Noblelift FE4P40N Operation And Maintenance Manual
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Noblelift FE4P40N Operation And Maintenance Manual

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WARNING
Do not use the forklift before reading and understanding the operating
instructions as well as the waring decals on the truck.
Keep for future reference.
FE4P40N, FE4P45N, FE4P50N
Operation and maintenance manual
FEXP type
battery counterbalanced forklift truck
NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD.

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Summary of Contents for Noblelift FE4P40N

  • Page 1 WARNING Do not use the forklift before reading and understanding the operating instructions as well as the waring decals on the truck. Keep for future reference. FE4P40N, FE4P45N, FE4P50N Operation and maintenance manual FEXP type battery counterbalanced forklift truck NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD.

  • Page 2: Table Of Contents

    Catalogue Forward ……………………………………………………………………………………………………… 4 Chapter one Attention when using the forklift truck ………………………………………………… 1、Transportation for forklift……………………………………………………………………………… 2、Deposit…………………………………………………………………………………………………… 5 3、Preparation before use………………………………………………………………………………… 4、Operation of truck……………………………………………………………………………………… 5、Battery charging………………………………………………………………………………………… 6 Chapter two The main performance parameters of forklift truck …………………………………… 7 Ⅰ、The truck’s outline dimension and performance parameters ……………………………………… 7 1.The truck’s outline dimension …………………………………………………………………………...
  • Page 3 6.1 Sumarry ……………………………………………………………………………………………… 46 6.2 Oil pump ……………………………………………………………………………………………… 46 6.3 Multiway valve ……………………………………………………………………………………… 46 6.4 Lift cylinder and lift chains ………………………………………………………………………… 59 6.5 Tilt cylinder ………………………………………………………………………………………… 6.6 Hydraulic cylinder ………………………………………………………………………………… 6.7 Hydraulic hose ……………………………………………………………………………………… 52 6.8Maintenance and adjustment ……………………………………………………………………… 53 6.9 Fault analysis…………………………………………………………………………………………...
  • Page 4 3．Truck’ s transportation ………………………………………………………………………………… 85 4．Howtoavoidoverturning,howtoprotectyourself ……………………………………………………… 86 5. Safety problem in Maintenance ……………………………………………………………………… 87 6． Safety problem in battery usage ……………………………………………………………………… 89 7．Plate …………………………………………………………………………………………………… 91 Chapter four Truck’s regular check and maintenance ………………………………………………… 92 Ⅰ、The check before operation…………………………………………………………………………… 92 1.Checkingpointandcheckingcontent ……………………………………………………………………...

  • Page 5: Forward

    Forward This manual briefly introduces the technical parameters as well as the construction,working principle and the requirements in operation and the maintenance of each main part of the four-wheel battery counter-balanced forklift truck of our company.Before operation,please read the manual carefully to ensure safe and efficient load portage by correct operation and maintenance,and to help the operator to use the battery forklift truck properly so as to make full use of it.It is hoped that the operator and the facility manager read the manual carefully before operation!Please perform strictly according to the attention matters in this manual,drive...

  • Page 6: Chapter One Attention When Using The Forklift Truck

    Chapter one Attentions when using the forklift truck The operator mast always keep in mind the principle of safety first.Conscientiously and cautiously read the maintenance manual.Undergo safe operate and canonical operate strictly following the demand in this manual 1 Transportation for forklift Pay attention to the following particulars when using container or automobile to convey forklift truck (1) Enable parking brake...

  • Page 7: 5、Battery Charging

    (10) The starting speed should not be too fast when starting to lift and lower the load (11) No operation of truck and it’s additions without sitting on the driver’s seat (12) Push handle immediately to middle position when the mast has tilted forward or backward to the extreme position (13) No driving or turning when the mast is lifting (14) When travelling,pay attention to passers by,obstacles,irregular road and the clearance of...

  • Page 8: Chapter Two The Main Performance Parameters Of Forklift Truck

    Chapter two The main performance parameters of forklift truck Ⅰ、The truck’s outline dimension and performance parameters 1. The truck’s outline dimension see figure 1-1 Figure 1-1 outline...

  • Page 9: Technical Data

    2.Technical data 2.1 FE4D40-50 Technical data(Single wheel drive)（list 1-1） Model number FE4D40 FE4D45 FE4D50 specifications Drive mode: Electromotion Electromotion Electromotion Operation mode: Seat-driving pattern Seat-driving pattern Seat-driving pattern 4000 4500 5000 Rated capacity Q(kg) Load center distance C(mm) Load distance x(mm) 1900 1900...
  • Page 10 2.2 FE4D40-50 Technical data (Double wheel drive)（list 1-2） Model number FE4D40 FE4D45 FE4D50 specifications Drive mode: Electromotion Electromotion Electromotion Seat-driving Operation mode: Seat-driving pattern Seat-driving pattern pattern 4000 4500 5000 Rated capacity Q(kg) Load center distance C(mm) Load distance x(mm) 1900 1900 1900...

