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Noblelift PSE Service Manual

Electric pallet stacker
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Service Manual
PSE - Electric Pallet Stacker
（PSE12BD / PSE12ND）
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.
This truck is only used in factory, tourist attraction
and amusement parks
Scan for more
Information
Service hotline：4008-836115
Version 04/2023
PSE12BD/PSE12ND-SM-003-EN

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  • Page 1 Scan for more Information Service hotline：4008-836115 Service Manual PSE - Electric Pallet Stacker （PSE12BD / PSE12ND） 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 Foreword Before operating the electric stacker, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation of the truck may create a danger situation. 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 Content 1. Correct application 2. Vehicle overview Overview of the main components b.Main technical data c.Description of the safety devices and warning labels d. Identification plate 3. The Warning, residual risk and safety instruction 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. Commissioning b.
  • Page 4 C. Brake system schematic diagram 13. Electronic System a -1 Overview b-1 Emergency switch b-1-1 Appearance and Specifications b-1-2 Function b-2 Controller and associated equipment b-2-1 Appearance b-2-2 Function b-2-3 Test b-3 Electrical control unit (562346033003) b-3-1 Electrical control unit (562346033003) 14 Tiller handle (562346011002) a-1 Function a-2 Tiller head detection...
  • Page 5 19. CURTIS Handheld Programmer 20. Troubleshooting for each fault code...
  • Page 6 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 7 Vehicle overview a. Overview of the main components 图. 1 主要零部件概述 Fig Overview of Main Components Mast 11. Cover 21. Charge spring cord Fork carriage 12. The bottom cover 22. Charging indicator light Load roller assembly 13. Protective board 23. Display panel Chassis 14.
  • Page 8 b. Main technical data Technical Data...
  • Page 9 Table: Main technical data for standard version Type sheet for industrial truck acc. to VDI 2198 PSE12BD PSE12ND Manufacturer`s type designation Battery Power (battery ,diesel, petrol, gas, manual) Operator type Pedestrian Load Capacity / rated load Load Capacity / rated load (mast lift) Q(t) Load Capacity / rated load (support arm lift) Load centre distance...
  • Page 10 0.65 Drive motor rating S2 60min Lift motor rating at S3 7.5% Battery acc. to DIN 43531/35/36 A, B, C, V/Ah 2 x 12 / 85 24 / 60 Battery voltage, nominal capacity K5 2 x 27 Battery weight Energy consumption acc: to VDI cycle Kwh/h 0.66 Type of drive control...
  • Page 11 Identification plate Designation, type Battery weight minimum/ maximum Serial number Nominal power in kW Rated capacity in kg Load center distance Supply voltage in V Manufacturing date Own mass (self weight) in kg without battery Option Name and address of manufacturer) If sold to the EU, here the place of the CE marking Fig.4: Identification plate...
  • Page 12 3. The Warning, residual risk and safety instruction DO NOT  When driving outside, lift loads 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 a Warning label definition The manual uses the following three warning labels: Dangerous, Warning, and Attention. Each label is intended to indicate to the reader the severity and nature of the potential harm, consequences, and precautions against the hazard. You will find these labels in the entire manual. Make sure you pay close attention to them as they are included for your safety.
  • Page 14 b Vocabulary  The following are the terms and descriptions used in this service manual Item Descriptions A device that converts mechanical motion to an analog voltage mode and Accelerator transmit to a controller to control the speed at which a vehicle is driven A device ( e.
  • Page 15 A maintenance tool program to calibrate and diagnose CURTIS controllers of Handheld trucks. Programmer Parking Brake A pair of brakes that electromagnetically activate their respective motors upon the stationary of the vehicle. A device that detects the direction and speed of a motor to produce a pulse Encoder signal.
  • Page 16 A part of rotating motor. Rotor A bar chart of an electrical or electronic component that uses symbols to show Outline the individual components as well as how the wires and connectors work electrically A port that communicates one-to-one with the controller. Serial Port An unwanted electrical connection between two or more components.
