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FE4P44-77N-SMS-001

WARNING

Do not use the pallet truck before reading and understanding these operating

instructions.

Keep for future reference.

Operation and maintenance manual

FE4P44-77

N series

battery counter balanced forklift truck

Noblelift Equipment Joint Stock Co., Ltd

Содержание FE4P16N

Страница 1: ...the pallet truck before reading and understanding these operating instructions Keep for future reference Operation and maintenance manual FE4P44 77 N series battery counter balanced forklift truck No...

Страница 2: ...1 4 Installation of wheel hub 14 1 5 Malfunction analysis 15 2 Brake system 15 2 1 Summarize 15 2 2 Brake paddle 15 2 3 Brake base pump 16 2 4 Brake staff 17 2 5 Parking brake operating device 19 2 6...

Страница 3: ...position 55 7 5 Maintenanceandregulation 56 7 6 Instructionsofinstallingaccessaries 58 8 Disassemblingandinstallation 58 8 1 Attentions 58 8 2Hoistinglocationforpartsdisassembled 58 Chapter Three Ope...

Страница 4: ...hapter four Truck s regular check and maintenance 90 The check before operation 90 1 Checkingpointandcheckingcontent 90 2 Checking procedure 90 Check after operation 95 Truck cleaning 95 1 Truck surfa...

Страница 5: ...e operation if not do so it should lead to injury on human or damage on equipments and fire 2 Regulations that you need to pay attention and have to comply with before operation if not do so it should...

Страница 6: ...and lower the mast tilt forward and backward the mast turn and brake the truck 11 Be sure that the polluting level of hydraulic oil is less than 12grade 4 Operation of truck 1 Only can the person oper...

Страница 7: ...ls with wedge if the parking time is long 21 The protection valves on multiway valve and on steering device are already regulated so the users shouldn t regulate randomly when using to prevent that th...

Страница 8: ...7 Chapter two The main performance parameters of forklift truck The truck s outline dimension and performance parameters 1 The truck s outline dimension see figure 1 1 Figure 1 1 outline...

Страница 9: ...5 Freelift height h2 mm 130 Lift height h3 mm 3000 Extended mast height h4 mm 3985 Overhead load guard height h6 mm 2190 Seat height h7 mm 1100 Traction pin height h10 mm 295 Overall length l1 mm 2981...

Страница 10: ...lift height h2 mm 120 Lift height h3 mm 3000 Extended mast height h4 mm 3977 Overhead load guard height h6 mm 2190 Seat height h7 mm 1058 Traction pin height h10 mm 295 Overall length l1 mm 3398 Lengt...

Страница 11: ...h2 mm 120 120 Lift height h3 mm 3000 3000 Extended mast height h4 mm 4080 4075 Overhead load guard height h6 mm 2190 2190 Seat height h7 mm 1100 1100 Traction pin height h10 mm 295 295 Overall length...

Страница 12: ...otor and make the twist moment rise from travel motor and then send the twist moment to differential lies between drive axle and travel motor see figure 2 1 1 O ring 2 bolt 3 bearing 4 O ring 5 bolt 6...

Страница 13: ...and arrester It is installed in the front of framework The shell is unit casted in construction the tyres are fastened on wheel hub with studs and nuts wheel hub is supported on axle shell by conical...

Страница 14: ...ll is cast steel which is good in rigidity and bearing capacity the main technical parameter see List 2 1 List 2 1The main technical parameter Truck model FE4P16 18N FE4P20 25N FE4P30N FE4P35N Constru...

Страница 15: ...b when it reachs the defined value start to screw up the nut starting moment 49N m 147N m figure 2 5 fgure 2 4 injection of grease figure 2 5 measurement of starting moment 4 Install lock plate and lo...

Страница 16: ...g Clamping stagnation of moving parts adjustment oil leak Contacting surface bolts loose tighten seal packing rings worn replacing noise gear damages replacing bearing damages replacing 2 Brake system...

Страница 17: ...one way valve and through brake pipeline flow into subsidiary pump Then the piston of each subsidiary pump pushes out to make the brake shoe wearing piece get contact with the brake drum and finally...

Страница 18: ...and Pressure spring contacts with fixing pin and another end of it contacts with regulator In addition there are brake packing device and automatic regulating device assembled on brake staff See figu...

Страница 19: ...ide of secondary brake shoe is installed on the side of leading brake shoe See figure2 12 3 gap self regulating device Gap self regulating device can keep a proper gap between wearing piece and brake...

