SERVICE & MAINTENANCE MANUAL Electric Pallet Truck
Contents
1. b4 mm mm bs mm m mm 510 1180 150 40 Polyurethane PU 48 160 1150 5 34 35 Aisle width for pallets 800 1200 lengthways Ast mm Turning radius Wa mm km h 1 Travel speed laden unladen 9 2 Lift speed laden unladen mm s 3 Lowering speed laden unladen mm s 5 8 Max gradeability laden unladen 5 10 Service brake 6 1 Drive motor rating 52 60min 6 2 Lift motor rating at S3 1096 6 3 Battery acc to DIN 43531 35 36 A B C no Battery voltage nominal capacity K5 V Ah 66 Energy consumption acc to VDI cycle kWh h Type of drive control Sound level at driver 5 ear acc to EN 12053 dB A 14 5 ov 5 c i p mm 15 electric pedestrian 1 5 600 946 1293 2 220 70 200 560 1140 160 40 2 80 93 250 30 340 800 1170 49 1950 1445 4 2 4 6 30 53 49 36 4 10 electromagnetic 0 45 0 8 no 2x12V 64 48 kg 0 39 MOSFET Control 69 1x 2 2 1718 48 160 1200 705 685 32 AST 16 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 the may not contain the same required additives or be of comparable viscosities Name Thickened hydraulic oil ISO Viscosity Grade O 840 HO Characteristics unt 402. connections used for load compensation and 0 to 800 mOhms speed estimation Control system performance depends on this parameter being set correctly it must be set to the actual cold motor resistance Resistance is automatically measured under a preset low current before the brake is released The measured motor resistance plays an important role in IR compensation Sets the current limit used for automatic resistance 5 to 50 testing as a percentage of the Main Current Limit see Current menu The Speed Scaler parameter sets the maximum voltage that can be applied to the motor It can be used to eliminate variations in maximum speed that would otherwise result when driving with a fully 20 to 27 volt charged battery vs a partially discharged battery If Speed Scaler is set to 23 volts for example the maximum vehicle speed will be the same whether the actual battery voltage is 27 volts or 23 volts or any value in between This parameter should be set to the current rating 0 to 30 Ampere provided the motor manufacturer Sets the maximum amount of time the motor is 0 to 80 Seconds un allowed to run at the main current limit When the motor overheats the drive current is cut back until it reaches the programmed Current Rating 0 to 100 90 The Cutback Gain determines how quickly this cutback will occur once the programmed Max Current Time has expired BDI menu Full Voltage 24 4 20 9 to 24 9 Volt Voltage when
3. Viscosity 2 Viscosity index 4 4 20002150 2150 Density at 15 C kg m 861 5 Vickers vane pump test loss of mass vanes after 100h mg lt 100 153 mg Diameter of wear spot 1200 r min 294 30min 75 C The oil for gear box Name Extreme pressure lithium based grease 1 Worked Peneraton omm 310630 _ 5 Similar viscosity 10 C 1051 Corrosion preventive properties 52 48h Wire points 100 24h J lt 17 3 ELECTRIC SYSTEM 3 1 ELECTRIC DIAGRAM WIRING DIAGRAM Electric diagram EPT 15 H 12 ce rn 10 R H LET T t 183 mw LD bal Med Lt Fuses 15 FU1 10 FU2 0 5 FUO1 60A FUO2 60A eat nse CURT ENED s s 1 s 19 CONNECTION DIAGRAM EPT MT VG H 20 CABLE SYSTEM Handle control cable Control cable Drive motor power cable 21 3 2 ELECTRICAL INSTALLATION 1 l E D oy 55059 ar i fre S clan 1 Inductive sensor NBN5 FT E2 8 Electrical installation board Relay ARP12F 1C 24VDC 3 Micro switch Charger 24V 8A 15 Buzzer HYD 4216W 24VDC WS1 Z5 W200R200 4 Motor for traction Charging indicator Protection module BD W 115
4. Pot to Off The throttle map parameter adjusts the static throttle map This parameter can be used to limit the controller s response to sharp throttle movements such as movements resulting from hand tremors Wigwag and unipolar throttle pots should be centered Setting this parameter to On inhibits driving and puts the controller into throttle autocalibration mode Current menu 32 Main Current Limit 15 to 90 Ampere 15 to 90 Ampere Braking Current Limit Boost Current Inhibit menu Type 0 to 5 Speed 0 to 100 Brake menu Fault Check Hold Voltage 10 to 24 Seconds volt 33 Sets the maximum current the controller will supply to the motor during 15 90 A normal driving By limiting the current supplied this parameter can be used to protect the motor from potentially damaging currents or to reduce the maximum torque applied to the drive system Sets the maximum current the controller will supply to the motor during braking By limiting the current supplied this parameter can be used to protect the motor from potentially damaging currents or to reduce the maximum braking torque applied to the drive system The Boost Current parameter defines the motor 90 to 90 Ampere 2 current limit during the boost period 0 to 10 Secondi This parameter sets the maximum time that the boost current is allowed The flexible speed input at J1 Pin 6 can be used to limit or to inhibit speed und
5. response Sets the rate in seconds that is used to slow down the vehicle when it is traveling in reverse at low speed and throttle is reduced Larger values represent slower response Sets the rate in seconds that is used to slow down the vehicle when it is traveling in reverse at low speed and throttle is reduced Larger values represent slower response Accel Max Speed Accel Min Speed Decel High Speed 0 2 to 1 5 seconds Decel Low Speed 0 6 to 8 0 seconds Rev Accel Max Speed Rev Accel Min Speed 0 2 to 1 0 seconds Rev Decel High Speed Rev Decel Low Speed 0 6 to 8 0 seconds Keyoff Decel 0 2 to 4 0 seconds gt OT N O e e 30 Sets the rate in seconds that is used to slow down the vehicle during emergency reverse i e when a throttle command gt 80 in the reverse direction is given while the vehicle is moving forward This gives the operator a way to stop more quickly when unexpected conditions arise Sets a pause before reversing direction after an emergency reverse stop This gives the operator time to return the throttle to neutral without moving backwards This parameter can be used to soften the bump associated with gear slack in the transaxle when throttle is applied from the neutral state Larger values provide a softer slack take up This parameter is intended to soften the bump associated with gear slack in the transaxle when 0 to 100 90 throttle is
