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User manual - Zhejiang Noblelift Equipment Joint Stock Co.,Ltd

1. Se O 1 Safety Valve 2 Micro Switch Support OO 3 Return Port 4 Lifting and Speed Regualtion Sensor Cover 26 2 18 Multiway Valve Shell Figure 2 18 1 Operation of slide valve take tilting slide valve as an example A Neutral Position Figure 2 19 In this case high pressure oil discharged from oil pump go back to tank through neutral B Push Slide Valve In Figure 2 20 Then neutral chunnel is closed oil from oil inlet open the one way valve and flow to cylinder joint b oil from cylinder joint a flow to tank through low pressure chunnel supported by return spring slide valve can return to neutral 3 F IE oil in one way oil in let Cylinder in cylinder in let B let A slide middle low pressure yalye tunnel tunnel Figure 2 19 Figure 2 20 C Draw Slide Valve Out Figure 2 20 Then neutral is closed oil from oil inlet open the one way valve and flow to cylinder joint a oil from cylinder joint b flow to tank through low pressure chunnel supported by return spring slide valve can return to neutral 2 Motion of Safety Overflow Valve Figure 2 21 There is a overflow valve between pump hp and low pressure chunnel LP Pressure liquid from lifting valve C play on different area of piston a and piston b to push both one way valve piston k and flooding lift valve piston d to locate on their valve seat respectively Pressure liquid of hp chunnel of pump play on s
2. Neutral Position R right Cornering Light Light On 14 tr A 1 K R DJ Check function of emergency button instrument board Normally few seconds after turn ignition key on instrument board displays as following 71 l 2 vase un HEBOO aan LLE 001827 hi 12 6 km 00200 sv 14 13 12 11 10 9 1 Lock Up Indication 2 hand Brake Indication 3 Malfunction Code 4 Speed Mode Of Pulling Motor Controller 5 Malfunction Code 6 Oil Filter Need Not 7 Time For Service 8 Malfunction Of Pump Motor Indication Controller 9 Steering Indication 10 Mode Conversion And 11 Battery Capacity 12 Timing Parameter Adjusting Button Indication Indication 13 Operating Manu 14 left Steering Indication Button 15 check overhead guard and backrest Check if there 1s looseness of bolt or nut 16 Check integrality of vehicle signs 17 Others Check if there is abnormal of other parts AN cron Off Ignition Key And Pull Out Battery Plug Before Checking Electrical System Except For Checking Light And Operating Condition 2 Check after operation Remove dirt on forklift and check as following after work 1 Check if there is damage or leakage for all parts 2 Check if there is deformation torsion damage or break 3 Infuse lubricating grease according to request 4 Lift fork to maximum height after work when fork haven t been lifted to the maximum height for daily use this action can help oil to run th
3. Battery Can Produce Hydrogen Spark Will Be Generated When Short Circuit Happens Which Can Lead To Explosion And Fire When Litten Cigarette Approaches Battery 2 Protection From Electricity Battery Includes High Tension Electricity Don T Touch Battery Conductor During Installation And Maintenance Otherwise May Cause Serious Burn 3 Connect Correctly A No Opposite Connection Of Anode And Cathode In Battery Charging Otherwise It May Lead To High Temperature Burnt Smoke And Explosion 4 It Is Forbidden To Put Metal Object On Battery Short Circuit Will Happen If Anode Touch Cathode Caused By Bolt Or Tools It Will Lead To Injury And Explosion 70 5 Forbidden To Over Discharge Don T Use Forklift Until It Cann T Move Otherwise Battery Lifespan Will Be Shorten Charge Battery When Battery Capacity Alarming Light Continuous Blink 6 Keep Clean Keep Battery Surface Clean Do Not Use Dry Cloth Or Chemical Fiber Cloth To Clean Battery Surface Do Not Use Polyethylene Film To Cover Battery Static Electricity Will Lead To Explosion Clean Uncovered Top Of Battery With Wet Cloth 7 Wear Protective Clothing Wear Blinkers Rubber Gloves And Rubber Boots During Battery Maintenance 8 Battery Electrolyte Is Harmful Battery Electrolyte Is Made Of Dilute Sulphuric Acid Be Cautious During Transportation It Will Lead To Blindness And Scald If Electrolyte Stick On Eye Skin And Cloth
4. 1 Vehicle Counter Size And Technical Performance Parameter 1 1 Outer Dimension See Figure 1 1 1 1 Outer Dimension 1 2 FE3D13 20 Parameter Table 1 1 Manufacturer Model FE3D13AC FE3D16AC FE3D18AC FE3D20AC E 1 3 a Drive Electric battery or mians Diesel Petrol Gas Manual Electric Electric Electric Electric Operation Manual Pedestrian Standing Seated Order picker Rated Capacity Q kg 1250 1600 1800 2000 2 Load centre distance C mm Front Overhang X mm 390 359 350 395 E Wheel Base Y mm 1458 1458 1458 1458 Self Weight Including Battery 3000 3220 3320 3500 22 Axle Loading Loaded Front Back Kg 3740 560 4245 575 4555 565 4825 675 Axle Loading Unloaded Front Back 1571 1429 1657 1563 1643 1677 1700 1800 Front Tyre Size 21x8 9 21x8 9 21x8 9 21x8 9 Back Tyre Size 15x41 2 8 15x41 2 8 15x41 2 8 15x41 2 8 3 6 Track Width Front Wheel 920 920 920 Character Weight W Heels 4 5 Extended Mast Height H4 3960 3960 3960 3960 4 19 Overall Length L 3220 3220 3220 3220 433 Working 1000x1200 Channe 1200 1 Width Ast Basic Dimenstion r Lifting Speed Loaded Unloaded mm s 250 360 Grade Ability Loaded Unloaded S 30min J N MEE N N S2 60 Min Driving Motor Power 6 2 S3 15 Lifting Motor Power 8 6 a x Ta wesen Bey te S Character N vo m N R epeo ______ Manufacturer Model Model FE3DI3AC2 FE3DI3AC2 3AC2 FE3
5. A Fit a new seal ring and a new retainer ring on front end cover of pump B Fit scaleboard on front end cover groove pay attention not to confuse oil inlet and oil outlet C Install driving and driven gears on front end cover D Install scaleboard on gear side to make groove aim at gear point pay attention not to confuse oil inlet side and oil outlet E Fit a new seal ring and a new retainer ring at back cover groove see figure 2 33 F Install back cover on pump body pay attention not to confuse oil inlet and oil outlet G Screw down connecting bolt to the rated torque 9 10kg m after completely assembled 33 1 Pump 2 Driving Gear 3 Driven Gear 4 Front End Body Cover 5 Back End 6 Scaleboard 7 Seal Ring 8 Retainer Cover Ring 9 Oil Seal 10 Elastic 11 Bolt 12 Washer Collar Figure 2 35 Gear Pump 4 Trial Run Trial run is to run in oil pump and check if operation is normal It is batter to test oil pump on test bed also can do it on forklift according to next steps If the pump 1s disassembled and repaired because of badly wear or blocked caused by hydraulic oil you should replace hydraulic oil and filter before trial run A Fit pump on forklift fit pressure meter on pressure testing interface of multiway valve B Loosen adjust screw by loosen overflow valve to make pump run with 500 1000rpm for 10min Ensure oil pressure is less than 10kg cm C Increase pump running speed up to 1500 2000rpm and keep r
6. EER ER RE Re ER EER RR RR RR RR RR Re RA RR ee 41 DUsage of New Vehicle AA ee ee ee ee Ge ee ee ee ee ee 41 2 Relationship between Load and Stability of Forklift naaa 41 Load Center and Load Curve X ee ee ee ee ee ek ee ee an ee ee ee ee ee ee ee ee ee ee ee ee kaka 42 Forklift Stability A ee ee kn ee ereere etuer ee ee ee ee de ee ee bebe ee ee ee ee ee ee ee ee 42 Transportation Loading and Unloading of Forklift ee ee ee ee ee ee ee 42 Preparation before Driving esse se se ee ee se ee ee ee ee ee ee ee naaa ee ee anna naa ee ee Re Ne ee 42 ID eh NN OO A E a a 43 Park ing and Temporary Park ee ee ee ee ee ee ee ee ee en ee ee ee ee ee ee ee ee ee ee kaa 44 Usage of Battery ee ee ee ee ee ee ee ee ee ee kk ee ee ee 45 D ane OE A A E GE OE EO De ee ee 46 AOE AR EE AN PE OO E 47 AS reid URE EE N EE AAA N 47 2 Usage ol Operan eties se EDE ED EE EE EE DE GE Oe EG N GO EE EE ER EE GE de A9 Components Schematic Diagram Of Operating Devices ee ee ee ee 49 OCombina Me ie eset EG DE Ee De Ee AA 49 E E EE A AAA A 49 ea IA AN A tn espn ia EA N Ar 50 a SE AA OE OR E E AA OOIE N ON 53 Bey Ws ie 5 RR ED A oa AE A A EG IE 55 DOperation Palce and Working Environment ee ee ee ee ee ee ee ee ee ee ee ee ee ee 2 PS aie R RE RO suse EG SE A AR 35 Transportation of Forklift cscsccccccscsececccsss
7. PC 313100 Email info noblelift com URL www noblelift com www noblelift cn Add 528 Changzhou Road Taihu Sub district Changxing Zhejiang 313100 China 90
8. nn Ee ca N eo ee nn EE De RE Sie GE Dee 23 Mia Brake PD sesse OP ON vee eb bee teen IR EE ED de nek Ge Ge 2 4 Parking Brake Operating DewfASW 0a RR RR RR REG Re Re 2 5 Brake Pedal Ad ustmeat MEEN SE EO Ge Aa Ai 2 6 Malfunction Analysis SQ SM 2 ese ee ee ee ee RR Re Re RR Re RR RR Re ee Re de 2 7 Maintenance N es Ee Ed EG OE DE EG N GE GE GE N Ed SUSE Tile TE ED EE OE ET EE EE N EN Olt UI ie 2c an AE E EO OE EE N EK EE OE TE IN 32 Cycloidal Full Hydraulic Redite tof ees ets nn nn Ana ede AA de se RD Ge oe Suid od EE EA OE N EE EO EA ER IE 3 4 Key Points of Adjusting and Maintenance iese ee ese ee ee ee ee ee ee ee ee ee ee Ee RE RR ER enna anes 3 5 Inspection after Reassembling of Steering SYStEM es cece cece cece cece cece cece ee ee ee ee SOV ALM Aa oe E Ge EE 4 Electrical System EE OO ORE OE OO EE OE EE N ON ee oe AS aie IR soe 25 EO RO OE N EE EE EE EN Pale e 5 9 ee Con ss RS EN RE EE De EE ERG Ge EE E E Ge AD E BEDING Men n Do IE EG EE Ee Ee Oe De ee ie ed Ee 4 4 Malfunction AnalysiS iese ee See ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee RR ee Re EEE EEE RR Re Re RR RR RR RR Re EEE EEE GP a ENE A EEE A EE E 5 1 Safety Iniotimation Of Baery csc scsnadesnder sa SE EE OS WE GE SEG ER GE ED EER Ee GEE De ee ss AL sper Henk a Cg SE EE eared cee os oe AN 3 Banen i Ba DING es Re GE De Din GE E AAA 24 5 4 Installation And Repl
9. Display Ed Ed EN GE ie rs Ms ES Da 2 KEYBOARD BUTTON ROLL DOWN 1 KEYBOARD BUTTON ROLL UP KEYBOARD BUTTON ENTER 3 KEYBOARD BUTTON SET UP 4 KEYBOARD BUTTON SET DOWN 5 KEYBOARD BUTTON QUT Figure 2 5 4 4 Malfunction Analysis Figure 2 5 Waddg Jo aooo a s Siby TE E ma Ka Em B OM S 06 Er 09 Field Ff Failure EN EF ma 13 B EN 15 16 Ed Eeprom Cont Ko Ca aa a 55 RgrSty T High Eeprom Offine 56 Pump Stoy1Hih High Field Cur a Capacitor Charge Ia 6 ieh Temperature 21 2 3 4 5 6 gi 8 9 50 51 52 53 54 55 56 01 02 03 04 05 07 10 11 12 13 14 15 16 17 18 19 66 24 Left Vmn Low Battery Low 29 68 Right Vmn High 69 Pump Vmn High 71 Power Failure 3 Lft No Full Cond Coil Interrupted 78 Pu No Full Cond TR Vaec Not Ok Contactor Closed 38 Contactor Open Forw Back Brake Con Closed Da 4 Bad Steer 0 Set Brake Cont Open DT Encoder Err a Dir Cont Closed E897 Bad EncoderSign Csa SteerSensorKo gm 92 Driveri SE Ko s6 Pete WireKo P o mero 88 Traction Brushes II f meon oo 89 Pump Brushes BT Position Hade 90 f oie e o O oi Dieko foo mo 5 Battery Battery Framework See Figure 2 16 22 5 1 Safety Information of Battery A Good ventilation is necessary Because hydrogen and oxygen will be generated at the later period of battery charging if there is spark
10. Manoeuvrab ility Whether connecting is loose Wear condition of connection to reducer casing Lever and inhaul cable etc Ll L 2l Ll L l AN amp 84 Damage leakage rupture Connection clamping lo J J J oseness ws v v v 7 v Check oil level and replacement Motion of brake gantry mountinger cylinder and wheel cylinder Leakage and damage of brake gantry mountinger cylinder and wheel cylinder Wear condition of piston cup one wa y valve of brake gantry mountinger cylinder and wheel cylinder rep lacement pipelin e Every 6 Day Week Month 8 Hours 50hours 1200hours Maintai Maintain n Items Contents Oil mass check and replacement oil absorbing filter element Whether Control connecting ling loose valve O 5 condition 85 Operating condition Multiw safety valve ay inclined valve valve self locking valve Measure safety valve pressure Whether there 1s leakage looseness Tube rupture fitting deformation damage Replace pipe Whether oil leakage noise hydraulic pump Wear condition of hydraulic pump driving gear 9 Lifting System Check tension chain whether there is deformation damage or rustiness on chain Lubricate chain chain a looseness riveting studs Check whether there is deformation damage on chain wheel check looseness wheel shaft Lifting Whether there is cylinde looseness rand d
11. Operation Of Fork Don T Operate The Vehicle On Load Stage In Order To Reduce Danger Of Moving When Fork And Load Are In A High Position Make Lifting Operation Only When Vehicle Is Very Close To Load Stage Parking and temporary parking A Parking Safely Parking Place Should Be Broad And Flat As Much As Possible When Unloaded Vehicle Has To Park On Slope Park It With Gantry Mounting Face Downward Block Wheels To Make It Not Moveable Park Vehicle At Safe Place Or Appointed Place Outside Of Working Place Use Attention Label Or Signal Lamp When Necessary Park On Firm Ground Notice To Prevent Skid And Caving In When Fork Can Not Be Lowered Because Of Vehicle Malfunction Hang Cloth On Fork Prong Facing To The Side Impassable For People And Vehicle Do Pay Attention To Skid Or Caving In Of Ground Lower Fork When Vehicle Is In Full Stop It Is Very Dangerous To Lower It When Moving Do Not Jump Off Vehicle When Get Off Vehicle Facing To Forklift And Use Footboard Make A Deceleration Operation Step Down Brake Pedal To Stop Forklift Push Shift Bar Arm To Neutral Position N Park Vehicle At A Place Where Is Convenient For Other Vehicle And Do As Following tof li A Pull back parking brake handle in place to activate Er parking brake f B Lower fork down to the ground FT C Turn ignition key to off position 1 D Take off key and keep it carefully Lif E B
12. To Pull Out Battery Plug To Prevent Danger Even When Ignition Key Is In Off Position There Is Still Voltage In Main Circuit This Plug Must Be Pulled Out To Cut Off General Supply Do Not Pull Out Plug Of Battery During Driving Unless Emergency Because It Can Lead Steering Malfunction 3 Safety Issue Safety is your business and responsibility This section describes the basic safety regulations and warnings of typical forklift but also applie to the vehicle which has special requirement of mast or accessaries 1 Operation Place and Working Environment 1 Ground Conditions Operation place of forklift should be firm ground with level surface good ventilation is also needed Forklift operating performance depend on ground situation moving speed should be regulated properly becareful when driving on ramp or rough surface which can increase the wear condition of tyre and noise of forklift 2 Working Environment Temperature Working Environment Temperature 20 C 40 C Humidity Less Than 80 3 Weather Condition When it s rainy snowy foggy or windy to assess the safety before use forklift the best is not to use for outdoor work if must driving and operation should be more carefully 2 safety Rules A WARNING J ei OS PICERTIFICATEE 2 Only qualified people who have been trained with driving license can operate the forklift a oe Driving 33 WARNING