  • Page 11: Ⅱ、The Construction,Principle And Adjustment Of The Truck's Main Parts

    Ⅱ、The construction,principle and adjustment of the truck’s main parts 1. Drive system :There are two configurations for the drive system: the front single-wheel drive and the front two-wheel drive. 1.1 Drive system(Single wheel drive) 1.1.1 Summarize The drive system consists of gear box assembly, differential mechanism assembly and drive axle, the reducer drive gear connects directly to drive motor.The travel speed increases with the increment of rotational speed of drive motor, And when the rotational direction of the motor changes, the travel direction changes too.
  • Page 12 Differential mechanism, of which the front connects to axle shell,is installed on the front-half shell by the bearing block in on two sides. The shell of the differential is left-right subdivision in construction,and there are two half axle gears and four planet gears in it.see figure 2-2 1.
  • Page 13 1.1.3 Drive axle The drive axle consists of axle shell,wheel hub and arrester. It is installed in the front of framework The shell is unit casted in construction,the tyres are fastened on wheel hub with studs and nuts,wheel hub is supported on axle shell by conical roller bearing,power is delivered by differential to differential axle by differential,wheel hub which drives front wheel to rotate is drived by differential axle.Differential shaft only bears the twisted moment delivered to wheel hub.There are seals inside left wheel hub to prevent water and dust or oil leakage installed in wheel hub.
  • Page 14 fgure 2-4 injection of grease figure 2-5 measurement of starting moment (4) Install lock plate and lock nut, and cock up lock plate to stop nut (5) Tyre assembly（figure 2-6） Fix gas pole and nut cap upon tyre,and assemble wheel rib pay attention to the following items: Attention: (a) Gas pole lies in the gap of the wheel rib...
  • Page 15 1.1.5 Malfunction analysis List 2-2 malfunction diagnose and adjustment malfunction possible reason adjusting method items shake a lot the fastening bolts loosen Tighten gear oil deteriorates replacing Too high of Un usual Oil level Supplying or reducing temperature Clamping stagnation of moving parts adjustment Contacting surface bolts loose tighten...
  • Page 16 1.2 Transmission system(Double wheel drive) 1.2.1 Overview The transmission system of forklift is composed of two reduction gearbox assembly and two travel motors. Driving gear of decelerator is connected directly with the travel motor, so the driving speed of forklift increases with the increase of motor speed and the driving direction can be changed by changing the direction of motor rotation.

  • Page 17: Drive System (Double Wheel Drive)

    1. Wheel hub 2. Wheel fixing screw 3. Needle cage 4. Shaft seal 5. Taper Roll. Bearing 6. Set-Right Spacer 7. Spacer 8. Breather plug 9. Socket head cap screw 10. Socket head cap screw 11. Socket head cap screw 12.

  • Page 18: 2．Brake System

    2. Brake system 2.1 Summarize Brake system,Being Two-front-wheel internal expansion oil pump type,consists of brake paddle,brake base pump and wheel brake staff 2.2 Brake paddle The construction of brake paddle is illustrated in figure 2-7.The paddle transfers the stamp force exerted by the pushing rod of brake base pump into the pressure of brake oil 1.

  • Page 19: Brake Staff

    correctly to prevent oil leaking and the case of air resistance which possibly occurs in emergency brake. 1.latch nut 2.pushing rod 3.antidust cover 4.locking steel wire 5.locking 6.assistant 7.piston 8.base leather washer leather cup 9.spring 10.cheak valve 11.valve 12.pump body supporter figure 2-8 base brake pump 2.4 Brake...
  • Page 20 33.protective cover 34.dust cover figure 2-9 brake stuff (1) Motion of brake stuff The brake drum is pressed by the leading brake shoe and the secondary brake shoe with the same force from subsidiary brake pump,when the top side of the brake shoe is stopped by the fixed pin,the brake shoe will move toward brake drum until being stopped by the fixed pin,then the friction between wearing piece and brake drum will increase.

