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

Battery counterbalanced forklift truck
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FE3R16-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
FE3R16
N/E SERIES
Battery Counterbalanced Forklift Truck
NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD.

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Summary of Contents for Noblelift N Series

  • Page 1 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 FE3R16 N/E SERIES Battery Counterbalanced Forklift Truck NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD.

  • Page 2: Table Of Contents

    Table of Contents Introduction…………………………………………………………………………………………… 4 Chapter 1 Precautions of using forklift…………………………………………………………… 5 Ⅰ. Forklift transportation ....................... 5 Ⅱ. Forklift storage ......................... 5 Ⅲ. Pre-use preparation ......................5 Ⅳ. Operation of the forklift ....................5 Ⅴ. Charging of accumulator cells ..................6 Chapter 2 Structure and main performance parameters of the forklift…………………………...
  • Page 3 6.1 Overview…………………………………………………………………………………… 32 6.2 Oil pump…………………………………………………………………………………… 32 6.3 Multi-way valve…………………………………………………………………………… 6.4 Lifting cylinder and the lifting chain……………………………………………………… 34 6.5 Governor valve…………………………………………………………………………… 6.6 Tilt cylinder………………………………………………………………………………… 36 6.7 Hydraulic oil cylinder…………………………………………………………………… 6.8 Maintenance and adjustment…………………………………………………………… 6.9 Failure analysis………………………………………………………………………… 7．Lifting system………………………………………………………………………………… 41 7.1 Overview…………………………………………………………………………………… 41 7.2 Inner and outer main frame………………………………………………………………...
  • Page 4 2. Safety rules........................60 3 Handling of the forklift ....................71 4 How to avoid rollover and how to protect yourself from accidents ......72 5 Safety issues during maintenance and protection ............74 6 Safety during use of the accumulator ................75 7 Signs ..........................

  • Page 5: Introduction

    Please contact our technical staff. 5）Product recall serive is available when serial faulties occur. Due to continuous product improvement, Noblelift reserves the right to make changes in product designs and specifications without prior notice. For the latest product parameters, please feel free...
  • Page 6 Manual.

  • Page 7: 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. Ⅰ. Forklift transportation The following shall be noted when transporting forklift by container or trucks: (1) Apply the parking brake;...

  • Page 8: Ⅴ. Charging Of Accumulator Cells

    (7) If the distance between loads‘ center of gravity and the fork arm is no more than 500mm, the maximum load shall be the rated capacity. If the distance between loads‘ center of gravity and the fork arm is more than 500mm, the maximum load shall be less than the rated capacity; (8) When carrying loads, the main frame should tit backwards to the maximum extent and the fork arm should be in contact with the goods.

  • Page 9: Chapter 2 Structure And Main Performance Parameters Of The Forklift

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

  • Page 10: Overall Dimension

    Figure 1-1 Overall dimension 2. Technical parameters (Table 1-1) Model No. FE3R16E FE3R16N Driving Method: Electric (accumulator or power supply), diesel, petrol, LPG, Electric Electric manual Operation Method: Manual, travel, standing, seat, picking out seat seat 1600 1600 Nominal Load Capacity Q (kg) Load Center Distance C (mm)

  • Page 11: Driving & Operation

    Attachment oil flow L/min Noise level audible by driver, based on EN 12 053 Ⅱ.Structure, principle and adjustment of the forklift’s main components 1. Driving & Operation 1.1 Overview The transmission system of forklift is composed of reduction gearbox assembly, differential assembly and drive axle.

  • Page 12: Braking System

    This actuation steering axle has the structure compact reasonable, the operational performance reliable, the transmission steady, the noise low status merit.The bridge shell uses the cast steel material, the rigidity is good, bearing capacity is big, the main performance parameter (sees Table 2-1) 2.

  • Page 13: Brake Master Cylinder

    1 Brake oil cup 2. Brake pedal 3. Brake master cylinder 4. Brake sensor 5. Brake support 6. Spacing bolt Figure 2-2 Brake pedal assembly 2.3 Brake master cylinder (Figure 2-3) The master cylinder includes a valve seat, a check valve, a return spring, the main cup, piston and auxiliary cup.

