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Noblift LPT22 Service Maintenance Manual

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NOBLELIFT EQUIPMENT
Service & Maintenance Manual
LPT22 Power Pallet Truck
V-LPT22-01.00
Date: 2011-02-26

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  • Page 1 NOBLELIFT EQUIPMENT Service & Maintenance Manual LPT22 Power Pallet Truck V-LPT22-01.00 Date: 2011-02-26...

  • Page 2: Table Of Contents

    CONTENTS FOREWORD ............................2 GENERAL............................3 1.1 INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS..........3 1.2 MEASUREMENT CONVERSIONS ..................7 SPECIFICATION..........................11 2.1 LOCATION OF COMPONENTS ....................11 2.2 SPECIFICATION SHEETS.....................12 LUBRICATION........................13 ELECTRICAL SYSTEM........................14 3.1 ELECTRICAL DIAGRAM.......................14 3.2 INSTALLATION OF ELECTRIC.....................17 3.3 DRIVE WHEEL........................19 3.4 POWER UNIT.........................19 3.5 BATTERY..........................19 3.6 CHARGER ..........................24 3.7 CURTIS CONTROLLER ......................29 3.8 BATTERY INDICATOR......................36...

  • Page 3: Foreword

    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.

  • Page 4: General

    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.
  • Page 5  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.
  • Page 6  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.
  • Page 7  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.

  • Page 8: Measurement Conversions

    1.2 MEASUREMENT CONVERSIONS Length Unit mile 0.01 0.00001 0.3937 0.03281 0.01094 0.000006 0.001 39.37 3.2808 1.0936 0.00062 100000 1000 39370.7 3280.8 1093.6 0.62137 2.54 0.0254 0.000025 0.08333 0.02777 0.000015 30.48 0.3048 0.000304 0.3333 0.000189 91.44 0.9144 0.000914 0.000568 mile 160930 1609.3 1.6093 63360...
  • Page 9 Pressure Unit kgf/cm Pa=N/m lbf/in lbf/ft kgf/cm 0.98067 98066.5 98.0665 14.2233 2048.16 1.01972 100000 14.5037 2088.6 Pa=N/m 0.00001 0.00001 0.001 0.00015 0.02086 0.01020 0.01 1000 0.14504 20.886 lbf/in 0.07032 0.0689 6894.76 6.89476 lbf/ft 0.00047 0.00047 47.88028 0.04788 0.00694 kgf/cm =735.56 Torr(mmHg)=0.96784atm Standard torque The following charts give the standard torque specification of bolts and nuts.
  • Page 10 INCH TABLE 4T, 5T Classification Bolt type Bolt size Torque kgf · m (lbf · ft) Torque kgf · m (lbf · ft) 0.6 ± 0.06 1.7 ± 0.2 5/16 1.2 ± 0.12 3.0 ± 0.3 2.0 ± 0.20 5.6 ± 0.5 7/16 3.2 ±...
  • Page 11 APPROXIMATE CONVERSIONS Conv Non–SI Conv Unit Factor Unit Factor Unit Torque newton meter (N·m) × 8.9 = ln·in × 0.113 = N·m newton meter (N·m) × 0.74 = lb·ft. × 1.36 = N·m newton meter (N·m) × 0.102 = kg·m ×...

  • Page 12: Specification

    2. SPECIFICATIONS 2.1 LOCATION OF COMPONENTS Control Handle Stabilizing Caster (Inside The Cover) Key Switch (ON/ OFF) Pump Unit (Inside The Cover) Emergency Stop Button Or Kill Switch Lift Cylinder Battery Indicator CURTIS 803 Battery (Inside The Cover) Controller assembly Load Roller Drive Wheel (Inside The Cover) CONTROL HANDLE...