Страница 20: ...ke handle 2 6 Gist of dismantlement and regulating for brake staff Instruction of decomposing assembling regulating and brake paddle adjusting method when the wheel and hub is disassembled 2 6 1 The d...

Страница 21: ...nal one then push out the rest one with finger See figure 2 22 figure 2 22 2 6 2 Brake device inspection Inspection of parts Repair and replacement of Damaged parts 1 Check up if there is any rust of...

Страница 22: ...spring on hand brake handspike hen fix handspike on brake hoof See figure 2 27 figure 2 25 figure 2 26 figure 2 27 8 Fix guide of brake shoe on brace pin then fix rebound spring of brake hoof Install...

Страница 23: ...en pulling adjusting bar a Ensure adjusting bar ejector pin ejector pin spring and spring are all fixed b Check rebound spring of ejector pin and spring of adjustor check adjuster gear for running sta...

Страница 24: ...witch to make clearance into A 1mm d To be sure when step pedal down the light of brake shall be open e Tighten the nut figure 2 32 braking light button 2 8 Malfunction and cause See List 2 3 List 2 3...

Страница 25: ...system leakage Repair or replace 2 Clearance of brake hoof is not ok Regulate adjustor 3 Air in brake system Deflate air 4 Brake pedal adjusting is not ok Adjusting again 2 9 Maintenance Before runnin...

Страница 26: ...lexion Now you can place retainer washer and tighten lock nut 3 Steering system 3 1 Summary Steering system see figure 2 33 consists mainly of steering wheel steering shaft steering device steering oi...

Страница 27: ...the parts as steering axle body steering cylinder connecting rod steering knob steering wheel and so on Steering trapezium is crank block in construction that the cylinder piston rod by connecting rod...

Страница 28: ...ting pad 14 nut M12 15 dust cover 16 bearing 17 bearing 18 nut M30 2 19 washer 30 20 dowel pin 6 3 55 21 wheel hub cover 22 hub 23 pin 24 nut M10 1 25 25 washer 10 26 bushing 27 grease nipple M6 28 le...

Страница 29: ...inder Steering cylinder designed as a double acting piston in pattern that is the piston rod connects on each end to kunckle with connecting rod and the pressure from fully hydraulic steering device m...

Страница 30: ...ure there is no loose of wheel hub 5 Tighten castle nut and make slot aim at split pin hole of kunckle 6 Tap wheel hub gently by wood hammer again rotate wheel hub 3 4 circle by hand to ensure rotatio...

Страница 31: ...re air in oil circuit exhaust air failure of steering reset Rivet spring slice broken or elasticity is not enough replace spring slice too big inside leakage of steering cylinder check piston seal For...

Страница 32: ...ry set Electrical system of FE4P30 35N is powered by 48V battery set traction power of the truck is powered by AC motor lifting power is produced when AC motor is driving the oil pump to produce oil p...

Страница 33: ...ng performance and complete operating performance of electric forklift can be achieved by setting correctly each motor technique data and control technique data and function value of controller 1 The...

Страница 34: ...nd oil pump motor controller Once malfunction occurs in the working of controller there will display malfunction code in indicating instrument which will stop the controller from working to ensure the...

Страница 35: ...ntroller digital code indicates controller failure specific code please refer to 4 4 failure analysis 3 the letter on the upper left means truck operating mode H means high efficiency mode S means nor...

Страница 36: ...2 truck overloaded 3 the controller is wrongly assembled Severe Undervoltage 1 7 Voltage too low 1 battery parameter is wrongly setted 2 non controller system power consumption 3 The battery impedanc...

Страница 37: ...r is too hot as a result the performance is not good 1 The motor temperature reach or above the setted program alert temperature lead the current output to reduce 2 motor temperature parameter is wron...

Страница 38: ...ncoder failure 1 motor encoder is failure 2 wrong wiring Motor Open 3 7 Motor is open corcuit 1 motor phase 2 wrong wiring Main Contactor Welded 3 8 Main contactor adhesions 1 Main contactor contact w...

Страница 39: ...e External Supply Out of Range 6 9 Externial battery output is out og range 1 externial loading is between 5V and 12V battery current is too big or too small 2 in the inspection menu CheckingMenu para...

Страница 40: ...brake command is setted 2 Electromagnetic brake braking force is too small Encoder LOS Limited Operating Strategy 9 3 Encoder operation is limited 1 Because motor blocked or encoder failure the limit...

