Page 1
FE4P25-32C-SMS-001 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. Operation Manual FE4P25-32C series Electric Forklift Truck NOBLELIFT INTELLIGENT EQUIPMENT CO., LTD.
Catalogue Introduction ............................3 Chapter one Attentions when using the forklift truck ................5 1 .Transportation for forklift ......................... 5 2. Deposit ............................... 5 3. Preparation before use ........................5 4. Operation of truck ..........................5 5.The Use of Lithium Battery ......................6 6.The Use of Lead-acid Battery ......................
Page 3
1. Checking point and checking content ................. 69 2. Checking procedure....................... 70 Ⅱ.Check after operation ........................73 Ⅲ.Truck cleaning ..........................73 1. Truck surface cleaning ......................73 2. Chains cleaning ........................73 3. Electric system cleaning ....................... 73 4. After cleaning .......................... 73 Ⅳ.
Introduction This manual briefly describes the technical parameters of the counterbalanced accumulator forklift made by our company, and the structure of its main components, working principle and requirements on operation and maintenance. Please read this manual carefully before operation, so as to achieve proper driving and maintenance, and to ensure safe and effective material handling.
Page 5
Due to continuous product improvement, Noblelift reserves the right to make changes in product designs and specifications without prior notice. For the latest product parameters, please feel free to contact us.
Chapter one Attentions when using the forklift truck The operator mast always keeps 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...
load uniformly distributed on the forks; to prevent load from deviation (7) When the distance between the load’ gravity center and yoke is equal or less than 500mm.The maximum load capacity should be the rated capacity, and when the distance between the load’...
(7) The charging temperature ranges from 0° C to 40° C. Under low temperature conditions below 0° C, charging at high rate may cause damage to the battery. Under low temperature conditions below 0° C, charge the vehicle immediately after use (8) Discharge temperature range: -20 ~ 50°...
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...
2.Technical data 2.1FE4P25C Technical data(list 1-1) Manufacturer's type designation FE4P25C Drive:electric electric Type of operation seated Load capacity/rated load lb(kg) 5000(2270) Load centre distance in(mm) 24(600) Load distance,centre of drive axle to fork in(mm) 17.3(440) wheelbase in(mm) 51(1295) 405(4350) Service weight incl. battery(see line 6.5)
Page 11
2.2 FE4P32C Technical data(list 1-2) Manufacturer's type designation FE4P32C Drive:electric electric Type of operation seated Load capacity/rated load lb(kg) 6500(2950) Load centre distance in(mm) 24(600) Load distance,centre of drive axle to fork in(mm) 17.5(445) wheelbase in(mm) 55(1395) 0175(4850) Service weight incl. battery(see line 6.5) lb(kg) Type:solid rubber,superelastic,pneumatic, solid rubber...
ⅡThe structure, principle and adjustment of the main parts of forklift 1.Transmission system 1.1 Overview The transmission system of forklift truck is composed of reducer assembly, differential assembly and drive axle. The driving gear of the reducer is directly connected with the traveling motor.
Rotating gear damage Replace Noise Bearing failure Replace Brake System 2.1 Overview - Schematic diagram of braking system The braking system is composed of brake pedal, brake master pump and wheel brake, which is the front wheel internal expansion hydraulic brake. (Schematic diagram of braking system) (1) When driving, when the foot brake is pressed, the brake fluid in the brake master pump is pushed through the brake steel pipe to enter the brake sub-pump, and the brake shoes...
Page 14
1.grease nipple 2.brake bearing 3.brake sensor 4.pedal stopper 5. brake pedal 6. brake master pump Figure 2-3 Brake pedal assembly 2.3 Brake master pump The master pump includes a seat, a check valve, a return spring, and a main bowl, piston and auxiliary bowl.
Page 15
1.lock nut 2.push rod 3.dust cover 4.brake cable wire 5.lock washer 6.auxiliary leather 7.piston 8.main leather bowl bowl 9.spring 10.check valve 11.valve seat 12.pump body Figure 2-4 Brake master pump 2.4 Brake The brakes are double-shoe brakes mounted on both sides of the drive axle. The brake consists of two sets of brake shoes, brake pump and regulator.
Page 16
2.5 Parking brake control device The parking brake handle is CAM type and the braking force can be adjusted by a regulator located at the end of the brake handle. Adjustment of braking force: Turn the regulator clockwise to increase the braking force; Turning the regulator counterclockwise reduces the braking force.
Page 17
Pedal stopper Push rod Brake pedal Figure 2-8 (5) Adjust the brake switch as shown in Figure 2-9 (a) Loosen the lock nut of the brake switch after the brake pedal height is adjusted; (b) Unplug the wire and let it separate; (c) Turn the switch so that the gap A=1mm;...
