Noblelift FE4P16-35N-SMS-001 User manual

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FE4P16-35N-SMS-001 Service Manual
Battery Weight Balanced Forklift

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1.General
1-1 How to Use This Manual....................................................11
1-1-1 Composition of This Manual......................................11
1-2-2 Definitions of Warning Signs.....................................12
1-2 Glossary.............................................................................13
1-3 Appearance and Specifications..........................................18
1-4 Safety Notes........................................................................22
1-5 Maintenance........................................................................31
1-6 Lube.....................................................................................35
1-6-1 Specification of Lubricant............................................35
1-7 Disassembly/Assembly Instructions ....................................37
1-8 Standard Torque..................................................................51
1-8-1 Standard Torque for Bolts and Nuts............................51
1-8-2 Standard Torque for Fastenings ................................53
2.Electronic System
2-1 General.................................................................................56
2-1-1 Configuration of Electrical System ............................56
2-1-2 Communication Protocol............................................57
2-2 Battery (Lead Battery)..........................................................59
2-2-1 Appearance and Specifications..................................59

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2-2-2 Functions..................................................................60
2-2-3 Test...........................................................................61
2-2-4 Maintenance.............................................................65
2-2-5 Disassembly and Installation....................................66
2-2-6 Lithium Battery..........................................................68
2-3 Emergency Switch .............................................................74
2-3-1 Appearance and Specifications................................74
2-3-2 Functions..................................................................74
2-4 Controller and Related Equipment......................................75
2-4-1 Appearance and Specifications................................75
2-4-2 Circuits and Functions..............................................75
2-4-3 Diagnosis and Troubleshooting................................80
2-4-4 Test...........................................................................81
2-4-5 Disassembly and Installation....................................84
2-5 Miscellaneous Load............................................................86
2-5-1 Maintenance.............................................................86
2-5-2 DC-DC Convertor.....................................................87
2-5-3 Lamp Bank.......... ....................................................88
2-5-4 Horn..................... .......... ........................................89
2-6 Instrument Board................................................................89
2-6-1 Appearance and Specifications................................89

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2-6-2 Functions.................... .......... ...................................90
2-6-3 Description and Function...........................................91
2-7 CURTIS Handheld Programmer ....... ..................................91
2-7-1 Operation Cautions....................................................91
2-7-2 Process of Vehicle Fault Reading..............................92
2-7-3 Vehicle signal Detection..................... .......................92
2-7-4 Contents of CURTIS Handheld Unit Menu.................93
2-8 Troubleshooting to Each Fault Code ....................................99
3.Driving/Braking System
3-1 General ................................................................................105
3-1-1 Component................ ................................................105
3-2 Drive Motor ........................ ..................................................106
3-2-1 Appearance and Specifications...................................106
3-2-2 How Does This Work ................ .................................106
3-2-3 Disassembly/Assembly and Testing of Drive Motor....109
3-2-4 Disassembly/Installation of Driving Wheel ..................112
3-3 Drive Axle ..............................................................................113
3-3-1 Appearance and Specifications...................................113
3-3-2 How Does This Work ..................................................114
3-3-3 Oil Replacement of Drive Shaft...................................115

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3-4 Accelerator............................................ ...............................116
3-4-1 Appearance and Specifications..................................116
3-4-2 How Does This Work .................................................117
3-4-3 Disassembly and Installation......................................118
3-5 Combination Switch..............................................................119
3-5-1 Appearance and Specifications..................................119
3-5-2 How Does This Work .................................................119
3-6 Service Brake Pedal.............................................................123
3-6-1 Appearance and Specifications..................................123
3-6-2 How Does This Work .................................................123
3-6-3 Air Removal of Brake Oil ............................................124
3-6-4 Adjustment of Brake Pedal .........................................125
3-6-5 Disassembly and Installation of Brake Pedal .............128
3-6-6 Disassembly/Assembly/Adjustment of Brake Pedal ...129
3-6-7 Disassembly/Installation of Master Cylinder.................135
3-6-8 Fault analysis and troubleshooting………………………137
3-6-9 Maintenance and service………………………………..138
3-7 Parking Brake ............................ ...........................................140
3-7-1 Appearance and Specifications...................................140
3-7-2 How Does This Work ..................................................140
3-7-3 Parking Brake Test ................... .................................141