Страница 41: ...n please read operation instruction manual carefully keep the manual with you after reading so as to get convenience of it at any time 5 2 Battery use requirements The lifespan of battery is between 2...

Страница 42: ...y your eye parallel with density and let floater locate central position and not to touch with pipe wall to avoid influencing reading accuracy If temperature is lower than 25 or upper than 25 measure...

Страница 43: ...ng course In normal charging Open cover of oil inlet check if the electrolyte level is in normal height otherwise regulate it to the normal height by distill water Connect charger to battery correctly...

Страница 44: ...c system diagram 6 2 Oil pump Oil pump is gear pump 6 3 Multiway valve The multiway valve is two piece four body in pattern the high pressure oil from working pump is distributed by multiway valve rod...

Страница 45: ...valve can return on neutral 2 Motion of safety flooding valve There is a flooding valve between pump HP and low pressure chunnel LP Pressure liquid from lifting valve c play on piston A and piston B...

Страница 46: ...into tilting cylinder through joint B liquid returned from cylinder play on piston through oil pore A Liquid return to tank through pore A or B of valve core See figure 2 53 b When pump is not working...

Страница 47: ...piston rod piston cylinder head etc Two lift cylinders located on rear of outer mast its bottom fitted on seat of lift cylinder of outer mast by pins and bolts the top of cylinder i e top of piston ro...

Страница 48: ...hain Stop valve motion principle There is a stop valve on bottom of cylinder figure 2 57 if high pressure pipe burst suddenly this valve can prevent load lowering sharply Liquid from lift cylinder flo...

Страница 49: ...t sleeve support piston rod seal ring retainer ring and dust ring to prevent leakage and dust it is screwed onto cylinder body with O ring See figure 2 59 Skid valve pushing forward high pressure oil...

Страница 50: ...Figure 2 60 6 7 Hydraulic oil pipeline Hydraulic system hydraulic oil pipelice See figure 2 61 1 joint 25 G1 32 2 rubber hose oil suction 3 Hose clamp QC T390 40 45 4 Hose clamp QC T390 22 26 5 oil r...

Страница 51: ...fixing plate 38 screw GB70 1 M8x35 8 8 39 hydraulic hose assembly 90 8 L1420 1SC 60 40 joint 7 2xM14x1 5 M16x1 5 60 41 hydraulic hose assembly 6 L600 1SC 60 figure2 61 hydraulic pipeline 6 8 Maintena...

Страница 52: ...ew seal and a new spacer ring b Fit lining slice on groove of front end cover c Fit a drive wheel and a driven wheel on front end cover d Fit lining slice on gear side to make groove aim at gear point...

Страница 53: ...g valve to make pump run about 10 minutes by 500 1000rpm to ensure that hydraulic pressure is less than 10kg cm c Increase rev of pump up to 1500 2000rpm about 10 minutes d Keep rev of pump between 15...

Страница 54: ...Amend valve base surface Enactment pressure too high Valve get stuck Break up cleaning 2 Hydraulic pump fault diagnosis See List 2 12 List 2 12 Fault Cause Elimination Liquid displacement too small L...

Страница 55: ...lting cylinder 7 spring washer 8 bolt 9 oil cup 10 bearing bush 11 supportor cover 12 Spring washer 13 bolt 14 roller wheel Figure 2 68 inner outer mast 7 3 Fork carriage figure 2 69 Fork carriage mov...

Страница 56: ...0 There are two rollers outer frame roller unit as well as inner frame and fork carriage roller unit witch is fitted on outer mast as well as inner mast and fork carriage respectively Each roller unit...

Страница 57: ...gulate shim to fit head of piston into upper beam of inner mast 2 Lift mast slowly to its maximum journey to check both of cylinder to move simultaneously 3 Put adjusting shim into between head of pis...

Страница 58: ...To be sure new roller is normal and fit it on its position and lock it by clip ring Figure 2 73 Figure 2 74 7 5 4 Replace mast roller see figure 2 74 1 Dismantle the fork carriage from inner mast with...

Страница 59: ...ease use normal tools use special appointed tools when requested 5 Choose optimum elevating equipment to hoist parts dismantled to prevent danger 6 Check slings for safety Keep slings tension during l...

