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Noblelift FEXP FE4P60-80N Service Manual

Battery counterbalanced forklift truck
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Service Manual
FEXP Battery Counterbalanced Forklift Truck
突然
（FE4P60-80N）
WARNING
Do not use the electric 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
Version 11/2024
FE4P60-80N- SM-EN

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Summary of Contents for Noblelift FEXP FE4P60-80N

  • Page 1 Service Manual FEXP Battery Counterbalanced Forklift Truck 突然 （FE4P60-80N） WARNING Do not use the electric truck before reading and understanding these operating instructions NOTE Please check the designation of your  present type at the last page of this Version 11/2024 document as well as on the ID-plate.

  • Page 2: Foreward

    As our products continue to be updated and improved, you may have a product that is slightly different from some of the descriptions in this manual. If there is any confusion, please contact to NOBLELIFT sales company or agents.
  • Page 3 一、 Environmental requirements for use of this vehicle： This vehicle is a special motor vehicle used only in the factory area, warehouse, freight yard and other specific areas specified in the Regulations on Special Equipment Safety Supervision. 1） This product is strictly prohibited for use in potentially explosive environments. 2）...

  • Page 4: Table Of Contents

    Catalog FOREWARD ............................2 CATALOG ............................... 4 ..........................7 ORRECT APPLICATION ........................7 1.1 F ORKLIFT USE PRECAUTIONS ..........................7 1.1 F ORKLIFT TRANSPORT ..........................7 1.2 F ORKLIFT STORAGE ........................7 1.3 P REPARATION BEFORE USE ..........................7 1.4 F ORKLIFT OPERATION ........................
  • Page 5 ............................42 3.11 U NSTACKING 3.12 S ..............................43 TORAGE 4 HAZARDOUS ENERGY CONTROL ..................... 44 4.1 L ....................44 ITHIUM BATTERY USAGE INSTRUCTIONS 4.2 L ....................48 ITHIUM BATTERY RECYCLING AND DISPOSAL 5 HYDRAULIC SYSTEM ........................49 ..............................49 5.1 O VERVIEW ..........................61 5.2 R ECOMMENDED .......................61 5.3 O...
  • Page 6 ..............................99 8.3 F ORK FRAME ..........................101 8.4 R OLLER POSITION ....................101 8.5 R EPLACE THE DOOR FRAME ROLLER 8.5.1 Lifting cylinder adjustment ......................101 8.5.2 Fork frame height adjustment .......................102 8.5.3 Replace the fork frame roller ......................102 8.5.4 Replace the mast roller .........................103 ..................103 8.6 A CCESSORIES INSTALLATION INSTRUCTIONS...

  • Page 7: Correct Application

    1 Correct application 1.1 Forklift use precautions Forklift drivers and management personnel must bear in mind the principle of "safety first", carefully read the use and maintenance instructions, strictly follow the contents and requirements of this manual for safe operation and standardized operation. 1.1 Forklift transport When loading forklifts in containers or cars, note the following: 1.
  • Page 8 1. Trained and licensed drivers are allowed to drive; The operator should wear shoes, hats, clothing and gloves that can be used for safety protection during operation; 3. In use, attention should be paid to the performance and working state of mechanical, hydraulic, electrical and MOSFET governor;...

  • Page 9: Use Of Lithium Batteries

    18. Do not handle unfixed or loosely stacked goods, and be careful to handle larger goods; 19. Avoid emergency braking when the forklift is driving with load; 20. When leaving the forklift, lower the cargo fork to the ground, put the gear handle into neutral, and disconnect the power supply.

  • Page 10: Use Of Lead-Acid Batteries

    performance may be negatively affected or damaged, which may shorten the service life of the battery, please avoid. 1.6 Use of lead-acid batteries 1. When charging the battery for the first time and supplementary charging, strictly comply with the ragulations of the battery manual; When the forklift is working, and the battery voltage is reduced to 41V, or the voltage of any single battery is reduced to below l.7V, or the instrument alarms, the forklift should stop working immediately, and can continue to use after charging or replacing the battery;...

  • Page 11: General Maintenance Instructions

    2 General maintenance instructions 2.1 Vehicle parameters 2.1.1 Overall dimensions of the vehicle Fig.2-1 Overall dimensions of the vehicle...