6. 009 0880068 M 7 08 005 _ INCH TABLE 4T 5T Classification Bolt type Bolt size Torque kgf m Ibf ft Torque kgf Ibf 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 50 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 5 718 25 5 12 55 71 6 7 2 1 38 0 3 80 106 9 10 7 1 1 8 54 1 5 41 152 2 152 1 1 4 74 2 7 42 208 9 20 9 1 3 4 98 8 59 88 277 8 27 8 1 1 2 128 2 12 82 360 7 36 1 The torque in above table shall not be applied to nylon or nonferrous bolts or washer The same is valid for not standardized ones H Newton meter 1 Nm O 1kgfm TIGHTENING TORQUE OF SPLIT FLANGE BOLTS The following torque shall be applied to the split flange bolts Diameter Flat width Torque mm mm 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 10 PF THREAD Plug Thread Torque kgf m 1 8 1 1 0 1 1 4 2 6 0 2 3 8 4 6 0 3 1 2 8 5 0 4 3 4 19 4 1 0 1 33 2 0 Connector O ring Swivel nut hose Tube O D inch Thread in Torque kgf m 1 2 UN 13 16 16 9 5 0 95 9 4 UN 4 3 16 12 18 51 8 1 UN 1 7 16 12 21 2 1 11 APPROXIMATE CON
7. 5 Battery indicator CURTIS 906 11 Power cord 17 Controller Curtis 1212 2501 T24BNBO Key switch Battery 12V 64Ah Fuse 10A 22 3 3 DRIVE WHEEL Type 19EL DC 0 45kw Drive Motor Model ZD11265 650W24V Rate voltage DC 24V R P M 2650rpm Rate output 0 45kw Rate hour 60 min Rated current 36 A Insulation class F class Electromagnetic Brake Model 05 06 DC 24V Output Torque 6N M Gear Box transmission ratio 1 28 3 4 PUMP STATION Type CMB3 VB1111131 030 Item EPT15 Rated voltage 24V Rated output 0 8kw R P M 4200 rpm Rated current 60A Rated hour 1 8 min Insulation class F class IP Code IP54 Displacement 1 0cc rec Max operating pressure 130bar 3 5 BATTERY The size of battery is according to English BS standard Rate Specification EPT15 Rated voltage 12V X2 Capacity 5 hours 60Ah Overall size L W H mm 260 172X215 23 20A DURATION OF DISCHARGING CURVE ENVIRONMENTAL TEMPERATURE 259 13 2 128 SER errs 126 12 3 M E ILL 12 0 gt 9 f S 11 7 A m S pu zu S 10 8 bee E ERE e Discharging min 100 DURATION OF DISCHARGING LIFE TEST CURVE ENVIRONMENTAL TEMPERATURE 25
8. 96 and another at the Throttle Dead band parameter Program gt THROTTLE DB this way you can easily toggle between the readout and the parameter 3 8 BATTERY DISCHARGE INDICATOR Type 906 Front View Rear View TERMINALS Pin 1 Battery Connected to the vehicle s main positive terminal Use as short a wire as practical Pin 2 Battery Connects to the vehicle s main negative terminal Use as short a wire as practical Note Pins 1 amp 2 are connected across the total battery pack Pin 3 Output Signal No Option Output Signal option 5 VDC x0 5 VDC 90 pA current source above Empty 0 0 1 VDC at Empty 1 VDC maximum 90 uA sink No Option Pin 3 is left open Pin 4 z Keyswitch Connects to Battery through the switched terminal of the Keyswitch 39 OPERATION o N Display 1 Only when the battery is properly charged is the right most LED lit 2 As the battery s state of charge decreases successive LEDs light up only one on at a time 3 The 2nd from left LED flashes indicating energy reserve 70 depth of discharge 4 The 2 left most LEDs alternately flash indicating empty 8096 depth of discharge Reset OCR Open Circuit Reset Upon reconnection of battery the indicator will reset at proper voltage level HVR High Voltage Reset Indicator stays connected to battery during charging Battery must remain at or abov
9. O C Discharqinq min z wana time CHARGING CURVE Voltage V Current A UE i 84 18 01889 3 6 Type QQE192 8CH17 26B for l Lu e j Lu LL l MAIN PRODUCT SPECIFICATION Output current Max output power battery capacity Input voltage Output voltage range A 240W 40AH 100AH 230Vac 28 2V de 8 150W 25AH 60AH 115 230Vac 29 AVdc ENVIRONMENTAL CONDITION Humidity 5 95 With package 2 Altitude 3000 Work normally Natural convection cooling Working under full load 25 ELECTRICAL CHARACTERISTICS Input characteristics Technical specification Rated input voltage 230 Input voltage range 180 264 230Vac AC input voltage 47 63 frequency 264Vac input start up 1 4 Inrush current 100 A cold condition environmental temperature is 25 C Max input current Vin 180Vac rated load When input is on voltage for fan is 12V When input voltage is off there is no output voltage for fan When input voltage is on Relay output wire BN and BU are disconnected When input voltage is off Relay output wire BN and BU are connected No Technical requirements Remark Fast charge voltage 37 02 Maintain voltage 21 6 24 Constantcurent 18 0 A 25 Crossregulation 399 28 1 1 Vin 230Vac rated load NER 2 6 Power
10. STATUS LED of Battery Indicator Not drive or lift 1311 HANDHELD PROGRAMMER watch the programmer is light or not Check the signal of 16 pin of The contr ller is fault the controller is OK or not replace it The controller is fault The key switch Natural flash replace it SY may be fault check it Main contactor L Check the socket connector of the of the KM is main contactor is OK operated 2 The micre switch SA and its role No 5 1 J1 13 is OK or not Yes 1 Check the resistance of the coil of the brake is OK or not 2 The role No J1 5 5 2 of the brake YB is OK or not 3 The clearance of The brake YB is OK or not Light Not drive can lift the brake is OK or not NO The wiring of 7 core for the handle is OK or not replace or repair 1 check whether the NO signal line J1 1 and J1 8 is conducted 2 Check whether the voltage between 5 10 and 2 4 is 24V Check the PCB board is normal All normal 1 PCB board is bad replace it Check A1 and A2 S1 Replace or repair and S2 of the drive motor is OK or not NO Check drive motor is OK or not 1 The last two lighting bars of battery indicator flash alternantly 1 please properly charge the battery 2 Check whether the No 3 of battery indicator input 2 If not 24V replace 24V voltage and battery indicator role
11. should always be disconnected during replacement of electrical components 5 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 breathing 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 caution sign in the operator s compartment for example Do not start of Maintenance in progress This will prevent anyone from starting or moving the machine by mistake When welding on the machine or working on the electrical 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 It is strong enough to burn skin and eat holes in clothing If you spill acid on your clothes or skin immediately flush with large quantities or 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 Keep sparks lighted matches and open flame away from the top of battery Ba
