Noblelift PT 27R User manual

重诺力行 物动随心
物料搬运·系统集成
1
PT27-36RM
1/2021
Service Manual
PT27-36R

重诺力行 物动随心
物料搬运·系统集成
2
Content
1. GENERAL............................................................................................................................................... 5
1.1 INTRODUCTION –MAINTENANCE SAFETY PRECAUTIONS ................................................5
1.2 MEASUREMENT CONVERSIONS.............................................................................................8
2. Sepcification.......................................................................................................................................... 14
2.1 Overview of the main components ............................................................................................14
2.2 Specification table......................................................................................................................15
3. Electrical system................................................................................................................................... 18
3.1Electrical circuit diagram PT27R............................................................................................. 18
4. Battery Using......................................................................................................................................... 21
4.1 Battery replacement................................................................................................................... 22
4.2 Maintenance of batteries (lead-acid batteries) ..........................................................................23
4.3 Test of the battery......................................................................................................................26
5. Charger .................................................................................................................................................28
5.1 Notes..........................................................................................................................................28
5.2 Instrument description................................................................................................................ 28
5.3 Common faults of charger.......................................................................................................... 29
6. Controller............................................................................................................................................... 30
6.1 Controller function......................................................................................................................30
6.2 Error code...................................................................................................................................30
6.3 Controller test............................................................................................................................. 31
6.4 Contactor and fuse.....................................................................................................................32
6.5 controller of driving motor disassemble / assemble ..................................................................32
6.6 Contactor and relay Common malfunctions ..............................................................................35
6.7 Error code list............................................................................................................................. 36
7. Meter..................................................................................................................................................... 48
7.1 Coulombmeter............................................................................................................................48
7.2 Meter disassemble/assemble ....................................................................................................49
7.3 Battery switch disassemble and assemble................................................................................ 49
7.4 Key disassemble and assemble................................................................................................ 49
7.5 Coded lock.................................................................................................................................50
8. Driving motor......................................................................................................................................... 51
8.1 Motor speed sensor ...................................................................................................................51
8.2 Overheat protection....................................................................................................................51
8.3 Stator testing..............................................................................................................................51
8.4 Drive motor disassemble and assemble....................................................................................53
8.5 Drive motor common fault.......................................................................................................... 54
8.6 gearbox remove/assemble......................................................................................................... 56
9. Hydraulic System.................................................................................................................................. 57
9.1 Hydraulic circuit.......................................................................................................................... 57
9.2 Disassembly of pump motor ......................................................................................................58
9.3 Replace pump motor carbon brush ........................................................................................... 59

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9.4 Replace oil seal of lifting cylinder............................................................................................... 60
9.5 Replace the sealing ring of the lifting cylinder...........................................................................61
9.6 Hydraulic motor fault.................................................................................................................. 63
9.7 Hydraulic pump fault .................................................................................................................. 64
10. Tiller ...............................................................................................................................................65
10.1 tiller operate ............................................................................................................................... 65
11. CURTIS..........................................................................................................................................68
12. Maintenance list............................................................................................................................. 74
12.1 Lubrication.................................................................................................................................. 75
12.2 Check fuse.................................................................................................................................76
12.3 Error analysis............................................................................................................................. 77

