Noblelift PS30RM manual 

Version 08/2015
PS 30RM-SMS-001-EN
INSTRUCTION HANDBOOK
Electric Stacker PS30RM
WARNING
Do not use the electric 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.

1
FOREWORD
Before operating the electric stacker, read this ORIGINAL INSTRUCTION HANDBOOK carefully and
understand the usage of the truck completely. Improper operation could create danger.
This handbook describes the usage of different electric stackers. When operating and servicing the truck,
make sure, that it applies to your type.
Chapter 11 describes specialized stipulations and regulations for the American
market. Follow these instructions and stipulations if you operate the truck within
the American market!
Keep this handbook for future reference. If this or the warning/ caution labels are damaged or got lost,
please contact your local dealer for replacement.
This truck complies with the requirements according to EN 3691-1 (Industrial trucks- safety requirements
and verification, part 1), EN 12895 (Industrial trucks- electromagnetic compatibility), EN 12053 (Safety of
industrial trucks- test methods for measuring noise emissions), EN 1175 (Industrial truck safety –
electrical requirements), assumed the truck is used according to the described purpose.
The noise level for this machine is 63 dB(A) according to EN 12053.
The vibration is 0.87m/s2 according to EN 13059.
ATTENTION:
• Environmentally hazardous waste, such as batteries, oil and electronics, will have a negative effect
on the environment, or health, if handled incorrectly.
• The waste packages should be sorted and put into solid dustbins according to the materials and be
collected disposal by local special environment protection bureau. To avoid pollution, it’s forbidden to
throw away the wastes randomly.
• To avoid leaking during the use of the products, the user should prepare some absorbable materials
(scraps of wooden or dry duster cloth) to absorb the leaking oil in time. To avoid second pollution to
the environment, the used absorbable materials should be handed in to special departments in terms
of local authorities.
• Our products are subject to ongoing developments. Because this handbook is only for the purpose of
operating /servicing the stacker, therefore please have understanding, that there is no guarantee out
of particular features out of this handbook.
NOTE: On this manual, the left sign means warning and danger, which can lead
to death or serious injury if not followed.
Copyright
The copyright remains with the company, mentioned on the CE- certificate at the end of this document or,
if sold within the USA, with the company, mentioned on the company sticker.

2
TABLE OF CONTENTS
1. CORRECT APPLICATION ............................................................................................ 4
2. DESCRIPTION OF THE STACKER .............................................................................. 5
a. Overview of the main components ............................................................................. 5
b. Main technical data .................................................................................................... 6
c. Description of the safety devices and warning labels (Europe and other, excepting
USA) ................................................................................................................................. 7
d. Identification plate ...................................................................................................... 8
3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS .................................. 9
4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING .................................... 10
a. Commissioning ........................................................................................................ 10
b. Lifting/ transportation ................................................................................................ 10
c. Decommissioning ..................................................................................................... 11
5. DAILY INSPECTION ................................................................................................... 11
6. OPERATING INSTRUCTIONS ................................................................................... 11
a. Parking ..................................................................................................................... 12
b. Residual lift diagram................................................................................................. 12
c. Lifting ...................................................................................................................... 12
d. Lowering .................................................................................................................. 13
e. Moving forks ............................................................................................................. 13
f. Fork tilting ................................................................................................................ 13
g. Travelling ................................................................................................................. 13
h. Steering .................................................................................................................... 14
i. Braking ..................................................................................................................... 14
j. Malfunctions ............................................................................................................. 15
k. Emergency ............................................................................................................... 15
7. BATTERY CHARGING AND REPLACEMENT............................................................ 15
a. Replacement .......................................................................................................... 16
b. Battery Indicator ....................................................................................................... 16
c. Charging .................................................................................................................. 16
8. REGULAR MAINTENANCE ........................................................................................ 17
a. Maintenance checklist .............................................................................................. 17
b. Lubricating points ..................................................................................................... 19
c. Check and refill hydraulic oil .................................................................................... 19
d. Checking electrical fuses ......................................................................................... 19
e. Removing, reattaching guarding .............................................................................. 20
9. TROUBLE SHOOTING ............................................................................................... 20
10. WIRING/ CIRCUIT DIAGRAM ..................................................................................... 22
a. Electrical circuit diagram .......................................................................................... 22
b. Hydraulic circuit ........................................................................................................ 23

