Service & Maintenance Manual LPT22 Power Pallet Truck
Contents
1. NOBLELIFT EQUIPMENT LL a Service amp Maintenance Manual 22 Power Pallet Truck V LPT22 01 00 Date 2011 02 26 CONTENTS FOREWORD uuu ee eee ee ree 2 lt ee ee ee ee 3 1 1 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS 3 12 MEASUREMENT CONVERSIONS 00 7 E ad 0 07 tel EE 11 2 1 LOCATION OF COMPONENTS 427004 11 2 2 SPECIFICATION KE 12 239 LUBHIGATIOI 13 3 ELECTRICAL SYSTEM 14 3 1 ELECTRICAL DIAGRAM eenst re peers MEQUE ee eee ee 14 3 2 INSTALLATION OF 17 DRIVE WHEEL E 19 3 4 POWER UNIT EE 19 35 BAIER 19 39 CHARGER EEN een 24 3 7 CURTIS CONTROLLER 4 29 3 8 BATTERY 36 3 9 REPLACING THE ELECTRIC PARTS 2 2 22 38 3 10 TOOL FOR REPAIRING THE PIN OF ELECTRICAL PLUG 43 4 HYDRAUL2. JOE Aaen soejdel Apz OU J 2 ape 90 2 Apadaid 10 SAUP Sur JO ZS pue LG Zy pue APE El p z pue 01 5 uegaqeq eui 32245 2 sl GLP pug L Lr Bull aui saaya nedal jo aeda JOU 51 Sen eiui JO ayl 6 10 81 34610 ZG ON BUL D 19 NO 8 24829 SU jo 2 au jo Soug siseJ au 32897 wedal eagjday Au WO S ELLE L 6 ON DL pue SUI Z EMO 81 1628063 JO i03 BY 10129009 195208 Bul 81 jme pu eu 6 Ap 10030 HO si duind ja agneup u au 8 61041 Jo 51 dwnd 8 UD 51 OIL 12942 8 yo 42945 5 Zou HO 51 dund jo Jojo 10 AEJ po 02 20 2 5 OL P GN e all t 100 Jo 8 EN esnj 42840 ajo pue indui BUL 7 usen Eye jo seg ow 136 BUL L St jE si peog god 42847 ON B8 Si au 20 8105 4
3. 57 T GASTER WHEEL EE 58 7 1 REPLACING OF THE CASTER WHEEL een 58 7 2 ADJUSTING THE PRESSURE FOR THE DRIVE 1 58 8 TROUBLE DIAGNOS IOS oneness eneen neren end 59 8 1 MAINTENANCE LIST RE 59 82 TROUBLE SOOT _____________ 8 _6____ 60 FOREWORD Proper operation maintenance troubleshooting and repairs are necessary to preserve the performance of the pallet truck over along period of time and ensure that fault and breakdowns do not occur The object of this service manual is to provide the information necessary especially in connection with the performance of inspections and repairs mainly in the maintenance areas WARNING The majority of this pallet truck consists of steel it can be completely recycled Waste material in conjunction with repairs maintenance cleaning or scrapping must be collected and disposed of in an environment friendly way and in accordance with the directives of respective countries Such work must be carried out in areas intended for this purpose Recyclable material should be taken care of by specialized authorities Environmentally hazardous waste such as oil filters batteries and electronics will have a negative effect on the environment or health if handled incorrectly CAUTION All of the information reported herein is based on data available at the moment of printing Our products are constantly being developed and renewed we reserv
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6. qo Protection characteristics Protection characteristics 00000000000 32 V voltage protection When the transformer temperature is higher than Thermal protection 125 C 130 the charger automatically EE protect stop charging Output current protection will not work battery protection permanent revers battery connection Charger LED indicator Remark Full Charging T OO LA DF2430 charger Equalizing charge Power switch BEFORE CHARGING The charger shall be installed in a special ventilated dry no dust no corrosive gas no interference from high electromagnetic field place The shell of the charger should be earthed the ground bolts are equipped at the lower part of the case The charger is only available for indoors off board charger No water should be in the charger The input power supply is 1 phases 220 5 230 5 50Hz or 110V 5 50Hz The lead section shall be no less than 4 while the capacity of mains switch shall be less than 30A You are recommended to use the dynamic mains switch Appropriate cables be employed according to the distance between power supply and the charger which makes the voltage drop no more than 5 Applicable environmental temperature for the charger is from 10 C to 40 C and the height less than 1000 meters During use the stumbling block that affects heat radiation of the charger
7. 1 Low power voltage 2 Small section area of lead for power input Failure of the preceding air switch 2 Incorrect matching of air switch 3 Small capacity of the air switch Internal short circuit of single battery of the group Failure of microcomputer control power 28 1 The power voltage may not lower than 95 of the rated voltage If the voltage is too low please change a new power supply 2 The section area of input lead of power supply may not less than the stipulated section area in the manual Rated current of the preceding stage air switch is more than that of the air switch of the charger The air switch must be type D type type type is dynamic illumination unavailable Check each terminal voltage of every single battery If some of the voltages are lower than their nominal voltages the internal polar plates suffers from short circuit please remove them and change new ones the service Please inform engineers 3 7 CURTIS CONTROLLER TICINO HALLO da A mies Dimensione m mmimeters na inches 29 CONNECTIONS Low Current Connections Three low current connectors J1 J2 J3 are built into the 1230 controller They are located in a row on the top of the controller 2 1 21 4 6 24 43 42 J1 The 24 pin connector J1 provides the logic control connecti
8. 1422 psi 0 070 EM newton mm X 145 04 psi 0 069 bar megapascal MPa x 145 psi X 0 00689 MPa Power r W J s kilowatt kW 1 36 PS cv 0 736 kW kilowatt kW 1 34 HP 0 746 kW kilowatt kW 0 948 Btu s X 1 055 kW watt W x 0 74 ft lb s X 1 36 W W J s Energy J N m kilojoule kJ 0 948 Btu 1 055 kJ joule J 0 239 calorie x 4 19 J J N m Velocity and Acceleration meter per sec m s x 3 28 ft s 0 305 mis meter per sec m s 3 28 ft s 0 305 mis kilometer per hour km h X 0 62 mph X 1 61 km h Horse Power Torque 5252 R P M TQ lb ft TQ Z R P M 5252 Temperature 32 1 8 F C Z 1 8 32 Flow Rate liter min dm min X 0 264 US gal minZ3 785 Note Non SI Unit 10 4 6 0 CLC 9 86 095 069 08r 09 OCE 086 006 09 OCL 08 OV OV 009 OV 00 006 086 096 OVC 066 006 081 09 oc Se 08 09 ie 06 Oct 7 99 694 2 SPECIFICATIONS 2 1 LOCATION OF COMPONENTS Control Handle Key Switch ON OFF Emergency Stop Button Or Kill Switch Battery Indicator CURTIS 803 Controller assembly 6 Foot Pedal CONTROL HANDLE AB en 11 10 11 12 Drive Wheel Inside The Cover Stabilizing Caster Inside The Cover Pump Unit Inside The Cover Lift Cylinder Battery Inside The Cover Load Roller Raise Lo
