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

Contents

1. 1 Fork frame 2 Outter main frame 3 Composite roller of outer frame 4 Inner main frame 5 Inner frame and composite roller of fork frame Figure 2 55 Roller position Note a adjust the clearance of side rollers at 0 5mm b Apply lubricant oil onto the main roller surface and the contact surface of main frame 7 5 Maintenance and adjustment 7 5 1 Regulating the lifting cylinder See Figure 2 56 After disassembling or replacing the lifting cylinder inner main frame or outer main frame re adjust the lifting cylinder stroke Adjustment method is as follows 1 Mount the piston rod without adjusting pad onto the beams of inner main frame 2 Slowly lift the main frame to its maximum extent of stretching and check the synchronization of two cylinders 3 Add the adjustment pad between the piston rod head of the cylinder and the beam on the inner main frame Thickness of the pad is 0 2mm or 0 5mm 4 Adjust the tightness of the chain 1 Upper beam on the inner main frame 2 Adjustment pad of lifting cylinder 3 Lifting cylinder Figure 2 56 Regulation of the lifting cylinder 7 5 2 Height adjustment of the fork frame Figure 2 57 1 Park the forklift on level ground and set the main frame vertical 2 Lower the fork bottom to make it reach the ground Then adjust the adjusting nuts on the upper end joint of the chains so that there will be a certain distance A be
2. 9 Standing under the fork and on the lifting fork are forbidden 10 The initial velocity should not be too fast when lifting and lowering goods 11 Never operate the forklift and accessories at places other than the driver s seat 12 When the main frame is moving forwards and backwards to the maximum extent or when the fork is lifted to its maximum height the operator must rapidly set the lever to the neutral position 13 When the main frame is lifting driving or turning of the forklift is not allowed 14 When driving the forklift drivers should pay attention to pedestrians road obstacles and potholes and also note the gap above the forklift 15 Drivers should be very careful when driving on ramps When driving on a ramp with slope gradient more than one tenth do move forward for up hilling and backward for down hilling Never perform steering during up hilling ad down hilling process And avoid loading and unloading when the forklift is down hilling 16 Slow down when steering on wet or slippery road surfaces be very careful and drive slowly when driving on docks or temporary boards 17 For forklifts with lifting height greater than 3 meters users shall be careful to guard against falling down of the goods overhead and take protective measures if necessary 18 Do not carry unfixed or loosely stacked goods and be careful when handling goods with large size 19 When driving the forklift with load emergency braking
3. The maximum stability can be ensured under the following operating status 1 The ground is flat and solid 2 Operate under standard no load or load Standard no load status fork or carrying accessories are 30cm away from the ground and the main frame can tilt backwards to the specified position without load Standard load status fork or carrying accessories are 30cm away from the ground allowable load capacity is carried at the standard load centre and the main frame can tilt backwards to the specified position 48 S when loading and unloading goods try to minimize the tilting degree when tilting forwards and backwards Never tilt forwards unless the load is close to or fixed by steel shelves or the lifting height is low 5 Transportation and handling of the forklift 1 Forklift transportation e When transporting with a truck stabilize the wheels and fix the forklift with ropes so that the forklift won t slide within the truck e During handling and road transportation the full length full width and full height of the forklift shall be in compliance with relevant laws and regulations 2 Loading and unloading of the forklift AM Use a slab with sufficient length width and intensity e Pull the parking brake in an effective and efficient way to stop the wheels e The slab shall be stably fixed to the truck centre and there shall be no oil and grease on the slab e The height at the left and right side of the slab shall
4. 45 3 Apply the hand brake and put pads under the rear wheels 4 Remove the lifting cylinder and the mounting bolts of inner main frame Lift the inner main frame and be careful not to loose the adjustment pad at head of the piston rod 5 Remove the connecting bolts on the lifting cylinder and at the bottom of the outer main frame and then remove the lifting cylinder and the tubing between the two cylinders without loosening the pipe joints 6 Lower the inner main frame and remove the main roller at the bottom of the inner main frame The main roller at the upper end of the outer main frame will be exposed out of the inner main frame top 7 Replace the main roller a Remove the main roller at the upper end with drawing tools and keep the adjustment pads appropriately b Install the new roller and the adjustment pads removed at the a step 8 Lift the inner main frame until all the rollers enter the main frame 9 Mount the lifting cylinder and the fork frame in reverse procedures of removing 7 6 Installation instruction of accessories A If you need to install accessories please contact our sales department and never install by yourselves 8 Removal and installation 8 1 Precautions 1 Only qualified operator can remove or repair the forkliftis parts 2 Before disassembling and detection operations park the forklift on a flat ground and wedge the wheels otherwise accidental movement of the forklift may occur Me
5. 65 SS O 2 4 4 During turning please slow down and Use the appropriate pallets or sleeper blow horns if you can t see the roads clearly when handling small objects in A TAE y T F If the loaded cargo is too high and blocks Obey the traffic rules and all warnings and signs your eyesight drive reversely or under the guidance of other people 66 When carrying load move uphill facing the ramp During up hilling process pay attention to and move down hilling by driving in reverse steep ramp and the lifting height of the goods When carrying no load move uphill by driving in reverse the ramp and move downhill facing the ramp 7 Avoid collision with people or objects Keep clear of other persons during working during turning of the forklift 67 Ah WARNING High speed during turning will cause Pedestrians are forbidden within workingoverturning due to unstable centre of gravity area of the forklift Changes in the rated capacity of the forklift val pay attention to the areas around should be noted wi en driving the forklift Please do not move the forklift when there are No one shall walk or stand below the people standing in front of it elevated fork 68 Goods have not been loaded from the forklift Do not carry damaged goods cases by shall not be handled your shoulders EN Be careful when loading the goods onto cars Never carry p
6. CE FE3R16AC SMS 001 NOBUEr N 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 FE3R16AC SERIES Battery Counterbalanced Forklift Truck ZheJiang Noblelift Equipment Joint Stock Co Ltd Table of Contents Igo leo AA O PE e EOI A 4 Chapter 1 Precautions of using forklift o oocoococccccoccnncccnnncccnnconnnnnarnnnna anno 5 Lc Forklift tansportatiON sensisse eean d 5 I Forklift storage cccooooccccccconcnncccnoncnnnnononnnnonononcnnnnonnnonnnnnnnnnnnnnnnnrnnnnnnnrnnnnonnnnrnnnnnnnnenenons 5 LU Presuse DSP ARAN ON rn iia cididncias 5 WV Operation of the Olla a e ar 5 V Charging of accumulator CellS ooocccccccccncnnnccnonnnnnncnnnnnnnnnnaconcnnonanonnnnnnnonnnonnnnonss 6 Chapter 2 Structure and main performance parameters of the forklift 7 I Overall Dimension and Technical Parameters ccccseecccceeeceeeeseceeseeeeeseeeeeeeeeeeeaeees 7 1 Overal dimensi sissies cscs cet estecsiaveiewrasssies enc vusade wee sess d 7 2 Technical Parameters ccccccccscccseeccseeceeeecececueccceeecaueceaeesseeseueeeaeecueeseeesueesaeessesenaees 8 II Structure principle and adjustment of the main Components ccccceeeeeeeeeeeeeeees 9 1 Driving amp Operation sccabsictcsvatecedeceeee
7. wheel is heavy Positioning spring is broken or lacks Replace the spring elasticity The inner leakage of steering cylinder is too Check the piston seal large The forklift moves unsteadily or in The spring is broken or lose elasticity Replace a snake like manner the forklift is working The inlet tube or filter is blocked Replace or clean it Guide sleeve seal of the steering cylinder is Oil leakage damaged or the joint or pipelines are Replace damaged 4 Electric system 4 1 Overview The electrical system mainly includes accumulator cells traction motor pump motor traction motor controller pump motor controller combination control switch instrumentation and lighting devices 23 iow n ld Hi i Emi t Do E A mua Hiu Ml E Ge iar H nj en ad i itd ag p Mi 3 4 2 Electronic system The forklifts AC frequency conversion traction motor AC frequency conversion steering motor controller dashboard display AC drives are all products from the Italian ZAPI Company the world s leading supplier of electric vehicle systems The AC frequency conversion motor is efficient durable and essentially maintenance free As it does not contain any commutator seen in DC motors acceleration is faster commutator limits acceleration and even limits braking torque during high speed driving The controller is one universally used in electric vehicles that communicate via CANopen p
8. C If the electrolyte level reduces after standing down you should add electrolyte to it original level Sulfuric acid electrolyte shall be prepared by mixing the accumulator acid and distilled water according to national standard GB4554 84 never use industrial sulfuric acid and tap water A During preparation please slowly fill the concentrated sulfuric acid into the distilled water by trickle and continuously stir with a acid proof glass rod or with a lead covered wood stick Filling of distilled water into the sulfuric acid is not allowed otherwise it will cause boiling and splashing of solution resulting in burning Connect the accumulator with the charger correctly in terms of polarity in a reliable manner namely ensure ro connect positive to positive and negative to negative For the first phase of initial charge please use 0 515A 60A for D 600 accumulator until the voltage of a single cell reaches 2 4V Then we could shift to the second phase of initial charge For the second phase of the initial charge you could use 0 2515A 30A for D 600 accumulator for charging The temperature of the electrolyte shall not exceed 45 C during charging Reduce the charge current by half or suspend the charge when the temperature is close to 45 C Continue charging after the electrolyte temperature drops to below 35 C In this case the charging time shall be extended appropriatly Evidence of fully charged In the second stage of the in
9. C during the charging process The temperature of the electrolyte during charging shall not exceed 45 C Suspend charging if the temperature is close to 45 C and continue charging when the electrolyte temperature drops to below 35 C When the accumulator charging comes to end the electrolyte density of the accumulator shall be checked and adjusted If the electrolyte density fails to meet the requirements draw some electrolyte from the original cells If it is less denser than normal fill concentrated electrolyte with density of 1 40 for adjustment if it is denser than normal dilute it by adding distilled water After adjustment the difference of electrolyte density of cells should not exceed 0 01 and the liquid level should meet relevant requirements After adjusting the density you could continue to charge with small current for 0 5 hours to mix the electrolyte Then review the electrolyte density and adjust it if necessary Finally wipe clean and mount the accumulator for future use 3 Balanced recharging Under normal circumstances although all the accumulator cells run under the same situation but for some reasons imbalance in the entire accumulator may occur In such case balanced recharging should be conducted to eliminate the charge difference between the accumulator cells so as to achieve a balanced charging between all cells of the battery Balanced recharging is simple and users can operate according to the instructions Perf
10. Only trained and licensed drivers can drive the forklift 2 Operators shall wear security shoes hats clothing and gloves for protection purpose 3 Operators should note the performance and working conditions of mechanical hydraulic electrical and MOSFET governor 4 Power on by switching on the key switch choose the right position of direction switch and then rotate the steering wheel to see if the forklift can steer If ok slowly depress the speed pedal and maintain an appropriate speed 5 Observe the voltage meter if the voltage indicated by the voltage meter is below 41V during working immediately stop operation and recharge the accumulator or replace with another fully charged accumulator 6 Weight of loads handled should not exceed the specified value and fork spacing and location should be appropriate The fork should be fully inserted below all the goods which shall be uniformly distributed on the fork Uneven loading shall be avoided 7 If the distance between loads center of gravity and the fork arm is no more than 500mm the maximum load shall be the rated capacity If the distance between loads center of gravity and the fork 5 arm is more than 500mm the maximum load shall be less than the rated capacity 8 When carrying loads the main frame should tit backwards to the maximum extent and the fork arm should be in contact with the goods Raise the fork to about 200mm away from the ground before driving
11. ccoocccocnncoccncconcnonocnnnnnnnonnnnonnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnrnnnnranonanennas 23 A elecmcal SSI Merit iento 23 AOS a ee en a ee ee 25 AS A e o OR E E O 23 SAC U A 28 5 1 Accumulator safety preCcautiONS oocococcoccccccoccncocnncconnncnonnncannnncnnnnnrannnnnnnnas 28 5 2 Accumulator use pPrecautiONS oocccccccccccccccccncccnnnnnnnannnnnnnnnnn nn nnnnnnnnnn nro 28 9 Charging ofthe accoulatoNeevstesrcrstta socie rll ein arabe 29 5 4 Installation and replacement of the accumulator ooooocccccccccccnccnncnnnccrnnonnns 31 6 Vara ul Sy SUSI corra ietiora ag Bt MO p AO COP O A SAGRE Ean a ORO A PEET E TTA espace EEEE EAEE ETET Oo MUWay VANG acere n Arrr E e dau Ea S r ae peca 6 4 Lifting cylinder and the lifting CNAIN oooooocccccccocccccoccncccnnncononcnnnnnnrannncnnos OO ETON VAN rosso espiar iabre decae eeapio od POTECI O AAPP CAES PO A E 6 7 ado Dedo Ro 010 PO CO 0OPOOQO0 P 0O000 UC OU OU OO 6 8 Maintenance and AdjUStMeN c cece cece cece eee ee eee eee eeeeeeeeeeeeeeeensaeeeeeaas 6 9 Failure AIAN SIS terra ita 7 Lifting SY SUCIM iste scnase din crvacccarisnartetbmarerocaanew ended duamwrede Snanam de dametionende dam atecnmv ede tmnnssmeelccuuun FV OVEINICW vic iat RD OU PR OO IU A 7 2 Inner and Outer main TaMe o ooocccccccccccccncccnnnnnnnnnnnnnnnnn nn nn nn rn eeeneeeaaeeeeeeeneees Zo Ob Sl a PE N a AE EAE AEE E IE S FA Location of TONCTS actaisiitsid stun
12. 2 Fix the main frame and counterweight with steel wires and use pads to wedge the corresponding positions at the front and rear tires 3 Start lifting from the positions indicated by the Craning Label on the forklift Il Storage of the forklift 1 Reduce the main frame to the lowest position 2 Turn off the electric lock place the lever rod to the Nertral position and unplug the power cord 3 Tighten the hand brake 4 Use pads to wedge the front and rear tires 5 If the forklift is to be left unused for a long time its wheels should be elevated The accumulator should be recharged once a month III Pre use preparation 1 Check if all instruments are normal 2 Check the tire pressure 3 Check the condition of the levers and pedals 4 Check if the accumulator voltage is within the working scope and if the specific gracity of the electrolyte and the height level of the liquid are appropriate 5 Check if the connectors and plug contacts of the electrical system are reliable 6 Check for leakage of the hydraulic fluid electrolyte and brake fluid 7 Check the tightness of major fasteners 8 Check if the lighting and signal lamps are normal 9 Release the parking brake 10 Conduct test actions such as lifting and lowering the main frame tilting forwards and backwards steering and braking 11 Contamination level of hydraulic oil shall not be greater than 12 IV Operation of the forklift 1