13. ac2 flsh inverter is suitbale for 3 0kw 8 0kw motor it is widespread used for the control of electric truck golf scooter multi purpose vehicle lifting power is produced by oil pressure which is generated by driving of dc motor to the pump through pipeline to the cylinder to achieve lifting of fork Special Performance of Electric Controller 4 2 1 Summary The power for electrical system of fe3d20ac three wheel ac electric forklift is supplied by 48v battery pack traction of the whole truck is supplied by ac motor lifting power is produced by oil pressure which is generated by driving of dc motor to the pump through pipeline to the cylinder to achieve lifting of fork Illuminating system use 24v power supplier 4 2 2 Peculiarity of Electrical System The ac frequency motor used for traction instrument panel display screen ac driver are all from zapi company from italy which is electric forklift system supplier leading in the international position The ac frequency adopted is high active and long lasting besides it exempts maintenance by and large There is no dc motor commutator in it commutator will limit the accelerating ability of the vehicle especially it will limit the brake twist moment when the vehicle is moving with high speed so it has a batter accelerating ability Controller is a kind of electric forklift general purpose controller which communicates only using canopen negotiation its simulating and numerical i o and communicati
14. acid in electrolyte If necessary regulate with distilled water or sulphuric acid of which the density is 40 to manage electrolyte density and liguid level to standard value in 2 hours when charging When initial charge finish clean battery surface and cover oil inlet 2 Normal Charge Do not use unsaturated battery Please pay attention to discharge when using the battery If discharge exceeds standard value charge it please Excessive discharge voltage is less than 1 7v cell 1s prohibited absulotely Stop discharging when electrolyte density decrease to 1 17 and recharge it in time do not lay up the battery for long time do not stop charge randomly during charging In normal charge open cover of oil inlet check if the electrolyte level is in normal height otherwise regulate it to the normal height with distilled water Connect the output of charger to battery correctly anode to anode cathode to cathode absolutely no error Charger matched with battery can regulate charging current automatically according to battery capacity until full of charging consult to charger manual instructions It is suggested to make record of charge discharge for each battery to know the battery condition in time During charging measure and write down current total voltage each cell voltage with number electrolyte density and temperature by 0 100 C mercury thermometer every 1 2 hours When there are lot of fine and closely bubble in electrolyte
15. at the input end of seat switch which allows seat switch can be off at one moment when thrashing 8 Safety protection function When the power element in controller is damaged during moving the controller will cut off main contactor as quickly as possible When the temperature ascending speed of controller is too high the controller will automatically limit the armature current of motor When the battery voltage is too low the controller will stop working to keep safe 9 There is self diagnose function both in pulling motor controller and oil pump motor controller Once malfunction occurs during working there will display malfunction code on indicating instrument which will stop controller from working to ensure the safety of operating system 10 Capacity of battery andintegrating working hour will be displayed on indicating instrument 4 3 combination Meter New pattern combination meter avail assistant function of control and vehicle condition displaying interface for driver It consist of control circuit accumulative time counter LED ammeter failure code display and other circuit The design of combination meter is based on brand new compact on structure hign robotization and hign quality There are five internal red LED in smart display it offers simple and convenient information to the operator about the structure and running state of forklift see figure 20 LEDS BATTERY DISCHARGE INDICATOR r ALPHANUMERIC DISPLAY
16. instrument Check damage and looseness of cable Check looseness of electrical circuit connection urs 50hours mad 2 Routine replacement of main safety parts Damnification or damage of some parts is difficult to detect through routine maintenance users should replace the parts presented by following list for further improvement of safety If these parts shows abnormal before replacing time replace them immediately 88 Name of key safety part Tenure Of Use Year Flexible hard brake hose Rubber hose for lifting system Lifting chain High pressure hose for hydraulic system Oil cup of brake fluid 4 Cylinder cover and dust cover of brake cylinder 1 Inner seal components and rubber components 2 of hydraulic system 2 l 5 Lubricating area and recommended grease 1 Lubricating area O O Ll Replace Fo Hydraulic Oil Supply Go Gear Oil Inspect and Adjust Cg Lubricating Grease Bo Brake Fluid W Distilled Water Lifting Chain CG j P ET i y Tubular Column Of Direction CG Mastr Supporter CG Lr uf LI ELE LE L f mm a Gear Box CG Brake Pedal CG Brake Oil Reservoir BO 2 Recommended Grease Capac Hydraulic oil 40 Industrial Lubricating Universal lithium base Grease Grease for automobile 89 NOBUET ZheJiang Noblelift Equipment Joint Stock Co Ltd Tel 86 572 6210776 6210788 Fax 86 572 6210777 6128612
17. level is in good range within the limit of h l model H L Fe3d20 33L 30L 76 9 Check Lif Chain Lift fork 200 300mm above ground ensure the left chain and right chain are equalize in tension check if cap bar finger is in neutral position if tension is differeent adjust it through chian join IN After Adjusting Screw Down Double Nut 10 Check Tyre Solid Tyre Check if there is dehiscence or leakage on tyre and its side face if there is deformation or damage on wheel rim and retainer 11 Check wheel nut FAN Looseness Of Wheel Nuts Is Very Dangerous In Case Of Looseness Wheel Will Probably Fall Off Which Will Result In Vehicle Overturning Check If There Is Looseness In Wheel Nuts It Is Very Dangerous Even One Of Them Is Loosen So Screw Them Down To The Rated Torque Value Beforehand Wheel Nut Tightening Torque Front Wheel 21x8 9 280 320n M Back Wheel 16x6 8 130 150n M eet te 12 Check battery charging l Measure specific gravity of battery when the specific gravity is between 1 275 1 285 at the temperature of 30 C means battery has been fully charged Check if there is looseness of connecting terminal and damage on cable conductor Battery Plug 13 Check head light steering signal light and horn Check if all lights and horn are working Chorn begin to sound when pushing horn button down Z a N a Check if emergency button is working left Cornering Light Light On
18. limit valve installed inside of the right lifting cylinder There is a cut off valve assembled on the bottom of cylinder When lifting gantry mounting t acts as protection in case of sudden outburst of high pressure pipe ee renee aaa zz GEE EE B TEER ES bs batters df TEEF EE Sas 12 13 14 PR ee ee a ui a aaa i Ag WEER EE ES FT EE SS ES N FLIED TA RENEE ae Nam Et _ Oe n yE a Yrs Yl Da L SS D N Pa SS ee ane FERFIERE i a SS ES NEE N Right Lift Cylinder 29 Left Lift Cylinder 1 Anti Dust 2 Shaft Seal 3 O Ring 4 Guide Sleeve 5 Steel Backed Ring Bearing 6 Piston Rod 7 Cylinder Body 8 Support Ring 9 Retainer Ring 10 Shaft Seal Assembly For Hole 11 Valve Bush 12 Steel Cable 13 Shut Off 14 O Ring 15 Chain Wheel Retainer Ring Valve 16 Chain 17 Nut 18 Chain 19 Split Pin Connector Figure 2 25 Lift Cylinder and Chain W Working State of Shut Off Valve There is a shut off valve on the bottom of lift cylinder to prevent load from sudden drop in case of sudden outburst of high pressure pipe see figure 2 26 oil from lift cylinder goes through shut off valve holes around slide valve make pressure difference between two cavity When the pressure difference is less than spring force slide valve will not work if high pressure pipe outburst it will occur large pressure difference which
19. makes slide valve move and block the oil holes around only a little oil float through small hole on the end of slide valve to make fork down slowly A di Normal State 7 dd Shut Off State 1 Lift Cylinder Body 2 Compression Spring 3 Spool Figure 2 26 Shut Off Valve 6 5 Speed Limit Valve Speed limit valve installed in right lift cylinder to control lowering speed of fork it acts as protection in case of sudden outburst of high pressure pipe Connecting Method Refer to Figure 2 27 1 Three Way Connection 2 Speed Limit Valve 3 Right Steel Pipe Assembly of Mast 4 Left Steel Pipe Assembly of Mast Figure 2 27 Installation Of Speed Limit Valve 6 6 Tilt Cylinder Tilt cylinder of which piston rod connects to gantry mounting by earloop is double acting structure The bottom of tilt cylinder connected to frame by pin There are two tilt cylinders on each side of forklift 30 Tilt cylinder consist of piston piston rod cylinder body cylinder bottom guide sleeve and seal piston and piston rod constructed by welding there is a bearing and two yx seals assembled on outside end of piston there are shaft sleeve yx seal retainer ring and anti dust ring assembled inside of guide sleeve this shaft sleeve support piston rod seal ring retainer ring and anti dust ring to prevent from oil leakage and dust it is screwed on cylinder body with o ring See figure 2 28 When slide valve push forward high pressure oil goes in through bot
20. space back forklift to prevent fork from crash bracket or goods 9 Ensure fork prong left the goods or bracket lower fork so as to drive 150 200mm above ground D unstacking When unstacking do the following procedures 1 Speed down when approach to the goods to be conveyed 2 Park in front of goods 30cm distance from fork prong to goods 3 Adjust position in front of goods 4 Make sure there is no overloading 5 Adjust mast vertical to ground 6 Observe the fork position when moving forward until the fork insert into the pallet completely When It Is Difficult To Insert Fork Completely Into Bracket A Insert 3 4 Of Fork Into Bracket And Lift Bracket A Little 50 100mm Pull Out Bracket For About 100 200mm Then Lower Bracket B Insert Fork Completely Into Bracket 7 After fork insert into bracket lift bracket 50 100mm 8 Look around and back forklift until goods has been lowered down 9 Lower goods until 150 200mm above ground 10 Tilt mast backward to ensure stability of goods 11 Transport goods to destination 2 Storage 1 Before Storage Before storage of forklift clean up thoroughly and check according to following procedures A Based on necessity clean up oil and grease stuck on vehicle body with cloth and water B When cleaning vehicle body check vehicle entirely especially if there is sinking or damage on vehicle body if tyre is worn out if there is nail or stone embeded in
21. which accord with en standard can be adopted to make up sulphuric acid electrolyte do not use industrial sulphuric acid and tap water Slowly infuse strong sulphuric acid into distilled water and stir liquid by a glass rod or lead covered wood stick do not infuse distilled water into sulphuric acid absolutely otherwise there will be liquid boiling and splashing to injure people To be sure the polarity of connection between charger and battery is correct that means anode to anode and cathode to cathode a reliable connection is necessary The first stage of initial charge use 0 5isa until voltage of single cell is up to 2 4v and then begins the second stage The Second Stage Of Initial Charge Use 0 251sa The temperature of electrolyte should not over 45 C during charging halve charging current or stop charging when the temperature almost reach 45 C wait until temperature is below 35 C then charge again But the charging time needs to be prolonged Indication of enough charging voltage is 2 6v in second stage of initial charging meanwhile voltage change is less than 0 005v density of electrolyte is up to 1 28 0 005 25 C there is no evident change within 2 hours and a lot of fine and closely bubble occurs means the charge is enough The charging capacity is 4 5 times than rated capacity and the charging time is about 70 hours 24 Check electrolyte density of each cell in last stage of charging to control percentage of sulphuric
22. with new gear oil II Check the tension of all fasteners if loose tighten it immediately III Check if there is leakage of oil between wheel hub and differential shaft if there is recoat airproof glue again 4 Technical Maintenance Every Month Is Check brake drum to see if there is destructive wear II Check the wear condition of brake shoe if it can not match the operating requirement replace the brake shoe at once II Check if the axle shell is normal if oil level is less than requested supply the oil in time Technical maintenance semiannually replace gear oil of axle shell semiannually Technical maintenance yearly strip inspection once per year 7 Check and debug requirement during installation When driving axle hub is rebuilt it is necessary to be careful to adjust the brake gap regulator make the clearance between brake shoe and wearing piece lie in 0 3mm 0 5mm The conical roller bearing of wheel hub should be infused with 100ml of 3 lithium base grease Adjust the clearance of bearing of wheel hub Screw down the inner latch nut until the wheel hub can hardly rotate Then reverse inner latch nut 1 8 circle At that time the brake hub could rotate freely without block and no obvious axial clearance or vibration Then fit on the locking washer screw down the outer latch nut in the end 13 3 Steering System 3 1 Summary Steering system see figure 2 7 consists of steering wheel steering shaft steer
23. 1 4 Needle Sleeve 1 hexagonal Screw 2 cylinder Plug 3 Elastic Collar 5 Seal Ring 6 Shaft Seal 7 Tapered Roller Bearing 8 Pressure Spring 9 Nylon Ring 10 Bolt 11 Porous Plug 12 Socket Cap Screws Ep one pele 15 Nut Ball Bearing Gear 19 Inner Disc 16 O Ring 17 Plug Screw 18 Magnetic Plug Suppor 20 Axle 24 Fey 21 Mounting Rack 22 Planet Carrier 23 Internal Tooth 25 Box Fey Ring 26 Gasket 27 Bolt as eee 29 Pin Gear 30 Pinion Bearing 33 Outer Friction 34 Inner 31 Shaft Seal 32 Round Pin Disk Friction Disk 35 Shell 36 Platen 37 Footstep Bearing 38 Pin 39 Platen 40 Brake Rod Figure 2 1 Transmission Case 2 Brake System 2 1 Summary Brake system is two front wheel internal expansion oil pump type consist of brake pedal brake master cylinder and wheel brake staff 2 2 Brake Pedal The construction of brake pedal is illustrated in figure 2 2 The pedal transfer the foot power exerted by pushing rod of brake master cylinder to the pressure of brake oil A Ti K Dam 1 Brake Pedal 2 Brake Oil Cup 3 Brake Master Cylinder 4 Brake Support 5 Brake Sensor 6 Stop Bolt 2 2 Brake Pedal Assembly 2 3 figure 2 3 Main Brake Pump Figure2 3 Base pump consist of a valve support a one way valve a return spring and base leather cup piston assistant leather cup The end of the base pump is fixed with lock washer and lock steel wire and the outside of it is protected with rubber dust prev