  • Page 21: Parking Brake Operating Device

    drum,the vertical distance of B point rotating grows,and the regulating device moves one tooth space.,then,regulating rod gets longer（see figure 2-14）tthe gap narrows,regulating gap lies between 0.4mm and 0.45mm. 2.5 Parking brake operating device（figure 2-15） Parking brake handle is cam in pattern.Adjuster lying at the end of handle is available to adjust the brake force.
  • Page 22 figure 2-16 figure 2-17 (3) Disassemble the fixed spring on leading brake shoe.See figure 2-18 (4) Disassemble the leading brake shoe and secondary brake shoe. Then disassemble the regulator and regulating spring.See figure 2-19 figure 2-18 figure 2-19 (5) Disassemble the brake tube from the driven brake pump,and disassemble the assembling bolts on the subsidiary brake pump.Then disassemble the subsidiary brake pump from brake device motherboard.See figure 2-20 (6) Disassemble the E baffle ring to fast the brake dragline from brake device...
  • Page 23 figure 2-23 figure 2-24 2.6.3 Assembling brake device (1) Wipe brake liquid on cup leather and piston of brake sub-pump, assembling spring, piston cup leather, piston and defend ring. (2) Install brake sub-pump on motherboard. (3) Mount motherboard on drive axle. (4) Wipe anti-heat lubricate grease on the region instructed in figure 2-25.

  • Page 24: Adjusting For Brake Pedal

    figure 2-28 figure 2-29 2.6.4 Operating trial for self-adjustor of clearance See figure 2-30 (1) Adjust diameter of brake hoof close to the regulation size first, rotate adjustor by pulling adjusting bar, when releasing hand, adjusting bar return original place but adjustor gear doesn’t rotate.

  • Page 25: Malfunction And Cause

    Bolt Push rod Pedal figure 2-31 (5) Adjusting brake switch as figure 2-32 (a) After adjusting brake pedal height,release lock nut of brake switch (b) Pull off plug to separate wire (c) Rotate switch to make clearance into A=1mm (d) To be sure when step pedal down, the light of brake shall be open. (e) Tighten the nut.

  • Page 26: Maintenance

    Brake badness Adjusting Mal-touching between brake drum and friction slice again 5 Dirt on friction slice Repair or replace 6 Impurity is in liquid Check brake liquid 7 Bad-regulate for brake pedal(inching valve) Regulate Repair or 1 Friction slice impurity or case hardening replace Repair or 2 Motherboard deformation or bolt loose...

  • Page 27: 3．Steering System

    (a) Check brake drum to see whether there is destructive abrasion. (b) Check brake shoe for abrasion,if it can not reach the operating requirement,replace the brake shoe at once. (c) Check whether the axle shell is normal,if the oil level is less than normal,supplement the ⑤...

  • Page 28: Steering Axle

    valve in valve body to be used to prevent damage on equipment when hydraulic pressure is too high produced by impact of outside force which is from ground to wheels during travelling. Both safety valve and two-way overloading valve are regulated in optimum by manufacturer, so, users shall not regulate it randomly.
  • Page 29 1.Left knuckle assembly 2. Left main pin 3.Steering bridge 4.spring washer 5.bolt 6. adjusting shim 7. adjusting shim 8.adjusting shim 9.grease cup 10. Rear axle support 11.Steel back bushing 12.Shaft end baffle 13.spring washer 14.bolt 15. close over 16.bearing 17.adjusting shim 18.bearing 19.
  • Page 30 (1) Kunckle Kunckle,combined by kunckle king pin,conical roller bearing,anti-dust cover,O ring,locates between upper and down side of the steering axle body terminals. the upper end of king pin is fastened on axle body by stop pin,and the lower end of it is fasten on axle body by forelock. The supporter is supported by conical roller bearing which is pressed-in the axle body.（see figure 2-36）...

  • Page 31: Gist For Adjustment And Maintenance

    1. piston rod 2. cylinder cover 3. scraper seal 4. Zocany ring 5. Guide ring for piston rod 6. bead flange 7. O-ring 8. cylinder block 9. T-type Turconger loop 10. O-ring 11. Guide ring for piston 12. Guide ring for piston 13.

  • Page 32: Diagnose Of Steering System

    3.6 Diagnose of steering system（list2-4） List 2-4 problem cause elimation damage or malfunction of oil pump replace steering wheel can not move hose connector is damaged or plug of pipeline replace or cleaning safety valve pressure is too low adjust pressure air in oil circuit exhaust air steering wheel...