3
11. SPECIALIZED STIPULATIONS FOR THE US- AMERICAN MARKET ............. 24
a. Foreword/ Compliance ............................................................................................. 24
b. Description warning labels (only US- market) .......................................................... 25
c. Technical data for US market ................................................................................... 28
12. DECLARATION OF CONFORMITY (valid, if sold within the EU) ................................ 30

4
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 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.
A wrong usage can cause human injuries or can damage equipment.
The operator/ the operating company has to ensure the correct usage and has to ensure, that this truck
is used only by staff, which is trained and authorized to use this truck.
The truck has to be used on substantially firm, smooth, prepared, level and adequate surfaces. The truck
is intended to be used for indoor applications with ambient temperatures between +5C and + 40C and
for intensive operations without crossing permanent obstacles or potholes. Operating on ramps is not
allowed. While operating, the load must be placed approximately on the longitudinal centre plane of the
stacker.
Lifting or transporting people is forbidden. If travelling the load must be lowered to the lifting point.
It is not allowed to use this truck on tail lifts or loading ramps.
The capacity is marked on the load diagram as well on the Identification plate. The operator has to
consider the warnings and safety instructions.
Operating lighting must be minimum 50 Lux.
Modification
No modifications or alterations to this truck which may affect, for example, capacity, stability or safety
requirements of the truck, shall be made without the prior written approval of the original truck
manufacturer, its authorized representative, or a successor thereof. This includes changes affecting, for
example braking, steering, visibility and the addition of removable attachments. When the manufacturer
or its successor approve a modification or alteration, they shall also make and approve appropriate
changes to capacity plate, decals, tags and operation and maintenance handbooks.
By not observing these instructions, the warranty becomes void.

5
Fig. 1: Overview main components
2. DESCRIPTION OF THE STACKER
a. Overview of the main components
1. Platform
2. Main cover
3. Protective arm cover
4. Protective arm
5. Upper cover
6. Emergency button
7. Discharge indicator and charging indicating
LED
8. Key switch
9. Tiller
10. Mast
11. Protective screen
12. Protective board
13. Middle cover
14. Battery cover
15. Load backrest
16. Fork
17. Load roller
18. Chassis
19. Apron
20. Tiller control lever
21. Belly button

6
b. Main technical data
Fig. 2: Technical data
Table1: Main technical data for standard version
Technical data sheet for industrial truck acc. to VDI 2198
Distinguishing mark
1.2
Manufacturer`s type
designation
PS 15RM
1600
1800
3000
3600
4500
1.3
Power (battery ,diesel,petrol
gas,manual)
Battery
1.4
Operator type
Pedestrian
1.5
Load Capacity / rated load
Q (t)
1.5
1.6
Load centre distance
C (mm)
600
1.8
Load distance ,centre of
drive axle to fork
X (mm)
466
1.9
Wheelbase
Y (mm)
1368
Weigh
t
2.1
Service weight
kg
1800
1850
2000
2200
2250
2.3
Axle loading, laden front/rear
kg
1500/1650
1530/1670
1570/1730
1600/1800
1660/1840
2.4
Axle loading, unladen
front/rear
kg
1370/480
1410/490
1485/515
1550/550
1620/580
Tires, Chassis
3.1
Tires
Polyurethane (PU)
3.2
Tire size, front
 x W
(mm)
124×60
3.3
Tire size, rear
 x W
(mm)
230×100
3.4
Steering wheel size
 x W
(mm)
250×82
3.5
Wheels, number
front/rear(x=driven wheels)
1x+2/2