  • Page 17 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. Commissioning Table 2: Commissioning data Type PSE12BD/ 3600 PSE12ND/ 3600 Commissioning weight [kg] Dimensions 3600 3600 [mm] After receiving our new stacker or for re-commissioning you have to do following before (firstly) operating the truck: ...
  • Page 18 Transportation DURING TRANSPORTATION ON A LORRY OR TRUCK ALWAYS FASTEN THE TRUCK SECURELY Lower the forks and park the truck securely. Fasten the truck according to Fig. 6 by fixing dedicated lashing belts to chassis, Fork carriage and mast, and fasten the other side at the transporting truck.
  • Page 19 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 20 6. Operation instructions BEFORE OPERATING THIS TRUCK, PLEASE FOLLOW THE WARNINGS AND SAFETY INSTRUCTIONS (CHAPTER 3). Make sure, that the load is palletized and stable and that the daily inspection is carried out. PSE12BD： Pull out the emergency button（20）,type the password on pin-code panel and press √...
  • Page 21 a. Parking DO NOT PARK THE TRUCK ON INCLINED SURFACES The truck is equipped with an electromagnetic failsafe stopping and parking brake. PSE12BD: Always lower the forks fully. Press the emergency switch (20). PSE12ND: Always lower the forks fully. Press the button, green LED ring is off (Fig.8), and press the emergency switch (20).
  • Page 22 This truck can be used as pallet truck and stacker. When press the fork lift button (Fig. 7, 31), the fork and pallet lift together, the maximum lift height is 120 mm, maximum load is 1200 kg. When the fork lifts to the height within 120 mm, press the pallet lift button (Fig. 7, 28), the pallet lifts for stacking, the maximum stack height is 1800 mm (the truck is used as pallet truck and stacker at the same time).
  • Page 23 e. Travelling TRAVEL ON INCLINES ONLY WITH THE LOAD FACING UPHILL DO NOT TRAVEL ON INCLINES MORE THAN SPECIFIED WITH THE TECHNICAL DATA. TRAVELLING IS ONLY ALLOWED IF THE FORKS ARE LOWERED DOWN TO THE LIFTING POINT (<300MM). Fig.12: Operating direction After starting the truck by activation from Pin-code panel carefully move the tiller to the operating zone (‘F’, fig.11).
  • Page 24 f. Steering ou steer the truck by moving the tiller to the left or right side. When travel in front direction (opposite to direction of forks) the turning of tiller bar to right side will cause the truck turning clockwise. g.
  • Page 25 7. Pin-code panel PSE12BD is equipped optional with a pin-code panel. PSE12ND is equipped standard with a pin-code panel and three ID cards. Introduction Pin-code panel is an electronic system which is similar with an electronic alarm system. Truck will not able to operate before typing a correct password, the main function is to prevent unauthorized operation.
  • Page 26 8.BATTERY CHARGING AND REPLACEMENT  Only qualified personnel are allowed to repair or charge the battery. Be sure to follow this manual and the battery manufacturer's instructions.  PS E12BD uses batteries with lead-acid batteries, and PSE12D uses lithium batteries ...
  • Page 27 Item Parameter Remark Specification 24V60Ah 8-LFP-60-EV-NOB Nominal Voltage 25.6V Rated Capacity 60Ah 0.5C Discharge Reference weight About 17kg Discharge Maximum Continuous Discharge 100A Current Maximum pulse discharge current 150A No more than 10 seconds Discharge cut-off voltage ≥22V Discharge Standard charging current Max.
  • Page 28 b. Safety instructions（lithium battery） Please observe the following requirements. If not, may cause property damage, injuries or even death. Prevent fire  Do not work above 60 °C  Do not put the battery near the heat source, such as stove, fireplace etc. ...
