Noblelift PS10M, Service Maintenance Manual

Page 1: ...NOBLELIFT EQUIPMENT Service Maintenance Manual PS10M Electric Pallet Truck V PS10M 01 00 Date 2013 11 20...

Page 2: ...REPLACING OF THE CONTROL HANDLE 44 4 2 REPLACING OF THE INTERLOCK SWITCH 46 4 3 REPLACING OF THE AIR SPRING 46 5 HYDRAULIC SYSTEM 47 5 1 HYDRAULIC FLOW DIAGRAM 47 5 2 INSTALLATION OF HYDRAULIC SYSTEM...

Page 3: ...ing must be collected and disposed of in an environment friendly way and in accordance with the directives of respective countries Such work must be carried out in areas intended for this purpose Recy...

Page 4: ...E MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER OR OPERATOR FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LlSTED IN THIS SECT...

Page 5: ...LOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT During maintenance do not allow any unauthorized person to stand near the machine Flames should never be used instead o...

Page 6: ...ntities of water When working on the battery wear goggles or safety glasses If splashed into the eyes flush with water and get medical attention immediately Battery terminals touched by metal objects...

Page 7: ...ul not to let any dirt or dust into the system Use only approved nonflammable cleaning solvents When changing the oil or fitter check the drained oil and filter for any signs of excessive metal partic...

Page 8: ...6400 1195800 a 0 01 100 0 0001 1 1076 4 119 58 ft2 0 092903 0 000929 1 0 1111 144 000 yd2 0 83613 0 008361 9 1 1296 00 in2 6 4516 0 000645 0 006943 0 000771 1 1ha 100a 1mile2 259ha 2 59km2 Volume Unit...

Page 9: ...ing charts give the standard torque specification of bolts and nuts Exceptions are given in the sections of Disassembly and Assembly METER TABLE Classification 4T 5T 10T Bolt type Bolt size Torque kgf...

Page 10: ...1 5 41 152 2 15 2 1 1 4 74 2 7 42 208 9 20 9 1 3 4 98 8 9 88 277 8 27 8 1 1 2 128 2 12 82 360 7 36 1 The torque specifications in above table shall not be applied to the bolts with nylon packings and...

Page 11: ...069 bar megapascal MPa 145 psi 0 00689 MPa Pa N m2 Power r W J s kilowatt kW 1 36 PS cv 0 736 kW kilowatt kW 1 34 HP 0 746 kW kilowatt kW 0 948 Btu s 1 055 kW watt W 0 74 ft lb s 1 36 W W J s Energy...

Page 12: ...rging indicating LED 15 Drive wheel 8 Key switch 16 Chassis CONTROL HANDLE 1 Raise Lower buttons Rocker switches adjusting fork height 2 FWD BWD REV travel button Control variable speed by turning kno...

Page 13: ...5 Extended mast height h4 mm 1970 2370 2090 2490 4 9 Height of tiller in drive position min max h14mm 934 1205 934 1205 4 15 Height lowered t h13mm 85 40 4 19 Overall length l1mm 1725 1765 4 20 Length...

Page 14: ...13...

Page 15: ...t Cleveland open cup O C 160 160 Pour point Max O C 35 35 Density at 15 O C kg m3 861 5 Copper corrosion 100O C 3h degree 1 1 Foaming 93 5 O C ml ml 30 0 30 0 Vickers vane pump test loss of mass on va...

Page 16: ...15 3 ELECTRICAL SYSTEM 3 1 ELECTRICAL DIAGRAM WIRING DIAGRAM FU1 10 A FU2 0 5 A FU01 150 A FU02 80 A...

Page 17: ...4V Rate Power 27W Output Torque 8 N M Gear Box transmission ratio i 1 30 3 3 PUMP STATION Type MR2 B V1B F4 5 PCMAV1Y TK05C F2 Item Specification Rated voltage 24V Rated output 0 8 kw R P M 3000 rpm R...

Page 18: ...17 100 DURATION OF DISCHARGING LIFE TEST CURVE ENVIRONMENTAL TEMPERATURE 25O C CHARGING CURVE...

Page 19: ...e 180 264 Vac 1 3 AC input voltage frequency 47 63 Hz 1 4 Inrush current 100 A 264Vac input start up in cold condition environmental temperature is 25 1 5 Max input current 3 0 A Vin 180Vac rated load...

Page 20: ...e internal temperature drops to 60 the charger comes back to previous charge mode 3 4 Output current limiting protection 8 A CC MODE 3 5 Output short circuit protection Short circuit protection should...

Page 21: ...20 LED TERMINATOR DIAGRAM DEFINITION FAN TERMINATOR DIAGRAM DEFINITION RELAY TERMINATOR DIAGRAM DEFINITION...

