Noblelift N Series Operation & Maintenance Manual
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Noblelift N Series Operation & Maintenance Manual

Battery counterbalanced forklift truck
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FE3R08-12-SMS-001
Warning
Operators should read and understand
this manual and all warning labels on
the forklift before using the forklift!
Keep the manual for future reference!
Operation & Maintenance Manual
FE3R08-12 N SERIES
 
Battery Counterbalanced Forklift Truck
       
     
NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD.

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  • Page 1 Operators should read and understand this manual and all warning labels on the forklift before using the forklift! Keep the manual for future reference! Operation & Maintenance Manual FE3R08-12 N SERIES   Battery Counterbalanced Forklift Truck              ...

  • Page 2: Table Of Contents

    Table of Contents Introduction…………………………………………………………………………………………… 4 Chapter 1 Precautions of using forklift…………………………………………………………… 5 . Forklift transportation ...................... Ⅰ . Forklift storage ........................ Ⅱ . Pre -use preparation ......................Ⅲ . Operation of the forklift ....................Ⅳ . Charging of accumulator cells ..................
  • Page 3 6.5 Governor valve……………………………………………………………………… 6.6 Tilt cylinder………………………………………………………………………………… 39 6.7 Maintenance and adjustment…………………………………………………………… 6.8 Failure analysis…………………………………………………………………………… 42 7．Lifting system………………………………………………………………………………… 44 7.1 Overview…………………………………………………………………………………… 44 7.2 Outer and inner main frame……………………………………………………………… 44 7.3 Fork frame………………………………………………………………………………… 7.4 Roller position………………………………………………………………………… 7.5 Maintenance and adjustment…………………………………………………………… 7.6 Installation of accessories………………………………………………………………… 48 8．Removal and installation……………………………………………………………………...
  • Page 4 3 .Clean the electric system ..................... 4 . After the cleaning ......................Ⅳ . Regular maintenance ..................... 1. Replace critical safety components periodically ............2. List of forklift oil ......................3.Maintenance list Ⅴ Repairing of the forklift ..................... 1. Failure diagnosis… ………………………………………………………………………… 2.

  • Page 5: Introduction

    5）Product recall serive is available when serial faulties occur.  Due to continuous product improvement, Noblelift reserves the right to make changes in product designs and specifications without prior notice. For the latest product parameters, please feel free to contact us. All parameters provided herein are as of the publication date of the...

  • Page 6: Chapter 1 Precautions Of Using Forklift

    Chapter 1 Precautions of using forklift Forklift drivers and managers must remember the principle of "safety first", and carefully read this maintenance manual. Operators shall be in strict accordance with this manual to ensure safe and normal operation. . Forklift transportation Ⅰ...

  • Page 7: Ⅴ . Charging Of Accumulator Cells

    (10) The initial velocity should not be too fast when lifting and lowering goods; (11) Never operate the forklift and accessories at places other than the driver's seat; (12) When the main frame is moving forwards and backwards to the maximum extent, or when the fork is lifted to its maximum height, the operator must rapidly set the lever to the neutral position;...

  • Page 8: Chapter 2 Structure And Main Performance Parameters Of The Forklift

    Chapter 2 Structure and main parameters of the forklift . Overall size and performance parameters of the forklift Ⅰ 1. Overall dimensions (as shown in Figure 1-1 ) Figure 1-1 Overall dimension...

  • Page 9: Technical Parameters

    2. Technical parameters (Table 1-1) Mode FE3R08 FE3R10 FE3R12 Drive mode: Electric Electric Electric Operation mode:Manual, walking, stand-up Sit-down Sit-down Sit-down driving, Sit-down driving, picking Rated loading capacity Q(Kg) 1000 1200 Load centre distance C(mm) Front overhang distance x(mm) Wheelbase y (mm) 841/923 951/1033...

  • Page 10: Ⅱ . Structure, Principle And Adjustment Of The Main Components

    Drive motor power S 60min Lifting motor power S Accumulator voltage/capacity K V/Ah 24/280 24/420 24/420 Accumulator weight Drive control type Working pressure of accessories Pa Oil volume of accessories l / min Noise level at driver's ear according to EN 12 053 EN 12 053 decible .Structure, principle and adjustment of the forklift’s main components Ⅱ...
  • Page 11 1. steering motor 2. screw 3. spring washer 4. washer 5. bolt 6. heel 7. spring washer 8. washer 9.bolt 10. proximity switch 11. Steering pinion 12. washer 13. Electromagnetic 14. motor 15. coder 16. bolt brake (optional) 19. Gearbox mounting 17.