7
3.6
Tread, front
b10 (mm)
680
3.7
Tread, rear
b11 (mm)
988
Dimensions
4.1
Tilt of mast/fork carriage
forward/backward
°
2/4
4.2
Lowered mast height
h1 (mm)
2196
2396
2096
1796
2096
4.3
Free Lift height
h2 (mm)
1600
1800
—
1200
1500
4.4
Lift
h3 (mm)
1600
1800
3000
3600
4500
4.5
Extended mast height
h4 (mm)
2485
2685
3885
4485
5385
4.9
Height of tiller in drive
position min./ max.
h14 (mm)
1415/1034
4.15
Height, lowered
h13 (mm)
50
4.19
Overall length
l1 (mm)
2240
4.20
Length to face of forks
l2 (mm)
1870
4.21
Overall width
b1 (mm)
1090
4.22
Fork dimensions
s/e/l
（mm）
35/100/950(1150)
4.25
Distance between fork- arms
b5 (mm)
200～760
4.26
Distance between supporting
arm and load side
b4 (mm)
790
4.28
Reach distance
l4 (mm)
610
4.32
Ground clearance, centre of
wheelbase
m2 (mm)
39
4.33
Aisle width for pallets
1000X1200 crossways
Ast (mm)
2730
4.34
Aisle width for pallets
800X1200 lengthways
Ast (mm)
2770
4.35
Turning radius
Wa (mm)
1726
Performance
data
5.1
Travel speed, laden/ unladen
km/h
5.0/5.5
5.2
Lift speed, laden/ unladen
m/s
1.1/1.65
5.3
Lowering speed, laden/
unladen
m/s
1.0/0.95
5.8
Max. gradeability, laden/
unladen
%
5/8
5.10
Service brake
Electromagnetic
Electric- motor
6.1
Drive motor rating
kW
1.6
6.2
Lift motor rating
kW
3.0
6.3
Battery acc. to DIN 43531/
35/ 36 A, B, C, no
A, 3Pzs
A, 4Pzs
6.4
Battery voltage, nominal
capacity
V/Ah
24/270
24/400
6.6
Energy consumption acc. to
VDI cycle
kWh/h
Additional
data
8.1
Type of drive control
AC-Speed Control
8.4
Sound level at driver`s ear
acc.to EN 12053
dB(A)
< 70
8.5
Side shifter lateral slide
distance left/right
mm
50/50
c. Description of the safety devices and warning labels (Europe and
other, excepting USA)
For the USA –market, the description of the safety and warning labels is mentioned in
chapter 1

8
A. Crane hook label
B. Warning decal: Do not step under or on the forks
C. Residual lift capacity sticker
D. Never reach through
E. Identification plate (ID-plate)
F. Sticker to read and follow these instructions
G. ‘No passengers’ decal
J. Sign oil filling point
The truck has an emergency button (6) which stops all
lifting-, lowering-, driving- functions and engages the
failsafe electromagnetic brake when it is pushed. By
pulling this button, the truck can be operated after the
controller checked the functions. Before operating,
insert the key and turn the switch (8) clockwise. To
prevent against unauthorized access, turn the key
anti-clockwise and remove it, if you not operate this
truck. The truck is equipped with a safety (belly) button
(21) which switches the driving function away from the
operator, if the truck travels towards the operator and the tiller is activated in the tillers operating zone.
Follow also the instructions given on the decals. Replace the decals if they are damaged or missing.
d. Identification plate
1 Designation, type
2 Serial number
3 Rated capacity in kg
4 Supply voltage in V
5 Own mass (self weight) in kg without battery
6 Name and address of manufacturer)
7 Battery weight minimum/ maximum
8 Nominal power in kW
9 Load center distance
10 Manufacturing data
11 Option
Fig.3: Safety and warning labels
1
2
3
4
5
11
10
9
If sold to the EU, here the place of
the CE marking
6
8
7
Fig. 4: Identification plate