  • Page 33: 4．Electrical System

    4. Electrical system Electrical system of FE4P40-50N is powered by 80V 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 80V to 24V voltage. 4.1 Electronic control assembly（Inmotion）...
  • Page 34 4.1.1 Electrical principle chate （Figure4-8.1 Single wheel drive and double pump ）...
  • Page 35 （Figure4-8.1 Double wheel drive and double pump）...
  • Page 36 4.1.2 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 protection, fault code and other information. At the same time, it can realize remote voice alarm and scheduling, vehicle positioning, remote locking, remote help and other industrial Internet functions. It can also modify the configuration parameters according to users, and provide online real-time communication.
  • Page 38 Icon Name Function Move the cursor up, or add 1 selected Upward numbers up and up. Main interface down - cut high contrast Left Move the cursor left Right Move the cursor to the right Move the cursor up, or subtract the Down selected number by 1 Lowering contrast under main Interface...
  • Page 39 Throttle analog fault Traction controller CAN Check CAN wire of controller and communication fault display Battery voltage low Need charge CPU fault Reset key Incorrect start Tilt switch Reset tilt switch active before key on Incorrect start Side switch Reset side switch active before key on Incorrect start Attachment Reset attachment switch...
  • Page 40 1、 DC bus voltage high DC bus voltage of traction controller is high 2、 The ramp is too steep DC bus voltage of traction Need to charge or check power controller is low wiring The default value of the Reset key traction controller is updated Traction drive limit Battery low vehicle speed limit...
  • Page 41 1、 Pump motor temperature sensor Pump motor temperature fault sensor fault 2、Pump motor temperature sensor connection wire is open 1、Pump motor speed sensor fault Pump controller encoder fault 2、Pump motor speed sensor connection wire is open DC bus voltage of pump DC bus voltage of pump controller is controller is high high...
  • Page 42 Charge protection Charge protection Temperature protection Temperature protection BMS CAN bus off BMS CAN bus off Seat switch off after a period of time, the direction of the Reset direction switch request to reset BMS indicates Limit Current BMS indicates Limit Current alarm alarm BMS indicates cutoff Current BMS indicates cutoff Current alarm...
  • Page 43 HPG CONTROLLER TURN OFF THE PUMP WAITING FOR MAIN CONCTACTOR PARAMETER CONTACTOR CHECK DISPLAY AND DISPLAY CAN FAULT CONTROLLER CAN CONNECTION...

  • Page 44: Electronic Control Assembly（Inmotion

    5．Battery Battery framework see figure 2-45. figure2-45 battery 5.1 Battery safety requirements △ Good ventilation is necessary. Because hydrogen and oxygen take place at the later period of charging battery, so, sparks will lead to explosion. △ There is acid mist taking place during charging,please exhaust it and cleaning battery and workplace immediately after charging.

  • Page 45: Battery Charging

    Rub-up dust of battery by cloth, if there is electrolyte stains, rub-up or cleanse by hot water, then dry it by cloth. Clean dirt and oxide of pole, rub-up lead and lead clip. Dredge venthole of oil inlet. Apply a thin industrial Vaseline on pole and lead clip. Check battery for liquid level.
  • Page 46 Warning: Slowly infuse strong sulphuric acid into distill water and stir liquid by a glass rod or lead cover wood stick, do not infuse distill water into sulphuric acid absolutely, otherwise, there will be liquid boiling and splashing to injure people. To be sure the polarity of connection between charger and battery is correct, that is anode to anode and cathode to cathode,a reliable connection is necessary.

  • Page 47: Installation And Replacement Of Battery

    5.4 Installation and replacement of battery Battery installation shall fix fastened, prohibit to overturn; Prohibit to hammer terminal and leading clips; Avoid impact during transporting. 6. Hydraulic system 6.1 Sumarry Hydraulic system consists of pump, multiway valve, lift cylinder, tilt cylinder and pipeline ect. See figure 2-46,Hyduaulic liquid supplied by pump and multiway valve distribute liquid to each cylinder.
  • Page 48 1. Safety valve 2. Inching switch support 3. Spill pore 4. Lift timing sensor cover figure 2-47 Multiway valve outline (1) Operation of Slide valve (To tilting slide valve,for example) (a) Neutral (figure 2-50) In this case,high pressure liquid out of pump to tank through neutral (b) Push slide valve in (figure 2-51) Then, neutral chunnel is closed, liquid from oil inlet to open one-way valve flow to cylinder joint B, liquid from cylinder joint A flow to tank through low pressure chunnel, supported by...
  • Page 49 Figure 2-52 (3) Motion of tilting self-locked valve There is tilting self-locked valve in tilting cylinder valve slice to prevent mast fall down suddenly when cylinder cavity take place negative pressure and danger when mal-operating tilting valve stick. Because this self-locked valve, if even thrusting joy stick, mast cannot be tilted when forklift motor stop work.
  • Page 50 1. tilting rod operation 2. lifting rod operation 3. accessary rod operation 4. connecting shaft 5. connecting rod 6. bracket figure2-55 multiway operation (5) adjust safety valve pressure Adjusted pressure for safety is 13.5/16.8MPa Safety pressure had been set it up by manufacturer, user shall not be setup by themself.
  • Page 51 left lifting cylinder right lifting cylinder 1. anti-dust ring 2. axes seal 3.steel cap 4. O-ring 5.bearing 6.cylinder 7.piston rod 8.adjusting bushing 9.O ring 10.spring 11. circlip 12.spring seat 13.piston 14.support ring 15.valve core 16.circlip 17.hole seal 18.check valve 19.circlip 20.valve 21.O ring 22.speed limit valve...