Page 22: ...D display rockertype keys for navigating through the display and for modifying parameters and three keys that can be used as bookmarks The 1311 programmer is easy to use with self explanatory function...

Page 23: ...Monitor THROTTLE and another at the Throttle Deadband parameter Program THROTTLE DB this way you can easily toggle between the readout and the parameter Connect the 1311 handheld programmer to the tr...

Page 24: ...g Left 70 0 180 Steer Angle Deadband Deg Right 110 0 180 Steer Angle Max Deg Right 180 0 180 Full Turn Speed 30 0 100 Hydro Setting Current set Lower PD Max Current 0 7 0 0 1 2 Ampere Lower PD Min Cur...

Page 25: ...rpm Kp 20 0 100 Ki 20 5 100 Accel Rate 1 8 0 1 30 Seconds Decel Rate 1 5 0 1 30 Seconds Brake Rate 1 0 1 30 Seconds Pump Enable Off Off On 1 Speed Mode Speed Controller Max Speed 3048 100 8000 rpm Kp...

Page 26: ...0 5 0 1 30 Seconds Pump Enable Off Off On 2 Torque Mode Speed Limiter Max Speed 4000 500 8000 rpm Kp 30 0 100 Ki 30 5 100 Kd 10 0 100 Response Accel Rate 1 0 1 30 Seconds Accel Release Rate 0 4 0 1 2...

Page 27: ...urrent Limit 100 5 100 Regen Current Limit 100 5 100 Brake Current Limit 100 5 100 EMR Current Limit 100 5 100 Interlock Brake Current Limit 100 5 100 Power Limiting Map PL Nominal Speed 500 100 4000...

Page 28: ...ke Brake Pedal Enable Off Off On Brake Type 5 1 5 Brake Deadband 0 5 0 5 Volt Brake Map 50 0 100 Brake Max 4 5 0 5 Volt Brake Offset 0 0 100 Brake Filter 10 2 125 Hz VCL Brake Enable Off Off On EM Bra...

Page 29: ...5 0 200 Volt Precharge Enable On Off On Proportional Driver PD Enable Off Off On Hyd Lower Enable Off Off On PD Max Current 0 0 2 Ampere PD Min Current 0 0 2 Ampere PD Dither 0 0 100 PD Dither Period...

Page 30: ...10 Seconds LOS Upon Encoder Fault On Off On LOS Max Speed 800 100 2000 rpm LOS Max Current 400 100 650 Ampere LOS Max Mod Depth 50 15 100 LOS Accel Rate 7 2 15 Seconds LOS Decel Rate 3 2 15 Seconds Te...

Page 31: ...100 Inner Wheel Speed 100 10 0 0 Steer Type 5 1 5 Steer Pot Min 0 5 0 5 Volt Steer Pot Zero 2 5 0 5 Volt Steer Pot Max 4 5 0 5 Volt VCL Steer Enable Off Off On Slave Turn Accel Rate 5 0 1 30 Seconds...

Page 32: ...lock Braking Enable On Off On Decel Rate HS 0 5 0 1 30 Seconds Decel Rate LS 0 5 0 1 30 Seconds Interlock Brake Timeout 5 0 8 Seconds CAN Interface CANopen Interlock Off Off On CAN Node ID 1 38 0 127...

Page 33: ...Dual voltage models When vehicle voltage is the higher voltage of the 2 operating voltages Pin 8 connects to battery Pin 7 open When vehicle voltage is the lower of the 2 operating voltages Pin 7 con...

Page 34: ...ects to a low voltage level as defined in Table 1 to activate the hour meter Leaving Pin 1 openor connecting it to high voltage gives control of the hour meter to the Hour Meter input Pin 3 Relay Pin...

Page 35: ...h battery voltage or battery not fully charged Resets w o charging battery Not connected directly to battery terminals EMPTY too soon B connected to wrong terminal or instrument voltage does not match...

Page 36: ...s fixing the charger with opener STEP 4 Remove the ground lead with 5mm Allen wrench then you can replace the charger REMOVING OF THE BATTERY STEP 1 Unplug the power line light line self preservation...

Page 37: ...36 STEP 2 Press two springs of the battery cable tie loosen it STEP 3 Take out the hook STEP 4 Remove the bolts fixing pole with 10mm wrench...

Page 38: ...n wrench STEP 2 Unplug the connector of the indicator remove 2 screws then you can remove it Instruction Blank positive pole input through the key switch positive pole output negative pole input Posit...

Page 39: ...rshins STEP 2 Unplug the connectors fixing the cable 3 5 then you can remove the key switch REPLACING OF THE EMERGENCY BUTTON STEP 1 Remove 2 screws fixing the emergency button with wrench Avoid losin...

Page 40: ...ncy button STEP 5 Remove B cable of the emergency button with 14mm wrench then you can remove it REPLACING OF THE FUSE ANG CONTACTOR STEP 1 Open the protective cap of the fuse holder and then you can...