  • Page 12: Technical Performance Parameters

    2.1.2 Technical performance parameters Table 2-1 FE4P60N parameter Table model FEXP Factory code FE4P60N Drive mode: electric (battery or power electric supply), diesel, gasoline, gas, manual Operation mode: manual, walkie, stand-on, sit-on sit-on, picking Rated load capacity 6000 Load center distance ...
  • Page 13 Working channel width,1000X1200 pallets 4.33 Ast( 4770 (1200 cross-fork placement) Working channel width,1200X1200 pallets 4.34 Ast( 4970 (1200 placed along the fork) 4.35 Turning radius 2980 Driving speed, full/no load Km/h 15/15.5 Increase speed, full/no load 340/390 Drop speed, full/no load 370/430 Maximum traction, full/no load Newton...
  • Page 14 Bridge load at no load, front/rear lead- 4000/6300(3400/6000) acid (lithium)) Tire: solid rubber, super elastomer, air solid tire, polyurethane tire Front Wheel Size 355/65-15 Rear wheel Size 250-15 Number of wheels, front/rear wheels (×= 2X/2 drive wheels) Front Wheel distance b10( 1574 Rear wheel distance...
  • Page 15 Lithium 96/554(618/840 optional) Battery weight 2510(550) Lead acid (lithium) Battery size, length/width/height 1420/610/570 Drive control type accessory working strss accessory oil content L/min Driver's ear noise level according to decibel EN 12 053 Table 2-2 FE4P70N model FEXP Factory code FE4P70N Drive mode: electric (battery or power supply), electric...
  • Page 16 Seat height 1430 4.12 Height of traction pin h12( 4.19 Total length 4412 4.20 Length of vehicle body (excluding fork) 3192 4.21 Total width 1870 4.22 Fork size s/e/l( 65/150/1220 4.24 Width of fork rack 1700 4.31 Ground clearance under the mast 4.32 Wheelbase center ground clearance Working channel width,1000X1200 pallets (1200...
  • Page 17 Operation mode: manual, walkie, stand-on, sit- sit-on on, picking Rated load capacity 8000 Load center distance front overhang wheelbase 2030 Implicit battery (see 6.5) when dead weight 11900(11200) lead-acid (lithium) Bridge load at full load, front/rear lead-acid 17730/2170(17240/1960) (lithium) Bridge load at no load, front/rear lead-acid 4800/7100(4320/6880) (lithium)) Tire: solid rubber, super elastomer, air tire,...

  • Page 18: Description Of Safety Devices And Warning Labels

    Drop speed, full/no load 390/430 Maximum traction, full/no load Newton 36000 Maximum climb, full/no load S 5 minutes 5.10 Drive brake hydraulic Drive motor power S 60 min Improving motor power S Battery type Lead-acid/lithium Lead-acid 96/945(1035 optional) Battery voltage (rated capacity) K V/AH Lithium 96/554(618/840 optional)
  • Page 19 Pass the forklift training and pass the assessment to have a driver's license to operate the forklift! No driving on the highway! Dress properly before driving, please wear work clothes! Always be alert: injured, rescue! Read the forklift manual carefully before driving! Without permission, it is forbidden to add or remove forklift parts at will!
  • Page 20 Turn off engine before maintenance! Know the traffic rules! Please check the forklift before use! Do not move the overhead guard! Keep the cab clean! Don't drive an unsafe forklift! The driver should be in good health! Make sure your forklift is safe!
  • Page 21 Work within the permitted limits! Don't drive a broken forklift! Hold the handrail tightly when you get on! Start the forklift correctly! Adjust your seat before driving! Make sure your forklift is in a safe operating condition!
  • Page 22 Appropriate fasten your seat belt! Always pay attention to the height of the forklift working area! Don’t expose your arms and body outside Turn on the lights in gray areas! the overhead guard while working! Avoid soft or unfinished surfaces and only run on firm, flat surfaces! Body under the fence on the vehicle roof! Avoid unbalance load!
  • Page 23 Check the location of the fork dowel pin! Pay attention to the safety in the work area! Try not to drive on smooth or slippery ground! Pay attention to the lateral stability of the forklift when it is unloaded! Be especially careful when carrying long or wide loads! Absolutely not allowed manned! When turning, if you can't see ahead clearly, honk your horn and drive slowly!
  • Page 24 Don't chase each other through driving! Don't allow anyone to stand on the goods! Don't look around while driving! Don't do stunts with forklifts! If the loading of cargo is too high and obstructs the view, reverse the driving! Follow traffic rules and all warnings and signs! Or someone to guide! When loading goods, drive uphill and downhill backwards! Pay attention to the steep slope and the lifting height...
  • Page 25 When no load, uphill backwards driving, downhill front driving! Pay attention to brake when starting forklift on slope! No turning allowed on the slope! The horn should be sounded when there is someone or something on the road! Turn should avoid encounter people or goods! The staff shall not be near the forklift when it is working!
  • Page 26 Turning too high speed will cause the center of gravity instability and rollover! The forklift work area pedestrians stopped! Pay attention to the change of the rated lifting weight of the forklift! Forklift driving should always pay attention to the surrounding area. Please use the cargo fork properly! Please slow down as much as possible when loading! Do not move the forklift when there is someone in front of it! No one is allowed to walk or stand under a raised fork!
  • Page 27 please bundle them before loading! It is not allowed to transport goods that have not been unloaded from forklifts！ Don't use people to carry the damaged cargo boxes! No abuse of forks! Be careful to load the goods into the car! Do not carry people at will! Do not abuse forklifts!
  • Page 28 Please do not stretch any part of your body out of the car while driving! Should drive smoothly do not sudden acceleration and deceleration driving! Special safety equipment must be used to carry people on high ground! Overload loading is strictly prohibited! Don’t work in explosive environments! Can't lift when the wind is too strong! If the forklift is damaged,...

