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Noblelift PS E12B Service Maintenance Manual

Electric pallet truck
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Service & Maintenance Manual
Electric Pallet Truck
PSL-type Stacker（PS E12B / PS E12N）
WARNING
Do not use the pallet truck before reading and
understanding these operating instructions.
NOTE:
 Please check the designation of your present
type at the last page of this document as well
as on the ID-plate.
 Keep for future reference.
1

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Summary of Contents for Noblelift PS E12B

  • Page 1 Service & Maintenance Manual Electric Pallet Truck PSL-type Stacker（PS E12B / PS E12N） WARNING Do not use the pallet truck before reading and understanding these operating instructions. NOTE:  Please check the designation of your present type at the last page of this document as well as on the ID-plate.

  • Page 2: Table Of Contents

    Content 1-1 How to use this manual ............................5 1-1-1 Build this manual ............................5 1-1-2 Warning label definition ..........................5 1-2 vocabulary ................................7 1-3 Appearance and specifications ..........................11 1-4 Safety notice ................................14 1-5 maintenance ................................17 1-6 lubricating oil .................................
  • Page 3 2-7-2 Vehicle fault reading process ........................42 2-7-3 Vehicle signal detection ........................... 43 2-7-4 CURTIS Handheld unit menu content ......................43 2-8 Troubleshooting for each fault code ........................49 3 Drive/brake system ..............................52 3-1 Overview ................................52 3-1-1 Component ..............................52 3-2 Drive assembly ...............................
  • Page 4 6 steering system ................................. 71 6-1 Overview ................................71 6-1-1 appearance ..............................71 6-1-2 How does this work ............................ 71 7 Schematic diagram ..............................73 7-1 Hydraulic schematic ............................... 73 7-2 Electrical schematic ............................... 74 8 Charger ..................................76 8-1 Lithium battery charger ............................76 8-1-1 Lithium battery charger introduction ......................

  • Page 5: How To Use This Manual

    1-1 How to use this manual 1-1-1 Build this manual This service manual provides information service engineers and technicians required for vehicle maintenance; it does not contain vehicle operating instructions. The introductory part of this manual provides an overview of the functions of the vehicle, with particular attention to its different components.

  • Page 7: Vocabulary

    1-2 vocabulary The following are the terms and descriptions used in this service manual Item Descriptions Accelerator A device that converts mechanical motion to an analog voltage mode and transmit to a controller to control the speed at which a vehicle is driven Actuator A device (e.g.
  • Page 8 Digital Signal A signal in which the element can be either of two different values, e.g. high voltage and low voltage. Diode A semiconductor device that allows current to flow from the anode to the cathode in one direction Directional Valve A valve that directs the flow of oil according to the position of the valve element.
  • Page 9 Needle Valve A valve to lower the backstay manually when the lifting lever is not available. Normal State A term used with switches or relays. Their "normal state" means that they are not under any control of stress,temperature, pressure or electricity.
  • Page 10 Magnetic Valve A directional valve that moves the valve element when the magnetic coil is equipped with a magnetic valve. Solid State A term that refers to semiconductor components or circuits that wired without moving parts, e.g. diodes and transistors. Stator a fixing part in the motor Steering Shaft...

  • Page 11: Appearance And Specifications

    1-3 Appearance and specifications...
  • Page 12 Type sheet for industrial truck acc. to VDI 2198 PS E12N Manufacturer`s type designation 3600 Power (battery ,diesel, petrol, gas, Battery manual) Operator type Pedestrian Load Capacity / rated load Q(t) Load centre distance c(mm) Load distance ,centre of drive axle x(mm) to fork Wheelbase...
  • Page 13 Max. gradeability, laden/ unladen 5 / 10 Electromagnetic 5.10 Service brake Drive motor rating S2 60min 0.65 Lift motor rating at S3 7.5% Battery acc. to DIN 43531/35/36 A, B, C, no Battery voltage, nominal capacity V/Ah 24 / 60 Battery weight Energy consumption acc: to VDI Kwh/h...

