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

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1. eeeeeeeeeeeeeeeeee 245 Introduction Welcome to use this series of power pallet trucks This manual gives clear information on how to master safe operation of the power pallet trucks The differences between various power pallet truck are described in detail in this manual During operation and maintenance please refer to the contents corresponding to the power pallet truck types you are using The safety instructions and important precautions are indicated with the following icons lt a gt 1 SIOP ____ This icon indicates the existence of a hazard that could result in personal injury if the safety instruction is not observed 2 A This 1con indicates that a failure to observe the described instruction could lead to equipment damage A Most parts of the product are made from recyclable steel The recycling and disposal Refers to general notes and instructions before use of cast offs resulted during using maintenance cleaning and disassembling the product has to comply with local regulations without pollution to the 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 in product designs and specifications without prior notice For the latest product parameters Due to continuous p
2. B J1 2 B 2 au 8765 4321 B t 7 ke Wool UM 0s CU 5 54 1 5 9 TS Rost Be r7 CJ 2 7 24V FT KM F E 26 zu 0124 GND FU 1 632 5 Belly N O Fun Et Leg 31 cu 2 2 CAN HI f FUO1 Kr re a J1 12 Cd 2 1 CAN LO ga n LEEREN m twisted pair Kup GN T2 Emg Reverse GB 6 GN T1 3 e e T i 5 3 5 4 1 55 5T 56 B CURTIS lg 12300 2405 Ku w GH L3 E ES i 3 22 Main Contactor F RD 32 4 Enc supply PWM output 1 MM J2 2 pue Output 1 E BU Enc A J1 24 FE ence PWM output ET 5 6 1 BK J2 5 Enc Ground CAN Hl 7 935 P CAN LO 34 12 CAN BUS Brake Return twisted pair HA vo un UNI 7 A 324 Brake B E e 2 2 2 3 7 2 LPL16 circuit diagram Noblelift handle B J1 2 oo FU Sf 2 P alia Es 413211 7 1 7 2 L KM SA gel B s val T If ar A Dee B KSI on ia T boom BU 2 15 Main Contactor 122 I I I LLLLI GND 3 Interlock ics m Tek Waal BK 0G GN UE TS Mode MA M2 1 14 Wael IL X 24V BN 7 15 1 Reverse me Heel ee f Kup GN T2 Forward i pue 414 GB 8 GN TI i MH isal is A5 22 an i Eng Reverse 177351 EISEAN ss 15 2 B Throttle Wiper E Mais M U I xd 2 1 EP 2 i V CURTIS ME S W 5 a 2 9 ra E af molg 1230 2402 EN es Tower Enc supply Li FO Ene B 22 Hall 8 i iss S576 Hom
3. Cleaning Operation Flammable liquid can not be used for cleaning the truck Before cleaning take safety precautions to prevent electric sparks e g sparks caused by short circuit When operating the accumulator connectors on it must be disconnected Use soft air suction or compressed air non conductive and anti static brushes to clean electric and electronic components A If you are going to use water spray or high pressure cleaner to clean the truck all electric and electronic components must be covered carefully in advance because moisture may cause them malfunction Never use steam nozzles for cleaning Operation of Electric System Operation on the electric system should only be performed by specially trained personnel Before performing any operation on the electric system precautions must be made to prevent electric shock When operating the accumulator connectors on it must be disconnected Traction motor and hoist motor are types of short term duty Traction motor S2 60min Hoist motor S3 15 Welding Operation To prevent electric components from being damaged remove these 18 electric components before welding Installation When repairing or replacing hydraulic components electric and electronic components make sure to install them back to their original positions Wheels Quality of the wheels has significant effect on stability and driving performance of the truck Modification on wheels can be performed on
4. Check braking function of the control lever Now the preparation before starting up is completed 5 4 Operation of the truck 5 4 1 Starting up Driving and Parking STOP Be careful during starting up and driving especially when part of your body stretches out of truck s outlines Do not carry any other person during driving Emergency Stop Pressing the emergency stop switch will stop all electric control functions Forced Braking When the control handle is released the truck will brake automatically emergently stop The control handle will enter the upper braking range B1 automatically gt STOP jr the lever enters braking range slowly make sure to find out its causes and troubleshooting the failure If necessary replace the air spring of the handle Starting up Start up the truck only when the battery cover is closed Starting up the truck 12 Driving Adjust driving speed by rotating the forward backward button Swing the control handle rightward or leftward to drive Rotate the control lever to driving range F and adjust the control lever in required direction the truck will move towards selected direction When the operator faces the pallet truck s moving direction while the loads are against the moving direction turn the lever clockwise to make a clockwise turning A When the truck comes across an obstacle the force applied to swing the lever should be smaller than dr
5. accumulator W STOP The batteries should be recharged in well ventilated areas The wartering cap of the battery for each unit must be opened Make sure no metal objects placed on the accumulator Check all cables connection and connectors for obvious defects Observe strictly all safety instructions e g replenishment of the accumulator and preparation for recharging 4 2 1 Balanced Recharging After using for a period voltage and concentration may vary from battery to battery Balanced recharging will eliminate the differences so that the performance of each cell becomes uniformed In following cases balanced recharging is necessary Voltage of an individual cell is frequently below 1 7V The set of cells with heavy duty For example Set of cells for starter motor and lifting motor for accumulators that are not recharged in time after discharging Over discharged accumulators and those are not in use for a long time Perform balanced recharging as follows A Recharge with a current of 0 115A B When the voltage up to 2 5V and there occur bubbles in the electrolyte continue recharging at a reduced current of 0 0515A C Recharge the accumulator to full capacity and stop recharging for half an hour and then continue recharging with further reduced current of 0 02515A for an hour D Stop recharging again for half an hour and continue recharging with a current of 0 025I5A for an hour E Repeat step D until bubbles occurs i
6. BK NE ene Ground M IF T 3 VD i i ad Brake Return l LJ 8 2 6 KMp 55 4 55 2 NUN Brake B f m VD Fr Me te 2 4 27 Names of electrical components of LPL16 are listed in the following sheet ee NESE SL Ten GB Accumulator 15 YB Electromagnetic brake ositive pole of s 16 Capacity indicator Accumulator Accumulator He pee e we F OT FUO FU me Ld 2 E owde met wor 2 WD ese _ NI N 7 TEE Lowering button Emergency stop button Lifting button Main contactor 10 Horn button Key switch 23 Emergency 11 Discharge module ee button at k janet nn J el Te 7 3 LPL16 Schematic diagram of hydraulic system NI an p MVD C r 614 6114 50 160bar Br 0 8KW 24V LPL20 SMS 001_EN Instruction Manual WP LPL20 Power Pallet Truck A Operators should read and understand this manual and all warning Labels on power pallet truck before using the truck Keep the manual for future reference Release July 2010 EG Konformitatserklarung EC Declaration of Conformity Hiermit erkl ren wir NOBLELIFT EQUIPMENT Jingyi Road Changxing Zhejiang China We herewith declare Da die nachfolgend bezeichnete Maschine aufgrund ihrer Konzipierung und Bauart sowie in der von uns in Verkehr gebrachten Ausf hrung den einschl gigen grundlegenden Sicherheits und Gesundheitsanforderungen der EG Rich
7. The recycling and disposal of cast offs resulted during using maintenance cleaning and disassembling the product has to comply with local regulations without pollution to the 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 in product designs and specifications without prior notice For the latest product parameters Due to continuous product improvement Noblelift reserves the right to make changes please feel free to contact us Note All parameters provided herein are as of the publication date of the Instruction Manual 1 Guidelines for Safe Operation 1 1 Requirements for the driver The power pallet truck should only be operated by personnel trained in operating the power pallet truck who can show to the user how to move and handle loads and instruct the user how to operate the power pallet truck 1 2 The right duty and responsibility of driver Clear with his own right and duty the driver should be trained in operating the power pallet truck and also knows the contents in this operation manual very well If the power pallet truck in use is controlled on foot the driver should wear safety boots during operation 1 3 Unauthorized persons are prohibited to use The driver is responsible for managing the
8. 50 work hours but at least once a week M3 Every 500 work hours but at least once every three months M6 Every 1000 work hours but at least once every six months M12 Every 2000 work hours but at least once every 12 months Additional operations should be performed in trial run period In initial 50 100 working hours or after two months Check the nuts on the wheels and tighten them if necessary Check the hydraulic components for leakage and tighten them if necessary Replace the hydraulic filter 19 6 4 Maintenance list of LPL16 Time interval of maintenance m W BONEEEERGEE Ie tii xt E storage Wheels 3 2 Check the ga make sure they fit well with U o d Steering 4 1 Check the steering control Bong system Braking Check the performance and adjust accordingly ie system 5 2 Check reset function of the air spring and check for leakage and damages Check the brake disk for wear Check the connection of brake and adjust necessary Lifting Mechanism 6 1 Check performance and wear and adjust accordingly si Vmalmeperhebedngwestrbodage fef 6 3 Check fork tips and pallet support for wear and damages Hydraulic 71 Check performance performance Check performance 1 e system 7 2 Check all connections for leakage and damages a rame tp l Check the cylinder for leakage and damages and if M the accessories are safe and se
