616838-05a - Mechanical Maintenance - 58508

NSP Service Manual
5 Mechanical maintenance
5.1 Lifting points
CAUTION
Lift or jack up the truck and support it with safety blocks or rigid stands.
Apply wheel chocks to the load wheels to prevent the truck from moving.
5.1.1 Jack points
Figure 18 below indicates the correct jack points for lifting the truck up for maintenance.
Figure 18. Jack points
Copyright© 2013 by MCFE. All rights reserved. Revision: B Document ID: 616838 36 (322)
NSP Service Manual
5.1.2 Hoist points
Figure 19 below indicates the correct hoist points for hoisting the truck up for
maintenance. Make sure that the capacity of the lifting device is sufficient.
Figure 19. Hoist points
NSP Service Manual
5.2 Transportation
When transporting the truck, it is important that you secure it safely to prevent it from
moving. Also support the traction wheel with blocks and lower the mast. If the truck is
equipped with an operator’s platform, lift the operator’s platform up.
CAUTION
Do not tie the truck from the tiller arm or it may break.
Figure 20 below shows an example on how to secure the truck safely for transportation.
Figure 20. Securing the truck for transportation
5.3 Ordering spare parts
When ordering spare parts, always contact your maintenance centre. Only use original
spare parts. To ensure that you receive the correct parts, include the following
information in your order:
• Truck type
• Serial number of the truck
• Order number of the part
• Name of the part
• Number of parts ordered
NSP Service Manual
5.4 Opening the covers
CAUTION
Before opening the truck’s covers, turn the key switch to the OFF position and
disconnect the battery plug/connector.
Figure 21. Truck covers overview
1. Front cover 3. Battery cover

2. Control panel
NSP Service Manual
5.4.1 Front cover
Figure 22. Front cover overview
1. Remove the two screws holding the

front cover in place.
2. Lift the front cover off the attachment
points at the base of the front cover.
NSP Service Manual
5.4.2 Control panel
Figure 23. Control panel overview
1. Control panel 3. Emergency switch

2. Key switch 4. Display
NOTE: You must remove the front cover and open the battery cover before you can
open the truck’s control panel.
1. Remove the two screws holding the

control panel in place.
2. Disconnect the emergency switch,
key switch and display connectors.
3. Remove the control panel.
NSP Service Manual
5.4.3 Battery cover
Figure 24. Battery cover overview
Open the battery cover by simply lifting it and close it by lowering it back down.
5.5 Transmission gear
Figure 25. Transmission gear overview
There is no need to change the transmission gear lubricant during the truck's lifetime.
During maintenance, check the transmission gear for any leaks.
NSP Service Manual
Transmission gear oil SAE 80W/90, API GL-5
Total transmission oil quantity 1.05 L
CAUTION
Transmission oil is hazardous waste that must be disposed of accordingly.
5.6 Bogie bearing
Figure 26. Bogie bearing overview
There is no need to change the bogie bearing lubricant during the truck's lifetime.
During maintenance, check the following:
• The bearing rotates easily when the traction wheel is raised up.
• The drive unit’s mounting bolts are tightened properly.
NSP Service Manual
5.7 Traction wheel
CAUTION
Before installing the traction wheel, make sure that the wheel shaft, the face of the rim
mounting, the wheel nuts and wheel bolts are clean, free from grease and undamaged.
NOTE: To access the traction wheel, lift the truck up (see the correct lifting points in
section 5.1 of this manual) and turn the transmission gear so that there is enough
space for you to access and remove the wheel.
When replacing the traction wheel, lower the castor wheel down. For instructions,
see section 5.8.1.
Figure 27. Traction wheel overview
Check the wear of the traction wheel:
• When the traction wheel’s diameter reaches 220 mm, adjust the castor wheel as
instructed in section 5.8.1.
• When the traction wheel’s diameter reaches 214 mm, replace the traction wheel
and adjust the castor wheel as instructed in section 5.8.1.
NSP Service Manual
5.7.1 Disassembly of the traction wheel
1. Remove the five rounded cone nuts