13. Power of lifting motor S3 15 kw pt Basic Dimension Performanc e Parameter Operation pressure for attachments MPa Noise level audible by driver based on EN 12 053 db fT 5 D 10 C 16 10 70 E Driving Control Type II Structure principle and adjustment of the forklifts main components 1 Driving 4 Operation 1 1 Overview The transmission system of forklift is composed of reduction gearbox assembly differential assembly and drive axle Driving gear of decelerator is connected directly with the travel motor so the driving speed of forklift increases with the increase of motor speed and the driving direction can be changed by changing the direction of motor rotation 1 Rotary bearing 6 gear pair 11 gear pair 16 gear pair 21 Tire bolt E 1 A LOG zaz LA Pz AN 6 A in ol 7 i Hide ANA WW f l 1 8 it FEIIET Se E j 7 h LIAERE ICAA NA ERRER VA A SSS SOOO L AN NASR EES 11 REA KK S 2 NPA Reser SA VAATL 44 L3 Al Ag 00 jl S PSST 14 6 H AH 15 7 bi b ES 16 A EEA Ea in gt xa 21 ri SA AA PPR IS ss IN A IS COGIDO 2 shell 3 Driving 4 Refueling 5 oil seal screw 7 Bearing 8 Center axis 9 O ring 10 Bearing 12 Gear axle 13 Bearing 14 screw 15 gear pair 17 Bearing 18 Oil tank 19 Put oil 20 Tire cover screw components 22 Tire nut 23 oil seal 24 Output shaft 25 O ring Figu re
14. The accumulator has high voltage so when you perform installation and maintenance do not touch the accumulator conductor which can cause serious burns 3 Correct connection e When the accumulator is charging ensure the positive and negative poles are not reversed otherwise heat fire smoke or explosion may be caused 4 Never place metal objects on the accumulator e Avoid reversed installing of the positive and negative bolts or tools which may lead to short circuit occurs causing injury and explosion 5 Avoid excessive discharge A Do not keep using the forklift until it can not move otherwise the accumulator life will be shortened If the accumulator capacity alarm indicator flashes continuously it means that the accumulator needs to be recharged 6 Keep clean e Keep cleanness of accumulator surface Do not use a dry cloth or chemical fiber cloth to clean the accumulator surface Do not use polyethylene film to cover the battery e Static electricity can cause an explosion e Clean the uncovered parts at the top of the accumulator with a damp cloth 7 Wear protective clothing e During maintenance of the battery you should wear goggles rubber gloves and rubber boots 8 Accumulator electrolyte could be harmful e Accumulator electrolyte is made of dilute sulphuric acid Be careful when handling e When the electrolyte adheres to skin and clothing or touch your eyes it will result in 75 vision loss or seri
15. The size of a opening in overhead guard is more than 150mm lf the cargo size is less than 150x150mm additional protective measures must be adopted to prevent accident falling of the cargo Unsteady installation removal or transformation before use are all dangerous actions that may lead to major accidents 3 Back rest Back rest is an import security component that prevents falling down of cargo on the fork to the operator Unsteady installation removal or transformation before use are all dangerous actions 4 Traction Pin Traction pin is only applicable to the following occasions When the forklift can not move such as tires sank into a side ditch etc e When the forklift is to be loaded or unloaded from a truck e Never use it for towing or towed operation 5 Locating pin of the fork The locating pin can lock the fork in a certain position To adjust the fork spacing pull up the location pin and turn it for 1 4 cycle Then adjust the fork to the required position Fork spacing should be adjusted based on the goods to be loaded Based on the principle that gravity center of goods shall be consistent that of the fork operators shall adjust the spacing until the spacing to left side and to the right side are the same After adjusting fix the fork with the location pin to make it immovable When adjusting the fork spacing lean your body against the back rest Stand still and 59 push the fork with your f
16. Threads on the regulating mechanism and other rotating parts Figure 2 20 5 Use a E shape retaining ring to seize the parking brake cable 6 Mount the brake shoe with a fixed spring See figure 2 21 7 Mount the compression spring on the push lever of hand brake and then mount the push lever onto the brake shoe See figure 2 22 Figure 2 21 Figure 2 22 8 Mount the brake shoe guide plate to the support pin and then mount the return spring of the brake shoe First install the main shoe and then install the auxiliary shoe See figure 2 23 9 Mount the regulator the regulator spring ejector Pin return spring of the ejector Pin The following points shall be noted a The screw direction and mounting direction of the regulator b The direction of spring in the regulator contact between regulator gear and spring is not allowed c The direction of return spring in the ejector pin the spring hook at the support pin side should be fixed at the side opposite to the ejector pin d The lower end of the adjustment lever must contact with the regulator gear 10 Connect the brake pipelines with the wheel cylinders 11 Measure the inner diameter of brake drum and outer diameter of brake shoe and then use the regulator to set the difference between inner diameter of brake drum and outer diameter of brake shoe at 0 3mm 0 5mm See figure 2 24 16 Figure 2 23 Figure 2 24 2 6 4 Operation test of the automatic clearance regulator as
17. and regulations rather than being dumped and abandoned e Develop comprehensive maintenance and repair program e Keep detailed record of each maintenance and repair e Forklift repairing without training is prohibited A No smoking Turn off the key switch and disconnect the accumulator plug before maintenance Except for conducting some of the troubleshooting checks e Clean electrical parts with compressed air and do not use water for cleaning e Never stretch your hands feet or any part of the body into the place between the main frame and instrument rack e The charged capacitor within the controller may cause electrical injury even if the key switch is off Be careful when contacting the controller 1 Regular maintenance schedule y Inspection calibration adjustment x Replacement 84 1 Accumulator Mainte Every 3 Every 6 Maintenance Per day per week per month pen content ss 8 hours 50 hours 200 hours Montos MANS Item 600 hours 1200 hours Electrolyte measure levels by sight Specific gravity of electrolyte a CA CO O power vel terminals Looseness of the connection Accum accumulator ulator surface If there is any tool placed on accumulator surface ventilation cover is tight and if the ventilation is uncovered Keep away from J J J J J fireworks 2 Controller 85 ha B is normal Check wear status presa IOMA AO IO O BRA of contacts Check if
18. ccccocccccccnccocnococnnconcncnnnncnnonnnnnnnnnnnnonnnnonnnnnnnnnnnnnnnnnannnnnnnns 78 2 Check o a 79 tLe Checking after Oper lO ainia cotas 83 MN e E UE E ES 83 1 Clean the forklift SUrface cooocccccccnccocncconccococnncnnnnonnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnanos 83 PP o 83 3 Clean the electric system ccccoccccconcnncconnncconnnnocononnnconnnononnnnnnannnononnnnnnannnnnannnannanans 83 4 After the CIO GING us cines Moni cittos 83 IV Regular Maintenance oooccccccoccnncccconononncnnnancnnnnananonnnn agan My cee Gosssceeceessseesseassenecseaees 83 1 Regular maintenance sSchedule ooccccoocccccnnncnccnnncion do ede sDbecsseceseeeseeeeeseeeeseeeesseeeeseeees 85 2 Replace critical safety components periodically 0o cicoocccccccccocnncconnnoonncconnnconnnnnnons 93 V Lubricating parts and recommended oils docacinnoc occccnnccooccnncnnoncnnncononnnnnnnnononononnnonons 94 Moi oo AAA rrrEE AY A 94 2 Recommended OJI S ooooooocoo a O MQ cccccconnccncnco ence eecasecaseseanecaneecsaesoeeeceeesaaes 94 VI Forklift noise and vibration parameters table ooocccoocccoccnccocnconnncconncnncnnnonos 95 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
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20. destination 12 Storage 1 Before storage Prior to storage thoroughly clean the forklift and conduct inspection according to the following procedure a If needed clean oil and grease attached to the forklift body with a cloth and water b When cleaning the forklift body check the overall condition of the forklift In particular check if there are dents or damage on the forklift body and if the tires are worn out or STO E embedded with nails or stones c Check for oil leakage Fam 1 as 200mm d Add lubrication grease if necessary e Check if the wheel hub nuts and joints of the cylinder piston rod is loose and if the rod surface have bumps or pull marks f Check if rollers of the main frame could rotate smoothly g Raise the lifting cylinder to the highest level to make the cylinder full of oil On you found that the forklift is in need of repair or it fails or is unsafe report to the management staff and stop using it until it returns to safe state 2 Daily storage a Park the forklift in designated areas and use wedge pads to fix the wheels b Place the shift lever in neutral position and pull the parking brake lever c Remove the key and keep in a safe place 3 Long term storage Conduct the following maintenance and inspection based on daily storage maintenance a Park the forklift on a high and solid ground to protect it from flood in rain seasons b Remove the accumulator from the forklift In humid
21. disconnecting the power connector hold the plug or handle instead of holding the cable A Do not pull out the cable e If the cable and power connectors are damaged please contact our sales department and replace the damaged cables and power connectors j Disconnecting the charging Disconnect the charging in strict accordance with steps required by the Maintenance Manual of the charger e Do not pull out the charger plug during charging or else danger may be caused by sparks 2 Replace the accumulator If the accumulator on the forklift completely runs out of power another fully charged accumulator should be timely used to replace the original one Then recharge the original accumulator FP sates replacing the accumulator ensure the new accumulator match the forklift If a accumulator doesn t match with the forklift used working hours of the forklift will shorten or may cause rolling of the forklift Replacement of the accumulator should be carried out on a platform Follow these steps to replace the accumulator A e When using another forklift to lift the accumulator to be replaced appropriate spreader accessory should be used e Only experienced operators could lift the accumulator a Disconnect the accumulator plug b Open the accumulator top cover Take advantage of gas spring or other means to ensure that the accumulator top cover is locked because its faliing may cause physical injury or damage to th
22. environment store the accumulator in a dry and cool place and charge it monthly even if the forklift is parked indoor c Apply rust proof oil on exposed parts such as cylinder piston rod and shafts that may get rusty d Cover parts from moisure e Start the forklift at least once a week Mount the accumulator remove the oil and grease on the piston rod and the axis start the engine and fully warm up slowly drive the forklift forwards and backwards and manipulate hydraulic controller for several times f Don t park the forklift on soft ground such as those paved with asphalt in summer 4 Operation of the forklift after long term storage a Remove the moisture proof covering b Remove anti rust oil on the exposed parts c Remove foreign bodies and water in the hydraulic tank 54 d Mount the charged accumulator onto the forklift and connect the accumulator plugs e Conduct pre start check carefully I Operation device and use method 1 Diagram on forklift parts and operation device see below a 1 Overhead guard 2 Rear view 3 Emergency 4 Instrumentation 5 Rear grouped switch lamps 6 Counterweight 7 Multiple unit 8 Seat 9 Right guard 10 Accumulator valve lever plate case cover 11 Back cover 12 Balance 13 Driving wheel 14 Accelerator 15 Horn Switch plate weight plate 16 Foot braking 17 tyre 18 Steering wheel 19 combination 20 Cover of pedal switch refueller 21 Fork frame 22 Hand braking 23 Fork 2
23. falling off of wheels and overturning of the forklift Check all the rim nuts for looseness Make sure they have been tightened to the specified torque to avoid danger Tightening torque of the rim nuts the rim nuts 130 150N m 12 Check the charging status Measure the specific gravity of the battery If the specific gravity of the accumulator is 1 275 to 1 285 when the accumulator is switched to 30 C indicating that the accumulator is fully charged Check for loosening of terminals and check cables damage Handle Battery Plug 13 Check the front headlight steering lamp and the horn Check if these lamps could light up normally and if the horn can sounds normally checking by pressing the horn button Check the emergency stop switch 81 Horn button emergency button 14 Check instrument panel Under normal circumstances the instrument panel will displays as below within a few seconds after turning on the key switch pen naa 7 Ca 8 7 Y DO 7 T T IO en E mm EIA O AAA j i FANN gt j na P SPEED 12 km h OPT dd EEEREEE sar 80 A Communication indicator B Fault indicator C Insufficient power indicator D Speed limit indicator E Accelerating indicator F Hand brake indicator G Manu button H Speed limit button Acceleration switch over button J Left button K Right button L Reviewing button M LCD 15 Chec
24. fork for 50 100mm move the forklift forward and stack the goods in the right position 8 Observe the rear space of the forklift and reverse the forklift to avoid collision of the fork with the pallet or cargo 9 After confirming that the front end of fork left the goods or the pallet lower the fork to facilitate moving I50 200mm away from the ground 11 Un stacking Conduct un stacking according to the following procedures 1 Slow down when close to the goods to be handled 2 Park in front of the goods distance between the goods and fork tip is 30cm 3 Adjust forklift position in front of the goods 4 Ensure to avoid overloading 5 The main frame shall be perpendicular to the ground 6 Observe the fork position and move forward the forklift until the fork is fully inserted into the pallet 53 When the fork can t be fully inserted into the pallet a Insert 3 4 of the fork length and lift the pallet a little for 50 100mm then pull out the pallet for about 100 200mm and lower the pallet b Fully insert the fork into the pallet x jao rombo 7 After inserting the fork into the pallet lift the pallet for 50 100mm an E 8 Observe the space around and drive the forklift as pz backwards until the goods have been lowered 9 Reduce the goods to 150 200mm away from the ground 10 Tilt the main frame backward to ensure stability of the goods 11 Handle the goods to the
25. lever is pulled back for reverse purpose the reversing lamp and warning lamp will light up and the reversing buzzer sounds Steering lamp switch will specify the turning direction When the switch lever is turned to the steering position the turning lamp flashes The left steering forward lamp blinks Neutral position The right steering backwards lamp blinks The switch of small and big lamp controls the lighting and extinguishing of the lamps The switch has two gears the small lamp lights up when rotating to the first gear and the small and big lamps light up together when rotating to the second gear gear gear Width lamp x o lights ON x lights OFF 4 Rear headlight switch Rear lamp switch is a single gear switch that controls the lighting and extinguishing of the rear lamp Pull the switch to light the lamp and push it to distinguish the lamp 4 Control parts 1 steering wheel and lever ball of the steering wheel The steering wheel can be operated in usual way namely when rotating the steering wheel rightwards the forklift will turn right Vice versa Steering wheel is mounted at the rear side of the forklift enabling the forklift rear part to swing out during turning 56 During turning grasp the lever ball of steering wheel with your left hand while place the right hand on control lever of the multiple unit valve or steering wheel Hydraulic steering system and tilt device of the steering wheel are stand
26. should be avoided 20 Before leaving the forklift lower the fork down to the ground set the lever at neutral position and disconnect power In case of parking on a ramp apply the parking brake Use wedge pads to fix the wheels if you need to park for a long time 21 The safety valve pressures of multiple unit valve and steering device have been tuned up before leaving the factory During use users shall not adjust it because excessive pressure may cause damage to the entire hydraulic system or its components and the motor 22 Tire inflation pressure shall be in line with that stipulated on the Air pressure plate 23 When moving with no load forklift with accessories shall be operated in a way as if carrying a load V Charging of accumulator cells 1 When charging the accumulator cells for the first time and further charging users should be in strict compliance with the instructions 2 When operating the forklift if the accumulator voltage decreases to 41V or that of its single cell drops below I 7V or the instrument alarms users shall immediately stop using the forklift and replace the accumulator or recharge it before further use 3 Check the specific gravity liquid level and temperature of the electrolyte from time to time during the charging process 4 Forklift must be recharged as soon as possible after use Never leave the forklift uncharged longer than 24 hours When charging pay attention to prevent insuf