12. the battery is fully charged Empty Voltage 0 0to 24 3 Volt Voltage when the battery is fully discharged Voltage when a charger is connected above which Volt Voltage above which the battery is considered to start charging Voltage at which the BDI calculator will be reset to Reset Voltage 25 8 24 5 to 36 0 Volt 100 after the charger is disconnected and the controller is powered up larger batteries which discharge more slowly batteries which discharge more slowly Sets the battery charge level at which maximum Low BDI Level 10 0 to 100 90 vehicle speed will be limited in order to protect the battery from deep discharge Sets the maximum allowed vehicle speed when the Low BDI Max Speed OW battery charge falls below the programmed Low BDI Level When programmed On Pin J1 9 will be used to receive an external lockout enable signal lift External lift lock 1 Lockout is controlled by external signal When programmed Off lift lockout is controlled by the controller See Lift Lockout Threshold When programmed On Lift lockout protection is enabled 34 System Resistance Resistance Auto Comp 0 to 1 NO N cO Auto Comp Current Limit Speed Scaler Current Rating Max Current Time Cutback Gain QD 0 Liftlock Threshold 20 0 to 50 7 Sets the battery charge level at which Lift locklock protection begins Compensation menu Sets the motor load compensation Higher values provide stronger
13. 6 08 09 OG L om 08 09 ie OG Oct 7 99169 2 SPECIFICATION 2 1 LOCATION OF COMPONENTS 2 Discharge indicator and charging Lift Cylinder sss 6 LoadWheels hs Drivecontrolswitch 7 Chargingcable 13 CONTROL HANDLE oafety belly button Lifting button Drive control switch Lowing button Horn button OL 14 Performance 2 2 SPECIFICATION SHEET 2 2 1 Technical Features 1 2 1 3 1 4 1 5 1 6 1 8 1 9 2 1 2 2 2 3 3 2 3 3 3 4 3 9 3 6 3 7 4 4 4 9 4 15 4 19 4 20 4 21 4 22 4 25 4 32 Type sheet for industrial truck acc to VDI 2198 Manufacturer 5 type designation Drive Operator type Load Capacity rated load Load centre distance Load distance centre of drive axle to fork Wheelbase Service weight Axle loading laden front rear Axle loading unladen front rear Tires Tire size front Tire size rear Additional wheels dimensions Wheels number front rear x driven wheels Tread front Tread rear Lift Height of tiller in drive position min max Height lowered Overall length Length to face of forks Overall width Fork dimensions Distance between fork arms Ground clearance centre of wheelbase r 3 3 x 3 i lt 3 i kg kg kg 3 i mm QIQIQ x x x 5 D4o mm b11 mm mm h14 mm h13 mm l mm l mm s e l m
14. ATOR 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 e When carrying out any operation or maintenance have trained and experienced personnel to carry out the work When carrying out any operation or maintenance carefully read operation and maintenance handbook Read all the precautions given on the decals which are fixed to the truck Be sure you fully understand the content of the operation It is important to prepare necessary tools and parts for maintain the truck 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 F Moving parts can e amp t ar crush hands i feel ae or laga 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 several times with the engine motor stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system co
15. E INDICATOR 422 4 4 4 4 2 39 3 9 REPLACE THE ELECTRIC PARTS 41 3 10 TOOL FOR REPAIRING THE PIN OF 46 4 HYDRAULIC SYSTEM B 48 4 1 PUMP STATION OPERATION a r 49 4 2 OPERATION OF 54 43 HYDRAULIC OIL FILLING 55 5 DRIVE WHEEL NEN a bI 56 5 1 REPLACE THE ___ 57 52 REPLACE THE ELECTRIC BRUSH 58 53 REPLACE THE 59 5 4 ADJUST THE AIR GAP OF THE 59 55 REPLACE THE DRIVE WrIEEL uuu u uu up US ee ee eee 60 0 GONIBOLTIANDEB uu uuu Duss 57 61 REMOVE THE AIR SPRING 2 65 62 REMOVE THE Lu 65 63 REPLACE THE SEN
16. ERGENCY BUTTON EE SL n remove the emergency button lid A Dismantle the plug Lift the board pull down the emergency button 44 REPLACE THE FUSE Remove 2 nuts then you can change the fuse E E Open the cover of the fuse seat then you can dismantle the fus and replace it REPLACE THE RELAY Dismantle two screws Dismantle the cables Then you can dismantle the relay and replace it When replacing the controller be carefully to check the plugs specially note the cathode pillar 45 Two plug terminals M1 and M2 are provided for the connections to the motor field winding Do not allowed to access anti Line otherwise the motor will be reversed x4 aka E 5 e EC When the temperature of the motor is more than 115 C the protect module will give a signal to the controller then driving speed will automatically change to low speed mode After the temperature reduces to 1159 the speed mode will change to normal mode If one line of the cable open circuit the driving speed will be slowly Dismantle the screw and the plug then you can dismantle the protect module and replace it 46 3 10 TOOL FOR REPAIRING THE PIN OF ELECTRIC 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 lock
17. No 4 role output 24V voltage 3 Check the Cannot lift can drive fuse FU2 is OK or not 3 Replace the fuse FU2 74 Cann t lower others normal Can forward not backward can backward not forward Can lift but the drive speed is very slowly 4 The role No J1 6 and 5 4 2 for the coil of relay for motor of pump KMp is OK or not 5 Check relay of pump motor is OK or not 6 Check micro switche SU is OK or not f The pump motor is normal or not 8 The hydraulic valve of the pump is OK or not dirty plugged etc 9 The hydraulic oil is insufficient 1 The lower magnet valve YV is damaged or the role No J1 9 and 5 7 is OK or not 2 The lower magnetic valve is plugged for dirty 1 Check the signal line J1 1 and J1 8 is conducted 2 Check whether the voltage between 5 10 and 2 4 is 24V 1 Check the snail speed switch is OK or not 2 Check the Protect module BD W 135 110 and its plug are OK or not 3 The PCB board of the control handle is OK or not 4 Repair or replace 16 pin plug of controller 5 Repair or replacement the relay 6 Adjust or replace micro switche SU 7 repair or replace the pump motor 8 Clean up the valve core 9 Add hydraulic oil Rapair or replace Replace the PCB board of the controll handle Repair or replace the cable in the handle Replace or repair it
18. SERVICE amp MAINTENANCE MANUAL Electric Pallet Truck CONTENT FOREWORD 3 1 4 1 1 INTRODUCTION MAINTENANCE SAFETY 5 4 12 MEASUREMENT CONVERSIONS 000 8 2 13 2 1 LOCATION OF COMPONENTS 2 122 111 13 22 SPEOIFIGCAMON SHEETS 14 2 2 1 TECHNICAL 5 14 728 MEES exqye S 17 3 1 011 22 11 31 c u u 18 3 1 ELECTRIC DIAGRAM 18 3 2 ELECTRICAL 0 22 23 DRIVE WHEEL u imet 23 34 QU E Jf un uu uuu cer er Te 23 59 BAITEN ecc RETE TT 23 3 6 CHARQGER 25 3 7 CURTIS CONTROLLER 1212 4 APA 28 3 8 BATTERY DISCHARG