  • Page 52: Tilt Cylinder

    Normal cylinder Cut off 1.lifting cylinder body 2.pressure spring 3.valve core figure 2-57 isolating valve 6.5 tilt cylinder Ttilting cylinder,whose piston rod connects to mast through earbob,is double-acting in pattern. The bottom of tilting cylinder connects to framework with pin. There are two tilting cylinders on each side of forklift.

  • Page 53: Hydraulic Hose

    8.6 Hudraulic oil cylinder Hydraulic oil tank is installed in rear right of framework. There are net filter in oil tank and breather on oil tank cover .see figure 2-60 1. dipstick 2.bolt 3.washer 4.spring washer 5. Sealing gasket 6. Combined washer 7.

  • Page 54: Maintenance And Adjustment

    6.7 Hydraulic oil pipeline Hydraulic system hydraulic oil pipelice. See figure 2-61。 1. Brake master pump 2. hydraulic steering gear 3. tilt cylinder 5. oil pump 6. oil tank 4．multiple unit valve 7．steering cylinder figure2-61 hydraulic pipeline 6.8 Maintenance and adjustment Working cylinder maintenance (1) Disassemble Cleaning thoroughly before assembling.
  • Page 55 and don’t contaminate or damage parts. (a) Clamp flange shell of pump by bench vice (b) Screw off bolt 11, rear end cover 5 and pump body 1. (c) Dismantle lining slice 6, drive gear 2 and driven gear 3. (d) Dismantle seal 7 and retainer ring 8 from front and rear end cover.

  • Page 56: Fault Analysis

    (b) Fit lining slice on groove of front end cover. (c) Fit a drive wheel and a driven wheel on front end cover. (d) Fit lining slice on gear side to make groove aim at gear point. Be careful not to mistake oil inlet side and oil outlet side.
  • Page 57 6.9 Malfunction analysis When hydraulic system has some failure, please consult table as below to find out cause and repair it. Multiway valve fault diagnosis (List 2-11） Figure 2-11 Fault Cause Elimination Slide valve get stuck Break up, cleaning Lift pressure too low Oil pore jam Break up, cleaning Slide valve get stuck...

  • Page 58: 7．Lifting System

    7. Lifting system 7.1 Summarize Lift system consist of dual mast (inner and outer mast respectively), roller lift and lower vertically, and fork. 7.2 Inner and outer mast (figure 2-68) inner and outer mast constructed by welding. Bottom of outer mast fit on drive axle by brace. Middle of outer mast connect with frame through tilting cylinder and it can tilt forward and backward actuated by tilting cylinder.

  • Page 59: Fork Carriage

    7.3 Fork carriage (figure 2-69) Fork carriage move inside inner mast by main roller, main roller fitted on shaft locked by clip ring, main roller shaft also welded on fork carriage, side roller fixed on fork carriage by bolts, rolling along outside of wing board of inner mast, it can be regulated by adjust shim.

  • Page 60: Lift Cylinder And Lift Chains

    1. Fork carriage 2. Outer mast 3. Outer frame roller unit 4. Inner mast 5. Inner frame and fork carriage roller unit figure 2-70 Roller position Notice: (a) Adjust clearance of side roller for 0.5mm; (b) Lubricate grease on main roller surface and working surface of mast. 7.5 Maintenance and regulation 7.5.1 Adjustment of lift cylinder See figure 2-71 It is needed to readjust journey of lift cylinder after dismantle or replace lift cylinder, inner mast...
  • Page 61 Inner mast Tyre fork carriage main roller fork Figure 2-72 (3) Lowering fork on ground and tilting it backward at max. angle. Keep both of two chains be same tension by adjusting nut which locate upper end of adjust chain. 7.5.3 Replacement of fork carriage roller (1) Place a pallet on fork and park forklift on level ground.