24. CE FE3D13 20 SMS 001 NOBUET ZN warning Operators should read and understand this manual and all warning labels on the forklift before using the forklift Keep the manual for future reference Operation amp Maintenance Manual FE3D13 20 SERIES Battery Counterbalanced Forklift Truck ZheJiang Noblelift Equioment Joint Stock Co Ltd Table of Contents AA EE AA A ER es LAticntions O Usma Pori nn nn nn r AAA Ee GE EE ER EE A a a IL lransportafion isa bdan GE Ge AN De Se ER EA AAA BARA Re ES AAA A SANA AA reel SES OE EE OE EE EE EE EE A OO Ee 3 Prepatation Beiere Uie iek ee ee eo Ge N DE Ge ER DE GED BO AGO REPE EN E E E EE ET EO EE EE EE EE T A E ales ERG ou EE E Ge ew Ee GE GE Ge DE Ee eens II Conformation And Main Performance Parameter Of Forklift 1 Vehicle Counter Size And Technical Performance Parameter iese ss ee ee ee ee ee ek Ee ee LI O adier Diens GR ass ne OE DE ORDE OR GE EE Ge AD er 1 2 Technical Performance Parameter A Wa 2 Construction Principle and Regulation for the Main Parts of Forklift D Driving Se ec EE esac cetacean acca cned cae MIM N GE EE EE EE iese AO EE OE ET n AE A 1 2 Transmission AssemblY es eee bene ab EE ee 2 NY ii ee SUC EE OE AA ae hese so a EE OE EE AR EE AR iia AAA AIN IN AE EO EA ON 2 2 Drake Pedal
25. D16AC2 FE3D16AC2 6AC2 FE3D18AC2 FE3D18AC2 8AC2 FE3D20AC2 D20AC2 14 Operation Manual Pedestrian Standing Seated Order picker Seated Seated Seated Seated Rated Capacity O kg Em E a aa ad Load centre distance Gam Front Overhang X mm 30 30 30 30 Os WheetBase Ta Axle a Unloaded Front Back 1571 1429 1657 1563 1643 1677 1700 1800 emma EWE be on Ka Ka a rr Rm ss ENE TE sa K s se WE TN 2 Lowered Mast Height eeuse SR aa a Seat de el ai iorra ao EENS EA NN oe a a Distance from Lower Part of Mast to the Ground 90 90 90 test rte ie Go EEDEN EET EE N EE DE 4 33 Working 1000x1200 Channe 1200 1 Width Lifting Speed Loaded Unloaded 310 420 300 420 260360 250 360 Grade Ability Loaded Unloaded S 30min NEE WEEK 4 5 S 60 Min Driving Motor Power 2x4 5 2x4 5 bawa Re me se se se o peman Tee ae er OE les weense o o o 2 Construction principle and regulation for the main parts of forklift 1 Driving System 1 1 Summary The drive system consists of two transmission assemblies and two drive motors The transmission driving gear connect directly to drive motor the move speed rises with the increment of rotational speed of drive motor and when the rotational direction of the motor change the move direction change too 1 2 Transmission Assembly Transmission assembly assembled directly on frame one end connected to drive motor another end connected to tyre see figure 2
26. Distance Fasten Fork By Fork Locating Pin To Stop From Moving After Adjusting FA When Ad just Space Between Fork Lean Against Body A On Loadguard And Stand Firmly Push Fork With Your Foot Don T Adjust By Hands Absolutely 6 Pedal and Armrest Pedal lies on left side of vehicle body armrest locates on left front brace of overhead guard Use pedal and armrest when get on or off vehicle to keep safe Pedal NNN Na ET ay I gt oy A 7 light Grouped lamps big installed in front of vehicle Cincluding illuminating lamp steering signal light parking light width light rear grouped lamps installed in backside of vehicle which includs tail light steering signal light brake light parking light back up light and flasher A The Working State Of Lights If Lamp Burning Out Lampshade Damaged Or Become Dirty Repair Or Replace Them Immediately 83 Rearview Mirror Rearview mirror installed on right of front beam of overhead guard Rearview Mirror Grouped Lamps Big Oy SES j DI Keep Cleanliness Of Rearview Mirror Surface I SSE i Regulate Rearview Mirror To A Proper Position if d U ad pi Where The Driver Can Have A Good Sight Of Backside Ii Rear Groubed l Lamps 9 Battery Plug LY cal Battery plug is used for connect or cut off power in normal situation it should always be connected 54 A If Its Necessary To Touch Inner Electric Parts By Hand It Is A Must
27. Month Month Month 50hours 200hours 600hours 1200hours Maintain Contents Whether there is wear leakage or damage Whether there is nail stone or other foreign matter on tyre Damage of J J J J wheel rim 6 Steering System Main Mantan Every Every Every Every 3 Every 6 tain a Tools Day Week Month Month Month Items a_i EI ME Ee sr da Check clearance clearance ee Mad of axile direction Check looseness of radial J J J J J direction FEE K nian condition Check loosenness of construction bolt Check leakage of interface between valve block and steering device of all connector Check loosenness construction bolt of rear axle Check bending deformation leakage damage replace lubrication bridge bearing 83 Check or replace the lubrication of steering wheel hub bearing Check operating condition of steering cylinder Check leakage of steering cylinder Check connecting 0 pinion and rack Check connecting and working condition of sensor HO a f pot EN EE EE 7 Brake System Every Every Every Every 3 Every Mani Maintain ain Caen Tools Day Week Month 20 Month Month Items 8 Hours 50hours Ohours 600hours 1200hours Dividin travel g Ruler Brake condition pedal Whether there is air in brake pipeline Whether brake is safe a and reliable g brag with enough travel operati on ia ility
28. Step Down Brake Pedal Ensure Your Foot Has Been Moved Away From Accelerator Pedal From left to right there are brake pedal And Accelerator Pedal In Turn Step down accelerator pedal slowly forklift speed is decided by stepped angle of accelerator pedal 52 6 Lifting Handle Pull backward lifting handle fork lift and push forward lifting handle fork lower lifting and lowering speed depend on tilting angle of handle the larger the angle is the faster the speed is Lifting Motion Can Not Be Achieved If Push Pull Lifting Handle And Turn On Ignition Key Simultaneously Don T Lower Fork Suddenly Or Stop Suddenly When Lowering Fork 7 Tilting Handled Pull backward tilting handle mast tilt backward push forward tilting handle mast tilt forward Tilting speed is decided by tilting angle of handle the larger the angle is and the faster the speed is A Motion Can Not Be Achieved If Push Pull Tilting Handle And Turn On Ignition Key Simultaneously 5 Bodywork 1 Seat Adjust the seat till its fit to the operator by adjusting the handle Lock will be released after pull the handle up Move seat to and fro gently after adjusting ensure the seat is practical locked Adjusting range of seat adjustable range of front and back is 120mm the vertical acceleration plays on driver from seat on dry cement ground is 2 130m s2 2 237m s integrative acceleration is 2 252m s 2 356m s 2 Overhead Guard O
29. WARNING Do Not Drive On Highway Always On Guard Against Be Injured And Rescue Check Forklift Before Use Do Not Move Overhead Guard 56 A WARNING as VEE Driver Should Be Healthy amp gt Ensure Your Forklift Is Safe Hold Armrest When Get On Forklift Start Up Forklift Correctly sf WARNING A WARNING Turn On Illuminating Lamp In Gloom Area Do Not Extend Arm And Body Out Of Overhead Guard A WARNING A WARNING Do Not Drive On Soft Or Uncleaned Ground Only Allowed To Run On Solid And Flat Ground Keep Your Body Under Overhead Guard 58 AN WARNING A WARNING Do Not Move On Smooth Or Skid Ground Pay Attention To The Stability Of Transverse Driving When Unloading 59 If Can Not See The Front When Turning Please Whistle And Drive Slowly Use Appropriate Pallet Or Sleeper When Carrying Small Object H j od 60 Don T Gaze Around When Driving Don T Act Stunt With Forklift A WARNING When Your Sight Is Blocked By High Load Drive Backward Or Forward Under Direction Of Others Observe Traffic Regulations As Well As All Warnings And Signs Drive Forward On Upgrade And Backward On Downgrade When Loading When Upgrade Pay Attention To The Steep Slope And Lifting Height Of Goods a gt d PN WARNING Ta 1N Drive Backward On Upgrade And Drive Forward On Downgrade When Unloaded Noti
30. acement Of BatterV ss EE EE cece cece cece cece cece cece ee ee ee ee ee ee 25 Ty dralle Gy AAA ER OE OE OE AAA A 25 6 SOEN ooo ER Ee Do ee ee DE AE OE AE SO EE SG EE Ge EE EE 25 62 OT O a A A A E E R 26 eV TAG A Is E E E E E EE E PE A EAE 26 6 4 Lifting Cylinder and Lifting Chain esse esse ee ee ccc ccc cece cece cece cece cece ee ee ee ee ee ee ee 28 OS pec damit Vall o ER RE GE ED ee He DER GE DEE DE A RA ee ee DO Ed EO OT 30 6 6 Tinie OVINE stens EE a EEE GE RE DE ED SE EE 30 id ly Gra ic Pipelines OO ene acta EE EE EE N IG EE NG Ee EG DE ee ee 31 06 Maneio and Adus see AAA AAA A An EE 32 69 Male GR AIS IS sed A ER EG ERG E E ENEA AAA AAA 34 CEM IAS AA A E A AES A AAA 36 7 MOM aE A AAA Si A Ee GE Ed ED EE 36 7 2 Inner and Outer Mast and Fork Carrier A see ee ee EE Ee 36 To ROUT Mes ie EE EE EE IT MOE N ED 37 7 4 Maintenance and Adjusting DA A a kanakkanak 38 7 5 Accessaries Installation Instructions A Ba ME EE EE EE EER RR RR Re ee 39 8 Assembling And Disassembling A Dae cde ee ee ee ee ee Re Re ee ee ee Re ek ee 39 Sol P AA AO TO A AT Pa 39 8 2 Hoisting Location For Parts Dismantled YA ee ee ee ee ee ee ee ee aaa 39 III Operation Usage and Safety of Forklift An u ioc cece ee ee ee ee ee ee ee ee ee ee Re ee ee ee ee ee ee 41 1 Driving and Operation AM
31. ach For Medical Treatment Immediately Don T Use Mast Assembly As Ladder It Is Forbidden To Put Your Hands Foot And Body Between Vehicle Frame And Gantry Mounting Assembly 4 Inspect And Replace Tyre Assembly And Disassembly Of Tyre Should Be Carried Out By Professional High Pressure Air Should Be Carried By Professional Wear Blinkers When Operating Compressed Air 69 When Disassembling Tyre Don T Loosen Bolt And Nut In Wheel Rib Joint Because There Is High Pressure Air In Tyre Looseness Of Bolt And Nut Can Cause Very Dangerous Situation You Must First Release The High Pressure Air In Tyre Before Disassembling Bolt And Nut In Wheel Rib Joint Use Special Tools 5 Use Jack When Replacing Tyre FAN When Lifting Forklift With Jack Don T Bore Into Bottom Of Forklift Ensure There Is No People Or Load On Forklift Before Lifting Forklift With Jack When Wheels Off The Ground Stop Using Jack And Put Cushion Block Under It To Prevent Forklift From Falling Down Measures Should Be Taken To Prevent Forklift From Skidding Before Lifting Forklift With Jack 6 Requirments Of Waste Discharge Electrolyte Oil Ect Scrapped Parts From Forklift Plastic Parts Electrical Elements Etc Exhausted Liquid Hydraulic Oil Brake Fluid Etc Should Be Recycled According To Local Government Stipulation Randomly Emission Is Not Allowed 6 Safety Matters When Using Battery 1 No Smoking
32. and voltage of cell is stable between 2 5 2 7v also there 1s no increase of electrolyte density and terminal voltage within 2 3 hours means the battery is fully charged If one or two cell emits bubble weakly or no bubble please find out the reason and make record The temperature of electrolyte should not exceed 45 C during charging If temperature close to 45 C stop charging until the temperature is lower than 35 C When charging is finishede check and regulate the density of electrolyte If density 1s abnormal spill some electrolyte if original liquid density is too low regulate with electrolyte of which density is1 40 if too high regulate with distilled water The difference of electrolyte density of each cell should less than 0 01 liquid level should be standard charge battery for 0 5 hour with low current after adjust the density to mix electrolyte equality then check electrolyte density again and adjust it if necessary At last clean the battery for use 3 Equalizing Charge Under normal situation although each cell of battery runs under the same condition there are still some reasons can cause imbalance of the whole battery pack In that case equalizing charge is necessary to eliminate the difference between cells to achieve equalization for the whole battery pack It s easy to do the equalizing charge according to manual instruction of charger Normal battery need equalizing charge every 2 3 months Equalizing charge
33. at that time it may lead to explosion A There is acid mist generated during charging please exhaust it and clean battery and its workplace immediately after charging A The person operate the battery should wear rubber gloves and protection goggles to prevent from skin burn or blindness caused by dilute sulphuric acid in battery in case that acid touches clothes or skin wash it immediately with plenty of water and ask doctor for body check and treatment The electrolyte on cloth can be washed by clean water A To avoid from injury of dilute sulphuric acid do not operate battery if you are unfamiliar with usage and risk of it A Do not place any metal object or tool on battery to avoid short circuit A Only after cutting off power entirely you can disconnect the connection of battery to power source do not plug or unplug of linker with power A Before installation please read operation instruction manual carefully Keep the manual with you after reading to read it at anytime for convenience 5 2 usage Attention Of Battery The lifespan of battery is between 2 3 years if use and maintenance are proper the lifespan can be more than 4 years it will be damaged within several monthes under unsuitable usage 1 Check electrolyte level regularly recharge and inspect battery in time It is easy for battery maintenance but you should be patient and careful Enough and standard density of electrolyte keeping battery and its terminals cleanliness ar
34. atment Discharge Into Downcomer Soil Burnt And So On Of Waste Oil Will Pollute Water Soil Air And So On Which Is Forbidden By Law 1 Check Points and Check Contents PN Check Points Check Contents i Brake Pedal Travel and brake force of foot brake pedal Brake System Brake Oil Volume and cleanliness and cleanliness Parking Brake ER and brake force of parking brake handle Steering Wheel Operation Tension steering forward backward movement Steering System ca ES dad diperap Running conditions of all parts 6 Function Function slit or not lubricating state Hydraulic Fa Oil Pipe Whether the pipe leaks oil Mast 8 Hydraulic Oil Mast 8 Hydraulic Oil Appropriate oil mass fine Chan Left chain and right chain should be equalize in tension Wheel Pressure value whether abnormal breakage ee Wheel Nut Tighten firmly Determine the battery capacity display Battery Charging status specific gravity plug should be firmly connected Head Light Tail Light Light Horn Back Up Light Steering Make break make to check if light horn and And Switch Light Horn And emergency button work normally Emergency Button deng When connected to key switch it should Displaying Function Licht display test state normal 74 Overhead Guard Backrest Bolt nut are tighten or not Name Plate And Sign Integrality Others 2 Check Procedure 1 Check Brake Pedal Check brake condition to ensure when step down the p