  • Page 12: Failure Analysis

    The drive steering axle has a characteritics of compact structure, reliable performance, smooth transmission and low noise. Axle shell is made of steel materials, which provides strong rigidity and high load capacity. See Table 2-1 for the main technical parameters. Table 2-1 main performance parameters Model FE3R08-10...

  • Page 13: Brake Master Cylinder

    1 Screw 2. Spring washer 3. Fixed plate 4.Axle 5. Bearing 6 Socket hexagonal screw. 7. Spacing bolt 8. Foot brake bracket 9. Brake pedal 10. Return spring 11.Brake pump assembly Figure 2-2 Brake pedal assembly 2.3 Brake master cylinder (Figure 2-3) The master cylinder includes a valve seat, a check valve, a return spring, the main cup, piston and auxiliary cup.

  • Page 14: Brake

    1． Locking nut 7． Piston 2． Pushing rod 8． Main cup 3． Dust cover 9． Spring 4． Stop steel wire 10．check valve 5． Stop washer 11． Valve seat 6．Auxiliary cup 12． Pump body Figure 2-3 Brake Master Cylinder 2.4 Brake The brake is a dual-shoe brake installed on both sides of the drive axle.
  • Page 15 Driven brake shoe Driving brake shoe Driven brake shoe Driving brake shoe Figure 2-5 Action when moving forwards Figure 2-6 Action when moving backwards (2) Parking brake Mounted in the wheel brake, the parking brake consists of the lever and push lever. The lever is mounted on side of the main brake shoe by a pin, and the pulling action spread through the push lever to the auxiliary brake shoe.

  • Page 16: Technical Points For Brake Disassembly And Adjustment

    Figure 2-9 Clearance self-adjusting mechanism 2.5 Technical points for brake disassembly and adjustment Disassembly, assembly and adjustment of the brake and adjustment of brake pedal when the wheel and wheel hub is removed. 2.5.1 Disassembly of the brake (1) Remove the support pin, regulating bar, regulating device and spring on the auxiliary brake shoe.
  • Page 17 brake cylinder, and remove the brake cylinder from the brake backing plate. See figure 2-15 6) Remove the E-shaped retaining ring used for fixing the brake cable on the brake backing plate. Then remove the mounting bolt on the brake backing plate and dismount the brake backing plate from the drive axle.
  • Page 18 (2) Mount brake cylinder on the brake backing plate. (3) Mount the brake backing plate on the drive axle. (4) Coat all the positions as shown in Figure 2-20 with heat-resistant grease, and be careful not to smear any oil on the friction disk. (a) Contact surface of the brake backing plate and brake shoe;...

  • Page 19: Adjustment Of Brake Pedal

    Note: Even if the regulator gear and the lever both return after the lever is let go, the regulator still works properly. (2) If the regulator can not finish the above actions when the lever is pulled, carry out the following checks: (a) Securely mount the adjustment lever, ejector pin, spring of the ejector pin and compression spring base;...

  • Page 20: Troubleshooting And Failure Analysis Failure Analysis

    5 There are foreign matters attached to the Repair or replace it friction disk. 6 The brake fluid is contaminated Check the brake fluid 7 The brake pedal hasn’t been adjusted Adjustment properly 1 The friction surface is hardened or with Repair or replace it foreign matters attached on it 2 The baking plate is deformed or the bolts...

  • Page 21: Steering System

    months of working. Annual technical maintenance: Disassemble the drive axle for inspection every year. ⑥ Check and debug requirements during the installation process: ⑦ When re-installing the wheel hub of the drive axle, users should regulate the clearance adjuster of the brake, so as to set the gap between brake drum and friction disk at 0.3mm ~ 0.5mm. Fill 100ml 3# lithium base grease into the tapered roller bearing on the wheel hub.
  • Page 22 order the traction motor to generate a braking torque, so as achieve the purpose of deceleration. Size of the braking force is controlled by the accelerator pedal.Regenerative braking refers to the forklift’s braking force generated by the controller when the forklift’s speed is relatively higher than the traction motor speed.
  • Page 23 Figure 2-28 Schematic of electrical system of FE3R06-12...