9
3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS
DO NOT
• Drive outside the stacking operation with a lifted load 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.
• Overload the truck.
• Put foot in front of the wheels, injury could result.
• Lift people. People could fall down and suffer severe injury.
• Push or pull loads.
• Use this truck on ramps.
• Use the truck without a removed protective screen (fig.1, pos. 19/ guarding).
• Side or end load. Load must be distributed evenly on the forks.
• Use the truck with unstable, unbalanced not stable load.
• Use truck without manufacturer’s written consent.
• Lifted loads could become unstable at wind forces. In the case of wind forces do not
lift the load if there is any influence to the stability
Watch difference in floor levels when driving. Load could fall down or the truck could get uncontrollable.
Keep watching the condition of load. Stop operating the truck if load becomes unstable. Brake the truck
and activate the emergency button (6) by pushing when sliding load on or off the truck. If the truck has
any malfunctions, follow chapter 8.
Practice maintenance work according to regular inspection. This truck is not designed to be water
resistant. Use the truck under dry condition. Prolonged continuous operation might cause damage of the
power pack. Stop operation if temperature of hydraulic oil is too high.
• When operating the truck, the operator has to wear safety shoes.
• The truck is intended to be used for indoor applications with ambient temperatures
between +5C and + 40C.
• The operating lighting must be minimum 50 Lux.
• It is not allowed to use the truck on ramps.
• To prevent unintended sudden movements when not operating the truck (i.e. from
another person, etc.) switch off the truck and remove the key.

10
4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING
a. Commissioning
Table 2: Commissioning data
Type
PS15RM Z
PS15RM Z/01
PS15RM D
PS15RM S
PS15RM S/01
Commissioning
weight [kg]
2250
2200
2050
1950
1900
Version/ Lift [mm]
4500
3600
3000
1600
1800
Dimensions [mm]
2130x1090x2010
2130x1090x1710
2130x1090x2010
2130x1090x2110
2130x1090x2310
After receiving our new truck or for re-commissioning you have to do following before (firstly) operating
the truck:
• Check if are all parts included and not damaged
• Eventually installation and charging the batteries (follow chapter 7)
• Do the work according to the daily inspections as well as functional
checks.
b. Lifting/ transportation
For transporting, remove the load, lower the forks to the lowest position
and fix the truck safe with dedicated lifting gear according to the following
figures.
Lifting
USE DEDICATED CRANE AND LIFTING EQUIPMENT
DO NOT STAND UNDER THE SWAYING LOAD
DO NOT WALK INTO THE HAZARDOUS AREA DURING
LIFTING
Park the truck securely and lash the truck according to the points identified in fig. 5
Lift the truck to its destination and place the truck securely before
removing the lifting gear.
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 each side of the truck’s crane hook holes and fasten the other side
Fig.5: Lifting with a crane
Fig. 6: Fixing points

11
at the transporting truck.
c. Decommissioning
For storage, remove the load, lower the truck to the lowest position, grease all in this handbook
mentioned greasing points (regular inspection), eventual protect the truck against corrosion and dust.
Remove the batteries and jack the truck safely, so that there will be no flattening after storage.
For final decommissioning hand the truck to a designated recycling company. Oil, batteries and electric
components must be recycled due to legal regulations.
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.
• Check for scratches, deformation or cracks.
• Check if there is any oil leakage from the cylinder.
• Check the vertical creep of the truck.
• Check the chain and rollers for damages or corrosion.
• Check the smooth movement of the wheels.
• Check the function of the emergency brake by activating the emergency button.
• Check, the tiller arm- switch braking function
• Check the lifting and lowering functions by operating the buttons.
• Check if the protective screen has no damages and that is correctly assembled.
• Check the audio warning signal.
• Check if all bolts and nuts are tightened firmly.
• Check the function of the key switch.
• Check the speed limitation switch.
• Visual check if there are any broken hoses or broken electric wires.
• If supplied with a backrest extension, check it for damages and correct assembling.
6. OPERATING INSTRUCTIONS
BEFORE OPERATING THIS TRUCK, PLEASE FOLLOW THE WARNINGS AND
SAFETY INSTRUCTIONS (CHAPTER 3).
BEFORE OPERATING THIS TRUCK, ENSURE THAT THE LOAD OR OTHER
EQUIPMENT NOT CAUSES INSUFFICIENT VISIBILITY!
Make sure, that the load is palletized and stable and that the daily inspection is carried out. For starting,
insert the key and turn it clockwise to the “ON”- position. Eventually before inserting the key, the
24