重诺力行 物动随心
物料搬运·系统集成
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Foreword
This specification briefly introduces the technical parameters of our pallet, the structure of the main
components, working principle and operation, maintenance, maintenance and other requirements and
contents. Please read this manual carefully before operation in order to ensure safe and effective material
handling through proper driving and maintenance. At the same time, it can help operators to use battery
vehicles reasonably, so that pallet play the maximum efficiency! It is hoped that operators and equipment
managers will read carefully before operating battery vehicles! Please strictly abide by the regulations and
matters needing attention in this specification, drive carefully, operate carefully and use carefully, so that
your pallet can be in the best working condition for a long time and play its best role. When you rent or
transfer a vehicle, please rent or transfer this manual with the car.
To highlight, the following icons are used in this manual:
---- Indicates a potentially dangerous state, if not avoided, may cause serious personal injury, serious
damage to the pallet or fire, etc.
---- Indicates a potentially dangerous state, if not avoided, that may cause minor injury to the person,
or local damage to the pallet, etc.
3. ---- General considerations and instructions when using
Most of this product is made of recyclable steel, and the waste produced in the process of use,
maintenance, cleaning and disassembly must be recovered and disposed of without pollution according to
local regulations. The recycling of such waste must be done by professionals in designated areas, such as
hydraulic fluids, batteries and electronic equipment, which, if not handled properly, may be hazardous to
the environment and human health.
Special statement:
1) this product is strictly prohibited from being used in potentially explosive dangerous environments.
2) the noise level of the normal use of this product is in accordance with the international standard EN
12053.
3) the normal vibration level of this product conforms to the international standard EN13059.
4) the environmental requirements for the normal use of this product are as follows: altitude is not more
than 2000 meters, temperature range is-5 °C-40 °C, humidity is not more than 90%, wind speed is not
more than 5 m / s.
If you need to use it in cold storage or special environment for a long time, please contact our technical
staff if you need to install special accessories.
5) implement product recall service in the event of batch problem
Due to the requirement of continuous product improvement, manufacturers reserve the right to change
their product design and specifications without prior notice. If you want to know the latest product
parameters, please contact us. All parameters of this manual shall be subject to the date of publication of
the specification.

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物料搬运·系统集成
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1. GENERAL
1.1 INTRODUCTION –MAINTENANCE SAFETY PRECAUTIONS
Maintenance work may cause injuries.Always take care to perform work safe, at least observing the
following. It is of utmost importance that maintenance personnel pay strict attention to these warnings
and precautions to avoid possible injury to themselves, others or damage to the equipment.A
maintenance program must be followed to ensure that the machine is safe to operate.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the
manual. These precautions are, for the most parts, those that apply when servicing hydraulic and larger
truck component parts.
MODIFICATION OF THE TRUCK WITHOUT CERTIFICATION BYA RESPONSIBLE
AUTHORITY THAT THE TRUCK ISAT LEASTAS SAFE AS ORIGINALLY MANUFACTURED, IS A
SAFETY VIOLATION.
SINCE THE TRUCK MANUFACTURER HAS NO DIRECT CONTROL OVER THE
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THISAREA RESPONSIBIUTY OF THE
OWNER OR OPERATOR.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS, LlSTED IN THIS SECTION
MAY RESULT
When carrying out any operation or maintenance, have trained and
experienced personnel to carry out the work.
When carrying out any operation or maintenance, carefully read operation and
maintenance handbook.
Read all the precautions given on the decals which are fixed to the truck.
Be sure you fully understand the content of the operation. It is important to
prepare necessary tools and parts for maintain the truck.
Your safety, and that of others, is the first consideration when engaging in the
maintenance of equipment. Always be conscious of weight. Never attempt to move
heavy parts without the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the equipment, ensure that
adequate support is provided.
It should be noted that the machines hydraulic systems operate atextremely high
potentially dangerous pressures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of the system. Relieve
system pressure by cycling the applicable control several times with the
engine(motor) stopped and ignition on, to direct any line pressure back into the

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reservoir. Pressure feed lines to system components can then be disconnected with
minimal fluid loss.
Remove all rings, watches and jewelry when performing any maintenance.
Wear well-fitting helmet, safety shoes and working Clothes When drilling grinding or
hammering always. Wear protective goggles.Always do up safety clothes properly so
that they do. Not catch on protruding parts of machines. Do not wear oily clothes.
When checking, always release battery plug. DO NOT WEAR LONG HAIR
UNRESTRAINED, OR LOOSE-FITTING CLOTHING 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 of lamps. Never use a naked flame to
check leaks or the level of oil or electrolyte.
Immediately remove any oil or grease on the floor of the operator’s
compartment or on the handrail. It is very dangerous if someone slips while on
the machine.
Always use pure oil or grease, and be sure to use clean containers.
Oil is a dangerous substance. Never handle oil, grease or oily clothes in places
where there is any fire or flame. As preparation for use of fire extinguishers and
other fire- fighting equipment.
Keep the battery away from fire hazards. The generated gases are explosive.
Store all the oils in a specified place.
Keep the flammable things away from the machine. Do not smoke at
the working place.
Battery should always be disconnected during replacement of
electrical components.
Always use the grades of grease and oil recommended by
NOBLELIFT choose the viscosity specified for the ambient temperature.
Exhaust gas is dangerous provide ventilation when working in a closed
space.
Avoid breathing dust that may be generated when handling components
containing asbestos fibers. Wear a gas mask if necessary.
When working on top of the machine, be careful not to lose your balance and
fall.
Hand a caution sign in the operator’s compartment (for example “Do not
start” of “Maintenance in progress”). This will prevent anyone from starting or
moving the machine by mistake.
When welding on the machine or working on the electrical system,
ALWAYS turn the key switch OFF and remove the battery plug from the
battery. Park the machine on firm, flat ground. Lower the fork to the min.
height and stop the motor.
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to