  • Page 24: Curtis Controller Fault

    4.4.Curtis controller fault...

  • Page 32: 5．Accumulator

    5．Accumulator Battery shape as shown in Figure 2-31. Figure 2-31 Battery 5.1 Accumulator safety precautions: △ Appropriate ventilation measures shall be adopted because hydrogen and oxygen will be generated at the end of the accumulator charging process. If spark occur during the process, explosion may be caused.

  • Page 33: Accumulator Use Precautions

    Service life of the accumulator is generally 2 to 3 years, or even 4 years if it can be properly used and maintained. In case of the improper use and maintenance, it may suffer early damage in a few months since initial use. During use of the accumulator, users should regularly check the electrolyte level and the remaining accumulator capacity.

  • Page 34: Charging Of The Accumulator

    shall be used as the benchmark. Therefore, if the electrolyte temperature is higher than ℃ , you should add 0.0007 to the actual measured value of density for an increase in ℃ temperature by 1 ; In contrast, if the electrolyte temperature is lower than 25 , subtract the ℃...

  • Page 35: Installation And Replacement Of The Accumulator

    discrepancy, please use distilled water or sulfuric acid with density of 1.40 to adjust. Ensure the electrolyte density and height level is adjusted to the specified value within 2 hours since the charging starts; Wipe clean the accumulator surface and cover the filler cap before putting into use. （(2) General Charge Do not use accumulator that is not fully charged.

  • Page 36: 6． Hydraulic System

    6. Hydraulic system 6.1 Overview The hydraulic system consists of working pump, multiple unit valve, lifting cylinder, tilting cylinder, pipelines and other component parts. See figure 2-48 The hydraulic oil will be supplied by the oil pump directly connected with the motor. The multiple unit valve will assign oil to each cylinder.
  • Page 37 1. Safety valve 2. Microswitch bracket 3. Oil returning hole 4. Lifting speed sensor sets Figure 2-33Shape of multiple unit valve (1) Operation of the slide valve (Take tilting slide valve as an example) (a) Middle position (Figure 2-34) At this time the high pressure oil discharged from the oil pump will return to the cylinder through the middle position.

  • Page 38: Lifting Cylinder And The Lifting Chain

    valve "E" and valve "C" will both land on the valve seat. Liquid flow at back of the flow valve "D" will be off, so the pressure inside is reduced. Pressure on pump "HP" channel side and the inside pressure are different, the valve "D" will open under the pressure difference and the oil will directly flow into the low pressure loop "LP".

  • Page 39: Governor Valve

    outer main frame, with the cylinder bottom fixed on the cylinder bearing with a pin and a bolt. And the top of the cylinder (ie the top of the piston rod) is connected with the beam on the outer door frame.

  • Page 40: Tilt Cylinder

    1. anti-explosion valve 2. angle 3. left steel tube 4. Straight joint 5. washer coupling 6. three-way valve 7. bolt 8. washer 9. washer 10. governor valve 11. Straight joint 12. right steel tube Figure 2-40 Built-in governor valve 6.6 Tilting Cylinder The tilting oil cylinder is double acting, with its piston rod end connected to the main frame through the earrings.

  • Page 41: Maintenance And Adjustment

    1. Retaining Ring 2. Joint bearings 3. Dust proof ring 4. Cylinder cover 5. Blank 6. Retaining Ring 7. shaft seal 8. O-ring 9. Retaining Ring 10. Piston rod 11. Cylinder 12. Nut 13. Cotter pin 14. Steel-backed 15. Hole sealed bearing 16.
  • Page 42 Replace a pair of gears in case of excessive wear. If size of D is less than the specified value, replace in pairs. 12.7 12.7 (0.5) (0.5) Figure 2-46 (e) If necessary, replace the seal rings, bushing seal, retaining ring, oil seal, spring ring. (3) Assembly (a) Mount a new seal ring and a new retainer ring at the front end cover of the pump.

