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Service & Maintenance Manual PS 12 16 18TSL 03/2019 PS XXN-SMS-001-CHN Version 02/2021...
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Foreword Proper operation, maintenance, trouble shooting and repair are necessary for long-term use of the vehicle while ensuring that the vehicle does not break down again. The purpose of this service manual is to provide the necessary information especially for inspection, repair and maintenance. The main material of this car is steel, which can be completely recycled.
1.GENERAL 1.1 Introductions – Maintenance safety precautions Maintenance work may cause injuries. Always take care to perform work safe, at least observing the following. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves, others or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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Battery should always be disconnected during replacement of electrical components. Always use the grades of grease and oil recommended by NOBLELIFT choose the viscosity specified for the ambient temperature. Exhaust gas is dangerous provide ventilation when working in a closed space.
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When changing the oil or fitter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials. Always use NOBLELIFT genuine parts for replacement. ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS. ...
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Conv Non–SI Conv Unit Factor APPROXIMATE CONVERSIONS Unit Factor Unit Torque Newton meter (N·m) × 8.9 = ln·in × 0.113 = N·m Newton meter (N·m) × 0.74 = lb·ft. × 1.36 = N·m Newton meter (N·m) × 0.102 = kg·m ×...
2.2Main technical data Type sheet for industrial truck acc. to VDI 2198 Manufacturer`s type designation (PS12TSL3600) (PS16TSL4600) (PS18TSL4600) Power (battery ,diesel, petrol, Battery gas, manual) Operator type Pedestrian Load Capacity / rated load Q(t) Load centre distance C(mm) Load distance ,centre of drive x(mm) axle to fork 1331...
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Wheels, number 1x+2/4 front/rear(x=driven wheels) b10(mm) Track, front h1(mm) Lowered mast height 2308 2108 2228 Free Lift height h2(mm) 1760 1520 1520 Lift height h3(mm) 3560 4530 4530 h4(mm) Extended mast height 4088 5088 5208 Height of tiller in drive position h14(mm) 890/1420 min./ max.
4. The Storage Battery Power supply • Only professionals are allowed to repair or charge the battery. Be sure to follow this manual and the battery manufacturer's instructions • The batteries used are lead-acid batteries • Battery recycling is subject to national regulations. Please comply with these regulations •...
•The weight of the battery has a certain impact on the vehicle's operating behavior. Please consider the maximum operating temperature of the battery. 4.1 Battery replacement Park the vehicle safely, close the stacker with the key (8) and press the emergency stop switch (6). Open the lid of the battery case, remove the hinge, and remove the lid.
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2. Unplug the battery 3. Use a tool to connect here, such as a hook, and then remove the battery Side-shift 1. Open the lid of the battery case 2. Unplug the power plug 3. Unscrew the bolt with the 5mm inner hexagon 4.
5. Take out the battery according to the direction indicated by the arrow, and the installation process is the reverse process of disassembly. 4.2 Maintenance of batteries (lead-acid batteries) 1. Cause of water supply of battery The battery recharge is due to the electrolytic effect of the battery at the later charging stage, which makes the moisture part of the electrolyte electrolyze.
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1.Unplug battery switch 2.Uncap plate bus-bar 3. Electrolyte lever is lower than bus-bar, then add 4. Can’t see the bus-bar for some models distill water Liquid lever is 10mm lower than plate, then add distill water...
Max lever Standard lever 5.Use a plastic funnel to add water. 6. add-water lever 4.3 Battery display The discharge condition is represented by 10 black block display segments. 图.13: 电池电量显示器 Only when the battery is fully charged correctly, the LED10 grid black block on the far right is all displayed. As the battery's charge status drops, the power display block lights decrease in turn, but only one at a time.
5. The Charger 5.1 an overview of the charger This charger is suitable for charging common lead-acid batteries on various electric vehicles such as electric pallet truck, electric moving truck, electric forklift truck, electric lift truck, electric tour bus, etc. 5.2 Main technical data Type CBZ3F...