19. SOR 66 64 REPLACE THE TILLER 66 65 REPLACE THE 67 6 6 REPLACE THE MICRO 5 68 7 CASIER WAHEED e ee 69 7 4 OPERATION OF THE CASTER 69 7 2 ADJUSTING THE PRESSURE FOR THE DRIVE WHEEL 70 8 MAINTENANCE CHECK LIST 71 9 TROUBLE SHOOTING Led 73 FOREWORD Proper operation maintenance troubleshooting and repairs are necessary to preserve the performance of the pallet truck over a long period and ensure that fault and breakdowns do not occur The purpose of this service manual is to provide necessary information especially in inspections repair and maintenance 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 specialized authorities Environmentally hazardous waste such
20. VERSIONS SI Conv 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 x 7 22 Pressure Pa N m kiloPascal kPa x 4 0 H20 0 249 kPa kiloPascal kPa X 0 30 3 38 kPa kiloPascal kPa X 0 145 psi X 6 89 kPa bar X 14 5 psi X 0 069 kg cm 1422 psi 0 070 Newton mm x 145 04 psi x 0 069 bar MegaPascal MPa x 145 psi X 0 00689 MPa Pa N m Power r W J s kiloWatt kW x 1 36 PS cv x 0 736 kW kiloWatt kW x 1 34 HP x 0 746 kW kiloWatt kW x 0 948 Btu s x 1 055 kW Watt W x 0 74 ft lb s X 1 36 W W J s Energy 4 5 Nm kiloJoule kJ 0 948 Btu X 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 B H P Temperature C 32 1 8 F C Z 1 8 32 Flow Rate liter min dm min X 0 264 US gal minZ3 785 min Note Non SI Unit 12 4 CLC 9 86 096 069 OSP 09 066 086 006 091 OCL 08 OV OV 009 OV OG 006 086 096 066 00
21. 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 reserves 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 Maintenance work may cause injuries Always take care to perform work safe 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 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 for the most parts those that apply when servicing hydraulic and larger truck component parts WARNING MODIFICATION OF THE TRUCK WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE TRUCK IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION WARNING SINCE THE TRUCK MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPONSIBIUTY OF THE OWNER OR OPER
22. bility of connection of all cables and if EINE Electrical system 83 Check the fuse size 2 Inspection of safety reliability and function of switches and fe unlocking cam equipment 8 5 Inspection of connector replace f damaged 1 86 inspection 9 1 Check the the brake adjustitifnecessay f tel Test the emergency switch function lt lt Test the meryency switch function 101 Motor 9 3 Clean motor frame with vacuum cleaner inspection of wearing state of commutator Check Check battery housing voltage of battery housing voltage of battery Check battery housing voltage of battery Je 0 2 Inspection of safety device applicability of grease N LA p y pplicability of g fet Clean terminal of battery inspection of compactness of fit 1411 Inspection of damage of battery cable replace it if necessary C Grease the truck according to the time schedule of lubrication Lubrication 11 1 feeding 12 1 Inspection of electrical leakage to the chassis Integrated 12 2 Inspection of driving speed and braking distance measurement 123 Inspection of iing ndiowerng speed 124 Inspection of safety valve andclosingvalve gt 13 1 Check the indicator replace it if necessary L 9 13 2 Check the micro switches of the tiller replace t
23. ded neutral when wiper at PotHigh 4 unipolar Voltage throttles 5 wigwag 6 inverted wigwag 7 single ended neutral when wiper lt PotLow 8 5 inverted single ended voltage neutral when wiper PotHigh 9 unipola Sets the maximum voltage for voltage throttles Types 5 9 For 5 3 wire pot throttles PotHigh is determined by the throttle itself Sets the minimum voltage for voltage throttles Types 5 9 For 5 3 wire pot throttles PotLow 15 determined by the throttle itself Sets the throttle range the controller interprets as neutral Increasing the parameter setting increases the neutral range This parameter allows the neutral deadband to be defined wide enough to ensure the controller goes into neutral when the throttle is released Sets the pot wiper voltage required to produce 10096 controller output Increasing the Throttle Max setting reduces the wiper voltage required and therefore reduces the stroke necessary to produce full output This feature allows reduced range throttle assemblies to be used When programmed On vehicle drive is inhibited if a throttle command outside the neutral deadband is issued before the controller is powered up Drive will continue to be inhibited until the throttle is returned to within the neutral deadband If the HPD fault is not cleared within 10 seconds This parameter is used to enable disable the speed limit pot If no speed limit pot is used set Speed Limit
24. disturbance rejection while lower values provide smoother operation Sets the motor load compensation after the throttle is Anti Rollback Comp 70 to 125 released to neutral and the speed 15 estimated to be near zero Higher values provide more hill holding force m Reverse menu Speed 1 How 100 to 100 Defines the maximum reverse speed of the motor P when emergency reverse is active as PWM output 0 0 to 10 0 Sets the Emergency reverse time Decel Rate 0 2 to 4 0 Accel Rate 0 2 to 8 0 Max Braking Current 0 15 to 90 Sets maximum braking current limit Switch Normally Closed Sets the Emergency reverse switch type NC or NO Misc menu Sets the delay time between the last throttle request or serial communication and when the controller goes 209p into sleep mode Setting the delay to zero disables the sleep function This parameter selects which set of fault identification Fault Code Type o he codes Type 0 1 or 2 will be flashed by the status LED see Section 7 The controllers hourmeter logs the total drive time since the last reset this record is accessible through Basel Dive Times Oori the Monitor menu Setting this parameter On zeroes the hourmeter and starts a new log this is typically done when the vehicle is serviced Reset Drive Time is automatically set to Off after the hourmeter is reset Emergency Stop When programmed On Emergency Stop is enabled Seconds Sets the rate at wh