12
emergency button must be pulled carefully.
Press the horn button (24) to activate the audible warning signal.
a. Parking
DO NOT PARK THE TRUCK ON INCLINED SURFACES
The truck is equipped with an electromagnetic failsafe stopping
and parking brake.
Always lower the forks fully and drive the truck to a safe area. Turn
the key anti- clockwise to the “Off” – position and remove the key.
b. Residual lift diagram
The residual lift diagram indicates the maximum capacity Q [kg] for
a given load centre c [mm] and the corresponding lift height H [mm]
for the truck with horizontal load.
The white markings on the mast indicate if the specific lifting limits
reached.
For instance with a load centre of gravity distance c of 600 mm and a
maximum lift height H of 4500 mm, the max. capacity Q is 1000 kg.
c. Lifting
DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 1500 kg.
LIFT ONLY CAPACITIES ACCORDING TO THE RESIDUAL LIFT DIAGRAM.
Fig.8: Key switch
Fig. 9: Residual lift diagram
Fig.7: Tiller operating controls

13
Travel with the lowered forks fully underneath the pallet and move the lifting cam towards you until you
reached the desired lifting height. The lifting speed can be adjusted by the movement of the cam.
d. Lowering
If the forks are in the racking, firstly travel out of the racking carefully with or without the pallet. By
travelling out of the racking, take care that the forks are not touching the racking.
Move the lever (fig. 7, 25) forwards. The lowering speed can be adjusted by the movement of the lever.
Lower the load until the forks are clear of the pallet, then drive the truck carefully out of the load unit.
e. Moving forks
Move the lever (26) forwards, the reach pantograph moves out
of the truck.
Move the lever (26) backwards, the reach pantograph moves
back into the truck.
f. Fork tilting
Move the lever (27) forwards, the forks moving upwards.
Move the lever (27) backwards, the forks moving downside.
g. 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.10: Load facing uphill
Fig.11: Operating direction

14
After starting the truck by turning the inserted key to the “ON”- position (fig. 8); and eventually by pulling
the emergency button carefully, move the tiller to the operating zone (‘F’, fig.11).
Turn the accelerator button to the desired direction forward ‘Fw.’ Or backwards ‘Bw.’(fig. 11).
Control the travelling speed by moving the accelerator button (22) carefully until you reached the desired
speed.
If you move the accelerator button back to the neutral position, the controller decelerates the truck until
the truck stops. If the truck stopped, the parking brake will be engaged.
Drive carefully the truck to the destination. Watch the route conditions and adjust the travelling speed
with the accelerator button.
THE TRUCK CAN BE EQUIPPED OPTIONAL WITH A FOLDABLE PLATFORM AND
SIDEWAYS PROTECTIVE ARMS.
PAY ATTENTION, THE BEHAVIOR FOR THE RIDE ON MODE IS DIFFERENT TO
THE PEDESTRIAN MODE.
Besides the pedestrian mode, following travelling modes can be used:
• Travelling with platform (1) folded downside and sideways arms (4) in protective position
Travelling with maximum speed.
• Travelling with platform (1) folded downside and sideways arms (4) folded downside
Depending on the Controllers parameter setting, the speed might be lower, but not higher than
6km/h.
• Travelling with platform (1) folded upright and sideways arms (4) folded downside
Depending on the Controllers parameter setting, the speed might be lower, but not higher than
6km/h.
h. Steering
THE TRUCK IS EQUIPPED WITH AN ELECTRIC STEERING SYSTEM. TAKE CARE BY
OPERATING A TRUCK WITH THIS KIND OF SYSTEM; THE BEHAVIOR OF THE TRUCK
MIGHT BE DIFFERENT THAN TO A TRUCK WITHOUT ELECTRIC STEERING SYSTEM.
You steer the truck by moving the tiller to the left or right side.
i. Braking
THE BRAKING PERFORMANCE DEPENDS ON THE TRACK CONDITONS AND THE
LOAD CONDITONS OF THE TRUCK
The braking function can be activated on several ways:
• By moving the accelerator button (22) back to the initial ‘0’ position or by releasing the button, the
regenerative braking is activated. The truck brakes until it stops.
• By moving the accelerator button (22) from one driving direction directly to the opposite direction,