  • Page 29 Environment Temperature Remaining discharge capacity of the battery 100% Note：Though the battery could discharge in a extremely low temperature，during the charging process, it could generate condensate water， thus damage the battery internal electronic equipment， causing the potential danger. Heat the battery slowly to the minimum allowable charging temperature and activate the charging function before charging the battery cell (it will take about 4 hours to return to normal temperature).
  • Page 30 PSE12ND: Preliminary Steps 1 Safely park the vehicle and remove the housing. 2 Turn off the power switch. Procedure 1 Remove the screws (9) and remove the battery mounting plate (7) 2 Disconnect the battery control connection wire 3 Remove the positive and negative battery screws and remove the battery power cable.
  • Page 31 Display An alpha-numeric liquid crystal display is fitted in the centre of the unit that shows the hours worked. The display is backlight (the backlight is normally lighted). Alarms The same display can also indicate the alarm state, showing a code corresponding to the type of alarm. Battery State of charge The battery's state of charge indication is integrated in the LCD display;...
  • Page 32 f. Lithium battery failure analysis and description Battery Pack System Failure Repair Form NO Fault Type Analysis Detection Method Confirmation Solution 1. The measurement of infinite resistance indicates that the CAN communication harness 1, check the alarm code is disconnected. First, on the vehicle display to the CANH and CANL confirm...
  • Page 33 charged, CANL harness Internal conductive normal switch components 2, connect the charger, indicator the system are check charger light is on damaged display fault code, shutdown state to see if charging port Not measured to 120Ω Replace terminals loose, resistance, CAN chip battery back terminals,...
  • Page 34 g. Charger  The automatic charger with the vehicle is only apply to the optional voltage of 110V or 220V.  The charging space must be kept well-ventilated.  Accurate charging conditions can be viewed only from the discharge display. To control the charging situation, you must interrupt the charging first and restart the vehicle Park the vehicle in the safety power supply area.
  • Page 35 Instruction WT2425ZMB charger, which is an efficient, fast, small size, ground charging device with CAN. The charger is a two-phase AC 220V voltage input with forced air cooling. It has the functions of input over-voltage, under-voltage, output over-voltage,over-current, output short circuit, fan fault protection and meets the requirements of RoHS and CE.
  • Page 36 Lithium battery charger indicator light description Indicator label No-load indication Red green lights flashing alternately Battery indicator Red light flashes at 1s interval and the battery power is less than 80%. Yellow light flashes at 1s interval, battery power > 80%; Green light flashes at 1s interval, battery power 100% error indication Overvoltage ( current ) failure...
  • Page 37 Troubleshooting Fault Explanation No power Check whether the AC input is correctly connected and the power cord is damaged. Can not charge Check whether the B+ and B-wires of the charger are connected properly Low Output Voltage Check that the CAN bus of the module is properly connected to the control PCB board, at Charge otherwise contact the manufacturer for after-sales service support Low Output Current...
  • Page 38 9. Maintain Security 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 39 Compressed air hazards When cleaning, please wear a protective mask, protective clothing and protective shoes. When cleaning, the maximum air pressure must be lower than 205 kPa (30 psi). Hydraulic oil hazards Please carefully follow the instructions below to carry out safety tips on hydraulic system maintenance.
  • Page 40 Store all oily wipes or other flammable materials in a protective container in a safe place. 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.
  • Page 41 10 Maintenance  Only qualified and trained personnel are allowed to maintain the vehicle  Before maintenance, 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.
  • Page 42 a. Maintenance checklist Intervals （Month） Hydraulic system  Check hydraulic cylinder if there is noise and leakage of piston  Check hydraulic connectors and tubing if there is damage and leakage  Check hydraulic oil level and recharge if necessary ...
  • Page 43  Check electromagnetic valve  Check emergency brake  Check reverse braking and regenerated braking  Check belly button  Check steering  Check Lift up and down  Check proximity switch of tiller  Check speed limit switch (lifting height >~300mm) Summary ...
  • Page 44 d. Check fuse Fig 17. Fuse position Fuses are in the position above. Fuse Spec see table blow . Table: Fuse Spec Rate 150A FU01 FU02 (PS E12NM) 1.5A...
