.1.2. The trucks
1.1.3. Genuine Parts
1.1.4. Authorised service personnel
1.1.5. 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. Towing/moving non-powered four-way reach truck
1.2.6. Welding on truck
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. Explanation of symbols
1.5.4. Type designation
1.5.5. Truck types
1.5.6. Dimensions
1.6. Component specification
1.6.1. Drive motor
1.6.2. Electric brake
1.6.3. Gearbox
1.6.4. Hydraulic unit
1.6.5. Control system for traction and pump motors
1.6.6. Steering servo motor
1.6.7. Controller system for steering
1.7. Recommended consumable materials
1.7.1. Oil and grease types
1.8. Code explanations
1.8.1. Colour codes for wiring diagrams
1.8.2. Designations for electrical components in electrical diagram
1.8.3. Standard abbreviations and units
1.8.4. Acronyms and abbreviations
2. SPECIAL TOOLS
2.1. List of tools
3. SERVICE
3.1. Pre-delivery Inspection (PDI)
3.2. Service schedule / inspection
3.2.1. Introduction
3.2.2. Safety
3.2.3. Service schedule explanation
3.2.4. Inspection daily / monthly / PDI and commissioning
3.2.5. First service (200 hours)
3.2.6. Main service
3.2.7. Extra service inspections
3.2.8. Service inspection
3.2.9. Dye penetration inspection instruction
3.3. Service schedule
3.4. Lubrication
3.4.1. Recommended lubricants
3.4.2. Symbol key lubrication chart
3.4.3. Lubrication chart, four-way reach truck
3.4.4. Cab lubrication schematic diagram (option)
4. CHASSIS
4.1. Design and function
4.1.1. Chassis frame
4.1.2. Machine housing
4.1.3. Overhead guard
4.1.4. Battery locking
4.1.5. Armrest and steering wheel
4.1.6. Foot plate
4.1.7. Covers and panels
4.1.8. Tightening torque for chassis plates
4.2. Repair and maintenance instructions
4.2.1. Panels
4.2.2. Load wheels
4.2.3. Machine housing
4.2.4. Driver seat
4.2.5. Overhead guard
4.2.6. Batteries
4.2.7. Battery rollers
4.2.8. Adjustable armrest
4.2.9. Fitting the antistatic chain
5. DRIVE UNIT
5.1. Design and function
5.1.1. Drive motor
5.1.2. Gearbox
5.2. Repair and maintenance instructions
5.2.1. Before work is performed
5.2.2. Drive unit
5.2.3. Traction motor
5.2.4. Removal and installation of the traction motor
5.2.5. First service
5.2.6. Preventive maintenance
5.2.7. Reconditioning the traction motor
5.2.8. Gearbox
5.2.9. Drive wheel
5.3. Diagnostics and troubleshooting
5.3.1. Troubleshooting chart
6. MAST SYSTEM
6.1. Design and function
6.1.1. Mast system
6.1.2. Fork carriage
6.2. Repair and maintenance instructions
6.2.1. Lift chains
6.2.2. Reach carriage
6.2.3. Fork carriage
6.2.4. Hydraulic fork spreading, four-way reach truck
6.3. Diagnostics and troubleshooting
6.3.1. Troubleshooting chart, triplex with free lift (DTFV)
6.3.2. Fault-finding chart for fork spreaders, four-way reach truck
7. STEERING
7.1. Design and function
7.1.1. General
7.1.2. Feedback sensors
7.1.3. Communication between the servo components
7.2. Repair and maintenance instructions
7.2.1. Steering wheel
7.2.2. Steering servo motor
7.2.3. Settings, adjustments and testing
7.2.4. Remove and install the zero position sensor
7.2.5. Options
7.3. Diagnostics and troubleshooting
7.3.1. Troubleshooting with TruckTool
8. HYDRAULIC SYSTEM
8.1. Design and function
8.1.1. Description
8.1.2. Hose rupture valve
8.1.3. Electric proportional valve
8.1.4. Electric solenoid valve
8.1.5. MTC (Mast Tilt Control)
8.1.6. Hydraulic diagram
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. Dismantling and assembling hydraulic hoses
8.2.6. Pump motor
8.2.7. Hydraulic oil tank
8.2.8. MTC (Mast Tilt Control)
8.3. Control valve
8.3.1. Operation of the control valve
8.3.2. Control valve overview
8.3.3. Removal and installation of the control valve
