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

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1-1 How to use this manual
1-1-1 Composition of this manual
This service manual mainly provides engineers and technicians service
information for forklift repair and maintenance, which excludes vehicle operation
instructions.
The introduction section of this manual introduces the functions of the
vehicle with particular attention to its different components. More detailed
specific information are available in the main body of this manual for you,
including the schematic diagram of the vehicle components, the principle they
work, the check lists, the maintenance procedures as well as the data and
information as needed for maintenance and repair
To facilitate a quick and easy access to the services and training
information as required by the readers, the sections of this manual are
categorized as per different systems of the vehicle (Please refer to the table
below).

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Section
Headings
1
General
2
Electronic System
3
3 Driving/Braking System
4
Hydraulic System
5
Lift/Tilt/Auxiliary System
6
Steering System
7
Schematic Diagram
8
Miscellaneous
9
Battery Charger
1-1-2 Definitions of Warning Signs
The following three warning signs are applicable to this Manual: "Danger",
"Warning" and "Caution". Each label is intended to indicate the severity and
nature of the potential hazard, the consequences, as well as preventive
measures against hazards. You will find these signs throughout this manual.
Please ensure your careful attention to such signs, as they are included for your
safety intensively.
Danger

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1-2 Glossary
The terms referred in this service manual and their descriptions are as
follows.
Item
Descriptions
Accelerator
A device that converts mechanical motion to an analog voltage mode
and transmit to a controller to control the speed at which a vehicle is
driven
Actuator
A device (e.g. a hydraulic cylinder and motor) that converts hydraulic
power into mechanical force and motion.
Ampere (A)
A measurement unit of current. The current of a voltage passing through
an ohmic resistor.
Battery
Two or more batteries which are inter-connected with each other to
provide current.
Coulomb meter
(Battery Discharge Indicator) an electrically controlled display that
shows the operator the current charge of a battery.
Busbar
A re-conducting conductor that wired to other smaller conductors.
Communication
Modes
CAN (Controller Area Network) is the standard for communication
among microcontrollers and/or devices.

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Condenser
A device for short-time electrical energy storage.
Goods Holder
A supporting structure on which a fork is mounted
Check Valve
A valve that allows oil to flow in one direction rather than in the other
Circuit
A path along which The current can travel from the positive (+) side of
the source to the negative (-) side. This can be
obtained with wires and electrical components.
Connector
A part of a wire assembly or harness wired to another wire assembly or
harness to for a easier Disassembly and Assembly operation.
Co-contactor
A switch, relay, or part of a contactor that opens or closes a circuit.
Components of
Co-contactor
An electrical element consisting of an electromagnetic coil and a set of
heavy contact tips, which controls current flow through the coil, create a
magnetic field, and close or open contact tips
Coil of
Co-contactor
An electromagnet used to open or close contact tips in a contactor
component.
Control Valve
A valve unit includes multiple directional blocks, each of which has a
corresponding actuator
Counterweight
The weight mounted on the back of the forklift to ensure a stable status,
especially when lifting heavy loads
Current Limiting
The maximum permissible armature current of the stopped drive motor
during the pulse.
Oil Cylinder
A container that maintains pressurized oil and converts hydraulic power
into rectilinear motion
DC-DC Convertor
A device that converts a high-voltage DC onto a low-voltage DC.
Digital Signal
A signal in which the element can be either of two different values,
e.g.high voltage and low voltage.
Diode
A semiconductor device that allows current to flow from the anode to the
cathode in one direction
Directional Valve
A valve that directs the flow of oil according to the position of the valve
element.
Instrument
An electrical device that converts an voltage input into an visual output.
Drive Axle
A device that receives power from a driving motor
Driving Controller
A control device to drive an electric motor, which includes an inverter
and a logic circuit.
Handheld
Programmer
A maintenance tool program to calibrate and diagnose CURTIS
controllers of trucks.
Parking Brake
A pair of brakes that electromagnetically activate their respective motors
upon the stationary of the vehicle.
Encoder
A device that detects the direction and speed of a motor to produce a
pulse signal.
Fan
A device that generates an airflow to cool an electric motor and a