  • Page 45 e. Removal and reinstallation of the cover plate Do not use the vehicle if the protection is damaged or not properly installed. Remove the clip protecting the guard and remove the guard. Setup is the opposite. Make sure the protective plate is properly fixed and intact.
  • Page 46 disassembly, loss of replacement parts, and repeated failures caused by the same problem. To prevent a mistake, record the fault and the required components.. Make sure to check and record the following information： Truck model number, serial number, and working hours Reason why the vehicle needs disassembly Check for the symptoms, location, and causes of the fault.
  • Page 47 Notes after disassembly When cleaning the components and keep them away from the contaminants. Pay special attention to removing contaminants from upper oil lines or component piping. When cleaning special parts, increase the number of detergent containers and cleaning them several times.
  • Page 48 Check during assembly In each step of the assembly process, check and record the parts number. Reassemble the gasket Install gaskets and washer in the same position as before and check if the clearance is correct. Assemble and adjust the links If not adjustment needed, assemble them into the same length as before.
  • Page 49 Lubricate the O-ring to avoid scratching its surface during installation. Silicone o-rings are easy to damage, so be careful not to overstretch. tiller oil seal Prevent oil seals from collecting dust, especially on lips, and make sure there is no hardening or scratches.
  • Page 50 When removing or installing the retaining ring, use a pair of right ring pliers and be careful not to apply too much pressure on the retaining ring. After installing the retaining ring, check that the retaining ring is inserted correctly. Assembly of fittings with straight thread and O-ring (for different applications) 1.
  • Page 51 if thread glue or other compounds are to be used. After loosening fasteners, they are kept in good condition and reused only under fine conditions. When replacing a new one, be sure to select fasteners of the same size and grade. Usually, you can identify the strength of the bolt by the number marked on the head, such as 8.8 or 10.9, as shown in 1-30.
  • Page 52 For the Metric Fasteners...
  • Page 53 f-2 Standard torque for O-ring seal fittings...
  • Page 55 Tapered pipe thread fittings...
  • Page 56 11. Troubleshooting Fault Fault reason Maintenance Lift only the maximum load as Goods over weight shown on the IDplate Battery discharging Charge the battery Goods cannot be The lift fuse has failed Check and replace the lift fuse lifted The hydraulic oil level is too low Check and fill with hydraulic oil Inspect tubing or cylinder for Oil leak...
  • Page 57 12．Electrical /Schematic diagram a. Electrical diagram FU1 : 10 A FU2 : 6 A FU01 : 150 A FU02 : 60 A Fig 18.PSE12BD Electrical Circuit Diagram...
  • Page 58 FU1 : 10 A FU2 : 6 A FU3 : 1.5 A FU01 : 150 A FU02 : 60 A Fig 19. PSE12ND Electrical Circuit Diagram...
  • Page 59 Description of electrical diagram Table 7: Code Item Code Item Code Item Sensor of speed reduction Auxiliary module Contactor on curve3 Tiller Pump motor Emergency button Controller Driving motor Fork limit switch1 FU01 Fuse 150A Inter-lock switch Mast limit switch2 FU02 Fuse 60A Button switch 1...
  • Page 60 FU1 : 10 A FU2: 6 A FU01: 150 A FU02: 60 A Fig. 20 PSE12BD Circuit Diagram...
  • Page 61 FU1 : 10A FU2: 6A FU3: 1.5A FU01: 150A FU02: 60A Fig. 21 PSE12ND Circuit Diagram...
  • Page 62 Description of electrical diagram Table 8: Code Item Code Item Code Item Auxiliary module Pump motor Fork limit switch1 Tiller Driving motor Mast limit switch2 Controller Inter-lock switch Safety switch FU01 Fuse 150A Button switch 1 Charger FU02 Fuse 60A Button switch 2 USB port Fuse 10A...