5.3 charging • Charge only with the included charger • Please fully understand the contents of the charger instruction manual before using the charger • Please comply with these rules • The charging room must be well ventilated. • Full charging can only be viewed from the discharge display. To control this situation, interrupt the charging process and start the vehicle Park the vehicle in a special secure area with dedicated power supply.
7.Meter Display Assembly Item Description Qty. Note. ZAPI F04264-MDI CAN Electricity meter Universal key switch LKS-101A DC power switch ZDK32-350 8. Replace electrical parts Power must be disconnected before replacing electrical parts Note: Lower the fork to the bottom before servicing, then turn off the key switch and disconnect the power.
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1.Remove the bolts shown below with an inner 6mm 2. Disconnect the power supply of the vehicle, i.e. hexagon wrench. unplug the battery connection port in the picture below. 3. Unscrew the four screws with the 6mm inner 4. Unplug three plugs hexagon wrench, and cut off the binding belt of the surrounding wiring harness 5.
emergency stop switch box with a 14mm wrench, and then remove the wiring 8.1 Replace the electric meter 1. Unscrew the two fixed nuts of the meter by hand 2. Remove metal ring 3. Replace the electric meter...
8.2 Replace the emergency button 1. Unscrew the two screws of the emergency button 2. Remove the screw and then remove the with a cross screwdriver mushroom head 3. Unscrew the screw with a cross screwdriver Separate the integrated blade panel from the instrument fixing plate 5.
7. Press the buckle on both sides of the micro switch by hand to unplug the micro switch, the installation process and the reverse process of the above process. 8.3 Replace the universal key switch 1. Use a wrench to unscrew the retaining nut on the 2.
8.4 Replace fuse 1, fuse 2, fuse 01 (refer to 3.1 circuit diagram) 1. Open the fuse box 2. After opening the fuse box, take out the old fuse, replace the new fuse, the installation process and the reverse process of the above process. Fuse Fuse1 Fuse2...
1. Unscrew the nut with a 13mm open wrench, remove the fuse, and replace it with a new fuse, the installation process and the reverse process of the above process. 8.5 Replace the contactor (refer to 3.7 Electronic Control Module 4) 1.
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3 Remove the copper bar 4. Unscrew the bolt with a 13mm open end wrench 5. Remove the copper bar 6. Unscrew the two screws with a cross screwdriver...
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7. Remove the contactor with mounting frame 8. Unscrew two screws with a screwdriver. 9. Remove the mounting frame, and the contactor can be replaced. The installation process is the reverse process of disassembly...
8.6 Replace the electric control 1. Remove the wiring on the electronic control in turn, pull out the connector, and note down the different ports corresponding to different wiring 2. Unscrew the five screws V, U, W, -P and -B with a 10mm open wrench, and remove the wiring in turn...
3. Unscrew four controller fixing screws with a cross screwdriver, that is, remove the controller, the installation process is the reverse process of disassembly 8.7 Replace the relay 1. Unscrew the setting screw with a cross screwdriver...
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2. Remove the relay and pull out the wiring 3. Relays can be replaced, and the installation process is the reverse process of disassembly...
8.8 Replace micro switch 1. 1. Unscrew the bolt with a cross screwdriver and remove the micro switch. 2. Remove shell with 2mm inner hexagon 3. Remove the wiring with a cross screwdriver and it can be replaced...
8.9 Replace the magnetic switch 2. Unplug the wire harness connector at the other end of the magnetic switch, and cut the tie that binds the wire harness, that is, remove the magnetic switch and replace it. 8.10 Replace wiring harness Pay attention to the corresponding position of each plug when replacing, and do not insert it wrong when installing.
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2. Unplug and remember the line number 3. Unscrew the screw with 13mm wrench, unplug the plug, and write down the line number 4. Unplug the plug and write down the line number. The position of the line number is shown in the table on...