9. and reliable to personnel after completion of above maintenance a After about initial 100 working hours check the nuts of wheels tighten them if necessary b After about initial 100 working hours check the hydraulic system connections for leakage and tighten it if necessary c After initial 500 working hours 6 5 Instruction on maintenance and repair 6 5 1 Preparing the pallet truck for maintenance and repair To prevent possible accidents during maintenance and repair work following preparations must be done Park the truck safely Press the emergency stop switch and disconnect the connectors on accumulator STOP When operating after fork is rising or pallet truck is lifted the operator shall adopt measures to prevent falling over or sliding down of the fork and pallet truck For information on lifting of the truck see related parts in Transportation and Trial Run above 6 5 2 Open the covers Park safely Press the emergency stop button and loosen four screws 2 see the chapter Transportation and trial running Remove covers 1 put them near the pallet truck 6 5 3 Check hydraulic oil level Install in a reverse order Get the truck ready for maintenance or repairing Loose the 4 screw 2 on the cover Open the covers 1 I Check hydraulic oil level in oil tank Check the hydraulic oil level only after the fork and main frame ar
10. on freight wagons Its carrying capacity is indicated on the nameplate label 2 2 Technical features 2 2 1 Outline drawing and technical parameters Type No LPL16 Power electric diesel gasoline liquefied petroleum gas Electric Pedestrian 1600 Drivi estrian stand on sit down uni Rated loading capacity Q k oad centre distance m 9 1268 4 380 90 970 1100 7 a lt 2 KO 3 O Q D 3 o 2 e O D Q Q P lt c 2 T O x ront overhang distance Track 8 8 8 Weight with accumulator Axle load at full load Drive side load side xle load without loading Drive side load side polyurethane wheels 230x75 Q84x70 Dimension of steering wheel 100x40 i dd a du omo po NEN 5 Wheel numbers X driving wheel Drive side load side D Ix 2 2 1x 2 4 omo omo omo omo omo omo omo km h ires rubber wheels high performance elastomer m Tyre size drive side m Tyre size load side CO 6 Wheel track front Drive side b10 m 5 w w e O p p p Ja ja 2 ja ja A lo Iin Jo In lo o o Im B ITO N jet O A IN Wheel track back load side bil m Lift height h3 4 1186 4 I eight of lever in middle position 14 15 9 eight of fork when being lowered h13 1600 Overall length 11 ength of truck body 12 Width of truck body bl m Fork dimension s e l m m r 7 60 160 11
11. power pallet truck in use and must prevent any unauthorized person from driving or operating the power pallet truck 1 4 Malfunction and Defects In case malfunction or defects occurs with the power pallet truck the driver should immediately inform the supervisor If the power pallet truck can not be operated safely e g with worn wheels and brake malfunction always stop using it until repaired completely 1 5 Safety operation and environment protection The checking and maintenance work described in this chapter should be executed according to the time intervals in the maintenance list STOP Never modify any parts especially safety devices of the power pallet truck without permission Never change the operation speeds of the power pallet truck All original spare parts from the factory are verified by Quality Assurance Department Only use spare parts from the manufacturer for the guarantee of the safety and reliability of power pallet truck operation The replaced material such as oil or fuel should be disposed of according to environment protection regulations 1 6 Dangerous area Dangerous area generally refers to these locations in which power pallet truck or its lifting mechanism e g fork or accessories is moving lifting or lowering thus being dangerous to persons in this area or in which the truck is handling loads Generally the scope of this area extends to locations to which the loads or accessories on the truck is lower
12. remove the key 17 6 Maintenance of the pallet truck 6 1 Safety operation and environment protection The checking and maintenance work described in this chapter should be executed according to the time intervals in the maintenance list Never modify any parts especially safety devices of the truck without permission Never change the operation speeds of the truck All spare parts provided by original manufacturer are strictly tested Only use spare parts from the manufacturer for the guarantee of the safety and reliability of truck operation The replaced material including oil should be collected and disposed of according to local environment protection and health regulations 6 2 Safety rules applicable to the maintenance of the pallet truck Maintenance technician The maintenance and service should only be performed by special personnel trained by the manufacturer After the technician sent by after sales department of the manufacturer completed maintenance and servicing work they should sign on the service log Lifting of the truck When the truck needs to be raised up for repairing the lifting device must be safe and reliable and must be strictly fixed to hook holes When the truck is raised up proper measures such as using wedges and wooden blocks must be applied to prevent the truck from sliding down or tilting over Only when the fork is fixed and connected with strong enough ropes can a hoisting device be used for lifting
13. shall be less than 70dB A please refer to 15804871 standard Continuous noise level is an average value of noise measured at the driver s ear during travelling lifting and being standby Electromagnetic Compatibility EMC The manufacturer confirms that the stacker complies with EN12895 and other relevant standards on limits of electromagnet radiation and interference and has been tested on static discharge manufacturer Never modify any part of electrical system without written permission from the 2 2 4 Operation Conditions Environment temperature Ambient temperature 5 C 40 C Altitude Below 2000m Particular protective measures shall be adopted on special devices during continuous operation of the pallet truck in an environment below 5 C or under conditions of low temperature and heavy moisture 2 3 Schematic diagram and description on various signs and nameplate locations of the pallet truck Button mark of pallet truck s lifting Button mark of pallet trucks descending Button mark of horn Button mark of pallet trucks advancing and retreating The nameplate of pallet truck Mark of lifting position LPL16 2 If there is quality problems with the truck or you need to order spare parts please specify serial number of the truck and part number Contents on the pallet truck s nameplate shall be understood before use 3 Transport and Trial Run 3 1 Transport with a crane A Load c
14. truck is proved to be safe and reliable to Euer a After about initial 100 working hours check the nuts of wheels tighten them if necessary b After about initial 100 working hours check the hydraulic system connections for leakage and tighten it if necessary c After initial 500 working hours 6 5 Instruction on maintenance and repair 6 5 1 Preparing the pallet truck for maintenance and repair To prevent possible accidents during maintenance and repair work following preparations must be done Park the truck safely Press the emergency stop switch and disconnect the connectors on accumulator STOP When operating after fork is rising or pallet truck is lifted the operator shall adopt measures to prevent falling over or sliding down of the fork and pallet truck For information on lifting of the truck see related parts in Transportation and Trial Run above 21 6 5 2 Open the covers Park safely Press the emergency stop button and loosen four screws see the chapter Transportation and trial running Remove covers put them near the pallet truck Install in a reverse order 6 5 3 Check hydraulic oil level Get the truck ready for maintenance or repairing Loosen the 6 screws on the covers open the front cover board 1 Check hydraulic oil level in oil tank Check the hydraulic oil level only after the fork and mai
15. wetrcontactes ee The accumulator capacity is Check the capacity indicator the brake and insufficient or the related cables The truck travels electromagnetic brake is tight very slowly or the related cables are not well contacted The controller is damaged Replace the controller The truck starts The button controlling Reset through repair or replace tt up suddenly backward or forward is not reset If above steps still can not solve the problems please contact the after sales service department of the manufacturer and have the problems solved by specially trained technicians 6 6 5 Oil and lubricant Greasing point fuel outlet Lubrication Cycle Table 25 No Refill point Lubrication Cycle 500 h 1000 h 2000h wheel bearing JIL A ai push rod FA gt Tanne EG EEE BEE ame 1 ew je le b Lubricating C Checking O Replacing Description tables of oil and lubricant Lubricant type Lubricant Name Lubricated area gt 15 C lt 15 C A Lubricant 2 Grease 2 Grease Bearings sleeves grease joints na 40 Hydraulic Oil 30 Hydraulic Hydraulic system Oil C Lubricant 2 Grease Lc ae Oil for gear W85 90 Gear W85 90 Gear Gear box LT hw um i 26 7 Schematic Diagrams of Electric and Hydraulic System 7 1 LPL16 circuit diagram REMA CAN handle
16. 000 The pallet truck Connectors on accumulator Check the connectors on the accumulator can not move are not connected connect them if necessary Electric lock is in position 0 Turn the Electric lock in position 1 Emergency stop switch is not Turn on the emergency stop switch turned on The accumulator capacity is Check the capacity of the accumulator recharge used up if necessary he control lever is not in drive Turn the control lever to drive range F range F Check the fuses FU02 and FUI The fuse is blown Loads can not The truck is not operating Do as methods in The pallet truck can not be lifted up Low hydraulic oil level move table The fuse is blown Check hydraulic oil The accumulator has only Check the fuses FUOI 20 30 of capacity Recharge the accumulator The UP switch is in bad contact Check UP switch and replace if necessary or damaged Loads can not Dirty oil blocks control valve Check hydraulic oil and clean control valve be lowered down The solenoid valve for lowering Replace the oil if necessary is not opened or is damaged Check or replace the valve for lowering It can not stop The UP switch is damaged Disconnect power supply and replace the UP when lifting up switch Moving in one The micro switch and the Check the micro switch in control lever and the direction connecting cable are not connecting cable 24
