SERVICE MANUAL

NSP
10N2/12N2/12N/14N2/
14N2I/16N2/16N2I/16N2S

English 2013
616838
NSP Service Manual

Only adequately trained service persons are allowed to carry out service operations. The terms of the
warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.

It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare
parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring
becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your
truck dealer for qualified, authorized and efficient maintenance service.

Copyright © 2013 by MCFE. All rights reserved.

CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow,” as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used without permission. All registered trademarks
are the property of their respective owners.

Unauthorized copying and lending are prohibited.

MCFA MCFE B.V.

2121 W. Sam Houston Pkwy. N. Hefbrugweg 77
Houston, TX 77043-2305 1332 AM Almere
USA The Netherlands

Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

RCB No.: 199203169H
No. 1, Tuas West Street
Singapore 637444

Approvals and version history

REVISION DATE DESCRIPTION OF CHANGE APPROVED BY

A 05.04.2013 First issue R&D

B 24.10.2013 Second issue R&D

Original instructions ___X___ / Translation of the original instructions _______

Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 2 (322)
NSP Service Manual

Contents

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 Control panel................................................................................................... 22
4.3.4 Driving position ............................................................................................... 27
4.3.5 Driving direction .............................................................................................. 27
4.3.6 Motor and electrical system ............................................................................. 28
4.3.7 Sensors........................................................................................................... 32
4.3.8 Mast unit ......................................................................................................... 33

5 Mechanical maintenance ...................................................................................... 36

5.1 Lifting points ............................................................................................. 36
5.1.1 Jack points ...................................................................................................... 36
5.1.2 Hoist points ..................................................................................................... 37
5.2 Transportation .......................................................................................... 38
5.3 Ordering spare parts ................................................................................ 38
5.4 Opening the covers .................................................................................. 39
5.4.1 Front cover ...................................................................................................... 40
5.4.2 Control panel................................................................................................... 41
5.4.3 Battery cover ................................................................................................... 42
5.5 Transmission gear.................................................................................... 42
5.6 Bogie bearing ........................................................................................... 43
5.7 Traction wheel .......................................................................................... 44
5.7.1 Disassembly of the traction wheel ................................................................... 45
5.7.2 Assembly of the traction wheel ........................................................................ 47
5.8 Castor wheel ............................................................................................ 47
5.8.1 Adjusting the castor wheel .............................................................................. 48

Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 3 (322)
NSP Service Manual

5.8.2 Disassembly of the castor wheel unit .............................................................. 49

5.8.3 Disassembly of the castor wheel ..................................................................... 50
5.8.4 Assembly of the castor wheel .......................................................................... 50
5.9 Tiller arm .................................................................................................. 51
5.10 Tiller arm joint........................................................................................... 53
5.11 Mast unit ................................................................................................... 57
5.11.1 Detailed construction....................................................................................... 57
5.11.2 Mast unit maintenance .................................................................................... 69
5.11.3 Lubricant and fluid recommendations .............................................................. 70
5.11.4 Removing the mast unit................................................................................... 70
5.11.5 Disassembly of the mast unit........................................................................... 85
5.11.6 Triplex mast with free lift................................................................................ 112
5.11.7 Inspecting the forks ....................................................................................... 123
5.11.8 Load wheels .................................................................................................. 129
5.11.9 Mast chains ................................................................................................... 130
5.11.10 Chain yoke .................................................................................................... 139
5.11.11 Guidance rollers ............................................................................................ 141
5.11.12 Main rollers ................................................................................................... 143
5.11.13 Free lift cylinder............................................................................................. 145
5.11.14 Side cylinders................................................................................................ 152
5.11.15 Initial lift cylinder............................................................................................ 162

6 Electrical operation ............................................................................................. 165

6.1 Using the schematic diagram ................................................................. 165
6.2 Power source ......................................................................................... 168
6.3 Safety circuit (emergency stop button) .................................................. 168
6.4 Key switch .............................................................................................. 168
6.5 Traction .................................................................................................. 169
6.6 AC motor operation ................................................................................ 169
6.7 Sensorless operation ............................................................................. 170

7 Battery maintenance ........................................................................................... 171

7.1 Safety regulations concerning the handling of lead-acid batteries ........ 172
7.2 Battery maintenance .............................................................................. 173
7.2.1 Daily maintenance......................................................................................... 173
7.2.2 Weekly maintenance ..................................................................................... 173
7.2.3 Monthly maintenance .................................................................................... 173
7.2.4 Annual maintenance ..................................................................................... 174
7.3 Recharging the battery ........................................................................... 174
7.4 Measuring the battery's specific gravity ................................................. 177
7.5 Replacing the battery ............................................................................. 177

8 Electric system maintenance ............................................................................. 180

8.1 Tiller arm ................................................................................................ 180
8.1.1 Removing the tiller head................................................................................ 181
8.1.2 Removing the tiller head switches ................................................................. 183
8.1.3 Removing the safety button ........................................................................... 184
8.1.4 Removing the accelerator ............................................................................. 186
8.1.5 Installing the accelerator ............................................................................... 188

Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 4 (322)
NSP Service Manual

8.1.6 Removing the controller for lifting and lowering ............................................. 189
8.1.7 Installing the controller for lifting and lowering ............................................... 190
8.2 Electric panel .......................................................................................... 191
8.2.1 Removing the controller cover ....................................................................... 192
8.2.2 Traction controller ......................................................................................... 193
8.2.3 Traction controller connectors ....................................................................... 194
8.2.4 Contactors and relays ................................................................................... 199
8.2.5 Fuses ............................................................................................................ 200
8.2.6 Accessing the controller fan .......................................................................... 201
8.3 Truck connector ..................................................................................... 203
8.3.1 Replacing the truck connector ....................................................................... 203
8.4 Motor compartment ................................................................................ 204
8.4.1 Removing the drive unit................................................................................. 205
8.4.2 Disassembly of the drive unit......................................................................... 205
8.4.3 Installation of the traction motor .................................................................... 206
8.4.4 Assembly of the splined shaft-hub connection ............................................... 207
8.4.5 Temperature sensor check ............................................................................ 208
8.4.6 Magnetic brake ............................................................................................. 209
8.5 Pump motor ............................................................................................ 210
8.5.1 Solenoid valve............................................................................................... 211
8.6 Sensors .................................................................................................. 212
8.6.1 Tiller sensor .................................................................................................. 212
8.6.2 Initial lift upper limit sensor ............................................................................ 214
8.7 Switches and buttons ............................................................................. 215
8.7.1 Emergency stop button ................................................................................. 215
8.7.2 Key switch..................................................................................................... 216
8.7.3 Tiller head microswitch .................................................................................. 217
8.8 Horn ....................................................................................................... 218
8.8.1 Diode test with a multimeter .......................................................................... 218
8.9 Wiring harnesses and cables ................................................................. 219
8.9.1 Installing the traction motor cables ................................................................ 221

9 Electric system adjustments and measurements ............................................ 223

9.1 Calibrating the accelerator ..................................................................... 223
9.1.1 Acquiring the VACC with TruckTool .............................................................. 223
9.1.2 Acquiring the VACC without Truck Tool......................................................... 224
9.2 Calibrating the controller for lifting and lowering .................................... 224
9.2.1 Acquiring the VACC with TruckTool .............................................................. 224
9.3 Insulation resistance test ....................................................................... 225
9.3.1 Test voltage .................................................................................................. 225
9.3.2 Checking the insulation tester ....................................................................... 226
9.3.3 Measuring the insulation resistance .............................................................. 226

10 Hydraulic operation ............................................................................................. 229

10.1 Hydraulic symbols .................................................................................. 232
10.2 Hydraulic oil recommendations .............................................................. 234
10.3 Maintenance points of the hydraulic system .......................................... 234
10.4 Hydraulic aggregate ............................................................................... 235
10.4.1 Setting the lifting pressure ............................................................................. 235
10.4.2 Disassembly of the hydraulic aggregate ........................................................ 237

Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 5 (322)
NSP Service Manual

11 TruckTool Diagnostics ........................................................................................ 238

12 Parameter descriptions ...................................................................................... 239

12.1 Traction controller .................................................................................. 239

13 Alarm codes ......................................................................................................... 247

13.1 Traction controller .................................................................................. 247

14 Service data ......................................................................................................... 266

14.1 Special tightening torques ...................................................................... 266
14.2 Tightening torque for standard bolts and nuts ....................................... 267
14.3 Maintenance check list ........................................................................... 269
14.4 Lubrication .............................................................................................. 272
14.4.1 Hydraulic oil .................................................................................................. 272
14.4.2 Transmission oil ............................................................................................ 272
14.5 Special tools ........................................................................................... 272

15 Options ................................................................................................................. 274

15.1 Load support .......................................................................................... 275
15.1.1 Installation of the load support....................................................................... 275
15.1.2 Installation of the load support (masts with straddle fork) .............................. 276
15.2 Accessory rack ....................................................................................... 276
15.2.1 Installation of the accessory rack................................................................... 277
15.2.2 Installation of the list bracket ......................................................................... 278
15.2.3 Installation of the computer rack .................................................................... 279
15.2.4 Installation of the bottle rack .......................................................................... 280
15.2.5 Installation of the pen rack ............................................................................ 281
15.3 Voltage converter ................................................................................... 282
15.3.1 Installation of the voltage converter ............................................................... 282
15.4 Battery connector ................................................................................... 283
15.4.1 Replacing the battery connector .................................................................... 284
15.5 Charger connector ................................................................................. 284
15.5.1 Replacing the charger connector ................................................................... 285
15.6 Internal charger and the internal charger connector .............................. 285
15.6.1 Installation of the internal charger and the internal charger connector ........... 286
15.7 Abbot ...................................................................................................... 288
15.7.1 Installation of the abbot ................................................................................. 289
15.8 Hydraulic block valve ............................................................................. 289
15.8.1 Installation of the hydraulic block valve.......................................................... 290
15.9 PIN code unit keyboard .......................................................................... 291
15.9.1 Installation of the PIN code unit keyboard ..................................................... 291
15.9.2 Activating the truck with the PIN code ........................................................... 292
15.9.3 Programming a new PIN code....................................................................... 293
15.9.4 Driver Present mode ..................................................................................... 293
15.10 Driving speed reduction ......................................................................... 294
15.10.1 Driving speed reduction sensor ..................................................................... 294

16 Technical specification ....................................................................................... 301

Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 6 (322)
NSP Service Manual

17 Index ..................................................................................................................... 311

APPENDIX A: Stickers................................................................................................... 315

Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 7 (322)
NSP Service Manual

1 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.

Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 8 (322)