9. Insert the hole with a small screwdriver then turn counter clockwise the mushroom head to remove it Take out the emergency button remove two bolts and then remove the cable then you can remove the emergency button and replace it 44 3 10 TOOL FOR REPAIRING THE PIN ELECTRICAL PLUG Application Tool for removal of pins sleeves Tool for application of pins sleeves Tool for release of lock Tool for application of secondary locking 2 pole Tool for application of secondary locking 4 pole Tool for removal of pins sleeves 45 4 HYDRAULIC SYSTEM 4 1 HYDRAULIC FLOW DIAGRAM INSPECTION OF HYDRAULIC OIL 950120 1 19 gt K fark JM 1 11241 2 80 60 8 External appearance Smell Condition Countermeasure Clear and no discoloration Possible to use l Inspect the viscosity and if fine Clear but the color becames bright Fine Mixed with other oil it be continuously used Color changed like milk Mixed with air and water Separate water or replace oil Color changed into dark brown 2 shat 8 ointseat 14 push _______ oring Mounting plate for valve 4 3 REPLACING THE POWER UNIT Remove the relay cable Nope nom Remove the pipe Remove 2 screws Then you can remove the power unit and replace it A
10. Always do up safety clothes properly so that they do Not catch on protruding parts of machines Do not wear oily clothes When checking always release battery plug DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT During maintenance do not allow any unauthorized person to stand near the machine Flames should never be used instead of lamps Never use a buring flame to check leaks or the level of oil or electrolyte Immediately remove any oil or grease on the floor of the operator s compartment or on the handrail It is very dangerous if someone slips while on the machine Always use the recommended pure oil or grease and be sure to use clean containers Oil is a dangerous substance Never handle oil grease or oily clothes in places where there is any fire or flame As preparation for use of fire extinguishers and other fire fighting equipment Keep the battery away from fire hazards The generated gases are explosive Store all the oils in a specified place Keep the flammable things away from the machine Do not smoke in the working site Battery should always be disconnected during replacement of electrical components Always use the grades of grease and oil recommended by NOBLELIFT choose the viscosity specified for the ambient temperature Exhaust gas is dangerous provide ventilation when working in a closed space Avoid brea
11. MOSFET Control Kr Za 15 Fork height lowered 4 19 Overall length 4 20 Length to front face of fork Overall width ork dimensions Overall fork width 32 Floor clearance center of wheelbase 34 Working aisle with 800x1200 pallet lengthwise gt 3 NS 3 3 3 Sy ve 3 SIN 3 3 Dimensions 85 3 3 3 3 313 13 13 3 3 3 2 turning radius Travel Speed laden unloaded 3 3 Lifting speed laden unloaded 3 3 3 Lowering speed laden unloaded Gradeability laden unloaded 0 1 Drive motor Brakes O O N Lifting motor O D gt Battery voltage normal capacity K5 Battery weight 5 Battery dimensions w h Type of drive control 4 Sound level at driver s ears Other Electric motor Performance A 3 lt Turning angle 12 2 3 LUBRICATION Hydraulic oil CAUTION Hydraulic oil must have anti wear qualities at least It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Name Thickened hydraulic oil ISO Viscosity Grade e Density at15 C kgm 865 The oil for gear box Name EXIIT pressure lithium based grease 14 Worked sss Dropping point C 0 O Similar viscosity 9C 1067 Corrosion preventi
12. TI UINT16 8320 PDO MOSI Index 7 TI_UINT16 8296 65535 PDO MOSI Index 2 TI_UINT16 8297 PDO MOSI Index 3 UINT16 8320 _ PDO MOSIIndex4 ____ __ TLUINT16 8324 s NOTE for standard parameter 1 Ozoff TROUBLESHOOTING CHART A Status LED is built into the controller It is visible through a window in the label on top of the controller EM ar muwm el 8 el o 65535 This Status LED displays fault codes when there is a problem with the controller with the inputs to the controller During normal operation with no faults present the Status LED flashes steadily on and off If the controller detects a fault a 2 digit fault identification code is flashed continuously until the fault is corrected 34 CURTIS 1230 CONTROLLER TROUBLESHOOTING CHART LED PROGRAMMER CODE LCD DISPLAY EXPLANATION POSSIBLE CAUSE Motor speed encoder pulses 1 Incorrect encoder wiring are not correct 2 Controller defective 1 Incorrect encoder wiring 2 Motor blocked 3 Insufficient braking torque Motor speed encoder Motor stalled motor turning Motor Failsafe faster than desired 4 Motor control P Gain and Gain settings too low 5 Failsafe delay too short 1 Incorrect motor wiring Motor Overcurrent Motor phase overcurrent 1 3 2 Controller defective Motor output protection feature 1 Incorrect motor wiring Moto
13. The Curtis 1311 handheld programmer provides programming diagnostic and test capabilities for the controller The power for operating the programmer is supplied by the host controller via a 4 pin Molex connector The programmer includes a 7 line alphanumeric LCD display rockertype keys for navigating through the display and for modifying parameters and three keys that can be used as bookmarks The 1311 programmer is easy to use with self explanatory functions After plugging in the programmer wait a few seconds for it to boot up and gather information from the controller For experimenting with settings the programmer can be left plugged in while the vehicle is driven 36 LCD Display seven lines alphanumeric Parameter Modification Key to increase and decrease values to move around through the programmer menus Bookmark Keys for jumping easily back and forth between fields The bookmark keys allow you to quickly go back to up to three selected items without having to navigate back through the menu structure To set a bookmark press one of the bookmark keys for about three seconds until the Bookmark Set screen is displayed To jump to a set bookmark location quickly press the appropriate bookmark key 1 2 or 3 Note that the bookmarks are not permanently stored in the programmer They are cleared when the programmer is unplugged The bookmark keys can be used to make parameter adjustment easier For
14. 2 1 Inspection of noise and leakage of driving system Inspection of oil level of driving system NE Replace lubrication BN Inspection of wearing and damage state Wheel part Inspection of bearings inside wheels and ensure n fit with EH wheels Steering system 41 inspection of steering operation motion 5 1 Inspection of performance and adjust it Hiel Inspection of reset function of gas spring and any leakage or Braking system damage en ne 54 Inspection of brake connection and adjust it if necessary 6 1 Inspection of performance wearingandadjustit Lifting equipment Inspection t of any block of loading wheel by sight OR Inspection of any wearing or damage of edge of forks and pallet 5 Inspection of performance Hiel Inspection of any leakage or damage of all joints CAKA 73 Inspection of any leakage or damage of hydraulic safety Hydraulic system reliability of attachment 74 Inspection of oil capacity capacity Inspection of oil capacity 2020 8 901 75 Replace hydreuie ol and tie 7 6 Inspection of adjustment function of pressure regulator __ 32 Inspection of safety and reliability of connection of all cables and if 84 Inspection of safety reliability and function of switches and unlocking cam equipment 8 5 Inspection of connector r