17. 3 Check the cylinder for leakage and damages and if M the accessories are safe and secure JN Chekmeollwl 5 9 75 fena uk oil and the filter element EN 76 Check the pressure regulator valve 9 je Electric E _ a system Check all cable connections for safety reliability and damages 18 8 3 Check if the amperage of fuses is proper 8 4 Check if the switches and release cam mechanism iul is secure and functions properly lee ye 8 5 Check the connectors and replace worn parts if BEE TL 86 Checkthewamingdevice 58 e Motor 19 1 Checthecabonbushforwar J e 92 Check safety of additional devices of motor e 9 3 Use a vacuum to clean motor frame Check the H MAE e Accumulator 10 1 Check the density of acid liquid capacity and B PRENNE 10 2 Check the safety devices on terminals and the Te A 10 3 Clean the connector of accumulator and check the e eres eT A 104 Check the cable for damages replace necessary Lubricant oil 11 1 Grease the truck according to time table for filling up lubricant General 121 Check the grounding connection of electric system 1e Test 122 Check the traveling speed and braking distance 1e 1123 Check te iting and lowering speed 9 124 Check the safety device and switch offdevices e Te are et 13 2 The truck is proved to be safe
18. 4V 25A 24 Ah 160 50 60Hz 13 5 Operation 5 1 Schematic diagram of the handle 1 Down Switch 2 Forward Backward 3 Horn Button 4 Backward button 5 Lifting button 5 2 REMA CAN handle 1 Up down switch Moving the fork upward or downward 2 Forward Backward button Control speed and direction of the truck forward or backward 3 Reverse button Emergency reverse button 4 Horn switch 5 Signal light Indicates speed of the truck 6 High Low speed Switch button Press the switch gently for low speed function When it is pressed first time the speed is lowered and the indicator glows red indicating low speed mode When it is pressed again the truck returns to high speed mode and the indicator glows green 5 3 Starting up the truck D TOP The driver should always make sure that no person stayed in dangerous area of the truck before starting up and operating the unit or lifting loads 14 Check before daily start up Check the entire unit for defects and failure especially the wheels and lifting mechanism Check if the accumulator is firmly fixed and well connected Starting up the truck Rotate and turn on the emergency stop switch Insert the key in electric lock and turn it clockwise to position The coulombmeter shows current battery level Check the horn Check braking function of the control lever Now the preparation before starting up is completed
19. 5 4 Operation of the truck 5 4 1 Starting up Driving and Parking Be careful during starting up and driving especially when part of your body stretches out of truck s outlines Do not carry any other person during driving STOP It has certain risks to use the truck in rainy snowy foggy and windy weather Before use in those conditions please evaluate the security Emergency Stop Pressing the emergency stop switch will stop all electric control functions Forced Braking When the control handle is released the truck will brake automatically emergently stop The control handle will enter the upper braking range B1 automatically STOP if the lever enters braking range slowly make sure to find out its causes and troubleshooting the failure If necessary replace the air spring of the handle g up STOP start up the truck only when the battery cover is closed Starting up the truck Rotate the control lever to driving range F and adjust the control lever in required direction Adjust driving speed by rotating the forward backward button 15 the truck will move towards selected direction Driving Swing the control handle rightward or leftward to drive When the operator faces the pallet truck s moving direction while the loads are against the moving direction turn the lever clockwise to make a clockwise turning When the truck comes across an obstacle the force applied to swin
20. 50 540 650 m NO L gt NO NO 3 D gt Oo 5 63 0 00 90 0 5 50 00 Lateral distance of fork b5 5 7 12 8 2 U gt istance from wheel base centre to ground m2 2135 1470 Driving speed full load no load km h 5 5 5 5 Lifting speed full load no load 25 35 Lowering speed full load no load 40 38 8 16 ight angle stacking aisle width pallet 800X1200 1200 placed along m m 5 Turning radius Wa n5 Aupiqede Climbing capacity full load no load 0 arking brake Electromagnetic brake k r ift motor power kw 2PZS Voltage of accumulator capacity discharge rate 5 hours V Ah 24 160 Accumulator weight 5 175 attery dimension length X width X height 680 210 490 Driving and control methods I FET control Noise heard by the driver lt 70 Turning angle 180 85mm Minimum height single wheel 84x93 ccumulator U K BS standard no oe NEN Drive motor power kw 1 2 AC EEE Wan 8 m m m m m m m m m m m m m m m m 8 gt Io lo l gt o lo n Io In n In a C1 A O IN 2 o O mE dw cq U See the technical parameter sheet for the overall dimensions and weight of the pallet truck The weight and dimensions of parts have clear descriptions in the corresponding technical drawings 2 2 2 Technical standard gt VDI 2198 technical standard is observed 2 2 3 EN standard Continued noise level
21. Load capacity of the crane in use must be sufficient The load weight equals the net weight of truck plus weight of accumulator see nameplate plate on the truck The hook holes are specially designed for transport the truck Park the truck in a safe position Hooks of the crane must be applied at hook holes A Hooks of the crane must be applied at hook holes ensuring the truck will not be slipped down During operation make sure the crane whose hooks must be applied at hook holes of the truck do not contact with the truck 3 2 Trial Run A The truck can only use accumulator as power supply Changing to use AC power will damage the electric circuit Cables connecting accumulator should be less than six meters To ensure the truck work normally after delivery and transportation following operations have to be completed Make sure all labels on the truck are complete clear and readable If not replace with new labels immediately Check if the completeness of all parts and components and check if they are in compliance with requirements If necessary install batteries without damaging the connection cable Recharge the accumulator immediately If customers want to replace the accumulator with a new one make sure that the new accumulator match with the accumulator coulombmeter or is permitted by service technician of manufacturer 3 3 Moving the pallet truck in case of driving device failure When tow
22. NOBUET LPL16 SMS 001 EN LPL20 SMS 001 EN LPL16 SMS 001 EN Instruction Manual LPL16 Power Pallet Truck A Operators should read and understand this manual and all warning Labels on power pallet truck before using the truck Keep the manual for future reference Release July 2010 EG Konformitatserklarung EC Declaration of Conformity Hiermit erkl ren wir NOBLELIFT EQUIPMENT Jingyi Road Changxing Zhejiang China We herewith declare Da die nachfolgend bezeichnete Maschine aufgrund ihrer Konzipierung und Bauart sowie in der von uns in Verkehr gebrachten Ausf hrung den einschl gigen grundlegenden Sicherheits und Gesundheitsanforderungen der EG Richtlinien entspricht that the following machine complies with the appropriate basic safety and health requirements of the EC Directive based on its design and type as brought into circulation by us Bei einer nicht mit uns abgestimmten nderung der Maschine verliert diese Erkl rung ihre G ltigkeit In case of alteration of the machine not agreed upon by us this declaration will lose its validity Bezeichnung der Maschine Elektrohubwagen Machine Description Power Pallet Truck Maschinentyp Machine Type LPL16 Einschlagige EG Richtlinien EG Maschinenrichtlinie 2006 42 EC Applicable EC Directives EC Machinery Directive 2006 42 EC Angewandte harmonisierte Normen insbesondere Applicable Harmonized Standards EN 1726 1998 EN1175 1 1998 Herst
23. ad side Tx 2 2 x 2 4 pA Wheel track front Drive side b10 495 3 7 Wheel track back load side b11 380 525 mm 44 Height of lever in middle position h14 pH 4 32 Distance from wheel base centre to ground m2 m 25 Right angle stacking aisle width pallet 800X1200 1200 placed 4 34 mm 2233 2273 along fork Ast Turning radius Wa 1572 1642 Driving speed full load no load 4 7151 Lifting speed ___ full load no load 18 22 Lowering speed full load no load 35 40 5 8 Climbing capacity full load no load 10 16 LM 15 10 Parkingbrke 1 Elcromagneti brake Drive motor power kin ooo RF OW seines UOISUBUUIG Ayiqedeg 6 1 Drive motor power kw 1 5 AC Lift motor power Km 6 3 Accumulator U K BS standard no 3VBS 24 210 6 5 Accumulator weight H 5 kg 185 I Battery dimension length X width X height ommo 645 196 570 8 1 Driving and control methods ooo o o o FET control lt 7 Tuming ande OO 180 kW Lift motor power kw kW kg mm d See the technical parameter sheet for the overall dimensions and weight of the pallet truck The weight and dimensions of parts have clear descriptions in the corresponding technical drawings 2 2 2 Technical standard VDI 2198 technical standard is observed 2 2 3 EN standard Continued noise level shall be less than 70dB A please refer to SO4871 standard travelling lifting and being standby Electromagneti
24. als in the maintenance list STOP Never modify any parts especially safety devices of the power pallet truck without permission Never change the operation speeds of the power pallet truck All original spare parts from the factory are verified by Quality Assurance Department Only use spare parts from the manufacturer for the guarantee of the safety and reliability of power pallet truck operation The replaced material such as oil or fuel should be disposed of according to environment protection regulations 1 6 Dangerous area Dangerous area generally refers to these locations in which power pallet truck or its lifting mechanism e g fork or accessories is moving lifting or lowering thus being dangerous to persons in this area or in which the truck is handling loads Generally the scope of this area extends to locations to which the loads or accessories on the truck is lowered STOP Unauthorized persons must be ordered to leave dangerous areas The driver should always give warning if there is any risk of human injury If the warned persons still stay in dangerous area the driver should stop the power pallet truck immediately STOP Use of this truck may cause crushing and shearing injuries to personnel 1 7 High risk environment Special protection measures shall be adopted in highly dangerous working environments A The truck is not designed for use in high risk environment 1 8 Safety devices and warning signs Suff