holding the traction wheel in place.
2. Remove the traction wheel.
3. Check the condition of the wheel
shaft bolts. Replace the bolts, if
needed. For instructions, see
section 5.7.1.1 below.
5.7.1.1 Replacing the wheel shaft bolts
Figure 28. Wheel shaft bolts overview
If the wheel shaft bolts of the traction wheel are defective, you need to replace them.
1. Unscrew the defective wheel shaft

bolt.
NSP Service Manual
2. Use e.g. a rod or a crowbar to lock

the wheel shaft in place.
3. Wet the new wheel shaft bolt with

Loctite 243.
4. Install the new wheel shaft bolt.
5. Tighten the new wheel shaft bolt.

The correct tightening torque is
27 Nm.
NSP Service Manual
5.7.2 Assembly of the traction wheel
1. Align the rim’s hole pattern with the

wheel shaft bolts and slide the
traction wheel into place.
2. Install the five rounded cone nuts
and tighten them. The correct
tightening torque for the nuts is
80 Nm.
5.8 Castor wheel
Figure 29. Castor wheel overview
Check the wear of the castor wheel:
• The diameter of a new castor wheel is 98 mm.

• It is recommended that the castor wheel is replaced when its diameter reaches
90 mm.
NOTE: To access the castor wheel, lift the truck up (see the correct lifting points in
section 5.1 of this manual).
NSP Service Manual
5.8.1 Adjusting the castor wheel
The castor wheel’s height needs to be adjusted according to the wear of the traction
wheel to straighten the truck vertically. The allowed deviation in the vertical straightness
of the truck is ± 6 mm at the height of 2 meters (see Figure 30). The castor wheel’s
height can be adjusted by ±6 mm.
Figure 30. Required vertical straightness of the truck
NOTE: Before you start adjusting the castor wheel, lighten the castor wheel load by
jacking the truck up slightly.
1. Remove the controller cover. For instructions, see section 8.2.1.
2. Use a 36 mm wrench to hold the

bottom of the castor wheel shaft in
place.
3. Use another 36 mm wrench to
loosen the nut above the castor
wheel shaft.
NSP Service Manual
4. Use a 14 mm hexagon wrench to

adjust the height of the castor wheel.
5.8.2 Disassembly of the castor wheel unit
Disassembly of the castor wheel unit:
1. Remove the bolts and nuts attaching

the castor wheel unit to the truck
frame.
2. Remove the castor wheel unit.
Assembly of the castor wheel unit:
1. Install the castor wheel unit.

2. Tighten the bolt and nut attaching the castor wheel unit to the truck frame.
3. Check that there is not too much play in the bearing of the castor wheel unit.
4. Check that the castor wheel rotates properly.
NSP Service Manual
5.8.3 Disassembly of the castor wheel
1. Open the nut holding the castor

wheel bolt in the bracket.
2. Remove the bolt holding the castor
wheel in the bracket.
3. Remove the castor wheel from the
bracket.
4. Remove the sleeves from the

bearing and save them.
5.8.4 Assembly of the castor wheel
1. Install the sleeves into the new castor wheel.

2. Place the castor wheel into the bracket.
3. Push the bolt through the bracket and the castor wheel. Be careful not to damage
the bolt threads.
4. Install and tighten the nut to the bolt.
5. Check that the castor wheel rotates properly.
NSP Service Manual
5.9 Tiller arm
Figure 31. Tiller arm overview
1. Tiller arm 3. Tiller connector

2. Tiller attachment crown
Removing the tiller arm:
1. Remove the covers. For instructions, see section 5.4.
2. Remove the tiller connectors from

the motor.
NSP Service Manual
3. Remove the brake wires from the

connector using the extraction tool
(RL360058).
4. Remove the bolts attaching the tiller

attachment crown to the magnetic
brake.
5. Remove the tiller attachment crown
and the tiller arm.
During the installation of the tiller arm, tighten the bolts of the tiller attachment crown
first by hand to make sure they fit the threads correctly. After that, cross-tighten the
bolts with a power tool, making sure that the crown is aligned correctly.
NSP Service Manual
5.10 Tiller arm joint
Figure 32. Tiller arm joint overview
1. Aisle pipe 6. Tiller sensor