  • Page 13: Specification Sheets

    2.2 SPECIFICATION SHEETS Model of manufacture LPT22 Power supply (electric, diesel, petrol, gas, mains Electric Type of operation (hand, pedestrian, stand on, rider Pedestrian Capacity / rated load 2200 Load center distance Load distance 963/1033 Wheelbase 1368 Weight (including battery)

  • Page 14: Lubrication

    2.3 LUBRICATION Hydraulic oil 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 Characteristics unit...

  • Page 15: Electrical System

    3. ELECTRICAL SYSTEM 3.1 ELECTRICAL DIAGRAM WIRING DIAGRAM...
  • Page 16 CONNECTION DIAGRAM...
  • Page 17 Horn DC24V DQ-10 Diodes 1N5408 DQ-34-2 Discharger protection, PC802 Master cable system drawing Serial Part No NL. Drawing No. Description Quantity 102043301 DQ-LPT22-X1 Drive motor cable 102043301 DQ-LPT22-X2 Pump motor cable 102043301 DQ-LPT22-X3 Main contactor cable 102043301 DQ-LPT22-X4 Controller power cable...
  • Page 18 CANBUS handle cable drawing NL. Drawing No. Serial No Part No Description Quantity 1020433019 DQ-LPT22-X6 Controller cable...

  • Page 19: Installation Of Electric

    3.2 INSTALLATION OF ELECTRIC Micro switch Washer Φ8 Elastic washer 6 Screw M4×20 Horn 125 24V Washer Φ6 Key switch Locking nut M8 Screw M6×30 Emergency button Screw M10X25 Plug Battery indicator 803 Elastic washer 10 Charger 24V/30A Screw M4×25 Nut M10 Battery Washer Φ4...

  • Page 20: Drive Wheel

    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...
  • Page 21 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 ).
  • Page 22  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.
  • Page 23 Chlorine(Cl) content 0.0005 ≤ Ammonia salt content ≤ 0.0003 Ammonia (NH ) content 0.0008 ≤ Deoxidized potassium permanganate (0) content 0.0002 ≤ Solonetz meatal oxide(CaO) content 0.005 ≤ Resustivity(25 C) Ω.cm 10x10 ≥ ELECTROLYTRE FOR LEAD ACID CELLS Index Index name Mg / l Appearance Achromatic, transparent...
  • Page 24 DISCHARGE CURVE 5hr discharge curve 2.05 1.95 1.85 1.75 1.65 time （ h ） 0.5hr disvharge curve 1.95 1.85 1.75 1.65 1.55 1.45 time （ min ）...

  • Page 25: Charger

    3.6 CHARGER Type: DF2430 (for 24V/210Ah battery) WIRING DIAGRAM FOR CHARGER 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...
  • Page 26 ELECTRICAL CHARACTERISTICS Input characteristics Item Technical specification Unit Remark Rated input voltage Input voltage range 209-231 220Vac input voltage 50—60 frequency Max input current DF2430：7 When input is on,voltage for fan,When input voltage is off,there is no Fan function output voltage for fan Output characteristics Item Technical requirements...
  • Page 27 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).
  • Page 28 charge. The charger enters floating charge, with current of 1-3 amperes. Please check electrolyte height 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 ...
  • Page 29 new one. ① Low power voltage. ① The power voltage may not lower than 95% of the rated voltage. If the voltage is too low, Instable charge current, not please change a new power reaching rated current supply. value. ② Small section area of lead for ②...