25. apacity of the crane in use must be sufficient The load weight equals the net weight of truck plus weight of accumulator see nameplate plate on the truck J The hook holes are specially designed for transport the truck Park the truck in a safe position Hooks of the crane must be applied at hook holes A Hooks of the crane must be applied at hook holes ensuring the truck will not be slipped down During operation make sure the crane whose hooks must be applied at hook holes of the truck do not contact with the truck 3 2 Trial Run A The truck can only use accumulator as power supply Changing to use AC power will damage the electric circuit Cables connecting accumulator should be less than six meters To ensure the truck work normally after delivery and transportation following operations have to be completed Make sure all labels on the truck are complete clear and readable If not replace with new labels immediately Check if the completeness of all parts and components and check if they are in compliance with requirements Check the entire unit for defects and failure especially the wheels and lifting mechanism lf necessary install batteries without damaging the connection cable Recharge the accumulator immediately If customers want to replace the accumulator with a new one make sure that the new accumulator match with the accumulator coulombmeter or is permitted by service technician o
26. ays drive in lower speed when passing curved passageways narrow passageways rotary doors or any obstructed places The driver should be able to measure by sight and keep enough stopping space from vehicles ahead all the time It is prohibited to make an abrupt stop unless in emergency rapid U turn and chase with each other in obstructed places Never operate the truck with the body stretching out of it 1 15 Visibility The driver must keep his eyes on moving direction and have a clear view of the road ahead In case the loads carried block sight of the driver the truck has to be driven reversely If this is not practical another person should walk in front of the truck giving corresponding guidance and warning to the driver 1 16 Driving on slopes and ramps when driving the pallet truck on a slope or ramp through an allowable narrow passageway make sure that the ground is clean and antiskid Drive safely on the slopes and ramps specified in the technical specification Instruction manual of the pallet truck Loads on the fork must face the upslope direction U type turning or parking on slopes or ramps are not allowed Pass a ramp at lower speed and get ready for braking at any time 1 17 Load capacity of the floor Check if the weight of truck and loads or wheel pressure on the floor exceeds the load capacity of the floor 1 18 The fork should be kept in the lowest position from the floor during non transportation driving Standing
27. c Compatibility EMC The manufacturer confirms that the stacker complies with EN12895 and other relevant standards on limits of electromagnet radiation and interference and has been tested on static discharge Continuous noise level is an average value of noise measured at the driver s ear during Never modify any part of electrical system without written permission from the manufacturer 2 2 4 Operation Conditions Environment temperature Ambient temperature 5 C 40 C Altitude bellow 2000m Particular protective measures shall be adopted on special devices during continuous operation of the pallet truck in an environment below 5 C or under conditions of low temperature and heavy moisture 2 3 Schematic diagram and description on various signs and nameplate locations of the pallet truck 15 Button mark of pallet truck s lifting 16 Button mark of pallet truck s descending 17 Button mark of horn Button mark of pallet truck s advancing and retreating Prohibition mark of No sitting on the pallet truck The nameplate of pallet truck Mark of lifting position WP LPL20 16 An Contents on the pallet truck s nameplate shall be understood before use If there is quality problems with the truck or you need to order spare parts please specify serial number of the truck and part number 3 Transport and Trial Run 3 1 Transport with a crane
28. can not be lifted up Loads can not be lowered down It can not stop when lifting up Moving direction in one Connectors on accumulator are not connected Electric lock is in position 0 Emergency stop switch is not turned on The accumulator capacity is used up he control lever is not in drive range F The fuse is blown he truck is not operating Low hydraulic oil level The fuse is blown The accumulator has 20 30 of capacity only The UP switch is in bad contact or damaged Dirty oil blocks control valve The solenoid valve for lowering is not opened or is damaged The UP switch is damaged The the micro switch and connecting cable are not well contacted 22 Check the connectors on the accumulator connect them if necessary Turn the Electric lock in position 1 Turn on the emergency stop switch Check the capacity of the accumulator recharge if necessary Turn the control lever to drive range F Check the fuses FU02 and FU Do as methods in The pallet truck can not move table Check hydraulic oil Check the fuses FUOI Recharge the accumulator Check UP switch and replace if necessary Check hydraulic oil and clean control valve Replace the oil if necessary Check or replace the valve for lowering Disconnect power supply and replace the UP switch Check the micro switch in control lever and the
29. connecting cable The accumulator capacity is Check the capacity indicator the brake and insufficient or the related cables The truck travels electromagnetic brake is tight very slowly or the related cables are not well contacted The controller is damaged Replace the controller The truck starts The button controlling Reset through repair or replace it up suddenly gt department of the manufacturer and have the problems solved by specially trained technicians backward or forward is not reset If above steps still can not solve the problems please contact the after sales service 23 6 6 5 Oil and lubricant Greasing point fuel outlet Lubrication Cycle Table No Refill point Lubrication Cycle 500 h 1000 h 2000h wheel bearing Ta push rod 2 Hydraulicsystem c e J B 2 1 1 it 1 d 1 mw je le P L Lubricating C Checking O Replacing Description tables of oil and lubricant Lubricant type Lubricant Name Lubricated area Lubricant 2 Grease 2 Grease ai sleeves 40 Hydraulic Oil 30 Hydraulic Oil Hydraulic system nt 2 Grease 2 Grease Bearing grease Shaft for gear W85 90 Gear W85 90 Gear Gear box ereasing ereasing 24 7 Schematic Diagrams of Electric and Hydraulic System of WP LPL20 7 1 WP LPL20 circuit diagram Noblelift handle B KSI Main Contactor P In
30. cure MJ 74 Checktheoilleve O stje Replace ae oil and the filter element EN c 76 Check the pressure regulator valve Ele Electric amp I Checkperformance n e system 8 2 Check all cable connections for safety reliability and damages 83 Checkiftheamperageoffusesispror A P 20 8 4 Check if the switches and release cam mechanism is secure and functions properly 8 5 Check the connectors and replace worn parts if necessary 6 Checkthewamingdevice s e Motor EBECDRGM EEG 92 Check Check safety of additional devices of motor si of additional devices of motor 93 Use a vacuum to clean motor frame Check commutator for wear Accumulator Check the density of acid liquid capacity and voltage of the accumulator 10 2 Check the safety devices on terminals and the conn e oe a 10 3 Clean the connector of accumulator and check the tt em e UN Check the cable for damages replace if necessary Lubricant oil 11 1 Grease the truck according to time table for filling m lubricant General 12 1 Check the grounding connection of electric system e Test 122 Check the traveling speed and braking distance 1e 1123 Check the liting and lowering speed je 124 Check the safety device and switch off devices Trial 13 1 Perform trial run under rated oad 13 2 The
31. e lowered to their lowest Install in a reverse order position 6 5 4 Check electrical fuse Get the pallet truck ready for maintenance and repairing Open the covers 1 Consult the sheet and check whether all the fuses have appropriate rated current Change fuses if necessary FUOI Fuse for lifting 80A FU Control circuit fuse 10A 6 5 5 Use Preparation after maintenance or repairing Use the truck only after following operations have been completed Clean the truck Check the brake Check the emergency stop switch Check the horn 6 6 Storage of the truck If the pallet truck has been in storage for more than two months park it in a dry and anti freezing place Before that take all the required actions The following measures shall be adopted during and after storage 20 A During storing the truck should better be placed with the wheels off the ground for protecting the wheels and the bearings within wheels If the storage time is over six months please consult the manufacturer on additional protection measures 6 6 1 Operations before storing Clean the truck thoroughly Check the brake Check the hydraulic oil level refill if necessary Apply lubricant oil or grease to protect all parts Refill grease according to detailed lubrication cycle table Recharge the accumulator again Disconnect and clean the accumulator Apply grease on terminal p
32. ed STOP Unauthorized persons must be ordered to leave dangerous areas The driver should always give warning if there is any risk of human injury If the warned persons still stay in dangerous area the driver should stop the power pallet truck immediately STOP Use of this truck may cause crushing and shearing injuries to personnel 1 7 High risk environment Special protection measures shall be adopted in highly dangerous working environments A The truck is not designed for use in high risk environment 1 8 Safety devices and warning signs Sufficient attention should be paid to safety devices warning signs and precautions described in above sections in this manual 1 9 Driving in public places The truck is prohibited to drive in public places except for special areas 1 10 Space between vehicles Remember to keep a proper distance from the vehicle ahead since it may stop suddenly at any moment 1 11 Passengers Never carry or lift persons with this truck 1 12 Operation in a lift or loading platform If the load capacity of the lift or platform is sufficient and the space is enough for power pallet truck operation they can be used for transportation with the permission from the power pallet truck user The power pallet truck must be confirmed by its driver himself before entering the lift or loading platform When entering the lift the loads must enter ahead And locate the power pallet truck in a suitable position
33. ellerunterschrift Datum Authorized Signature Date Dec 29 2009 Angaben zum Unterzeichner Title of Signatory President Table of Contents Introduction 2222222222 42r pue aa 4e ES TS IPS eA ES 2 Guidelines for Safe Operation 2 2 Overview of the Power Pallet Truck 5 3 Transport and Trial Run 9 4 Maintenance Recharging and Replacement of the Accumulator eee 10 5 Operation eeeeee RR RR ee eee 13 6 Maintenance of the pallet truck 18 7 Schematic Diagrams of Electric and Hydraulic System Introduction Welcome to use this series of power pallet trucks This manual gives clear information on how to master safe operation of the power pallet trucks The differences between various power pallet truck are described in detail in this manual During operation and maintenance please refer to the contents corresponding to the power pallet truck types you are using The safety instructions and important precautions are indicated with the following icons l SIOE ____ This icon indicates the existence of a hazard that could result in personal injury if the safety instruction 1s not observed p A This icon indicates that a failure to observe the described instruction could lead to equipment damage u Refers to general notes and instructions before use A Most parts of the product are made from recyclable steel