  • Page 43: Failure Analysis

    multiple unit valve. (b) Loosen the adjusting screw of the overflow valve to keep the pump working for 5001000-1000rpm for about 10 minutes. Ensure that the oil pressure is lower than 10kg/cm ². (c) Increase the pump speed to 1500-2000rpm and keep it running for about 10 minutes. (d) Set the pump operating speed at 1500-2000rpm.

  • Page 44: 7．Lifting System

    ring Adjust pressure Overflow valve is not well overflow valve adjusted specified value with pressure gauge ●Re-tighten the side tubing There within of the oil inlet system ●Add oil ●Replace the oil pump seal The inlet tube is damaged or Check the tube or repair oil the filter is blocked filter...

  • Page 45: Outer And Inner Main Frame

    1. Outer main frame 2. Inner main frame A. Composite roller 3. Adjustment screw 4. Lock washer 5. nner ring roller 6. Roller 7. Side roller base 8. Dust ring 9. Roller pin 10. Side roller pipe 11. Outer ring roller axis 12.

  • Page 46: Fork Frame

    1. Block shelves 2. Washer 3. Spring washer 4. Bolt 5. Carriage A. Composite roller 6. Adjustment screw. 7. Lock washer 8. Inner ring roller 9. Side roller base 10. Dust ring 11. Roller pin 12. Side roller pipe axis 13.

  • Page 47: Roller Position

    1. Fork frame 2. Outer main frame 3. Composite roller of outer frame 4. Inner main frame 5. Inner frame and composite roller of fork frame Figure 2-50 Roller position Note: (a) adjust the clearance of side rollers at 0.5mm; (b) Apply lubricant oil onto the main roller surface and the contact surface of main frame.
  • Page 48 1. Fork assembly 2. Fork frame 3. Inner main frame 4. Composite roller 5. Composite roller 6. Tires 7. Outer main frame Figure 2-52 (3) Lower the fork to the ground and tilts it backward in place. Adjust the upper end joints of the chain and then regulate the nut to set tightness of the two chains at the same degree.

  • Page 49: Installation Of Accessories

    (5) Remove the connecting bolts on the lifting cylinder and at the bottom of the outer main frame, and then remove the lifting cylinder and the tubing between the two cylinders without loosening the pipe joints. (6) Lower the inner main frame and remove the main roller at the bottom of the inner main frame.
  • Page 50 (2) Lifting description of the overhead guard as shown in Figure 2-56 Overall Dimension L×W×H Weight (kg) (mm) 935×773×1400 Figure 2-56 Lifting ring (3) Lifting description of the counterbalance as shown in Figure 2-57 The lifting ring on the counterbalance can be used to lift the balance weight only.

  • Page 51: Chapter 3 0Peration, Use And Safety Of The Forklift

    Chapter 3 0peration, use and safety of the forklift Ⅰ Transportation and test turn 1 lifting The use of lifting equipment must be large enough to have the bearing capacity (greater than the weight of the forklift; see the nameplate of the forklift). The lifting point is especially designed for easy transportation of the forklift.

  • Page 52: Use Of A New Forklift

    1. Bolt 2. Washer 3. Oil-holder 4.Shaft 5. Bushing 6. lock washer 7. Connecting shaft 8. Working settings 9．Body assembl a) First, use the lifting device to hang the main frame (8) and fork body assembly (9) together b) Second, fix them up by the shaft (7) then fit with a Snap Ring (6). c) then use shaft(4) again, fixed them up, then do not forget to pay attention to fix the shaft by bolt (1) and washers (2).

  • Page 53: Forklift Stability

    1) Reduce loads equal to the weight of the accessories. 2) Since adding of accessory will move the load centre forward, the allowable load will be reduced accordingly. The installation of accessory will cause load centre shift forward, which is known as the "loss of load centre.”...

  • Page 54: Safety Features Of The Forklift

    1、brake pedal 2、accelerator pedal 3、stopping braking 4、lifting lever 5 、 Tilting lever 6 、 Belonging to joystick 1 7 、 Belonging to joystick 2 8、Gear switch 9、Emergency stop switch 10、steering wheel 11、key switch 12、turn signal swich 13、appearance 14、horn button 2. The safety features of the forklift This forklift made full equipment of safety to minimize accident's occurrence.