Страница 60: ...gure 2 79 6 Hoisting directions for working motor see figure 2 80 Type outline dimension length width height mm Weight kg FE4P16 18N 980 398 760 695 FE4P20 25N 980 538 760 970 FE4P30 35N 980 688 760 1...

Страница 61: ...and cargo cg Said figure of load curve show you relation of 2t forklift load centre and permitted load figure of load curve is adhibited on vehicle if figure damaged to renew it in time If forklift is...

Страница 62: ...rn on ignition key and keep it at ON position Even after ignition key is turned to ON position 1 second is needed between brake circuit starting to work and starting to move If gear shift lever is in...

Страница 63: ...g simultaneously Inching operation a Traveling first let fork prong be close to goods about 3 5m distance b Step brake pedal down perfectly standstill c Step accelerator down to be in optimum speed d...

Страница 64: ...truction of operating manual a Keep liquid on normal level Keep liquid level on normal situation to prevent battery from being over hot or being burn out If electrolyte is not enough the life span of...

Страница 65: ...of battery to avoid cover fall down to injure human or bodywork c When hoisting battery out forklift be careful for touching steering wheel or other forklift parts d After finish installation of batt...

Страница 66: ...of goods 11 Transport the goods to destination 12 Deposit 1 Before diposit Before forklift deposits clean it thoroughly check up as following a If necessary clean grease and oil of bodywork by cloth a...

Страница 67: ...nd water of hydraulic tank d Install full charged battery on forklift andconnect it e Check carefully before startup Using instruction of operating devices 1 Components schematic diagram for operating...

Страница 68: ...ed by direction switch steering switch and big and small light switch 1 direction switch 2 steering switch 3 big and small light switch Direction switch controls travelling direction and delivers sign...

Страница 69: ...of multiway valve Both hydraulic steering system and steering wheel tilting device are standard equipment of forklift According to driver seat to adjust steering wheel to optimum angle Lock steering...

Страница 70: ...andle step down the parking paddle 5 Brake paddle and accelerating paddle Do not step accelerator pedal suddenly to prevent the vehicle from starting or accelerating suddenly Ensure your foot remove f...

Страница 71: ...t operating handle Lock will be released after pull the handle up you can move seat to and fro gently To be sure seat locked after adjusting Seat adjusting range To and fro is 120mm When traveling on...

Страница 72: ...roof grard when get on or get off please use foot pedal and armrest to ensure your safety 7 Lamps There are head light and front light assembled on the head of vehicle direction indicator lamp parking...

Страница 73: ...hould be adjusted appropriately in ramps or rough pavement to be especially careful when driving Driving on a ramp or rough roads will speed up the forklift tire wear and increased noise 2 Work enviro...

Страница 74: ...hange parts on forklift arbitrary Read the instruction manual carefully before without permission driving Turn off the engine before maintenance Understand traffic regulations Before use please check...

Страница 75: ...s cap clean Do not drive an unsafe forklift Drivers should have a healthy body Be sure your truck is safe Work in specified area Do not drive a damaged truck Hold tightly when get on the truck Start f...

Страница 76: ...ition Appropriate fasten seat belts Always pay attention to the height of work place Turn on lights in dark area Do not put arm and body outside of the overhead guard during work Avoid driving on soft...

Страница 77: ...y front fork when loading Check fork pin position Note the security of the work region Do not run on smooth or slippery ground Note the horizontal driving stability of the truck when it is un load Be...

Страница 78: ...lowly handling small objects Do not chase each other through the traffic Not allowed to stand on the goods Not allowed to gaze around while driving Do not use the forklift to do stunt when goods is so...

Страница 79: ...lifting height When no load travel backward in upgrade Note using brake when start truck on and travel forward in downgrade the slopes Not turn when driving on a slope People or things moving on road...

Страница 80: ...cident because of unstable center of gravity Notice the change of rated load weight Pay attention to the area where forklift before use forklift is driven Use the fork correctly when loading Slow down...

Страница 81: ...r Please bind the goods which is difficult than the goods rest to fix before load Do not carry the goods from forklift by Do not let people to carry the goods have manpower been damaged Do not misuse...

Страница 82: ...n and deceleration Must use special equipment to lift people Do not overload safely to lift people safely to work at height Do not lift when there is excessive wind Not allowed to work in explosive en...

Страница 83: ...key 3 Move the truck Forbid hoisting from the top Forbid hoisting on the frame Hoisting the forklift correctly Hoisting the forklift Tie firmly steel cable on two terminal holes of outer mast beam and...