27. shown in Figure 2 25 1 First adjust the diameter of brake shoe to be close to the stipulated installation size pull the lever to rotate the regulator When letting the lever go the regulator lever will return to its original position and the regulator gear won t rotate Note Even if the regulator gear and the lever both return after the lever is let go the regulator still works properly 2 If the regulator can not finish the above actions when the lever is pulled carry out the following checks a Securely mount the adjustment lever ejector pin spring of the ejector pin and compression spring base b Check the return spring on ejector pin and the regulator spring for damage and then check the rotation of its regulator gear and its meshing parts tovsee if there is excessive wear or damage Check whether the pin contacts with the gear Replace damaged parts Inflation direction Figure 2 25 2 7 Adjusting the brake pedal as shown in Figure 2 26 a 1 Shorten the push lever 2 Regulate the pedal spacing bolt and adjust the pedal height as shown in Figure 2 26 b 3 Adjust the length of the push lever until its front end contacts with the piston of master cylinder Then turn back 1 2 circles to guarantee a free travel of the pedal between the 10mm 20mm 4 Lock the nuts of push lever and the pedal spacing bolt 17 Push lever S Pedal Spacing bolt Figure 2 26 5 Adjust the brake
28. switch as shown in Figure 2 27 a After the height of the brake pedal has been adjusted release the brake switch and lock the nut b Disconnect the plug to separate the wires c Rotate the switch to set the gap A at 1mm d Make sure the brake light be lit when depressing the brake pedal e Finally lock the nuts Figure 227 Brake light switch 2 8 Troubleshooting and Failure Analysis Table 2 3 Table 2 3 Problems Causes analysis Solutions 1 Oil leaks in the brake system 2 The brake shoe clearance is not Adjust the regulator well tuned 3 The brake is over heated Check if the brake is slipping Abnormal 4 Brake drum and friction disk are not Readjust it braking appropriately contacted 5 There are foreign matters attached to the me Repair or replace it friction disk 6 The brake fluid is contaminated Check the brake fluid 7 The brake pedal micro valve hasn t been Adjustment adjusted properly 1 The friction surface is hardened or with Repar orreoaceii foreign matters attached on it P P 2 The baking plate is deformed or the bolts Repair or replace it a are loosen Noise in 3 The brake shoe is deformed or is not E the brake installed correctly p P 5 The wheel bearing is loosened Repair or replace it 1 There are oil stain on the friction disk Repair or replace it 18 braking 2 The brake shoe clearance is not Adjust the regulator is well tuned uneven 3 The wheel cylinder fails Repair or replace
29. the mechanical movement of the contactors is good Check if the operation of micro switch pedal is Controller normal Check the connection between the motor accumulator and the power units Check if the For the troubleshooting fi irst 2 system of controller years 3 Motor Per month 200 hours Per day per wee months months a 2d O body on the motor shell 50 pe the bearing Check for wear of carbon brushes and commutator Also check if the spring force is normal Check if the wiring is correct and reliable changeover plate and add carbon powder on the changeover 4 Transmission system 86 Check for leakage Repiace treat Gearbox status of brake and Check the gear wheel operation reduction Check looseness of mechanism the bolts at the connection with the Check the tightening Torque Wrench y y y y y e OS damage nails stones or other foreign body on the tire Damage ofwheelfim Y 6 Steering system 87 Item content 8 hours 50 month months months hours 200 600 1200 hours hours hours Check the clearance y y a E E Steering llooseness looseness a f status Check for looseness of the mounting Check the leakage on contact surface y y Check the sealing condition of the NES y interface connectors Check for looseness of the mounting bolts on rear axle Check bending deformation cracking and damage Steer
30. the lubricating port Please conduct lubrication timely if you clean the forklift frequently 2 Clean the chain A Do not use chemical detergents acids and other corrosive liquids to clean the chain e Place a container under the main frame e Use gasoline and other petrochemical derivatives to clean the chain e Do not use any additives when cleaning with a steam nozzle e Wipe the chain pin and water on chain surface immediately after cleaning 3 Clean the electric system Do not use water to clean the pump control and the connectors so as to avoid damage to the electrical system Use non metallic brush or low power dryer to clean the electric system according to the manufacturer s instructions Do not move the protective cover 4 After cleaning e Thoroughly wipe off water stains on the forklift compressed air could be used e Start the forklift according to the procedures If moisture penetrates into the motor you should first remove the moisture to prevent short circuits O Moisture will reduce brake performance so you shall conduct braking to dry the brake V Regular maintenance e Regular inspection and maintenance of the forklift shall be conducted to keep it in good performance status Use spare parts made by Noblelift Machinery 83 Do not use different types of oil when replacing or refilling oil e The oil and accumulator being replaced shall be disposed according to local environmental protection laws
31. the oil temperature before further testing e After testing set the overflow pressure at 175kg cm and measure the flow traffic 39 Determine the flow traffic by measuring lifting speed 6 9 Failure nalysis If the hydraulic system fails please find out the causes according to the table below and conduct necessary repairs 1 Failure analysis of the multiple unit valve Table 2 8 Table 2 8 Pressure of the lifting oil line Jamming of the slide valve Clean it after disassembling can t be increased Oil hole is blocked Clean it after disassembling Steering oil pressure is Jamming of the slide valve Clean it after disassembling greater than the specified value Oil hole is blocked Clean it after disassembling Less than the required oil Overflow valve is not well Adjustment volume adjusted Vibration Jamming of the slide valve Clean it after disassembling Pressure rise is slow Inadequate exhaust of air Full exhaust Overflow valve is not well Adjustment With noise adjusted Wear of sliding surface Replace the overflow valve Leakage external Aging ay 7 po Replace the O seal ring The spring is damaged Replace the spring The set pressure is low Damage of valve seat Adjust or replace the surface overflow valve Leakage internal YE or vave ocal Fix the seat surface The set pressure is high Jamming of the valve Clean it after disassembling 2 Failure Analysis of the oil pump Table 2 9 Table 2 9 Fault Ca
32. travel length of steering wheel when moving forwards and backwards are about 7 If the actual travel length falls within the scope rotation of the steering wheel can be deemed as Normal 79 Rebound stroke 50 100mm 5 Check the ature Rotate the ste Nise and counter clockwise and check the working condition of the power steeri _ 6 Check the hydraulic system and the function of main frame Check if the operations of lifting tilting forward and ackward are normal and smooth A 7 Check the oil pipe Check the lifting cylinder tilting cylinder and all the piping for oil leakage 8 Check hydraulic oil Lower the fork to the ground and check the oil level of hydraulic oil with a gauge If the oil level is within the range of H toL the hydraulic oil volume is appropriate 9 Check the lifting chain Lift the fork to 200 300mm away from the ground and ensure that the tightness of left and right chains are the same Check whether the finger lever is in the neutral Lifting lato position Adjust the chain joints in case of difference in tightness well Chain joint E Double nut Cotter pin A e Double nut should be tightened after this adjustment 10 Check the tires solid tire Check tires and the side surfaces for damage or cracking and then check the wheel rim and the lock ring for deformation or damage 11 Check the rim nuts Looseness of rim nuts could be very dangerous as it may lead to
33. ventilated e The site should have fire fighting equipment 2 Precautions before maintenance e No smoking e Wear all kinds of protective equipments helmets shoes glasses gloves and boots and appropriate clothing e Timely and wipe out overflowed oil e Use a brush or cloth or clean dust or dirty oil before adding lubrication oil e Turn off the key switch and pull out the accumulator plug except for some certain cases e Lower the fork to the ground before carrying out maintenance of forklift e Use compressed air to clean electrical components 3 Precautions on care and maintenance e Take care not to put feet below the fork and not to be tripped by the fork e When upgrading the fork use pads or other things as cushion below the main frame to avoid sudden drop of the fork and main frame e Take care to open and close the front chassis and accumulator cover plate so as not to pinch fingers e When your job can t be completed within a day make a mark to continue work next time e Use right tools and never use makeshift tools e Because of the high pressure of hydraulic circuit never carry out maintenance work before the internal pressure of oil circuit is reduced e When injured by high voltage electricity immediately seek medical treatment e Do not use the main frame assembly as a ladder e Do not put your hands feet and body between the forklift frame and the main frame assembly 4 Inspection and replacemen
34. will be adjusted to be in certain proportional of the remaining pressures in the brake pipeline and the brake cylinder so that the cylinder cup will be correctly placed to prevent oil spilling and to eliminate air resistance that may occur during emergency brake i A aim x i A OA ON 1 Locking nut 2 Pushing rod 3 Dust cover 4 Stop steel wire 5 Stop washer 6 Auxiliary cup 7 Piston 8 Main cup 9 Spring 10 Check valve 11 Valve seat 12 Pump body Figure 2 3 Brake Master Cylinder 11 2 4 Brake The brake is a dual shoe brake installed on both sides of the drive axle The brake consists of two groups of brake shoes brake cylinders and regulators One end of the brake shoe contacts the fixed pin and the other end contacts the regulating device The return spring and the compression spring bar hold the parking brake In addition the parking brake mechanism and automatic regulating device are also assembled onto the brake See figure 2 4 3 Cylinder sleeve 1 Brake cylinder 2 Brake cylinder 4 Brake cylinder spring Piston 5 Brake cylinder shield 6 Piston rod of brake _ 7 Oil plug of brake cylinder 8 Thread guard cylinder 9 Bleeder screw of brake 10 Bleeder screw 11 Brake shoes with 12 Brake shoes with cylinder shield assembly front assembly back 13 Brake backing plate 14 Clearance 15 Spring farrowed device 16 Compression spring assembly adjuster bar 17 Compression spring 18 Spring 19 Rubber
35. 2 1 Driving amp Operation This actuation steering axle has the structure compact reasonable the operational performance reliable the transmission steady the noise low status merit The bridge shell uses the cast steel material the rigidity is good bearing capacity is big the main performance parameter sees Table 2 1 2 Technical parameters Table 2 1 Biggest wheel speed r min Biggest wheel torque Nem 1 2 Failure Analysis Table 2 2 Failure Diagnosis and Correction High Looseness of fastening bolts at the installation a the bolts vibration and connection points Deterioration of gear oil Replace Excessive oil Abnormal oil level Add or reduce oil OM pereue Jamming of moving parts Adjustment Looseness of bolts at the combining surfaces Tighten the bolts Oil leakage Noise 2 Braking system 2 1 Overview The braking system consists of the brake pedal brake master cylinder and wheel brakes The two wheel brakes in the front are hydraulic internal expansion brakes 2 2 Brake pedal The structure of brake pedal is shown in Figure 2 2 The pedal would transfer the pedal force into brake oil pressure through the push rod on the brake master cylinder 10 1 Brake oil cup 2 Brake pedal 3 Brake master cylinder 4 Brake sensor 5 Brake support 6 Spacing bolt Figure 2 2 Brake pedal assembly 2 3 Brake master cylinder Figure 2 3 The master cylinder includes a valve seat a check valve a return spring th
36. 4 Back rest 25 Lifting cylinder 26 Combination 2 Front 28 Chain 29 Main frame lights before headlight assembly 2 Combination instrument See4 Electric system 3 Switch parts 1 Emergency stop switch In the event of an emergency press the red mushroom shaped button to cut off the control power of the forklift disabling the walking turning and lifting operation of the forklift Rotate the button as indicated by the arrow above the button to restore operation 2 Key switch Key switch can be turned on or off for power control OFF The switch is off at this position and keys can be inserted and pulled out 55 ON The switch can be connected and the forklift will start if you rotate forward from the OFF position e Do not step on the accelerator pedal when turning on the key switch e When you leave the forklift take out the keys to protect it from being misused After parking the forklift or when recharging take out the keys to protect it from being misused 3 Combination switch Combination switch is combined by the direction switch steering lamp switch as well as the switchs of small and big lamps 1 Direction switch 2 Steering lamp switch 3 Switch of small and big lamps Direction switch controls the direction the forklift and would convey the signal to the instrument for display Push the lever to move forwards and pull back it to move backwards The middle position is the neutral position When the
37. Check the surface of the brake cylinder and peripheral surface of the piston for rust then measure the clearance between the piston and the brake cylinder Standard size 0 03mm 0 10mm Maximum size 0 15mm 2 Conduct visual inspection of the piston cup for damage and deformation Replace the cup if there is any abnormality 3 Measure the free length of brake cylinder spring Replace it if it exceeds the baseline 4 Measure the thickness of friction disk Replace it if the wear degree exceeds limit Figure 2 17 Standard thickness 8 0mm Minimum thickness 2 0mm 5 Conduct visual inspection on the inner surface of brake drum for damage and uneven wear Then grind the brake drum for correction purpose and replace it if it can t be corrected Standard value 314mm Maximum value 316mm See Figure 2 19 15 Figure 2 18 Figure 2 19 2 6 3 Brake assembly 1 Coat the cup and piston on the brake cylinder with brake fluid and assemble the spring piston cup piston and protection loop in sequence 2 Mount brake cylinder on the brake backing plate b 3 Mount the brake backing plate on the drive axle E 4 Coat all the positions as shown in Figure 2 20 with heat resistant grease and be careful not to smear any oil on the friction disk a Contact surface of the brake backing plate and brake shoe b Fixed pin c Contact surface of the brake shoe and spring compression base AAA AA d Support pin of the hand brake lever e e
38. Co Ltd Tel 86 572 6210776 6210788 Fax 86 572 6210777 6128612 PC 313100 www www noblelift com Email info noblelift com Add No 528 Jing Yi Road Economic Development Zone Changxing 96
39. Figure 2 9 Clearance Figure 2 10 Parking brake lever self adjusting mechanism 2 6 Technical points for brake disassembly and adjustment Disassembly assembly and adjustment of the brake and adjustment of brake pedal when the wheel and wheel hub is removed 2 6 1 Disassembly of the brake 1 Remove the support pin regulating bar regulating device and spring on the auxiliary brake shoe See figure 2 11 2 Remove the return spring on the shoe See figure 2 12 Figure 2 11 Figure 2 12 3 Remove the fixing spring on the main brake shoe See figure 2 13 4 Remove the main and auxiliary brake shoes And also remove the regulator and the regulator spring See figure 2 14 14 Figure 2 13 Figure 2 14 5 Remove the brake pipe from the brake cylinder Then remove the mounting bolt of the brake cylinder and remove the brake cylinder from the brake backing plate See figure 2 15 6 Remove the E shaped retaining ring used for fixing the brake cable on the brake backing plate Then remove the mounting bolt on the brake backing plate and dismount the brake backing plate from the drive axle See figure 2 16 Figure 2 15 Figure 2 16 7 Disassemle the brake cylinder Remove the dust proof ring Press on one end of the piston to push out the other end and then press down the headed out end of piston with fingers See figure 2 17 E Figure 2 17 2 6 2 Check of the brake Inspect the parts and then repair or replace damaged ones 1