35. back to cell where it was 8 Supply Electrolyte If liquid level 1s too low you should complement distilled water no tap water no river water or well water to prevent impurity that can cause the failure of self discharging also do not complement electrolyte otherwise the concentration of electrolyte will increase to shorten the life of battery The liquid level can not be too high in order to prevent liquid overflow to cause short circuit After adjusting liquid level charge the battery for more than half an hour to mix electrolyte and distilled water equally otherwise it may freeze inside of battery in winter 9 Check for Electrolyte Density 23 The density of electrolyte varies with the level of charging or discharging of battery Decrease of density of electrolyte means that battery had discharged To know the level of discharging of battery you should measure the density of electrolyte of each cell A Measuring method a screw off each cover of cell sip liquid up by densimeter until floater float up To read the scale put the densimeter in parallel with your sight line and let floater located in central position not to touch the pipe wall to avoid influence of reading accuracy If temperature is lower than 25 C or upper than 25 C measure the actual temperature of electrolyte with thermometer to modify the density value of electrolyte B Measuring method b there is some error of electrolyte density among different tempera
36. capacity Whether connecting terminal 1s loose Whether connecting line is loose Cleaness of battery surface 80 Whether tools battery surface Whether ventilation cover 1S tighten ventilator scoop 1S unblocked Far away from fireworks 2 Controller Every Week 50hours Maintain Contents Check wear condition of contactor Check whether mechanical motion of contactor 1S ok Check whether pedal microswitch is ok Check whether connecting between motor battery and power unit are ok Check whether failure judgment system normal 3 Motor Every Day 8 Hours Every Week SOhours Maintain Contents Maintain Items 81 Every 6 Every Month Month 200hours Every Month Po uu 1200hours Every 6 Month 1200hours Every 3 Month 6OOhours Month 200hours clean foreign matter on motor casing clean replace bearing Whether carbon brush commutator 1S worn whether spring force is normal Whether connection is correct and reliable Flush carbon dust in commutator bar groove and on surface 4 Drive System Maintain 6 Contents Month 1200hours Check working condition of arrester Check working condition of gear Check looseness of bolt connected to the gantry mounting Check tightening torque of wheel hub bolt 5 Wheel Front and Back Wheel 82 Every Every Every Every 6 Week
37. ce To Brake When Start Up Forklift On Slope 61 A WARNING Ay WARNING Pay Attention Not To Touch People Or Object When Steering Do Not Approach To Forklift When Its Working lt Driving Too Fast Will Result In Unstable Gravity Center And Overturning Do Not Walk In Working Area 62 Pay Attention To The Variation Of Rated Load Pay Attention To The Area Surrounding Forklift When Driving Ak WARNING Ah WARNING Select The Right Fork Slow Down When Loading Try To Prevent Loads From Exceeding Backrest Fasten The Goods Which Is Difficult To Bind Before Loading 63 Ah WARNING Do Not Extend Any Part Of Your Body Out Of Vehicle During Moving 64 Drive Smoothly And Forbidden To Accelerate Or Decelerate Suddenly A WARNING No Operation Under Explosive Atmospheres Ay WARNING Park Damaged Forklift At Specified Area Park Unused Forklift At Specified Area A warning Forbidden To Park Forklift On Slope 65 Ai WARNING When Forklift Is Not In Use You Should Brake Push Direction Lever In Neutral Position Lower Fork To The Ground Tilt Gantry Mounting Forward Take Off Key G Transport Of Forklift A WARNING Forbidden To Hoist From Mast Correct Transport Of Forklift hoist Forklift Tie steel cable firmly on two terminal holes of outer gantry mounting beam and traction bar then hoist forklift with hoisting device Steel cable which connected t
38. celerator pedal generated by the controlling of controller the brake power can transfer to electric power and present back to battery Especially when the vehicle is coasting downwards slop in order to properly reduce the speed regenerative braking can be achieved by properly releasing of accelerator pedal to prolong the one charge moving distance of battery 4 Function of backward slip prevention on slope forklift which use ac pulling motor has advantage of stay on slope without glide 5 The maximum moving speed can be set The setting of the maximum moving speed of electric forklift can prevent pulling motor from overloading caused by excessive vehicle speed 6 Speed functional relation between two motors scale of steering angle and bearing wheel track one signal to the steering angle comes from the change of sensor potentiometer but the ratio of wheel track is constant this depend on its size data needs to tansfer to zapi then the controller give feedback to the motor to achive left or right turning of forklift 7 Shut down static recovery Controlling device will be shut down if seat switch or ignition key is off only when the direction controlling rod is switched to neutral position can restart the vehicle that is to say anytime when the driver returns back to the vehicle it is necessary to switch the direction controlling rod to neutral position to restart This function can prevent unexpected insecurity There is two seconds of time delay
39. cvecececvcvecececesscvesecucesssssvesecucucs 66 How to Avoid Overturning How to Protect Yourself ee ee ee ee ee ee ee 67 Safety Matters during Maintenance ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 68 Safety Matters when Using Battery ee ee anak ee ee ee ee ee ee ee ee ee ee 70 GIE ie EE sete EE E EE N N N 72 V Routine Check And Maintenance of Forklift sesse ee ee ee es ee ee Re ee ee ee ee Re ee ee ek ee ee 74 LiCheeck Before Operation sia EE ER DE EE AA A EE Ee kd EE 74 DChecking Points and Checking Contents ee ee ee ee ee ee ee ee ee ee ee ee 74 Checking Procedufe ee errr ee ee ee ee ee ee ee ee ee ee ee ee ed 75 od leek Aller OPSOM 2e AE EE EED GR AS EE OSSE EE EE 78 OT ie AA EA OR AO A a 79 DForklift Surface EIE a bn naa ia Re SG De A Ge Ge oe eb Ge Kai 79 Oe ie EO Ie EO OE OO RE EE N 79 Electrical System Clean ee ee ee ee ee be ee ee ee ee ee ee ee ee 79 CO Nie ie AE AE errr A AR IE Oe 79 A Routine Maintenance SS Ee Se eb eo ed A EE RE DE ER aaa 80 DRoutine Maintenance Schedule SE ee ee ee ee ee ee ee ee ee ee ee 80 2 Routine Replacement Of Main Safety Parts 4 4 4 ee ee ee ee ee ee ee 88 o Lubricating Area and Recommended Grease 4 Is ee ccc ee ee Re ee eee nee ee ee Re ee ee Re ee ee 89 DLubricating Area SE EE ee ee ee ee ee ee ee ee 89 2 Reco
40. cylinder joint A cannot return to tank cylinder cannot move See figure 2 23 connect to conngct to oil connect to connect oil inlet A to self locked self locked valve valve Figue 2 22 Figue 2 23 4 Multiway Valve Operation Figure 24 Multiway valve operated by joy stick all of joy stick installed on a connecting shaft shaft fixed on bodywork by bracket and joy stick controls slide valve by connecting rod 1 Tilting Operating Rod 2 Lifting Operating Rod 3 Accessary Operating Rod 4 Connecting Shaft 5 Connecting Shaft 6 bracket Figure 2 24 Multiway Valve Operation 5 Adjustment of Safety Valve Pressure Adjusted pressure for safety is 13 5 16 8mpa Safety pressure had been adjusted by manufacturer user should not adjust by them 6 4 Lift Cylinder and Lift Chain See Figure 2 25 Lift cylinder piston 1s single action piston consist of cylinder body piston rod piston cylinder head 28 There are steel backed bearing and oil seal assembled on the head of cylinder to support piston rod Piston is fastened on piston rod with elastic steel wire oil seal and support ring are assembled on the and to prevent from dust entering etc Two lift cylinders located on the back of outer gantry mounting their bottom fixed on support of lift outer race of pistion cylinder of outer mast by pins and bolts the top of cylinder 1 e top of piston rod connected with beam which is on outer gantry mounting and there is speed
41. d if skid 4 Bad contact between brake drum and wearing poor Stop eet piece 5 S Impurity stuck on wearing piece S Impurity stuck on wearing piece on wearing piece Repair of replace 6 Impurity interfused into brake liquid Check brake liquid 7 Bad adjustment of foot brake pedal brake Has 1 Case hearding or impurity stuck on wearing Repair or replace Noise piece 2 Deformation of motherboard or looseness of bolt Repair or replace 3 Deformation of brake shoe or wrong i Repair or replace installation 4 Wear condition of wearing piece Replace 12 ma 5 Looseness of wheel bearing Repair or replace 1 Grease dirt on wearing piece surface Repair or replace 2 Bad adjustment of brake shoe clearance Regulate adjuster fom Uniformity 3 Sub pump malfunction Repair or replace Of Brake 4 Damage of rebound spring of brake shoe 2 7 Maintenance Before running trial of new drive axle you need to infuse gear oil select gear oil according to the specification strictly Fill oil into filler located on top of axle shell until 011 spill over fuel level hole which located on middle of axle shell 2 The thickness of wearing piece of brake shoe is 8mm normally it can not be less than 2mm Check it once per month replace it immediately when it s badly worn to prevent accident 3 Technical Maintenance Every 50 Hours Is After 50h working time of new axle replace the gear oil clean inner cavity of axle thoroughly before replacing
42. daui l Latch Nut 2 PushingRod 3 Dust Cap 4 Locking Steel Wire 5 Locking 6 Assistant 7 Piston 8 Base Leather Wire rope Washer Leather Cup Cup 9 Spring 10 0ne Way 11 Valve 12 Pump Body Valve Supporter 2 4 Parking Brake Operating Device Figure 2 4 Parking brake handle is cam structure adjuster lying at the end of handle is available to adjust the brake force Turn the adjuster clockwisely the brake force increase turn the adjuster counter clockwisely the brake force decrease pulling force Pulling Force 196n 294n 2 5 Brake Pedal Adjustment Figure2 5 A 1 Shorten Handspike 2 Adjust stop bolt of pedal to achieve optimum height of pedal See Figure 2 5 B 3 Stretch handspike until the front end of handspike touch the piston then unthread for 1 to 2 circles to make freepath between 10mm 20mm 4 Tighten Handspike Nut And Limit Nut Of Pedal 11 Free stroke 10mm 20mm 120mm 130mm Brake Pedal Handspike es Bolt figure2 5 5 Adjustment of brake switch See Figure 2 6 A After adjusting of brake pedal height release lock nut of brake switch B Pull out plug to separate wire C Rotate switch till clearance a lmm D Ensure that the stoplight light on when step down the pedal E Tighten the nut brake switch 2 6 Brake Lamp Switch lock nut 2 6 Malfunction Analysis 2 2 2 Clearance of brake shoe is not ok Regulate adjuster 3Braketoohot 3Braketoohot too hot Check ifski
43. e necessary for longevity of battery 2 Check if there is standing water in battery box once find it and absorb it immediately 3 Do not keep battery with electrolyte When storing used battery with full capacity in short time please charge it once per month to compensate self discharging and to prevent polar plate from sulfuration or eliminate the sulfuration 4 Ifbattery can not be fully charged and fully discharged during working time do it once per month to keep standard capacity of battery and prevent its polar plate from sulfuration 5 Keep battery exterior clean rub up dust of battery by cloth if there is electrolyte spill rub up or clean it with cloth or hot water then dry it by cloth Clean dirt and oxide of pole rub up terminal and lead clip Dredge and clean venthole of oil inlet Apply thin industrial Vaseline on pole and lead clip surface 6 Check battery and fixed state of lead clip Check for battery shell if there is dehiscence or damage check for pole and lead clip if there is burning out 7 Check Liquid Level of Battery Insert a glass pipe with about 6 8mm inner dia and 150mm length into oil inlet vertically until touching top surface of pole piece then cover top mouth of pipe by thumb and nip glass pipe out from oil inlet by index finger middle finger and ring finger the liquid level of the glass pipe equals the liquid level of battery which is overtop the pole slice should be 15 25mm finally put electrolyte
44. e very careful when get on or get off vehicle F Park forklift When Leaving Forklift Pull Parking Brake Handle Entirely And Tilt Gantry Mounting 44 Forward A Little Lower Fork To Ground When Parking Forklift On Slope Put Wedges Under Wheels When Leaving Forklift Take Off Key 9 Usage Of Battery 1 Battery Charging Choose a proper charger to charge battery and operate strictly according to operation and maintenance instruction of charger A Electrolyte level of battery should not be too low Keep Battery Electrolyte At Rated Level Or It Will Lead To Too Hot Of Battery Or Burning Loss Of It The Lifespan Of Battery Will Be Shorten By The Lack Of Electrolyte B Infuse Distilled Water C No Over Charging D Keep A Good Ventilation For Charging Area Battery Charging Procedure Should Be Carried Out In A Well Ventilated And Dry Place To Avoid Damp E Open Battery Cover Hydrogen Will Be Generated In Course Of Battery Charging Open Battery Cover When Charging F Check connecting terminal cable conductor and connector Before Charging Check Connector And Cable To Ensure There Is No Damage Don T Charge In The Following Situation Connector Pole Damage Rust Or Wear Condition Of Connecting Terminal Or Cable Conductor All these situations stated will probably lead to spark to burn and to explode G Charge after turn off ignition key H Check specific gravity Before charging it is