  • Page 14: Brake

    2.4 Brake The brake is a dual-shoe brake installed on both sides of the drive axle. The brake consists of two groups of brake shoes, brake cylinders and regulators. One end of the brake shoe contacts the fixed pin and the other end contacts the regulating device. The return spring and the compression spring bar hold the parking brake.
  • 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

    Parking Brake Along this direction elong elongtion Wire rope Figure 2-9 Clearance Figure 2-10 Parking brake lever self-adjusting mechanism 2.6 Technical points for brake disassembly and adjustment Disassembly, assembly and adjustment of the brake and adjustment of brake pedal when the wheel and wheel hub is removed.
  • Page 17 Figure 2-13 Figure 2-14 (5) Remove the brake pipe from the brake cylinder. Then remove the mounting bolt of the brake cylinder, and remove the brake cylinder from the brake backing plate. See figure 2-15 6) Remove the E-shaped retaining ring used for fixing the brake cable on the brake backing plate.
  • Page 18 Figure 2-18 Figure 2-19 2.6.3 Brake assembly (1) Coat the cup and piston on the brake cylinder with brake fluid and assemble the spring, piston cup, piston and protection loop in sequence. (2) Mount brake cylinder on the brake backing plate. (3) Mount the brake backing plate on the drive axle.
  • Page 19 Figure 2-23 Figure 2-24 2.6.4 Operation test of the automatic clearance regulator as shown in Figure 2-25 (1) First, adjust the diameter of brake shoe to be close to the stipulated installation size; pull the lever to rotate the regulator. When letting the lever go, the regulator lever will return to its original position and the regulator gear won’t rotate.

  • Page 20: Troubleshooting

    Break Pedal Pedal Push lever Spacing bolt Figure 2-26 (5) Adjust the brake switch as shown in Figure 2-27 (a) After the height of the brake pedal has been adjusted, release the brake switch and lock the nut; (b) Disconnect the plug to separate the wires; brake switch (c) Rotate the switch to set the gap A at 1mm;...

  • Page 21: Maintenance

    braking 2 The brake shoe clearance is not Adjust the regulator well-tuned uneven 3 The wheel cylinder fails Repair or replace it 4 The return spring of brake shoe is Replace damaged 5 The brake drum is deflected Repair or replace it 1.Oil leaks in the brake system Repair or replace it 2 The brake shoe clearance is not...

  • Page 22: Overview

    this moment wheel brake drum can be freely rotated without jamming, significant axial clearance or deflection. Finally, assemble the washer pad and tighten the outside locking nut. 3. Steering system 3.1 Overview The steering system (Figure 2-28) mainly consists of the steering wheel, steering shaft, steering gear, Hydraulic cycloid motor and Rotary bearing.

  • Page 23: Hydraulic Cycloid Motor And Rotary Bearings

    without permmision. 1. Limitation column 4. Couple shaft 7.Rotor 2.Valve body 5.Spring 8.Stator 3. Valve core 6.Connection block 9.Valve sleeve Figure 2-29 Cycloidal full hydraulic steering gear 3.3 hydraulic cycloid motor and rotary bearings The pinion gear under the hydraulic cycloid motor is meshed with the large gear on the transmission case ( as shown in Fig .
  • Page 24 1. gerotor motor 2. pinion 3. big gear wheel 4．gear-box Figure 2-30 hydraulic cycloid motor and rotary bearings 3.4 Check the steering system after reinstalling (1) Turn the steering wheel leftwards and rightwards to the maximum extent to see whether the rotation is uniform and smooth;...
  • Page 25 3.5 Failure analysis (Table 2-4) (Table 2-4) Problems Causes analysis Solutions The steering The oil pump is damaged or faulted Replace wheel gets The rubber hose or fitting is damaged or the Replace or clean it stuck pipe is blocked The pressure of the safety valve is too low Adjust the pressure There is air in the oil pipeline...