40. anwhile set the main switch at the off position and disconnect the accumulator plug 3 Before disassembling and testing operations remove all the rings watches and other metal objects on your body to avoid accidental short circuit 4 Please use the right tools for the disassembling process and use the specified tools if required 5 Please choose an appropriate spreader according to the size and weight of the removed parts so as to avoid danger 6 Be sure to mount sling steadily before lifting to prevent falling of the cargo Please keep the sling tightened during the lifting process 7 When removing a heavy part from the forklift be careful to keep balance and to avoid damage 8 2 Lifting points of the detached parts 1 Lifting description of the lifting system as shown in Figure 2 60 Overall Dimension LxWxH Weight Y Model LP Y mm kg Hy FE3R16 AC 1700 X 1010 X 2150 VIA Lifting KA Hole rigure 4 OU 46 2 Lifting description of the overhead guard as shown in Figure 2 61 Lifting Hole Overall Dimension LxWxH Weight kg mm FE3R16 AC 1300X980 X 1400 igure 2 61 3 Lifting description of the counterbalance as shown in Figure 2 62 A The lifting ring on the counterbalance can be used to lift the balance weight only Do not use it for lifting the whole fork Overall Dimension l FE3R16 AC 540 X 990 X 810 900 Ce Lifting ring F1gur2 62 4 Lifting description of th
41. ard equipments on the forklift oe e Adjust the steering wheel to the best angle according to the driver s position e After adjusting the tilt steering wheel lock steering column with star shaped lever l 1 BA 11 dl Il LL TA A mA 2 Horn button 4 Press the rubber cover in the centre of the steering wheelto make a buzzing sound The horn can sound even when the key switch is closed ww 3 Direction switch lever Indicating the direction of travel Moving forward F push forward the lever and depress the accelerator pedal Moving backward B pull back the lever and depress the accelerator pedal When parking the forklift place the direction switch lever in the neutral position N 57 4 Parking brake lever To prevent moving of the forklift fully pull back parking brake lever when parking the forklift Push forward the parking brake lever to its maximum level before driving ie When operating the parking brake lever depress the brake pedal 5 brake pedal and accelerator pedal e Do not slam on the accelerator pedal otherwise the forklift will suddenly start or accelerate Before depressing brake pedal make suresto remove the foot from the accelerator pedal From left to right respectively the brake pedal and accelerator pedal 3 Depresses the accelerator pedal slowly and the speed of forklift depends on how much the accelerating pedal has been dep
42. atcreawddaaninw vides gowsead sadate ade tits Weuwanadeieueneddahantewds 7 5 Maintenance and adjuStMent 00 cccce cece cece eee ee o encarna 7 6 Installation Of ACCESSOLIES cc cece cece cee cececcuccemecscuDnecuccueueeueeucuetuutansnnnnnaes 8 Removal and installation ccc c cece ccc cee ceeccedsdbedcsDeccuccuccecceuceuceuucucenuneanees 8 1 PreCAUtlONS ccc cece cece cece cece ee cence cee ae I coccion nr 8 2 Lifting points of the detached parts 6 Deke cece cece cece cece eee eeeesaeeeeeenaes Chapter 3 Operation use and safety of the forklifts 4 co c cece cence cence eeaeeeeenaas I Driving and Operation cccoonnncccccnnnnn ll MAR Waaa cnn nn nan n nn nn nana nnnrnnanannnnnnnns 1 Use of a new forklift Wi ooooocccoococccocccoccocccccncnncccnnnnnononnncnonanenns 2 The relationship between forklift Stability and load ccooocccnccoccoccconnnononcnnonanoss 3 Load centre and load curve MBA cccccccccccsccecesceceueeecseeecaeeeseasecsaeessaeseseaeessaeessaes 4 Forkifts tabi AA A a a E aes 5 Transportation and handling of the forklift ooocccconcnccccccnccocnonononnnconanonononcncnnnos 6 Preparation beforeddrIWINAO ccoooonococonncoccononocononoconnnnononnnonnnnnnononnnnnonnnnnnnnonennanens PE cc A 8 Parking and temporary parkinQ oocccoccnccccncccccnnnncnnnnnnnnoncnonncnnonanononnnnnnnnnn
43. ature decrease by 1 C If the temperature difference is large the density value shall be corrected by the following formula Density of electrolyte under standard temperature 25 C can be converted by the following formula D25 Dt 0 0007 t 25 D25 Electrolyte density when the temperature is 25 C D25 Measured electrolyte density when the temperature is t C t The electrolyte temperature when measuring the density 9 3 Charging of the accumulator 29 1 Initial charge generally initial charge has been conducted to the products before leaving the factory so users could omit this operation The quality of initial charge would greatly impact the future performance of accumulator So initial charge shall be conducted by experienced operators Initial charge should be carried out to new accumulators before use You should wipe clean the surface of the accumulator and check for damage before the initial charge Open the cover on the liquid filler to ensure that the vent is unblocked When the charger is under normal working conditions you could fill sulfuric acid electrolyte with density of 1 26 0 005 25 C and temperature below 30 C into the accumulator In this case liquid level shall be 15 25mm higher than the protection plate Place the accumulator aside for 3 to 4 hours but ensure the time will never be more than 8 hours Conduct initial charge only after liquid temperature is reduced to below 35
44. be the same so that the forklift can move smoothly during loading and unloading process e To avoid dangers please do not change direction or move laterally when driving on a slab e Slowly reverse the forklift to achieve simultaneous boarding of the left and right tires when loading the forklift onto a truck 6 Preparation before driving 1 Check the position of the direction switch lever Place the switch lever in the middle position N 2 Turn on the key switch Seize lever ball of the steering wheel and then turn the key switch t e Even if the key switch is turned to the ON position it will take about 1 second for the brake circuit to start off after it starts action e If the gear lever is placed at forward F or reverse R position before turning the key switch to the ON position please shift the lever to the middle position N e If the accelerator pedal is rapidly depressed it is likely that the forklift will accelerate suddely be sure to pay attention 3 Tilting backward of main frame Pull back the lever to lift the fork to 150 49 200mm away from the ground and pull back the lever to tilt the main frame backward 4 Operation of the direction switch lever Use the direction switch lever to decide the driving direction forward backward Forward F push the direction switch lever forward Backward F push the direction switch lever l Sa backward Y AAA 5 Release the park
45. brake drum See Figure 2 8 for its structure Clearance self adjusting mechanism works only when the forklift is moving in reverse 1 Pin 2 lever 3 Driving brake 1 Regulating 2 Spring 3 Cable shoe mechanism 4 Driven 5 Support rod 4 Guide groove 5 lever brake shoe Figure 2 7 Parking brake Figure 2 8 Clearance self adjusting mechanism 4 Action of the automatic clearance adjusting mechanism If braking during reversing of the forklift the auxiliary and main brake shoes contact with each other and rotate together so that the lever will rotate rightwards around A point as shown in Figure 2 13 and B point is then elevated After the brake is released the lever will rotate leftwards by the spring force to lower B point When the clearance between brake hub and friction disk is enlarged the vertical distance of B point s rotation will increase The regulator will be toggled for one more tooth and the regulating lever lengthens see Figure 2 9 so that the clearance shrinks Clearance adjustment range falls within 0 40mm 0 45mm 2 5 Control device of parking brake Figure 2 10 The regulator located at the cam type parking brake lever can be used to adjust the braking force Braking force adjustment Turn the regulator clockwise to increase the braking force turn the regulator counter clockwise to reduce the braking force Pulling force 196N 294N 13 Parking Brake Wire rope Alongs this direction elons elonstion
46. braking force is controlled by the accelerator pedal Regenerative braking refers to the forklifts braking force generated by the controller when the forklifts speed is relatively higher than the traction motor speed The force can be transformed into electrical energy and returned to the battery group In order to reduce the speed of the forklift when moving downwards users can release the accelerator pedal to a certain extent to achieve regenerative braking so as to extend the driving distance enabled by a single battery charge 4 Function of avoiding slipping backwards on a ramp Electric forklift with AC traction motor could excellently avoid downwards moving of the forklift on a ramp 5 The maximum driving speed could be regulated By setting a reasonable vmaximum speed of the electric forklift users can avoid overload of traction motor due to excessive speed 6 Static response off lf the seat switch or key switchs off the control device will be turned off either Re start is enabled only when the directional control lever is placed on the neutral position If the driver leaves the forklift and then return he needs to place the directional control lever on the neutral position to re start the forklift This feature eliminates accidental occurrence of unsafe operation A few seconds of latency have been setto the input end of seat switch so as to realize momentary disconnection of the seat switch in case of turbulence 7 Function of security pro
47. e accumulator as shown in Figure 2 63 Overall Dimension Lifting Hole PE3RIGAC 825x485x630 Figure 2 63 Figure 2 63 A The accumulator also functions as a counterbalance so users shall not arbitrarily change it otherwise the overall balance and other features may be affected 47 Chapter 3 Operation use and safety of the forklift I Driving and operation In order to ensure good performance safety operation and economic use of the forklift we specify the precautions below that should be noted during proper driving operation 1 The use of a new forklift All the package materials removed from a new forklift shall be recycled according to local regulations e Test run should be carried out before using a new forklift to see if the forklift parts can work properly The service life of your forklift depends on your initial operation When using it in the first 200 hours please pay great attention to the following issues e Heat engine operation shall be conducted before use no matter what season it is e Conduct maintenance in a timely and through manner e Never operate it violently or rudely 2 The relationship between forklift stability and load In the load curve the front wheel centre of the forklift is taken as the fulcrum to keep the forklift body and load on the fork balanced Pay attention to load quantity and load centre when driving to maintain stability of the forklift Oi case the load exceeds the
48. e forklift 52 c When lifting the accumulator out of the forklift be careful not to damage the steering wheel or other forklift parts d After a group of fully charged accumulator is well placed securely connect the accumulator plug e Cap the accumulator cover JIN when fitting on the accumulator cover be careful not to hurt your fingers e Be careful to keep it stable when lifting the accumulator so as not to cause collision damage to the forklift body 10 Stacking e Check the following items prior to operation of forklift a Ensure the goods in the loading area will not fall and be damaged b Ensure that no obstruction for the goods or cargo in the way Conduct stacking according to the following procedures 1 Slow down when driving close to the stacking area 2 Park before the stacking area 3 Check the safety status around the stack area 4 Adjust the forklift position to place it in front of the stacking area 5 The main frame shall be perpendicular to the ground and the lifting fork shall be higher than the stacking height 6 Check the stacking position and driving forward to park in the right place 7 Ensure that the goods is right above the stacking position and slowly lower the fork to put the goods in place E when the goods are not fully placed on the shelf or cae bracket a Lower the fork until it no longer carry any weight b Reverse the forklift for 1 4 of the fork length c Lift the
49. e main cup piston and auxiliary cup Stop washer and stop steel wire are used to fix the ends of the cylinder and rubber dust cover is applied to protect its external surface Master cylinder piston works by depressed the brake pedal to touch the push rod When the brake pedal is depressed the push rod will push the piston forward and the brake fluid in the cylinder will flow back to the storage tank through the oil return hole until the main cup block the oil returnhole When the main cup block the oil return hole the brake fluid in front cavity of the master cylinder is compressed and the check valve is opened The fluid will flow to the wheel cylinder through the brake pipelines Thus each wheel cylinder piston will protrude and the friction disk of the brake shoe will contact the brake drum to achieve slowing down or braking At this point the back cavity of piston will be filled with brake fluid from the oil return hole and the oil inlet When the brake pedal is released the piston will be pressed backwards by the return spring and at the same time the brake fluid in each brake cylinder is also compressed by the return spring of the brake shoe so that the brake fluid will flow back to the master cylinder front cavity of the piston through the check valve Then the piston will return to its normal position while the brake fluid in the master cylinder flows back to the storage tank through the oil returning hole The pressure of the check valve
50. ear side when turning e In the case of steering the faster the forklift moves the smaller turning radius will be and more easily the forklift will overturn Please be quite careful 4 Simultaneous operation of driving and lifting micro operation a First drive the forklift until the front end of fork is 3 5m away from the goods b Fully depress the brake pedal Travel stop c Depress the accelerator pedal to obtain the right operation speed d Operate the lifting lever to start lifting operation 50 i operation of driving and lifting micro operation require high level of skills The operator must correctly understand the form gravity centre and other features of the goods and ensure stability of the forklift before carrying out low speed lifting and lowering operations Be extremely careful when conducting simultaneous operation Tilting operation involves high risk Never conduct other operations than extending or retracting of the fork on a cargo platform e To eliminate the danger of lifting during driving conduct lifting only when the forklift is close to the cargo platform 8 Parking and temporary parking Park safely e The parking place should be spacious and the ground shall be flat e If you have to park the forklift without load on a ramp the main frame side shall be placed down hilling and fix the wheels to avoid sliding e Please park the forklift in a safe place other than the operation site or d
51. ed with steering wheel through gimbal joints The steering column can tilt backwards or forwards to an appropriate position The Rotary bearing is bolted to the tailstock on the frame rear end The Hydraulic cycloid motor will push the Driving wheel through the chain so that the steering wheel will deflect to achieve steering Fig 2 28 Steering device 3 2 Cycloidal full hydraulic steering gear The hydraulic steering gear Figure 2 29 can according to the rotation angle of the steering wheel transmit the oil from steering pump to the steering cylinder through the oil pipeline When the pump can not supply oil the operator can rotate it manually The steering gear is composed of a general steering and a combination valve on which there is a hole serving as the safety valve of the system Within the valve there is a two way overload valve which could protect the parts from unexpected damage If accident external shocks cause high pressure within the hydraulic system during the driving process of the forklift The safety valve and two way overload valve has been tuned up by the manufacturer and users should not adjust it without permmision 20 1 Limitation column 4 Couple shaft 7 Rotor 2 Valve body 5 Spring 8 Stator 3 Valve core 6 Connection block 9 Valve sleeve Figure 2 29 Cycloidal full hydraulic steering gear 3 3 hydraulic cycloid motor and rotary bearings Hydraulic cycloid motor and rotary bearing connection as s