Page 41: ...Remove the fixing screws of the contactor with wrench then you can remove it REPLACING OF THE CONTROLLER STEP 1 Unplug the connectors remove screws fixing pole and 3 wiring harness U V W with 5mm All...

Page 42: ...he controller with 5mm Allen wrench There is some thermal Silicone Grease on the back of the controller REPLACING OF THE MAGNET SWITCH STEP 1 Unplug the connectors fixing the truck body STEP 1 Remove...

Page 43: ...Figure Application 1 Tool for removal of pins sleeves 2 Tool for application of pins sleeves 3 Tool for release of lock 4 Tool for application of secondary locking 2 pole 5 Tool for application of sec...

Page 44: ...Bushing 23 19 17 10 8 Air spring 2 Handle mounting bracket 9 Handle cable 3 Shaft 17 10 Micro switch Z 15GW2 4 Roll pin 4x24 11 Screw M4x25 5 Socket hex bolts M8x25 12 Cover 6 Elastic washer 8 13 Scr...

Page 45: ...or toggle button right 8 Socket hexagonal Screw M3X16 23 Tapping screw ST4 2X25 9 Washer 3 24 LED bicolor 10 Butterfly right 25 Housing for LED two parts 11 Edge Shaft 26 Spring RH throttle torsion 1...

Page 46: ...STEP 4 Remove the driving switch axle STEP 5 Remove the screws fixing the PCB board unplug the connectors and then you can replace the PCB board Don t miss the shaft sleeve when removing the PCB boar...

Page 47: ...Dismantle 2 screws fixing SA from the left of the handle lever with Allen wrench 4 3 REPLACING OF THE AIR SPRING STEP 1 Remove the upper screws fixing the air spring with 6mm Allen wrench STEP 2 Remo...

Page 48: ...r but the color becames bright Fine Mixed with other oil Inspect the viscosity and if fine it can be continuously used Color changed like milk Fine Mixed with air and water Separate water or replace o...

Page 49: ...of the pump with 24mm wrench STEP 3 Remove the cable FP fixing the contactor and cable E2 fixing the motor Then remove cable 5 4 1 J1 4 of contactor coil Watch out for the hydraulic oil spilling check...

Page 50: ...you can replace the lowering magnetic valve 5 5 REPLACING OF THE CONTACTOR OF THE PUMP STEP 1 Remove the screw fixing the cable on the contactor with 13mm wrench STEP 2 Loosen the screw of the hoop wi...

Page 51: ...the carbon brush will pop up by the spring 5 7 REPLACIING OF THE CYLINDER STEP 1 Remove 6 screws fixing the cover of the cylinder STEP 2 Lower the forks to the bottom remove the cotter pin of the tig...

Page 52: ...circlip plier STEP 6 Remove the pin roll of the chain wheel STEP 7 Take out the chain wheel STEP 8 Fix the chain wheel base then remove the screws with 18mm wrench STEP 9 Take out the chain wheel bas...

Page 53: ...2 Lift up the truck until it higher than cylinder STEP 11 Pull up the cylinder and then you can replace it 6 DRIVE WHEEL 6 1 REPLACING OF THE SENSOR Lift up the truck before operating Take care of you...

Page 54: ...nsor and replace it 6 2 REPLACING OF THE BREAK No Part name No Part name 1 Gaiter 6 Spring 2 Friction plate 7 Carrier 3 Screw 8 Body magnetic 4 Break disk 9 Screw M5x45 5 Break anchor plate 1 STEP 1 R...

Page 55: ...M STEP 1 Remove 2 screws fixing the cable board and 3 screws fixing the wiring harness U V W with 3mm wrench and 10mm wrench then unplug the connector STEP 2 Remove 10 screws fixing the rim with 5mm A...

Page 56: ...antle the caster and replace it 7 2 ADJUSTING THE PRESSURE FOR THE DRIVE WHEEL After using some time the drive wheel might wear off the pressure for the drive wheel will not be enough and drive wheel...

Page 57: ...no abnormal abrasion Check the items emphasized maintenance checklist a maintenance checklist Interval Month 1 3 6 1 Hydraulic 1 Check the hydraulic cylinder piston for damage noise and leakage 2 Che...

Page 58: ...the main power cable for damages 32 Check the start up protection during charging Function 33 Test the audio warning signal 34 Check the air gap of the electromagnetic brake 35 Test the emergency brak...

Page 59: ...uid type is H LP 46 DIN 51524 Viscosity is 41 4 47 Depending on the type the amount Is 3 0L Waste material like oil used batteries or other must be probably disposed and recycled according to the nati...

Page 60: ...l quantity Truck not starts operating Battery is charging Charge the battery completely and then remove the main power plug form the electrical socket Battery not connected Connect the battery correct...