15. Discoloration Became inferior in quality by oxidizing or Replace the oil mixed with other particles CAUTION Because the electric current of the Relay for the lifting motor is very big and work continually hourly the contact terminal of the relay is easy damaged Please check it continually 50 CAUTION The Magnet valve is a wearing parts If the forks automatically lower after lifting the magnet valve may be blocked or damaged remove and clear it or repalce it HYDRAULIC PIPE For shocking the joint of the hydraulic pipe and hydraulic pipe might be loosed and leak oil 50 usually check it and tighten it 51 5 5 DRIVE WHEEL Mol II 8 2 JA Brake 10 Uppercover 23 Bot 11 Sealwasher 4 Tillerbarplate 12 Bo 52 Bolt for adding Gear box 8 Holding bearing 51 REPLACING THE DRIVE SYSTEM AND WHEEL N Step1 Remove the cover marked 1 above right picture Step2 Remove the handle marked 2 above right picture Step3 Remove the mounting plate marked as above right picture Step4 Loosen the screws marked A as the right picture Step5 Remove all the cables that fixed in the motor Step6 Hoist the vehicle through the hole marked 4 as bove picture Step7 Then you can remove the drive motor from chassis and replace it Or you can directly replace the wheel A WARNING Cut of
16. areas distilled water can be 19 used Slowly pour sulphuric acid into a container containing exclusive water or distilled water and churn it up with an acid resistant stick Keep it still until the fluid temperature drops to 35 C then it can be poured into cells The concentration of confected electrolyte is 1 280 0 005 25 C The conversion forrnula of electrolyte is S25 S 0 0007 t 25 which S s The concentration of electrolyte in standard temperature of 25 C Sc The actually measured concentration of electrolyte T Actually measured temperature When confecting electrolyte avoid pouring water into concentrated sulphuric acid for fear that sulphuric acid splashes and leads to physical injury In addition please wear protective appliance Wipe up the cells check the nuts be tight for reliable connection Pour configured electrolyte into grouped batteries with fluid level 15 20mm higher than protective slice Keep it still for 4 6 hours maximum duration no more than 12 hours Only when the cells temperature drops below 35 C can it be connercted to DC and charge If cell s temperature exceeds 35 it should be taken to cool it down Check the cells in the battery for reverse polarity with DC voltmeter to assure proper polarity Connect the anode of the power supply to of the battery the cathode of the power supply to of the battery Avoid reverse polarity for fear of reverse charging The voltage of the charge
17. example in adjusting the throttle deadband you might set a bookmark at the Throttle readout Monitor gt THROTTLE 96 and another at the Throttle Deadband parameter Program gt THROTTLE DB this way you can easily toggle between the readout and the parameter 37 3 8 BATTERY INDICATOR Type CURTIS 803RB2448BCJ3010 CURTIS Front View Rear View TERMINAL ASSIGNMENT Pin 7 or 8 Battery Single voltage models Pin 8 to battery Pin 7 open Dual voltage models When vehicle voltage is the higher voltage of the 2 operating voltages Pin 8 connects to battery Pin 7 open When vehicle voltage is the lower of the 2 operating voltages Pin 7 connects to battery Pin 8 open The discharge indicator uses Pin 7 or 8 for its battery state of charge measurements Connection are to be made as close as possible to battery to prevent voltage drops that will cause errors in discharge indicator readings The connection is not to be switched by the vehicle s keyswitch Pin 5 Battery Connect to battery ground as close to battery as possible Pin 2 Keyswitch The keyswitch turns on and off the LED display of the battery discharge indicator Monitoring of the battery continues when Pin 2 is turned off and the display is not lit The hour meter display is unaffected by Pin 2 although it cannot accumulate more time as long as the keyswitch pin is not energized The control inputs HRM and HRM are enabled by the keyswitch Pin 2
18. for seesaw Spring Hinge spring 18 Spring for belly botton switch 22 7 Socket hexagonal Screw M6X10 Seesaw right or toggle button right board ll TT 6 1 REPLACING THE CONTROL HANDLE 57 REMA RTH CAN Cd 2 1 24 2 10 Se CJ 2 4 GND 4 CJ 2 5 Belly N 0 CJ 2 2 CAN HI 1142104 2 1 CAN LO CAN BUS twisted pair Bam NH Remove the bolt to remove the throttle lever once the bolt i removed from the throttle Tever the opposing throttle lever and throttle shaft can be pulled out through the oppsoing side of the handle 58 L m eet BI E Er mar e 1 ah CURTIS T 12302485 TI dk FEM TI E T nac L Hi HS wua Da iar prt i When inspection the PCB ensure the micro switch rocker lever And the plug connections are firmly connected to the cirsuit board and are servicable 6 2 REPLACING THE AIR SPRING AND MICRO SWITCH Once the throttle levers are removed the PCB power control board can be removed B FERAS TEZEN r4 ET prog zl 24 PAR EI Eel ry Hiii FEAR LT Ek pik ceri Remove 4 bolts 59 KSI Interlock adjustm
19. is connected to the vehicle s keyswitch Pins 1 amp 6 Hour Meter Control In normal operation Pin 1 or 6 is connected and the other is left open Only one of these pins is connected when using normal hour meter function It is possible to or the hour meter between the two inputs so that it accumulates the total time either system is on Hour meter control logic is detailed in Table 2 Pin 6 Hour Meter HRM for use with a switched positive voltage Pin 6 connects to a high voltage as defined in Table 1 to activate the hour meter Leaving Pin 6 open or connecting it to a low voltage gives control of the hour meter to the Hour Meter input See Table 2 Pin 1 Hour Meter HRM for use with a switched ground Pin 1 connects to a low voltage level as defined in Table 1 to activate the hour meter Leaving Pin 1 openor connecting it to high voltage gives control of the hour meter to the Hour Meter input Pin 3 Relay Pin 3 connects in series with the lift coil circuit or the circuit to be switched at empty For 38 holding relay J Pin 3 must be electrically closer to battery than Pin 4 Pin 4 Relay Pin 4 also connects in series with the circuit to be switched at empty HOUR METER CONTROL LINES amp IMPEDANCE SPECIFICATIONS Min Impedance Low Voltage max Hight Voltage min HOUR METER CONTROL LOGIC Pin 1 HRM Pin 6 HRM Hour Meter Status of DISCHARGE ADJUSTMENTS Th