  • Page 14: Safety Notice

    1-4 Safety notice The safety section includes the following subsections: general, personal safety, maintenance safety, compressed air hazards, hydraulic oil hazards, mechanical hazards, electrical hazards, and fire and burn hazards. Under each heading are listed the precautions you should take to ensure that you stay safe while working on the vehicle.
  • Page 15 Maintain safety Pre-maintenance Ensure that the vehicle is in a clean, open environment and not affected by traffic and other people. Ensure that the vehicle is parked safely and that the vehicle does not move suddenly. Place wooden props in front of and behind the wheels and make sure the parking brake is properly engaged.
  • Page 16 Hydraulic oil hazards Please carefully follow the instructions below to carry out safety tips on hydraulic system maintenance. De-oiling under pressure, even if the pinhole size leaks, it can penetrate body tissues, causing serious injury and possibly death. Wear gloves, goggles, and make sure your arms and legs are completely covered.

  • Page 17: Maintenance

    unauthorized personnel. Store all oily wipes or other flammable materials in a protective container in a safe place. Do not weld or flame cut pipes or pipes that contain flammable fuel. Before welding or flame cutting, clean them thoroughly with a non-flammable solvent. Remove all residual flammable materials from the vehicle。...
  • Page 18 Check the hydraulic system for oil leakage and damage. Check whether the drive is leaking. Door frame Lubricate the beam where the rollers are located。 Tires Check the tires for wear, cuts, grooves and contamination。 Check every 500 service hours or 3 months item Inspection standards and methods Crosshead roller...

  • Page 19: Lubricating Oil

    1-6 lubricating oil The following is a detailed description of the required lubricant and the parts to be lubricated. 1-6-1 Lubricant specifications The following lubricants are recommended for chains and connecting rods： item specification DIN 51825 Standard grease 1-6-2 Hydraulic oil（HYDO） The hydraulic oil should have anti-wear, anti-foam, anti-rust and anti-oxidant additives for heavy-duty use as stated by the petroleum supplier.
  • Page 20 To prevent malfunction, please record the malfunction and the parts required for replacement. Also make sure to check and record the following information： Vehicle model, serial number and business hours The reason why the vehicle needs to be disassembled Check the symptom, location and cause of the malfunction. (If necessary, reproduce the same failure).
  • Page 21 Precautions after disassembly clean Clean the disassembled parts and keep them away from contaminants. Pay special attention to removing contaminants from the oil pipeline or component pipeline. When cleaning special parts, increase the number of detergent containers and clean them several times.
  • Page 22 Check during assembly In each step of the assembly process, check and record each part number。 Reassemble the gasket Install gaskets and washers in the same positions as before, and then check if the gap is correct。 Assembly adjustment link If there is no need to adjust, please assemble them to the same length as before。...
  • Page 23 Remember to check the condition of the O-ring. Do not use O-rings that have hardened. Only use the O-ring specified in the parts list. For example, O-rings used for engine oil are made of special materials, such as silicone rubber, and are resistant to heat and aging. In this case, installing different types of O-rings may cause serious damage to the system and its components.
  • Page 24 1. Seal the lock nut (3), support washer (4) and O-ringPlace the piece (5) as far as possible on the main body (2) of the accessory. 2. Turn the joint to the part it uses until the support washer (4)Just touched the surface of the part. 3.

  • Page 25: Standard Torque

    1-8 Standard torque 1-8-1 Standard torque of bolts and nuts Be careful to avoid mixing metric and imperial size fasteners. Mismatch or incorrect The fasteners may cause vehicle damage or malfunction, or may cause personal injury. If necessary, exceptions to these torques can be given in the service manual. Before installing any hardware, make sure that the components are in a near new state.
  • Page 26 For metric fasten...

  • Page 27: Standard Torque For Fastening Accessories

    1-8-2 Standard torque for fastening accessories...

  • Page 29: Electronic System

    Thread fittings for air conditioning and conical pipes 2 electronic system 2-1 Overview This model is equipped with an electrical system consisting of the following components: 1 The battery powers the electrical system. 2 Press the power switch in an emergency to turn off all DC and AC circuits. 3 Motors, controllers and related equipment provide the necessary drive and pump power for the vehicle based on their interaction with sensors, switches, relays and actuators and many parameter settings.