  • Page 26: Electrical System

    (4) Electrical System Electrical system of FE3D is powered by 48V battery set, .traction power of the truck is powered by AC motor，lifting power is produced when AC motor is driving the oil pump to produce oil pressure. Lighting system is powered by battery 48Vto 24V voltage. 4.1 Electric control assembly（Curtis）...
  • Page 27 （Figure 4-2）...
  • Page 28 4.1.2 Main functions and settings Safe and high efficient working performance and complete operating performance of electric forklift can be achieved by setting correctly each motor technique data and control technique data and function value of controller. 1. The creeping speed of electric forklift can be set,the electric forklift work for a long time under a low speed,through creeping speed seting function of controller.
  • Page 29 potentiometer spring can stretch out or draw back to the maximum level or setted levels.Check once every three months. (5)、Check the contactor mechanical movement, the contactor should move freely without adhesion, mechanical movements of the contactor shall be inspected once every 3 months. 4.1.4 Combination instrument Using new combination instrument, the main function is to realize auxiliary control and provide the vehicle display interface to the driver.
  • Page 30 4.1.5 Failure analysis 1232SE/1234SE Controller fault table and diagnostics guide Code Code display on display on Troubleshoot Fault cause the programmer instrument 1、motor outside U,V or Wconnection shour current Controller controllercurrentoverload Overcurrent 2、motor parameter mismatching 3、controller failure 1， motor U、 V、 W truck circuit， lead Current Sensor Current sensor failure to current leakage...
  • Page 31 1， battery power is insufficient 2， Battery parameter is wrongly setted 3， non controller system power Voltage too low, as a consumption Undervoltage result the performance is 4， The battery impedance is too Cutback not good large 5， battery connection is disconnected 6，...
  • Page 32 1， connected load is open circuit Main contactor coil is or short circuit Main Open/Short open circuit or short 2， connecting pin is stained circuit 3， wrong wiring 1. connected load is open circuit or Drive 2 output linkng coil Coil2 Driver short circuit is open circuit or short...
  • Page 33 Pot Low potentiometer current is 1，potentiometer impedance is too Overcurrent too low EEPROM Failure EEPROM failure 1，EEPROM storage failure 1，The key start, interlock, direction, and the accelerator input HPD/Sequencing High pedal protection order is wrongly setted. Fault /operation order failure 2，...
  • Page 34 1， In the process of motor matching, code contrast： 0=normal 1=The controller receives the encoder signal, but impulse quantity is undefined.Please manually set pulse value 2=motor temperature sensor failure 3= motor high temperature Motor response failure Characterization Motor matching failure 4=motor overheating response Fault failure...
  • Page 35 4.2 Electronic control assembly（Inmotion） The Inmotion controller of ACS AC controller in the Zapi group, the type of controller of high security, reliability, flexibility, convenient operation and a body, through the advanced control software to ensure the motor in different modes, running smoothly, including regenerative braking speed and large torque condition, zero speed and torque control input / output port and proprietary software, ensure the controller for the economy and efficiency of electromagnetic brake and hydraulic control system.
  • Page 36 （Figure4－5） 4.2.2 Main functions and settings By correctly setting the motor's technical parameters and control technology parameters and function values of the controller, the electric forklift's safety and high efficiency performance and complete operation function can be realized. 1, advanced design and production process to ensure the best quality and reliability. 2, a powerful ARM core processor and operating system, while meeting functional tasks and motor control requirements.
  • Page 37 occurring. There is a time delay of several seconds at the input end of the seat switch. To allow the seat switch to be temporarily disconnected in the event of a jolt. 7. Safety protection function. If the power component of the controller is damaged in operation, the controller will disconnect the main contactor in the shortest time;...
  • Page 38 Parameter name Adjectival Description The figure shows the current accumulated working time of the vehicle 5 digits display; ① hourmeter After the key switch is connected to the power supply vehicle, the working timer starts to work; The arrow represents the direction of the steering ②...
  • Page 39 Switch to mode at main interface"S、P、 Number 2 E" Switching between the main interface Number 3 and the secondary interface Speed unit KM/h and MPH unit Number 4 switching 4.2.5 Fault analysis ACS Controller fault table and diagnostics guide Code Code display display on on the...
  • Page 40 1、 Traction controller encoder fault Traction controller encoder 2、Traction motor speed sensor fault connection wire is open Traction controller Traction controller temperature is temperature is low low alarm Traction controller Traction controller temperature is temperature is high high alarm Traction controller Traction controller temperature temperature sensor fault sensor fault...
  • Page 41 1、 Vehicle overload or Mechanical Traction controller over clamping current 2、Traction motor speed sensor fault Traction controller precharge Replace the pre charge resistance failed DC bus voltage of traction Battery need charge controller is low cut back DC bus voltage of traction DC bus voltage of traction controller controller is high cut back is high cut back...
  • Page 42 Pump controller temperature is high cut back Pump motor temperature is Pump motor temperature is high high cut back alarm Pump controller current Reset key calibration error Pump controller precharge Replace the pre charge resistance failed DC bus voltage of pump DC bus voltage of pump controller is controller is low cut back low cut back...
  • Page 43 DC MOTOR VOLTAGE HIGH RESET KEY DC MOTOR OPERATING HPG CONRTOLLER SENSOR CURRENT IS ZERO FAULT HPG CONRTOLLER OVER HPG CONRTOLLER OVER CURRENT CURRENT HPG CONTROLLER HPG CONTROLLER TEMPERATURE HIGH NEED TEMPERATURE HIGH COOL HPG CONTROLLER HPG CONTROLLER BATTERY BATTERY LOW LOW NEED CHARGE HPG CONTROLLER HPG CONTROLLER DRIVER...