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burn skin and eat holes in clothing. If you spill acid on your clothes or skin, immediately flush with large
quantities or 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 can cause short circuit and burn you. Keep tools away from
the terminals.
Keep sparks, lighted matches, and open flame away from the top of battery.
Battery (hydrogen) gas can explode.
When disassembling and assembling the battery, make sure that the battery
terminals (+, –) are correctly connected.
If water gets into the electrical system, abnormal operation or failure can result. Do
not use water or steam on sensors, connectors and instruments in the cab.
Do not handle electrical equipment while wearing wet gloves, or in wet places, as
this can cause electric shock.
When working with other, choose a group leader and work according to his
instructions. Do not perform any maintenance beyond the agreed work.
Unless you have special instructions to the contrary, maintenance should always
be carried out with the motor stopped. If maintenance is carried out with the motor
running, there must be two technicians present: One operating the stacker and the
other one performing the maintenance. In such a case, never touch any moving part.
Before making adjustment, lubricating or performing any other maintenance, shut off all power
controls.
When removing parts containing O-ring Gaskets or seal clean the mounting surface and replace
with new sealing parts.
Thoroughly clean the machine. In particular, be careful to clean the grease fittings and the area
around the dipsticks. Be careful 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
particles or other foreign materials.
Always use NOBLELIFT genuine parts for replacement. ENSURE REPLACEMENT PARTS OR
COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
When checking an open gear case, there is a risk of dripping things in. Before removing the covers
to inspect such cases, empty everything from your pockets. Be particularly careful to remove
wrenches and nuts.

重诺力行 物动随心
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1.2 MEASUREMENT CONVERSIONS
Length
Unit
cm
m
km
in
ft
yd
mile
cm
1
0.01
0.00001
0.3937
0.03281
0.01094
0.00000
6
m
100
1
0.001
39.37
3.2808
1.0936
0.00062
km
100000
1000
1
39370.7
3280.8
1093.6
0.62137
in
2.54
0.0254
0.000025
1
0.08333
0.02777
0.00001
5
ft
30.48
0.3048
0.000304
12
1
0.3333
0.00018
9
yd
91.44
0.9144
0.000914
36
3
1
0.00056
8
mile
160930
1609.3
1.6093
63360
5280
1760
1
1mm=0.1cm, 1 m=0.001mm
Area
Unit
cm2
m2
km2
a
ft2
yd2
in2
cm2
1
0.0001
–
0.000001
0.001076
0.000012
0.15500
0
m2
10000
1
0.000001
0.01
10.764
1.1958
1550.00
0
km2
–
1000000
1
10000
1076400
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
cm3 = cc
m3
l
in3
ft3
yd3
cm3 = m l
1
0.000001
0.001
0.061024
0.000035
0.000001
m3
1000000
1
1000
61024
35.315
1.30796
l
1000
0.001
1
61.024
0.035315
0.001308
in3
16.387
0.000016
0.01638
1
0.000578
0.000021
ft3
28316.8
0.028317
28.317
1728
1
0.03704
yd3
764529.8
0.76453
764.53
46656
27
1
1gal(US)=3785.41 cm3=231 in3=0.83267gal(US)
Weight

