Noblelift PS 12DL Service Manual

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Service Manual

PSL Pallet Stacker

(PS 12DL,PS 16DL)

Warning

You must read and understand the operating

instructions in this manual before using it.

 Caution:

 - Please check the last page of this

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current product type designations.

 - Take care for future use.

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Hotline：4008-836115

Version 003/2023

PS 12/16DL-SM-003-EN

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Summary of Contents for Noblelift PS 12DL

Page 1 Scan for more Hotline：4008-836115 Service Manual PSL Pallet Stacker (PS 12DL,PS 16DL) Warning You must read and understand the operating instructions in this manual before using it.  Caution: Version 003/2023  - Please check the last page of this...
Page 2 FOREWORD Before operating the electric stacker, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation could create danger. This handbook describes the usage of different electric stackers. When operating and servicing the truck, make sure, that it applies to your type.
Page 3 1. CORRECT APPLICATION 2. DESCRIPTION OF THE STACKER a. Overview of the main components b.Main technical data c.Description of the safety devices and warning labels (Europe and other, excepting USA) 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING a.
Page 4 b.Pump station d. Troubleshooting Pump motors b.Mast 12.REGULAR MAINTENANCE a.Maintenance checklist b.Lubrication points c. Check and refill the hydraulic oil d. Check the electrical fuse e. Remove and reinstall the guard 13 TROUBLE SHOOTING 14.WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram b.
Page 5 1. CORRECT APPLICATION It is only allowed to use this electric stacker according to this instruction handbook. The trucks described in this handbook are self propelled pedestrian controlled electric power stacker, with electrically powered low height lifting function. The trucks are designed for stacking operations in dedicated racking by lifting and lowering the palletized load up to the desired lifting height.
Page 6 2. DESCRIPTION OF THE STACKER Overview of the main components Fig. 1: Overview main components Chassis 11. Accelerator Battery compartment 12. Tiller assembly Load roller assembly 13. Main cover Load backrest assembly 14. Emergency button Fork carriage 15. Discharge indicator and charging indicating Hydraulic system Mast assembly 16.
Page 7 Fig. 2: Technical data Table1: Main technical data for standard version Type sheet for industrial truck acc. to VDI 2198 PS 12DL PS 16DL Manufacturer`s type designation 3600 4600FFL Battery Power (battery ,diesel, petrol, gas, manual) Operator type...
Page 8 4.15 h13(mm) Lowered mast height 4.19 Overall length l1(mm) 1998 2042 4.20 Length to face of forks l2(mm) 4.21 Overall width b1(mm) 4.22 Fork dimensions s/e/l(mm) 60/180/1150 4.25 b5(mm) 570/685 Width across forks 4.32 Ground clearance, centre of wheelbase m2(mm) 4.33 Aisle width for pallets 1000X1200 lengthways Ast(mm)
Page 9 1) load roller lowered: +72mm Lowered mast Extended mast Free Lift height Lift height Lift+fork height Type height height h2(mm) h3(mm) h3+h13(mm) h1(mm) h4(mm) PS 12DL 1958 — 2830 3380 2920 Two stage mast 2108 — 3130 3680 3220 2308 —...
Page 10 c.Description of the safety devices and warning labels (Europe and other, excepting USA) For the USA –market, the description of the safety and warning labels is mentioned in chapter 11. A Crane hook label Warning decal: Do not step under or on the forks C Residual lift capacity sticker Never reach through Identification plate (ID-plate)
Page 11 e. Identification plate Identification plate location Fig. 5: located on the body of the vehicle. Pallet stacker truck Special equipment manufacturing license no. Model xxxx Rated load weight xxxx Rated capacity dead weight xxxx Maximum battery weight Minimum battery weight No load without battery weight Maximum lifting height xxxx...
Page 12 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS DO NOT  Drive outside the stacking operation with a lifted load higher than the lifting point.  Put foot or hand under or into the lifting mechanism.  Allow other person than the operator to stand in front of or behind the truck when it is moving or lifting/lowering.