  • Page 63 b. Hydraulic circuit Fig 22. hydraulic circuit Description of hydraulic circuit Table 9 : Code Item Code Item Hydraulic power unit Cylinder（Mast） Check valve Cylinder（Leg） Electromagnetic valve Safety valve Overflow valve Solenoid valve Throttle valve...
  • Page 64 c. Brake system schematic diagram Fig. 23:Brake schematic...
  • Page 65 13. Electronic System a -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 66 b-1 Emergency switch b-1-1 Appearance and Specifications Specifications ITEM Part number 920200100007 ZDK32-350-1 b-1-2 Function The emergency stop switch is used to stop the operation of the vehicle by cutting off the current in the electrical system in an emergency. When pressed, all DC and AC circuits are open. The DC circuit is open Once the emergency stop switch is turned on, the battery's positive terminal and the key switch are disconnected, thereby cutting off power to all loads supplied by the key switch.
  • Page 67 Removal and installation Preliminary steps 1 Park the vehicle safely and remove the cover. 2 Turn off the key switch. 3 Disconnect the battery connector. Procedures 1 Disconnect the button switch (8) and the USB power cable. 2 Remove the emergency stop switch cap screw (12) and remove the emergency stop switch cap (11) 3 Remove instrument panel screw (7) and remove instrument panel (15)
  • Page 68 2). Curtis controller 1212e(20CE/EN1175) butting connector：8 芯 Molex Mini-Fit Jr. 16 core Molex Mini-Fit Jr. b-2-2 Function The controller is connected through the following sensors, switches, relays and actuators. Key switch switch accelerator tiller proximity switch Emergency reverse switch Hydraulic control switch These devices provide DC power, interact with a controller, and the controller activates or receives data from them to control the motor based on a number of parameter settings.
  • Page 69 accelerator pedal when operating an electric vehicle. By setting the acceleration rate, the vehicle can meet the requirements of acceleration operation under different working conditions. 3. The maximum driving speed can be set. Reasonable setting of the maximum driving speed of the electric vehicle can prevent the traction motor from being overloaded due to excessive vehicle speed.
  • Page 70 Normal range Multimeter terminal ITEM Resistance Red test lead Black test lead Polar value measurement determination Over40KΩ Over80KΩ Over80KΩ Over60KΩ 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)
  • Page 71 b-2-4 Removal and installation Access control panel 1．Lower casing to enter drive motor controller. 2．Close the key switch and emergency stop switch 3．Disconnect the battery 4．Leave the key switch on to make the power module discharge. Two 30 seconds 5．Turn off key switch Note: Remember that the controller contains AN ESD (electrostatic discharge) sensitive component.
  • Page 72 b-3 Electrical control unit (562346033003)
  • Page 73 b-3-1 Electrical control unit (562346033003) Item Code Mark Item Description Qty. Substitute Note 532233020001 Mounting Plate 920100200002 Fuse 920500100007 Horn 920100400001 Fuse Holder 920100400006 Fuse Holder 505633020003 Copper Busbar 920100100007 Fuse 920100400002 Fuse Holder 920100100003 Fuse 921400100081 Controller 532221520027 Baffle 921200100016 Module CAN Communication...
  • Page 74 14. Tiller handle (562346011002)
  • Page 75 02 Tiller handle（562346011002） Item Code Mark Item Description Qty. Substitute Note 532298510022 tiller Cap Kit 532298510023 tiller Cap Kit IC card 1.01 910200200003 Screw 1.02 910400500002 Spring Washer 1.03 508098520014 Traction lever 1.04 910200200159 Screw 1.05 508098520027 ID Card With RFID card function 1.06 532298510054 Display Screen kit...
  • Page 76 a-1 Function tiller 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) C accelerator (26) D Turtle speed switch (30) E Horn switch (27)
  • Page 77 a-2 Tiller handle detection 1 Use the multimeter to measure the resistance between 4 and 5 feet. A:Lift & lower B+input B:Lift signal input C:Lower signal input D: Horn B+ input E: Crashproof B+ input F: Crashproof signal input G: Horn signal input 1: Battery positive pole 2: Crashproof signal output 3: Battery negative pole...