52. eet Never adjust spacing by hands 6 Foot pedal and handrail The foot pedal is located at left side of the forklift and the handrail is on the left front strut of the overhead guard Use the pedal and handrail when on boarding and de boarding the forklift to ensure safety 7 Lighting The front of the forklift is equipped with front headlights and front combination lights steering lamp parking light width light The rear of the forklift is equipped with combination lamps which include taillight steer lamp brake light parking light reverse light and flasher e Check the working conditions of lights if the lamps are burned damaged or dirty replace or repaired immediately 8 Rear view Rear view is installed at the right side of the front beam on the overhead guard N e Keep rear view surface clean e The rear view can be adjusted to a position allowing complete rear view 9 Accumulator plug Accumulator plug is used to connect or disconnect the accumulator and forklifts electrical components Generally connection operation is more common o A If you have to touch the internal electrical components disconnect the accumulator plug first to prevent danger e Voltage still exist in the main circuit even if the key switch at the OFF position If you want to cut off the main power please pull the plug e If the accumulator plug is disconnected during driving process steering will be disabled So never unplug the acc
53. eople Do not abuse the forklift 69 Ah WARNING 7 WARNING Do not stretch any part of the body out of the Drive smoothly Sudden acceleration and forklift slow down is not allowed Special safety equipment shall be used when y not overload carry out manned operation a A WARNING Damaged forklifts need to be placed in When not in use the forklift shall be designated areas parked in designated areas 70 Ah WARNING It is prohibited to park the forklift on a slope 3 Transportation of the forklift Lifting from the forklift top is prohibited Lift the forklift correctly when handling goods iN WARNING When you do not use the forklift Brake Place the direction lever at the netural position Lower the fork to the ground Tilt the main frame forward Remove the key Lifting from the forklift frame is prohibited Lift the forklift Fasten the steel wire to the holes at the two ends of the outer frame beam and to the counterweight hook and then hoist the fork by using the lifting equipment And the steel wire connected to counterweight shall pass through overhead guard notch and shall not exert force on the overhead guard e When lifting the forklift be sure the steel wire is not twisted around the overhead guard e The steel wire and lifting devices shall be firm enough to support the forklift safely because the forklift is extremely hea
54. er and users shall not adjust it wilfully 6 4 Lifting cylinder and lifting chain See figure 2 42 The lifting cylinder is a single acting piston cylinder which consists of the cylinder piston rod piston and cylinder head For the series of forklifts the two lifting cylinders are installed behind the outer main frame with the cylinder bottom fixed on the cylinder bearing with a pin and a bolt And 34 the top of the cylinder ie the top of the piston rod is connected with the beam on the outer door frame The right lifting cylinder is equipped with a governor valve Piston is fixed to the piston rod with a elastic steel wire Oil seal and support ring are mounted to the outer ring of piston A shut off valve is mounted at the bottom of the cylinder which serves as a protection device if the high pressure pipe suddenly burst in case of lifting of the main frame Cylinder head is fitted with steel bearing and oil seal to support the piston rod and to protect the cylinder from dust Left lifting cylinder Right lifting cylinder 1 Dust proof ring 2 Shaft seal 3 Steel 1 O ring 5 Steel backed cover bearing 6 Left cylinder body 7 Piston rod 8 Adjustment 9 O ring 10 Spring sleeve 11 Stell wire washer for 12 Spring 13 Piston 14 Supporting 15 Buffer valve hole base ring for hole core 16 Retainer ring 17 Hole seal 18 Check 19 Spring washer 20 Shut off valve for hole valve 21 O ring 22 23 O ring 24 Cotter pin 25 Chain joint Gove
55. ering lah p he h b 13 lamps Porn and can light up Press the horn button to see if the horn could sound and check if the emergency power switch emergency power off switch is normal Inspection and When the key switch is turned on it Features n n displaying should display normal test state lamps Braking system Lights horn and switches VEEN guard If the bolts and nuts are tightened ao Others 16 Nameplate and labels Completeness Other parts If there is abnormality 2 Check the procedure 1 Check the foot brake pedal Check the braking status Ensure that if the brake pedal is fully depressed the travel distance of the brake pedal should be more than 50mm and the braking distance of no load forklift shall be about 2 5m 78 2 Check brake fluid e Open the oil cup cover and check the quantity of brake oil and other conditions 3 Check the parking brake lever Push forward the parking brake lever and check the following items e If the pull distance is appropriate e Degree of braking force e If the parts are injured If the operator find the manipulation force of the lever standard force is 17 22kg approprate Operators can adjust the screw at the top of the lever Parking brake lever 4 Check the rotation of the steering wheel Gently rotate the steering wheel clockwise and counterclockwise to check if rebound occurs The suitable travel length for rebound shall be 50 100mm The
56. esignated parking places e When necessary pay attention to the sign and signal lights e Park on solid ground and try to avoid sliding and falling e If the fork can be lowered due to failures of the forklift rap a cloth around the fork tip and adjust it to face the direction where no people and vehicles will pass e Pay great attention to road conditions to see if it is slippery or have any collapse e Lower the fork after the forklift completely stops Reducing the fork of the forklift during driving could be quite dangerous e Do not jump from the forklift e When getting off you shall face the direction of the forklift and step on the pedal for de boarding e For deceleration depresses the brake pedal to stop the forklift and set the gear lever switch to neutral position N e Park the forklift in a place that would not hinder operation of other vehicles according to the following procedures a Pull the parking brake lever to the specified place to activate the parking brake b Lower the fork until it reach the ground c Turn the key switch to the OFF position d Remove the key and keep it safe e Be careful when boarding and de boarding f Park the forklift When leaving the forklift fully pull the parking brake lever to slightly tilt forward the main frame Lower your fork to the ground When parking the forklift on a ramp place pads under the wheels e Remove the keys when leaving the forklift 9 U
57. ficient charging and over charging so as not to damage the battery 5 Users should conduct balanced recharging to the forklift in normal use once a month so as to adjust the proportion among the accumulator units Please refer to the relevant sections of this Mannual for detailed charging and maintenance methods Chapter 2 Structure and main parameters of the forklift I Overall size and performance parameters of the forklift 1 Overall dimensions as shown in Figure 1 1 0 e S a4 EOU J T A J FNP E oS iii e BESRA FY a 100 Ast Figure 1 1 Overall dimension 2 Technical parameters Table 1 1 Model No FE3R16AC Driving Method Electric accumulator or power supply diesel petrol LPG manual Operation Method Manual travel standing seat picking out 1 5 Nominal Load Capacity Q kg 1600 Load Center Distance C mm 1 9 84 3 6 l Axial Distance y mm ar ra DN 21 meso carage it angie owerdbackware Sy 4 2 Mast lowered height h4 mm 2195 Free lift height Lift height 4 5 Mast extended height Overhead guard height he mm Seat height h mm Towing pin height hio mm Body amp 2010 8 0 2 0 Overall length mm 2789 Body length excluding fork lo mm Overall width b b mm Fork dimension s e l mm Fork carriage width b3 mm 4 31 Mast bottom ground clearance mi mm 79 Turning radius Wa mm Power of driving motor S2 60 min kw i
58. g plate and replace it if the surface is damaged or if the lining thickness is less than the specified value Specified value of the lining thickness 4 94mm Oil inlet hole Liner plate Groove l Oil outlet Oil discharge Figure 2 49 Figure 2 50 c Check of the front and rear pump cover If the inner surface of the bush discolours turn brown exceeding the range of 150 replace d Check of the driving and passive gears Replace a pair of gears in case of excessive wear If size of D is less than the specified value replace in pairs Figure 2 51 e If necessary replace the seal rings bushing seal retaining ring oil seal spring ring 3 Assembly a Mount a new seal ring and a new retainer ring at the front end cover of the pump b Mount the upper liner plate at the front end cover trench Be careful not to mis distinguish the oil abortion hole and the oil discharge hole c Mount the drive and passive gears on the front end cover 38 d Mount the liner plate on the gear side to align the groove to the gear points Be careful not to mis distinguish oil suction side and oil discharge side e Mount a new seal ring and a new retainer ring on the groove at the rear end cover See Figure 2 52 f Mount the rear cover on the pump body and pay attention to distinguish the oil abortion hole and the oil discharge hole g When all the parts have been installed tighten the connecting bolts to the specified torque
59. h Remove dirt and oxides on the post piling and wipe clean the external of lead cable and lead chuck Unblock and clean up the vent on the filler cap During the installation process apply a thin layer of industrial Vaseline on the pole and lead chuck Check the accumulator fluid level Vertically insert a glass tube with a diameter of 6 8mm and length of 150mm into the filler until reaching the upper edge of the plate Then press the upper end of the tube with thumb and clip out the glass tube with the index finger middle finger and ring finger The height of the electrolyte within the tube is the height of electrolyte above the plate accumulator surface which should be 15 25mm Finally return the electrolyte to the original single cell accumulator Add electrolyte If the electrolyte level is too low distilled water should be promptly added other than tap water river water or well water so as to avoid failure of self discharge caused by impurities Plus do not add electrolyte otherwise the electrolyte concentration will increase shortening the accumulator life Note that the electrolyte level can not be too high in order to prevent spill over of the electrolyte during charging and discharging process that may cause short circuit After adjusting the electrolyte level charge the accumulator for 0 5 hours or more to well mix the added distilled water with the original electrolyte Otherwise the interal parts of the accumulator tend to be fr
60. he forklift are used to illustrate the use and precautions of it They are for the benefits of both you and the forklift Immediately re paste the labels if they fall off 76 ee NOBLEUFT 4 1 Nameplate 2 curve of load 3 Side shifter notice 4 reading the Operation amp Maintenance Manual 9 No carrying people 6 Suspension point 7 Prohibit suspension poin 8 Watch Your Hands 9 Tyre pressure 10 Corporate logo 11 Strong point 12 hydraulic oil 13 Product Model 14 safety belt Chapter IV Periodic inspection and maintenance Conduct a comprehensive inspection of forklift to avoid failure and to extend its service life Service hours indicated in the Maintenance Procedures is based on the assumption that the forklift works 8 hours a day and works 200 hours a month In order to ensure safe operation maintain the forklift regularly according to the maintenance procedures Routine maintenance and repair work shall be carried out by the forklift driver and other inspection and maintenance work shall be done by professional maintenance personnel I Check before operation In order to ensure safe operation and to keep the forklift in good condition please undertake the statutory duty to conduct a comprehensive inspection of the forklift before operation If any problems are found please contact the sales department of our company e A small fault will cause a major accident Don t operate or move the forklift before the comp
61. hown in figure 2 30 it by rotary bearings chain and sprocket wheel and hydraulic cycloid motor parts is composed Hydraulic motor driven by hydraulic pressure rotor shaft through the sprocket and chain drive axles by rotary bearings to realize 21 A J I li il 8 Re 1 Double row roller 2 Chain bolt 3 Chain terminals 4 Articulation bolt chain 5 spring column pin 6 Chain nut 7 Bolt 8 screw 9 spring washer 10 Hydraulic 11 Bolt 12 Support cycloid motor 13 adjusting 14 chain wheel 15 washer 16 plat washer washer 17 Bolt 18 Rotary bearing Figure 2 30 hydraulic cycloid motor and rotary bearings 3 4 Check the steering system after reinstalling 1 Turn the steering wheel leftwards and rightwards to the maximum extent to see whether the rotation is uniform and smooth 2 Check if the layout of hydraulic piping is correct and if the left and right steering are mounted reversely 3 Jack up rear wheels and slowly rotate the steering wheel leftwards and rightwards for several times to remove air in the hydraulic pipelines and oil cylinder 22 3 5 Failure analysis Table 2 4 Table 2 4 The steering The oil pump is damaged or faulted wheel gets The rubber hose or fitting is damaged or the stuck pipe is blocked Replace or clean it The pressure of the safety valve is too low Adjust the pressure There is air in the oil pipeline The steering The reset function of steering gear fails
62. ht meet requirements lf not please fill distilled water to adjust the liquid level to the required height Connect the output of the charger with the accumulator in accordance with the requirements Connect positive to positive and negative to negative Pay attention not to connect it reversed 30 The charger compatible with the accumulator could automatically regulate the charging current according to the charging capacity and conduct charging until the accumulator is fully charged Please refer to the manual of charger for details on observation of the charging state In order to keep the accumulator status updated it is recommended to record each charge and discharge conducted for each accumulator so as to provide useful basis for determining whether or not the accumulator in the future or not During the charging process measure and record the current total voltage voltage of each single cell the cells shall be numbered changes in the electrolyte density and temperature measure with a 0 100 C mercury thermometer every 1 2 hour If large quantities of even and fine bubbles come into being voltage of single cell is stabilized at 2 0 2 V and electrolyte density and terminal voltage stops rising in 2 3 hours then it can be determined that the accumulator is fully charged If any cells have no or few bubbles try to find out the reasons and fix the problem Then record it in your work log Electrolyte temperature shall not exceed 45
63. inder 4 humper 5 washer 6 pin 7 Cotter pin 8 shaft pin 9 Spring washer 10 bolt Figure 2 53 Link between the mast and chassis 7 3 Forklift frame Figure 2 54 Forklift frame will roll within the inner main frame through the main roller which is mounted onto the main roller shaft and fixed by elastic rings The main roller shaft is welded onto the fork frame and the side roller is integrated into the adjustable composite roller that rolls along the wing plate of the inner main frame Use two fixed side rollers to roll along the outside of the wing plate in the inner main frame to eliminate rolling gap The longitudinal load will be born by the main roller When the fork rises to its highest level the top roller will be exposed from the main frame top Lateral load will be born by the side roller 1 Back rest 2 Fat washer 3 Spring 4 Bolt 5 Roller washer 6 Spring washer for shaft 7 Composite roller 8 Fork frame 9 Fork assembly Figure 2 54 Fork frame 7 4 Roller position Figure 2 55 There are two types of rollers outer frame composite roller composite roller of inner frame and fork frame The two rollers are installed in the outer door frame inner door frame and fork rack Composite roller consists of the main roller and the side roller with the former bearing loads from the front and rear sides and the latter bearing loads from the side to achieve free movement of the inner door frame and fork frame 43