Page 13 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING Commissioning Table 2: Commissioning data PS 12DL / 3600 PS 16DL / 4600FFL Type Commissioning weight 1100 1410 [kg] 3600 4600 Version/ Lift [mm] After receiving our new truck or for re-commissioning you have to do following before (firstly) operating the truck: ...
Page 14 5. DAILY INSPECTION This chapter describes pre-shift checks before putting the truck into operation. Daily inspection is effective to find the malfunction or fault on this truck. Check the truck on the following points before operation. Remove load from truck and lower the forks. DO NOT USE THE TRUCK IF ANY MALFUNCTION IS FOUND.
Page 15 6. OPERATING INSTRUCTIONS BEFORE OPERATING THIS TRUCK, PLEASE FOLLOW THE WARNINGS AND SAFETY INSTRUCTIONS (CHAPTER 3). BEFORE OPERATING THIS TRUCK, ENSURE THAT THE LOAD OR OTHER EQUIPMENT NOT CAUSES INSUFFICIENT VISIBILITY! Fig.9: Tiller operating controls Make sure, that the load is palletized and stable and that the daily inspection is carried out.
Page 16 Fig. 9: Residual lift diagram (stacking) Fig. 10: Residual lift diagram (double lifting) Lifting DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 2000kg WHEN THE LOAD CENTER IS 600MM. (ONLY USED AS PALLET TRUCK) LIFT ONLY CAPACITIES ACCORDING TO THE RESIDUAL LIFT DIAGRAM. Travel with the lowered forks fully underneath the pallet and press the lifting button (Fig.
Page 17 Lowering If the forks are in the racking, firstly travel out of the racking carefully with or without the pallet. By travelling out of the racking, take care that the forks are not touching the racking. Press the lowering button (Fig. 7, 18) carefully. Lower the load until the forks are clear of the pallet, then drive the truck carefully out of the load unit.
Page 18 Steering You steer the truck by moving the tiller to the left or right side Appearance Operate the vehicle by turning the Tiller to the left or right. When the vehicle is moving forward (opposite to the fork direction), turning the Tiller to the right will make the vehicle turn clockwise. Braking THE BRAKING PERFORMANCE DEPENDS ON THE TRACK CONDITIONS AND THE LOAD CONDITIONS OF THE TRUCK...
Page 19 Malfunctions If there are any malfunctions or the truck is inoperative, please stop using the truck and activate the emergency button (14) by pushing it. If possible, park the truck on a safe area, turn the key switch (18) anti- clockwise and remove the key. Inform immediately the manager and, or call your service.
Page 20 BATTERY CHARGING AND REPLACEMENT Controller appearance Item Name Quantity Electronic control assembly Mounting plate Mounting plate Controller Controller Mount Relay Fuse holder Fuse 350A Fuse holder Testing and troubleshooting The current fault code can be viewed on the instrument panel and hand-held programmer.
Page 21 Test a. Controller Measure the diode voltage of the AC MOSFET circuit inside the controller and check whether it is burnt or damaged. The test shall be carried out according to the following table. Each test item must be tested repeatedly for more than 3 times.
Page 22 b. Line contactor and fuse For line contactor and line fuse, connect an ohmmeter at the point shown in the figure and check whether it measures the specified value. c. Instrument assembly...
Page 23 Number Item Quantity Note Electricity meter Universal key switch LKS-101A DC power switch ZDK32-350 d.Replace electrical parts Disconnect the power supply before replacing electrical parts Note: Before maintenance, lower the fork to the bottom, then turn off the key switch and disconnect the power supply.
Page 24 1. Remove the bolts in the figure below with an 2. Disconnect the vehicle power, that is, unplug the internal 6mm hexagonal wrench. battery connection port in the figure below 4. Unplug the three plugs 3. Use a 6mm Allen wrench to unscrew four screws and cut the binding band around the wire harness 6.
Page 25 Emergency stop switch replacement 1. Use a Phillips screwdriver to unscrew the two 2. After removing the screws, you can remove the screws of the emergency stop switch mushroom head 4. Separate the integrated leaf-type panel from the 3. Use a Phillips screwdriver to instrument fixing plate unscrew the screws 5.
Page 26 7. Press the micro switch on both sides of the snap by The installation process is the reverse of the above hand, you can pull off the micro switch process.