  • Page 30: Communication Protocol

    2-1-1 Communication protocol In order to enable all electrical equipment of the vehicle and provide users with diagnostic and parameter calibration functions, data needs to be shared between these controllers and instruments. For this, CAN (Controller Area Network) is used as the standard protocol. Note: For information on how to install the app to check the condition of the vehicle and perform parameter calibration via CAN communication, please refer to section 2-7.

  • Page 31: Lithium Battery

    2-2 lithium battery 2-2-1 Appearance and specifications ITEM parameter Remarks Specification 24V60Ah 8-LFP-60-EV-NOB Nominal voltage 25.6V Rated Capacity 60Ah 0.5C Discharge reference weight approximately 16.5kg Discharge Maximum continuous discharge 100A current Maximum pulse discharge current 150A No more than 10 seconds Discharge cut-off voltage ≥22V Discharge...

  • Page 32: Analysis And Explanation Of Lithium Battery Fault

    Charge control CAN bus control 2-2-2 Analysis and explanation of lithium battery fault Battery pack system fault repair table Number fault types preliminary Detection method Failure to confirm The measures judgment 1. When the resistance is infinite, it indicates that CAN communication 1, check the monitor wiring harness is...
  • Page 33 light is not voltage is total voltage of the system insufficient is normal; 2. Use the multimeter conducting file to measure Wire harness failed whether the two wiring when both ends of Replace the harnesses of the panel wire harness failed to battery communication wire conduct properly...

  • Page 34: Removal And Installation Of Lithium Battery

    2-2-3 Removal and installation of lithium battery Preliminary steps 1 Park the vehicle safely and remove the cover。 2 Turn off the key switch。 Program 1 Remove screw (9) and remove battery mounting plate (7) 2 Disconnect the battery control cable 3 Remove the positive and negative screws of the battery and remove the battery power cord。...
  • Page 35 pause point locked. When pulling up, there is also a reliable sense of suction。 B) Electrical properties Put the digital multimeter in on-off gear, and connect the two meter pens on the metal terminals on both sides of the emergency stop switch. When the emergency stop switch is not pressed down, the multimeter buzzer will call (that is, it is in the on-off state).

  • Page 36: Controller And Associated Equipment

    2-4 Controller and associated equipment 2-4-1 appearance Logical part plug-in：14 core Molex Mini-Fit Jr., P/N 39-01-2140 Electromagnetic brake plug：2 core Molex Mini-Fit Jr., P/N 39-01-2020； Handheld programming port plug-in：4 core Molex Mini-Fit Jr., P/N 39-01-2040； Power part plug-in：AMP The plug-in, P/N 12076SL02 2-4-2 Features The controller is connected through the following sensors, switches, relays and actuators.

  • Page 37: Test

    3、The maximum travel speed can be adjusted. Reasonable setting of the maximum travel speed of electric vehicles can prevent the traction motor from overloading due to excessive vehicle speed。 4、Safety protection function. If the power element of the controller is damaged during the operation of the vehicle, the controller will disconnect the main contactor in the shortest time;...

  • Page 38: Removal And Installation

    Multimeter terminal Normal range ITEM Red test lead Black test lead Polar value determination Resistance measurement 40KΩ 以上 80KΩ 以上 80KΩ 以上 60KΩ 以上 0.3-0.6V 0.3-0.6V Pull the multimeter to the Ω position (determination of resistance value) Pull the multimeter to the diode position (determination of polarity value) 2-4-4 Removal and installation Access control panel...

  • Page 39: Horn

    150A FU01 FU02 1.5A A. Remove and install Preliminary steps 1.Remove the shell to get inside the vehicle 2.Close the key switch and emergency stop switch. 3.Disconnect the battery connector. program 1 Open the fuse cover to take out the fuse (FU01). 2 Remove bolts and washers, then remove fuses (FU1 and FU2) 3.