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Unit
g
kg
t
oz
lb
g
1
0.001
0.000001
0.03527
0.0022
kg
1000
10
0.001
35.273
2.20459
t
1000000
1000
1
35273
2204.59
oz
28.3495
0.02835
0.000028
1
0.0625
lb
453.592
0.45359
0.000454
16
1
1 tone (metric)= 1.1023 ton(US)=0.9842 ton(UK)
Pressure
Unit
kgf/cm2
bar
Pa=N/m2
kPa
lbf/in2
lbf/ft2
kgf/cm2
1
0.98067
98066.5
98.0665
14.2233
2048.16
bar
1.01972
1
100000
100
14.5037
2088.6
Pa=N/m2
0.00001
0.001
1
0.001
0.00015
0.02086
kPa
0.01020
0.01
1000
1
0.14504
20.886
lbf/in2
0.07032
0.0689
6894.76
6.89476
1
144
lbf/ft2
0.00047
0.00047
47.88028
0.04788
0.00694
1
kgf/cm2=735.56 Torr(mmHg)=0.96784atm
Standard tightening torque
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in sections of “Disassembly and Assembly”
METER TABLE
Classification
4T, 5T
10T
Bolt type
Bolt size
Torque kgf ·m (lbf ·ft)
Torque kgf ·m (lbf ·ft)
M4
0.2 ±0.02
0.4 ±0.04
M5
0.3 ±0.03
0.8 ±0.08
M6
0.5 ±0.05
1.4 ±0.14
M8
1.2 ±0.12
3.3 ±0.3
M10
2.3 ±0.23
6.5 ±0.7
M12
4.0 ±0.4
11.3 ±1.1
M14
6.4 ±0.6
17.9 ±1.8
M16
9.5 ±0.9
26.7 ±2.7
M18
13.5 ±1.4
38.0 ±3.8
10.9

重诺力行 物动随心
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M20
18.6 ±1.9
52.2 ±5.2
M22
24.7 ±2.5
69.4 ±6.9
M24
32.1 ±3.2
90.2 ±9.0
M30
62.6 ±6.3
176.1 ±17.6
M36
108.2 ±10.8
304.3 ±30.4
M42
171.8 ±17.2
483.2 ±48.3
M45
211.3 ±21.1
594.3 ±50.4
INCH TABLE
4T, 5T
10T
Classification Bolt type
Bolt size
Torque kgf ·m (lbf ·ft)
Torque kgf ·m (lbf ·ft)
1/4
0.6 ±0.06
1.7 ±0.2
5/16
1.2 ±0.12
3.0 ±0.3
3/8
2.0 ±0.20
5.6 ±0.5
7/16
3.2 ±0.32
8.9 ±0.9
1/2
4.7 ±0.47
13.4 ±1.3
9/16
6.8 ±0.68
19.0 ±1.9
5/8
9.3 ±0.93
26.1 ±2.6
3/4
16.0 ±1.60
45.1 ±4.5
7/8
25.5 ±2.55
71.6 ±7.2
1
38.0 ±3.80
106.9 ±10.7
1-1/8
54.1 ±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 in above table shall not be applied to nylon or nonferrous bolts or washer. The same is valid for
not

重诺力行 物动随心
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standardized ones.
H Newton meter : 1 Nm = 0.1kgfm
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
The following torque shall be applied to the split flange bolts.
.
PF THREAD
Thread
Torque (kgf·m)
1/8
1.1 ±0.1
1/4
2.6 ±0.2
3/8
4.6 ±0.3
1/2
8.5 ±0.4
3/4
19 ±1.0
1
33 ±2.0
TORQUE FOR SWIVEL NUT WITH O-RING
Tube O.D (inch)
Thread (in)
Torque (kgf·m)
1/2
UN 13/16 - 16
9.5 ±0.95
3/4
UN 1 3/16 - 12
18 ±1.8
1
UN 1 7/16 - 12
21 ±2.1

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物料搬运·系统集成
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Replacement tool for electrical plug-in connection
No.
PIc
Application
1
Remove pin
2
Install pin
3
Loose lock
4
Two-hole lock
5
Four-hole lock
6
Remove pin

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2. Sepcification
2.1 Overview of the main components
1
Foot plate
12
Shelves
2
Cover
13
Pallet fork
3
Left knee pad
14
Wheel bearing
4
Key switch
15
Battery
5
Electricity meter
16
Battery plug
6
Handle
17
Switch seat
7
Bulley button
18
Electric meter cover
8
Bulley button
19
Right knee pad
9
Accelerator
20
fuel tank
10
Handrest cover
21
Steering wheel
11
Storage cover
22
Drive motor and drive wheel
23
Handle cover