34. f manufacturer 3 3 Moving the pallet truck in case of driving device failure When towing the truck without driving ability release electromagnetic brake before moving Press the emergency stop button switch off power and remove the key 10 Open the front cover and remove it Rotate the fixing screw on the electromagnetic brake of the driving motor anticlockwise until the electromagnetic brake comes off Now the pallet truck can move STOP After arriving at the destination location recover the truck to original status A When the pallet truck stops at the destination tighten the screw clockwise until braking function is recovered 4 Maintenance Recharging and Replacement of the Accumulator 4 1 Maintenance of the accumulator The pallet truck uses a maintenance free accumulator featuring simple operation 4 2 Charging of the accumulator The LPL16 pallet truck is equipped with built out charger for charging A Before connecting the accumulator for charging purpose make sure that the charger emergency stop switch and electric lock switch are off Perform charging in a well ventilated place and keep away from sources of ignition Charge idle pallet truck once a month Charge the pallet truck s accumulator frequently and regularly When the power running out lamp lights up during operation of the pallet truck charge it immediately Turn off the electric lock remove the key and press the emergenc
35. f the handle Down Switch Forward Backward Horn Button Backward button Lifting button 4 4 n ses we que de 5 2 REMA CAN Handle 1 Up down switch Moving the fork upward or downward 2 Forward Backward button Control speed and direction of the truck forward or backward 3 Reverse button Emergency reverse button 4 Horn switch 5 Signal light Indicates speed of the truck 6 High Low speed Switch button Press the switch gently for low speed function When it is pressed first time the speed is lowered and the indicator glows red indicating low speed mode When it is pressed again the truck returns to high speed mode and the indicator glows green 5 3 Starting up the truck Q The driver should always make sure that no person stayed in dangerous area of the truck before starting up and operating the unit or lifting loads 11 lt a gt STOP thas certain risks to use the truck in rainy snowy foggy and windy weather Before use in those conditions please evaluate the security Check before daily start up Check the entire unit for defects and failure especially the wheels and lifting mechanism Check if the accumulator is firmly fixed and well connected Starting up the truck Rotate and turn on the emergency stop switch Insert the key in electric lock and turn it clockwise to position I The coulombmeter shows current battery level Check the horn
36. g Cleaning Operation Flammable liquid can not be used for cleaning the truck Before cleaning take safety precautions to prevent electric sparks e g sparks caused by short circuit When operating the accumulator connectors on it must be disconnected Use soft air suction or compressed air non conductive and anti static brushes to clean electric and electronic components A If you are going to use water spray or high pressure cleaner to clean the truck all electric and electronic components must be covered carefully in advance because moisture may cause them malfunction Never use steam nozzles for cleaning Operation of Electric System Operation on the electric system should only be performed by specially trained personnel Before performing any operation on the electric system precautions must be made to prevent electric shock When operating the accumulator connectors on it must be disconnected Traction motor and hoist motor are types of short term duty Traction motor S2 60min Hoist motor S3 15 16 Welding Operation To prevent electric components from being damaged remove these electric components before welding Installation When repairing or replacing hydraulic components electric and electronic components make sure to install them back to their original positions Wheels Quality of the wheels has significant effect on stability and driving performance of the truck Modification on wheels can be performed only wi
37. g the lever should be smaller than driving in normal status In such case turn the steering wheel arm carefully to break away from the obstacle by moving forward or backward Driving on a slope AN Always keep loads face the downward slope when transport loads on a slope Take following safety measures against the rolling down With the control button in position O quickly press the handle backward The driver should release the handle as required to make the electromagnetic brake work automatically controlling the speed and direction if the driver find the truck is rolling down lt a gt STOP end In case the truck is rolling over the operator should get away from the truck right away Braking The braking performance of the truck depends on floor condition The driver must be clear about this point Three braking methods are available Electromagnetic brake control handle Use reverse current brake from the controller Brake with the sensor i e release the lever to brake Braking with the Electromagnetic Brake In case of an emergency always stop the truck only with electromagnetic brake control lever 16 Turn up or down the control handle to braking range B1 or B2 the drive motor will be stopped mechanically When the control handle is released it will enter the upper braking range B1 automatically After the truck is stopped the electromagnetic brake works as parking brake Braki
38. he accumulator Apply grease on terminal poles on accumulator Besides these the accumulator must be protected according to special requirements stated in accumulator instruction manual 6 6 2 Cautions during storage Every one months Recharge the accumulator A Operations related to accumulator lt is very important to recharge the accumulator periodically Otherwise the accumulator will self discharge resulting complete loss of capacity and the accumulator may become worn out thoroughly 6 6 3 Trial Run Again Clean the truck thoroughly Refill grease according to lubrication cycle table Clean the accumulator apply pole lubricant on the terminal poles and reconnect the conneciors Recharge the accumulator again Check if there is moisture in gearbox oil If so replace gearbox oil Check if there is moisture in hydraulic oil If so replace hydraulic oil 23 Start up the truck contact detergent spray and repeat this operation to remove oxide layer on these connectors If the switches in electric system do not contact well clean all exposed connectors with STOP Perform several electromagnetic brake tests immediately after trial run again 6 6 4 Determination of faults This chapter provides a guide to users on finding out and solving simple faults of the pallet truck The following table introduces faults determination and solving methods Fal Cause Countermeasures
39. he electric lock and remove the key to prevent unauthorized operation for a long time before recharging Please disconnect the wires linked to batteries if the power pallet truck will not be used 1 22 Signalling Warning signals can be sent by the horn on the truck 1 23 Protection shoes According to EU standard EN 345 1 S1 standard protective shoes must be worn when operating on the power pallet truck 1 24 Attaching device Attaching device or equipment that may interfere with or complement the pallet truck s functions can only be installed with the written approval of the manufacturer If necessary permission from local authorities shall be obtained Revision of the attaching devices without approval may affect the stability and rated load of the pallet truck 1 25 Truck modification Unauthorized truck modification is not permitted No modifications or alterations to a powered industrial truck which may affect for example capacity stability or safety requirements of the truck shall be made without the prior written approval of the original truck manufacturer its authorized representative or a successor thereof This includes changes affecting for example braking steering visibility and the addition of removable attachments When the manufacturer or its successor approve a modification or alteration they shall also make and approve appropriate changes to capacity plate decals tags and operation and maintenance handbooks On
40. icient attention should be paid to safety devices warning signs and precautions described in above sections in this manual 1 9 Driving in public places The truck is prohibited to drive in public places except for special areas 1 10 Space between vehicles Remember to keep a proper distance from the vehicle ahead since it may stop suddenly at any moment 1 11 Passengers Never carry or lift persons with this truck 1 12 Operation in a lift or loading platform If the load capacity of the lift or platform is sufficient and the space is enough for power pallet truck operation they can be used for transportation with the permission from the power pallet truck user The power pallet truck must be confirmed by its driver himself before entering the lift or loading platform When entering the lift the loads must enter ahead And locate the power pallet truck in a suitable position to prevent from contacting walls around If passengers take the lift together with the power pallet truck they have to enter after the power pallet truck enters and stops firmly and leave before the power pallet truck 1 13 Pallet truck handling in narrow passageways and work areas under the particular circumstances that the pallet truck has to pass through a narrow passageway unauthorized personnel must leave the work area and heavy loads must be kept in specially prepared equipment 1 14 Operation Management Driving speeds must be suitable to local conditions Alw