20. power supply should be higher than 1 5 times of the charged battery When all the work is properly done the cells can be charged according to parameters outlined in the list below Charging current A Model initial charge common charge Initial charges are conducted in 2 phases in phase when terminal voltages of the cells rise to 2 4V the current should be converted into phase2 and continue to charge until air bubbles come out from the electrolyte keep voltage under constant current steady for 3 hours When the concentration of confected electrolyte reaches 1 280 E 0 005 it should remain unchanged within hours At this moment the total quantity of electric charge should be 4 5 times the rated capacity and the charging duration will be 70 hours If the concentration of the electrolyte is not 1 280 0 005 it should be adjusted The method is if the concentration is too high draw out some electrolyte and add some water or distilled water until the concentration equals to the prescribed value if the concentration is too low draw out some electrolyte and add some pre confected dilute sulfuric acid with a concentration of 1 400g cm until the concentration equals to the prescribed value When the concentration of electrolyte is adjusted it should be charged for 1 hour for consistency The density ratio of electrolyte is as follows Concentration of electrolyte Volumeratio of water to Capacity ratio of water to sulfuric acid su
21. IC SYSTEM 7 44 4 44 HYDRAULIC FLOW DIAGRAM 44 4 2 INSTALLATION OF HYDRAULIC 44 43 REPLACING THE POWER UNIT 2 2 00 45 44 REPLACING THE 46 45 CLEANING OIL TANK AND 41 2 47 46 TROUBLE DIAGNOSTICS 24 48 5 DRIVE WHEEL B __ 50 51 REPLACING THE DRIVE SYSTEM AND 51 52 REPLACING THE CARBON BRUSH 2 52 5 3 REPLACING THE uuu au hasa SEE 52 54 THE BRAKE CLEARANCE 52 b CONTROL HANDLES Lu u 54 61 REPLACING THE CONTROL 12 42 95 6 2 REPLACING THE AIR SPRING AND MICRO SWITCH
22. Slip Boost OEM OEM JTLUNT8 1 1 Accel Comp om TLUNT8 Regen Voltage Offset OEM OEM vor TLUNTB 0 system Batey j Empty Battery Voltage OEM OEM Vot m unne 173 09 201 _____ j Enable Total Service Hours OEM OEM um 900000014 Enable Drive Service Hours OEM om nmn Ol Ol 1 33 Set Total Hous omm omm Pe o o 1 Drive Hous omm omm TENMB 900900001 Drive Service Hours OEM OEM Hours TI 1 16 5000 100 5000 Total Disable _____ oem Hours TLUNT6 0 s0 Drive Disable Hous oem OEM Hous Une 0 800 Drive Disable Speed oem omm In mune 0 10 Service Total Expired Sevice Service o 1 Service Drive Expired Service Service 1 ModulelD fom s x Weier om om 0 gt Bwe OM o 0 gt Manufacturing Date OEM racoy m umnme 0 0 6555 OEM Fingerprint OEM TLUNTI6 o mus 8 0 Lon 5 _ PDO MiSO Index4 ____ __ at J TLUINTI6 8319 _ ss mes 0 TLUINT16 8480 0 __0 870 65535 PDO MISO Index 6 TI_UINT16 8319 PDO MISO Index 7 PDO MISO Index 8
23. WARNING Collapse the forks to the loweredd position Then drain the hydraulic oil from the power unit 47 44 REPLACIING THE CYLINDER i m 75 17 44 Disconnect two bolts and the other bolts in the other side Remove two screws 777 Remove the oil pipe emove two elastic washers 27 Remove the shaft which pass through the cylinder then you can remove the cylinder and replace it 48 4 5 CLEANING OIL TANK AND FILTER WARNING Collapse the forks to the loweredd position Then drain the hydraulic oil from the power unit Loosen two screws marked A remove all cables and the oli pipe then you can take out the power unit Loosen four screws marked C and two screws markd B then you can separate the power unit into the motor No 1 the mounting plate of vavle No 4 the suction filter No 12 the oil tank No 13 e Clean up the mounting plate for valve No 4 etc e Clean up the filter by compressed air then inspect to check if the filter is blocked or damaged And If the filter is blocked or damaged it need be replaced e Cleaning up the oil tank remove dust or foreign material form the oli tank e Finally assemble all parts 49 4 6 TROUBLE DIAGNOSTICS Check if there is any place Bubble in hydraulic oil Mixed with air where can be enteted aw the loosened part again Mixed with and water with and water Replace he ol the oil
24. able drawing 1020433019 DQ LPT22 X6 Controller cable 17 3 2 INSTALLATION OF ELECTRIC Noblelift Handle Canbus Hand Ga LP EE 4 6_ 15 numo Batey lowngntM4 screw mxo 19 605 16 screw We ll 3 3 DRIVE WHEEL Type 3EL DC 0 75 Drive Motor Model YDQ1 3 4BT Rate voltage 16V AC R P M 3200rpm Rate output 1 3kw Rate hour 60min Rated current 76 2A Amperager rating max 110 7HZ Amperager rating min H class Insulation class YDQ1 3 4BT Electromagnetic Brake Model G072 REB0510 20 P R Rate voltage DC 24V Rate Power 30W Output Torque 16N M Gear Box transmission ratio i 1 30 3 4 PUMP UNIT Type MR2 B V1B F4 5 PCMAV1Y TKOS5C F2 Item opecification Rated voltage 24V Rated output 0 8 kw R P M 2500 rpm Rated current 60A Rated hour 1 8 min Insulation class F class IP Code IP54 Displacement 0 7 operating pressure 250bar 3 5 BATTERY Rate Specification Rated voltage 24V Capacity 5 hours 210Ah Overall size L W H 67 mm 196mm 555mm Initial charge e When the battery is charged for the first time you should prepare the exclusive sulfuric acid and excluslve water of lead acids If no excusive water is present in local
25. e followed table lists the voltages per cell under load that correspond to an empty indication on the W W gauge lockout point IN Volt Cell 1 57 1 68 1 73 178 1 82 1 84 1 86 1 89 1 91 1 93 at Empty NOTE factory setting RESET TYPE LEVEL AFTER OR DURING RECHARGE CTR Charge Tracking Reset If the gage is connected to the battery during recharge the gage will track the battery charge level OCR Open Circuit Reset If the gage is disconnected from the battery during recharge the gage will retain the last indication It will advance to full when reconnected only if the battery voltage is above the OCR level For standard reset OCR 2 09 VPC VPC volts per cell TROUBLESHOOTING Problem Possible Causes No display Terminals not connected or improper voltage Instrument voltage does not match battery voltage B connected Stays at FULL to the wrong terminal Instrument voltage does not match battery voltage or battery not Will not reset fully charged Resets w o charging battery Not connected directly to battery terminals EMPTY too soon B connected to wrong terminal or instrument voltage does not 39 match battery voltage or terminals not directly connected to battery 3 9 REPLACING THE ELECTRICAL PARTS REPLACING THE BATTERY i Step 1 Remove 2 screws No 2 loosen nuts No 4 2 lt gt gt and washers No 3 lt Ste
26. ective Precharge Precharge fault 2 Low battery voltage 1 Brake coil open 22 2 Brake missing oF 39 Brake Fault Brake wiring or driver fault 3 Wire to brake missing 4 Brake driver shorted Service Total Disable Total disable timer has expired 1 Expired total disable timer 4 1 Service Driver Disable Drive disable timer has expired 1 Expired drive disable timer Service Total Expired Total maintenance timer has TT Je expt mater ter Service Driver Expired Drive maintenance timer has pete meer expedite nator ine 2 Operation with charger attached 1 Battery voltage gt overvoltage cutback Battery Overvoltage Battery voltage is too high limit 1 Battery voltage lt undervoltage cutback limit Battery Undervoltage Battery voltage is too low 2 Corroded battery terminal 3 Loose battery or controller terminal Controller heatsink is too hot or 2 Excessive load on vehicle 4 3 Temperature Cutback too cold 3 Improper mounting of controller 4 Operation in extreme environment 1 Mode switch shorted to B Mode switch activated at 4 4 Anti Tiedown startup 2 Mode switch tied down to select M2 permanently Hardware Failure Hardware failure 1 Controller defective 5 2 Software Failure Software failure 1 Controller defective 3 Parameters Corrupt Parameters corrupt 1 Controller defective 1 Temperature gt 85 Cor lt 25 C CURTIS 1311 HANDHELD PROGRAMMER