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the right 5. Unscrew the relay with a cross screwdriver, unplug the plug, 5-3- 9-7- 5-3-1 6. Remember the plug corresponding to each line number, as shown in the picture on the right.
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7. Unplug the two plugs on the speaker and write down the line number 8. Unscrew the screw with 13mm wrench, remove the wiring, and write down the wiring number 9. Unscrew the screws with a 13mm wrench, remove the wiring, and write down the wiring number.
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10. Unplug all plugs on the right side, which are one-to-one corresponding. 11. Remove the instrument panel by unscrewing the four screws with a 6mm inner hexagon wrench.
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12. Unplug the plug one by one and write down the line number 13. Unplug each plug in turn. This plug is one-to-one 14. Unscrew the wire harness holder with a 14mm corresponding cross screwdriver...
15. The wiring harness can be removed and replaced 9. Hydraulic system The hydraulic circuit 9.1 Replace the pump station The pallet rack must be lowered before replacement to allow the hydraulic oil in the tubing to return to the hydraulic tank of the pump station. 1.
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2. Remove the hydraulic tubing with 22m and 22mm 3. Unplug the connector by hand open end wrenches. Note: hydraulic oil will leak out when removing the tubing. It is recommended to put back yarn or rag on the pad when removing the tubing.
9.2 Replace hydraulic oil 1. Take out the oil pump, unscrew the cap of the oil tank, waste oil can be poured out, then the oil tank can be installed to the car, the installation process is the reverse process of disassembly. 3.
Check and refill the hydraulic fluid The type of hydraulic oil required is: • H-LP 46, DIN 51524 • Viscosity is 41.4 -- 47 • According to the model, the amount of oil is 6.0~9.5L Waste materials such as waste oil, batteries or other materials must be treated and recycled according to national regulations, and if necessary, sent to the recycling company for recycling.
3. Unscrew the screw with a cross screwdriver, then take out the carbon brush and replace it. The installation process is the reverse of the above process. 9.5 Adjust oil pump pressure 1. Unscrew the horn fixing bolt and remove the horn 2.
3. Adjust the pressure of the oil pump with a 6 mm 4. Tighten bolts with a 24 mm hexagon socket inner hexagon wrench wrench 9.6 Replace the outer oil cylinder The outer cylinder on the right 1. Remove the oil pipes at the lifting cylinder on both sides with 19mm open spanner. Note: hydraulic oil will leak out when removing the oil pipes.
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2. Use a 12mm wrench to remove both sides of the 3. Remove the bolt at the top of the oil cylinder by the return tubing 12mm inner hexagon 4. Using the 6mm inner hexagon screw down the 5. Remove the fixing bolt of the cylinder base with a cylinder pressure plate fixing bolt 12mm inner hexagon wrench.
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6. Remove the oil cylinder, and the installation process is the reverse of the above process The outer cylinder on the left 1. Remove the oil pipe at the bottom of the cylinder 2. Remove the top oil pipe of the cylinder with a with a 22mm open spanner 22mm open end wrench...
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3. Remove the two bolts fixed between the top of the 4. Remove the four bolts on the press plate of the left left and right oil cylinders and the door frame with the and right oil cylinders with the 6mm inner hexagon 12mm inner hexagon 5.
9.7 Replace the middle oil cylinder 1. Knock down the spring clamp with the punch and remove the protection plate 2. Unscrew the oil pipe at the bottom of the middle oil 3. Remove split pin cylinder with a 22mm open spanner...
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4. Remove the pin shaft and remove the chain 5. Unscrew the hoop bolt with a 13mm open wrench and take the hoop...
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6. Remove the middle oil cylinder 7. Remove the snap with the snap pliers 8. Remove sprocket shaft...