  • Page 44: 5．Accumulator

    5．Accumulator Accumulator seen as figure 2-34 Figure 2-34 Accumulator 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 45: Charging Of The Accumulator

    eliminating minor vulcanization of the accumulator plates. Plus, users shall check the accumulator status frequently during the storage period. If the accumulator is being used, please conduct a fully discharge together with a fully charge each month. This could help maintain accumulator capacity and avoid plate salvation. Please keep the external surface of the accumulator clean.
  • Page 46 (1) Initial charge (generally initial charge has been conducted to the products before leaving the factory, so users could omit this operation) The quality of initial charge would greatly impact the future performance of accumulator. So initial charge shall be conducted by experienced operators. Initial charge should be carried out to new accumulators before use.

  • Page 47: Installation And Replacement Of The Accumulator

    The charger compatible with the accumulator could automatically regulate the charging current according to the charging capacity and conduct charging until the accumulator is fully charged. (Please refer to the manual of charger for details on observation of the charging state) In order to keep the accumulator status updated, it is recommended to record each charge and discharge conducted for each accumulator, so as to provide useful basis for determining whether or not the accumulator in the future or not.

  • Page 48: 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 49 1. Safety valve 2. Microswitch bracket 3. Oil returning hole 4. Lifting speed sensor sets Figure 2-36 Shape of multiple unit valve (1) Operation of the slide valve (Take tilting slide valve as an example) (a) Middle position (Figure 2-37) At this time the high pressure oil discharged from the oil pump will return to the cylinder through the middle position.
  • Page 50 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 51 which is on outer gantry mounting .and there is speed-limit valve installed inside of the right lifting cylinder. Piston is fastened on piston rod with elastic steel wire; oil seal and support ring are assembled on the outer race of pistion There is a cut-off valve assembled on the bottom of cylinder.
  • Page 52 6. Piston Rod 7. Cylinder Body 8. Support Ring 9. Retainer Ring 10. Shaft Seal Assembly For Hole 11. Valve Bush 12. Steel Cable 13. Shut -Off 14. O-Ring 15. Chain Wheel Retainer Ring Valve 16. Chain 17. Nut 18. Chain 19.

  • Page 53: Hydraulic Oil Cylinder

    The tilting cylinder is mainly composed by piston, piston rod, cylinder, cylinder bottom, guide sleeve and seals. The piston and piston rod adopt welded structure, with the piston outer surface mounted with a bearing outer ring and two Yx seal rings. In the internal hole of guide sleeve there mounts an axle sleeve, Yx seal ring, retaining ring and dust ring.

  • Page 54: Maintenance And Adjustment

    1. bolt 2. washer 3. Cover plate of oil cylinder 4. Paper washer 5.Cover of refueller 6. cover board assembly 7. Paper washer 8. oil tube 9. Clamp 10. Breathing device 11. Meshy filter Figure 2-46 6.8Maintenance and adjustment Maintenance of working oil pump (1) Disassembling Clean it thoroughly before disassembling.
  • Page 55 (d) Check of the driving and passive gears Replace a pair of gears in case of excessive wear. If size of D is less than the specified value, replace in pairs. 12.7 12.7 (0.5) (0.5) Figure 2-51 (e) If necessary, replace the seal rings, bushing seal, retaining ring, oil seal, spring ring. (3) Assembly (a) Mount a new seal ring and a new retainer ring at the front end cover of the pump.