  • Page 29: Safety Issues In Upkeep And Maintenance

    - Place the steering bar in the middle position - Lower fork to ground - Tilt the mast forward - Take the key. 2.2.3 Safety issues in upkeep and maintenance 1. Maintenance place · Adequate equipment and safety protection facilities shall be provided to the service organization at the designated site.

  • Page 30: Labels

    · Because the hydraulic circuit has a high pressure, do not perform maintenance work before reducing the internal pressure of the oil circuit. · When injured by high voltage, consult a doctor immediately. · Do not use the mast assembly as a ladder. ·...

  • Page 31: Frame Number Location

    There are many special warning signs on the forklift truck. Please refer to the picture below for the detailed location and content. Please take the time to familiarize with these signs. Fig.2-2 1、nameplate 2、operation tip 3、warningsign 4、Hydraulic oil 5、load curve 6、notes for use 7、Lubrication chart 8、reading tips...

  • Page 32: Disassembly And Installation

    intentionally damaged. In case of damage, please contact relevant departments or our company in time. Fig.2-3 ：XXXXXXXXX Frame number Frame number location：A or B，(Open the above of the rear panel of the machine cover) The manufacturer reserves the right to change the product design and specification without prior notice for the requirement of continuous product improvement.

  • Page 33: Description Of Lifting Point Of Each Disassembled Part

    3. Remove all rings, watches and other metal items from your body before starting the disassembly and inspection operation to avoid accidental short circuits. 4. Please use the correct tools in the disassembly process, if required, please use the marked special tools.
  • Page 34 Lifting position Fig. 2-5 Balance weight lifting instructions Figure 2-22 Maximum weight less than 3000 kg Lifting position Lifting hole Fig.2-6 The lifting ring on the balance weight is only allowed to lift the balance weight, not the whole vehicle. Battery box lifting instructions Figure 2-23 Weight see battery nameplate Lifting position...

  • Page 35: Test Handling Equipment

    Fig.2-7 The battery has the performance of balance weight at the same time, the user shall not be replaced at will, otherwise it will affect the balance of the whole vehicle and other performance. 5. Walking motor lifting instructions Maximum weight less than 200 kg Lifting position Fig.2-8 3 Test handling equipment...

  • Page 36: Use In A New Car

    Operating table introduction Fig.2-9 1、Brake pedal 2、Accelerator pedal 3、Parking brake 4、Walking/lifting/horn joystick 5、tilt control lever 6、accessory control lever 1 7、accessory control lever 2 8、Gear switch 9、Emergency switch 10、Steering wheel 11、key switch 12、Turn signal switch 13、Instrument 14、horn button 3.2 Use in a new car ·...

  • Page 37: Relationship Between Load And Forklift Stability

    following matters during the first 200 hours of operation： · No matter what season, before the operation, the heat engine must be run. · The maintenance, think to do. · Do not operate violently, do not use irrationally. The run-in of the new vehicle In the initial stage of being put into use, forklifts should operate under low load, especially within 100h, and the following requirements should be met: —...

  • Page 38: Forklift Stability

    Do not exceed the allowable load attached to the load curve of the vehicle or equipment. 3.5 Forklift stability The stability standards of forklifts are specified in IS0 or other standards, however, the stability described in these standards does not apply to all operating states, and the stability of forklifts varies according to the operating state.