  • Page 30: Curtis Controller

    3.7 CURTIS CONTROLLER...
  • Page 31 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: 4-pin 6-pin 24-pin The 24-pin connector (J1) provides the logic control connections for the contactor drivers and switches that are wired directly to the vehicle.
  • Page 32 A 6-pin low power Molex connector (J2) 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. Note: In some applications using a tiller multiplexer, J2 Pins 3 and 6 are used for a proportional valve instead of an electromagnetic brake.
  • Page 33 Text Readaccess Writeaccess Unit Type Value Min. Max. Vehicle User Rates User M1 Accel Rate User User Seconds TI_UINT8 M2 Accel Rate User User Seconds TI_UINT8 M3 Accel Rate User User Seconds TI_UINT8 M4 Accel Rate User User Seconds TI_UINT8 M1 Decel Rate User User...
  • Page 34 Main Contactor Check TI_ENUM8 Brake User Brake Fault Check TI_ENUM8 Brake Delay Seconds TI_UINT8 Brake Hold Voltage TI_UINT8 Brake Driver Type TI_UINT8 Anti Rollback Time TI_UINT16 1000 Emergency Reverse User Speed TI_UINT8 Direction Interlock TI_ENUM8 Time Limit Seconds TI_UINT8 Accel Rate Seconds TI_UINT8 Motor User...
  • Page 35 Adjust Hours Hours TI_UINT32 999999 Set Total Hours TI_ENUM8 Set Drive Hours TI_ENUM8 Total Service Hours Hours TI_UINT16 5000 5000 Drive Service Hours Hours TI_UINT16 5000 5000 Total Disable Hours Hours TI_UINT16 Drive Disable Hours Hours TI_UINT16 Drive Disable Speed TI_UINT8 Service Total Expired Service...
  • Page 36 CURTIS 1230 CONTROLLER TROUBLESHOOTING CHART PROGRAMMER CODE LCD DISPLAY EXPLANATION POSSIBLE CAUSE Motor speed encoder pulses 1. Incorrect encoder wiring. Motor speed encoder are not correct. 2. Controller defective. 1. Incorrect encoder wiring. 2. Motor blocked. 1, 2 Motor stalled, or motor turning 3.
  • Page 37 3. Wire to main contactor missing. 4. Main contactor stuck closed. 5. Main contactor driver shorted. 1. Controller defective. Precharge Precharge fault. 2. Low battery voltage. 1. Brake coil open. 2. Brake missing. 3，3 Brake Fault Brake wiring or driver fault. 3.
  • Page 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).

  • Page 39: Battery Indicator

    3.8 BATTERY INDICATOR Type: CURTIS 803RB2448BCJ3010 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.
  • Page 40 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 & IMPEDANCE SPECIFICATIONS Min.

  • Page 41: Replacing The Electric Parts

    match battery voltage, or terminals not directly connected to battery 3.9 REPLACING THE ELECTRICAL PARTS REPLACING THE BATTERY Step 1: Remove 2 screws (No.2), loosen nuts (No.4) and washers (No.3). Step 2: Remove the battery cover (No.1) Step 3: Separate the plugs (No. 6 and 7) Step 4: Use two lifting hook to hook the hole of the battery box.
  • Page 42 REPLACING THE POWER UNIT Remove the relay cable. Remove the pipe. Remove 2 screws. Then you can remove the power unit and replace it. REPLACING THE BATTERY INDICATOR 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.
  • Page 43 Open the black cover of the fuse seat, then you can remove the fuse and replace it. REPLACING THE MAIN RELAY Remove cables Remove two screws Remove the cables. Then you can remove the main relay and replace it. REPLACING THE CONTROLLER Step2: Remove two screws Step1: Remove all cables Step2: Remove two screws.
  • Page 44 REPLACING THE THERMAL PROTECTION When the temperature of the motor is more than C, the module will give a signal to the controller, then driving speed will automatically change to low-speed mode. After the temperature reduces to 110 C, the unit will change back to nomal speed.
  • Page 45 REPLACING THE EMERGENCY BUTTON Turn 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. Insert the hole with a small screwdriver, then turn counter-clockwise the mushroom head to remove it.

  • Page 46: Tool For Repairing The Pin Of Electrical Plug

    3.10 TOOL FOR REPAIRING THE PIN OF ELECTRICAL PLUG Application Figure 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...

  • Page 47: Hydraulic System

    4. HYDRAULIC SYSTEM 4.1 HYDRAULIC FLOW DIAGRAM INSPECTION OF HYDRAULIC OIL External appearance Smell Condition Countermeasure Fine Fine Clear and no discoloration Possible to use Inspect the viscosity and if fine Clear but the color becames bright Fine Mixed with other oil it can be continuously used Color changed like milk.