  • Page 56: Failure Analysis

    5. Rear-end cover 6. Liner plate 7. Seal ring 8. Retainer ring 9. Oil seal 10. Flexible ring 11. Bolt 12. Washer Figure 2-52Gear pump (4) (4) Test run Conduct running-in of the pump to check if it functions properly. Then perform oil pump testing on the test bench or test by the following steps on the forklift truck: (If oil pump is subject to decomposition and maintenance due to serious wear and jamming caused by the hydraulic oil, the hydraulic oil and filter should be replaced before test-running on...

  • Page 57: 7．Lifting System

    （2）Failure Analysis of the oil pump（Table 2-9 Table 2-9 Fault Cause Countermeasures The oil level in the oil tank is Add oil to the specified value Low volume of oil discharge The tube or filter is blocked Clean or replace as needed ●Liner plate damage ●Bearing damage ●Poorly functioned seal ring,...
  • Page 58 shaft pin spring ring Tilting oil cylinder humper washer Cotter pin shaft pin Spring washer bolt Figure 2-53 Link between the mast and chassis...

  • Page 59: Fork Frame

    7.3 Forklift frame (Figure 2-54) Forklift frame will roll within the inner main frame through the main roller, which is mounted onto the main roller shaft and fixed by elastic rings. The main roller shaft is welded onto the fork frame and the side roller is integrated into the adjustable composite roller that rolls along the wing plate of the inner main frame.

  • Page 60: Maintenance And Adjustment

    1. Fork frame 2. Outter main frame 3. Composite roller of outer frame 4. Inner main frame 5. Inner frame and composite roller of fork frame Figure 2-55 Roller position Note: (a) adjust the clearance of side rollers at 0.5mm; (b) Apply lubricant oil onto the main roller surface and the contact surface of main frame.
  • Page 61 Figure 2-57 1. Fork 2. Fork frame 3. inner mast 4. Main roller 5. Main roller 6. Tires 7. outer mast (3) Lower the fork to the ground and tilts it backward in place. Adjust the upper end joints of the chain and then regulate the nut to set tightness of the two chains at the same degree.

  • Page 62: 8．Removal And Installation

    (2) Drive the forklift to a level ground and jack up the front wheels for 250-300mm. (3) Apply the hand brake and put pads under the rear wheels. (4) Remove the lifting cylinder and the mounting bolts of inner main frame. Lift the inner main frame and be careful not to loose the adjustment pad at head of the piston rod.
  • Page 63 (2) Lifting description of the overhead guard as shown in Figure 2-61 Lifting Hole Model Overall Dimension L×W×H Weight (kg) (mm) FE3R13-16 1300×980×1400 Figure 2-61 (3) Lifting description of the counterbalance as shown in Figure 2-62 The lifting ring on the counterbalance can be used to lift the balance weight only . Do not use it for lifting the whole forklift.

  • Page 64: Chapter 3 0Peration, Use And Safety Of The Forklift

    Chapter 3 0peration, use and safety of the forklift Ⅰ. Driving and operation In order to ensure good performance, safety operation and economic use of the forklift, we specify the precautions below that should be noted during proper driving operation. 1.

  • Page 65: Transportation And Handling Of The Forklift

    backwards to the specified position.  · When loading and unloading goods, try to minimize the tilting degree when tilting forwards and backwards. Never tilt forwards unless the load is close to or fixed by steel shelves or the lifting height is low. 5.

  • Page 66: Driving

    (3) Tilting backward of main frame Pull back the lever to lift the fork to 150 - 200mm away from the ground and pull back the lever to tilt the main frame backward. (4) Operation of the direction switch lever ⑤ Use the direction switch lever to decide the driving direction (forward - backward).