  • Page 62: Instructionsofinstallingaccessaries

    (7) Replace main roller (a) Dismantle the upper side main roller with drawing tools, Not to lost the adjusting pillow (b) Install the new roller together with the djusting pillow dismantled in step(a) (8) Sling the inner mast until all of the engaged in it. (9) Install the lifting cylinder and fork carriage adverse to the steps as dismantled.
  • Page 63 1068×112×440 FE4D45 1138×329×1215 1068×112×440 FE4D50 1138×329×1215 figure 2-77 (4) Hoisting for battery box See figure 2-78 outline dimension Weight Type length×width×height（mm） （kg） FE4D50 1048×913×866 1840 FE4D45 1048×913×866 1840 FE4D40 1048×913×866 1740 figure 2-78 Battery has the function of counterweight,so users can not replace it at will otherwise it will affect the balance of entire vehicle and other performances.

  • Page 64: Chapter Three Operation,Use And Safety For Forklift

    Chapter three Operation,use and safety for forklift Ⅰ、 Driving and operation There are some information for operating normally as below and it favor you about good running performance, using safely, running economically. 1. Usage of new vehicle ·All of the parking parts from the new vehicle should be reclaimed according to the establishment of local government.

  • Page 65: 5．Transportingandloadingforforklift

    rigidity loading goods frame, or low lift height. 5. Transporting and loading for forklift (1) Transportation of forklift ·Transporting with truck,Wedge forklift wheel or tighten forklift by rope to prevent it moving during transportation. ·Pay attention to obey regulation of full-length, full-width, full-height of forklift during transportation on traffic road.

  • Page 66: 8．Parking And Temporary Parking

    ·Do not startup or brake suddenly to prevent cargo falling down . (2) Speed slow down Release accelerator slowly. If necessary, step brake pedal down. Except emergency brake, release accelerator to make slow down slowly until parking. If even release accelerator suddenly, emergency brake is also impossible.

  • Page 67: 9．Usage Of Battery

    cloth on fork prong forward dead corner. ·Pay attention for road surface slide or cave in. ·To lower fork after parking perfectly, it is very dangerous to lower fork during traveling. ·Do not jump off vehicle. ·When get off forklift, you have to face vehicle and take favour of footboard. ·Slow down first and step brake pedal down and standstill and put gearshift on “N”.

  • Page 68: 10．Stacking

    ·According to 《operation and maintenance manual》of the used charger to break charging procedure. ·Do not pull out charger plug during charging, otherwise there will be spark take place to lead to danger. (2) Replace bettery When forklift has been used continuously for a working period and the battery has entirely excharged,replace the battery with another fully charged one and charge the battery been replaced.

  • Page 69: 11．Unstacking

    (b) Backing forklift for distance of 1／4 length of fork. (c) Lift fork 50—100mm up and drive forklift forward for stacking to be optimum. (8) Look at rear space, backing forklift in order to avoid impact between fork and pallet or goods. (9) Ensure fork prong to be off goods or pallet, lower fork to avail driving.(from ground 150—200mm) 11．...

  • Page 70: 12．Deposit

    (c) Rub anticonosive oil on bared surface of piston rod and shaft ect. (d) Cover parts prevent raining and wet. (e) Startup vehicle at least once a month, install battery, clean the grease on piston and shaft, startup engine and preheating, make vehicle move forward and backward slowly, meanwhile operating hydraulic control for several times.

  • Page 71: 1． Components,Schematicdiagramforoperatingdevices

    2. Instrument unit see figure 2.4 Electrical system（ page 30） 。 3. Switches （1）Emergency stop button When emergency, press red mushroom-head button down to cut off power to stop function of traveling, turning, lifting. To resume the function,rotate the botton according to the arrowhead indication. (2)Key switch key can turn on or turn off controlling power Turn off (0FF): In this position,power is cut off and key can be inserted...

  • Page 72: 4．Control

    Tail light switch is a single gear which controls on&off of the light. Pull switch up, light open; push down, light off. 4. Control Ssteering wheel①and steering wheel handlebar② Steering wheel operation is traditional: steering wheel turn right, vehicle move right; steering wheel turn left,vehicle move left.There is steering wheel at backside of forklift to make backside of forklift swing toward outside when turning.
  • Page 73 (4) Parking brake handle⑥ In order to prevent forklift from moving,when park forklift,pull up entirely parking brake handle. It is necessary to push parking brake handle to end before driving. ·When operating the parking barke handle,step down the parking paddle. (5) Brake paddle⑦and accelerating paddle⑧...