Page 18
4.Friction plate wear Replace 5.Wheel bearing loose Repair or replace 1.There is oil on the surface of the friction sheet Repair or replace 2.Brake shoe clearance is adjusted at last Adjust regulator Uneven 3.Split pump failure Repair or replace braking 4.Brake shoe return spring is damaged Replace 5.Brake drum deflection...
should be able to rotate freely, no stuck phenomenon, and no obvious axial clearance and yaw phenomenon, then assemble the lock washer, and finally lock with the outer lock nut. 3. Steering system 3.1 Overview The steering system (Figure 2-14) is mainly composed of a steering wheel, steering shaft, steering device, steering oil pump and steering bridge.
spring broken or insufficient elasticity. There is too much leakage in the steering Check the piston seal cylinder. forklift snake The spring is broken or unelastic. Replace swing The oil level in the tank is low. Add oil Loud work noise Suction tube or oil filter is blocked.
Page 22
4.3 Combination instrument 4.3.1 Instrument display function (Curtis system) Parking 13 Steering Angle Seat 14 Display Menu Brake Pedal 15 Display Menu Lift lock 16 Display Menu Fault alarm 17 Display Menu Safety Belt 18 H Mode Forward/Reverse 19 S Mode Battery level 20 E Mode Working Time...
Page 23
5.The fuse is disconnected, or main contactor is not connected. 1. The controller working environment is too harsh; 2. Truck overloaded; Severe Overvoltage Voltage too high 3.Regenerative braking when the battery connection is disconnected. 1.The detected motor Speed exceeds the limit set by Max Speed;...
Page 24
regenerative braking; 2. Battery parameter is wrongly set; 3. The battery impedance is too large; 4. Regenerative braking Controller output 5V, 1.External load impedance Ext 5V Supply Failure poer supply failure is too low. Fault type: External load impedance +12V power supply is too low.
Page 25
stained; 3. The cable connection is incorrect. 1. Loss of regulation; 2. Pulse of overcurrent trip loss; 3. Speed signal pulse loss; Encoder Fault Encoder fault 4. Automatic characterization; 5. The power supply (voltage) of the encoder is faulty. 1. Motor phase missing or broken;...
Page 26
» Configuration. The associated diagnostic Accelerator output is brake input source (assign Pot2 Wiper Low analog X input) is triggered by the corresponding fault. 1. Non-volatile (NV) memory cannot be read or EEPROM Failure NV memory fault written. 2. The internal controller is faulty.
Page 27
invalid 2. The entry of dirt moisture in the switch. 1.The forward switch/backward signal is displayed during power-on. VCL Tra HPD Fault Travelling HPD failure 2.The accelerator is on signal when it is powered When powered on, lift. Tilt. Pump HPD Fault Pump HPD fault Lateral shift.
Page 28
1.Motor stalling. 2. Motor encoder failure. 3. The cable connection is Stall Detected Motor stalling incorrect. 4. The power supply of the input motor encoder is faulty. 1. The data did not match during the inspection. 2. Inspect the internal damage of the Supervisor Fault Supervisor Fault...
4.5 Maintenance of circuit system (1) Check the contact wear condition; replace the contact if it’s worn and the contact should be checked every three months. (2) Check the pedal and tiller micro switch; Measuring the voltage drop at the ends of the micro switch, there is no resistance when the micro switch micro open closure should be without resistance, when released should have a clear voice.
Page 30
lead to environmental damage. Please contact Nori Sales or professional waste disposal agency to properly dispose of these materials. ● As part of routine pre-operation inspection, check the entire forklift to ensure there are no oil leaks or fluid leakage. Leakage can contaminate the environment and may indicate mechanical failure of the forklift.
Page 31
● Do not short-circuit the positive and negative electrodes of the battery pack; ● Connect the positive and negative terminals of the battery pack in strict accordance with the signs and instructions, do not reverse charge; ● Do not use nails or other sharp objects to Pierce the battery pack housing, do not hammer or foot the battery pack;...
6. Hydraulic system 6.1 Overview- Hydraulic system schematic diagram The hydraulic system consists of oil pump, multi-way valve, lifting cylinder, tilt cylinder and pipeline components. As shown in Figure 2-14 The hydraulic oil is supplied by a hydraulic pump connected to the motor and then distributed to the cylinders by a multi-way valve.
Page 33
control the system pressure; The self-locking valve is located on the tilt valve disc, which is mainly used to prevent the tilt cylinder from misoperating the joystick under the condition of no pressure source and causing serious consequences. A one-way valve is arranged between the oil inlet and the oil inlet of the lifting valve disc and between the oil inlet of the lifting valve disc and the oil inlet of the tilt valve disc.