27. ent upon re installation Use a Phillps screwdriver to remove two screws then you can dismantle the air spring and replace it fy een A Wm lt k r 22 2 i i i D Bed 22 a T 1 y Zen d j ZN 1 E T 4 A 4 gt 4 i 4 4 ID W i D 9 4 m 27 Lay Lg B ch Sas 1 4 ae k SC H ku Si ni f lt L AN 4 Eg lt KT P 77 h P NOS 4 2 Y 4 4 4 ES 4 y 4 K PN fy E 5 7 E mg RU pe T Remove this bolt Then you can remove the micro switch and replace it 60 7 CASTER WHEEL 7 1 REMOVING OF THE CASTER WHEEL First let the pallet truck to be slanting then dismantle four screws Note to help the nut when turning the screws Then you can dismaantle the caster and replace it 7 2 ADJUSTING THE PRESSURE FOR THE DRIVE WHEEL After using some time the drive wheel might wear off the pressure for the drive wheel will not be enough and drive wheel can not bit into the ground and slip You can adjust it according to following steps Step 1 Loose the four bolts do not need to dismantle them Step 2 Take away one or two piece washer 61 8 TROUBLE DIAGNOSTICS 8 1 MAINTENANCE LIST Maintenance Time Interval Standard e a oe Chassis and 111211 pars ruck frame
28. eplace the worn part if necessary 56 Inspection function of alarm equipment 81 hh CN 93 Clean motor frame with vacuum cleaner inspection of wearing of commutor Inspection of density and capacity of acid voltage of battery Inspection of safety device of connection terminal applicability of WM Battery grease Clean connector of battery inspection of compactness of fit Inspection of damage of battery cable replace it if necessary 1411 Paint grease to the truck according to the time schedule of 8 Lubrication 11 1 lubrication feeding Inspection of the fault in grounding of electrical system Integrated Inspection of driving speed and braking distance measurement Inspection of lifting and lowering speed _ Inspection of safety device and closing device 1411 Commissioning under load rating Demonstration After above maintenance the truck is certificated to be reliable for NM operator a About 100 hours after initial operation check if any loose nuts on wheels and tighten them if necessary M ES EN ES EN D a b About 100 hours after initial operation check if any leakage of hydraulic parts and tighten them if required c 500 hours after initial operation 62 8 2 TROUBLE SHOOT 1 eq Kew AS uds 1 Spe Mey Sl au 1
29. es the right to modify our own products at any moment without prior notice and incurring in any sanction So it is suggested to always verify possible updates 1 GENERAL 1 1 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS Careless performing of the easy work may cause injuries Take care to always perform work safely at least observing the following It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are those that apply when servicing hydraulic and larger machine component parts AWARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER OR OPERATOR WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION When carrying out any operation or maintenance have trained and experienced personnel carry ou
30. f the power before operating Remove 5 nuts with the spanner Then you can remove the drive wheel and replace 5 2 REPLACING THE BRAKE Remove 3 screws remove the connector then you can remove the brake and replace it 5 3 BRAKE CLEARANCE ADJUSTMENT Brake coil must always be connected to the power 24v when energized the brake will dis engage If the brake system loose power while unit is use the unit may lose speed and motor may reduce excessive heat Step 1 Measure the resistance by multimeter 20002 and The Winding resistance 25 2 normal 1 1 Loosen the three bolts that hold the brake 54 Step 3 Adjust the brake spacer plate bolts in or out to adjust the Clearance of the brake plate Be sure not to over tighten the bolts Step 4 Adjust the above mentioned bolts counter clockwise adjust 2 3 revolutions to reduce the spring tension 55 CONTROL HANDLE 1 13 G gon d 12 ew MA 11 Ww 8 1 ZIN gt ex 21 10 go P 3 1 v 2 3 4 No Patnam __ 000 Bushing 23 19 17 10 9 Air spring 1 Handle mounting bracket Handle cable Shaft 017 Micro switch Z 15GW2 Roll pin 4 24 Screw M4x25 Elastic washer 8 Screw M4x10 56 Patnam No Patname 1 Butterfly left or throttle switch left Seesaw left or toggle button left Button for horn Magnet holder
31. he controller be careful to check the tightness of the power connection nut Be sure to check the terminal connections Taking part A and B for example part A It includes anode terminal and cathode terminal if you connect by mistake the circuit will be short out and the controller will be damaged Part B there are three terminals marked U V W If you connect by mistake the drive motor polarity will be reversed and will be demage the unit 42 REPLACING THE THERMAL PROTECTION Kr When the temperature of the motor is more than GND et f 130 C the module will give a signal to the Schau em Mode controller then driving speed will automatically 1 NIT change to low speed mode After the temperature reduces to 110 C the unit will change back to Mt CUF nomal speed 123 If one line of the cable open circuit the driving esx speed will remain slow ilb Remove the screw and the plug then you can EM mi 2 Enc supply remove the module and replace it FE A Ene Ground REPLACING THE LOCK KEY SWITCH LKS 101A Lift the mounting plate Remove the nut of the key switch remove the cable of the key switch 43 Then you can remove the key switch and replace it REPLACING THE EMERGENCY BUTTON T the mushroom head of the emergency button in order to make the hole of the mandril and the groove of the sleeve be in the same line
32. lfuric acid 1 100 9 80 1 5 84 1 1 200 4 33 1 2 36 1 1 270 2 80 1 1 57 1 1 280 2 75 1 1 49 1 1 400 1 90 1 1 00 1 e After charging close the vent plug and it only can be put into use after its surface is cleaned clear Balanced charge When in use nonuniformity of voltage capacity electrolyte and concentration may occur Through balanced charge such nonuniformity can be eliminated and all cells in the battery can be of uniform conditions Balanced charge is essential monthly for the batteries in use or following situation Cells whose discharge voltages are usually below the final voltage 1 7 V cell Cells with heavy discharge current in circumstances where the drive motor and lift motor operate synchronously with heavy load or in circumstance with steep slope Cells not timely recharged after discharged Undercharged cells of cells not used for along time METHODS OF BALANCED CHARGE Normally charge the cells when it is fully charged shut off the charge power supply keep it still for half an hour then switch on the power supply and continue to charge with the current of phase 2 When air bubbles come out convert to 1 2 of the current of phase 2 and continue to charge the cells when air bubbles are produced shut off the charge power supply keep is still for half an hour then switch on the power supply and continue to charge with 1 2 of the current of phase 2 until air bubbles are produced stop charging a