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controller.
Filter
A mechanical device used to accommodate a filter element, or a filter
device used to prevent contamination flow through a system
Flow Protector
A valve that prevents the hydraulic oil extraction of the control valve
from the lifting cylinder when the hydraulic line breaks unexpectedly,
which prevents the backstay from dropping suddenly.
Flow Regulator
A valve that reduces the pressure by limiting the flow of a hydraulic line
Pallet Fork
L shape rod for cargo pickup
Friction Plate
When meshing with helical gears, the friction disc stops the drive shaft
movement when it is compressed by the steel plate
Fuse
A component of a circuit that opens upon an overlarged current flowing
through a given part of the circuit
Fixture
A fitting o secure an assembly consisting of two or more wires
Radiator
A mounting frame for cooling semiconductors.
Hydraulic System
A hydraulic element circuit to convey oil pressure
Hydraulic Oil Tank
A chamber for the oil storage in a hydraulic system
Mandatory Sign
A symbol indicating the state of a vehicle when it is on or flashing.
Seat Switch
A switch to disable the vehicle movement when the operator leaves the
seat.
Main Hydraulic
Pump
A gear pump uses mechanical power from an electric motor to
pressurize the oil stored in a tank and distribute to various actuators
Portal
The front vertical structure of the forklift extends and retracts to lift and
lower the load.
Master Cylinder
The hydraulic cylinder which is responsible for the start-up of the driving
brake
Needle Valve
A valve to lower the backstay manually when the lifting lever is not
available.
Normal State
A term used with switches or relays. Their "normal state" means that
they are not under any control of stress,temperature, pressure or
electricity.
Ohm (Ω)
A resistance unit. The resistance will be such that one volt shall push
one ampere of current through it only.
Timely
The time it takes for a current to flow through a transistor.
Open Circuit
A connection or component of a circuit without continuity.
Hole
A limited passage in a hydraulic circuit, including a limited flow or
pressure generation in a given chamber
(e.g. a small bore).
Top Cover
A overhead frame structure which protects the operator from falling
objects
Overload
A condition that the existing voltage or current is greater than the
capacity of a given circuit or component.
Piston Rod
A part that push oil into the cylinder chamber

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Suffocated
The part of an electric brake in which the current generated is directed
back to the armature.
Port
An input or output point on a hydraulic element
Power Socket
A connecting socket that installed on the forklift.
Pressure
a fluid force as per unit area
Proximity Detector
A sensor which can detect the presence of objects nearby without any
physical contact.
Pump Controller
Unit
A control device for a hydraulic motor, which includes an inverter and a
logic circuit.
Safety Valve
A valve that limits the pressure of the hydraulic system by releasing
excess oil
Resistance
A component made of a material with a specific current impedance.
Return Filter
A filter to collect contaminants in oil returned to a hydraulic tank
Rotor
A part of rotating motor.
Outline
A bar chart of an electrical or electronic component that uses symbols to
show the individual components as well as how the wires and
connectors work electrically
Serial Port
A port that communicates one-to-one with the controller.
Service Brake
A pair of brakes built into the drive shaft to enable the vehicle when the
operator applies the pedal
for stationary
Short Circuit
An unwanted electrical connection between two or more components.
Side Shifter
An accessory that moves the fork and its load to the left and right
Socket
The male contact of the connector which slides over the male contact of
the other connector (pin).
Magnetic Valve
A directional valve that moves the valve element when the magnetic coil
is equipped with a magnetic valve.
Solid State
A term that refers to semiconductor components or circuits that wired
without moving parts, e.g. diodes and transistors.
Stator
a fixing part in the motor
Steering Shaft
A column that connects the steering wheel to the steering gear to allow
the operator to use steering wheel controller
Jociey Stick
A hydraulic component that deliver oil to the right or left side of the
steering cylinder as required by the operator
Steering System
Hydraulic element loop, including steering unit, circuit and actuator
Steering Gear
A axle mounted on the rear wheel of a vehicle
Switch（SW）
The component to control a circuit by opening or closing the circuit.
System
Electrical components, circuits, and connections that provide power for
specific tasks.
Thermal Sensor
a sensor activated at a pre-conditioned temperature.
USB
A connecting device providing a power supply of 5V.
Valve
A component that controls the pressure, direction, or velocity of a

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hydraulic system
Voltage
A measurement unit of electrodynamic force. A volt is the force that
required for an ampere of current to pass through an ohmic resistor in a
circuit.
Watt
A unit of power measurement. The power for one volt to push one
ampere of current through an ohmic resistor.
The outcomes of amperage (current) multiplied by volts (voltage) is
watts (power).
Wire
A path of conductors to provide for current flow in and out of different
electrical components.
Wiring Diagram
A visualized figure that represents a component in the way it actually
looks. which is used to show the locations of components,
and the connections between them.
Zener Diode
A special diode to regulate voltage or protect a system from overvoltage.

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1-3 Appearance and Specifications

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Model
FE4P16 N
FE4P25 N
Drive Mode
Electromotion
Operating Mode
Seated
Rated Capacity of Load
Q(kg)
1600
2500
Center Distance of Load
C(mm)
500
Front Overhang
x(mm)
381
381
Wheel Base
y(mm)
1360
1360
Self weight with battery
kg
3120
3120
Bridge load of full load,
front/rear kg
3950/770
3950/770
Bridge load of empty load,
front/rear kg
1470/1650
1470/1650
Front Wheel Size
6.50-10-10PR
Rear Wheel Size
5.00-8-10PR
Front wheel tread
b10(mm)
970
Rear wheel tread
b11(mm)
920
Portal inclination
(forward/backwarding)α/β(° )
6/10
Retraction Height of Portal
h1(mm)
2025
Retraction height of free
lifting h2(mm)
130
Lifting height
h3(mm)
3000
Extension height of Portal
h4(mm)
3985
Height of overhead guard
h6(mm)
2190
Height of seat
h7(mm)
1100
Height of traction pin
h10(mm)
295
Total length
2981