25. e controller provides the low current logic control connections Ji Pini pot wiper JIPin2 high HPin3 horn switch Ji Pins mode switch open M1 closed M2 Pins keyswitch input KSI Pin 6 speed inhibit JiPin7 B Ji Ping porlow Jt Pin 9 speed pot Ji Pin10 status LED JiPin11 BDI JiPin12 reverse switch 13 B Ji Pinis push switch The mating connector is a Molex Mini Fit Jr receptacle p n 39 01 2140 with appropriate 45750 series crimp terminals 19 A 4 low power connector is provided for the J Pin Rx programmer and the battery charger The mating J2 Pin 2 B connector is a Molex Mini Fit Jr 39 01 2040 with appropriate 45750 series crimp terminals A mating connector is provided with the 1311 handheld programmer J2Pin3 Tx charge inhibit 42 Pin 4 B A 2 pin low power connector is provided for the electromagnetic brake The mating connector is a Molex Mini Fit Jr receptacle p n 39 01 2020 with appropriate 45750 crimp terminals J3 Pin 1 Brake 4 J3 Pin 2 Brake High Current Connections Four 1 4 Faston terminals are provided for the high current connections The motor connections M1 M2 and battery 29 Connections B have one terminal each STANDARD PARAMETER Parameter standard Unit DESCRIPTION Software parameter Drive menu Sets the rate in seconds at which the speed comma
26. e proper voltage level for a continuous 6 minutes TROUBLESHOOTING Possible Cause Keyswitch On Terminals not connected or improper voltage and no display Keyswitch not high Indicator voltage does not match Stays at Full battery voltage Indicator voltage does not match battery Will not reset voltage or battery not fully charged Reset without Not connected directly to battery terminals charging battery Indicator voltage does not match battery voltage or Empty too soon terminals not connected directly to battery 40 3 9 REPLACE THE ELECTRIC PARTS Remove 4 pc the screws Then remove the main cover and the motor cover REPLACE THE CHARGER Remove 4 screws Remove AC input plug 41 Remove ground plug and Dismantle the wire connecting the charger positive negative plug of output and the battery dismantle 3 pairs of connectors Then you can dismantle the charger and replace it REPLACE THE BATTERY 7 EAM g SE Remove M6 internal hexagonal Screws and other 2 screws so that we can raise up the whole electronic control board for repairing Remove the bolts nuts washers which fix the power cable to the battery 42 Take out the battery After dismantle the battery REPLACE THE BATTERY INDICATOR Dismantle 4 plugs then you can dismantle the battery indicator and replace it Circuit Diagram of Battery Indicator 43 REPLACE THE EM
27. efficiency QD Protection characteristics Technical requirements Remark protection The charger software limits the maximum output voltage to a level suitable for the connected battery system When the internal temperature rises to 85 it turns Software over voltage protection QD o o z O Cc 2 into pulse charge mode The pulse mode charges battery minutely with alternate currents 2A and 8A which will reduce charger internal temperature When the internal temperature drops to 60 C the charger Thermal cutback comes back to previous charge mode Fi protection protection remove the condition battery protection battery connection 3 7 Cell short circuit timer Internal software protection Charger LED indicator No Status LED Remark LED GREEN ON ON CC MODE li LED OFF Fast Charge LED RED Floating Charge LED ORANGE ON Full Charging LED GREEN ON 26 INPUT TERMINAL DIAGRAM amp DEFINITION OUTPUT TERMINAL DIAGRAM amp DEFINITION 350 0 2 0 1 1015 BLACK 168 UL1015 RED 168 Scr EE QQES BE LED CONNECTOR DIAGRAM amp DEFINITION RELAY CONNECTOR DIAGRAM amp DEFINITION 27 3 7 CURTIS CONTROLLER 1212 f E H T r t Dimensions in millimeters and finches 28 CONNECTIONS Low Current Connections A 14 pin Molex low current connector in th
28. er certain conditions For example a switch could be installed under the seat so that if the operator drives the scooter while they are standing the max speed will be limited The Inhibit Type parameter is used to select how the inhibit function will be implemented Depending on how the inhibit switch is wired into the system set this parameter to 0 B active 1 B active 2 Open circuit active 3 B inactive 4 B inactive 5 Open circuit inactive This parameter limits the maximum speed allowed during speed inhibit mode A setting of 0 prevents drive during inhibit mode Sets the length of delay between when zero speed is commanded and the electromagnetic brake 15 engaged Enables disables the fault detection on the EM brake A high initial voltage is applied to the brake coil when the brake is first released After approximately 1 second this peak voltage drops to the programmed Hold Voltage The parameter should be set high enough to hold the brake released under all the shock and vibration conditions the vehicle will be subjected to When set to On the horn output J1 Pin 3 will act as a brake light driver The brake light must be driven by a relay When programmed On the horn will sound whenever the vehicle is being driven in reverse Sets the reverse beep to be a constant tone when programmed On or a 1Hz pulse when programmed Off Sets the system resistance motor brushes wiring
29. 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 wrenches and nuts 1 2 MEASUREMENT CONVERSIONS Length m m m m 4 w im 00254 0000025 008333 00277 0000015 1mmz0 1cm 1um 0 001mm Area m 4555 0000646 0006943 1 1 100 1milez 259ha 2 59kmz Volume 1gal US 3785 41 cms 231 ins 0 83267gal US Weight o 9 1 0001 0000 0002 1000000 1000 35273 2204 59 28 3495 0 02835 0 000028 0 0625 1 tone metric 1 1023 ton US 0 9842 ton UK Pressure kgf cm bar kPa Ibf inz Ibf ft kgf cm 0 98067 980665 98 0665 142233 2048 16 bar 1 01972 100000 14 5037 2088 6 0 00001 0 001 0 001 0 00015 0 02086 0 01020 0 14504 Ibf in 0 07032 0 0689 6894 76 6 89476 144 Ibf ft 0 00047 0 00047 47 88028 0 04788 0 00694 kgf cm2 735 56 Torr mmHg 0 96784atm Standard tightening torque The following charts give the standard tightening torques of bolts and nuts Exceptions are given in sections of Disassembly and Assembly METER TABLE Bolt type M _ _ M 2