64. ing gear and Vavle block Check or replace the lubrication on axle supporting bearing Check or replace the Rear axle lubrication on bearing of the steering wheel hub MEN Check the operating conditions of steering cylinder Posse Y the steering cylinder dardak of gear and rack a A working status 7 Braking system Every 3 Every 6 Maintenance Maintenance months months Item content 1200 Per day per week per month Pedal trave Y Y yo Operating y Brake pedal conditions _ AED the brake lines If the brake control is safe and reliable Manipulation of parking and with enough travel brake control A 2 O L and etc connection Wear of the joints Hp with ag rupture Pipelines Connection clamping parts and y y y looseness status Check the oil level and replace oil Action of master cylinder and wheel Braking Leakage and Master damage of master a cylinder and wheel an L L Wheel Check wear and Cylinders damage of master cylinder wheel cylinder piston cups and check valve 8 Hydraulic system 89 Hydraulic dl the cylinder The control valve rod Multiple valve and unit self locking vavle Hydraulic Pump Cylinders 9 Lifting system Every 6 months 1200 hours y a p gt O ajal e E ka y y x 1 to 2 years y y SPTOCKGL Riveting pin and its loosenes
65. ing brake lever HP Depress the brake pedal al Fully release the parking brake lever forward seize ANI ee the steering wheel with your left hand and place your right hand gently on the steering wheel 7 Driving 1 Starting Release the brake pedal and gradually depress the accelerator pedal and the forklift will start moving Change in acceleration depends on how much the accelerator pedal has been depressed E O J a i 3 Do not suddenly start or stop otherwise the goods loaded may fall down 2 Deceleration Slowly release the foot pedal Depress the brake pedal if necessary If it is not for an emergency brake slowly release the accelerator pedal to decelerate until the forklift stops But even if the accelerator pedal is released rapidly emergency brake won t be activated Under emergency situations please press the brake pedal to perform emergency braking AM Slow down in the following cases a When turning at a crossing b When moving close to the goods or tray c When moving close to the goods d When staying in a narrow channel e When the ground road condition is bad e During reversing operation you must watch the rear side directly and ensure safety through visual confirmation Relying only on the rear view mirror may cause dangerous 3 Turning Unlike common cars forklift adopts rear wheel steering So operators shall slow down and watch the r
66. it 4 The return spring of brake shoe is Replace damaged 5 The brake drum is deflected Repair or replace it 1 Oil leaks in the brake system Repair or replace it The 2 The brake shoe clearance is not Adjust the regulator braking well tuned gt 3 Air is mixed within the brake system Let out the air enough 4 The brake pedal is not adjusted Readjust it appropriately 2 9 Care and maintenance 1 Before conducting running in test of a new drive axle users shall fill in gear oil gear oil shall be selected in accordance with the instructions Please refer to Table 2 1 for the specific requirements Fill oil into the hole at top of the axle shell until oil is spilled out of the oil level hole in central axle 2 The thickness of friction disk on brake shoe is 8mm The minimum thickness allowed is 2mm These two are key components of the braking system and should be checked monthly If excessive wear is found the components shall be timely replaced to avoid accidents 3 Technical maintenance after each 50h I Change the gear oil if a new axle has been working for 50h along with the forklift Clean the axle before refilling new oil Il Check all the fasteners If any looseness is found tighten it immediately III Check the wheel axle and wheel hub connection for any oil leakage Re apply sealant if any leakage is found 4 Monthly technical maintenance I Check the brake drum for any destructive wear II Check the wea
67. itial charging charging voltage will be up to 2 6V and the voltage change shall be less than 0 005V When electrolyte density is 1 28 0 005 25 C if there is no significant change within 2 hours and fine bubbles emerges intensely the accumulator can be considered fully charged The charging power is 4 to 5 times of the rated capacity and the charging time is about 70 hours In order to accurately control the content of sulfuric acid in the electrolyte the density of the electrolyte should be checked at the end of the charging process In case of any discrepancy please use distilled water or sulfuric acid with density of 1 40 to adjust Ensure the electrolyte density and height level is adjusted to the specified value within 2 hours since the charging starts Wipe clean the accumulator surface and cover the filler cap before putting into use 2 General Charge Do not use accumulator that is not fully charged Users should pay close attention to the discharge level of accumulator during use If the discharge level exceeds the set value conduct charge in time Excessive discharge is strictly forbidden When the voltage drops o 1 7V cell electrolyte density decreases to 1 17 stop discharge timely and conduct charge soon Never delay charging for a long time Don t stop halfway without reason during the charging process When conducting general charge first open the flip cover on the filler cap cover and check whether the electrolyte heig
68. its piston rod end connected to the main frame through the earrings Bottom of the tilting oil cylinder is connected with the frame by pins and there is a tilted cylinder at each side of the forklift The tilting cylinder is mainly composed by piston piston rod cylinder cylinder bottom guide sleeve and seals The piston and piston rod adopt welded structure with the piston outer surface mounted with a bearing outer ring and two Yx seal rings In the internal hole of guide sleeve there mounts an axle sleeve Yx seal ring retaining ring and dust ring The shaft sleeve support the piston rod seals retaining ring and dust ring that protects from oil spills and dust all of which are mounted to the cylinder together with the O ring See Figure 2 59 When the tilt sliding valve is pushed forward the high pressure oil will flow from the cylinder bottom to push the piston moving the main frame titling forward When the slide valve is pulled backwards the high pressure oil will flow into from the front end of the cylinder to pull the piston backward moving the main frame titling backward 36 A A D EZ gt PTW ti ia RQ SAAS Y a imi ET APRA AO iP re T 20 19 18 17 16 l 1 Retaining 2 Joint bearings 3 Dust proof ring 4 Cover of 5 Barrier chip ring for shaft cylinder 6 Retainer 7 Shaft seal 8 O ring 9 Retainer 10 Piston rod Ring Ring 11 Cylinder 12 Nut 13 Pin 14 Stee
69. ity Recharge the accumulator if necessary Accumulator maintenance is relatively simple but requires patience and meticulousness Timely supplementing and density control of the electrolyte as well as cleanup of accumulator and polarity terminals can effectively extend the service life of accumulator Check if there is water in the accumulator box and drain the water immediately if any In addition the accumulator should not be stored with electrolyte in it In case of short term storage of a fully charged accumulator please charge the it every month during the storage period to compensate for self discharge of the accumulator preventing vulcanization of accumulator plate or 28 eliminating minor vulcanization of the accumulator plates Plus users shall check the accumulator status frequently during the storage period If the accumulator is being used please conduct a fully discharge together with a fully charge each month This could help maintain accumulator capacity and avoid plate salvation Please keep the external surface of the accumulator clean Check the accumulator and the fixing status of wire leads There should be no looseness Check the accumulator case for cracking and damage and then check the pole and lead chuck to see if they are burnt Wipe clean dust on the external surface of the accumulator with a cloth If electrolyte overflows to the surface please wipe with a cloth or rinse with hot water and wipe it dry with a clot
70. k medical aid in case of injuries 61 WARNING A WARNING Don t change forklift parts without permission Please read the instructions before operating the forklift A WARNING Understand the traffic rules Ay WARNING A WARNING Check the forklift before use Do not move the overhead guard 62 Ah WARNING fi WARNING Hold the handrail during on boarding Start the forklift in a correct way 63 WARNING Appropriately fasten the seat belt gt e gt JESN NCE e Ve A h i y hy i 1 6 cani 5 cl i i he ks Turn on the lights in dark areas Avoid driving on soft or unprepared ground Drive on flat and solid surface Ah WARNING Make sure that your forklift is under safe working condition Always pay attention to the height of the working area of forklift Do not expose your arm and body outside the overhead guard A WARNING Lo Ugur SI A E e ik HA e Keep the body under the overhead guard Avoid eccentric loading Pay attention to keep the projecting fork clear from goods ahead WARNING Don t drive on smooth or slippery ground Ensure the lateral driving stability when the forklift is running without load Be especially careful when handling Carrying passengers is absolutely goods with relatively large length or width prohibited
71. k the overhead guard and backrest Check the bolts or nuts for looseness 16 Check the integrity of the labels 17 Others Check for abnormalities on other components e In addition to checking of the lights and operating conditions turn off key switch and unplug the accumulator before check the electric system Il Checking after operations 82 After work remove dirt from the forklift and check the following items 1 Inspect all parts and components for damage or leakages 2 Check for deformation distortion damage or breakage 3 Add grease if necessary 4 Lift the fork to the maximum height for several times after operations are finished After you do not lift the fork to its maximum height in daily work this allows the oil flow through the cylinder to prevent rusting 5 Replace abnormal components that cause failures during work e A small fault will cause a major accident Do not operate or move the forklift before completion of repair and inspection I11 Clean the forklift e Park the forklift at the specified location e Pull the parking brake lever e Press the emergency stop switch e Turn off the key switch and remove the key e Disconnect the accumulator plug 1 Clean the forklift surface Do not use flammable liquids to clean the forklift and take safety measures to prevent short circuits Use water and soluble detergent to clean the forklift Carefully clean the oil filler and the periphery of
72. l 15 Hole sea body backed bearing 16 Support 17 Oring 18 Piston 19 Adjusting 20 Steel backed ring sleeve bearing Figure 2 45lting oil cylinder 6 7 Hydraulic oil cylinder The hydraulic cylinder is installed at right rear of the frame Meshy filter is mounted to the cylinder and breather is mounted to the cylinder cover See Figure 2 60 12 3 4 5 6 7 8 9 10 ae 1 bolt 2 washer 3 Cover plate of oil cylinder 4 Paper washer 5 Cover of refueller 6 cover board assembly 7 Paper washer 8 oil tube 9 Clamp 10 Breathing device 11 Meshy filter Figure 2 46 6 8Maintenance and adjustment Maintenance of working oil pump 1 Disassembling Clean it thoroughly before disassembling Removed parts should be placed on a clean paper or cloth Be careful not to make the parts dirty or damaged a Place the pump flange at the clamp table b Remove the connecting bolt 11 rear end cover 5 and pump 1 c Remove the liner plate 6 drive gear 2 and passive gear 3 d Remove the seal ring 7 and retaining ring 8 from the front and back end cover Note If you do not plan to replace the seal ring do not remove it from the front end 2 Check 37 Check the disassembled parts and clean them with gasoline except rubber parts a Pump check If the contact length of pump cavity and gear is greater than 1 2 of the circumference replace the pump Figure 2 47 Figure 2 48 b Check of liner plate Check the contact surface of the linin
73. let check Oil inlet hole Middle Figure 2 37 Figure 2 38 c Pull out the slide valve Figure 2 38 The middle position is closed at this time oil from the inlet hole openes the check valve and flowes into the cylinder interface A Oil flows from interface B will flow to the cylinder through the low pressure channel Then the slide valve can return to the middle position with the help of the return spring 2 Action of safety overflow valve Figure 2 39 The overflow valve is installed between the HP interface of the oil pump and the low pressure channel LP The oil that flows through the lifting valve C will acts on the different areas of diameter A and B so the check valve K and overflow lifting valve D all land on the valve seat The preset pressure in the oil pump HP channel will act on the spring of pilot valve and the check valve E will open Oil will flow around the valve into the low pressure LP side through the open end hole Once the pilot valve E is open the pressure at the inside of valve C will decrease and the 33 valve E and valve C will both land on the valve seat Liquid flow at back of the flow valve D will be off so the pressure inside is reduced Pressure on pump HP channel side and the inside pressure are different the valve D will open under the pressure difference and the oil will directly flow into the low pressure loop LP Figure 2 39 3 Action of the self locking til
74. letion of repair and inspection work T1 e Conduct checking the forklift on a platform e Before checking the electrical system of the forklift turn the key switch off and unplug the accumulator before check e Improper handling of waste oil such as dumping into water pipes soil or burning them will cause pollution to the water soil and air thus are strictly prohibited 1 Check MO and ce No Check Check points Check contents contents Travel distance and braking force of the Brake pedal foot brake pedal 2 Brakeol oil Brake oil Quantity and cleanliness Quantity and cleanliness cleanliness Travel distance and braking force of the 2 pees brake parking brake lever Manipulation of steering Tightness rotation forward and backward Steering wheel movement em vanpuation The operation of all components hydraulic steering 6 Features Function cracks and lubrication status dde EEE LTS ME system Pipeline If the oil pipeline leaks and main 8 Hydraulic Oil Appropriate oibvolume Appropriate oibvolume volume frame Tightness of the left and right chains Lifting chain should be the same o a Pressure size and if there is any damage Wheels or abnormalit 11 Rimnut A nut Firmly tighten it Check the display status of accumulator Accumulator Charging capacity the specific gravity and firm connection of the plugs Headlights tail lamps Switch on and off the lamps to see if they reversing lamp ste
75. load curve rear wheels may be lifted and subject to extreme cases and the forklift may rolling over causing serious accidents If goods are stacked at a place close to the sharp tip of fork the risks above also exist In this case decrease the load weight 3 Load centre and load curve Load centre refers to the distance between the front surface of the fork and the cargo s centre of gravity Load curve label indicating the relationship between the load centre and the allowed loading quantity allowable load is attached to the forklift Replace the plate in case of damage or loss O If the forklift is equipped with accessories for cargo handling such as the side shifter bucket or rotating fork the allowable load shall be less than standard forklift without accessories for the following reasons 1 Reduce loads equal to the weight of the accessories 2 Since adding of accessory will move the load centre forward the allowable load will be reduced accordingly The installation of accessory will cause load centre shift forward which is known as the loss of load centre Do not exceed the allowable load indicated by the load curve attached to the forklift or the accessory 4 Forklift stability 4 Standard of forklift stability is specified in ISO or other standards However the stability described in these standards does not apply to all the running status and the stability of forklift varies with different operational status
76. 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 19 refers to a potential danger if not avoided it may cause serious human injury vehicle damage or fire Z A refers to a potential danger if not avoided it may cause minor human injury or local damage to the vehicle 3 Refers to general cuations and instructions during use Dial parts of the product are made from recyclable steel The recycling and disposal of cast offs resulted during use maintenance cleaning and disassembling of 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 ma