33. lower is on the inserted into the controller plug of charger can not start and the electric vehicle charge and the monitor is not display 1 Although the charger and 0 Check each connection bolt battery is connected however and wiring some part of which is The indicator light for power is disconnected on the indicator light for failure The battery is aging becomes 2 Check total voltage of is on the blower is on the invalid and low voltage battery and each single voltage charger can not start and of the battery In case of open charge and the monitor is not circuit aging invalid low display voltage of the battery please change a new one 3The battery is connected Correct the incorrect oppositely connection The indicator light for power is Failure of DC output fuser Open the side door to check the on the indicator light for failure fuser If the fuser is broken is on the blower is on the please change a new one charger can not start and charge and the display Instable charge current more Long term heating poor contact Check the copper plates if it is or less or loose by the output plugs unavailable please change a Instable charge current not reaching the rated current value Air switch of the charger does not trip and the preceding stage switch trips Excessive overcharge for the battery The display signals of the display face rolling deadlock and clobber
34. lyte or water are spattered into the unintentionally please discharge with the exclusively equipped plastic pipes 22 DISCHARGE CURVE voltage V2 1 95 1 9 1 85 1 8 1 75 1 7 1 65 1 6 1 55 1 5 1 45 1 4 voltage V2 ohr discharge curve 0 2 3 time Ch 0 5 disvharge curve 0 10 15 20 25 30 35 time min 3 6 CHARGER Type DF2430 for 24V 210Ah battery WIRING DIAGRAM FOR CHARGER Ti de mL AA WARNING The battery generates flammable and explosive gases during charge so excellent ventilation is required Open the liquid refilling cap or seal cap Do not smoke around the battery during charge Any fire and spark is forbidden MAIN PRODUCT SPECIFICATION Battery Output current Type Input power Input voltage Output voltage capacity ENVIRONMENTAL CONDITION Humidity 5 80 With package Altitude 2000 Work normally Fan convection cooling Working under full load 24 ELECTRICAL CHARACTERISTICS Input characteristics Technical specification Rated input voltage Input voltage range 209 231 220Vac AC input voltage 1 3 50 60 Hz frequency Max input current DF 2430 7 When input is on voltage fan When input voltage is off there is 1 5 Fan function output voltage for fan 24 Fastcharge voltage 288 S 24 Constant current DF2430 0
35. n connector J1 it can alternatively be plugged into J3 and unplugged when the programmer is used Only Pins 2 3 and 4 of J3 are needed for the display Six round tin plated brass studs are provided for the high current connections to the battery B and B the fuse F and the three motor phases U V W located as shown in Figure 2 The studs are threaded to accept M5 bolts This simplifies the assembly and reduces the mounting hardware necessary for the power connections Appropriate screws washers and cable lugs should be used to provide secure vibration resistant connections on all power terminals The tightening torque applied to the bolts should not exceed 10 7 4 ft lbs Exceeding this limit could damage the studs internal threads resulting in loose connections 31 a ___ j Rates We M1 Accel User user Seconds TUNT 2 9040005 2 Accel Rate User User ____ Seconds 2 ot 5 M3 Accel Rate User User Seconds Ti Unts 2 9040005 4 Accel Rate User User ____ Seconds 2 040005 M1 Brake Rate User User Seconds TLUINT 1 040006 M2 Brake Rate User User Seconds TUN 1 5 Brake Rate User User Seconds TLUNTS 1 O1 5 4 Brake Rate User User Seconds TLUNTS 1 ot 5 Fast Stop Rate OEM OEM Seconds We 1 ot 5 Accel Release Rate OEM OEM Seconds 0 ol 1 Speeds er X _ Mimin Speed Use
36. nches and nuts 12 MEASUREMENT CONVERSIONS Length m 39 4 oon 10936 0 00062 mmm 1 ror Ima ma 0 000025 0 08333 0 02777 0 000015 mas oss ooo 1 03333 000015 914 ooms 0 0000 36 1 0000568 1mmz0 1cm 1um 0 001mm Area CEA 0 000001 1550 000 voo bore 90 19 ooo 1 1 144000 x osea Lee 1 129600 i 456 00055 a A oo 1 1 100 1milez 259ha 2 59kmz Volume 1gal US 3785 41 cms 231 ins 0 83267gal US Weight ut M t b 0 001 0 000001 0 03527 0 0022 kg 1000 0 001 35 273 2 20459 1000000 1000 35273 2204 59 28 3495 0 02835 0 000028 0 0625 1 tonne metric 1 1023 ton US 0 9842 ton UK Pressure kgf cm bar kPa Ibf inz kgf cm 0 98067 980665 98 0665 14 2233 2048 16 bar 1 01972 100000 14 5037 2088 6 kgf cm2 735 56 Torr mmHg 0 96784atm Standard torque The following charts give the standard torque specification of bolts and nuts Exceptions are given in the sections of Disassembly and Assembly METER TABLE Classification Bolt type Bolt size Torque kgf m lbf ft 042004 5 INCH TABLE 4 5 Classifica
37. nd left it still Repeat the procedure for several times until air bubbles are produced as soon as power supply is connected In balanced charge voltage of each cell as well as the electrolyte concentration should be measured and recorded Before the charge is completed the electrolyte concentration and height should be adjusted to the prescribed parameters SULFURIC ACID FOR CELLS Sulphuric acid H2504 WATER FOR LEAD ACID CELLS Index name lt Manganese Mn content lt 0 00001 Ferrum Fe content lt 0 0004 21 Chlorine Cl content lt 0 0005 Ammonia NH content lt 0 0008 Deoxidized potassium permanganate 0 content 0 0002 lt Solonetz meatal oxide CaO content lt 0 005 50 Resustivity 25 C Q cm gt 10x10 ELECTROLYTRE FOR LEAD ACID CELLS Index Index name mm O O 7 Mg 0 00004 Ammonia salt content 0 0003 Ignition residue content Manganese content A Ferrum Fe content 0 004 0 048 Arsenic As content 0 00003 0 00036 Chlorine Cl content Ammonia salt content N 0 0007 0 0005 0 0008 0 0032 WARNING Don t spatter electrolyte or water into the batteries otherwise the battery tank will be eroded and the battery will automatically discharge which will lead to low performance of battery and Copper Cu content Deoxidized potassium permanganate content A Content calculated by even shorter life If electro