  • Page 55: Loading And Unloading Of The Goods

    There are five kinds of methods to realize the brakes: a) to release the accelerator pedal(and had better put the forward back switch in middle), then brake. The brake is soft, smooth, people should often use this method. b)by putting the forward back switch in middle to brake. The brake is soft and smooth. c) reverse braking, for example, to change the driving direction, which is about to putting the forward back switch to the driving reverse direction.

  • Page 56: Ⅲ . About Safety

    - Ensure that the forklift enter into goods. - Ensure that the forklift leave the shelves. - Main frame sloping slowly -Set down the goods slowly - until the maximum Angle. - From the ground to a certain height (200 mm or so), -now you can put the goods to the destination safely 1) Do not leaning the main frame when the goods are in a high position!

  • Page 57: Safety Rules

    2.Safety rules Only qualified people who has been trained and has driver license can operate the forklift! Forbid to drive on the highway! Put fatigue dress on before driving! Vigilant: injuries, the ambulance! Do not change parts on forklift arbitrary Read the instruction manual carefully before without permission.
  • Page 58 Turn off the engine before maintenance! Understand traffic regulations Before use, please check on the truck! Do not move the overhead guard! To keep driver’s cap clean! Do not drive an unsafe forklift! Drivers should have a healthy body! Be sure your truck is safe!
  • Page 59 Work in specified area Do not drive a damaged truck! Hold tightly when get on the truck! Start forklift correctly! Adjust seat before driving! Make sure your forklift is in safe operating condition! Appropriate fasten seat belts! Always pay attention to the height of work place!
  • Page 60 Turn on lights in dark area! Do not put arm and body outside of the overhead guard during work! Avoid driving on soft ground, only Keep body under the guards! allowed to run on solid and flat ground. Avoid eccentric loading! Pay attention to encounter item by front fork when loading! Check fork pin position!
  • Page 61 Do not run on smooth or slippery ground! Note the horizontal driving stability of the truck when it is un-load! Be especially careful when handling long Forbid handling people! or wide cargo! If can not see the front when turning, Use appropriate pallets or sleeper when please whistle and drive slowly.
  • Page 62 Not allowed to gaze around while driving! Do not use the forklift to do stunt! when goods is so high to keep out line Should obey the traffic rules and all of sight,drive backward or forward under warnings and signs! direction of others when loading,travel forward in upgrade Pay attention to the steep uphill slopes...
  • Page 63 Not turn when driving on a slope! People or things moving on road should be warned by whistle! Be careful to crush people or goods Operators are not allowed to close when the when turning! truck is working! While turning a high speed can cause People are not allowed to start in work place! accident because of unstable center of gravity! Notice the change of rated load weight...
  • Page 64 Use the fork correctly when loading! Slow down when loading! Do not move the truck when there is It is forbidden to stand or walk under someone in front of the truck! the elevatory fork! Do not load the goods which is higher Please bind the goods which is difficult than the goods rest.
  • Page 65 Do not misuse the fork! Be careful when load the container! Do not pick up people! Do not misuse forklift! Do not extend any part of body outside Drive the truck smoothly to avoid sudden when driving! acceleration and deceleration! Must use special equipment to lift people Do not overload! safely to lift people safely to work at height!
  • Page 66 Do not lift when there is excessive wind! Not allowed to work in explosive environments! The faulty trucks should be put into the park the forklift to the indicated area! indicated area! Do not park the forklift on the slope! When the forklift is not in use,please do the follow.

  • Page 67: Transportation Of The Forklift

    3 Truck’ s transportation Forbid hoisting from the top! Forbid hoisting on the frame! Hoisting the forklift correctly! Hoisting the forklift ·Tie firmly steel cable on two terminal holes of outer mast beam and on counterweight hoisting hook,then,hoist forklift with hoisting device.the side of steel cable connecting to counterweight should go through notch of roofguard without exerting pressure on roofguard.
  • Page 68 Prohibit eccentric loading of goods! To avoid driving on slippery roads! When the truck is not in the horizontal Prohibit crossing the obstacle such astrench, position, do not load or unload! mound and railway! When moving, the distance between fork and whether load or no-load,don’t turn in a high ground should less than 150mm to 200mm! speed or in a large radian ! when no-load fork is lifted,please turn with...

  • Page 69: Safety Issues During Maintenance And Protection

    Do not jump in the event of forklift rollover! Please wear helmets when driving! In case of tipping, it is safer when you stayed in the forklift with seat belt than jumping out of the forklift. If the forklift begins to tip: 1.