Page 27 Controller replacement 1. Take off the wiring on the electric control in turn, pull out the connector, and write down the different ports corresponding to different wiring 2. Unscrew V, U, W, -P, -B five screws with a 10mm open-end wrench, and remove the wiring in turn 3.
Page 28 e.Tiller Tiller assembly PCB motherboard replacement 1. Use 6mm hexagonal wrench to unscrew the outer 2. After unscrewing the screws carefully open the Tiller cover screws housing, and unplug the connection plug...
Page 29 3. Use a 2mm hexagonal wrench to unscrew the 4. Carefully remove the drive switch screw securing the drive switch 5. Use a Phillips screwdriver to remove the set 6. Remove the old PCB board, and unplug the plug wires in screws PCB motherboard replacement turn, the installation process and the reverse process of the above process...
Page 30 1. Pull out the rubber plug. 2. Unscrew the bolt with a 6mm hexagonal wrench. 3. Use a 13mm open-end wrench to unscrew the screws at the lower end of the fixed gas spring. 4. Remove the gas spring Installation of gas springs is the reverse process of disassembly...
Page 31 f.Steering Drive system components 1.3kw drive wheel Drive wheel gearbox lubricant oil change...
Page 32 1. There is an oil filling hole in the front of the drive 2. There is an oil drain hole at the bottom of the drive wheel wheel 3. Use a jack to lift the body to a certain height 4.
Page 33 5. Use 7mm hexagonal wrench to unscrew the oil filling 6. Fill the lubricant through the oil pipe. hole bolt lubricant used is 85W/90 GL-5 heavy-duty vehicle gear oil Brake disc replacement 1. Screw the two bolts into the bolt holes of the brake with a 4mm hexagonal wrench, the bolt size is M6×40...
Page 34 2. Use a 4mm hexagonal wrench to attach the brake to 3 bolts unscrewed 4. Unplug and cut the cable ties 5. You can remove the brake, the installation process is the reverse process of disassembly.
Page 35 Brake clearance adjustment: use a 4mm hexagonal wrench to unscrew the three screws and use a stopper to measure the brake clearance to control at 0.3mm. You need to use the stopper to measure the three bolts one by one to ensure that the clearance is 0.3mm.
Page 36 Depending on the version, the truck is equipped with following liquid acid traction battery- type: PS 12DL 1 PCS 2PzB 24V/ 180 Ah (C5) [660 x 146 x 657 (LxWxH)] PS 16DL 1 PCS 3VBS 24V/ 270 Ah (C5) [752 x 172 x 657 (LxWxH)] IT IS ONLY ALLOWED TO USE LIQUID ACID TRACTION BATTERIES.
Page 37 Fig. 13: battery replacement...
Page 38 1. Pull out the hinges and remove the battery box cover. 2. Remove the battery power plug 3. Connect here with tools, such as hooks, and then remove the battery...
Page 39 1. Open the battery box cover 2. Unplug the power supply 3. Unscrew the bolt with a 5mm hexagonal wrench . Unplug the pins Take out the battery in the direction indicated by the arrow. The installation process is the reverse of the disassembly process...
Page 40 b.Battery maintenance 1. Unplug the power switch 2. Unscrew the battery water cap Converters Battery 3. When the battery liquid level is lower than the sink, make up water 4. Some models of battery filling holes can not see the sink, the liquid level drops to 10mm from the battery partition, to make up water Maximum liquid level...
Page 41 c.Power indicator The discharge situation is indicated by 10 red LED display segments. Battery discharge Battery full Figure Battery discharge The rightmost LED lights up only when the battery is properly charged. As the battery charge condition decreases, the LEDs light up sequentially, but only one at a time. ...
Page 42 9. Supply power (lithium battery) Brief introduction a.Product features (1) The product is specially designed for pure electric forklifts and pure electric trucks to strengthen the structure and be able to withstand strong vibration and environmental impact. 2）The battery pack is equipped with intelligent battery management system, which has the functions of voltage and temperature collection, under voltage, over voltage, over temperature, over current, short circuit protection, etc.
Page 43 b.Technical parameters Item Parameter Note Specification Standard 24V 150Ah Optional 24V 200Ah Nominal voltage Rated capacity 150Ah 0.5C discharge Reference weight 72kg Maximum continuous discharge current Dischar Maximum pulse 180A 30seconds discharge current Discharge cut-off ≥20V voltage Standard charging current Chargin Maximum charging current...