38. ons for the contactor drivers and switches that are wired directly to the vehicle The mating connector is a 24 pin Molex Mini Fit Jr connector part number 39 01 2245 using type 5556 terminals J1 gt XP N E 312131415 817 49 2 d E gt J gt o lt as sa is 16 17 te 20 29 21212 mS neet 0 30 A 6 pin low power Molex connector 42 is provided for the speed encoder and electromagnetic brake connections The mating connector is a Molex Mini FitJr p n 39 01 2065 using type 5556 terminals J2 Pin 1 encoder power output J2 Pin 2 encoder A J2 Pin 3 E M brake coil return J2 Pin 4 encoder B J2 Pin 5 encoder ground reference output J2 Pin 6 E M brake driver output Note In some applications using a tiller multiplexer J2 Pins 3 and 6 are used for a proportional valve instead of an electromagnetic brake Led J3 Pin 1 receive data 45V J3Pin 2 ground B J3 Pin 3 transmit data 5 Pin 4 15V supply 100 High Current Connections A 4 pin low power connector 43 is provided for the 13 programmer A complete programmer kit including the appropriate connecting cable can be ordered see Curtis programmer manual for further information on the various programmers available for programming Curtis controllers J3 can also be used for the Curtis Model 840 Spyglass display Although the display is typically wired directly into Pins 19 20 and 21 of the 24 pi
39. p 2 Remove the battery cover No 1 ES 4 Step 3 Separate the plugs No 6 and 7 x e Step 4 Use two lifting hook to hook the hole of the battery box Then you can use a crane to take away the battery and replace it Remove screws Then remove the right cover and left cover VW m You will see the appearance as the following three pictures when you remove the cover REPLACING THE POWER UNIT Remove the relay cable Hydra Del e Mel Moor piar Remove the pipe 4 a m yt A d mj F e Remove 2 screws Then you can remove the power unit and replace it IEN REPLACING THE BATTERY INDICATOR 1 2 P 18171815 413 2 1 544 591 22 de Remove two plastic nuts under the mounting board remove the U clamp disconnect the 8 pins plug Then you can remove the battery indicator and replace it REPLACINGTHE FUSE 41 Open the black cover of the fuse seat then you can remove the fuse and replace it REPLACING THE MAIN RELAY x 4 m lt s W D Remove cables Remove two screws Remove the cables Then you can remove the main relay and replace it Step2 Remove two screws 1 Step1 Remove all cables Step2 Remove two screws Step3 then you can remove the controller and replace it When reconnecting t
40. r nu O so 2 Speed User User L TLUNTS 10 0 50 MB Min Speed User User mum 10 0 50 Min Speed User User 10 O 50 Speed Limit Tye Jomm __ wuel Ol o 7 rant Tiedoun OEM __ nm of 1 Tote We Throttle Deadband om OEM 9000009 TwoteMex User User 90 use SRO TUN 2 60 O1 O1 O Main Contactor Interlock UINT8 Main Contactor Open Delay UINT8 32 Brake Je Brake FaultCheck um Brake Delay OEM OEM Seconds 1 om Brake Hold Voltage OEM OEM TI UINT8 100 0 100 OEM OM us o 2 Ant Rollback Time OEM SEM ms TLUNTIG ml o 1000 Emergency Reverse usr lll Direction intero OEM wm of o 1 Jomm oem ____ Seconds 15 0 10 Moor we Min MoterVotage OEM OEM vor munne ol ol 6 Current Limit PGain OEM om ___ 25 o 100 Current Limit pen om om 062 unne o 100 5 4 2 8 Encoder Pulses perRev OEM om wus 6 32 128 Cow ee Pein Jom TLUNTI Lean TLUNTI6 __0 n
41. r Output Fault has been triggered 2 Controller defective 1 sequence of KSI interlock and direction inputs 2 Wrong SRO type selected 3 Misadjusted throttle pot 4 Direction switch open 1 4 Static Return To Off SRO sequencing error 5 Sequencing delay too short 6 Wrong throttle type selected 1 Throttle input wire shorted to B Throttle wiper voltage is too high Throttle Wiper High 2 Defective throttle pot 3 Wrong throttle type selected 4 Incorrect speed limit pot wiring Emergency reverse wiring 2 2 EMR Wiring Open fault 1 Emerg Rev wire or check wire broken 1 Improper sequence of KSI interlock NO and throttle inputs 2 Wrong HPD type selected 3 Misadjusted throttle pot 4 Interlock switch open 2 3 High Pedal Disable HPD sequencing error 5 Sequencing delay too short 6 Wrong throttle type selected 1 Throttle input wire shorted to B Throttle wiper voltage is too 2 4 Throttle Wiper Low 2 Defective throttle pot low 3 Wrong throttle type selected 1 MUX card not plugged in 3 1 Multiplexer Fault Tiller multiplexer error 2 MUX not wired properly 3 MUX card defective 3 2 Main Contactor Missing or welded main 1 Main contactor coil open contactor 2 Main contactor missing 35 3 Wire to main contactor missing 4 Main contactor stuck closed 5 Main contactor driver shorted 1 Controller def
42. r in wet places as this can cause electric shock When working with others choose a group leader and work according to his instructions Do not perform any maintenance beyond the agreed work 5 Unless you have special instructions to the contrary maintenance should always be carried out with the motor stopped If maintenance is carried out with the motor running there must be two men present one operating the pallet truck and the other one performing the maintenance In such a case never touch any moving part Before making adjustment lubricating or performing any other maintenance shut off all power controls When removing parts containing O ring Gaskets or seal Make sure clean the mounting surface and replace with new sealing parts Thoroughly clean the machine In particular be careful to clean the grease fittings and the area around the dipsticks Be careful not to let any dirt or dust into the system Use only approved nonflammable cleaning solvents When changing the oil or fitter check the drained oil and filter for any signs of excessive metal particles or other foreign materials Always use NOBLELIFT genuine parts for replacement ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS When checking an open gear case there is a risk of dripping things in Before removing the covers to inspect such cases empty everything from your pockets Be particularly careful to remove wre
43. shall be 0 6 meter away from it Please check the blower is running normally or not regularly In case of failure of microcomputer controller please inform the service engineer or maintenance staff Check height of electrolyte in the battery in accordance with the manufacturer s instructions COMMON CHARGE Connect cable plug of the battery to corresponding output plug of the charger firmly Connect the battery firstly then connect it to the power supply and finally start it If the output plug is connected to the electric control terminal of the vehicle mistakenly the charger fails to work the indicator light for failure is on please correct it timely Connect the charger to power supply first then turn on the power air switch and the charger starts after the power is connected The indicator light for power supply is on and the charger is under self examination condition The display indicates current system version chargeable battery voltage current battery voltage maximum chargeable current and other data After the self examination process is completed the charger begins charging The display indicates voltage V charge current A charge time H shows Hour Minute and charged electric quantity AH When the display indicates Charge completion and the indicator light is on the battery finishes 26 charge The charger enters floating charge with current of 1 3 amperes Please check electrolyte heigh