  • Page 70: Safety During Use Of The Accumulator

    assembly. (4) Inspection and replacement of tires • Removal and installation of tires must be operated by professionals. • Handling of high-pressure air shall be done by professionals • Wear a goggle when using compressed air. • During disassembling of tires, do not loose bolts and nuts at rim connection. As there is high-pressure gas within the tires, looseness of bolts, nuts and rims could cause danger.
  • Page 71 • Keep cleanness of accumulator surface ·Do not use a dry cloth or chemical fiber cloth to clean the accumulator surface. Do not use polyethylene film to cover the battery. • Static electricity can cause an explosion. • Clean the uncovered parts at the top of the accumulator with a damp cloth. (7) Wear protective clothing •...

  • Page 72: Signs

    • Do not drain the electrolyte from the battery • Do not disassemble the battery. • Do not repair the battery. (14) Storage • When the accumulator is to be unused for a long time, it should be stored in well-ventilated places with low possibility of fire.

  • Page 73: Chapter Iv Maintenance And Repairing Of The Forklift

    Chapter IV Maintenance and reparing of the forklift Conduct a comprehensive inspection of forklift to avoid failure and to extend its service life. Service hours indicated in the Maintenance Procedures is based on the assumption that the forklift works 8 hours a day and works 200 hours a month. In order to ensure safe operation, maintain the forklift regularly according to the maintenance procedures.

  • Page 74: Ⅲ .Clean The Forklift

    Overhead guard, If the bolts and nuts are tightened backrest Nameplate and labels Completeness Others Other parts If there is abnormality .Checking after operations Ⅱ After work, remove dirt from the forklift and check the following items: (1) Inspect all parts and components for damage or leakages. (2) Check for deformation, distortion, damage or breakage.

  • Page 75: Clean The Forklift Surface

    • Regular inspection and maintenance of the forklift shall be conducted to keep it in good performance status. •Use spare parts made by Noblelift Machinery. •Do not use different types of oil when replacing or refilling oil . • The oil and accumulator being replaced shall be disposed according to local environmental protection laws and regulations rather than being dumped and abandoned.

  • Page 76: List Of Forklift Oil

    2. List of forklift oil Name Trademark Capability(L) Remark L-HM32 ≥-5℃ Hydraulic oil L-HV32 ≥-20℃ 85W/90GL-5 -15℃ ~ +49℃ Gear oil 80W/90GL-5 -25℃ ~ +49℃ Brake fluid Caltex DOT3 Battery electrode Industrial Vaseline column Grease 3# Lithium Grease 3. Maintenance and care list Implement and abide by their respective cycle according to below maintenance list, maintenance cycle introducts as follows: W1 = every work 50 hours, but at least once a week.
  • Page 77 Check the oil volume ● ＃ Replace hydraulic oil, filter ● ＃ Check the oil cylinder is normal or not ● ＃ Performance examination ● Check if all the wire connection are safe, reliable, ● and damage Check if the fuse amperes are proper Check if the switches and steering device are safe Electrical system ●...

  • Page 78: Ⅴ Repairing Of The Forklift

    V、Repairing of the forklift 1. Failure diagnosis Fault Cause Countermeasures Battery connectors - connecting connected -Set electricity lock switch is on "on" - Electricity lock switch is on "0 position FF" position - Rotate openthe Emergency stop - Emergency stop button do not button open - Charging...

  • Page 79: The Preparation Work Before Repairing

    If through the above method still can not resolved the problem, please inform the person who are specially trained by manufacturers of after-sales service agencies . 2. The preparation work before repairing In order to prevent the accident happened during the period of maintenance and caring, people must finished the following preparations: Safety-parking.

  • Page 80: Operations Before Storage

    3. Re-test turn forklift After having a long storage,the Forklift should re-test turn before using it again, to make sure that all the parts are in good condition, each function can run normally, to ensure the safe use of forklift. - clean the forklift thoroughly.
  • Page 81 Maintenance record Date Maintenance content Note...
  • Page 82 NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD. Service hotline：4008-836115 Wechat：nuolijixie Postcode：313100 email address: info@noblelift.com Website：www.noblelift.com Version：Otc,2018...

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