2. Locking spring 7. Mounting plate
3. Gas spring 8. Locking screw
4. Tiller attachment crown 9. Tiller joint shaft
5. Tiller arm joint 10. Bearings
11. Wire clip
Disassembly of the tiller arm joint:
1. Remove the tiller arm and the tiller attachment crown. For instructions, see
section 5.9.
2. Remove the tiller head. For instructions, see section 8.1.1.
3. Remove the lower bolt from the tiller

arm.
4. Pull the aisle pipe up.
NSP Service Manual
5. Remove the locking spring from the

gas spring’s head.
6. Remove the cable tie attaching the

wiring to the gas spring.
7. Remove the screws attaching the

tiller attachment crown to the tiller
joint.
8. Carefully pull the tiller attachment
crown and the gas spring away from
the tiller joint.
NSP Service Manual

tiller sensor to the tiller joint.
10. Remove the tiller sensor wire from
the stick-on wire clip.
11. Remove the tiller sensor.
12. Pull the wiring out from the tiller arm

joint. Be careful not to damage the
wiring.
13. Remove the gas spring from the

mounting plate.
mounting plate to the tiller
attachment crown.
15. Remove the mounting plate.
NSP Service Manual
16. Pull the wiring through the tiller

attachment crown. Be careful not to
damage the wiring.
17. Remove the locking screw of the

tiller joint shaft.
18. Remove the tiller joint shaft.

19. Remove the bearings of the tiller
joint shaft.
To assemble the tiller arm joint, repeat the steps in reversed order.
NSP Service Manual
5.11 Mast unit
CAUTION
To service mast units, you must be qualified to work on both mechanic and hydraulic
systems.
5.11.1 Detailed construction
5.11.1.1 Simplex mast units
Figure 33. Simplex mast
1. Mast unit 7. Chain wheel

2. Lifting carriage 8. Chain yoke
3. Free lift cylinder 9. Main roller
4. Free lift cylinder collar 10. Load wheel
5. Chain 11. Level rod
6. Chain anchor 12. Guard
NSP Service Manual
Figure 34. Simplex mast with initial lift
1. Mast unit 8. Chain yoke

2. Lifting carriage 9. Main roller
3. Free lift cylinder 10. Load wheel
4. Free lift cylinder collar 11. Level rod
5. Chain 12. Initial lift leverage
7. Chain wheel 14. Initial lift cylinder
NSP Service Manual
Figure 35. Simplex mast with straddle fork

3. Free lift cylinder 10. Straddle fork
5. Chain 12. Level rod
7. Chain wheel
NSP Service Manual
5.11.1.2 Duplex mast units
Figure 36. Duplex mast with one lift cylinder

2. Internal mast 9. Guidance roller
4. Lift cylinder 11. Hydraulic pipe
5. Chain 12. Load wheel
7. Chain wheel
NSP Service Manual
Figure 37. Duplex mast with clear view

2. Internal mast 9. Chain yoke
3. Lifting carriage 10. Guidance roller
4. Side cylinder 11. Main roller
5. Side cylinder collar 12. Hydraulic pipe
6. Chain 13. Load wheel
NSP Service Manual
Figure 38. Duplex mast with free lift
1. Mast unit 9. Chain

2. Internal mast 10. Chain anchor
3. Lifting carriage 11. Chain wheel
4. Side cylinder 12. Chain yoke
5. Side cylinder collar 13. Guidance roller
6. Free lift cylinder 14. Main roller
7. Free lift cylinder collar 15. Hydraulic pipe
8. Free lift cylinder mounting plate 16. Load wheel
17. Guard
NSP Service Manual
Figure 39. Duplex mast with free lift and initial lift

2. Internal mast 12. Chain yoke
7. Free lift cylinder collar 17. Initial lift leverage
8. Free lift cylinder mounting plate 18. Guard
9. Chain 19. Initial lift cylinder
10. Chain anchor
NSP Service Manual
Figure 40. Duplex mast with straddle fork
1. Mast unit 10. Chain anchor