44. t the work When carrying out any operation or maintenance carefully read out Operation and Maintenance Manual Read all the precautions given on the decals which are fixed to the machine Be sure you fully understand the contents of the operation It is important to prepare necessary tools and parts and to keep the machine Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided e Moving parts can cC eut er crush hands i feel arma or It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Relieve system pressure by cycling the applicable control lowering button several times with the motor stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss Remove all rings watches and jewelery when performing any maintenance Wear well fitting helmet safety shoes and working Clothes When drilling grinding or hammering always Wear protective goggles
45. t in the battery frequently and fill distilled water timely as required Disconnect the power switch and disconnect the output cable plug of the charger and plug of battery and the charge is completed EQUALIZING CHARGE When the battery group has been used for some time the performance parameters of the batteries may vary differently so equilibrium constant current charge is required If equalizing charge is required press the key for Balance charge turn on the power switch then the indicator light for Balance is on The charger enters into equalizing charge status the current value reduces from the rated value to a constant current value during charge meanwhile the display indicates When the equalizing charge is completed manual turning off is required note the output current of the charger under equalizing charge is constant without stop manual turning off is necessary Press the key for Balance charge after turning off the charger to make it return to normal charge WARNING The equalizing charge is a manual operation Appointed personnel are required to observe and check voltage and specific gravity of the batteries and determine charge time manual power off and charge stop as required TROUBLESHOOTING The indicator light for power is The battery is not connected or Connection of the battery should on the indicator light for failure the output plug of the charger is be corrected is on the b
46. thing dust that may be generated when handling components containing asbestos fibers Wear a gas mask if necessary When working on top of the machine be careful not to lose your balance and fall Hand a caution sign in the operator s compartment for example Do not start of Maintenance in progress This will prevent 2 anyone from starting or moving the machine by mistake staat ET When welding on the machine or working on the electical system ALWAYS turn the key switch OFF and remove the battery plug from the battery Park the machine on firm flat ground Lower the fork to the min height and stop the motor Sulfuric acid in battery electrolyte is poisonous Ist is strong enough to burn skin and eat holes in clothing If you spill acid on your clothes or skin immediately flush it with large quantities of water When working on the battery wear goggles or safety glasses If splashed into the eyes flush with water and get medical attention immediately Battery terminals touched by metal objects can cause short circuit and burn you Keep tools away from the terminals When disassembling and assembling the battery make sure that the battery terminals are correctly connected If water gets into the electrical system abnormal operation or failure can result Do not use water or steam on sensors connectors and instruments in the cab Do not handle electrical equipment while wearing wet gloves o
47. tion Bolt type Bolt size Torque kgf m lbf ft Torque kof lbf ft 1 4 0 6 0 06 1 7 0 2 5 16 1 2 0 12 3 0 0 3 3 8 2 0 0 20 5 6 0 5 7 16 3 2 0 32 8 9 0 9 1 2 4 7 0 47 13 4 1 3 9 16 6 8 0 68 19 0 1 9 5 8 9 3 0 93 26 1 2 6 3 4 16 0 1 60 45 1 4 5 7 8 25 5 2 55 71 6 7 2 1 38 0 3 80 106 9 10 7 1 1 8 54 1 5 44 152 2 152 1 1 4 74 2 42 208 9 20 9 1 3 4 98 8 9 88 277 8 27 8 1 1 2 128 2 12 82 360 7 36 1 The torque specifications in above table shall not be applied to the bolts with nylon packings and nonferrous metal washers or the ones with specifically designated torque and standard H Newton meter 1 N m 0 1kgf m TIGHTENING TORQUE OF SPLIT FLANGE BOLTS The following torque shall be applied to the split flange bolts Diameter Flat width Torque mm mm kgf m N m 10 14 6 7 0 7 66 7 6 8 12 17 11 5 1 112 9 8 16 22 28 5 279 29 APPROXIMATE CONVERSIONS 51 5 5 Unit Factor Unit Factor Unit Torque newton meter N m 8 9 In in X 0 113 Nm newton meter N m X 0 74 x 1 36 Nm newton meter N m x 0 102 7 22 Pressure N m kilopascal kPa x 4 0 in H20 0 249 kPa kilopascal kPa 0 30 Hg 3 38 kPa kilopascal kPa X 0 145 psi 6 89 kPa bar 14 5 psi 0 069 kg cm
48. ve properties 52 C 48h Wire points oil 100 C 24h 13 ELECTRICAL SYSTEM 3 ELECTRICAL DIAGRAM 3 1 WIRING DIAGRAM Tz Y QA WH 184 pasim 8118 8 6 et TI M He ns g 6 1 5 Chi Sna NYJ 07 rro IH NYO enm O N 4188 8 2 lang 9 2 0 1924 LT NY2 H1H 91 aye ayelg ES X V 97 NYO punos 203 TT rz nano wi 823 wang x SEH y mdino muq 6999 203 40011 10 28 u07 M EEL 1 I 6095 90551 on SILYND n bua 21 ES 89 mE Ng Atz T a 43 1153 2 1014 13 3 PEN n 414 5 48 14 CONNECTION DIAGRAM i o mj VER d 15 1 BI M WG541 Motor for traction DC16V 1 3kw 1 8 DQ3 7 Main relay 100 120 DC24V 71 9 K DQ21 Thermal protection BD W135 110 1 13 EU 1 14 5 DQ 48 Emergency button ZDK31 250 1 2161 P DQ27 Battery Indicator CURTIS 803 1 17 B WG5 OContolhande 94300 00 1 Master cable system drawing 2 1 L E 4 a t 1 wc 21 DQ LPT22 X1 DO LPT22 X4 16 CANBUS handle c
49. wer buttons Rocker switches adjusting fork height FWD BWD REV travel button Control variable speed by turning knob Emergency Reverse button Emergency reverse button or commonly known as the belly button switch Horn button Indicator light Indicates high low speed status Green indicates high speed red indicates slow speed Shift button Shift button for high speed and low speed 2 2 SPECIFICATION SHEETS 1 2 Model of manufacture EE 1 3 Power supply electric diesel petrol gas mains 963 1033 Polyurethane 230 75 2 xD84x70 084x93 2 100 40 1x 2 2 1 2 4 1 Type of operation hand pedestrian stand on rider Capacity rated load 1 6 Load center distance Characteristics 1 8 Load distance Wheelbase Weight including battery N A 213 3 12 N A o 2 Axle loadings laden drive end load end NO 3 Axle loadings unloaded drive end load end Tyres rubber Vulkollan pneumatic polyurethane 2 Tyre size Dia x width drive end Tyre size Dia x width load end A o E 3 Castor wheels dimensions Wheels number x drive wheel 6 Track width front drive end b Track width rear load end Lift height 9 Tiller height in neutrality position Wheels types Weight CO 00 380 525 85 N lilo A O 665
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