15
the truck brakes regenerative until it starts travelling into the opposite direction.
• The truck brakes, if the tiller is moved up or down to the braking zones (‘B’). If the tiller is released,
the tiller moves automatically up to the upper baking zone (‘B’).
The truck brakes until it stops.
• The safety (belly) button (21) prevents the operator from being crushed. If this button is activated,
the truck decelerates and/ or starts travelling into the backwards direction (‘Bw.’) for a short distance
and stops. Please consider, that this button also operates, if the truck is not travelling and the tiller is
in the operating zone.
j. Malfunctions
If there are any malfunctions or the truck is inoperative, please stop using the truck and activate the
emergency button (6) by pushing it. If possible, park the truck on a safe area, turn the key switch (8) anti-
clockwise and remove the key.
Inform immediately the manager and, or call your service. If necessary, tow the truck out of the operating
area by using dedicated towing/ lifting equipment.
k. Emergency
In emergencies or in the event of tip over (or off dock), keep safe distance immediately. If possible push
the emergency button (6). All electrical functions will be stopped.
7. BATTERY CHARGING AND REPLACEMENT
• Only qualified personnel are allowed to service or charge the batteries. The
instructions of this handbook and from the battery- manufacturer must be observed.
• The batteries are liquid acid traction batteries. Optional maintenance free batteries
might be available; for these batteries re- filling is prohibited.
• Recycling of batteries undergoes national regulations. Please follow these
regulations.
• By handling batteries, open fire is prohibited, gases could cause explosion!
• In the area of battery charging neither burning materials nor burning liquids are
allowed. Smoking is prohibited and the area must be ventilated.
• Park the truck securely before starting charging or installing/changing the batteries
• Before finishing the maintenance work, make sure, that all cables are connected
correctly and that there are no disturbing towards other components of the truck.
The truck is equipped with following sealed liquid acid traction battery- type:
1 pc 5PzS 24V/ 400Ah (C5) [830x273x627 mm (LXWXH)]

16
IT IS ONLY ALLOWED TO USE LIQUID ACID TRACTION BATTERIES.
THE WEIGHT OF THE BATTERIES HAS AN INFLUENCE TO THE TRUCKS
OPERATING BEHAVIOR.
PLEASE CONSIDER THE MAXIMUM OPERATING TEMPERATURE OF THE
BATTERIES.
a. Replacement
Park the truck securely and switch off the stacker with the
key (8) and activate the emergency button (6). Push the
mast forward according to Fig. 12, open the battery cover
(14), disconnect the battery plug, then remove the battery
with a crane. If you don’t push the mast forward, then
open the battery cover (14), loosen the screw and take
away the battery cover, then remove the battery with a
crane. The installation is in the reverse order of the
removal. Otherwise the tuck could be damaged.
b. Battery Indicator
The discharge status is indicated by ten red LED segments.
Only when the battery is properly charged, the most right LED lit. As the battery’s state-of-charge
decreases, successive LEDs light up, only one on at a time.
• The 2nd from left LED flashes, indicating “energy reserve” (70% depth of discharge).
• The 2 most left LEDs alternately flash, indicating “empty” (80% depth of discharge).
c. Charging
• Before charging ensure that you are using an appropriate charger for charging the
installed battery!
Battery discharged
Battery charged
Fig.13: Battery discharge indicator
Fig. 12: battery replacement