8.3.4. Adjusting the working pressure
8.3.5. Inspection and adjustment of the lowering rate
8.3.6. Calibrating the hydraulic functions
8.3.7. S3 valve
8.3.8. Emergency lowering valve
8.3.9. Hose rupture valve
8.4. Diagnostics and troubleshooting
8.4.1. Troubleshooting the hydraulic system
8.4.2. Troubleshooting chart
8.4.3. Troubleshooting the control valve
9. HYDRAULIC CYLINDERS
9.1. Design and function
9.1.1. Reach cylinder
9.1.2. Tilt cylinder
9.1.3. Free lift cylinder
9.1.4. Final stroke cylinder
9.2. Repair and maintenance instructions
9.2.1. General
9.2.2. Reach cylinder
9.2.3. Tilt cylinder
9.2.4. Free lift cylinder
9.2.5. Final stroke cylinder
9.2.6. Removal and installation of the gasket in the hydraulic cylinder
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. Traction system
10.2.4. Hydraulic system
10.2.5. Sensors
10.2.6. Maximum drive speed and drive stop
10.3. Design and function
10.3.1. Battery
10.3.2. Battery capacity measurement (lead-acid)
10.3.3. Battery parameters
10.3.4. Display
10.3.5. VCM (Vehicle Control Module) (truck computer)
10.3.6. TMC (Traction Motor Controller)
10.3.7. PMC (Pump Motor Controller)
10.3.8. EPS (Electrical Power Steering) controller
10.3.9. Connector specifications
10.4. Repair and maintenance instructions
10.4.1. Wiring diagram
10.4.2. Preventive maintenance
10.4.3. Remove and install the multi function display (HMI-20)
10.4.4. Remove and install the horn
10.4.5. Remove and install the emergency stop
10.4.6. Remove and install the direction selector button (option)
10.4.7. Remove and install the DC/DC converter (option)
10.4.8. Ergologic unit
10.4.9. Remove and install the electrical components
10.4.10. Traction and pump regulation
10.4.11. Insulation resistance
10.4.12. Temperature measurement and management
10.4.13. System for detecting the reach carriage position
10.4.14. Electrical monitoring of battery locking
10.4.15. Maintaining and changing the battery (Lead Acid)
10.4.16. TruckTool
10.5. Diagnostics and troubleshooting
10.5.1. General instructions for all types of faults in combination with a loss of voltage
10.5.2. Troubleshooting – operational disturbances
10.5.3. Troubleshooting table – battery
11. SPEED CONTROL AND BRAKE SYSTEMS
11.1. Design and function
11.1.1. Electric brake
11.1.2. Speed and brake sensor
11.2. Repair and maintenance instructions
11.2.1. Electric brakes
11.2.2. Brake Pedal Assembly
11.2.3. Left-foot switch
11.2.4. Speed Controller
11.3. Diagnostics and troubleshooting
12. MISCELLANEOUS
12.1. Options
12.1.1. General
12.1.2. Service indication
12.1.3. Trucks equipped with restart
12.1.4. Side shift and tilt centring
12.1.5. Speed reduction
12.1.6. Automatic logging off
12.1.7. Buzzer when the battery voltage is low
12.1.8. Hand-controlled direction selector
12.1.9. Cold storage cab
12.1.10. Battery on motor-powered rollers
12.1.11. Levers
12.1.12. Electrically heated drivers seat (option)
12.2. Level selector and height indication
12.2.1. Pulse height preset
12.2.2. Level Assistance System, LAS
12.2.3. Height indication on the display
12.2.4. Checking the fork offset
12.3. Stability Support System, S3-1
12.3.1. Identification
12.3.2. Functionality, S3-1
12.3.3. Drive Speed
12.3.4. Hydraulic functions
12.3.5. Technical description
12.4. Weight system
12.4.1. Introduction
12.4.2. Enable options
12.4.3. Accompanying hardware
12.4.4. Premises and requirements
12.4.5. Calibration of the weight system
12.4.6. Weight indication
12.5. Fork Safe Zone System, four-way reach truck
12.6. Delivery mode
12.6.1. Driving in delivery mode and platform mode

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