  • Page 74: 5．Bodywork

    (6) Lifting handle⑨ Pull backward lifting handle,fork lifts,and push forward lifting handle,fork lowers.lifting and lowering speed depend on tilting angle of handle,the larger the angle,the faster the speed is. ·Lifting operation cann’t be made,if push or pull lifting handle when turn on ignition key. ·Don’t lower fork suddenly or stop suddenly when lowering fork.
  • Page 75 (4) Traction rod Only in the following situation shall be possible to use traction rod. ·To escape from the trouble of being not able to travel(for example wheel trapped in ditch) ·Forklift need to be loaded on or be unloaded from lorry. ·No using for towing or to be towed operation absolutely.

  • Page 76: Ⅲ、Safety Issues

    Ⅲ、Safety issues Safety is your business and responsibility. This section describes the typical forklift often used in the basic safety regulations and warnings, but also applies to the door frame with special specifications. 1 Operation place and working environment (1) Ground conditions The operation place of forklift should be ground with flat and firm surface,a good ventilation is needed.
  • Page 77 Vigilant: injuries, the ambulance! Do not change parts on forklift arbitrary Read the instruction manual carefully before without permission. driving! Turn off the engine before maintenance! Understand traffic regulations Before use, please check on the truck! Do not move the overhead guard!
  • Page 78 To keep driver’s cap clean! Do not drive an unsafe forklift! Drivers should have a healthy body! Be sure your truck is safe! Work in specified area Do not drive a damaged truck! Hold tightly when get on the truck! Start forklift correctly!
  • Page 79 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! 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!
  • Page 80 Avoid eccentric loading! Pay attention to encounter item by front fork when loading! Check fork pin position! Note the security of the work region! 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!
  • Page 81 or wide cargo! If can not see the front when turning, Use appropriate pallets or sleeper when please whistle and drive slowly. handling small objects! Do not chase each other through the traffic! Not allowed to stand on the goods! Not allowed to gaze around while driving! Do not use the forklift to do stunt! when goods is so high to keep out line...
  • Page 82 direction of others when loading,travel forward in upgrade Pay attention to the steep uphill slopes and backward in downgrade and goods lifting height! When no-load,travel backward in upgrade Note using brake when start truck on and travel forward in downgrade! the slopes! Not turn when driving on a slope! People or things moving on road should...
  • Page 83 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 Pay attention to the area where forklift before use forklift. is driven! Use the fork correctly when loading! Slow down when loading!
  • Page 84 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. to fix before load! Do not carry the goods from forklift by Do not let people to carry the goods have manpower! been damaged!
  • Page 85 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! 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!

  • Page 86: 3．Truck' S Transportation

    Do not park the forklift on the slope! When the forklift is not in use,please do the follow. — Brake — Put direction pole in neutral position. — Lower the fork to the ground — Frame forward tilt. — Take off the key 3.

  • Page 87: 4．Howtoavoidoverturning,Howtoprotectyourself

    ·When lifting the truck, be sure not to wire rope and overhead guard around together. ·Wire rope and lifting equipment to be very strong, enough to secure bearing fork lift, because the truck is extremely heavy. ·Do not use the cab (overhead guard) to hoist the forklift. ·Forklift upgrade, do not enter the truck underneath.

  • Page 88: Safety Problem In Maintenance

    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 Be sure to fasten seat belts! a narrow range.
  • Page 89 (2) Precautions before maintenance ·No smoking ·Wear all protective equipment (helmets, shoes, glasses, gloves and boots), and suitable clothing. ·Wipe out the oil in time. ·When add lubricating oil, you should clean out dirty oil or dust with a brush or cloth, then add oil.

  • Page 90: 6． Safety Problem In Battery Usage

    6. Safety problem in battery usage (1) No smoking ·Batteries produce hydrogen gas. Short circuit will produce sparks when lit cigarette near the battery, it will cause an explosion and fire. (2) Avoid electrical attack · Battery with high voltage, when the installation and maintenance, do not touch the battery conductor, which can cause serious burns.
  • Page 91 (8) Battery electrolyte is harmful ·Battery electrolyte is made of diluted sulfuric acid, be careful when handling. ·When electrolyte adhesion conglytination on eyes, skin and clothing, it will result in vision loss and burns. (9) Emergency dealing methods ·When the accident occurred, deal according to the following methods of emergency treatment and contact a doctor immediately.

  • Page 92: 7．Plate

    Plate Signs sticked on vehicle are to illustrate using method and attention matters of vehicle,which not only takes consideration of you but also of the vehicle.stick the signs plate on again if they fall 1．Battery maintenance instructions 2．Warning 3．Company identification 4．Hoisting marking 5．hydraulic fluid 6．Model...