17
• Before using the charger, please fully understand the instructions of the charger
instructions.
• Always follow these instructions!
• The room, where you are charging must be ventilated.
• The exactly charge status can be only checked from the dischrge indicator. To
control the status, the charging must be interrupted and the truck must be started.
Park the truck at a dedicated secured area with a dedidcated power supply.
Lower the forks and remove the load.Open the battery cover and let it stay upright.
Switch the truck off and connect the battery plug to the charging plug of the charger.
The charger starts charging the battery if the charger is connected to the main power supply.
Disconnect the battery plug (28) after the charger finished charging.
Connect the battery plug (28) with the plug at the truck.
Close the battery cover.
8. REGULAR MAINTENANCE
• Only qualified and trained personnel are allowed to do maintenance on this truck.
• Before maintaining, remove the load and lower the forks to the lowest position.
• If you need to lift the truck, follow chapter 4b by using designated lashing or jacking
equipment. Before working, put safety devices (for instance designated lift jacks,
wedges or wooden blocks) under the truck to protect against accidental lowering,
movement or slipping.
• Please pay attention by maintain the tiller arm. The gas pressure spring is
pre-loaded by compression. Carelessness can cause injury.
• Use approved and from your dealer released original spare parts.
• Please consider that oil leakage of hydraulic fluid can cause failures and accidents.
• It is allowed to adjust the pressure valve only from trained service technicians.
• If you need to change the wheels, please follow the instructions above. The castors
must be round and they should have no abnormal abrasion.
Check the items emphasized maintenance checklist.
a. Maintenance checklist
Table 3: Maintenance checklist
Interval (Month)
1
3
6
12
Hydraulic
1
Check the hydraulic cylinder, piston for damage noise and leakage
•
2
Check the hydraulic joints and hose for damage and leakage
•
3
Inspect the hydraulic oil level, refill if necessary
•
4
Refill the hydraulic oil ( 12 month or 1500 working hours)
•
Mechanical system
5
Inspect the forks for deformation and cracks
•
6
Check the chassis for deformation and cracks
•
7
Check if all screws are fixed
•

18
8
Check mast and chain for corrosion, deformation or damages, replace if
necessary
•
9
Check the gearbox for noise and leakage
•
10
Check the wheels for deformation and damages, replace if necessary
•
11
Lubricate the load wheel bearing
•
12
Inspect and lubricate the pivot points
•
13
Lubricate the grease nipples
•
14
Replace the guarding and/or protective screen if it is damaged
•
Electric system
15
Inspect the electric wiring for damage
•
16
Check the electric connections and terminals
•
17
Test the Emergency switch function
•
18
Check the electric drive motor for noise and damages
•
19
Check the working status of sensor
•
20
Check if correct fuses are used, if necessary replace.
•
21
Test the audio warning signal
•
22
Check the contactors
•
23
Check the frame leakage (insulation test)
•
24
Check function and wear of the accelerator
•
25
Check the electrical system of the drive motor
•
Braking system
26
Check brake performance
•
Battery
27
Check the battery voltage
•
28
Clean and grease the terminals and check for corrosion and damage
•
29
Check the battery housing for damages
•
Charger
30
Check the main power cable for damages
•
31
Check the start-up protection during charging
•
Function
32
Test the audio warning signal
•
33
Check the air gap of the electromagnetic brake
•
34
Test the emergency braking
•
35
Test the reverse and regenerative braking
•
36
Test the safety (belly) button function
•
37
Check the steering function
•
38
Check the lifting and lowering function
•
39
Check the tiller arm switch function
•
40
Test the key switch of damages and function
•
41
Test the speed limitation switch (lifting height >~600mm)
•
42
Test the speed limitation switch (lifting height >~1800mm)
•
General
43
Check if all decals are legible and complete
•
44
Check if the protective screen and or guarding is not damaged
•

19
45
Inspect the castor, adjust the height or replace it, if worn out
•
46
Carry out a test run
•
b. Lubricating points
Lubricate the marked points according to the
maintenance checklist. The required grease
specification is: DIN 51825, standard grease.
c. Check and refill hydraulic oil
The required hydraulic fluid- type is
• H-LP 46, DIN 51524
• Viscosity is 41.4 - 47
• Depending on the type the amount
Is 15L
Waste material like oil, used batteries or other must be probably disposed and recycled according to the
national regulations and if necessary brought to a recycling company.
The oil level height shall be in the not lifted position min.14.9L to 15.1L.
If necessary add oil at the filling point.
d. Checking electrical fuses
Remove the main cover. The fuses are located according to fig. 15; the size is according to table 4.
1. Guide rail
2. Bearing
3. Pin axle
4. Chain
5. Mast
6. Drive wheel gear
Table 4: Size of the fuses
Rate
FU1
10A
FU01
150A
FU02
200A
FU03
30A
Fig. 14: Lubricating points