41. ing the truck without driving ability release electromagnetic brake before moving Press the emergency stop button switch off power and remove the key Open the front cover and remove it Rotate the fixing screw on the electromagnetic brake of the driving motor anticlockwise until the electromagnetic brake comes off Now the pallet truck can move lt a gt STOP After arriving at the destination location recover the truck to original status A When the pallet truck stops at the destination tighten the screw clockwise until braking function is recovered 4 Maintenance Recharging and Replacement of the Accumulator 4 1 Maintenance of the accumulator The pallet truck uses a maintenance free accumulator featuring simple operation 4 2 Charging of the accumulator WP LPL20 is equiped with special built out charger A Before connecting the accumulator for charging purpose make sure that the charger emergency stop switch and electric lock switch are off Perform charging in a well ventilated place and keep away from sources of ignition Charge idle pallet truck once a month Charge the pallet truck s accumulator frequently and regularly When the power running out lamp lights up during operation of the pallet truck charge it immediately STOP Hydrogen will be precipitated in the charging process So the accumulator room should be well ventilated and the hydrogen content shall be strictly controlled t
42. iving in normal status In such case turn the steering wheel arm carefully to break away from the obstacle by moving forward or backward Driving on a slope N Always keep loads face the downward slope when transport loads on a slope STOP In case the truck is rolling over the operator should get away from the truck right away Take following safety measures against the rolling down With the control button in position 0 quickly press the handle backward The driver should release the handle as required to make the electromagnetic brake work automatically controlling the speed and direction if the driver find the truck is rolling down 5 T Braking The braking performance of the truck depends on floor condition The driver must be clear about this point Three braking methods are available Electromagnetic brake control handle Use reverse current brake from the controller Brake with the sensor i e release the lever to brake Braking with the Electromagnetic Brake In case of an emergency always stop the truck only with electromagnetic brake control lever Turn up or down the control handle to braking range B1 or B2 the drive motor will be stopped mechanically When the control handle is released it will enter the upper braking range B1 automatically After the truck is stopped the electromagnetic brake works as parking brake Braking with reverse current brake If
43. lean and antiskid Drive safely on the slopes and ramps specified in the technical specification Instruction manual of the pallet truck Loads on the fork must face the upslope direction U type turning or parking on slopes or ramps are not allowed Pass a ramp at lower speed and get ready for braking at any time 1 17 Load capacity of the floor Check if the weight of truck and loads or wheel pressure on the floor exceeds the load capacity of the floor 1 18 The fork should be kept in the lowest position from the floor during non transportation driving Standing or sitting pallet truck It is better to driver in reverse direction of the fork to get good vision and mobility Driving with the fork forward may cause unpredictable mobility problems 1 19 Load characteristic Goods must be carried in a correct safe and reliable way Never carry loads piled higher than the pallet truck s top or protective devices 1 20 Driving on loading platform or approach bridge Before driving the truck onto loading platform or approach bridge of a truck make sure to check load capacity of the approach bridge and if it is equipped with anti sliding devices The driver must also check load capacity of the truck and if there are devices to prevent the truck from moving 1 21 Safe Parking Pay attention to safety when parking the truck Never park the truck on a slope or on a ramp The fork must be lowered down to the lowest position after parking Turn off t
44. llet truck A Recharge timely after power is running out otherwise damage may be caused to the accumulator W STOP The batteries should be recharged in well ventilated areas The wartering cap of the battery for each unit must be opened Make sure no metal objects placed on the accumulator Check all cables connection and connectors for obvious defects Observe strictly all safety instructions e g replenishment of the accumulator and preparation for recharging 4 2 1 Balanced Recharging After using for a period voltage and concentration may vary from battery to battery Balanced recharging will eliminate the differences so that the performance of each cell becomes uniformed In following cases balanced recharging is necessary Voltage of an individual cell is frequently below 1 7V The set of cells with heavy duty For example Set of cells for starter motor and lifting motor for accumulators that are not recharged in time after discharging Over discharged accumulators and those are not in use for a long time Perform balanced recharging as follows A Recharge with a current of 0 115A B When the voltage up to 2 5V and there occur bubbles in the electrolyte continue recharging at a reduced current of 0 0515A 12 C Recharge the accumulator to full capacity and stop recharging for half an hour and then continue recharging with further reduced current of 0 025I5A for an hour D Stop recharging again for half an hou
45. ly in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck provided however that the user shall a arrange for the modification or alteration to be designed tested and implemented by an engineer s expert in industrial trucks and their safety b maintain a permanent record of the design test s and implementation of the modification or alteration c approve and make appropriate changes to the capacity plate s decals tags and instruction handbook d affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration and the name and address of the organisation that accomplished the tasks a AN Failure to comply with these instructions will invalidate the guarantee The guarantee is also invalidated if the hand operated scissor lift pallet trucks are exported by the customer or a third party illegally without the consent of Noblelift 2 Overview of the Power Pallet Truck 2 1 Main uses and application scope The LPL16 Power Pallet Truck is specially designed for conveying goods on flat roads With its compact structure the LPL16 Power Pallet Truck is particularly suitable for use in factories plants wharfs and small warehouses It can also be used for handling goods
46. ly with the approval from the manufacturer When replacing wheels ensure that the truck is levelled as delivery state wheels must be replaced in pairs i e replace right wheel together with left one During the use of the steering wheels n case that the handle can be tightened or the two wheels will be not parallel Please take off the steering wheels and add proper adjusting washer Item code 1000404031 1000404032 In this way the truck can recover for use Lifting chain It will soon wear out without lubrication oil The time interval in the maintenance manual is applicable to normal use In bad operating condition dust temperature lubrication oil is needed frequently Hydraulic tubing tubing must be replaced once every six years Change tubing of hydraulic system when replacing hydraulic components 6 3 Maintenance and checking It is very important for safe operation of the truck to perform overall professional maintenance Failure in performing maintenance according to specified interval may cause malfunction of the truck and potential risk to human and equipment AN Maintenance periods listed in this manual apply to single shift a day under normal operation conditions If using in dusty environment the ambient temperature varies remarkably or in multi shift situation the maintenance period has to be shortened Maintain the truck according to following maintenance list Maintenance periods are as follows W1 Every
47. n frame are lowered to their lowest position a B 6 5 4 Check electrical fuse m Get the pallet truck ready for maintenance and repairing Open the front cover board 1 Consult the sheet and check whether all the fuses have appropriate rated current Change fuses if necessary FUI Control fuse for traveling 10A FUOI Lifting fuse 80A 6 5 5 Use Preparation after maintenance or repairing Use the truck only after following operations have been completed Clean the truck 22 Check the brake Check the emergency stop switch Check the horn 6 6 Storage of the truck If the pallet truck has been in storage for more than two months park it in a dry and anti freezing place Before that take all the required actions The following measures shall be adopted during and after storage A During storing the truck should better be placed with the wheels off the ground for protecting the wheels and the bearings within wheels If the storage time is over six months please consult the manufacturer on additional protection measures 6 6 1 Operations before storing Clean the truck thoroughly Check the brake Check the hydraulic oil level refill if necessary Apply lubricant oil or grease to protect all parts Refill grease according to detailed lubrication cycle table Recharge the accumulator again Disconnect and clean t
48. ng with reverse current brake A If the control system or driving power fails braking with reverse current is possible urn controller in reversed direction of driving until the truck stops Release the controller Braking by the inertia When the controller is released it returns to position O and brakes by inertia of the motor The slowing down rate depends on the position of controller If the controller position is set to 0 and the inertia braking unit is removed by service technician you have to use electromagnetic brake or reverse current brake to brake the truck 5 4 2 Operation of lifting and lowering loads EN Before lifting loads the driver must check if the loads are placed on the pallet completely and the weight of loads does not exceed the loading capacity Do not transport in full load status for a long time Make sure the fork reach under the loads as far as possible When operate with Up or Down button the fork will move upward or downward at a fixed speed Lifting of the fork Press the Up Switch until the fork arrives at required height Lowering of the Fork Press Down Switch until the fork is lowered to required height Safe Parking Pay attention to safety when parking the truck Never park the truck on a slope or on a ramp The fork must to be lowered to its lowest position after parking Lower the fork Turn electric lock from position 1 to 0 and