  • Page 39: Drive

    middle position (N). 2. Turn on the key switch Hold the steering wheel handle ball, then turn on the key switch so that the key switch is at "0N". · Even if the key switch is turned to "0N", it will take about 1 second from the start of the braking circuit to the start.

  • Page 40: Parking And Temporary Parking

    When turning at a road junction; When approaching goods or pallets; When approaching the cargo pile; In narrow passages; When the ground/pavement is not good. · When driving in reverse, must look behind: directly confirm the safety of the rear, relying only on the rearview mirror to reverse is dangerous.
  • Page 41 wheel and make it unable to move. · Parking in a safe place or designated place outside the work observation area. · Use attention signs and signal lights when necessary. · Should be parked on very hard road, pay attention to prevent sliding and sinking. ·...

  • Page 42: Stacking

    · When leave the forklift, take away the key 3.10 Stacking · Before starting to operate the forklift, check the following items: Ensure that there is no falling or damaging cargo in the loading area. Make sure that no items and cargo piles get in the way of safety. When stacking, the following procedures should be followed: 1.

  • Page 43: Storage

    2. Stop in front of the goods (30cm away from the goods and the fork tips). 3. Adjust the position of the forklift before the load. 4. Make sure the goods are not overloaded. 5. Mast vertical ground. 6. Observe the position of the fork and move the forklift until the fork is fully inserted into the pallet. ·...

  • Page 44: Hazardous Energy Control

    Daily storage Stop the forklift truck in the designated place and use the wedge to cushion the wheel. Put the shift handle in neutral and pull the parking brake handle. Take off the key and keep it in a safe place. Long-term storage On the basis of "daily storage"...
  • Page 45 Discharge temperature range: -25 ~ 50℃, the discharge capacity at low temperature (-25 ~ 0℃) may be reduced compared with normal temperature conditions. The battery can be used at an ambient temperature of 40 ~ 50℃, but the temperature of the battery is too high, especially if the battery is in a high temperature environment for a long time, it will accelerate the aging of the internal materials of the battery and shorten the service life of the battery.
  • Page 46 instructions. Reverse charging is prohibited； Do not Pierce the battery pack case with nails or other sharp objects. Do not hammer or step on the battery pack. Disassembling battery packs and cells in any way is prohibited; Do not place the battery pack in a microwave oven or pressure vessel; When electrolyte leaks, avoid skin and eye contact with electrolyte.
  • Page 47 · The steps of the disconnected charging process must be strictly operated in accordance with the requirements of the "Operation and Maintenance manual" of the charger used. · Do not unplug the charger when charging, otherwise it will produce electrical sparks and cause danger. Replace the battery When the forklift has been used for a continuous working cycle and the battery power is completely used up, the battery on the original forklift should be replaced with another set of fully charged batteries in time,...

  • Page 48: Lithium Battery Recycling And Disposal

    4.2 Lithium battery recycling and disposal In order to avoid environmental damage, do not dispose of used machine lubricating oil, battery and filter by yourself. Dispose of such waste products in accordance with local laws or by contacting Noblelift distributors or authorized waste disposal agencies.