Page 44 -No puncturing -Do not throw it into fire or water C. Installation and use 1). Installation environment Recommended installation environment: temperature 0~35℃, humidity 5%~95%. Avoid excessive temperature difference (more than 5℃) on both sides of the battery. 2). Installation method Install vertically downward, avoid violent bump, impact and drop during installation, and the charging port should be facing the opposite direction to the discharge port of the whole vehicle for charging.
Page 45 1). Charging requirements The battery has a built-in protection system, when the system is over-discharged, the internal relay will cut off the output and exhibit a high resistance state (OD). The maximum charging voltage of the charger is limited to 29.2V, and the voltage and current output is controlled by the battery BMS.
Page 46 10.Hydraulic system a. Overview The hydraulic system is composed of working oil pump, lifting cylinder and piping and other components. Hydraulic oil is supplied by the oil pump directly connected with the motor. The oil pump will pump the hydraulic oil to the cylinder. 1) Components The hydraulic system operates the lifting cylinders by pressurized hydraulic oil from the main hydraulic pump and pumps out the oil discharged from these cylinders.
Page 47 The pump motor operates when the following conditions are met. The key emergency stop switch is closed. The limit switch and rise button are closed. Pump motor contactor is engaged Pump motor contactor detects. For the pump motor contactor, follow the diagram shown in and check that it measures the specified value.
Page 48 b.Pump station Material Code ITEM Quantity NOTE Pump station 950900100015 534798510006 Motor 534798520026 Carbon Brush 534798510007 Valve block Provided together with the coil 534798520024 Solenoid Valve Spool 534798520025 Coils Provided together with the coil...
Page 49 c. Hydraulic schematic...
Page 50 Troubleshooting Pump motors Failure Possible cause Poor connection or blown fuse. Check battery connection. Check key fuse. Check hydraulic pump motor for possible blown fuse. Key switch, upper limit switch, line contactor not closed. Turn off the key switch. Use a multimeter to check power flow through key switch, line contactor coil and line contactor.
Page 51 Hydraulic Pumps Failure Possible cause Low oil level. Oil is very thick (viscosity is too high) Pump inlet piping has restrictions. Noise in the pump. Wear parts in the pump. The oil is dirty. Air leaks into the inlet line. Low oil level.
Page 52 11.mast system a.Overview Lifting system is powered by the main hydraulic pump. Forks: two fork-shaped objects to support the load Chain: the part that lifts the pallet and the mast Lifting cylinder: single acting cylinder pulling back the chain of the pallet mast: the vertical structure at the front of the forklift that extends and retracts to lift and lower the load b.Mast Apearance...
Page 53 gravity to the tank. As the oil is discharged, the cylinder rod and the attached internal mast will retract. When the internal mast is lowered, the tension on the lift chain will be slackened and the forks will be lowered as well. Fork 1) Fork inspection Forks should be inspected at least once every 12 months.
Page 54 Chain 1. Lift the pallet rack, pad the wood, so that the chain does not stress the state 2. Remove the cotter pin at the top end of the chain 3. Remove the pin 4. Remove the cotter pin at the lower end of the chain 5 Remove the pin...
Page 55 5. You can remove the chain and replace it, the installation process is the reverse process of disassembly...
Page 56 We need to use two 24mm open-end wrenches to tighten the chain bolts so that the chain is still under force when the pallet is in the lowest position. Then use your fingers to press each chain until you feel the same rebound force.
Page 57 1. Use the 19mm open-end wrench to remove the oil pipe at both sides of the lifting cylinder, note: hydraulic oil will seep out when dismantling the oil pipe, it is recommended to put back the yarn or rag when dismantling.
Page 58 4. Unscrew the cylinder lever fixing bolt with a 6mm 5. Use 12mm hexagonal wrench to take off the cylinder hexagon socket base fixing bolt, 6. Remove the cylinder, the installation process and the reverse of the above process...