45. ed during use maintenance cleaning and disassembling of the product has to comply with local regulations without pollution tothe environment The recycling and disposal of the cast offs should only be operated by specialised personnel in the designated area The cast offs such as hydraulic oil batteries and electronic units if improperly disposed may be hazardous to the environment and human health Special Declaration 1 This product is strictly prohibited for potentially explosive hazardous environments 2 The Noise level of the normal use of this product is compliant with international standards EN 12 053 3 The vibration level of the normal use of the product is compliant with international standards EN13059 4 The normal use of the product s environmental requirements as follows no more than 2000 meters above sea level and the temperature range of 5 C 40 c humidity should no more than 90 The wind speed is not more than 5m s If you need to use in the freezer for a long time Or in special environment it is needed to install special attachments Please contact our technical staff 5 Product recall serive is available when serial faulties occur Due to continuous product improvement Noblelift reserves the right to make changes in product designs and specifications without prior notice For the latest product parameters please feel free to contact us All parameters provided herein are as of the publication date
46. edal completely the downward travel of brake pedal which is calculated from back plane should be more than 50mm brake distance of forklift should be about 2 5m when unloaded 2 Check Brake Oil Open Brake Oil Cup Cap And Check Brake Oil Volume And Other Status Brake Oil Cup 3 Check parking brake handle Push forward parking brake handle and observe following status If there is proper pull travel Brake force value If there is damaged parts or not If handle operating force is feasible for operator Operator may adjust by a screw installed on the top of handle 75 parking handle 4 Check steering status of steering wheel Turn steering wheel clockwise and counterclockwise gently to check if there is rebounding proper rebounding travel is about 50 100mm turning travel of steering wheel is about 7 if the conditions mentioned above can be met steering wheel is normal Rebound stroke 50 100mm E 5 Check power steering function Turn steering wheel clockwise and counterclockwiseto check working condition of power steering 6 Check function of hydraulic system and mast Check if lifting and tilting operation is smooth and normal Lift chain UL Chain join ii Hexagon Nut Pin 7 Check oil pipe Check 1f there is oil leakage in lifting cylinder tilt cylinder and all pipeline 8 Check hydraulic oil Lower fork down to the ground check hydraulic oil level with oil meter Hydraulic oil
47. eformation damage on piston piston rod thread cylinde and connection 86 r Operating condition Check wear damage on pin and steel backed bearing Whether there deformation wear damage on fork Wear condition of fork locating pin Check whether there is dehiscence or wear on welding position of root part of fork Check whether there is dehiscence or damage on inner gantry mounting outer gantry mounting and welding part of beam Check whether there is poor weld dehiscence or damage on welding part between tilt cylinder bracket and gantry mounting Check whether there is poor weld dehiscence or damage on inner outer gantry mounting Check whether there is poor weld dehiscence or damage on fork carrier Check wear condition damage on gantry mounting supporting bearing pad Check whether bolt of gantry mounting supporting cover is loose Check whether head bolt and bending board bolt of lifting cylinder piston are loose Check dehiscence damage on roller roller shaft and welding part Testing humme r 87 10 Others Every Every Every Month Month Month 200hours 600hours 1200hours Maintain Contents Whether installation Check whether there 1S deformation dehiscence damage Steeri ng indic ator Installation and working condition Installation and working condition Installation and working condition Installation and working condition Working condition of
48. enting cover The base pump work under the assistance of pushing rod by operating brake pedal step down the brake pedal the rod pushs the piston the brake fluid flow back to oilcan through oil return hole until the base leather cup plugs the oil return hole After the base leather cup push over the oil return hole the brake fluid of the front cavity of base pump is compressed and 10 open the one way valve and through brake pipeline flow into subsidiary pump then the piston of each subsidiary pump pushes out to make the brake shoe wearing piece get contact with the brake drum and finally stop the truck or make it slowdown Now the back cavity is supplied with the fluid by the brake fluid from oil return hole and oil in hole Release the brake pedal the piston is push backward by the brake shoe return spring at the same time the brake fluid in each subsidiary brake pump is compressed by the return spring which make the brake fluid flow back to base pump through one way valve the piston returns back to initial position the brake fluid in base pump flow back to oilcan through oil return hole one way valve pressure is adjusted in specific gravity to the residual pressure in brake pipeline and subsidiary brake pump the leather cups in subsidiary pump should be placed correctly to prevent oil leaking and the case of air resistance which possibly occurs in emergency brake Parking Brake TE Dhat z al nine ed ah MA An 1 i 3 4 b v d d
49. er Mast 5 Inner Mast Fork Carrier Composite Roller Figure 2 37 Roller Position Remark A Adjust Side Roller Clearance to 0 5mm B Add grease on main roller surface and mast contacting surface 37 7 4 Maintenance 7 4 1 Lift Cylinder Adjustment When dismantling or replacing lift cylinder inner mast or outer mast travel of lift cylinder needs to be adjusted again Do it as following 1 Put head of piston rod into top rail of inner mast without adjusting shim 2 Lift mast slowly to the maximum length of cylinder to check if two cylinders act simultaneously 3 Add adjusting shim between head of cylinder pistion rod and top rail of inner mast 0 2mm HI 0 5mm Adjust tension of chain 1 Inner Mast 2 Adjusting Shim of Lift Cylinder 3 Lift Cylinder Figure 2 38 Lift Cylinder Adjustment 7 4 2 Fork Carrier Height Adjustment Figure 2 39 1 Park forklift on level ground and keep mast vertical 2 Make underside of fork touch ground regulate adjusting nut on top end connector of chain to keep a certain distance a between main roller and underside of inner mast a 24 29 Inner Mas Figure 2 39 3 Lower fork down to ground and tilt mast backward in place Adjust upper end connector of chain adjust nut until two chains are equal in tension 7 4 3 Replace Fork Carrier Roller 1 Place a salver on fork and park forklift on level ground 2 Lower fork and salver to ground 3 Dismantle upper end connector of chain and take o
50. erflow valve Oil leakage inside Valve seat surface broken Set pressure too high Valve get stuck Clean after disassembling 2 Oil Pump Malfunction Analysis Figure 2 7 Figure 2 7 Low oil level in oil tank Infuse oil to rated quantity Oil pipe or o1 filter jam Clean or replace Scaleboard damaged Supporter damaged Seal ring bush seal Replace components or retainer ring get bad Pump pressure too low Incorrect overflow valve Adjust overflow valve pressure adjustment to rated value by pressure meter Tighten oil pipe of oil inlet or side again Air in system refuel replace oil seal oil absorptive hose damage or oil check pipe or repair oil filter filter jam Oil inlet side loosen and leak Tighten loose point Replace oil of which viscosity Too high of oil viscosity is fit to running temperature of pump AAA Gil Find out reason for bubble and take measure Pump oil seal or seal ring damage Pump oil leakage pease Vibration Slide valve jam Clean after disassembling Low oil extraction Noise when running 35 7 Lifting System 7 1 Summary Lifting system is second class rolling contact and vertical dilation structure It consists of inner mast outer mast and fork carrier 7 2 Inner And Outer Mast and Fork Carrier Inner and outer masts are weld assembly Middle part of outer mast is assembled on bodywork by hanging scroll The bottom part of outer mast connected with bodywork by tilt cylinde
51. es 9 Emergency Disposal Method When Accident Occurs Carry Out Emergency Treatment According To Following Method And Contact With Doctor As Soon As Possible Electrolyte Splash On Skin Clean With Water For 10 15min Electrolyte Splash To Eyes Clean With Water For 10 15min Large Area Contaminated Counteract Electrolyte With Dry Soda Baking Soda Or Clean It Out With Water Swallow Electrolyte Drink A Lot Of Water Or Milk Splash Electrolyte On Clothes Take Off It Immediately 10 Fasten Battery Upper Cover Fasten Battery Upper Cover To Prevent Electrolyte From Leaking Notice Not To Infuse Too Much Of Electrolyte Because Spilling Of Electrolyte Will Lead To H Leakage Of Electricity 11 Waterproof Battery Can T Be Wetted By Rainwater Or Seawater Or It Will Damage Battery Or Lead To Fire 12 Abnormal Phenomenon Of Battery Please Contact With Our Sales Department When The Battery Has Following Problems Battery Smells Electrolyte Get Dirty Electrolyte Temperature Get Higher Too Fast Of Electrolyte Decreasing 13 No Disassembling IN Don T Pump Electrolyte Out Of Battery Don T Disassemble Battery Don T Repair Battery 14 Storage When Battery Is In Long Term No Use Deposite It To The Place With Well Ventilated And Unlikely To Fire 15 Treatment Of Used Battery AN Get Contact With Our Sales Department When Treating Used Battery D Label Labels
52. ff chain from chain wheel 4 Lift inner mast See QM Of Figure 2 40 5 Make sure that fork carrier is separated from outer mast back forklift see of figure 2 40 6 Replace Main Roller A Dismantle all spring retainer rings take off main roller with drawing tools notice to hold adjusting shim 38 B Make sure that new roller is the same to the one to be replaced fit new roller on fork carrier and clamp it well with elastic collar Figure 2 40 Figure 2 41 7 4 4 Replace Mast Roller Refers to Figure 2 41 1 With the same method as replacing fork carrier roller stated in 7 5 3 dismantle fork carrier from inner mast 2 Drive forklift to level ground and underlay front wheels upto 250 300mm Strain hand brake chock up back wheel with wedge block 4 Dismantle bolt between lift cylinder and inner mast Hang up mast notice not to lose the adjusting shim on head of piston rod 5 Dismantle connecting bolt between lift cylinder and bottom of outer mast dismantle lift cylinder oil pipe and oil pipe between two cylinders not to loose oil pipe connector 6 Lay down the inner mast dismantle the main roller on the bottom of inner mast then the main roller on upper side of outer mast will also show out from the top of inner mast 7 Replace Main Roller A Dismantle upper side main roller with drawing tools not to lose adjusting shim B Fit on new roller together with adjusting shim dismantled in step a 8 Sling inner mast unt
53. g But even release accelerator pedal suddenly emergency brake can not be achieved When there is an emergency situation step brake pedal down to achieve emergency brake A Speed Down Under The Following Situations A Turning At Crossing B Approach To Goods Or Pallet C Approach To Stockpile D At Narrow Aisle E Bad Ground Or Road Surface When Driving Backward Must Look Backward To Ensure Safety It Is Dangerous To Drive Backward Only Depend On Backview Mirror 3 Steering Forklift is different to auto because forklift steers with back wheels speed down when steering and pay attention to swing of back part of forklift A Notice That When Steering The Faster The Vehicle Moves And The Less The Steering Radius Is The Easier It Will Overturn 43 4 Move and lift simultaneously Cinching operation A Move first let fork prong approach to goods about 3 5m B Step down brake pedal entirely standstill C Step down accelerator pedal to achieve a proper working speed D Operate lifting handle to start lifting with fork Operation Of Moving And Lifting Simultaneously Inching Operation Is A Work Which Asks For A High Level Of Proficiency Be Sure To Understand Goods Characters Such As Shape Gravity Center And So On Lift And Lower Fork Slowly After Affirm The Stability Of Forklift Please Be Careful During Operation It Is Very Dangerous To Tilt When Fork And Load Are In A High Position Except For In And Out
54. hen Leaving Forklift Take Away Key To Prevent Other From Mishandling When Parking Forklift Or Charging On Forklift Take Away Key To Prevent Other From Mishandling 3 Combination Switch Combination switch is combined by direction switch turn signal switch and switch combination of small big lamp 1 Direction Switch 2 Turn Signal Switch 3 Switch Combination Of Small Big Lamp Direction switch controls moving direction and delivers signal to instrument for display Push handle forward vehicle move forward and pull handle backward vehicle move backward Middle position 1s neutral When handle is on backward back up lightand caution light light on back buzzer begin to sound Turn signal switch shows steering direction of forklift when handle turned to steering position steering lamp begin to blink Push Left Steering Lamp Forward Blink Pull Right Steering Lamp Backward Blink Switch combination of small big lamp controls on amp off of big small lamp switch has two gears rotate to first gear small lamp light on rotate to second gear both small and big lamp light on First Second Gear Gear ice Taillight Head Lamp O Light On Light Off 4 Back Headlight Switch Back headlight switch is a single gear which controls on amp off of back headlight pull switch up light on push down light off 4 Controlling DOAnd Steering Wheel Handle Ball Steering Wheel Steering wheel operation is tradi
55. il all rollers engaged in it 9 Install lift cylinder and fork carrier in reverse order of dismantling 7 5 Accessaries Assembling Instructions A If Users Need To Assemble Accessaries Please Inform Our Sales Department Do Not Assemble By Yourself 8 Disassembly and Assembly 8 1 Attention 1 Only qualified operator can repair or dismantle parts on forklift 2 Before dismantling and inspecting park forklift on level ground and wedge truck to prevent moving suddenly meanwhile turn main switch off and cut battery off 3 Before dismantling and inspecting remove metal ring watch and other metal item from you to prevent sudden short circuit 4 During disassembling please use right tools use special appointed tools when requested 5 Choose optimum elevating equipment to hoist parts dismantled to prevent danger 6 Check slings for safety Keep slings tension during lifting 7 Be careful to prevent falldown of heavy parts attributing to unbalance during disassembling operating 8 2 Hoisting Location for Parts Dismantled 39 1 Hoisting for Lifting System See Figure 2 42 igh Model Mm Profile LxWxH Mm vee Kg FE3D20 154310602200 2 Hoisting for Overhead Guard See Figure 2 43 ht Profile LxWxH Mm pa FE3D20 1390x1020x1555 Lifting Hole Lifting Hole Figure 2 42 Figure 2 43 3 Hoisting for Balance Weight See Figure 2 44 Profile LxWxH Mm FE3D20 460x 1060x938 4 Hoisting for Batte