  • Page 78 a-3 Removal and installation Preliminary steps 1.Remove the shell to access the vehicle interior 2.Turn off the key switch and emergency stop switch. Procedures 1.Remove the fixing screw of the lower cover of the tiller and disconnect the cable to remove the lower cover of the tiller (25) 2.Remove the tiller upper cover fixing screw to remove the tiller upper cover (24) Perform the above steps in reverse order to install the tiller head assembly (26).
  • Page 79 a-7 Dual Lift tiller Fig 1 Fig 2 1.On the dual lift tiller, the lift and lower buttons of the mast are marked in the photo. Fig 3 Fig 4 2．The buttons shown in Fig. 3 are the car body up button, and the buttons shown in Fig. 4 are the car body down button.
  • Page 80 15 Drive/brake system a-1 Overview a-1-1 Components 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 send them to the corresponding wheels (mechanical power).
  • Page 81 a-2-2 How does this work On the electric side, the driving motors rotate their drive wheels so that the vehicle can move forward/backward Controlled by the controller Each drive motor is connected to the controller via M1 and M2 lines. The controller runs the drive motor based on input from multiple switches and sensors and internal parameter Settings.
  • Page 82 Removal/assembly of drive assembly Drive unit (532246013501) Preliminary steps 1. Safely park the vehicle and remove the shell 2. Close key and emergency stop switch. 3. Disconnect the battery connector. Procedures 1. Remove steering wire rope assembly (7). 2. Remove the steering shaft screw (5) and remove the steering shaft (6) 3.
  • Page 83 Follow the steps in reverse order to install the drive assembly a-2-3 Drive motor disassembly/assembly and test Drive assembly (532246013001)
  • Page 85 02 Drive assembly (532246013001) Item Code Mark Item Description Qty. Substitute Note 508098510078 Drive Unit PU wheel 508098510079 Drive Unit Anti-skip wheel 508098520002 Brake 508098520040 Rubber Strip 910200200019 Screw 508098510015 Gear Components 910700200004 Bearing 508098520011 Gear Ring 508098510016 Motor Check 532246013002 508098520032 Seal 508098520003...
  • Page 86 a-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. Procedures 1. Use the crane to lift the vehicle safely. 2. Disconnect the connection line of the drive motor. 3.
  • Page 87 Due to the failure of the drive system, the drive system consumes too much battery power. Check brake adjustment. Check wheel bearings, axles, and other mechanical components for correction and troubleshooting purposes. Switch to tires with less friction Due to lifting failure, the hydraulic system consumes too much battery power, or the working cycle hydraulic conditions are incorrect Check whether the mast is restricted during...
  • Page 88 a-3-2 Driving box Possible cause The problem Noise or vibration in the No lubricating oil: gearbox Add the correct amount of lubricant oil Use non-standard oils: Replace oil with standard oil. Gear gets damaged or dented: Replace the gear. Bearing damage: Replace the bearing.
  • Page 89 16 The hydraulic system a-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. a-1-1 Components...
  • Page 90 01 Hydraulic unit （562346024001) Item Code Mark Item Description Qty. Substitute Note 910200200074 Screw 532223520001 Plate 910400100006 Flat Washer 910200200053 Screw ------------ Pump Unit Check 532246023501 950400300007 Joint 562324510005 Hose 562324510004 Hose 910400100007 Flat Washer 910400500007 Spring Washer 910100300038 Bolt 562324510001 Cylinder 950400400003...
  • Page 91 Hydraulic oil circulation The hydraulic oil tank stores hydraulic oil, which is supplied to the main hydraulic pump through a filter. The main hydraulic pump pressurizes the supplied oil and sends it to the lifting cylinder. When hydraulic oil is received, these systems perform their functions and then drain the waste oil to the tank through a return filter.