  • Page 49: Hydraulic System

    5 Hydraulic system 5.1 Overview Fig.5-1 Hydraulic system schematic diagram The hydraulic system is composed of working oil pump, multi-way valve, lifting cylinder, tilt cylinder and pipeline. As shown in the figure, the hydraulic oil is supplied by the oil pump connected with the motor, and then the multi-way valve distributes the oil to each cylinder.
  • Page 50 the mast hydraulic pressure and the steering brake hydraulic pressure. The gear pump for mast work is an external meshing helical gear pump with axial clearance automatic compensation and radial hydraulic balance. Three open structure with "8" shape stop positioning is adopted. DU bushings are installed in the front and back covers of cast iron, and the intermediate is a special aluminum alloy forging.
  • Page 51 Check oil pump seal After the air bubbles in the tank disappear, use the oil pump. The oil suction side hose is Adjust or replace twisted or the filter screen hoses and clean is blocked to produce air filters. cavitation The air is inhaled from the Retighten each joint loose joint on the suction...
  • Page 52 Fig. 5-2 Multi-way valve figure shape Table 5-2 Mult-iway valve parameter table Order Parameter Parameter Valve stem diameter 20mm Inlet flow 180L/min Allowable back pressure 1.5Mpa Main safety valve sets the 21Mpa pressure Control ≤2Mpa Forward tilt pressure back pressure Internal valve leakage...
  • Page 53 1. Lift joystick 2. Tilt joystick 3. Side shift joystick 4.Accessory joystick 5. Connecting rod Fig.5-3 Multi-way valve operating mechanism Note: The pressure of the safety valve has been set by the manufacturer, and the user shall not adjust it by himself. Fault analysis If the hydraulic system faults, find out the cause according to the table below and make the necessary repairs.
  • Page 54 tilting lever Tilt back pressure valve Replace the spring is operated, spring is broken and the mast is tilted Tilt valve stem O-ring damaged Replace the O-ring forward. Tilting cylinder seal failed Maintenance cylinder Tilt back pressure valve Replace the tilt The mast is unstable when failure...
  • Page 55 of rotor and stator, namely cycloidal pin gear pair; When rotating the steering, it acts as a metering motor to ensure that the amount of oil in the steering cylinder is proportional to the Angle of the steering wheel; In the manual steering equivalent to manual oil pump;...
  • Page 56 Oil thread M20x1.5 O-ring Sealing mode of Cone angle seal oil port Weight Table 5-5 Common faults and elimination: Order Fault Possible reason Elimination The bolt at the binding position between Interval and Steering gear back the rear cover stator and evenly tighten bolts cover, stator, the valve body is loose...
  • Page 57 steering is stuck, it should be stress-free cleaned; In both cases, the recovery effectiveness of the sealing tape should be checked. Clean the relief valve (need to check The relief valve is the effectiveness of blocked by dirt or spring the seal belt No-load or failure or the seal ring...
  • Page 58 position When the The radial clearance Replace the rotor power is off, or axial clearance of the and stator meshing the steering stator is too large pairs wheel rotates Change hydraulic but the cylinder Oil viscosity is low does not move The pressure Two-way buffer valve Clean the two-way...
  • Page 59 Fig.5-4 Oil return filter Table 5-6 Parameter table Order Feature Parameter Filter type SPB-10x10 Filter head type SPH-10 Filter element type SPBX-10x10 Maximum working 0.7Mpa pressure Bypass valve opening 0.25Mpa pressure Burst pressure 2.0Mpa Maximum oil return 320L/min flow Filtration accuracy 10um Fitting joint pipe R1 1/4...
  • Page 60 When the pointer is in the red area, it means that the filter element blockage has been quite serious, the bypass valve of the filter head is open, and the filter does not play a filtering role at this time, and the new filter core must be replaced.

  • Page 61: Recommended Oils

    17. Tilt steel pipe 5.2 Recommended Oils Name Number Capacity（L） Note 70（FE4P60-80） L-HM32 Temperature of use≥-5℃ Hydraulic oil 80（FE4P60-80）Three-stage L-HV32 Temperature of use≥-20℃ mast 85W/90GL-4 -15℃~ 49℃ Temperature of use Gear oil 80W/90GL-4 -25℃~ 49℃ Temperature of use Brake fluid DOT3/DOT4 Castrol Lubricating...
  • Page 62 2.Remove piston, then remove retaining ring 4. Remove dustproof seal and shield ring and Y-type seal...

  • Page 63: Common Fault Analysis Of Hydraulic Motor

    5. Remove o-seal and shield ring, then repair hose . Installation way is in reverse sequence 5.4 Common fault analysis of hydraulic motor Possible reason Fault Poor connection or blown fuse. Check the battery connection. Check the key fuse. Check the hydraulic pump motor for possible fuse blowouts.

  • Page 64: Common Fault Analysis Of Hydraulic Pump

    Research and question the use of the vehicle in its full operating conditions, select and purchase the appropriate battery capacity to understand the operating time. The battery is not fully charged during the battery charging operation. Check that the battery is charged evenly The battery will not last the full normal (charging makes all batteries the same weight).
  • Page 65 the pump or keyway. The seal lip is dry and hardened by heat. The oil content in the tank is low. Pump inlet line limited. Pump can’t transfer fluid There is a leak in the pump inlet line. Loose bolt. Bay suction line defect.

  • Page 66: Drive/Brake System

    6 Drive/brake system 6.1 Drive axle overview The drive axle consists of the main reducer assembly (including the differential and parking brake), the wheel side reducer and the housing. The spline sleeve at the input end of the main reducer is connected with the walking motor.