56. ing by running of gear shaft which is driven by the movement of teeth bar pushed by cylinder Steering axle 1s fixed on the tail bracket of frame There is wheel hub on each side of steering axle Wheel hub is assembled by two conical roller bearings on main axle wheels are fastened on wheel hub by wheel frame There are oil seals installed inside of the bearings to keep lubricating grease stay in the cavity of steering knuckle 1 Hexagonal Nut 2 Gasket 3 Retainer 4 Seal Ring 5 Bearing 6 Teeth Bar 7 Seal Ring 8 Guide Sleeve 9 Seal Ring 10 Bush 11 Seal Ring 12 Cylinder 13 Cylinder 14 Bearing 15 Seal Ring Cover Body 16 Gear Shaft 17 Main Axle 18 Plug 19 Pin 20 Gasket 21 Seal Ring 22 Bearing 23 Wheel Hub 24 Bearing 25 Washer 26 Hexagonal 27 Split Pin 28 Cover Nut Fgure 2 9 Steering Axle 3 4 Key points of adjusting and maintenance 1 Lubricate inner cavity of wheel hub inside or outside bearing and cover of wheel hub meanwhile lubricate oil seal 2 Fit bearing outer ring on wheel hub and fit wheel hub on main axle is 3 Fit washer and tighten castle nut its torque is 206 235n m 21 24kgm then loose castle nut tighten nut again at this time the torque is 9 8n m 1kgm 4 Tap wheel hub gently by wood hammer and rotate wheel hub for 3 4 circles to ensure there is no looseness of wheel hub 5 Tighten castle nut and make slot aim at split pin hole of main axle 6 Tap wheel hub gently by wood ha
57. ing device steering oil pump and steering axle and so on Steering shaft is connected to steering device by universal joint connecting shaft connected to steering wheel by universal joint the steering column can tilt forward and backward to reach a proper position steering axle installed on the tailbracket of frame there is a knuckle on both left and right side which can achieve the turning of steering wheel by pushing of piston through connecting rod to achieve steering A A Figure 2 7 Steering Device 3 2 cycloidal Full Hydraulic Redirector Full hydraulic redirector figure 2 34 can transfer pressure liquid from pump to oil cylinder according to rotatory angle of steering wheel When hydraulic system failure steering operation can be done manually Redirector consist of a normal redirector and a assembled valve the safety valve located on the top cover of assembled valve also there is a two way overloading valve in valve body to protect the components when hign pressure generated in hydraulic system caused by impact of outside force to the wheel during moving both safety valve and two way overloading valve are regulated by manufacturer users should not regulate it randomly 6 5 4 YI Ee 14 1 Limited Post 4 Universal Driving Shaft 7 Rotor 2 Valve Body 5 Spring Piece 8 Stator 3 Valve Disc 6 Joint Piece 9 Valve Bush Figure 2 8 Cycloidal Full Hydraulic Redirector 3 3 Steering Axle Steering axle achieve steer
58. ing motor pump motor pulling motor controller pump motor controller combination switch of steering controller of multiway valve isplay instrument switchgroup instrument and illuminating lamp etc Electrical Diagrams See Figure 2 13 16 it MI HE ii i OO OOD OPPIE EIE T T by a D MY W 3 J WI de Sai RT R 10H dg SE a a EF ETT th mai t Li 4i T ET EFASE I 20 2 20 bn MAKE P B 1253 F U BAHN s mA M T O EA man D ed Es Dt i u B 3 1 a JT uD PAD ey DAE THE 17 Code Name Remarks Code Name maa M2 Oil Pump Motor Pump Motor aa ja Backup Buzzeer o E aa Controller Of Traction amp Oil Pump iene Sach Motor Fa Fuse In Hom Switch Horn Switch EIER LN N de _ ts fot 6 se id we je lasse er omer Da er lg sy imas ea O a aa EE mafe Ga Toere Ee fre Ee aaa Er rw Ci on ara mafe D Ina Er fe wang roy EF aan a O fo sewes mf N aa O feo ew le ties O sa fr le v a aaa o Riga comera a fo reai To utne Penis ra seess O ENE EN WEN WEE EE 4 2 Electric Controller The electrical controller assembly consist mostly of the nucleus assemblies of dualac2 amp hp traction amp oil pump motor controller of dualac2 this system 1s wonderful in performance energy conservation and credible in quality 18 Figure 2 14 Basic Working Principle In mos series
59. is also necessary for battery which is out of work for long time before use 5 4 Installation And Replacement Of Battery Fix tightly when installing and replacing the battery to avoid overturn do not use hammer to strike terminal and lead clip avoid strong impact during transportation 6 Hydraulic System 6 1 Summary 2 Hydraulic system consists of working pump multiway valve lift cylinder tilt cylinder and pipeline ect See figure 2 17 Hydraulic liquid supplied by oil pump which connected directly to the oil pump multiway valve distribute liquid to each cylinder Figure 2 17 Hydraulic System Diagram 6 2 Oil Pump Oil pump is gear pump 6 3 Multiway Valve The multiway valve is two pieces four body structures the high pressure oil from working pump is distributed to lifting cylinder or tilt cylinder by multiway valve rod There are safety valve and self locking valve inside of multiway valve Safety valve which controls the pressure of the system setted on the upper side of oil inlet of multiway vavle The main function of self locking valve is to prevent serious consequences caused by mishandling of controlling rod when there is no pressure source for tilt cylinder is setted on inclined valve plate There are one way valves fitted between oil inlet and oil suction inlet of lifting valve plate also between oil inlet of lifting valve plate and oil inlet of inclined valve plate Multiway Valve Shell See Figure 2 18 l 2
60. ition Key Hold handle ball of steering wheel then turn on ignition key and keep it at on position A Even After Ignition Key Is Turned To On Position 1 Second Is Needed From Brake Release To FWE handle ball of steering wheel Startup 42 Before Turn Ignition Key To On Position If The Shift Bar Arm Is At F Or R Position Push It To N Position Do Notice That If Step Down Accelerator Pedal Suddenly Vehicle Will Probably Accelerate Suddenly 3 Tilt Mast Backward Pull lifting handle backward to lift fork up about 150 200mm above ground then pull tilting handle backward to tilt backward the mast 4 Operation of direction switch handle5 Direction switch handle decide moving direction forward backward Forward F Push Handle Forward Backward R Pull Handle Backward 5 Release Parking Brake Handle Step Brake Pedal Down Release parking brake handle forward perfectly hold steering wheel by left hand and rest right hand on steering wheel 7 Driving 1 Start Up Remove foot from brake pedal and step accelerator down gradually then forklift start to move Acceleration vary with travel stepped down of accelerator pedal Ap Not Startup Or Brake Suddenly To Prevent Cargo From Falling Down 2 Deceleration Release accelerator pedal slowly If necessary step brake pedal down Except emergency brake release accelerator pedal to speed down slowly until parkin
61. m deposite A Take away damp proof cover B Remove anti dust oil on exposed parts C Clean away the water and frontign matter in hydraulic oil tank D Put charged battery on forklift connect battery to the power E Check carefully before start up 48 2 Usage of operating devices 1 Components schematic diagram of operating devices 1 Overhead 2 Backview 3 Instrument 4 Multiway Control 5 Grouped Guard Mirror Lever Lamps 6 Seat 7 Cover For 8 Back Cover 9 Counterweight 10 Traction Bar Battery Box Plate 11 Back Tyre 12 Left 13 Steering 14 Combination 15 Hand Brake Guard Board Wheel Switch 16 Control Pedal 17 Front Tyre 18 Fork Carrier 19 Fork 20 Backrest 21 Lifting 22 Chain 23 Mast 24 Grouped Cylinder Assembly Lamps Big 2 Combination Meter See 4 1 3 Combination Meter Page 19 and 4 2 3 Combination Meter Page 24 3 Switch 1 Emergency Stop Switch When emergency press red mushroom head button down to stop function of moving steering and lifting by cut off the power To resume the function rotate the botton according to the arrowhead indication 2 Ignition Key Ignition key can connect or cut off controlling power Off in this position power is cut off and key can be inserted and pulled out Stop 49 Emergency ritch On rotate forward from off position switch is turned on forklift start up FAN Don T Step Down Accelerator Pedal When Turn On Ignition Key W
62. mmended Grease ER ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 89 Introduction This manual briefly describes the technical parameters of the counterbalanced accumulator forklift made by our company and the structure of its main components working principle and requirements on operation and maintenance Please read this manual carefully before operation so as to achieve proper driving and maintenance and to ensure safe and effective material handling Meanwhile this manual aims to guide operators to use the forklift in an appropriate way and to maximize its performance We hope that operators and equipment managers could read it carefully before use Please strictly observe the provisions and cautions stipulated in this manual and operate the forklift with caution and care so that the forklift can be maintained in its best status and optimal performance can be ensured When you lease or transfer your forklift always keep this manual with it For highlighting purpose the following icons are used in this manual 1 S Refers to a potential danger if not avoided it may cause serious human injury vehicle damage or fire 2 A Refers to a potential danger if not avoided it may cause minor human injury or local damage to the vehicle 3 GE Refers to general cuations and instructions during use ZN vos parts of the product are made from recyclable steel The recycling and disposal of cast offs result
63. mmer again rotate wheel hub for 3 4 circles by hand to ensure smooth running then measure rotation torque the value should between 2 94 7 8nm 0 3 0 8kgm 7 If rotation torque is more than standard value you can untread 1 6 circle and then measure it again 8 After rotation torque is regulated to its standard value lock castle nut by split pin 3 5 inspection After Rebuilding Of Steering System 1 Run steering wheel right and left to its end to check if it runs uniform and stable 2 Check the lay out of hydraulic pipeline to see if there is misplace 3 Jack rear wheel up move steering wheel right and left slowly repeat for several times till exhaust air out of hydraulic pipeline and oil cylinder 3 6Malfunction Analysis Figure 2 3 Figure 2 3 Steering wheel Damage or malfunction of oil pump can not move Hose connector is damaged or block of pipeline Replace or clean Safety valve pressure 1s too low Adjust pressure Air in Airinoileireuit SE Airinoileireuit SE Exhaustair Exhaustair Steering wheel dullness Failure of steering reset hold down spring broken or not enough elasticity Replace spring piece Too big inleakage of steering cylinder Check piston seal MOVE OT sway Block of suction pipe or filter ReplaceOrClean Or ReplaceOrClean Oilicakase Guide sleeve of steering cylinder or pipeline or connector damage Too big noise 4 Electrical System 4 1 Summary Electrical system consists of battery pull
64. necessary to test electrolyte specific gravity of each battery cell to find out abnormal situation To know the electrolyte specific gravity of battery before charge can avoid accident happening I Hold connector or handle instead of cable conductor when inserting or pulling out power connector A Don T Pull Out Cable Conductor When Cable Conductor Or Power Connector Is Broken Get Contact With Our Sales Department To Replace The Damaged Cable Conductor And Power Connector J Break charging procedure Break Charging Procedure Strictly According To The Operation And Maintenance Instruction Of Charger 45 Don T Pull Out Plug Of Charger When Charging Otherwise Electric Spark Will Be Generated And Lead To Danger 2 Replace Battery When forklift has been used continuously for a working period and the battery has been entirely consumed replace the battery with another fully charged one and charge the battery been replaced es Replacing Battery Make Sure That Battery Matches Forklift If Not Working Time Will Be Shorten Or Forklift Will Overturn When Moving Replacement Of Battery Should Be Made On Platform Replace battery according to following steps Take Favor Of Proper Hoisting Tools Accessaries To Replace Battery When Using Another Forklift As Hoisting Device Hoisting Battery Should Be Carried Out By Professional A Pull out battery plug B Open battery upper cover Use gas spring or other method
65. o counterweight should go out through the gap of overhead guard without exerting pressure on overhead guard A When Hoisting Forklift Don T Wind Steel Cable Together With Overhead Guard 66 Steel Cable And Hoisting Device Need To Be Strong Enough To Support Forklift Safely Because Forklift Is Very Heavy Do Not Use Driving Cab Overhead Guard To Hoist Forklift Do Not Stand Under Hoisted Forklift 4 How to avoid overturning how to protect yourself Forbidden To Lift Load With Mast Tilting Forward To Prevent From Overturning Forbidden To Lift Load With Mast Tilting Forward A WARNING Do Not Load Or Unload When Forklift Is Not In Horizontal Position Forbidden To Move Through Obstacles Which Is Possible To Cause Overturning Such As Entrenchment Hillock And Railway 67 A warning A WARNING Re r 3 EF El Aas ana EEN MEN VEE When Lifting With Unloaded Please Turn At A Small Range To Avoid Overturning Do Fasten Safety Belt avs Do Not Jump Out Of Vehicle When Forklift Overturns Wear Safety Helmet When Driving A It Can Protect Yourself Better To Stay On Vehicle With The Help Of Safety Belt Than Jump Out Of Vehicle If Forklift Begin To Overturn Do As Following 1 Step Down Firmly And Hold Steering Wheel Tightly 2 Don T Jump Out Of Vehicle 3 Lean Your Body Toward To The Opposite Direction Of Overturning 4 Lean Your Body Forward 5 Safety Matters Du
66. of the Instruction Manual I Attentions of Using Forklift The operator must always keep in mind the principle of safety first conscientiously and cautiously read the maintenance manual following the instruction strictly to make safe and standard operation 1 Transportation Pay attention to the following particulars when using container or automobile to transport forklift truck 1 Skid parking brake 2 Fasten mast and counterweight with steel wire in both two sides chock the font and back wheels with wedge to proper position 3 Hoist the forklift according to the lifting mdication 2 Storage 1 Lower the mast to the lowest position 2 Switch off power push all the operating rods to neutral positionyand pull out power plug 3 Stretch hand brake rod 4 Chock front and back wheels with wedge 5 When truck is in long term non use wheels should besoverhead and battery should be charged once per month 3 Preparation before using 1 Check all the meters 2 Check tire pressure 3 Check the state of each handle and pedal 4 Check whether the voltage of battery 1s in operating range and whether electrolyte specific gravity and the electrolyte level are ok 5 Check whether the contact of all connectors and plugs of electrical system is ok 6 Check if the hydraulicdiquid electrolyte or brake fluid is leaking 7 Check the condition of all main fasteners 8 Check if the illuminators signal lamps are ok 9 Loo