Page 59 1. Use 22mm open-end wrench to remove the oil pipe at the bottom 2. Use 22mm open-end wrench to remove the top oil pipe of the of the cylinder cylinder 3. Use a 12mm hexagon socket to remove the two bolts holding the 4.
Page 60 1. Use a punch to knock down the spring clamp and remove the protection plate 2. Use 22mm open-end wrench to unscrew the 3. Remove the cotter pin oil pipe at the bottom of the middle cylinder.
Page 61 4. Take out the pin, you can take off the chain 5. Use 13mm open-end wrench to unscrew the hoop bolt and take off the hoop 7. Remove the middle oil cylinder 8. Remove the spring with a spring clamp 9.
Page 62 10. Remove the side cover with a 12mm hexagonal wrench to remove all parts for replacement and repair. The installation process is the reverse process of disassembly.
Page 63 12.REGULAR MAINTENANCE  Only qualified and trained personnel are allowed to do maintenance on this truck.  Before maintaining, remove the load and lower the forks to the lowest position.  If you need to lift the truck, follow chapter 4 b by using designated lashing or jacking equipment. Before working, put safety devices (for instance designated lift jacks, wedges or wooden blocks) under the truck to protect against accidental lowering, movement or slipping.
Page 64 a.Maintenance checklist Table 3: Maintenance checklist Interval (Month) Hydraulic Check the hydraulic cylinder, piston for damage noise and leakage Check the hydraulic joints and hose for damage and leakage Inspect the hydraulic oil level, refill if necessary Refill the hydraulic oil ( 12 month or 1500 working hours) Check and adjust the function of the pressure valve (1200/1600 kg +0/ +10%) Mechanical system Inspect the forks for deformation and cracks...
Page 65 Test the emergency braking Test the reverse and regenerative braking Test the safety (belly) button function Check the steering function Check the lifting and lowering function Check the tiller arm switch function Test the key switch of damages and function Test the speed limitation switch (lifting height >~300mm) General Check if all decals are legible and complete...
Page 66 b.Lubrication points Lubricate the marked points according to the maintenance list. The required grease specification is: DIN 51825 standard grease. 1 Load wheel bearing 2 mast 3 Chain 4 Hydraulic system 5 Steering bearing Fig. 18: Lubrication point c. Check and refill the hydraulic oil The required hydraulic oil type is: Ambient –5℃~25℃...
Page 67 d. Check the electrical fuse Remove the main cover, the fuse is located in the position shown in Figure 19. Fuse specifications are shown in Table 4: Fuse Specifications Specification Fuse 1 Fuse 2 Fuse 01 350A Figure . 19: Fuse position e.
Page 68 13 TROUBLE SHOOTING If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 5: Trouble shooting TROUBLE CAUSE REPAIR Load weight too high Lift only the max. capacity, mentioned on the ID-plate Battery discharged Charge the battery Lifting fuse faulty Check and eventually replace the lifting fuse...
Page 69 heat sensor The controller is damaged. Replace the controller. The stacker starts up The accelerator not moves back to its Repair or replace the accelerator. suddenly neutral position. If the truck has malfunctions and can’t be operated out of the working zone, jack the truck up and go with a load handler under the truck and safe the truck securely.
Page 70 14.WIRING/ CIRCUIT DIAGRAM Electrical circuit diagram Fuse 1 : 10 A Fuse 2 :10 A Fuse 01 : 350 A CODE ITEM CODE ITEM...
Page 71 Tiller Indicator Capacitor S1,S2,S3,S4 Inching switch Controller Inter-lock switch FU01,FU1,FU2 Fuse SH1,SH2 Magnetic switch Battery DC power switch Horn SU1,SU2 Micro switch Relay Key switch Main contactor Electromagnetic brake Pump motor Proportional valve Traction motor YV2,YV3 Electromagnetic valve Fig.20: Electrical diagram (EPS) Table 6: Description of electrical diagram...
Page 72 Hydraulic circuit Fig.21 Hydraulic circuit...
Page 73 c.Brake system schematic Figure.22 Braking schematic...
Page 74 15 The use of ZAPI handheld programmers The power supply In the battery car, the traction battery can be used as the power supply voltage for the handheld programmer. For lead-acid batteries, the nominal battery voltage is 12V-80V. For batteries with a nominal voltage greater than 8 0 V, the intelligent controller can be powered by internal batteries.