  • Page 67: Common Troubleshooting Methods

    drive, and the driving bevel gear and driven bevel gear are installed vertically to change the direction of the power, reduce the speed, and increase the transmitted torque, and then the power is transmitted to the wheel edge through the differential and half shaft, and the movement and torque are transmitted to the left and right driving wheels after the wheel edge reduction mechanism is further decelerated.

  • Page 68: Braking System

    1、Oil seal 1、Replace the oil burning and seal aging 2、Tighten the 2、The bolt bolts is loose 二 3、Improve leakage 3、Poor lubrication lubrication 4、Release oil to 4、The oil the specified level is too position high 1、Poor 1、Improve Axle lubrication lubrication housing 2、Improper 2、Adjust 三...
  • Page 69 so on. Fig.6-3 Brake schematic figure 1) When driving, when stepping on the foot brake, by pushing the brake fluid in the brake master pump through the brake steel pipe into the brake branch pump, push the brake shoe to realize the service brake, release and cancel the service brake;...
  • Page 70 Rated working pressure 10Mpa Brake fluid DOT3或DOT4 Hydraulic pressurization, Type internal expansion front wheel mechanical Service braking brake Brake shoe wear limit 0.25-0.5mm (to rivet head) Brake shoe wear limit (to ＞0.5mm rivet head) Mechanical, acting Type on the parking brake Parking control 50mm（Control force...
  • Page 71 3mm, and lock the nut; ◎ When the brake pedal is gradually pressed down 10mm-20mm, the brake light switch should be fully switched on, and the brake switch should be disconnected when the foot is released to this state. Hydraulic booster The hydraulic booster and the steering system share a set of hydraulic oil source, can work separately, if necessary, can be used jointly, and do not interfere with each other.
  • Page 72 The master pump includes a seat, a check valve, a return spring, and a main skin bowl, piston and auxiliary skin bowl. The end is fixed with a stop washer and stop wire, and the exterior is protected by a rubber dust cover. The piston of the master pump is operated by the brake pedal through the push rod.
  • Page 73 Fig.6-6 Brake master pump The brake master pump brake is a double shoe brake, which is installed on both sides of the drive axle. The brake is composed of two sets of brake shoes, brake pump and regulator. One end of the brake shoe is in contact with the fixing pin and the other end is in contact with the regulating device.
  • Page 74 Fig.6-6 Service brake Parking brake control device The parking brake system adopts a hand-pulled soft-shaft mechanism, which acts on the brake of the input shaft of the main reducer of the drive axle. Use the parking brake system only when the forklift is stopped.

  • Page 75: Common Troubleshooting Methods

    Fig. 6-7 Parking driving control Fig.6-8 Parking control handle Parking brake control handle adjustment: When the free travel of the parking brake control handle is too large, it should be adjusted. First relax the parking brake lever forward to the limit position, adjust the nut of the brake pull wire with an open wrench, tighten it clockwise and loosen it counterclockwise.
  • Page 76 Cause analysis Fault 1 Brake system leaking oil 2 Brake shoe clearance is not adjusted properly Poor 3 Brake Overheating braking 4 Poor contact between brake drum and friction plate 5 Impurities are attached to the friction plate 6 Impurities are attached to the friction plate 7 Impurities are attached to the friction plate...

  • Page 77: Common Fault Analysis Of Drive Motor

    to the main reducer and 1.2L to each wheel reducer. Gear oil selection GL-4 85W/90 heavy duty vehicle gear oil.  Check the movement of each transmission member without abnormal sound.  Check that the external fasteners of the wheel reducer, main reducer and brake are loose and tightened.
  • Page 78 The signal is bad. Blown fuse: Check the battery connection. Check the battery connector connection. Check fuses, drives and logic. Replace the fuse if it is blown. Check the drive motor and control panel for possible fuse blowouts. Some of the reasons are: Working under excessive load, the current limit is too high Low battery voltage:...
  • Page 79 Change to a tire with less friction After a work shift, the vehicle is working beyond its designed capacity without available power The battery is dirty and the electrolyte is on top of the battery and in contact with the frame. The positive (+) or negative Current flows through the battery box, which applies...

  • Page 80: Electrical System

    7 Electrical system 7.1 Overview FE4P60-80N electric forklift truck's electrical system is powered by a 96V lead-acid/lithium battery pack, and traction power is provided by an AC asynchronous motor. The lifting power of goods is driven by AC motor oil pump to produce oil pressure, and then by hydraulic pipeline through the hydraulic cylinder on both sides of the mast to achieve the lifting, tilt and side movement of fork.
  • Page 81 braking torque to achieve the purpose of vehicle deceleration. Braking force is controlled by the accelerator pedal. Regenerative braking is generated by the control of the controller under the condition that the speed of the vehicle is relatively higher than the speed of the traction motor. The energy of the vehicle braking can be converted into electric energy and returned to the battery.