  • Page 40: Handle The Head

    2-6 Handle the head 2-6-1 appearance 2-6-2 function Handle head through up and down button, belly switch, turtle speed button, Accelerators and combination locks fight with controllers to control some of the vehicle's actions。 A Combination lock（18） A Up and down（28,29） B Belly switch（16）...

  • Page 41: Removal And Installation

    2-6-4 Removal and installation Preliminary steps 1 Remove the shell to access the vehicle interior 2 Turn off the key switch and emergency stop switch. program 1.Remove the fixing screw of the lower cover of the handle and disconnect the cable to remove the lower cover of the handle (25) 2 Remove the handle upper cover fixing screw to remove the handle upper cover (24) Perform the above steps in reverse order to install the handle head assembly (26).

  • Page 42: Curtis Handheld Programmer

    1 Safe parking。 2 Close the key switch and emergency stop switch。 Program 1 Press down the handle to disconnect the proximity switch from the handle harness。 2.Remove the fixing screw (10) at the lower end of the air spring. 3.Remove pin retainer (8) and pin shaft (9) to remove handle Follow the steps above to install handles in reverse order.

  • Page 43: Vehicle Signal Detection

    2-7-3 Vehicle signal detection After connecting the handheld unit to the controller, turn on the key switch According to the menu list of the CURTIS handheld unit, find: Monitor... If necessary, open the corresponding sub-item of the detection menu, run the vehicle, and observe the change of the handheld value。...
  • Page 44 1 Power on the programmer Insert the cable of the handheld programmer into the programming port of the controller to connect to the controller. After connecting to the controller, the handheld programmer will automatically power on and display the control information on the programmer。...
  • Page 45 Function keys Since the functions of these three buttons are determined according to the specified content, these three buttons are blank. At any specific time, the function of the button will be displayed on the upper LCD screen. Arrow keys The displayed information can be selected up, down, left, and right through the 4 direction buttons.。...
  • Page 46 displayed at the top of the screen。 Nine menus 3 Fault diagnosis menu In the main menu, select the "Diagnostics" fault diagnosis icon and press the corresponding function key of Select to enter the fault diagnosis menu. The fault diagnosis menu includes 2 folders: "Present Errors"...
  • Page 47 "Clear All" is used to clear the historical fault folder. A function key will only be highlighted when there is a historical fault in the historical fault folder, and will be grayed out when there is no historical fault. 4 Programming edit menu In the main menu, select the "Programming"...
  • Page 48 other enter parameter editing page, figure below...

  • Page 49: Troubleshooting For Each Fault Code

    2-8 Troubleshooting for each fault code Fault code measures Fault Fault name cause of issue Source of failure code LOW_BDI low power 1212C-2503 Controller The lifting or lowering switch acts PUMP_SRO_FAULT 1212C-2503 Controller before the key switch The operation sequence of SRO_FAULT direction, interlock and key switch is 1212C-2503 Controller...
  • Page 50 CONTROLLER_OVERTEMP_CUTBACK Controller over temperature cut off 1212C-2503 Controller Electronically controlled low CONTROLLER_UNDERTEMP 1212C-2503 Controller temperature Severe electric control over CONTROLLER_SEVERE_OVERTEMP 1212C-2503 Controller temperature OVERVOLTAGE_CUTBACK Overvoltage cut off 1212C-2503 Controller SEVERE_OVERVOLTAGE Severe overpressure 1212C-2503 Controller UNDERVOLTAGE_CUTBACK Low pressure cut off 1212C-2503 Controller SEVERE_UNDERVOLTAGE Severe low pressure 1212C-2503 Controller...
  • Page 51 Under Voltage Battery voltage is too low Over Current Battery overcurrent Over Temperature Protect The battery temperature is too high Temperature Protect Battery temperature is too high...

  • Page 52: Drive/Brake System

    3 Drive/brake system 3-1 Overview 3-1-1 Component The drive/brake system includes the following: 1 The drive motor controlled by the controller transmits the rotational force to the drive shaft (electricity  mechanical power). 2 The drive shaft converts the rotational force transmitted from the drive motor into torque and speed suitable for driving through its gear set, and sends them to the corresponding wheels (mechanical power).
  • Page 53 2. Move the handle to the operating area. 3 determine the driving direction, 4 Twist the accelerator on the handle Removal/assembly of drive assembly Preliminary steps 1．Safely park the vehicle and remove the shell 2. Close key and emergency stop switch. 3.