  • Page 67: Parking And Temporary Parking

    d) Operate the lifting lever to start lifting operation. · Simultaneous operation of driving and lifting (micro-operation) require high level of skills. The operator must correctly understand the form, gravity centre and other features of the goods and ensure stability of the forklift before carrying out low-speed lifting and lowering operations.
  • Page 68 • Maintain the electrolyte at the required level, otherwise the accumulator may be overheated or burned. • When the electrolyte level is low, the accumulator life will be shortened. b) Add distilled water c) Overcharge is not allowed d) Charging should be carried out in a well ventilated place •...

  • Page 69: Stacking

    c) When lifting the accumulator out of the forklift, be careful not to damage the steering wheel or other forklift parts. d) After a group of fully charged accumulator is well placed, securely connect the accumulator plug. e) Cap the accumulator cover. ·...

  • Page 70: Storage

     · When the fork can't be fully inserted into the pallet： a) Insert 3 / 4 of the fork length and lift the pallet a little (for 50-100mm), then pull out the pallet for about 100-200mm, and lower the pallet. b) Fully insert the fork into the pallet.

  • Page 71: Ⅱ. Operation Device And Use Method

    d) Mount the charged accumulator onto the forklift and connect the accumulator plugs. e) Conduct pre-start check carefully . Ⅱ. Operation device and use method 1. Diagram on forklift parts and operation device (see below) 1. rearview mirror 2. overhead guard 3.
  • Page 72 • Do not step on the accelerator pedal when turning on the key switch. • When you leave the forklift, take out the keys to protect it from being misused. • After parking the forklift or when recharging, take out the keys to protect it from being misused.
  • Page 73 hand on control lever of the multiple unit valve or steering wheel. Hydraulic steering system and tilt device of the steering wheel are standard equipments on the forklift.  • Adjust the steering wheel to the best angle according to the driver's position. •...
  • Page 74 (4) Parking brake lever ⑥ To prevent moving of the forklift, fully pull back parking brake lever when parking the forklift. Push forward the parking brake lever to its maximum level before driving. • When operating the parking brake lever, depress the brake pedal. (5) brake pedal ⑦...

  • Page 75: Forklift Body

    (6) Lifting lever ⑨ Pull back the fork lever to lift the fork and push forward the fork lever to lower the fork. Lifting and lowering speed can be controlled by the tilting angle of the lever . The greater the angle is, the greater the speed will be. •...
  • Page 76 The size of a opening in overhead guard is more than 150mm. If the cargo size is less than 150×150mm, additional protective measures must be adopted to prevent accident falling of the cargo. Unsteady installation, removal or transformation before use are all dangerous actions that may lead to major accidents.