30. hem if necessary 133 Check the horn function o 134 Test the emergency braking TT _ 13 5 Test the reverse and regenerative braking fe Test the safety belly button function Charger 141 Check the function of the charger replace it if necessary e gt Geneal 154 Check the clearance of the castors adjust the distance if necessary e Sticker 164 Check the sticker of the truck add the new one if necessary _ e gt 72 9 TROUBLE SHOOTIN 1 The Key switch SY Emergency button S is off or damaged Its plug is tight 2 The battery cables are tight 2 connected to the post head of Reconnect the battery it Not light 3 Reconnect or replace 3 The plug of battery indicator is loose or bad 4 The plug of charger is not 4 tight connected to the socket Reconnect XS or XS is damaged or replace 1 The fuse FUO1 or FUO2 is OK or not 2 7 core handle wiring harness are in good condition Without any actions abnormal 3 The plugs of Replace or repair the Wiring board in the contro handle 8 pin are in good condition 4 The PCB board of the control handle is OK or not Replace control handle or controller Use CURTIS 1311 Natural HANDHELD gt PROGRAMMER to check and clearing of fault Check it according to LED CODE list page 26 and 27 and clearing of fault Not natural Check the
31. ich the vehicle brakes to a stop Seconds when emergency reverse is activated and the vehicle is moving forward Sets the rate at which the vehicle accelerates in the opposite direction after it has been brough to a stop Seconds Ampere NOTE for standard parameter 1 0n Ozoff 35 TROUBLESHOOTING CHART The 1212 controller provides diagnostics information to assist technicians in troubleshooting drive system problems The diagnostics information can be obtained in two ways by reading the appropriate display on the handheld programmer or by observing the fault codes issued by the status LED PROGRAMMER DIAGNOSTICS The handheld programmer presents complete diagnostic information in plain language Faults are displayed in the Faults menu and the status of the controller inputs outputs is displayed in the Monitor menu Additionally the fault history file in the Faults menu provides a list of the faults that have occurred since the file was last cleared Checking and clearing the fault history file is recommended each time the vehicle is brought in for maintenance Refer to the troubleshooting chart Table 3 for suggestions about possible causes of the various faults Faults are listed alphabetically For information on 1311 programmer operation see Appendix C LED DIAGNOSTICS During normal operation with no faults present the status LED is steadily on If the controller detects a fault the status LED flashes a fau
32. ing 4 pole Tool for removal of pins sleeves 47 4 HYDRAULIC SYSTEM HYDRAULIC FLOW DIAGRAM Lift cylinder Lowering valve Throttle valve Pressure valve Motor and pump Oil tank INSPECTION OF HYDRAULIC OIL External appearance Smell Condition Measurement Clear and no discoloration Possible to use l Inspect the viscosity and if fine Clear but the color becames brighte Fine Mixed with other oil it can be continuously used Color changed like milk Mixed with air and water Separate water or replace oil Color changed into dark brown Clear but there are small black i Fine Mixed with other particles Use after filtering spots 48 41 PUMP STATION OPERATION 49 Remove M6 internal hexagonal screws Remove 2 screws on two sides so that we can up the pump station Dismantle the power cable screw under the pump station with wrench N RE lt lt r Dismantle 2 screws at the bottom of the pump station with internal hexagonal wrench so that we can replace the oil tank Remove 4 screws pump station cable following 2 pictures show the replacement of one screw 50 Dismantle the magnet valve Dismantle the plug with wrench Remove the pump station so that we can add oil and replace motor 51 CLEAN OIL TANK AND FILTER WARNING Put the fork of the gr
33. lt identification code continuously until the fault is corrected Refer to the troubleshooting chart Table 3 for suggestions about possible causes of the various faults Faults are listed alphabetically Note The status LED can only indicate one fault at a time If multiple faults are detected the highest priority fault code flashes until it is cleared Three sets of fault codes are available The Fault Code Type parameter Program gt Misc gt Fault Code Type is used to select which set of fault codes will be used Type 0 Type 1 or Type 2 The codes are listed in Tables 2 0 2 1 and 2 2 36 Table3 TROUBLESHOOTING CHART BATTERY DISCONNECT nnercte FAULT Poor connection to battery terminals Electromagnetic brake driver open 1 Electromagnetic brake coil shorted 3 2 5 BRAKE FAULT brake fault Electromagnetic brake driver shorted 1 Electromagnetic brake coil open 9 CURRENT SENSE FAULT Short in motor or in motor wiring Controller failure EEPROM CHECKSUM EEPROM fault EEPROM failure or fault Motor voltage does not correspond to throttle request 1 Short in motor or in motor wiring 3 Controller failure HPD High Pedal Disable Improper sequence of throttle and KSI push or inhibit inputs Misadjusted throttle pot 2 3 8 MAIM FAULT main contactor fault Main contactor welded or stuck open 2 contactor driver fault MAIN OFF FAULT main c
34. mponents can then be disconnected with minimal fluid loss Remove all rings watches and jewelry when performing any maintenance Wear well fitting helmet safety shoes and working Clothes When drilling grinding or hammering always Wear protective goggles 3 Always do up safety clothes properly so that they do Not catch on protruding parts of machines Do not wear oily clothes When 3 checking always release battery plug DO NOT WEAR LONG HAIR UNRESTRAINED 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 naked 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 pure oil or grease and be sure to use clean containers Oil is a dangerous substance Never handle oil grease or oily e clothes in places where there is any fire or flame As d Buy preparation for use of fire extinguishers and other fire fighting equipment K 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 at the working place Battery
35. nd increases when throttle is applied with the speed limit 0 2 to5 0 seconds pot is in its maximum speed position and the vehicle is traveling forward Larger values represent slower response Sets the rate in seconds at which the speed command increases when throttle is applied while the speed limit 1 8 to 8 0 seconds pot is in its minimum speed position and the vehicle is traveling forward Larger values represent slower response Sets the rate in seconds that is used to slow down the vehicle when it is traveling forward at high speed and throttle is reduced Larger values represent slower response Sets the rate in seconds that is used to slow down the vehicle when it is traveling forward at low speed and throttle is reduced Larger values represent slower response Sets the rate in seconds at which the speed command increases when throttle is applied while the speed limit 0 2 to 5 0 seconds pot is in its maximum speed position and the vehicle is traveling in reverse Larger values represent slower response Sets the rate in seconds at which the speed command increases when throttle is applied while the speed limit 1 8 to 8 0 seconds is in its minimum speed position and the vehicle is traveling in reverse Larger values represent slower response Sets the rate in seconds that is used to slow down the vehicle when it is traveling in reverse at high speed and throttle is reduced Larger values represent slower