67. on device is very suitable for forklift moving 1 0 operation controlling and signal displaying it can inspect the discharging of battery with many kinds of protecting functions Instrument panel displaying screen eco smart plays many kind of data display it can be used for manufacturer setting or customer setting and has more other functions such as imput customer order 4 2 3 Main Function and Parameter Setting Electric forklift can achieve safe and hign efficient working performance and integrated operating function by set up all the motor technical parameter and control technical parameter and functional yield correctly 1 The creeping speed of electric forklift can be set the electric forklift can work for long time under a low speed by creeping speed setting function of controller 19 2 Rate of rate can be adjusted rate of rate is the sense of softness or hardness of accelerator pedal when operating electric forklift By setting rate of rate forklift can meet the need of accelerating operation under different working conditions 3 Plug braking and regenerative braking In the course of moving there appears when reversing direction rod plug braking signal which through the controlling of motor driver to pulling motor presents a brake moment so as to brake the vehicle The amount of brake power is controlled by accelerator pedal Regenerative braking is under the condition that the vehicle speed is higher than the rated value of ac
68. on vehicle describe the usage and attentions of vehicle which not only takes you into consideration but also vehicle Stick the label on again if they fall down 72 8 9 Nameplate curve of load Side shiiter notice reading the Operation amp Maintenance Manual No carrying people Suspension point Prohibit Suspension poin Watch Your Hands Corporate logo 10 Strong point 11 hydraulic oil 12 AG identifying 13 Product Model 14 safety belt 19 No climbing 16 Warning labels 73 V Routine Check and Maintenance of Forklift Checking forklift entirely beforehand can prevent forklift from malfunction and falling short of the lifespan it should has Working hours stated in maintenance procedure is based on 8 hours per day and 200 hours per month of forklift please follow maintenance procedure for safe operation Daily maintenance should be carried out by driver other inspection and maintenance should be carried out by professional 1 Check Before Operation To keep forklift in good condition and for safe operation check forklift completely before operation this is statutory duty contact with us if you find any problem INA Small Mistake Will Lead To One Serious Accident So Don T Operate Or Move Forklift Before IUS Been Completely Repaired And Inspected Forklift Should Be Checked On Platform Turn Off Ignition Key And Pull Out Battery Plug Before Check Electrical System Of Forklift Improper Tre
69. ope pull tightly the brake apparatus and chock the wheels with wedge if the parking time is long 21 The protection valves on multiway valve and on steering device have already been commisoned so the users shouldn t adjust randomly when using to avoid that the excessively high oil pressure leads to the damage of the whole hydraulic system and burnout of the electric motor 22 Inflate the tyres according to the pressure value stated in tire pressure label 23 Treat empty truck with additional apparatus as loaded truck 5 Battery charging 1 During first time charging or boost charging of battery act strictly according to the rules stated in battery specification 2 When the forklift is working if the battery voltage drops to 41v or one cell voltage drops to 1 7v or the meter alarms stop working immediately charge the battery or change to another fully charged battery 3 Check at any moment the specific gravity the level and the temperature of electrolyte when charging battery 4 Charge battery as soon as possible after using the forklift do not store the empty battery for 24h do not under charge or over charge in order not to damage the battery 5 In order to adjust the specific gravity of each cell make a equalizing charge of the battery in regular service once per month please refer to the related chapter to get the details of charging method and maintenance Il Construction of Forklift and Main Performance Parameter
70. pacity 8 When fork is loaded tilt backwards the mast mostly the fork carrier should always be contact with goods lift fork upto 200mm above ground before driving 9 No standing under fork no standing on fork when lifting 10 The starting speed should not be too fast when lifting or lowering the goods 11 It is not allowed to operate truck and it s additions without sitting on driver s seat 12 Push handle immediately to middle position when the mast has tilted forward or backward to the extreme position 13 No driving or turning when the mast is lifting 14 Pay attention to passers obstacles irregular road and notice the clearance of upper side of forklift when driving 15 Be careful when moving on slope when the angle of slope is more thanl0 move forward upslope and move backward downslope No turning on slope no loading or unloading when moving downslope 16 Speed down when turning on the damp or slick road take care and drive slowly when moving on dock or on temporary board 17 When operating high lift range truck of which the lifting height is more than 3m pay attention to the dropping of the load and take measures to prevent it when necessary 18 Don t transport unfastened or loosely stacked load abe careful when conveying large size load 19 Do not emergency brake when moving with load 20 When leaving the truck lower the fork to ground put lever to neutral position switch off power when parking on sl
71. pring of guide valve one way valve e will be open Liquid flows into low pressure LP through holes around valve circumference If open guide valve E mner pressure of valve c decrease both piston of valve e and valve c will locate on their valve seat respectively Inner pressure decrease because liquid which flow to the back of valve d will be cut off pressure between oil pump HP passageway and its inside is inbalance under the effect of differential pressure valve d opens and the oil flow directly to low tension loop LP Figure 2 21 3 Motion of Tilting Self Locked Valve There is tilting self locked valve in tilt cylinder valve plate to prevent mast from fall down suddenly when cylinder cavity generate negative pressure and danger when misoperation of inclined valve stick Because this self locked valve if even thrusting joy stick mast cannot be tilted when forklift motor stop worki ng Direction of flow liquid is same as figure 2 21 here mast is tilting backward When valve disc is pushed in 21 A When pump is working push vavle disc in liquid from main pump flow into tilt cylinder through joint b liquid returned from cylinder play on piston through oil pore a Liquid returns to tank through pore a or b of vavle disc See figure 2 22 B When pump is not working push vavle disc in there 1s no liquid go to cylinder joint B so pressure of point p cannot be up So piston cannot move liquid of
72. r it can tilt forward and backward by the action of tilt cylinder Fork carrier moves inside of inner mast through main roller Main roller is clamped on main roller shaft by elastic collar main roller shaft is welded on fork carrier side roll roll through wing plate of inner mast is assembled on composite roller can be adjusted In order to prevent rolling clearance two fixed side rollers roll through outside of wing plate of inner mast Longitudinal loading is borne by main rollers and when lifting fork to top upper roller will stand out from top side of mast transverse load is borne by side rollers 1 Inner mast 2 Director plate 3 Adjustable pad 4 Outer 5 Roller wheel mast 6 Bolt 7 Spring washer 8 Tilt cylinder 9 Grease 10 Mast pin pin cup 11 Composite roller Figure 2 36 a Inner Mast and Outer Mast 36 1 Load backrest 2 Washer 3 Spring washer 4 Bolt 5 Roller wheel 6 Circlips for shaft 7 Composite 8 Fork arm 9 Fork roller carrier Figure 2 36 b Fork arm carrier 7 3 Roller Position Figure 2 37 There are two kinds of roller outer mast composite roller and inner mast fork carrier composite roller installed on outer mast inner mast and fork carrier Composite roller consist of main roller and side roller main roller bears front and back load and side roller bears side load to make inner mast and fork carrier move freely 1 Fork Carrier 2 Outer Mast 3 Outer Mast Composite Roller 4 Inn
73. ring Maintenance 68 1 Location Of Maintenance Should Be Appointed Location Which Can Provide Service Organization With Enough Device And Security Protective Facilities This Location Should Be Level Ground This Location Should Be Good In Ventilation This Location Should Have Fire Extinguishing Plant 2 Attentions Before Maintenance No Smoking Wear All Kinds Of Protective Articles Helmet Shoes Glasses Gloves And Boot And Suitable Clothes Wipe Away Effluent Oil Before Adding Lubricating Oil Clean Up Dirty Oil Or Dust On Connectors With Brush Or Cloth In Addition To The Needs For Some Special Cases Turn Off Ignition Key And Pull Out Battery Plug Lower The Fork To The Ground When Maintaining Clean Up Electric Elements With Compressed Air 3 Attentions Of Maintenance A Notice Not To Place Foot Under Fork Do Not Be Tripped Over By Fork When Fork Is Lifted Place Cushion Block Or Other Object Under Inner Gantry Mounting To Prevent Fork And Gantry Mounting From Falling Down Suddenly Open And Close Front Motherboard And Battery Box Cover Carefully To Prevent From Crash Finger When Work Can Not Be Completed Make A Mark To Avail Next Time Of Continuance Make Use Of Right Tools Do Not Use Temporary Tools Because There Is High Pressure In Hydraulic Circuit So Don T Carry Out Maintenance Before Reducing Inner Pressure Of Oil Pipe When Shocked By High Votage Ser
74. rough the whole cylinder to prevent forklift from rusting 5 Replace abnormal parts which can cause malfunction during work IN Small Mistake Will Lead To One Serious Accident So Don T Operate Or Move Forklift Before It Been Completely Repaired And Inspected 78 3 Forklift Cleaning A Park Forklift In Specified Area Pull Up Parking Brake Handle Press Down Emergency Button Switch Off Ignition Key And Take It Off Pull Out Battery Plug 1 Forklift surface cleaning Don T Clean Forklift With Flammable Fluid Take Safety Measures To Prevent Short Circuit Clean forklift with water and soluble abluent Clean oil filter and periphery of grease tap carefully If Clean Forklift Often Please Lubricate In Time 2 Chain Cleaning Pitan Use Corrosive Liquid Such As Chemical Abluent Acidic Liquid Etc To Clean The Chain Place a container under mast Use petrochemical derivatives such as gasoline to clean the chain Do not add any additive when cleaning with steam nozzle Wipe off water stain on the surface of pin roll and chain after cleaning 3 Electrical System Cleaning Ar Clean Pump Controller And All Kinds Of Connector With Water To Prevent Electrical System From Damage Use non metal brush or low power blower to clean electrical system according to the instruction from manufacturer don t move protecting cover 4 After Cleaning Wipe off water stain on forklift like use compres
75. ry Box See Figure 2 45 Profile LxWxH Mm FE3D20 830x630x770 Figure 2 44 Figure 2 45 A Has The Function Of Counterweight So Users Can Not Replace It At Will Otherwise It Will Affect The Balance Of Entire Vehicle And Other Performances 40 II Operation Usage and Safety of Forklift 1 Driving And Operating In order to keep a wonderful performance safe usage and economically running here introduce some notice for standard operation Q Usage of New Vehicle A Each Packing Thing From New Vehicle Should Be Reclaimed According To The Stipulation Of Local Government It Is Necessary To Carry Out A Trial Run Before Use Of New Vehicle To Affirm That Every Part Of Forklift Can Work Normally See In Page 75 In Detail 1 Check Before Operation The lifespan of your vehicle depend on usage of your new truck in first 200h of initial running pay attention to the following attentions A Whatever Season It Is You Must Run The Truck Warm Before Operation Do Maintenance Better Than Normal No rude operation no unreasonable usage 2 Relationship between load and forklift stability Within load curve forklift takes front wheel center as pivot to keep balance of vehicle body and load pay attention to load center and load capacity to keep vehicle stably When Exceeding Load Curve There Will Be Danger For Back Wheel To Be Uplifted And If The Working Condition Is Bad Forklift Maybe Overturn And Lead To Serious Acciden
76. s to ensure block upper cover of battery to avoid cover fall down to injure human or bodywork C When hoisting battery out of forklift pay attention not to crash steering wheel or other parts D After installing a pack of battery which is fully charged connect battery plug tightly E Cover battery upper cover Notice Not To Squeeze Finger When Cover Battery Upper Cover Notice Not To Crash Bodywork By Swing Of Battery Box When Hoisting Battery 0 Stacking IN Before Use Forklift Check Following Items A Ensure That There Is No Goods Falling Or Damaged Goods In Loading Area B Ensure There Is No Goods Or Stockpile Adverse To Safety When stacking do the following procedure 1 Speed down when approach to stacking area 2 Park in front of stacking area 3 Check safety around stacking area 4 Adjust forklift position to ensure that forklift lies in front of stacking area 5 Adjust mast vertical to ground and lift fork until it exceed the height of stockpile 6 Check stacking direction and move forward park vehicle at a proper position 5 Ensure goods is in upper side of stacking position lower fork slowly and place goods correctly and safely 46 When Goods Is Not Put Entirely On Shelf Or Bracket A Lower Fork Until It Doesn T Carry Any Weight B Back Forklift For Distance Of 1 4 Length Of Fork C Lift Fork 50 100mm Up Move Forward And Put Goods On Proper Stacking Position 8 Check back