  • Page 77: Ⅲ. About Safety

    Ⅲ. About safety Ensure safety is your business and responsibility. This section describes the basic safety regulations and warnings during use of the forklift, but also applicable to forklifts with special specifications and with the main frame and accessories. 1. Site and working environment of the forklift (1) Ground conditions The forklift should used on solid ground in well-ventilated environment.
  • Page 78 Driving on highways are prohibited! Drivers shall wear working clothes before driving! Alert: seek medical aid in case of injuries! Don’t change forklift parts without permission! Please read the instructions before operating the forklift!
  • Page 79 Turn off the engine before maintenance! Understand the traffic rules! Check the forklift before use! Do not move the overhead guard! keep the cab clean! Do not drive an unsafe forklift!
  • Page 80 The driver should be healthy! Make sure that your forklift is safe! Work within the permitted scope! Do not drive damaged forklift! Hold the handrail during on-boarding Start the forklift in a correct way! Adjust the seat before driving! Make sure that your forklift is under safe working condition...
  • Page 81 Appropriately fasten the seat belt! Always pay attention to the height of the working area of forklift! Turn on the lights in dark areas! Do not expose your arm and body outside the overhead guard! Avoid driving on soft or unprepared ground . Keep the body under the overhead guard! Drive on flat and solid surface! Avoid eccentric loading!
  • Page 82 Check the position of the location pin! Check the safety of working areas! Don’t drive on smooth or slippery ground! Ensure the lateral driving stability when the forklift is running without load! Be especially careful when handling Carrying passengers is absolutely goods with relatively large length or width! prohibited! During turning, please slow down and...
  • Page 83 blow horns if you can’t see the roads clearly! when handling small objects! Do not chase each other driving across the road! No one shall stand on the goods! Looking around is not allowed while driving! Do not do stunt with the forklift! If the loaded cargo is too high and blocks Obey the traffic rules and all warnings and signs! your eyesight, drive reversely.
  • Page 84 goods! When carrying no load, move uphill by Perform braking when starting on the ramp! driving in reverse the ramp and move downhill facing the ramp! Turning on the slope is not allowed! Blow the horn when there are people walking ahead! Avoid collision with people or objects Keep clear of other persons during working during turning!
  • Page 85 workingoverturning due to unstable centre of gravity! area of the forklift! Changes in the rated capacity of the forklift Always pay attention to the areas around should be noted! when driving the forklift! Please use the fork for loading! Slow down when loading! Please do not move the forklift when there are No one shall walk or stand below the people standing in front of it!
  • Page 86 back-rest! before loading! Goods have not been loaded from the forklift Do not carry damaged goods cases by shall not be handled! your shoulders! Abuse of the fork is not allowed! Be careful when loading the goods onto cars! Never carry people! Do not abuse the forklift! Do not stretch any part of the body out of the Drive smoothly.
  • Page 87 forklift! slow down is not allowed! Special safety equipment shall be used when Do not overload! carry out manned operation Lifting is not allowed when it is too windy! Operating in an explosive environment is not allowed! Damaged forklifts need to be placed in When not in use, the forklift shall be designated areas! parked in designated areas!
  • Page 88 It is prohibited to park the forklift on a slope! When you do not use the forklift: —Brake —Place the direction lever at the netural position —Lower the fork to the ground. — Tilt the main frame forward — Remove the key 3.
  • Page 89 To avoid tipping, tilting forward to lift the load Tilted loading of the goods is is forbidden! prohibited! Eccentric loading of the goods is prohibited! Avoid driving on slippery surface! Do not load or unload if the forklift is not on a Do not drive over trenches, other obstacles that level ground! cause tipping!

  • Page 90: Safety Issues During Maintenance And Protection

    When the empty fork is lifting, please turn Be sure to fasten your seat belts! within a narrow range to avoid tipping! In the event of forklift tipping, please do not Please wear a helmet while driving! jump! In case of tipping, it is safer when you stayed in the forklift with seat belt than jumping out of the forklift.
  • Page 91 (3) Precautions on care and maintenance • Take care not to put feet below the fork and not to be tripped by the fork. • When upgrading the fork, use pads or other things as cushion below the main frame to avoid sudden drop of the fork and main frame. •...
  • Page 92 • The accumulator has high voltage, so when you perform installation and maintenance, do not touch the accumulator conductor, which can cause serious burns. (3) Correct connection • When the accumulator is charging, ensure the positive and negative poles are not reversed, otherwise heat, fire, smoke or explosion may be caused.
  • Page 93 • Put on accumulator top cover tightly to prevent electrolyte leakage. • Do not add too much electrolyte, otherwise the electrolyte will overflow and cause current leakage. (11) Waterproof • The accumulator can not be wet by rain or sea water, otherwise the accumulator will be damaged, causing fire.
  • Page 94 1． Battery Maintenance 2． NOBLELIFT 3． Hoisting 4． Hydraulic oil 5． Product model 6． Hand squeezing 7． Prohibition of lifting 8． Safety belt 9. No Climbing 10． Safety label 12． Battery box cover opening 11．Whole car hoisting 13． Safety marking against rollover 14． Prompt sticker 15．...

  • Page 95: Ⅰ. Check Before Operation

    works 8 hours a day and works 200 hours a month. In order to ensure safe operation, maintain the forklift regularly according to the maintenance procedures. Routine maintenance and repair work shall be carried out by the forklift driver and other inspection and maintenance work shall be done by professional maintenance personnel.
  • Page 96 Other parts If there is abnormality 2. Check the procedure (1) Check the foot brake pedal ⑦ Check the braking status. Ensure that if the brake pedal is fully depressed, the travel distance of the brake pedal should be more than 50mm, and the braking distance of no-load forklift shall be about 2.5m. (2) Check brake fluid •...
  • Page 97 deemed as Normal. Rebound stroke 50—100mm (5) Check the power steering feature Rotate the steering wheel clockwise and counter-clockwise, and check the working condition of the power steering. (6) Check the hydraulic system and the function of main frame Check if the operations of lifting, tilting forward and ackward are normal and smooth. (7) Check the oil pipe Check the lifting cylinder, tilting cylinder and all the piping for oil leakage.
  • Page 98 tightness. • Double-nut should be tightened after this adjustment, . (10) Check the tires (solid tire) Check tires and the side surfaces for damage or cracking, and then check the wheel rim and the lock ring for deformation or damage. (11) Check the rim nuts ·...
  • Page 99 Neutral position Horn button Right steering emergency button lamp lights up (14) Check instrument panel Under normal circumstances, the instrument panel will displays as below within a few seconds after turning on the key switch. 1. Tips locking instructions 2.parking brake insdicator 3.traction controller fault code 5.oil pump controllerfault code 6.it’s tome for maintanance 4.speed mode...