  • Page 93: Chapter Four Truck's Regular Check And Maintenance

    Chapter four Truck’s regular check and maintenance Conduct a comprehensive pre-inspection of forklift trucks and forklifts to avoid failure and fail to produce the life it deserves. Maintenance program is based on the number of hours listed in forklift work 8 hours a day, working 200 hours a month the case may be, in order to maintain safe operation and maintenance procedures should be maintained on the forklift.

  • Page 94: Checking Procedure

    2. Checking procedure (1) Check the brake pedal Check brake condition and to ensure a fully depresses the brake pedal when the plane from the floor counting down the brake pedal travel should be more than 50mm, no-load forklift truck braking distance about 2.5m.

  • Page 95: Ⅱ、Check After Operation

    (4) Check the steering wheel rotation case The steering wheel clockwise and counterclockwise rotating gently, check whether there is rebound phenomenon, a suitable spring trip to 50-100mm. Steering wheel before and after the trips of about 7 °, if the above situation, turn the steering wheel shall be normal. (5) Check the function of steering system The steering wheel clockwise and counterclockwise rotation, check the power steering work.
  • Page 96 (10) Check tires (pneumatic tires) Unplug the nozzle cap, measuring tire pressure with a tire air pressure. After check air pressure, nozzle mouth should ensure that gas will not leak before installed the cap. ·Forklift tire pressure is higher than the car’s; it should not exceed the prescribed pressure value.
  • Page 97 Check whether the normal bright lights, speakers is normal (when pressing the horn button, horn ring) Check whether the emergency stop is normal. left steering light is bright neutral right steering light is bright (14) Check instrument panel features （15）Check the overhead guard and load backrest Check whether there are loose bolts or nuts (16) Check the integrity of vehicle identification (17）Others...

  • Page 98: Ⅲ、Truck Cleaning

    Ⅱ、Check after operation After the completion of the work remove the dirt on forklift and check the forklift according to the follow items： (1) Check all the parts if there is damage or leakage. (2) If there is deformation, distortion, damage or breakage? (3) Add lubricating grease according to the situation.

  • Page 99: Ⅳ、Regular Maintenance

    Ⅳ、 After cleaning ·Thoroughly dry water stains on the truck (use compressed air as a example). ·Start the forklift according to the procedures. ·If moisture penetration into the motor, you must first remove the moisture, to prevent short circuits Moisture will reduce brake performance, brake truck briefly to drying the brake. 1.
  • Page 100 （3）Motor Every- Every Every Three Maintena- Maintenance item Tools week month months months nce item (8h) (50h) (200h) (600h) (1200h) Remove the eyewinker from √ √ √ the motor shell √ Clean or change bearing IfCarbon brushes, √ √ √ commutator is worn, Motor the spring force is normal...
  • Page 101 √ √ √ √ √ Check radial losse √ √ √ √ √ Check operation condition Check if mounting bolts are √ √ √ loose Steering Check valve block interface gear √ √ √ √ √ with steering leak case valve block √...
  • Page 102 parts √ √ √ √ √ Leakage situation Check oil level, √ √ √ × oil changing. √ √ Brake Pump situation pump √ √ Pump leakage, damage Pump piston cups, one-way valve wear damage, × replace （8）Hydraulic system Every- Every Every Three...
  • Page 103 Chain wheel deformation, √ √ √ damage If Bearings of chain wheel √ √ √ loosen Check whether in normal √ √ √ Attachment state Whether Piston rod, piston rod thread and the √ √ √ √ √ connection is loose, deformation, damage Lifting and √...

  • Page 104: Regular Replacement Of Key Safety Parts

    Indicator √ √ √ √ √ light for Work and installations steering √ √ √ √ √ Horn Work and installations Lamps and √ √ √ √ √ Work and installations bulbs Reversing √ √ √ √ √ Work and installations Buzzer √...

  • Page 105: Ⅴ、Area Lubricated And Lubricant Recommended

    Ⅴ、Area lubricated and lubricant recommended 1. Area lubricated ○：Change FO： Hydraulic oil ◎：reinforce GO： Gear oil □：Check and adjust CG： Grease BO： Brake fluid W： Distilled water □◎ Lifting chain ◎ Direction pipe column ◎ Tilt cylinder pin □◎ Battery ◎...
  • Page 106 Maintenance record Date Maintenance content Noter...
  • Page 107 FE4P40N FE4P45N FE4P50N NOBLELIFT INTELLIGENT EQUIPMENT CO.,LTD. Service hotline：4008-836115 Wechat：nuolijixie Postcode：313100 Email address: info@noblelift.com Website：www.noblelift.com Version：Jan,2019...

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