  • Page 54: Drive Motor Disassembly/Assembly And Test

    3-2-3 Drive motor disassembly/assembly and test Disassembly/assembly 1. Remove the fixing screw of the electromagnetic brake and remove the electromagnetic brake (3) 2 Remove the electromagnetic brake gear. 3. Remove the drive housing screw and remove the housing. 4. Loosen and exit the motor fixing screw. 5.

  • Page 55: Drive Wheel Removal/Installation

    3-2-4 Drive wheel removal/installation Preliminary steps 1. Safely park the vehicle and remove the shell 2. Close key and emergency stop switch. 3. Disconnect the battery connector. program 1. Use the crane to lift the vehicle safely. 2. Disconnect the connection line of the drive motor. 3.

  • Page 56: Removal/Installation Of Electromagnetic Brake

    3-3-4 Removal/installation of electromagnetic brake Preliminary steps 1 Park the vehicle safely and remove the shell 2 Turn off the key and emergency stop switch. 3 Disconnect the battery connector. program 1 Use a hoist to lift the vehicle safely. 2 Disconnect the connecting wire of the electromagnetic brake.
  • Page 57 Neither traction hydraulics will last The vehicle has too small a battery： throughout the normal operating period Battery is not fully charged during battery charging: Check that the battery is charged Check the battery charger for faults. The battery replacement interval is too long or the battery cooling time is too short.

  • Page 58: Driving Box

    Systems. If the drive motor fails, test the motor assembly 3-4-2 Driving box The problem Probable cause Noise or vibration in the gearbox No lubricating oil: Meet the correct amount of lubricant Use non-standard oils: Replace oil with standard oil. Gear damaged or dented: Replace gear。...

  • Page 59: The Hydraulic System

    4 The hydraulic system 4-1 overview The hydraulic system is composed of working oil pump, lifting cylinder and pipeline. Hydraulic oil is supplied by a pump directly connected to the motor. The pump sends the hydraulic pump to the cylinder。 4-1-1 component The hydraulic system uses pressurized hydraulic oil from the main hydraulic pump to operate the lifting cylinders and draw out the oil discharged from these cylinders.

  • Page 60: Pump Station Assembly

    4-2 Pump station assembly 4-2-1 Appearance and specifications item specification power 0.8KW speed 1618rpm frequency 55.5hz Insulation level 4-2-2 test The pump motor transmits power to the main hydraulic pump electrically to pump hydraulic oil to operate the hydraulic system. The pump motor is connected to the controller through a motor contactor.

  • Page 61: Removal/Installation Of Pump Motor And Hydraulic Pump

    Pump motor contactor detection: For the pump motor contactor, according to the figure, And check if it measures the specified value. 4-2-3 Removal/installation of pump motor and hydraulic pump Note: When assembling and disassembling the hydraulic pump, do not apply any pressure to the motor Program 1.

  • Page 62: Pump Motor Disassembly/Assembly And Testing

    4-2-4 Pump motor disassembly/assembly and testing Disassembly/assembly 1. Disconnect the connection of the pump motor contactor and remove the contactor. 2. Loosen the fixing screws of the pump motor and pump. 3. Remove the motor from the vertical pump station upwards. 4.

  • Page 63: Hydraulic Oil Tank And Filter

    4-3 Hydraulic oil tank and filter 4-3-1 appearance 4-3-2 Replacement of hydraulic fluid and filter Preliminary steps 1. When the fork reaches the top, press the drop button several times to eliminate residual pressure in the hydraulic system 2. Open the case and disconnect the battery. 3.

  • Page 64: Troubleshooting

    4-4 troubleshooting 4-4-1 Pump motor Failure phenomenon possible reason Poor connection or blown fuse. Check the battery connection. Check the key fuse. Check whether the hydraulic pump motor may cause the fuse to blow。 The key switch, upper limit switch, and line contactor are not closed.