49. ntensely and instantly when switching on the charger 9 A Perform balanced recharging to accumulator once a month in normal use 4 3 Capacity indicator of the accumulator Capacity indicator of the accumulator The status of accumulator discharging is indicated on the indicator with 10 bar graphs each bar represents 10 percent of increment As the consumption of accumulator capacity the lighting bars will fall down from the top Preset Warning marks will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of the standard accumulator is 30 percent Warning mark will appear and you can recharge the accumulator Preset Warning mark and a flashing Stop mark will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of standard accumulator is 20 Stop mark will appear and keep lighting When the Stop mark keeps lighting lifting function of the truck will be cut off automatically Capacity sufficient Recharging needed Low battery IN function can only be performed after recharging the accumulator to at least 70 of capacity If the indicator shows low battery when lifting loads for a not very long period lifting 4 4 Specifications of accumulator and charger Rated Voltage V Rated Capacity Input AC115 230V Output DC24V 30A 24 Ah 210 50 60Hz 10 5 Operation 5 1 Schematic diagram o
50. o ensure safety STOP To ensure safe operation install the accumulator shield before using the pallet truck Turn off the electric lock remove the key and press the emergency stop button before charging During charging the environment should be dry well ventilated and away from the flames WP LPL20 with external charger the charging process is as following Press the emergency stop switch so that the truck is in the off position Open the battery box cover Pull out the vehicle battery connector plug Now open all the water plug caps on the battery Connect the output plug of the charger and battery input plug and then turn on the battery charger switch If the truck or the battery stay idle for a long time it is necessary to charge the battery at least once a month The WP LPE20 uses an automatic smart charger After the plug on the charger is connected with power the charging lamp flashes red The charger can automatically adjust current flow according to the residual capacity in the accumulator to achieve best charging state After the accumulator is fully charged the charging indicator flashes green and the charger automatically stops charging and turns off the power The accumulator needs about 7 8 hours to be fully charged lt a gt STOF Close the cover of battery completely before operating the truck A Recharge timely after power is running out otherwise damage may be caused to the
51. oles on accumulator Besides these the accumulator must be protected according to special requirements stated in accumulator instruction manual 6 6 2 Cautions during storage Every one months Recharge the accumulator A Operations related to accumulator It is very important to recharge the accumulator periodically Otherwise the accumulator will self discharge resulting complete loss of capacity and the accumulator may become worn out thoroughly 6 6 3 Trial Run Again Clean the truck thoroughly Refill grease according to lubrication cycle table Clean the accumulator apply pole lubricant on the terminal poles and reconnect the connectors Recharge the accumulator again Check if there is moisture in gearbox oil If so replace gearbox oil Check if there is moisture in hydraulic oil If so replace hydraulic oil Start up the truck If the switches in electric system do not contact well clean all exposed connectors with contact detergent spray and repeat this operation to remove oxide layer on these connectors STOP Perform several electromagnetic brake tests immediately after trial run again 21 6 6 4 Determination of faults This chapter provides a guide to users on finding out and solving simple faults of the pallet truck The following table introduces faults determination and solving methods Fal Cause Countermeasures The pallet truck can not move Loads
52. or sitting pallet truck It is better to driver in reverse direction of the fork to get good vision and mobility Driving with the fork forward may cause unpredictable mobility problems 1 19 Load characteristic Goods must be carried in a correct safe and reliable way Never carry loads piled higher than the pallet truck s top or protective devices 1 20 Driving on loading platform or approach bridge Before driving the truck onto loading platform or approach bridge of a truck make sure to check load capacity of the approach bridge and if it is equipped with anti sliding devices The driver must also check load capacity of the truck and if there are devices to prevent the truck from moving 1 21 Safe Parking Pay attention to safety when parking the truck Never park the truck on a slope or on a ramp The fork must be lowered down to the lowest position after parking Turn off the electric lock and remove the key to prevent unauthorized operation for a long time before recharging Please disconnect the wires linked to batteries if the power pallet truck will not be used 1 22 Signalling Warning signals can be sent by the horn on the truck 1 23 Protection shoes According to EU standard EN 345 1 S1 standard protective shoes must be worn when operating on the power pallet truck 1 24 Attaching device Attaching device or equipment that may interfere with or complement the pallet truck s functions can only be installed with the wri
53. ove the key 15 6 Maintenance of the pallet truck 6 1 Safety operation and environment protection The checking and maintenance work described in this chapter should be executed according to the time intervals in the maintenance list STOP Never modify any parts especially safety devices of the truck without permission Never change the operation speeds of the truck All spare parts provided by original manufacturer are strictly tested Only use spare parts from the manufacturer for the guarantee of the safety and reliability of truck operation The replaced material including oil should be collected and disposed of according to local environment protection and health regulations 6 2 Safety rules applicable to the maintenance of the pallet truck Maintenance technician The maintenance and service should only be performed by special personnel trained by the manufacturer After the technician sent by after sales department of the manufacturer completed maintenance and servicing work they should sign on the service log Lifting of the truck When the truck needs to be raised up for repair the lifting device must be safe and reliable and must be strictly fixed to hook holes When the truck is raised up proper measures such as using wedges and wooden blocks must be applied to prevent the truck from sliding down or tilting over Only when the fork is fixed and connected with strong enough ropes can a hoisting device be used for liftin
54. r and continue recharging with a current of 0 02515A for an hour E Repeat step D until bubbles occurs intensely and instantly when switching on the charger Perform balanced recharging to accumulator once a month in normal use 4 3 Capacity indicator of the accumulator Capacity indicator of the accumulator The status of accumulator discharging is indicated on the indicator with 10 bar graphs each bar represents 10 percent of increment As the consumption of accumulator capacity the lighting bars will fall down from the top Preset Warning marks will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of the standard accumulator is 30 percent Warning mark will appear and you can recharge the accumulator Preset Warning mark and a flashing Stop mark will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of standard accumulator is 2096 Stop mark will appear and keep lighting When the Stop mark keeps lighting lifting function of the truck will be cut off automatically Capacity sufficient Recharging needed Low battery function can only be performed after recharging the accumulator to at least 70 of capacity If the indicator shows low battery when lifting loads for a not very long period lifting 4 4 Specifications of accumulator and charger Rated Voltage V Rated Capacity Input AC115 230V Output DC2
55. roduct improvement Noblelift reserves the right to make changes please feel free to contact us Note All parameters provided herein are as of the publication date of the Instruction Manual 1 Guidelines for Safe Operation 1 1 Requirements for the driver The power pallet truck should only be operated by personnel trained in operating the power pallet truck who can show to the user how to move and handle loads and instruct the user how to operate the power pallet truck 1 2 The right duty and responsibility of driver Clear with his own right and duty the driver should be trained in operating the power pallet truck and also knows the contents in this operation manual very well If the power pallet truck in use is controlled on foot the driver should wear safety boots during operation 1 3 Unauthorized persons are prohibited to use The driver is responsible for managing the power pallet truck in use and must prevent any unauthorized person from driving or operating the power pallet truck 1 4 Malfunction and Defects In case malfunction or defects occurs with the power pallet truck the driver should immediately inform the supervisor If the power pallet truck can not be operated safely e g with worn wheels and brake malfunction always stop using it until repaired completely 1 5 Safety operation and environment protection The checking and maintenance work described in this chapter should be executed according to the time interv
56. ry 50 work hours but at least once a week M3 Every 500 work hours but at least once every three months M6 Every 1000 work hours but at least once every six months M12 Every 2000 work hours but at least once every 12 months Additional operations should be performed in trial run period In initial 50 100 working hours or after two months Check the nuts on the wheels and tighten them if necessary 17 Check the hydraulic components for leakage and tighten them if necessary Replace the hydraulic filter 6 4 Maintenance list of WP LPL20 Time interval of maintenance Chassis Oe I lei B er 22 Check oillevelindrive system e 25 Replace ubican o ee 3 2 Check the bearings and make sure they fit well with BER mel Steering 4 1 Check the steering control i NEUEN Braking Check the performance and adjust accordingly le l system 5 2 Check reset function of the air spring and check for leakage and damages S3 Check the brake aisktorwean e 5 4 Check the connection of brake and adjust if ial bs NEUEN Lifting 6 1 Check performance and wear and adjust Mechanism ial accordingly I 6 2 Visually inspect the loading wheels for blockage a RL DIN 6 3 Check fork tips and pallet support for wear and ae Hydraulic 7 1 Check performance Checkpefomace 1 1 1 8 e system 7 2 Check all connections for leakage and damages ld uiam d id O O 7