Page 34
Relief valve pressure adjustment The safety valve pressure has been set by the manufacturer, the user is not allowed to adjust. 6.4 Fault analysis If the hydraulic system fails, find out the cause according to the table below and make the necessary repairs.
The suction pipe is damaged or Check pipes or repair oil filters the oil filter is blocked The oil suction side is loose Tighten loose particles and leaking Noise during operation Replace viscosity Oil viscosity is too high suitable for the pump operating temperature Find out the cause of the There are bubbles in the oil...
Page 36
1.fork arm carrier 2. outer mast 3.outer mast composite roller 4.inner mast 5inner mast and fork arm carrier composite roller Figure 2-17 Position of roller Note: (a) Adjust the clearance of side rollers to 0.5mm; (b) Butter main roller surface and mast contact surface. 7.4 Maintenance 7.4.1 Lifting cylinder adjustment (figure 2-18)
Page 37
Inner mast Tire Fork arm carrier Main roller Fork Figure 2-19 Fork arm carrier height adjustment (3) Land the fork and lean back into position. Adjust the upper end connector of the chain and adjust the nut to make both chains tensioned to the same degree. 7.4.3 Replacement of fork armcarrier roller (1) Fork a pallet and park the car on a level ground.
(5) Remove the connection bolt between the lifting cylinder and the bottom of the outer mast, remove the lifting cylinder and the oil pipe between the two cylinders, do not loosen the oil pipe joint. (6) Put down the inner mast and remove the main roller at the bottom of the inner mast. The main roller of the outer gantry will also be exposed from the top of the inner mast.
Page 39
Lifting hole (2) Figure 2-23 shows how to lift the top shelf The maximum weight is not more than 150Kg Figure 2-23 (3) Figure 2-24 shows the balanced lifting Lifting ring Figure 2-24 The maximum weight is not more than 1500Kg. The lifting ring on the balance weight is only allowed to lift the balance weight, not the whole vehicle.
Chapter Three Operation, use and safety for forklift Ⅰ.Driving and operation There is 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.
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.
accelerating paddle is stepped down. · 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.
· If fork can not lower because of fault, hang 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.
· 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 battery 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.
· Before load placed on shelves or bracket: (a) Lower load until fork no longer carry any load. (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.
Page 46
Based on daily deposit, please make check and maintenance according to the follow items. (a) Considering the raining season, park the vehicle on high and rigid ground. (b) Unload battery from forklift. Even indoor parking, if the place is muggy, dry and shade-cool are necessary for the battery depositing.
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 button 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...
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 Steering wheel① and steering wheel handlebar② Steering wheel operation is traditional: steering wheel turn right, vehicle move right; steering wheel turn left, vehicle move left.
Page 50
(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 brake handle, step down the parking paddle. (5) Brake paddle⑦...
(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 can’t be made, if push or pull lifting handle when turn on ignition key.
Page 52
(3) Goods rest · Goods rest is an important device to protect operator from being impacted when cargo slides toward operator. Loose installation, usage after dismantling and usage after modification are all dangerous. (4) Traction rod Only in the following situation shall be possible to use traction rod. ·...
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 mast 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 54
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 55
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 56
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 57
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 58
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 59
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 60
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 61
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 62
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!
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.
· 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. ·...
whether load or no-load, don’t turn in a high When moving, the distance between fork and 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 66
(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.
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 68
(8) Battery electrolyte is harmful · Battery electrolyte is made of diluted sulfuric acid, be careful when handling. · When electrolyte adhesion conglutination on eyes, skin and clothing, it will result in vision loss and burns. (9) Emergency dealing methods ·...
7. labeling 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 off. 1.nameplate 2.load curve 3.Use the information lubrication chart 5.warning sign...
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.
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 72
(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 73
(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.
In addition to checking lights and operating conditions, the key switch must be turned off and disconnect the battery plug before check the electrical system. Ⅱ.Check after operation After the completion of the work remove the dirt on forklift and check the forklift according to the follow items:...
· 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. Ⅳ. Regular maintenance ·...
Page 76
(3)Motor Every- Every Every Three Maintena- Maintenance item Tools week month months months nce item (8h) (50h) (200h) (600h) (1200h) Remove the eye winker from √ √ √ the motor shell √ Clean or change bearing If Carbon brushes, √ √...
Page 79
Rivet pin and loose √ √ √ conditions Chain wheel deformation, √ √ √ damage If Bearings of chain wheel √ √ √ loosen Check whether in normal √ √ √ Attachment state Whether Piston rod, piston rod thread and the √...
Need help?
Do you have a question about the FE4P25C and is the answer not in the manual?
Questions and answers