  • Page 100: Ⅲ.clean The Forklift

    Ⅱ.Checking after operations After work, remove dirt from the forklift and check the following items: (1) Inspect all parts and components for damage or leakages. (2) Check for deformation, distortion, damage or breakage. (3) Add grease if necessary. (4) Lift the fork to the maximum height for several times after operations are finished. (After you do not lift the fork to its maximum height in daily work, this allows the oil flow through the cylinder to prevent rusting.) ) (5) Replace abnormal components that cause failures during work.

  • Page 101: Regular Maintenance Schedule

    • 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 102 from fireworks （2）Controller Every Every 3 Maintenance Maintenance Per day month months Tools week months Item content (8 hours) (200 (600 (50 hours) (1200 hours) hours) hours) Check wear status √ √ of contacts Check if the mechanical √ √ movement of the contactors is good Check if the...
  • Page 103 （4）Transmission system Every Every Maintenance Per day week month Maintenance content Tools months months Item (8 hours) (200 (600 (1200 hours) hours) hours) hours) √ √ √ √ √ If any noise √ √ √ √ √ Check for leakage Replace the oil ×...
  • Page 104 （6）Steering system Every 3 Every 6 per week Maintenance Maintenance Per day month months months Tools Item content (8 hours) (200 (600 (1200 hours) hours) hours) hours) √ √ √ √ √ Check the clearance Check the axial √ √ √...
  • Page 105 （7）Braking system Every 3 Every 6 Per day per week per month Maintenance Maintenance months months Tools (200 Item content (600 (1200 hours) hours) hours) hours) hours) Graduated √ √ √ √ √ Free travel scale √ √ √ √ √...
  • Page 106 （8）Hydraulic system Every 3 Every 6 Maintenance Maintenanc Per day per week per month months Tools months Item e content (8 hours) (50 hours) (200 hours) (600 (1200 hours) hours) Oil volume check and √ √ √ √ × replacemen t of oil Clean the Hydraulic...
  • Page 107 （9）Lifting system Every 3 Every 6 Maintenance Maintenance Tools week month months months Item content (50 hours) (200 hours) (600 hours) (1200 hours) hours) Check the tightness of the chain and see if there is √ √ √ √ √ deformation, damage and corrosion...
  • Page 108 welding parts at the root of the fork Crack or damage on the inner main frame, outer √ √ √ main frame and welded parts on the beam Bad welding, cracking, damage on the welded parts √ √ √ between tilt cylinder bracket and the main frame...

  • Page 109: Replace Critical Safety Components Periodically

    (10) Others Every Every Maintenance Maintenance week month 6 months Tools months Item content (200 (1200 (600 hours) hours) hours) hours) hours) firmly Test √ √ √ √ √ installed hammer Overhead Check guard and deformation, √ √ √ √ √...

  • Page 110: Ⅴ. Lubricating Parts And Recommended Oils

    Ⅴ. Lubricating parts and recommended oil 1. Lubricating parts ○: Replacement FO: Hydraulic oil ◎: adding GO: Gear oil □: Check and adjustment CG: Lubricant grease BO: Brake oil W: Distilled water □◎ Lifting chain ◎ Brake tank □ Directional string ◎□...
  • Page 111 Maintenance record Date Maintenance content Note...
  • Page 112 NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD. Service hotline：4008-836115 Wechat：nuolijixie Postcode：313100 email address: info@noblelift.com Website：www.noblelift.com Version：Jan,2018...

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