77. nannnnrnnonnnnnnnos 9 Use method of the accumulator occccconcncccocnncccononononnnnncononononnnnnnannnonnnnnnnnnnnnnnonons e e GB o o PP e UE ESO O e O CERO Pr e o E A A E E A II Operation device and use method ooccccccconccncncconncnnnccononnncnonancnnnononcnnnnononennncnnnconenoss 1 Diagram on forklift parts and operation device occccooccccoccccconnccocnnconcnononnnononocononononos 2 Combination INSTUMONE eisciricnscsria sd indeds cxnndedientdi aveexsdugescassevecdevsccdenctacdseracene bh A Sn nn N XA 5 Forklift DOV song rex hsp scteccecsecexeenecepimeneg neni rombos costes cientes TANEN ASEE ME POE ANS ccc ete cs ee sa tse ecco ssc ee weno ee pees se ee 1 Site and working environment of the forklift ooocccooncncoccccncconcnnonocononanononononnos ES e 3 Handling OF the Torla ic 71 4 How to avoid rollover and how to protect yourself from accidents ccoocccccocnncco 12 5 Safety issues during maintenance and protection ooccccooccccocncconnncconnncconoconononononos 74 6 Safety during use of the accumulator occccccooccccccnncnnocnconccnnnnnonenenonnancnnnnnnnnnnanennnnos 75 PP een ere eee ee 77 Chapter IV Periodic inspection and maintenance of forklift o ccooccconcoconccornnononos 78 I Check before OperatiON occccoocccccccnnccocononcconnnnononnnnonononononnnononnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnns 78 1 Check points and ContentS
78. of full battery power 2 Lever Malfunction indicator light flashes the forklift is in alarm 3 Temperature Temperature indicator light flashes the stacker is in alarm due to high temperature of IMS 4 Seat Seat indicator light flashes the operator has left the seat 5 Handbrake Handbrake light flashes handbrake function is activated When the main switch is off Eco Smart display will perform a comprehensive test and turn off all the LCDs in turn Meter fault code CNME A E DIR CONT OPEN or CHOPPER ronne fas RIGHT con CLOSED 02 NO COMMUNICATION 44 RIGHT CONT OPEN 03 UNKNOWN CHOPPER 4 o CONSOLE terr AS 47 06 SERIAL ERROR 1 48 26 ACI TO EA aR Co O A AE EEPROM CONF KO EEPROM OFFLINE LOGIC FAILURE 4 Cis f Locic raue 2 6o CAPACITOR CHARGE FORW VN HICH BACK VN HIGH Ca fern e y e w LEFT VAN HICH RIGHT WN LOW Cee g N BATTERY LEVEL 1 RIGHT VYN HIGH eo CURRENT SENS Ko POMP VAN LON 70 ii VIN LOW NO FULL COND LFT NO FULL CONO Cs f comeron oes so OR eak Cse Pma veo o eoa Css macron BRUSHES 9e weno OO Cso f Poe seoses E E O A 9 EE a oeo o o 27 5 Accumulator Accumulator seen as figure 2 34 Figure 2 34 Accumulator 5 1 Accumulator safety precautions A Appropriate ventilation measures shall be adopted because hydrogen and oxygen will be generated at the end of the accumulator charging process If Spark occur during the process ex
79. of 9 10kg m 1 Pump body 2 Driving gear 3 Passive gear 4 Front end cover 5 Rear end cover 6 Liner plate 7 Seal ring 8 Retainer ring 9 Oil seal 10 Flexible ring 11 Bolt 12 Washer Figure 2 52Gear pump 4 4 Test run Conduct running in of the pump to check if it functions properly Then perform oil pump testing on the test bench or test by the following steps on the forklift truck If oil pump is subject to decomposition and maintenance due to serious wear and jamming caused by the hydraulic oil the hydraulic oil and filter should be replaced before test running on the forklift a Mount the pump onto the forklift and mount the pressure gauge onto the test hole of the multiple unit valve b Loosen the adjusting screw of the overflow valve to keep the pump working for 5001000 1000rpm for about 10 minutes Ensure that the oil pressure is lower than 10kg cm c Increase the pump speed to 1500 2000rpm and keep it running for about 10 minutes d Set the pump operating speed at 1500 2000rpm Perform pressure increment of 20 30kg cm and keep it running for 5 minutes after each increase until the pressure reaches 175kg cm Then keep each oil line working for 5 minutes and replace the oil returning filter When increasing the oil pressure pay attention to the oil temperature pump surface temperature and the operation sound If the oil temperature or the pump surface temperature rises excessively reduce the load to lower
80. orm balanced recharging to the accumulator once every two or three months during normal use accumulators that are left unused for a long time should be charged before use 5 4 Installation and replacement of the accumulator Perform installation and replacement of batteries in a fixed and reliable manner to avoid tipping Beating on the polar column and lead chuck with a tool is strictly forbidden in the handling process pay attention to avoid strong impact 31 6 Hydraulic system 6 1 Overview The hydraulic system consists of working pump multiple unit valve lifting cylinder tilting cylinder pipelines and other component parts See figure 2 48 The hydraulic oil will be supplied by the oil pump directly connected with the motor The multiple unit valve will assign oil to each cylinder Il eo Lo In ae o E y i Eu ea 9 amp 2 1 9 Figure 2 35 Diagram of t hydraulic system 3 First valve 7 The speed limit valves 10 Full hydraulic steering gear 2 The gear pump 6 Tilt oil cylinder 1 Nets type oil filters 5 With oil cylinder of 9 Hydraulic cycloid motor 6 2 Oil pump The oil pump is a gear pump 6 3 Multiple unit valve 4 Many paths valves 8 Lifting cylinder The multiple unit valve includes two four piece valves Controlled by the valve rod of the multiple unit valve the hydraulic oil from the work pump will assign high pressure oil to the lifting cylinder or tilting c
81. ous burning 9 Emergency treatment When an accident occurs perform following emergency treatment and contact a doctor immediately e spilled on skin rinse with water for 10 15 minutes e spilled in eyes rinse with water for 10 15 minutes e contamination in large area use soda sodium bicarbonate or clean with water e Ingestion Drink plenty of water or milk e spilled on clothing immediately take off the clothes 10 Put on the accumulator top cover A Put on accumulator top cover tightly to prevent electrolyte leakage e Do not add too much electrolyte otherwise the electrolyte will overflow and cause current leakage 11 Waterproof e The accumulator can not be wet by rain or sea water otherwise the accumulator will be damaged causing fire 12 Abnormality of accumulator When the following problems occur to the battery please contact our sales department e Accumulator stinks e The electrolyte gets dirty e The electrolyte temperature gets higher e The electrolyte volumes reduce quicker than normal 13 Prohibiting disassembling e Do not drain the electrolyte from the battery e Do not disassemble the battery e Do not repair the battery 14 Storage e When the accumulator is to be unused for a long time it should be stored in well ventilated places with low possibility of fire 15 Disposal of waste battery e Contact our sales department for disposal of waste battery 7 Lables Labels posted on t
82. ozen in winter Check the electrolyte density The electrolyte density varies with the different degree of accumulator charging and discharging Drop of the electrolyte density is an indication of accumulator discharging To measure the electrolyte density in each cell is a manifestation of the accumulator discharge level 1 Measurement method Remove the liquid filler cap in the single cells in the accumulator and draw the electrolyte from the liquid filler cap with a density meter until the float of density meter floats up When observing the readings you should raise the density meter to a position that flush with your eye sight and put the float in the center of the glass tube without touching the tube wall so as not to affect the accuracy of reading If the temperature is below 25 C or higher than 25 C a thermometer should be used to measure the actual temperature of the electrolyte for correcting the value of electrolyte density 2 Correction of electrolyte density errors exist in the density of the electrolyte at different temperatures so the electrolyte density value shall be corrected accordingly Electrolyte density at 25 C shall be used as the benchmark Therefore if the electrolyte temperature is higher than 25 C you should add 0 0007 to the actual measured value of density for an increase in temperature by 1 C In contrast if the electrolyte temperature is lower than 25 C subtract the density by 0 0007 when the temper
83. plosion may be caused A Harmful acid mist will also be generated during charging Remove the mist promptly after charging and clean up the accumulator and the charging place promptly A Please wear protective glasses and rubbergloves when charging the accumulator as it contains sulfuric acid Careless use may cause skin burns and loss of vision If you splash electrolyte acid in your eyes or skin immediately wash with plenty of water and visit a doctor for treatment Electrolyte on clothes can be washed off with water A People who are not familiar with the operating method of the accumulator and its dangerousness shall not use the accumulator so as to avoid harm to personnel caused by the dilute sulfuric acid A Never place any metal objects or tools on the accumulator to eliminate the danger of short circuit A Unplug the power connector of the accumulator only when power is fully turned off Hot plugging is strictly prohibited A Before installing the accumulator please read the instruction manual carefully After reading please keep it with you for future reference 5 2 Accumulator use precautions Service life of the accumulator is generally 2 to 3 years or even 4 years if it can be properly used and maintained In case of the improper use and maintenance it may suffer early damage in a few months since initial use During use of the accumulator users should regularly check the electrolyte level and the remaining accumulator capac
84. plug 20 Return spring base 21 Guide plate 25 pallet 29 Hand braking bars 33 Braking wiring 22 retainer spring 26 Pin 30 pin 34 sring 23 Orientation block 2 Hand braking 31 spring washer 35 Bolt 24 Spring 28 Spring 32 Stem pin block circle assembly Figure 2 4 Brake 1 Brake action Brake cylinder exerts the same force to the main brake shoe and auxiliary brake shoe to suppress the brake drum until the upper end of auxiliary brake shoe contacts against the fixed pin Then the brake shoe will move towards the rotation direction of the brake drum After contact against the fixed pin the friction between friction disk and brake drum will increase The main brake shoe will exert a pressure larger than the brake cylinder pressure on the auxiliary brake shoe resulting in a large braking force See Figure 2 5 When moving backwards the brake action is in reverse to that of moving forwards See Figure 2 6 12 Driven brake shoe Figure 2 5 Action when moving forwards Figure 2 6 Action when moving backwards 2 Parking brake Mounted in the wheel brake the parking brake consists of the lever and push lever The lever is mounted on side of the main brake shoe by a pin and the pulling action spread through the push lever to the auxiliary brake shoe See figure 2 7 3 Clearance self adjusting mechanism The clearance self adjusting mechanism can maintain appropriate clearance between the friction disk and the
85. r condition of brake shoe If wearing is so serious that the brake shoe fails to meet requirements the brake shoe should be replaced immediately II Check if the oil level in axle shell meets standards If the oil level reduces users should promptly fill up Semi annual technical maintenance Change the gear oil within the axle once every six months of working 6 Annual technical maintenance Disassemble the drive axle for inspection every year 7 Check and debug requirements during the installation process When re installing the wheel hub of the drive axle users should regulate the clearance adjuster of the brake so as to set the gap between brake drum and friction disk at 0 3mm 0 5mm Fill 100ml 3 lithium base grease into the tapered roller bearing on the wheel hub Adjustment of the bearing clearance on wheel hub tighten the inner locking nut until the wheel brake drum can barely turn up Then rotate the inner locking nut in reverse for 1 8 circle At this moment wheel brake drum can be freely rotated without jamming significant axial clearance or deflection Finally assemble the washer pad and tighten the outside locking nut 19 3 Steering system 3 1 Overview The steering system Figure 2 28 mainly consists of the steering wheel steering shaft steering gear Hydraulic cycloid motor and Rotary bearing The steering shaft is connected with steering gear through gimbal joints while the connecting shaft is connect
86. rake hose or tube Hydraulic hose for the lifting system Lifting chain High pressure hose and tube for the hydraulic system 1 L L Oil cup of the brake fluid Brake master cylinder cover and dust proof cover Internal seals and rubber parts of the hydraulic system 93 V Lubricating parts and recommended oil 1 Lubricating parts o Replacement FO Hydraulic oil o adding GO Gear oil o Check and adjustment CG Lubricant grease BO Brake oil W Distilled water litig chain CG Direction column CG Accumulator ow Drive axle OG 4 A ES S7 y DA SN is e 4 z gt j y Ls j i a A A l LA i Brake pedal CG 4 e a Y tT Y 1P 7 Brake oi tank BO 2 Recommended oil Name Nameplate code Remarks liters Hydraulic Oil 40 Hydraulic fluid Caltex Dora o2 accumulator Industrial l 2 electrode Vaseline column Lubricant Universal lithium grease grease for automobiles 94 VI Forklift noise and vibration parameters table Forklift model FE3R16AC Biggest speed Vibration without load parameters m s ue Noise parameters dB BO Biggest speed Vibration 0 214 with full load parameters m s Noise parameters d8 BO Note 1 The noise testing method accord with the European Union noise testing method 12053 2001 2 Tire excessive wear or the ground condition will increase noise poor value 95 NOBUEL ZheJiang Noblelift Equipment Joint Stock
87. ressed 6 Lifting lever Pull back the fork lever to lift the fork and push forward the fork lever to lower the fork Lifting and lowering speed can be controlled by the tilting angle of the lever The greater the angle is the greater the speed will be e If you push or pull the lever when turning on the key switch the fork will not lift e Do not suddenly reduce the fork or suddenly stop lowering the fork 7 Tilt lever The main frame will tilt backward when pulling the tilt lever backward and tilt forward when push the lever forward Speed of titling forward and backward can be controlled by the tilting angle of the lever The greater the angle is the greater the speed will be 58 A If you push or pull the lever when turning on the key switch the fork will not tilt 5 Forklift body 1 Seat By adjusting the lever the operator can tune the seat position for greater comfort Pull the lever upwards to activate the adjustment function After completing adjustment try to move the seat back and forth gently to confirm if the seat has been locked Adjustment range of seat position is within 120mm When driving on dry concrete ground the seat will exert a vertical acceleration on the driver at the speed of 2 130m s 2 237m s and the integrated acceleration is 2 252m s 2 356m s 2 Overhead guard IN Overhead guard is a import component that prevent falling of objects overhead and protect the operator s safety
88. rnor valve 26 Nut 27 Chain 28 Chain wheel Figure 2 42ifting cylinder and chain 35 WE Working status of the shut off valve A shut off valve is mounted at the bottom of the lifting cylinder see Figure 2 43 When the high pressure hose suddenly bursts it could avoid sharp decline of the goods Oil from the lifting cylinder will flow through the shuut off valve and slide valve The oil hole around the slide valve will generate pressure difference between the two cavities If this pressure is less than the spring force the slide valve does not move For example if high pressure hose bursts forming a large pressure difference the slide valve will move to block the holes around so that only a small amount of oil will flow through the small hole at the slide valve end to slowly decline the fork 3 Normal status Shut off status 1 Lifting cylinder 2 Pressure spring 3 Valve core Figure 2 43hut off valve 6 5 Governor valve The governor valve is installed within the right lifting cylinder to control the decline speed of fork and to ensure safety in case of rupture at high pressure and other unexpected situations See Figure 2 58 for the connection method WW 1 Lifting cylinder 2 Valve core 3 Pressure spring 4 Screw plug Figure 2 44uilt in governor valve 6 6 Tilting Oil Cylinder The tilting oil cylinder is double acting with