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3-7-4 Adjustment Parking Brake Switches...........................142
3-7-5 Disassembly/Installation of Parking Brake Bar...........143
3-8 Troubleshooting ........................ ..........................................145
3-8-1 Drive Motor ....................... ........................................145
3-8-2 Drive Axle ......................... ........................................147
3-8-3 Service Brake.................. ..........................................148
3-4 Parking Brake ............................. .........................................149
4.Hydraulic System
4-1 General
4-1-1 Component................... .............................................150
4-1-2 Oil Flow.................... ..................................................151
4-2 Pump Motor
4-2-1 Appearance and Specifications..................................153
4-2-2 How Does This Work ....................... .........................155
4-2-3 Disassembly/Installation of Pump Motor and Main Hydraulic
Pump...........................................................................157
4-2 Disassembly/Assembly and Testing of Pump Motor.....159
4-3 Main Hydraulic Pump
4-3-1 Appearance and Specifications..................................161
4-3-2 How Does This Work .................................................162

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4-3-3 Disassembly and Installation.....................................163
4-4 Multiway Valve and Priority Valve
4-4-1 Appearance and Specifications.................................167
4-4-2 How Does This Work ................................................168
4-5 Hydraulic Tank and Filter.
4-5-1 Appearance and Specifications.................................171
4-5-2 How Does This Work ................................................172
4-5-3 Replacement of Hydraulic Tank and Filter. ...............174
4-6 Troubleshooting ...................................................................175
4-6-1 Pump Electric Motor...................................................175
4-6-2 Main Hydraulic Pump.................................................177
5.Lift/Tilt/Auxiliary System
5-1 General
5-1-1 Component..................................................................179
5-1-2 Oil Flow.......................................................................181
5-2 Control Valve
5-2-1 Appearance and Specifications...................................185
5-2-2 How Does This Work .................................................186
5-2-3 Adjustment/Disassembly/Installation of Lever and Switch
Units............... ..................... ...............................................195

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5-2-4 Disassembly/Installation of Multiway Valve................197
5-3 Mast
5-3-1 Appearance and Specifications..................................199
5-3-2 How Does This Work ................................................200
5-3-3 Service of Pallet Fork ................................................203
5-3-4 Side Shifter........................ .......................................209
5-3-5 Service of Chains.......................................................213
5-3-6 Service of Tilting Cylinder ....... .................................218
5-3-7 Service of Main Lifting Cylinder.................................224
5-3-8 Service of Transportation............. .............................227
5-3-9 Mast Service.................... .........................................232
5-4 Troubleshooting .................................................................233
6.Steering System
6-1 General
6-1-1 Component.................................................................238
6-1-2 Oil Flow......................................................................239
6-2 Steering Control Group
6-2-1 Appearance and Specifications.................................241
6-2-2 How Does This Work ................................................242

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6-2-3 Air Removal of Steering System................................248
6-2-4 Pressure Test of Steering System... .........................249
6-2-5 Disassembly/Installation of Steering Wheel Cover....252
6-2-6 Disassembly/Installation of Steering Wheel...............253
6-2-7 Disassembly/Installation of Steering Wheel Column..255
6-3 Steering Axle
6-3-1 Appearance and Specifications.................................256
6-3-2 How Does This Work ...............................................257
6-3-3 Disassembly/Installation/Adjustment of Rear Wheels and
Wheel Hub............... .... ..................... ...............................262
6-3-4 Disassembly/Installation of Steering Shaft.................262
6-3-5 Disassembly/Installation of Link Rod and Steering
Cylinders .. ..................... ..................... ..................... ........264
6-3-6 Disassembly/Installation of Steering Cylinder...........264
6-3-7 Disassembly/Installation of Knuckle, Pin and Bearing..267
6-4 Troubleshooting……………………………………………….…268
7.Schematic Diagram
7-1 Hydraulic Schematic Diagram......... .....................................270
7-2 Electrical Schematic Diagram......... .....................................271
8.Others
8-1 Disassembly/Installation of Engine Hood.............................272

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8-2 Disassembly/Installation of Overhead Cover.......................273
8-3 Disassembly/Installation of Floor..........................................274
8-4 Disassembly/Installation of Top Cover and Counterweight...275
9.Battery Charger
9-1 Introduction of Battery Charger.............................................277
9-2 Introduction of Control Panel ................................................278
9-3 General Faults of Battery Charger.........................................280