77. sed air Start up forklift according to the procedure If There Is Dampness Leaks Through Motor Remove It To Prevent Short Circuit Damp Will Degrade The Performance Of Brake Brake Forklift Shortly And Repeatedly Can Keep Brake Device Dry 19 4 Routine Maintenance Forklift needs to be inspected and maintained regularly to keep good performance Use standard spare parts from noblelift Always use same type of oil when replacing or adding oil Oil and battery has been replaced can not be dumped and abandoned randomly it should be managed according to the law of environmental protection of local government Institute a thorough maintenance project Make integrate record after maintenance No repairing of forklift without training A No Fireworks Before Maintenance Switch Off Ignition Key And Pull Out Battery Plug Except For Part Malfunction Elimination Clean Electrical Parts With Compressed Air Don t Use Water Don T Extend Hand Feet Or Any Part Of Body Between Gantry Mounting And Dial Holder Even Ignition Key Switched Off There Is Still Electricity In Controller Capacitor So Becareful Not To Be Shocked By Electricity When Touching Controller Routine Maintenance Schedule v Check Proofread and Correct Adjust x Replace 1 battery Mainta Manan Every 6 S Contents Moa Items 1200hours Visual Electrolyte Measur battery Level Electrolyte Specific Gravity Battery
78. sen parking brake 10 Try to lift and lower the mast tilt forward and backward the mast turn and brake the truck 11 Be sure that the class of pollution of hydraulic oil is less than 12 grades 4 Operation 1 Only the person who has been trained with driver s license can operate the truck 2 Operator should wear safe protective shoes cap costume during work 3 Pay attention to the performance and working conditions of mechanical hydraulic electrical and mosfet governor when operating 4 Switch on the power turn on the key select the position of direction switch roll the steering wheel to see if the truck is in order step down the speed governing pedal slowly keeping a proper starting acceleration 5 Check the voltage meter when the truck is in working if the value stated in the meter is less than 41v stop working immediately charge the battery or change another fully charged battery 6 During transportation of goods the load should not exceed the rated capacity the separation and position of fork should be appropriate insert the fork completely downside the load make the load uniformly distributed on the fork to prevent load from deviation 7 If the distance between load gravity center and fork carrier 1s equal or less than 500mm the maximum load capacity should be rated capacity If the distance between load gravity center and fork carrier is more than 500mm the maximum load capacity should be less than rated ca
79. t Load Close To The Prong Has The Same Result With Add The Weight Of Load In That Case Loading Capacity Should Be Decrease 3 Load Center and Load Curve Load center is distance from front fork end to load gravity center The plate stuck on vehicle describes the relationship between load center and permissible load rated load If it is damaged or lost replace it with a new one If There Are Accessaries Such As Side Shifter Scraper Bucket Or Rotating Fork Installed On Vehicle The Reson Why Rated Load Is Less Than Standard Load With No Accessary Refers To Following Items 1 Have Decreased Load Equal To That Of Accessaries 2 Length Of Accessory Leads To Front Moving Of Load Center Rated Load Should Be Decreased For The Same Reason It Is Called Losing Of Load Center That Installation Of Accessory Leads To Front Moving Of Load Center Do Not Exceed Rated Load In Load Curve Stuck On Vehicle Or Accessaries 41 4 Forklift Stability There 1s forklift stability standard defined in iso or other standards however the stability stated in these standards is not suitable for all operation state because forklift stability is different in different operation state In following operation state maximum stability can be ensured 1 Hard smooth ground 2 Run under standard load or unloaded Standard unloaded condition lift fork or other bearing accessaries lie 30cm high from ground tilt gantry mounting backward in place withou
80. t load Standard loaded condition lift fork or other bearing accessaries lie 30cm high from ground carrying rated load at standard load center tilt gantry mounting backward in place When Loading Or Unloading Tilt Forward Or Backward With Minimum Extent Unless Load Is Fastened Or Use Rigid Fork Carriage Or Low Lifting Height Otherwise Do Not Tilt Forward 5 Transport Loading and Unloading of Forklift 1 Transport Transporting With Lorry Lock Wheels And Fasten Forklift Entirely With Slope So As To Stop Forklift From Moving During Transportation When Loading Or Unloading Or Transport On High Way Please Watch The Overall Length Overall Width And Overall Height Relevant Laws And Regulations 2 Loading and Unloading of Forklift Please Use Gangplank With Enough Length Width And Strength Practically And Efficiently Stretch Parking Brake Of Lorry To Stop Wheels Gangplank Is Practically Fastened In The Center Of Carriage No Grease Sticking On It Left And Right Of Gangplank Should Be Equal In Height So That Vehicle Can Move Smoothly When Loading Or Unloading In Order To Prevent Danger Please Don T Steer On Gangplank Or Move Crosswise On It When Loading Onto Lorry In Order To Let Left And Right Wheels Step On Simultaneously Please Back Lorry Slowly 6 Preparation Before Driving EE 1 Check position of direction switch handle and push it to 3 f A k neutral position n aS ae 2 Turn On Ign
81. tional steering wheel turn right vehicle move right steering wheel 50 turn left vehicle move left there is steering wheel assembled at backside of forklift to achieve swing toward outside when steering When steering hold steering wheel handle ball by left hand put right hand on steering wheel or control handle of multiway valve Both hydraulic steering system and steering wheel tilting gearing are standard equipment of forklift Adjust Steering Wheel To Optimal Angle According To Driver S Position After Adjusting Tilt Angle Of Steering Wheel Lock Steering Pipe By Star Handle 2 4Horn Button Press down rubber cover located in the center of steering wheebto make buzzing sound Even when ignition key is turned off the horn can still sound 3 Direction Switch Handle Indicate Moving Direction Push forward handle and step down accelerator pedal Pull backward handle and step down accelerator pedal When parking forklift direction switch handle should be put to neutral position n Fl 4 Parking Brake Handle In order to prevent forklift from moving when parking forklift pull up parking brake handle entirely It is necessary to push parking brake handle to end before driving When Operating Parking Brake Handle Step Down Brake Pedal 5 Brake Pedal And Accelerator Pedal A Do Not Step Down Accelerator Pedal Suddenly To Prevent Forklift From Start Up Or Accelerating Suddenly Before
82. tom of cylinder so as to push pistion forward to make gantry mounting tilt forward OOS INES CO 10 11 12 AI 14 15 16 117 16 g EA Tals SIR f NN 6 N N RAT AR TT Zz YS NS Nat pa AA SSA 9 AY D i le df a o y AEE e ol Nee N EFF or T 1 Swivel Joints 2 Bearing 2 4 Tilt 5 O Ring 6 Y Seal Ring Without Oil CyAnti Dust Cylinder Ring Head 7 Tilt Cylinder 8 Set Screw 9 Guide Ring 10 Tilt L1 Cylinder 12 Adjusting Cap Cylinder Pole Bush Barrel 13 Pistion 14 Y Seal Ring 15 Guide 16 0 Ring 17 Nut 18 Split Pin Sleeve Figure 2 28 Tilt Cylinder 6 7 Hydraulic Pipeline Hydraulic Pipeline of Hydraulic System See Figure 2 29 31 1 Double wire hoop 5 Pump suction hose 9 Oil connector into the multi way valve 13 Steering gear Multi valve hose 17 O ring 21 Steering cylinder hose I 25 Spring washer 6 8 Maintenance 2 Steering return line 6 Double wire hoop 10 Rectangular return oil connector 14 Right angle connector 18 Steering cylinder hose II 22 Multi way valve oil return hose 3 After the tilt tubing LG Pump joint suction 11 Pump out the oil hose 15 Multi way valve oil inlet hard tube 19 Steering cylinder joint 23 six way valve Figure 2 29 Hydraulic Pipeline Maintenance of Hydraulic Pump 1 Disassemble 4 Multi valve six way valve hose 8 gear pump 12 Multi way valve outlet joint I 16 Multiple valve six way val
83. ture so it is necessary to modify the measured density value When measuring if the temperature is upper or lower than 25 C each 1C higher add 0 0007 to measured value on the contrary each 1 C lower reduce 0 0007 from measured value If the range of temperature is too big modify according to the following formulas 25 C Electrolyte Density Calculated As Following Formula D25 Dt 0 0007 T 25 D25 Electrolyte Density When The Temperature is 25 C Dt Actual Measurement of Electrolyte Density T Electrolyte Temperature When Measuring Density 5 3 Battery Charging 1 Initial charge Cour products has been initially charged normally users need not do this work The result of initial charge has a rather important influence to battery have experience is necessary for operator to do this job Unused battery should be initially charged before use Clean battery surface and check damage before initial charge Open cover of oil inlet to ensure vent hole unblocked Under the working condition of charger infuse battery with sulphuric acid electrolyte of which the density is 1 26 0 005 25 C and the temperature is under 30 C and the fluid level must be 15 25mm higher than guard board Put battery stand for 3 4 hours not exceed 8 hours After temperature is lower than 35 C initial charge can be made if the electrolyte level descend after stand it 1s necessary to be complemented Only electrolyte and distilled water
84. tyre surface groove C Check oil leakage z D Infuse lubricating grease if necessary E Check if there is looseness on interface between wheel nut and piston rod check if there is bumping or scratch on piston rod surface 1 50 200mm F Check rotational stability of gantry mounting roller G Lift lifting cylinder to the top to filled cylinder with oil 47 Once Forklift Needs To Be Repaired Broken Or Has Unsafe Factor Report To The Related Person And Stop Using The Forklift Till It S Repaired 2 Daily Storage A Park forklift at appointed area block wheel with wedge B Push gear shift bar to neutral position pull parking brake handle C Take off key and keep it in safe area 3 Long Term Storage Check and maintain as following based on daily deposit A Considering rainy reason park vehicle on upper and hard ground B Dismantle battery form forklift battery should be put in dry and shady area and charged once per month if forklift is parked in hygrothermal environment even indoor C Brush anti rust oil on exposed parts such as cylincer piston rod and shaft which is possible to rust D Cover parts liable to be damped E Run vehicle at least once per month Put on battery get rid of grease on piston rod and shaft activate motor and warm it up enough move forward and backward slowly run hydraulic control for several times F Do not park vehicle on soft ground such as asphalt road in summer 4 Operation after long ter
85. unning for 10min D Keep pump running with speed of 1500 2000rpm increase pressure with 20 30kg cm once for 5min until pressure get up to 175 kg cm Then run each oil circuit for 5min after that replace oil returning filter When increasing oil pressure notice the temperature of test oil pump surface temperature and running sound If oil temperature or pump surface temperature increase too much reduce load to decrease oil temperature then test again E Keep overflow valve pressure at 175kg cm after testing test rate of flow through lifting speed 6 9 Malfunction Analysis If there is failure in hydraulic system find out reason and carry out necessary service according to following list 1 Multiway Valve Malfunction Analysis Figure 2 6 34 Figure 2 6 Malfunction Repair Method Too low of lifting oil circuit Slide valve jam Clean after disassembling pressure Oil hole jam Clean after disassembling Pressure ascends slowly Insufficient air exhausting Exhaust thoroughly Steering oil circuit pressure is Slide valve jam Clean after disassembling higher than rated value Oil hole jam Vean after disassembling l I fl l Fall short of rated oil mass ee EE Adjust adjustment Incorrect overflow valve AA a Adjust Noise adjustment Sliding surface worn Replace overflow valve Oil leakage Coutside O Ring is aging or damaged Spring broken Replace spring Set pressure too low gt Valve seat surface broken Adjust or replace ov
86. ve joint 20 bonded washer 24 Screw Clean completely before disassembling Put the disassembled parts on clean paper or cloth be carefully not to contaminate or damage the parts A Clamp pump flange on bench clamp b Dismantle connecting bolt 11 back end cover 5 and pump body 1 c Dismantle scaleboard 6 driving gear 2 and driven gear 3 d Dismantle seal ring 7 and retainer ring 8 from front and back end cover Attention if seal ring needs not to be replaced do not dismantle it from front end 2 check Check dismantled parts and wash them with gasoline rubber parts excluded A Check Pump Body If contact length between pump body and gear 1s longer than 1 2 of perimeter replace pump body Figure 2 30 B Check Scaleboard 32 Figure 2 31 Check contact surface of scaleboard if it is damaged or its thickness is less than rated value replace scaleboard rated thickness value 4 94 mm groove scaleboard linlet port side eS P sk i i I outlet port side oil out mouse Figure 2 32 Figure 2 33 C Check Front and Back Pump Cover If color changing to brown extent of inner surface of bush exceeds range of 150 replace it D Check Driving and Driven Gear If worn badly replace one pair if d is less than rated value replace two pairs Figure 2 34 E If necessary replace seal ring bush seal component retainer ring oil seal spring retainer ring 3 Assembling
87. verhead Guard Is An Important Part To Prevent Upper Object From Falling And To Protect Operator One Of Roof Hatch Dimensions Of Overhead Guard Is Larger Than 150mm So If Goods Dimension Is Smaller Than 150x150mm Measures Should Be Taken To Prevent Goods From Falling And Leading To Accident Installation Looseness Operation Without Overhead Guard And Use Overhead Guard After Modification Are All Dangerous And Will Probably Lead To Serious Accident 3 Backrest Backrest Is An Important Safety Part To Prevent Goods Loaded On Fork From Skidding Toward To Operator Installation Looseness Operation Without Overhead Guard And Use 53 Overhead Guard After Modification Are All Dangerous And Will Probably Lead To Serious Accident 4 Towing Pin Towing pin can only be used in following situation Used for escape from trouble when can not move such as tyre stuck in groove Had ia Used for conveyance of forklift when loading on or unloading _ EN 1 from lorry f lt gt _ Do Not Use It For Towage Or In Tow Operation Absolutely 5 Fork Locating Pin Fork 1s locked by fork locating pin to a particular position When adjusting space between fork pull up fork locating pin turn 1 4 circle and adjust fork to specified position Adjust space between forks according to goods to be loaded PAN To The Principle Of Load Gravity Center Sho Armrest shicle Center Left And Right Should Be Adjusted To Be Equal In

User manual - Zhejiang Noblelift Equipment Joint Stock Co.,Ltd

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