  • Page 92 a-2 Pump Station Assembly a-2-1 Appearance and specifications Item Specification Power 0.8KW Speed 1618rpm Frequency 55.5hz Insulation level a-2-2Test 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. The controller operates the pump motor contactor based on inputs from multiple switches and sensors and internal parameter settings.
  • Page 93 a-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 Preliminary steps 1. Lower the fork to the bottom, press the lower button many times to eliminate the residual pressure in the hydraulic system.
  • Page 94 a-2-3 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 95 a-3 Troubleshooting a-3-1 Pump motor Fault phenomenon Possible reason Poor connection or blown fuse. Check the battery connection. Check the key fuse. Check whether the hydraulic pump motor cause the fusing The key switch, upper limit switch, and line contactor are not closed. Turn off the key switch.
  • Page 96 a-3-2 Hydraulic pump Fault phenomenon Possible reason Oil level is low The oil is very thick (too viscous) Noise in the pump Pump inlet line is limited Worn parts in the pump. Oil is very dirty Air leaked into the inlet pipeline Oil level is low The oil duct is restricted The oil is too thin...
  • Page 97 17 Lifting system a-1 Overview a-1-1 components 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 98 a-2 Mast a-2-1 Appearance Two stage mast (562346044001)
  • Page 99 01 Two stage mast (562346044001) Item Code Mark Item Description Qty. Substitute Note 562344020010 Guard Plate 2600 562344020009 Guard Plate 2900 562344020008 Guard Plate 3200 562344020002 Guard Plate 3600 562344020003 Guard Plate 940400300001 Spring Buckle 562344013001 Outer Mast (2600,570x1150) 2600,570x1150 562344013002 Outer Mast (2600,685x1150) 2600,685x1150...
  • Page 100 01 Two stage mast (562346044001) continuation Item Code Mark Item Description Qty. Substitute Note 910300500001 910200500015 Screw 920200400030 Proximity Switch 562344020004 Plate 910200200033 Screw 206044520060 Chain Anchor 941100800010 910600600006 Cotter Pin 910600600019 Cotter Pin 532244020027 Fixing Plate 910200200077 Screw 910400500007 Spring Washer 910400100007 Flat Washer...
  • Page 101 01 Two stage mast (562346044001) continuation Item Code Mark Item Description Qty. Substitute Note 910100300049 Bolt 910400500008 Spring Washer 532244010020 Chain 2600 532244010007 Chain 2900 532244010014 Chain 3200 206044510103 Chain 3600 532233010002 Wire Harness 921500100077 Cable 532244010016 Cylinder 2600 532244010001 Cylinder 2900 532244010009...
  • Page 102 a-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. Check carefully for cracks in the fork. Special attention should be paid to the heel part, all welding areas and mounting brackets.
  • Page 103 B Fork Removal / installation 1. Fill 10cm-thick sleepers under the forks and lower the forks completely. 2. Disconnect the chain and fork. 3. Slowly raise the main frame to make the fork frame separate from the main frame and take out the fork. 4.
  • Page 104 Lifting chain removal/installation 1. Raise the fork and place sleepers under it. 2. Lower the forks onto the sleepers to release tension from the main lifting chain. 3. After removing the cotter pin (5), pull out the cotter pin (4) and remove the chain from the chain anchor.
  • Page 105 18. Steering system 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 tiller rotation shaft (20) and a drive rotation shaft (6), which are connected by a steel wire chain (7).
  • Page 106 Upper wire rope Lower wire rope...
  • Page 107 19. CURTIS Handheld Programmer a-1 Operation Cautions The prompt function of the programmer is designed for the convenience of vehicle inspection and maintenance, Adjustments to the controller parameters are not allowed without the approval of the vehicle manufacturer，so as to avoid vehicle and personal safety accidents.