57. sted pair HA vo 12 6 Brake p 2 2 2 3 Names of electrical components of WP LPL20 are listed in the following sheet DEG INE IRINMMIMNE positive pole of I 16 KM Lift tact EC DEAN hib i 17 solenoid valve Accumulator Eat a a 9 9 6 8 Hamde 20 VD ooe HIR e TET Tum St kik Key switch paaa eaa a DA ae 141 3 O 12 S5 Hombunen 26 X Connector L1 99 emergency ston 27 K Ry o L d nn Protective module 26 7 3 LPL20 22 Schematic diagram of hydraulic system E 050X120 EN E E p 24V D C 7 3 ct 50 160b Silke 0 8KW 24V 27
58. te s decals tags and instruction handbook d affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration and the name and address of the organization that accomplished the tasks AN Failure to comply with these instructions will invalidate the guarantee The guarantee is also invalidated if the hand operated scissor lift pallet trucks are exported by the customer or a third party illegally without the consent of Noblelift 2 Overview of the Power Pallet Truck 2 1 Main uses and application scope WP LPL20 Power Pallet Truck is specially designed for conveying goods on flat roads With its compact structure the WP LPL20 Power Pallet Truck is particularly suitable for use in factories plants wharfs and small warehouses It can also be used for handling goods on freight wagons Its carrying capacity is indicated on the nameplate label 2 2 Technical features 2 2 1 Outline drawing and technical parameters 3 1 2 Type No WP LPT20 Power electric diesel gasoline liquefied petroleum gas Bene 1 4 Driving mode hand pedestrian stand on sit down unit pick Pedestrian 16 Load centredistance Co m 80 3 1 _ Tres rubber wheels high performance elastomer polyurethane polyurethane wheels 32 34 Dmensonofsterngwhel oowoo 3 5 Wheel numbers X driving wheel Drive sidello
59. terlock 22 ua By Tag Me MIND reverse J 14 Iy versa __ gp FP avi ia as we i KGN 12 Forward _ T LES Sa 15a i I Emg Reverse Bee H JAS an e 15 2 Throttle Wiper pq Lh cse c i OBEREN ur I ce v CURTIS 1 5 Kn W 5 5 W 4 ra RD 42 1 MS 2402 S et 8 16 Lower F Be dee Enc A VD bi E 80 24 Enep eee el ss 14 Mm BK J2 5 Ene Ground eee HAL gt ay aes 42 3 vD YB Brake Return fo 3 PL J2 6 Brake 2 6 KMp KDE S2 Lift B VD 11 1 11 m E 24 25 7 2 WP LPL20 circuit diagram REMA CAN handle Jiz P 8716 5 1 432 5 MA RTH CAN vo FU1 TM E jig REMARTH CA t9 24 CJ 2 7 24V FT KM Fs zn PI 2 4 GND SA CJ 2 5 Belly N O FUO2 Et Ley Hei 22 CAN HI lt pop peg 0 2 1 CAN LO Bu ksi ot aad GND IYE T twisted pair Mode Interlock LEE 29V BN 5 19 11 14 GN T2 Emg Reverse __ 8 Ten ri N 2 B 5 3 5 5 0 5 6 Mt CURTIS LS i 1230C 2405 MM KL owl e qW Main Contactor ns Mp wel ee J1 23 WH J J1 16 E 2 Enc A Output 1 H 2 E 80124 Ence PWM output 2 BK 32 5 CAN HI 1 11 5 8 1 Enc Ground 4 183 C pne CAN BUS t 194 J1 12 YB 7 Brake Return twi
60. th the approval from the manufacturer When replacing wheels ensure that the truck is levelled as delivery state wheels must be replaced in pairs i e replace right wheel together with left one will be not parallel Please take off the steering wheels and add proper adjusting washer Item code During the use of the steering wheels in case that the handle can be tightened or the two wheels 1000404031 1000404032 In this way the truck can recover for use Lifting chain It will soon wear out without lubrication oil The time interval in the maintenance manual is applicable to normal use In bad operating condition dust temperature lubrication oil is needed frequently Hydraulic tubing tubing must be replaced once every six years Change tubing of hydraulic system when replacing hydraulic components 6 3 Maintenance and checking It is very important for safe operation of the truck to perform overall professional maintenance Failure in performing maintenance according to specified interval may cause malfunction of the truck and potential risk to human and equipment AN Maintenance periods listed in this manual apply to single shift a day under normal operation conditions If using in dusty environment the ambient temperature varies remarkably or in multi shift situation the maintenance period has to be shortened Maintain the truck according to following maintenance list Maintenance periods are as follows W1 Eve
61. the control system or driving power fails braking with reverse current is possible Turn controller in reversed direction of driving until the truck stops Release the controller 14 Braking by the inertia When the controller is released it returns to position 0 and brakes by inertia of the motor The slowing down rate depends on the position of controller If the controller position is set to 0 and the inertia braking unit is removed by service technician you have to use electromagnetic brake or reverse current brake to brake the truck 5 4 2 Operation of lifting and lowering loads A Before lifting loads the driver must check if the loads are placed on the pallet completely and the weight of loads does not exceed the loading capacity Do not transport in full load status for a long time Make sure the fork reach under the loads as far as possible When operate with Up or Down button the fork will move upward or downward at a fixed speed Lifting of the fork Press the Up Switch until the fork arrives at required height Lowering of the Fork Press Down Switch until the fork is lowered to required height Safe Parking STOP Pay attention to safety when parking the truck Never park the truck on a slope or on a ramp The fork must to be lowered to its lowest position after parking Lower the fork Turn electric lock from position 1 to 0 and rem
62. tlinien entspricht that the following machine complies with the appropriate basic safety and health requirements of the EC Directive based on its design and type as brought into circulation by us Bei einer nicht mit uns abgestimmten nderung der Maschine verliert diese Erkl rung ihre G ltigkeit In case of alteration of the machine not agreed upon by us this declaration will lose its validity Bezeichnung der Maschine Elektrohubwagen Machine Description Power Pallet Truck Maschinentyp Machine Type WP LPL20 Einschl gige EG Richtlinien EG Maschinenrichtlinie 2006 42 EC Applicable EC Directives EC Machinery Directive 2006 42 EC Angewandte harmonisierte Normen insbesondere Applicable Harmonized Standards EN 1726 1998 EN1175 1 1998 Herstellerunterschrift Datum Authorized Signature Date Dec 29 2009 Angaben zum Unterzeichner Title of Signatory President Table of Contents Introduction eeee fate AE ME 1 Guidelines for Safe Operation sesssse 2 2 Overview of the Power Pallet Truck 3 3 Transport and Trial Run ccccccceceeeeeeeeeeeeeeeeeeeseeeeeees T 4 Maintenance Recharging and Replacement of the Accumulator eee 8 5 Operation nennen nennen nennen nenne nenne nenne 11 6 Maintenance of the pallet truck 16 7 Greasing and lubricant
63. to prevent from contacting walls around If passengers take the lift together with the power pallet truck they have to enter after the power pallet truck enters and stops firmly and leave before the power pallet truck 1 13 Pallet truck handling in narrow passageways and work areas under the particular circumstances that the pallet truck has to pass through a narrow passageway unauthorized personnel must leave the work area and heavy loads must be kept in specially prepared equipment 1 14 Operation Management Driving speeds must be suitable to local conditions Always drive in lower speed when passing curved passageways narrow passageways rotary doors or any obstructed places The driver should be able to measure by sight and keep enough stopping space from vehicles ahead all the time It is prohibited to make an abrupt stop unless in emergency rapid U turn and chase with each other in obstructed places Never operate the truck with the body stretching out of it 1 15 Visibility The driver must keep his eyes on moving direction and have a clear view of the road ahead In case the loads carried block sight of the driver the truck has to be driven reversely If this is not practical another person should walk in front of the truck giving corresponding guidance and warning to the driver 1 16 Driving on slopes and ramps when driving the pallet truck on a slope or ramp through an allowable narrow passageway make sure that the ground is c
64. tten approval of the manufacturer If necessary permission from local authorities shall be obtained Revision of the attaching devices without approval may affect the stability and rated load of the pallet truck 1 25 Truck modification Unauthorized truck modification is not permitted No modifications or alterations to a powered industrial truck which may affect for example capacity stability or safety requirements of the truck shall be made without the prior written approval of the original truck manufacturer its authorized representative or a successor thereof This includes changes affecting for example braking steering visibility and the addition of removable attachments When the manufacturer or its successor approve a modification or alteration they shall also make and approve appropriate changes to capacity plate decals tags and operation and maintenance handbooks Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck provided however that the user shall a arrange for the modification or alteration to be designed tested and implemented by an engineer s expert in industrial trucks and their safety b maintain a permanent record of the design test s and implementation of the modification or alteration C approve and make appropriate changes to the capacity pla
65. y stop button before charging Perform charging in a well ventilated place and keep away from sources of ignition lt a gt STOP Hydrogen will be precipitated in the charging process So the accumulator room should be well ventilated and the hydrogen content shall be strictly controlled to ensure safety W STOP To ensure safe operation install the accumulator shield before using the pallet truck LPL16 is equipped with the built out charger t should be charged as below Press the emergency switch and leave it off position open the battery cover 11 Take out the plug of the battery Now you can open all of the cover of the filler on the battery Connect the plugs of output and input on the charger and open the switch forbatterycharger If the truck or the battery stay idle for a long time it is necessary to charge the battery at least once a month The LPL16 uses an automatic smart charger After the plug on the charger is connected with power the charging lamp flashes red The charger can automatically adjust current flow according to the residual capacity in the accumulator to achieve best charging state After the accumulator is fully charged the charging indicator flashes green and the charger automatically stops charging and turns off the power The accumulator needs about 7 8 hours to be fully charged lt a gt TOP Shut the cover of the accumulator box before operating the pa

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