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2.2 Specification table
PT 27R 货叉尺寸
PT 36R 货叉尺寸
Fork length
mm
915
1067
1220
1372
1525
2440
2135
2362
2440
Actual fork length
l
mm
908
1060
1213
1365
1518
2433
2128
2355
2433
Overall length
l1
mm
2025
2177
2330
2482
2635
3550
127.8
136.8
3550
wheelbase
y
mm
1305
1458
1615
1765
1917
2835
2130
2130
2130

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Load distance ,centre
of drive axle to fork
x
mm
723
875
1028
1180
1333
2248
1567
1567
1567
fork end size
l-x
mm
185
185
185
185
185
185
560
795
864
Turning radius
Wa
mm
1840
1992
2145
2297
2450
3365
2660
2660
2660
Fork width
e
mm
230
255
Type sheet for industrial truck acc. to VDI 2198
General
data
1.2
Manufacturer`s type designation
PT 27R
PT 36R
1.3
Power (battery, diesel, petrol,
gas, manual)
Battery
Battery
1.4
Operator type
Pedestrian
Pedestrian
1.5
Load Capacity / rated load
Q (kg)
2700
3600
1.6
Load centre distance
c (mm)
600
1220
1.8
Load distance ,centre of drive
axle to fork
x (mm)
1035
1345
1.9
Wheelbase
y (mm)
1615
2130
Weight
2.1
Service weight
kg
1070
1150
2.2
Tires
kg
1390/2380
1300/3470
2.3
Tire size, front
kg
830/240
920/250
Tires,
chassis
3.1
Tire size, rear
聚氨酯轮
聚氨酯轮
3.2
Additional wheels(dimensions)
x w
(mm)
310 x 105
310x 105
3.3
Wheels, number
front/rear(x=driven wheels)
x w
(mm)
82x 82
82 x 70
3.4
Track, front
x w
(mm)
125 x60
125x 60
3.5
Track, rear
1 x +2/4
1 x +2/8
3.6
Service weight
b10 (mm)
455
455
3.7
Tires
b11 (mm)
560/685
585/710
Dimensions
4.4
Lift height
h3 (mm)
150
150
4.9
Height of tiller in drive position
min./ max.
h14 (mm)
880/1550
880/1550
4.15
Height, lowered
h13 (mm)
83
83
4.19
Overall length
l1 (mm)
2330
3350
4.20
Length to face of forks
l2 (mm)
1095
1095
4.21
Overall width
b1 (mm)
940/960
940/960
4.22
Fork dimensions
s/e/l (mm)
60/230/1220
60/255/2440
4.25
Distance between fork-arms
b5 (mm)
560/685
585/710

重诺力行 物动随心
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4.32
Ground clearance, centre of
wheelbase
m2 (mm)
25
25
4.34
Aisle width for pallets 800X1200
lengthways
Ast (mm)
2700
3900
4.35
Turning radius
Wa (mm)
2145
2660
5.1
Travel speed, laden/ unladen
km/h
11/14
9.5/12
5.2
Lift speed, laden/ unladen
mm/s
38/49
30/40
5.3
Lowering speed, laden/ unladen
mm/s
55/50
45/42
5.8
Max. gradeability, laden/ unladen
%
8/15
6/15
5.10
Service brake
电磁制动
电磁制动
6.1
Drive motor rating S2 60min
kw
3.8
3.8
6.2
Lift motor rating at S3 10%
kw
2.2
2.2
6.3
Battery acc. to DIN 43531/35/36
A, B, C, no
no,5Pzs
no,5Pzs
6.4
Battery voltage, nominal
capacity K5
V/ Ah
24/350
24/350
6.5
Battery weight
kg
320
320
6.6
Energy consumption acc: to VDI
cycle
Performance
8.1
Type of drive control
交流变频控制
交流变频控制
8.4
Sound level at driver’s ear acc.
to EN 12053
dB(A)
68
68
8.6
steering
Manual
steering
Manual
steering

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3. Electrical system
3.1 Electrical circuit diagram PT27R

重诺力行 物动随心
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PT36R
Electrical assembly

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No.
Art No.
New Code
Description
1
9000010237
506333010002
Cable-U-50-8-10-900
506333010003
Cable-V-50-8-10-800
506333010004
Cable-W-50-8-10-700
2
9000010160
506233010006
Cable-FP-25-6-8-1150
506233010007
Cable-E1-25-8-8-150
506233010008
Cable-E2-25-8-8-1050
3
9000010161
506233010009
Power supply cable