  • Page 108 Warning： The control system will affect the performance of vehicle's acceleration, deceleration, hydraulic system and brakes. Hazardous conditions may occur if the vehicle control system is incorrectly programmed or beyond safety limit. Only the vehicle manufacturer or authorized service agent may program the control The programmer has two interfaces with a battery box and a memory card slot, of which one is used to communicate with electric control, and the other is used to communicate with PC.
  • Page 109 Function keys The three keys will be blank because the function of the three keys is based on the specified content. At any given time, the functions of the buttons are displayed on the LCD screen above. Directional arrow key The information displayed can be selected by pressing up, down, or left or right through 4 directional keys.
  • Page 110 2. Menu structure The main menu consists of nine submenus, each of which is displayed with a specific icon, and each item of the submenu is arranged in a hierarchy. Some menus contain one item only, but most menus contain more than one item, and you can access the next level of submenus through each folder.
  • Page 111 "Clear All" is used to Clear the history failure folders. A function key will be highlighted separately if there is a history failure in the history failure folder, and will be grayed out if there is no history failure. 4.Programming edit menu In the main menu, Select the "Programming"...
  • Page 112 Parameters can be adjusted or modified in two ways: one is in the parameter list page as shown in the figure below; The other is through the parameter edit page as shown below...
  • Page 113 20. Troubleshooting for each fault code 1212C-2503 controller fault code NL-200tiller fault code check list Fault description Fault reason Source 1212C-2503 LOW_BDI Low power controller 1212C-2503 PUMP_SRO_FAULT Lift / lower action key start switch controller operating sequence is not correct including 1212C-2503 SRO_FAULT moving、lock，start switch...
  • Page 114 controller 1212C-2503 MOTOR_OPEN Motor open circuit controller CONTROLLER_OVERCUR 1212C-2503 Controller overcurrent RENT controller MOTOR_TEMP_HOT_CUT 1212C-2503 Motor hot cutback BACK controller CONTROLLER_OVERTEM 1212C-2503 Controller overtemp. Cutback P_CUTBACK controller CONTROLLER_UNDERTE 1212C-2503 Controller low temp. controller CONTROLLER_SEVERE_O 1212C-2503 Controller severe high temp. VERTEMP controller 1212C-2503 OVERVOLTAGE_CUTBACK Over-voltage cut off...
  • Page 115 BMS Communication BMS Communication overtime Tiller Outage Over Voltage Battery high voltage Li-battery Over Discharge Battery over discharging Li-battery Communication Outage Battery Communication overtime Li-battery Under Voltage Battery low voltage Li-battery Over Current Battery over current Li-battery Over Temperature Protect Li-battery Battery extra high temperature Temperature Protect...
  • Page 116 Throttle wiring fault Incorrect 21-2 throttle type setting 21-3 Incorrect throttle operation Steering Angle Pot wiring 21-4 fault Incorrect throttle operation HPD Sequencing 1212E Controller 22-1 Throttle defective 23-1 Main Relay Welded Main relay defective 1212E Controller Main relay defective 24-1 Main Relay Did Not Close Incorrect relay pull in...
  • Page 117 53-4 54-1 Incorrect operation 54-2 sequence 54-3 PUMP SRO Fault 1212E Controller Switch defective 54-4 Incorrect parameter settings 54-5 55-1 EMR switch defective EMR Incorrect operation EMR SRO Fault 1212E Controller 55-2 sequence Incorrect parameter settings 55-3 56-1 56-2 Incorrect operation Creep SRO Fault 1212E Controller sequence Cost...
  • Page 118 Tiller Turtle speed button failure, Turtle speed button Mode fault Tiller detected closed before power on Rise button failure, the rise button is detected as being Lift fault Tiller pressed before the power is turned on. Faulty drop button, the drop button is detected as being Lower fault Tiller...
  • Page 119 Battery voltage is too low, 1, long-term storage, not in time to charge. 2, the Under Voltage Lithium Battery battery internal cell damage, resulting in the inability to charge into the power. Battery overcurrent, 1, the use of equipment is not in accordance with the original program set by the controller to run.

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