9. Remove the side cover with 12mm inner hexagon wrench, and then remove all parts for replacement and maintenance. The installation process is the reverse process of disassembly. 9.8 Replace the sealing ring of the outer oil cylinder (outer cylinder on the right) 1.
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2. Remove the new o-ring with a small screwdriver 3. Use a screwdriver to remove the dust ring 4.Take out sealing ring used for shaft 5. Take out the Stepseal, the oil cylinder head sealing ring can be disassembled and replaced The left cylinder...
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1. Unscrew the oil cylinder head with a crescent 2. Pull out the piston rod. wrench. 3. Remove the piston with pipe tongs. Heat the connection between the piston and the piston rod before using the pipe tongs because there is threaded glue inside.
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4. Remove oil cylinder cap 5. Use a small screwdriver to take out the new O-ring, 6.Take out the dust ring with a screwdriver 7. Take out the the sealing ring used for shaft 8. Take out the stepseal, the cylinder head sealing ring can be disassembled and replaced...
9.9 Replace the sealing ring of the middle cylinder 1. Remove the oil cylinder head with pipe tongs after removing the middle oil cylinder according to instruction 9.6. 2. Pull out the piston rod and remove the shaft at the bottom of the piston rod with the support ring...
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3. Use a small word screwdriver to take out the dust ring, retaining ring and Y-type sealing ring in the cylinder head.
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4. Remove the O-ring and retaining ring on the cylinder head to repair the entire tubing. The installation process is the reverse process of disassembly.
10.1 Replace PCB motherboard 1. Unscrew the outer cover screw with 6mm inner 2. After unscrewing the screw, carefully open the hexagon wrench handle housing and unplug the connecting plug 3. Unscrew the screw fixing the drive switch with a 4.
5.Remove the retaining screw with a Phillips head 6. Remove the old PCB board and unplug the plug in screwdriver turn. The installation process is the reverse process of the above process. 10.2 Replace air spring (refer to handle assembly drawing) 1.
4. Remove gas spring 10.2.1 Mounting air spring 1. Put the gas spring into the handle and tighten the 2. Use the iron rod to Jack up the air spring and upper bolt tighten the bolt to the bolt hole...
10.3 Replace the interlock switch 1. Unscrew the bolt with 2mm inner hexagon wrench 2. Use a 6mm hexagon socket wrench to unscrew the housing 3. Open the handle housing 4.Unplug the connector (pay attention to the harness number)
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5. Remove the entire switch 6. Unscrew the screw with a cross screwdriver 7. The interlock switch can be replaced...
11. Driving wheel 11.1 Replace the small wheel 1. Place the jack on the side of the drive wheel to lift the 2. Rotate the handle to this position body. 3. Unscrew 5 fixing bolts with 17mm socket wrench through the repair hole on the car body. Due to the small area of the hole, before each screw is unscrewed, it is necessary to control the driving wheel rotation through the handle and align the bolt that needs to be unscrewed with the maintenance hole so that the socket wrench can unscrew the bolt.
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4. Remove the wheel by unscrewing five retaining bolts. 5. Take out the driving wheel from the bottom and replace it. The installation process is the reverse process of disassembly.
11.2 Replace lubricating oil in drive wheel gearbox 1.There is an oil injection hole on the front of the 2. There is an oil drain hole at the bottom of the driving wheel driving wheel. 3. Raise the car to a certain height with a jack 4.
5. Use a 7 mm hexagon socket wrench to unscrew the 6. Lubricating oil through tubing. The lubricant used is oil hole bolts 85W/90 GL-5 heavy duty vehicle gear oil. 11.3 Replace the sensor 1. Unscrew the fixing bolt with 4mm inner hexagon wrench...
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2. Unplug the sensor 3. Take out the connecting plug from the cable mounting frame. 5. Separate the plug, 6. Use diagonal pliers to cut the tie that binds the wire harness.
7. Remove the sensor and it can be replaced. The installation process is the reverse process of disassembly 11.4 Braking part 1. Two bolts are screwed into the bolt hole of the brake with a 4mm hexagon wrench. The size of the bolt is M6 ×...