Страница 84: ...ad guard to hoist the forklift Forklift upgrade do not enter the truck underneath 4 How to avoid overturning how to protect yourself Prohibit forward tilt to enhance loading Prohibit lifting goods tip...

Страница 85: ...is more safe to stay under the protection of seat belt than jump down the truck If the forklift began to tip over 1 Tap foot and clench the steering wheel tightly 2 Do not jump 3 The body bend to the...

Страница 86: ...e search for medical treatment immediately Do not use the door frame assembly as a ladder Strictly forbidden to put your hands feet and body between frame and door frame assembly 4 Inspect and replace...

Страница 87: ...battery Do not let positive and negative contacts cause a short circuit by bolts or tools which will result in injuries and explosions 5 Against excessive discharge Do not use forklift until it can no...

Страница 88: ...ctrolyte from leaking Do not add too much electrolyte electrolyte overflow will cause leakage 11 Waterproof Batteries can not be wet with rain or sea water this will damage the battery or cause fire 1...

Страница 89: ...88 Left safety mark Right safety mark Usage of forklift Forklift nameplate Lubrication system signs Load graph signs Add hydraulic oil signs hoisting signs prohibiting hoisting signs...

Страница 90: ...89 Truck hoisting signs Prohibiting climbing signs Handbrake signs Tyre pressure signs Tyre removal signs Note signs of injury...

Страница 91: ...nto the water pipe under the soil burning etc will pollute the water soil atmosphere etc which is prohibited by law 1 Checking point and checking content No Checking points Checking contents Brake sys...

Страница 92: ...distance about 2 5m 2 Check the brake oil Open the lid and check the brake oil and other conditions 3 Check parking brake handle Push forward parking brake handle and observe following status If there...

Страница 93: ...rame function Check the upgrade and after dumping the normal operation is smooth 7 Check pipeline Check lift cylinder tilt cylinder and all pipeline whether oil leak 8 Check the hydraulic oil Land the...

Страница 94: ...eck the availability of loose wheel nut it is very dangerous even one of them is loose so be screwed to the provisions of pre torque value Wheel nut tightening torque Front wheel 6 50 10 10PR 130 150N...

Страница 95: ...pump controllerfault code 6 it s tome for maintanance 7 mode selection 8 slow speed mode 9 seat switch indication 10 electric quantity alarm indication 11 gear neutral indication 12 timing indication...

Страница 96: ...rake handle Press the emergency stop switch Turn off the key switch and remove the key Disconnect the battery plug 1 Truck surface cleaning Do not use flammable liquid to clean trucks take safety meas...

Страница 97: ...ge 1 Battery Maintena nce item Maintenance item Tools Every day 8h Every week 50h Every month 200h Three months 600h Six months 1200h Battery Electrolyte levels Eye survey Electrolyte specific gravity...

Страница 98: ...Transmission system Maintena nce item Maintenance item Tools Every day 8h Every week 50h Every month 200h Three months 600h Six months 1200h Gearbox and Wheel Reducer Noises Check leakage Change oil C...

Страница 99: ...age Check or replace the lubrication of bridge bearing Check or replace lubrication of bridge bearing Check steering cylinder operating conditions Check whether steering cylinder is leaking Check rack...

Страница 100: ...Hydraulic oil tank Check the oil oil change Suction filter cleaning Exclude eyewinker Control lever Whether the connection is lossen Operation condition Multitande m valve Leakage Safety valve and sel...

Страница 101: ...rk Damage deformation wear of allocation pin cracking and abrading status in hooker welding of fork root Mast fork frame welding between inner mast outer mast and beam is cracking or damaged or not Ti...

Страница 102: ...c replacement of critical safety components When some parts difficult to find through regular maintenance of injury or damage in order to further improve security the user should replace the parts giv...

Страница 103: ...commended Name Trademark Capability L Remark Hydraulic oil L HM32 40 Winter L HM46 Summer Gear oil AFT DEXRON 4 5 Brake fluid Caltex DOT3 0 2 Industrial Vaseline 2 Battery electrode column Grease Auto...

Страница 104: ...103 Maintenance record No Date Maintenance content Noter...

Страница 105: ...ment Joint Stock Co Ltd Service hotline 4001 603611 Wechat nuolijixie Postcode 313100 email address info noblelift com Website www noblelift com Address 528 Changzhou Road Taihu Jiedao Changxing Zheji...

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