36. ndard torque Standard torque Nm Air gap mm Replace the brake or brake disc if the air gap exceeds 0 35 mm CAUTION slide should not contain grease and nothing is blocked inside Connected with plug connection should connected firmly 55 REPLACE THE DRIVE WHEEL Remove thrust screw with special tool 61 s C V Using a crane to lift the truck remove the drive wheel module 62 Remove the screws of both sides dismantle the cables on the drive wheel Pull out the handle control cable and remove the handle Remove the bearing then you can replace it Remove 4 screws and remove the drive wheel seat then you can replace the drive wheel 6 CONTROL HANDLE N Partname No Patmame 1 ter 9 Retainingring 2 Sew 000000 Shattoftilr O al 5 Tileram 18 sm Mam re sm 222 a sm 00 Spring 64 10 11 12 13 4 Remove air spring screws with internal hexagonal wrench 6 2 REMOVE THE HANDLE Remove the elastic collar with circlip pliers a j otrick out the shaft of the tiller bar with a hammer hold the other side so that keeping it from missing 65 LE CN Dismantle 4 screws to remove the metal cover The electric parts in the handle will appear Check the cables if they re tight or not you can snip the nylon belt with scissors
37. ontactor driver fault Main contactor driver failed open main contactor driver On fault Main contactor driver failed closed Battery voltage 531 volts Vehicle operating with charger attached 3 Intermittent battery connection 3 3 PREC AUL orechar Brake driver shorted L Precharge circuit damaged 3 MOSFET failure 1 3 7 SPEED POT FAULT ced limi vir Speed limit pot wire s broken or shorted THERMAL FAULT over under temperature Temperature gt 80 C or lt cutback 2 Excessive load on vehicle 3 Operation in extreme environments Electromagnetic brake not releasing PotLow and or PotWiper Throttle input wire open or shorted out of range Throttle pot defective Battery voltage 17 volts Bad connection at battery or controller HPD fault present gt 10 sec Misadjusted throttle 2 Broken throttle pot or throttle mechanism 37 CURTIS 1311 HANDHELD PROGRAMMER Curtis programmers provide programming diagnostic and test capabilities for 1212 controllers The power for operating the programmer is supplied by the host controller via a 4 pin connector Two programmers are available the PC Programming Station 1314 and the handheld programmer 1311 The Programming Station has features not available on the handheld unit on the other hand the handheld programmer has the advantage of being more portable Typically the Programming Station is used to set up
38. ound and drain out the hydraulic oil Remove out the pump station Loosen the hoop No 12 Remove the oil tank No 18 Remove the suction filter No 16 8 17 Cleaning of oil tank and filter Clean the Fix plate for valve No 7 etc Clean up with compressed air and inspect if the filter is stopped or damaged If the filter is stopped or damaged replace it e Remove dust or foreign material from the tank Then assemble them TROUBLE DIAGNOSTICS Check if there is any place Bubble in hydraulic oil Mixed with air where can be entered Tighten the loosened part again Mixed with air and water Replace the oil Became inferior in quality by oxidizing or l l ped 9 Replace the oil mixed with other particles 52 The Plug Screw of port for adding oil is ventilating When lower the air will come out from the tank it might take out little oil vapor So it might appear little oil stains on the plug Wait a little and ensure that there is no oil leakage CAUTION For 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 CAUTION The Magnet valve is a wearing part If the forks automatically lower after lifting the magnet valve may be blocked or damaged remove it to clear or replace shocking the joint of the hydraulic pipe and hydraulic pipe migh
39. r than the programmed Rev Max Speed During forward operation defines the requested M2 Max Speed 20 to 100 90 speed at full throttle when the speed limit pot is in its maximum speed position During forward operation defines the requested speed command at full throttle when the speed limit M2 Min Speed 0 to 100 pot is in its minimum speed position Min Speed cannot be set higher than the programmed Max Speed During reverse operation defines the requested M2 Rev Max Speed 50 10 to 100 speed at full throttle when the speed limit pot is in its maximum speed position During reverse operation defines the requested speed command at full throttle when the speed limit 0 to 60 pot is in its minimum speed position Rev Min Speed cannot be set higher than the programmed Rev Max Speed EN e M2 Rev Min Speed N gt Throttle menu 0 to 9 3 0 to 5 0 volt 0 0 to 2 0 volt Neutral Deadband 5 to 30 Throttle Max Speed Limit Pot Throttle Map 30 50 40 to 100 1 1 20 to 80 0 to 100 Tremor Suppression Calibration 1 he 1212 controller can accept inputs from both 5kO 3 wire pot throttles and voltage throttles Set the throttle type parameter to match the throttle used in your application 5 3 wire pot throttles 0 wigwag 1 inverted wigwag 2 7 single ended neutral when wiper at PotLow 3 inverted single en
40. released and then reapplied while the vehicle is still moving Larger values provide a softer slack take up Creep Speed helps to prevent vehicle rollback on inclines when the brake is released with very little throttle applied It is activated when the throttle request exceeds the throttle deadband threshold Sets the speed at which a gentler deceleration is 0 to 30 90 initiated when the throttle is released to neutral larger values start the soft stop deceleration sooner E Stop Decel 0 2 to 4 0 seconds On E Stop Pause 0 0 to 1 0 seconds Soft Start Oto 100 Gear Soften Creep Speed 0 to 10 90 Soft Stop Speed N Speed menu During forward operation defines the requested 20 to 100 speed at full throttle when the speed limit pot is in its maximum speed position During forward operation defines the requested speed command at full throttle when the speed limit 0 to 100 pot is in its minimum speed position Min Speed cannot be set higher than the programmed Max Speed During reverse operation defines the requested 10 to 100 speed at full throttle when the speed limit pot is in its maximum speed position During reverse operation defines the requested speed command at full throttle when the speed limit e e M1 Max Speed M1 Min Speed M1 Rev Max Speed O M1 Rev Min Speed O to 100 90 pot is in its minimum speed position Rev Min Speed cannot be set highe