Page 75 4) Cable red crocodile clipping vehicle power positive pole, black crocodile clipping vehicle power negative pole. 5)Once the CNX8 voltage is available, the ZAPI manual programmer opens and the home screen appears. The handheld programmer CAN connect to the Zapi controller inside the CAN line. The main screen When the Zapi logo appears, the home screen is rendered In addition, the green LED must be turned on and kept bright.
Page 76 requests the connection speed. Use the up/down keys to move between rows and the left/right keys to change the value of each item. Once the correct value is set, press OK to try to communicate with the node/child node. SELECT NODE 2 Is the connection point of the walking controller SELECT NODE 3 Is the connection point of the pump station controller Press ESC to abort connection attempts at any time.
Page 77 controller has no " hide" menu, which requires pressing multiple buttons immediately to reach: all menus are now visible. Use the up and down keys to browse the list: Press OK when you find the menu you want. Change the parameters Go to the parameter change menu from the main menu.
Page 78 adjustments, hardware settings, etc. Monitoring menu The monitoring menu has changed significantly compared to the standard handheld. Immediately display four variables: scroll the menu as usual using the up/down key. A variable may be "stuck" and it will keep scrolling. Once the desired variable is selected, right-click: it will be selected in a different color.
Page 79 Press the left button to " unlock" the last locked variable. Pressing the left button up to three times will unlock all variables. Press ESC to return to the main menu. Note that pressing the F1 key activates the time- exceeded graphical representation of the selected variable. The graphics tester is not fully functional: it will be activated in future firmware.
Page 80 Use the up/down key to select an alarm in the list: If you press OK, other information about the alarm will be displayed. Press F1 to delete the controller alarm log: When the key is pressed, the controller will request confirmation. Program VACC The program VACC menu has changed slightly compared to the old controller.
Page 81 When ESC is pressed, the controller asks to store or delete the set value. End connections Return to the home screen to end the connection: at this point, the cable may be removed from the target controller. If the cable is removed from another menu, the controller will return to a no communication alarm state. Controller shutdown Once the cable is removed, the controller will automatically shut down.
Page 82 16.ZAPI Fault Code List Fault name Solution ALARM CODE CODE Start sequence failure Start sequence is not correct, possible causes. 1. The direction switch has been closed before the machine INCORRECT is turned on. START 2. Wrong operation sequence. 3. The wire connection is not correct. 4.
Page 83 Logic Card Failure 2 LOGIC Logic card on the phase voltage feedback hardware FAILURE#2 circuit part failure, replace the controller Logic card failure 1 The fault occurs when the low voltage or overvoltage LOGIC protection function occurs. In a 24V system, the FAILURE#1 controller detects a voltage of more than 45V or less than 9V;...
Page 84 connection is correct; motor to ground whether there is leakage, whether there is a motor coil break. 2, replace the controller Contactor sticking When closing the main contact coil, the controller CONTACTOR should first detect whether the main contactor contacts CLOSED are sticking or not.
Page 85 2, charging resistor disconnection, charging circuit failure, power supply module problems, need to replace the controller So that the controller's own temperature down to 85 ° HIGH Controller over- below, if this fault still exists, it is possible that the TEMPERATURE temperature temperature sensor failure or the controller's own logic...
Page 86 possible that the alarm is caused by electromagnetic interference on the sensor bearings. If none of the above, replace the controller. Please note that human intervention may also cause the controller to display this fault, in which case it is necessary to power down and restart the vehicle.
Page 87 The controller will always detect, when there are two FORW+ BACK Forward and reverse directions at the same time to request the operation of signals are present at the signal will be alarmed. Possible causes. same time (direction switch 1. Broken wire sticking) 2.

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