2. Internal mast 11. Chain wheel
3. Lifting carriage 12. Chain yoke
4. Side cylinder 13. Guidance roller
5. Side cylinder collar 14. Main roller
6. Free lift cylinder 15. Hydraulic pipe
7. Free lift cylinder collar 16. Straddle fork
8. Free lift cylinder mounting plate 17. Load wheel
9. Chain 18. Guard
NSP Service Manual
5.11.1.3 Triplex mast units
Figure 41. Triplex mast

2. First internal mast 9. Chain wheel
3. Second internal mast 10. Guidance roller
5. Side cylinder 12. Hydraulic pipe
6. Side cylinder collar 13. Load wheel
7. Chain 14. Guard
NSP Service Manual
Figure 42. Triplex mast with free lift

3. Second internal mast 12. Chain yoke
8. Free lift cylinder collar 17. Guard
9. Chain
NSP Service Manual
Figure 43. Triplex mast with free lift and initial lift

2. First internal mast 12. Chain yoke
3. Second internal mast 13. Guidance roller
5. Side cylinder 15. Hydraulic pipe
6. Side cylinder collar 16. Load wheel
7. Free lift cylinder 17. Initial lift leverage
8. Free lift cylinder collar 18. Guard
9. Chain 19. Initial lift cylinder
10. Chain anchor
NSP Service Manual
Figure 44. Triplex with free lift and straddle fork

3. Second internal mast 12. Chain yoke
7. Free lift cylinder 16. Straddle fork
9. Chain 18. Guard

616838-05a - Mechanical Maintenance - 58508

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NSP Service Manual

5.1 Lifting points

5.1.1 Jack points

Figure 18. Jack points

5.1.2 Hoist points

Figure 19. Hoist points

Figure 20. Securing the truck for transportation

5.3 Ordering spare parts

5.4 Opening the covers

Figure 21. Truck covers overview

1. Front cover 3. Battery cover

5.4.1 Front cover

Figure 22. Front cover overview

1. Remove the two screws holding the

5.4.2 Control panel

Figure 23. Control panel overview

1. Control panel 3. Emergency switch

1. Remove the two screws holding the

5.4.3 Battery cover

Figure 24. Battery cover overview

5.5 Transmission gear

Figure 25. Transmission gear overview

During maintenance, check the transmission gear for any leaks.

Transmission gear oil SAE 80W/90, API GL-5

Total transmission oil quantity 1.05 L

Transmission oil is hazardous waste that must be disposed of accordingly.

5.6 Bogie bearing

Figure 26. Bogie bearing overview

During maintenance, check the following:

5.7 Traction wheel

Figure 27. Traction wheel overview

Check the wear of the traction wheel:

5.7.1 Disassembly of the traction wheel

1. Remove the five rounded cone nuts

5.7.1.1 Replacing the wheel shaft bolts

Figure 28. Wheel shaft bolts overview

1. Unscrew the defective wheel shaft

2. Use e.g. a rod or a crowbar to lock

3. Wet the new wheel shaft bolt with

4. Install the new wheel shaft bolt.

5. Tighten the new wheel shaft bolt.

5.7.2 Assembly of the traction wheel

1. Align the rim’s hole pattern with the

5.8 Castor wheel

Figure 29. Castor wheel overview

Check the wear of the castor wheel:

• The diameter of a new castor wheel is 98 mm.

5.8.1 Adjusting the castor wheel

Figure 30. Required vertical straightness of the truck

1. Remove the controller cover. For instructions, see section 8.2.1.

2. Use a 36 mm wrench to hold the

4. Use a 14 mm hexagon wrench to

5.8.2 Disassembly of the castor wheel unit

Disassembly of the castor wheel unit:

1. Remove the bolts and nuts attaching

Assembly of the castor wheel unit:

1. Install the castor wheel unit.

5.8.3 Disassembly of the castor wheel

1. Open the nut holding the castor

4. Remove the sleeves from the

5.8.4 Assembly of the castor wheel

1. Install the sleeves into the new castor wheel.