  • Page 82: Electrical Schematic Diagram

    Electrical schematic diagram Fig.7-3 Electrical schematic diagram—Curtis system...
  • Page 83 Fig.7-4 Electrical schematic diagram—Inmotion system...

  • Page 84: Replacement Tool For Electrical Plug-In

    7.5 Replacement tool for electrical plug-in 序 Picture Applicaton 号 Take off pin Mounting pin Loose lock Two hole lock Four hole lock Take off pin...

  • Page 85: Electronic Control Element

    7.6 Electronic control element AC controller, this type of controller sets high safety, reliability, flexibility, easy operation in one, through advanced control software to ensure that the motor in different modes, can run smoothly, including full speed and high torque state regenerative braking, zero speed and torque control, proprietary input/output ports and software, it ensures the economy and high efficiency of the control of electromagnetic braking and hydraulic system.
  • Page 86 Fig.7-6 Reversing lights 3: Replace it...

  • Page 87: Instrument Interface Function Display

    7.9 Instrument interface function display （Curtis System） Table 7-1 Instrument display function（Curtis System） Parking Steering Angle Seats Instrument Menu Braking Instrument Menu Prompt lock Instrument Menu Fault Identifier Instrument Menu Seat belt H(High performance) Forward/backward S(Regular performance) Fig.7-7 Instrument display function Battery Power E(Economic performance)

  • Page 88: Controller Fault Code Table

    7.10 Controller fault code table Table 7-3 Fault code table（Curtis System） Original code Instrument code Fault explanation Fault reason 1、motor external U, V or W connection short circuit Controller Over current Controller Over current 2、motor parameters do not match 3、The controller is faulty 1、...
  • Page 89 2. Improper monitoring parameters for travel control. 3． See: Programmer » Application Settings » Trip Control Monitor menu. 1. The controller working environment is Controller Overtemp Controller Overtemp harsh Cutback Cutback 2. Vehicle overload 3. The controller is incorrectly installed 1.
  • Page 90 Enable must be set to "OFF" 1. Connect the load open circuit or short circuit MAIN DRIVER MAIN DRIVER 2. Connection pins are stained 3. Wrong wiring 1. Connect the load open circuit or short circuit EM Brake Driver EM Brake Driver 2.
  • Page 91 1. Throttle voltage exceeds analog low or analog high Analog input parameters are defined for throttle input. Throttle Wiper Low Throttle Wiper Low 2. See Programmer » Controller Settings » Input » Analog 1 type. 3. See Programmer » Controller Settings » Input »...
  • Page 92 Invalid 2.Dirt moisture to enter in the switch. 1. A forward switch or backward signal is displayed during power-on VCL Tra HPD Fault VCL Tra HPD Fault 2. The accelerator is in signal state when it is powered on When powered on, lift, tilt, side shift, Pump HPD Fault Pump HPD Fault accessories have signals...
  • Page 93 Supervision Input Check Supervision Input Check Internal controller failure. 1. PDO Map data is overallocated or incompatible with byte maps with objects. PDO Mapping Error PDO Mapping Error 2. Adjust PDO Settings. See Programs » Application Settings »CAN Interface »PDO Settings.
  • Page 94 1. Please check the CAN line (C21 and C23) Traction driver CAN communication 2. Check whether the resistance between the CAN line (C21 and failure C23) is 120Ω or 60ohm resistance 3. The controller is faulty 1. Timely charging is required Battery low voltage 2.
  • Page 95 1. Speed sensor fault of traction motor Traction motor speed sensor error 2. The traction motor speed sensor connection line is disconnected The traction driver has a high DC 1. High battery voltage bus voltage 2. The ramp is too steep regenerative braking is too strong 1.
  • Page 96 Pump driver temperature sensor The temperature sensor of the controller is faulty error 1、The temperature sensor of the controller is faulty Pump motor temperature is low 2、The temperature sensor of the controller is faulty 1、The temperature of oil pump motor is too high Pump motor temperature is high 2、Thermistor fault of oil pump motor Pump motor temperature sensor is...