41. sis and 1 1 Inspection of any damage of bearing parts 91 12 mspecionofaljomtsorbos fr pe 2 11 21 11 22 Replacelubricaton 1119 bearings nso wa ad anse som e Wheel part 32 Inspection of bearings inside wheels and ensure compact fit with wheels Steering system 41 Inspection of steering operation motion e 5 1 Inspection of performance and adjustt Jej 52 Inspection of reset function of filler gas spring and any leakage or Braking system damage 53 Inspection of wearing state of brake disc 54 Inspection of brake connectors and adjust if necessa y 6 1 Inspection of wear and adjustifnecessary Inspection by sight of any wear of loading wheel HNIC of any wearing or damage of edge of forks and pallet lej 7 1 Inspection Inspection of any leakage or damage of all joints any Inspection of any leakage or damage of all joints or damage of all joints del Inspection of any leakage or damage of hydraulic safety 7 2 and reliability of attachment Hydraulic system 73 Inspection of hydraulic oillev 74 Replace hydraulic oil and filter 7 5 Inspection of adjustment function of pressurevalve s necessary Inspection of safety and relia
42. t be loosed and leak oil so usually check and tighten it 53 4 2 OPERATION OF CYLINDER REPLACE THE CYLINDER Firstly dismantle the connector of the cylinder Remove these 2 screws Using a crane to lift the truck then the cylinder came out Dismantle the cylinder at the bottom of the chassis After dismantle the cylinder 54 STRUCTURE AZ oe i M M uie 5 No Patnam No Patmme 2 0 2 8 45565 Pitonga 9 g _ e san 9 5 4 3 HYDRAULIC OIL FILLING Dismantle the lid on the top of the tank and fill the oil 55 DRIVE WHEEL No 7 Patnam jN Partname 3 al Seingmg 4 7 20 M we 5 Skeleton oil seal ee Oo QO IN gt 56 5 1 REPLACE THE WHEEL Lift the truck with wooden block dismantle the cover Dismantle the power cable of the motor and the brake and the temperature sensor T asa Dismantle the screws of the cable plate Remove the cable plate the wheel appears Use four screws 8 8T or more better to Screw in four technologic screw holes so Remove 10 pcs screws then you can replace the wheel that ejection the wheel 57 2 pc guide pin holes 10 pc screw holes 4 pc technologic screw holes 52 REPLACE THE ELECTRIC BRUSH You can see the electric brush a
43. t the Remove 4 screws and dismantle fixed back of the cover plate of electric brush 58 Remove the screw fixed the electric brush dismantle the Electric brush spring then you can remove and replace the electric brush 53 REPLACE THE BRAKE Part name Gag bit 8 JQovrbord 000000 Splined sleeve Elastic washer No 3 Friction disc componens 9 Connectscrewv 6 A4 Spring 112 gt 59 Then you can replace the brake or repair it 54 ADJUST THE AIR GAP OF THE BRAKE Rated air gap z is large due to wear To ensure that the brakes have enough brake torque must adjust the air gap before it reach the maximum air gap Air gap can be adjusted several times when the thickness of the friction brake reach to the most small thickness friction brake disc must be replaced The brake torque noise is relative to the air gap When the air gap exceed the maximum value it might cause the brakes not releasing friction braking burn braking or retention decrease or even cause a major accident Must be checked on a regular basis and adjust air gap attention must disconnect the main power 60 Step 1 Adjust the three hollow screws Step 3 Use a feeler gauge to check the air gap z value is a rated air gap value or not Step 1 Loose the three screws that fix the brake Keep the same clearance as showing Install screw tightening torque Nm Sta
44. the parameters initially and the handheld programmer is used to made adjustments in the field Several versions of each programmer are available User Service Dealer OEM the User programmers can adjust only User access parameters whereas the OEM programmers can adjust all the parameters 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 LCD Display seven lines alphanumeric Parameter Modification Key to move around through to increase and the programmer menus decrease values Bookmark Keys for jumping easily back and forth between fields 38 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 example in adjusting the throttle dead band you might set a bookmark at the Throttle 95 readout Monitor gt THROTTLE
45. to take out the plugs Dismantle the plugs with your hands finally the handle can be removed from the truck The front and back of the handle 66 O Brown positive power cable B Blue negative power cable B 6 3 REPLACE THE SENSOR Fur 4 p Dismantle 2 screws of the sensor then you can check and replace it Remove 6 screws with internal hexagonal wrench Push slightly the upper cover about 10mm then open it 67 Remove 4 screws then you can remove the tiller 6 Remove 3 screws then you can remove the module 68 io ee m quM IIT I OOO 6 6 REPLACE THE MICRO SWITCHES Dismantle the screws 69 Dismantle the micro switches and replace them Ensure the micro switch is in the middle position 7 CASTER WHEEL 7 1 OPERATION OF THE CASTER WHEEL First let the pallet truck to be slanting second dismantle four screws Then you can dismantle the caster and replace it 70 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 t bit into the ground and slip You can adjust it according to following steps Step 1 Remove the four screws Step 2 Take away one or two piece washer Note the normal gap of the wheel and ground is 3 4 71 8 MAINTENANCE CHECK LIST mm Chas
46. ttery hydrogen gas can explode 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 or in wet places as this can cause electric shock When working with other choose a group leader and work according to his instructions Do not perform any maintenance beyond the agreed work 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 technicians present One operating the stacker 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 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
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