  • Page 48: Replacing The Power Unit

    Elastic washer Mounting bracket Combination washer Shaft Joint seat Pump motor Bush O-ring Mounting plate for valve Holding bracket Rubber oil pipe Oil tank cylinder bolt Bush Bolt Combination washer 4.3 REPLACING THE POWER UNIT Remove the relay cable. Remove the pipe. Remove 2 screws.

  • Page 49: Replacing The Cylinder

    4.4 REPLACIING THE CYLINDER Disconnect two bolts and the other bolts in the other side Remove two screws. Remove the oil pipe Remove two elastic washers Remove the shaft which pass through the cylinder, then you can remove the cylinder and replace it.

  • Page 50: Cleaning Oil Tank And Filter

    4.5 CLEANING OIL TANK AND FILTER 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 ...

  • Page 51: Trouble Diagnostics

    4.6 TROUBLE DIAGNOSTICS Symptom Abnormality and cause Countermeasure Check if there is any place Bubble in hydraulic oil Mixed with air where enteted. Tighten the loosened part again. Mixed with air and water Replace the oil. Discoloration Became inferior in quality by oxidizing or Replace the oil.
  • Page 52 HYDRAULIC PIPE For shocking, the joint of the hydraulic pipe and hydraulic pipe might be loosed and leak oil, so usually check it and tighten it.

  • Page 53: Drive Wheel

    5. 5. DRIVE WHEEL Part name Part name Bolt Bolt Brake Upper cover Bolt Seal washer Tiller bar plate Bolt Motor Wheel Bolt Bolt, for adding oil Gear Gear-box Holding bearing...

  • Page 54: Replacing The Drive System And Wheel

    5.1 REPLACING THE DRIVE SYSTEM AND WHEEL A （14pcs） Step1: Remove the cover marked 1 as above right picture. Step2: Remove the handle marked 2 as above right picture. Step3: Remove the mounting plate marked 3 as above right picture. Step4: Loosen the screws marked A as the right picture.

  • Page 55: Replacing The Brake

    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（200Ω）, and The Winding resistance: 25Ωnormal (+1,-1...
  • Page 56 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.

  • Page 57: Control Handle

    6. CONTROL HANDLE No. Part name No. Part name Bushing, 23/19*17*10 Air spring Handle mounting bracket Handle cable Shaft, 17 Micro switch Z-15GW2 Roll pin, 4x24 Screw, M4x25 Socket hex bolts M8x25 Cover Elastic washer 8 Screw, M4x10 Socket hexa bolts M8X16 Tillerarm...

  • Page 58: Replacing The Control Handle

    No. Part name No. Part name Butterfly left or throttle switch left Seesaw-left or toggle button left Button for horn Magnet holder for seesaw Spring Hinge spring Bearing for camshaft Contact base Magnet Belly switch cover Spring for belly botton switch Optional cover Socket hexagonal Screw, M6X10 Seesaw right or toggle button right...
  • Page 59 6 pin plug, must be firmly connected to the controller. Remove the screw to remove the circuit board Remove the bolt to remove the throttle lever once the bolt is removed from the throttle lever the opposing throttle lever and throttle shaft can be pulled out through the oppsoing side of the handle.

  • Page 60: Replacing The Air Spring And Micro Switch

    6.2 REPLACING THE AIR SPRING AND MICRO SWITCH Remove 4 bolts. The signal to the #2 pin of CURTIS1230C Micro Switch and Air Spring Ensure the micro switch is mounted in the correct position. The switch may require adjustment upon re-installation. Use a Phillps screwdriver to remove two screws, then you can dismantle the air spring and replace it.

  • Page 61: Caster Wheel

    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.

  • Page 62: Trouble Diagnostics

    8. TROUBLE DIAGNOSTICS 8.1 MAINTENANCE LIST Maintenance Time Interval Standard=● Refrigerating house=＃ 6 12 Inspection of any damage of bearing parts ● Chassis Inspection of all joints of bolts ● truck frame Inspection of noise and leakage of driving system ●...

  • Page 63: Trouble Shoot

    8.2 TROUBLE SHOOT...

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