  • Page 65: Hydraulic Pump

    4-4-2 Hydraulic pump The fault phenomenon possible reason Oil level is low。 The oil is very thick (too viscous) Pump inlet line is limited。 Pump noise。 Worn parts in the pump. Oil is very dirty。 Air leaked into the inlet line。 Oil level is low。...

  • Page 66: Lifting System

    5 Lifting system 5-1 Overview 5-1-1 Component The lifting system is powered by the main hydraulic pump. Fork: Two fork-shaped objects to support the load  Chain: the part that lifts the bracket and mast Lifting cylinder: single-acting cylinder pulls back the chain of the bracket Mast: the vertical structure at the front of the forklift, which extends and retracts to lift and lower the load...

  • Page 67: Door Frame

    5-2 Door frame 5-2-1 appearance A. Lifting of doorframe The gantry assembly USES two gantries and a single acting oil cylinder to lift the load. Rollers mounted on the inside and outside of the cargo fork and door frame, respectively, facilitate these up/down movements。...

  • Page 68: Pallet Fork

    gantry descends, the tension of the lifting chain relaxes and the fork follows. 5-2-2 Pallet fork A Fork inspection The forks should be inspected at least every 12 months. If the vehicle is used in multiple shifts or heavy operations, it should be inspected every six months. 1.

  • Page 69: Lifting Cylinder

    aligns with the upper pin of the other link, keeping the pointer window on the correct square found in step 2. 5. If the chain is too worn, replace the lifting chain B. Chain tension check 1. Lower the forks to the lowest level. 2.

  • Page 70: Troubleshooting

    5-3 Troubleshooting Failure phenomenon possible reason There is a leak, allowing air to enter the hydraulic system on the inlet side of the hydraulic pump The hydraulic system does The emergency lowering valve is opened manually. not lift the load。 The hydraulic pump is too worn 多...

  • Page 71: Steering System

    6 steering system 6-1 Overview The steering system is a set of devices that steer the vehicle left or right. In this vehicle model, the steering system is mechanically structured and consists of a handle rotation shaft (20) and a drive rotation shaft (6), which are connected by a steel wire chain (7).

  • Page 73: Schematic Diagram

    7 Schematic diagram 7-1 Hydraulic schematic number Codename name number Codename name Hydraulic power unit Throttle valve (motor and oil pump) Check valve Cylinder Solenoid valve Safety valve The overflow valve...

  • Page 74: Electrical Schematic

    7-2 Electrical schematic...
  • Page 75 number Code Name number Code name number name name name Code name pump Height limiting handle motor microswitch Traction button switch controller motor fuse Interlock charger switch battery Lifting wire speed switch horn Turning Electromagnetic reduction brake switch Oil pump Dc power Descending contactor...

  • Page 76: Charger

    8 Charger 8-1 Lithium battery charger 8-1-1 Lithium battery charger introduction WT2425ZMB type charger, this charger is an efficient, fast, small-sized, floor-standing charging device with CAN communication. The charger adopts two-phase AC 220V voltage input and adopts forced air cooling. It has input over-voltage, under-voltage, output over-voltage, under-voltage, over-current, output short-circuit, fan failure protection functions, and meets RoHS and CE requirements 8-1-2 Technical parameters of lithium battery charger...

  • Page 77: Lithium Battery Charger Indicator Light Description

    8-1-3 Lithium battery charger indicator light description Indicator label No-load indication Traffic lights flash alternately Battery indicator Red light flashes one second apart， battery power <80%； yellow light flashes one second apart， battery power >80%； green light flashes one second apart， battery power 100% error indication Overvoltage (flow) fault...

  • Page 78: Lithium Battery Charger Maintenance

    8-1-4 Lithium battery charger maintenance 1. In daily use, pay attention to cleaning the dust on the charger. After charging, put the power cord in place. 2. Pay attention to the use environment of the charger, try to avoid using the charger in harsh environments such as high temperature and high humidity 8-1-5 Troubleshooting Failure phenomenon...

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