89. rotocol With its analog and digital O and communication devices the controller is ideal for managing forklift movements O for controlling operation and for displaying information In addition it can perform discharging and monitoring of the battery group and offers a variety of protection Dashboard display ECO SMART can show a variety of data and can be set at factory or by users Plus other functions such as entering of user commands are also avaliable 24 4 2 1 Main functions and settings By properly setting the motor parameters control parameters and corresponding functional value of the controller users can acheive safe and efficient performance as well as full operational capabilities of the electric forklift 1 The crawling speed of electric forklift can be regulated By setting the crawling speed of the controller users can operate the electric forklift under low speed in a long time 2 Acceleration rate can be regulated Under different acceleration rate the hardness and softness feel of the accelerator pedal varies By setting of the acceleration rate users can meet various accelerating demands in different conditions 3 Reverse braking and regenerative braking When the direction lever is placed reversely during moving of the forklift a reverse braking signal will be created and then the motor drive will order the traction motor to generate a braking torque so as achieve the purpose of deceleration Size of the
90. s Deformation If the sprocket of bearings are loose Lifting cylinder and Over tilt cylinder PStTaung conditions Damage wear of the location inner main frame outer main frame and welded parts on the Bad welding between tilt cylinder bracket and the main frame inner and outer main frame Bad welding cracking or bearing of the main frame Looseness of bolts on the Only for main frame the first Only for the first 10 Others Maintenance Maintenance Tools Per per per Every Every Item content day week month 3 6 months 92 8 50 200 months 1200 hours hours hours 600 hours hours are firmly Test MR Check the deformation 4 N cracking and damage Steerin Working and J installation y y y y y amp status Working and status all i ERE EE one installation y y y y light bulbs status y y y Overhead guard and backrest L L Working and Back up installation buzzer status Working Instrument status of y instrument Damage and loosening of Wiring aarne Loosening of ae DP connection 2 Replace critical safety components periodically If injury or damage of some parts is difficult to find through regular maintenance users shall conduct periodic replacement of parts given in the following table to further improve security If these parts are abnormal before the due replacement time replace them immediately Name of key safety components B
91. se of the accumulator 1 Charging of the accumulator Choose appropriate charger for charging of the accumulator and operate in strict accordance with the Maintenance Manual of the charger a Don t maintain the electrolyte at a too low level 51 A Maintain the electrolyte at the required level otherwise the accumulator may be overheated or burned e When the electrolyte level is low the accumulator life will be shortened b Add distilled water c Overcharge is not allowed d Charging should be carried out in a well ventilated place e Charging should be carried out in a well ventilated and moisture proof place b Open the accumulator cover A Hydrogen will be generated during the charging process Open the accumulator cover during charging f Check the connecting terminal cables and connectors e Users should check the connectors and cable lines for damage before charging Never conduct charging in case of the following conditions The connector electrode is damaged Connection terminals and cable lines are corroded These conditions can result in sparks burning fire or explosion g Conduct charging after the key switch is turned off h Check the specific gravity Measure the specific gravity of electrolyte in all the single cell accumulator before charging to identify abnormality of the accumulator Understanding the specific gravity before charging could help eliminate the possibility of accidents i When connecting and
92. t of tires e Removal and installation of tires must be operated by professionals e Handling of high pressure air shall be done by professionals e Wear a goggle when using compressed air e During disassembling of tires do not loose bolts and nuts at rim connection As there is high pressure gas within the tires looseness of bolts nuts and rims could cause danger e Before removing bolts and nuts at the rim connection you must first exhaust the high pressure gas within the tires with special tools 5 Use of jack replace the tires e When jacking up the forklift do not keep any part of your body below the forklift e When jacking up the forklift ensure that there are no one and no load in the forklift e When the forklift wheels are lifted off the ground stop use the jack and place pads below the forklift to protect it from falling down e Take measures to prevent the forklift from sliding before jacking up the forklift 6 Requirements on waste discharge electrolyte liquid oil etc Waste parts on the forklift plastic parts electrical components etc and waste liquid hydraulic oil brake fluid etc should be recycled according to the local regulations rather than discharged 6 Safety during accumulator use 74 1 No smoking The accumulator can produce hydrogen Spark will generate in case of short circuit and lit cigarette near the accumulator may cause explosion and fire 2 Prevent electric shock
93. t valve Self locking tilt valve is mounted in the tilt cylinder valves The self locking valve could prevent sudden fall of the main frame when negative pressure occurs in the cylinder and also eliminate dangers if the valve rod is titled due to misuse With this self locking valve when forklift motor stops working the main frame will not tilt forward even if the control lever is shoved Oil flow direction when valve core is pulled out is the same with that shown in Figure 2 38 at which time the main frame is tilting backwards a When the valve core is inserted pump is working oil from the main pump will flow into the tilt cylinder through interface B and the oil flowes back from the cylinder will be used to the piston through the role of port A Oil will return to the cylinder through the holes A and B on the valve core See Figure 2 40 b When the valve core is inserted pump is not working there will be no oil that flows into interface B of the cylinder so that the pressure in part P will not increase Therefore the piston will not move and oil in the cylinder Interface A can not return to the oil cylinder which won t move See Figure 2 41 Oil inlet A Oil inlet B Oil inlet A Oil inlet B Wie ALIN Jia Self locki Self locki Figure 2 40 Figure 2 41 4 Pressure adjustment of the safety valve The pre set pressure of the safety valve 13 5 16 8MPa Pressure of the safety valve has been set by the manufactur
94. tection If damage occurs to the controller s power components when forklift is running the controller will disconnect the main contactor in the shortest time if the controller s temperature is too high the controller will automatically limit armature current of the motor if the battery voltage is too low the controller will stop working to ensure safety 8 Both the traction motor controller and pump motor controller are equipped with a self diagnostic function Fault code will show on the meter display and the controller will be automatically disabled to ensure the operating system s security whenever controller fault occurs during its working process 9 The meter display will show the battery power and its cumulative work hours 4 2 2 Maintenance of the electrical system 1 Check wear status of contacts and change them if worn Contactor contacts should be inspected every 3 months 2 Check the micro switch of pedal or handle and measure voltage drop at both ends of the micro switches No resistance shall be found when the micro switch is open or closed and crackling sound shall be heard during release Check once every 3 months 3 Check the main circuit accumulator controller connection cable of motor Ensure good cable insulation and tight electrical connection Check once every 3 months 4 Check the mechanical movement of the pedal See if spring deformation is normal and if potentiometer spring is retractable within the maxim
95. tween main roller and the lower end of the inner main frame A 24 29 44 i oo A p ECEFTELIF ED TEE ETE a A EEEE ES RED i lt Figure 2 57 1 Fork 2 Fork frame 3 inner mast 4 Main roller 5 Main roller 6 Tires 7 outer mast 3 Lower the fork to the ground and tilts it backward in place Adjust the upper end joints of the chain and then regulate the nut to set tightness of the two chains at the same degree 7 5 3 Change or replace the roller of the fork frame 1 Place a tray on the forklift and park it on level ground 2 Lower the fork and tray down to the ground 3 Remove the upper end joint of the chain and remove the chain from the chain wheel 4 Lift the inner main frame in Figure 2 58 5 Reverse the forklift after confirming that the fork frame has been separated from the outer main frame 2 in Figure 2 58 6 Replace the main roller a Remove all of spring rings and remove the main roller with drawing tools Pay attention to the adjustment pad b Confirm that the new roller is the same with the newly replaced one Mount the new rollers to the fork frame and fix it with an flexible washer Figure 2 58 Figure2 59 7 5 4 Replace the roller of main frame as shown in Figure 2 59 1 Accoding to the method of replacing fork frame roller as described in 7 5 3 remove the fork frame from the main frame 7 5 3 2 Drive the forklift to a level ground and jack up the front wheels for 250 300mm
96. um level or to a set level Check once every 3 months 5 Check once every 3 months the mechanical movement of the contactor which should move freely without adhesion 4 3 4 Combination instrument The forklift uses new combination instrument that provides auxiliary control function and displays the forklift condition to the driver It consists of control circuit cumulative time counter on 25 LCD accumulator meter fault code display and other display circuit In order to meet the current demands and requirements on electric forklift the instrument adopts new design on control circuit and display form featuring compact structure elegant appearance high automation level and reliable quality providing drivers with intuitive information of the forklift status Smart monitor is equipped with six built in red LCD displays which could provide basic information of the forklift s operation status to the operator See the Figure below 8 9 10 11 12 13 1 Latency light 2 Failure alarm light 3 Battery level mark 4 Display of speed time and battery level 5 Temperature warning 6 Indication light of 7 Indication light of seat 8 Meter function keys light hand braking 9 Function selection 10 Function selection 11 Parameter adjustment key 12 Parameter key up key down adjustment key 13 Exist function key 14 Battery indicator 1 Battery Battery indicator lights on the measured battery capacity is less than or equal to 10
97. umulator unless circumstance requires UI About safety Ensure safety is your business and responsibility This section describes the basic safety regulations and warnings during use of the forklift but also applicable to forklifts with special specifications and with the main frame and accessories 1 Site and working environment of the forklift 1 Ground conditions The forklift should used on solid ground in well ventilated environment Forklift performance depends on the road condition Running speed should be adjusted to an appropriate level Be especially careful when driving on ramps or rough roads When driving on ramps or rough roads the forklift will soeed up increasing tire wear and the noise 2 Working environment Ambient temperature for use of the forklift should be within 20 C 40 C and the ambient humidity shall be less than 80 3 Weather conditions In days of fog rain snow and strong winds pre assess the safety of using the forklift It s better not to use it for outdoor operations If it is must be done be extremely cautious during driving and operation 2 Safety rules 60 A WARNING Safety Helmet ARRE ASS Safety glasses E eE G Earmuff GCERTIFICATE fal a ES fat Only trained personnel who owns a driving license of forklift could operate it rivers shall wear working clothes before driving Alert see
98. use Countermeasures The oil level in the oil tank is Add oil to the specified Low volume of oil discharge low value The tube or filter is blocked Clean or replace as needed eLiner plate damage eBearing damage ePoorly functioned seal ring Replace bushing seal or retaining ring Low pressure of the pump Adjust the pressure of Overflow valve is not well overflow valve to the adjusted specified value with a pressure gauge There is air within the eRe tighten the side tubing system of the oil inlet 40 O O PAS eReplace the oil pump seal the filter is blocked filter peer or leakage of the Tighten the loosened parts Replace the oil with With noise when running viscosity compatible with Excessive oil viscosity the pump operating temperature Find out the cause of Bubbles in the oil bubbles and take measures accordingl Replace The pump leaks oil i 7 Lifting system 7 1 Overview Composed by the inner and outer main frames as well as the forklift frame the lifting system is a roller vertical elevating system with two levels 7 2 Link between the mast and chassis Figure 2 53 Inner and outer main frames are welded structures The outer door frame with support into the bottom thing The central part of the outer main frame is connected with the frame by the tilting cylinder and can tilt forward and backward under the action of the tilting cylinder 41 l shaft pin 2 Spring ring 3 Tilting oil cyl
99. vy e Do not use the cab frame overhead guard to lift the forklift e When lifting the forklift do not stay underneath the forklift 4 How to avoid rollover and protect yourself To avoid tipping tilting forward to lift the load Tilted loading of the goods is is forbidden prohibited f WARNING Eccentric loading of the goods is prohibited Avoid driving on slippery surface Do not load or unload if the forklift is not on a Do not drive over trenches other obstacles that level ground cause tipping 12 A WARNING A WARNING Avoid fast and wide turning no matter carrying load or not A WARNING ha a as F i ir oa nia i C CA When the empty fork is lifting please turn within a narrow range to avoid tipping LL In the event of forklift tipping please do not Please wear a helmet while driving jump IN In case of tipping it is safer when you stayed in the forklift with seat belt than jumping out of the forklift If the forklift begins to tip 1 Step on the brake pedal and clench the steering wheel tightly 2 Do not jump 3 Bend your body to the opposite direction of tipping 4 Tilt your body forward 5 Safety issues during maintenance and protection 1 Maintenance location A The premise should be designated places that can provide enough equipment and security facilities to the service organization e The site should be level ground 73 e The site should be well
100. y 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 1500 meters above sea level and the temperature range of 10 C 50 c humidity should no more than 90 If you need to use in the freezer for a long time 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 of the Instruction Manual Chapter 1 Precautions of using forklift Forklift drivers and managers must remember the principle of safety first and carefully read this maintenance manual Operators shall be in strict accordance with this manual to ensure safe and normal operation Forklift transportation The following shall be noted when transporting forklift by container or trucks 1 Apply the parking brake
101. ylinder Safety valve and self locking valve are installed in the multiple unit valve Safety valve is located in the upper side of oil inlet in the multiple unit valve to control the system pressure self locking valve is located in the tilt valve plate to prevent serious consequences due to misoperation of control lever in case of no pressure source of the tilting cylinder A check valve is mounted between the oil inlet and the oil abortion hole of the lifting valve plate as well as between the oil inlet and the oil abortion hole of the lifting valve plate with check valve Please see Figure 2 36 for the shape of the multiple unit valve 1 Safety valve 2 Microswitch bracket 3 Oil returning hole 4 Lifting speed sensor sets Figure 2 36 Shape of multiple unit valve 1 Operation of the slide valve Take tilting slide valve as an example a Middle position Figure 2 37 At this time the high pressure oil discharged from the oil pump will return to the cylinder through the middle position b Pull in the slide valve Figure 2 38 The middle channel is closed at this time oil from the inlet hole openes the check valve and flow into the cylinder interface B Oil flows from interface A will flow to the cylinder through the low pressure channel Then the slide valve can return to the middle position with the help of the return spring In

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