  • Page 97: Maintenance Of The Circuit System

    Pump driver DC bus voltage high High battery voltage (hardware monitoring) Drive speed control failure Restart the key switch, no effect is the controller fault Driver speed control failure Controller fault BMS CAN bus Off BMS CAN communication fault BMS CAN fault BMS CAN communication error Sequential fault Operation sequence fault (HPG DC pump control fault)

  • Page 98: Lifting System

    8 Lifting system 8.1 Overview The lifting system is two-stage roller type vertical lifting and shrinking, which is composed of inner and outer mast and fork frame. 8.2 Inner and outer mast The inner and outer mast are welded parts. The middle part of the outer mast is mounted on the frame with a self-lubricating joint bearing.

  • Page 99: Fork Frame

    16.Bolt12 17.Spring 18.With trunnion 19.Bearing 20.Support cover washer12 φ50 bush 21.Spring 22.Bolt24 23.Pipe clamp 24.Bottom washer24 bottom plate Plate 8-2 Mast Mast dismantling Fig. 8-3 Fig. 8-4 Figure 1，Figure 2，two disassembly can lift the mast away. 8.3 Fork frame The fork frame is rolled through the main roller inside the mast, the main roller is mounted on the main roller shaft and jammed with an elastic stop ring, the main roller shaft is welded to the fork frame, and the side roller rolling along the inner mast is bolted to the fork frame through 4 side rollers and adjusted with adjusting washer.
  • Page 100 Fig.8-5 fork frame 1.Load 2.fork 3. Elastic 4. Main roller 102 5.Side axle backrest frame retaining ring head 35 for shaft 35 6.Flat washer 7.bolt 22 8. Main roller 9. Elastic 10.bushing 152.5 retaining ring for shaft 55 11.Flat 12.washer22 13.Side rollerφ...

  • Page 101: Roller Position

    8.4 Roller position There are two kinds of rollers: the outer frame compound roller and the inner frame and the fork frame compound roller. Install on outer mast, inner mast and fork frame respectively. The compound roller is composed of a main roller and a side roller. The main roller bears the load in the front and rear direction, and the side roller bears the side load, so that the inner mast and the fork frame can move freely.

  • Page 102: Fork Frame Height Adjustment

    Fig.8-7 lifting cylinder adjustment 1、inner door mast beam 2、lifting cylinder adjustment pad 3、lifting cylinder 8.5.2 Fork frame height adjustment Park the vehicle on the level ground and make the mast vertical. Make the bottom surface of the fork contact the ground, and adjust the adjusting nut of the upper end joint of the chain so that the main roller has A certain distance from the lower end face of the inner mast (A=24 ~ 29).

  • Page 103: Replace The Mast Roller

    Fig. 8-9 Fig. 8-10 8.5.4 Replace the mast roller Remove the fork frame from the inner mast in the same way as described in 7.2.3 for replacing the fork frame roller. Drive the forklift to the level ground, and pad the front wheel up 250-300mm. Pull the hand braking and pad the rear wheel with a wedge.

  • Page 104: Steering System

    9 Steering system 9.1 Overview The steering system (Figure 9-1) is mainly composed of steering wheel, steering shaft, steering gear, steering oil pump and steering axle. The steering shaft is connected with the steering gear through the cardan joint, and the connecting shaft is connected with the steering wheel through the cardan joint.
  • Page 105 back of the frame by the front and rear pins through the fixed plate, that is, the shock absorber pad, so that the bridge can swing around the pin shaft, there is a steering joint on the left and right of the steering axle, the rear hub is mounted on the steering joint shaft with two tapered roller bearings, the wheel is fixed on the hub through the rim, and the bearing is equipped with an oil seal to keep the grease in the hub and the steering joint cavity.

  • Page 106: Steering Cylinder

    49.Hose clamp/130-150 50.Sheath 51. Steering axle 52.Left steering assembly joint 53.Steering joint main 54.Main pin end 55.90°curved neck cover (top) grease nozzle The hub is mounted on the steering joint with two tapered roller bearings, the wheel is pry to the hub through the rim, the bearing is equipped with an oil seal inside, so that the grease is kept in the hub and the steering joint cavity, and the bearing tightness is adjusted with nuts.

  • Page 107: Troubleshooting Methods

    10. Retaining ring 11. O-ring 110x5.7 12. Support ring 85x100x3 13.Piston rod assembly 9.4 Troubleshooting methods Table 9-1 Fault analysis table order Fault feature Possible reasons exclude Wheel nut loose Fastening Hub bearing exceeds adjust adjustment range Unstable Incorrect installation of driving adjust axle end adjustment gasket...

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