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2. Unscrew the 3 bolts of installing the brake with 4mm inner hexagon wrench 3. Unplug the plug and cut the tie...
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4. Take out the brake, and the installation process is the reverse process of disassembly. Brake clearance adjustment: use 4mm hexagonal wrench to twist the three screws, use the feeler to measure the brake clearance, control at 0.3mm. The three bolt fixing points need to be measured one by one by a feeler to ensure that the clearance is 0.3mm.
2. Punch the axle out 3. When the axle is removed, the axle and other components of the wheel group can be replaced. The installation process is the reverse process of disassembly 12.2 Maintenance steering group 1. Remove the clamp spring with clamp pliers...
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2. Remove the wheel frame with punch 3. Take out the clamping spring at the bottom of the 4. Take out both axles with punch. bearing seat with clamping spring pliers. 5. Take out the axle, sleeve, clamp spring and other parts, can be replaced and maintained, the installation process is the reverse process of disassembly.
13.1 Replace the bearing wheel 1. First lift the tray rack to a certain height 2.Jack the car to a certain height 3. Place the body on the repair rack and remove the 4. Remove the axle and remove the entire component. elastic cylindrical pin with a punch.
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5.Take out the elastic pin with punch 6. Take out the axle and the wheel 7. Take out the two bearings with the punch and then repair and replace them. The installation process is the reverse process of disassembly.
14. The chain 14.1 Replace the chain 1. Lift the tray rack and pad it with wood, so that the chain can reach the state of no stress 2. Remove the cotter pin from the top of the chain 3. Remove pin shaft...
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4. Take out the split pin at the bottom of the chain 5. Take out the pin shaft 5. Remove the chain and replace it. The installation process is the reverse process of disassembly...
14.2 maintain the chain 1. In the long-term use of products, there will be a loose chain phenomenon, we need to use two 24mm open-ended spanner to tighten the chain bolt, so that the pallet in the lowest position of the chain is still stressed.
15.Mast System 15.1 Remove the mast 1. Remove split pin 2. Pull out the latch 3. Unscrew the fixing bolt at the top of the oil cylinder 4. Raise the door frame. with a 12mm inner hexagon wrench...
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5. Raise the tray rack 6. Lower tray rack 7. Raise the maste and remove the tray frame.
15.2 Replace the roller The whole mast system has the same roller, which will be damaged in the process of use and needs to be replaced. 1. Remove the snap spring with the snap pliers 2. Remove the gasket 3. Remove the roller...
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4. Use the punch to remove the roller so that it can be replaced 15.3 adjustable roller In the use process, the gap between the portal frame and the portal frame will become larger and need to be adjusted. 1. Open the locating pin...
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2. With a word screwdriver screw bolts to adjust, also desirable bolt, for replacement.
17.Maintenance list Maintenance list Intervals(Month) Hydraulic system Check hydraulic cylinder if there is noise and leakage of piston Check hydraulic connectors and tubing if there is damage and leakage Check hydraulic oil level and recharge if necessary Add hydraulic oil after 12 months or 1500 hours of work ...
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Check if main cable is damage Check startup protection procedures during charging Function Check Horn Check electromagnetic valve Check emergency brake Check reverse braking and regenerated braking Check belly button Check steering Check Lift up and down ...
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Check and finally fill with hydraulic Hydraulic oil level is too low fluid Check the sealing of tubing and The spill cylinder The height limiting micro switch is wrong Check and repair the microswitch Check and verify that the port is Controller driver port is damaged working and replace the controller Check whether the rise button on...
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Inspect and replace the heat The thermal sensor is out of order sensor if necessary Check and verify the controller Controller parameters do not match parameters Check and finally replace the Interlock switch damaged interlock switch Check and eventually replace the Main contactor damaged main contactor The stacker's electric meter...