Noblelift EPT15 User manual

Version 12/2012
EPT -SHFW-001
SERVICE & MAINTENANCE MANUAL
Electric Pallet Truck
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CONTENT
FOREWORD..............................................................................................................................................3
1. GENERAL...........................................................................................................................................4
1.1 INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS.............................................. 4
1.2 MEASUREMENT CONVERSIONS ...........................................................................................8
2. SPECIFICATION ..............................................................................................................................13
2.1 LOCATION OF COMPONENTS..............................................................................................13
2.2 SPECIFICATION SHEETS....................................................................................................14
2.2.1 TECHNICAL FEATURES.....................................................................................................14
2.3 LUBRICATION ......................................................................................................................17
3ELECTRIC SYSTEM ........................................................................................................................18
3.1 ELECTRIC DIAGRAM.............................................................................................................18
3.2 ELECTRICAL INSTALLATION...............................................................................................22
3.3 DRIVE WHEEL.........................................................................................................................23
3.4 PUMP STATION ......................................................................................................................23
3.5 BATTERY.................................................................................................................................23
3.6 CHARGER ...............................................................................................................................25
3.7 CURTIS CONTROLLER 1212.................................................................................................28
3.8 BATTERY DISCHARGE INDICATOR ....................................................................................39
3.9 REPLACE THE ELECTRIC PARTS........................................................................................41
3.10 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG ......................................................46
4. HYDRAULIC SYSTEM......................................................................................................................48
4.1 PUMP STATION OPERATION ...............................................................................................49
4.2 OPERATION OF CYLINDER..................................................................................................54
4.3 HYDRAULIC OIL FILLING......................................................................................................55
5. DRIVE WHEEL..................................................................................................................................56
5.1 REPLACE THE WHEEL..........................................................................................................57
5.2 REPLACE THE ELECTRIC BRUSH…….……………………………………………………….58
5.3REPLACE THE BRAKE..........................................................................................................59
5.4ADJUST THE AIR GAP OF THE BRAKE..............................................................................59
5.5 REPLACE THE DRIVE WHEEL……...………………………………….…….………….………60
6. CONTROL HANDLE ........................................................................................................................57
6.1 ................................................................................................REMOVE THE AIR SPRING.. 65
6.2 .......................................................................................................REMOVE THE HANDLE 65
6.3 REPLACE THE SENSOR …………………………………………………………………………66
6.4 REPLACE THE TILLER…………………………………………………………………. … …… 66
6.5 REPLACE THE ACCELERATOR……..………………………………………………………….67
6.6 REPLACE THE MICRO SWITCHES…………………………….………….…………..……… .68
7. CASTER WHEEL .............................................................................................................................69
7.1 OPERATION OF THE CASTER WHEEL................................................................................69
7.2 ADJUSTING THE PRESSURE FOR THE DRIVE WHEEL.................................................. 70
8. MAINTENANCE CHECK LIST.........................................................................................................71
9. TROUBLE SHOOTING ....................................................................................................................73
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FOREWORD
Proper operation, maintenance, troubleshooting and repairs are necessary to preserve the performance
of the pallet truck over a long period and ensure that fault and breakdowns do not occur. The purpose of
this service manual is to provide necessary information especially in inspections, repair and
maintenance.
The majority of this pallet truck consists of steel, it can be completely recycled. Waste
material in conjunction with repairs, maintenance, cleaning or scrapping, must be collected and disposed
of in an environment-friendly way and in accordance with the directives of respective countries. Such
work must be carried out in areas intended for this purpose. Recyclable material should be taken care of
specialized authorities. Environmentally hazardous waste, such as oil filters, batteries and electronics,
will have a negative effect on the environment or health, if handled incorrectly.
All of the information reported herein is based on data available at the moment of
printing. Our products are constantly being developed and renewed, we reserves the right to modify our
own products at any moment without prior notice and incurring in any sanction. So, it is suggested to
always verify possible updates.
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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 BY A RESPONSIBLE
AUTHORITY THAT THE TRUCK IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A
SAFETY VIOLATION.
SINCE THE TRUCK MANUFACTURER HAS NO DIRECT CONTROL OVER THE
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIUTY OF THE
OWNER OR OPERATOR.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS, LlSTED IN THIS SECTION
MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY
VIOLATION.
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.
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It should be noted that the machines hydraulic systems operate at
extremely 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
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.
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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
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.
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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.
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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 0.000006
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 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1mm=0.1cm, 1µm=0.001mm
Area
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 – 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
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
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)
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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
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
10.9
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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
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.
Diameter
(mm) Flat width (mm) Torque
kgf·m N·m
10 14 6.7 ± 0.7 66.7 ± 6.8
12 17 11.5 ± 1 112 ± 9.8
16 22 28.5 ± 3 279 ± 29
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O – ring Plug
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
Connector O – ring Swivel – nut hose
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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APPROXIMATE CONVERSIONS
SI Conv Non–SI Conv SI
Unit Factor Unit Factor Unit
Torque
N
ewton meter (N·m)
×8.9 = ln·in ×0.113 = N·m
N
ewton meter (N·m)
×0.74 = lb·ft. ×1.36 = N·m
Newton meter (N·m) ×
0.102
= kg·m
×
7.22
= lb·ft.*
Pressure (Pa = N/m
2
)
kiloP
ascal (kPa)
×4.0 = in. H2×0.249
O = kPa
kiloP
ascal (kPa)
×0.30 = in. Hg ×3.38 = kPa
kiloP
ascal (kPa)
×0.145 = psi ×6.89 = kPa
(bar)
×14.5 = psi ×0.069 = bar*
(kg/cm2×14.22
)
= psi ×0.070
=
k f/ 2*
Newton/mm
2
×145.04
= psi ×0.069 = bar*
MegaPascal (MPa) ×
145
= psi
×
0.00689
= MPa
(Pa=N·m
2
)
Power r (W = J/s)
kiloW
att (kW)
×1.36 = PS (cv) ×0.736 = kW
kiloW
att (kW)
×1.34 = HP ×0.746 = kW
kiloW
att (kW)
×0.948 = Btu/s ×1.055 = kW
W
att (W)
×0.74 = ft·lb/s ×1.36 = W
(W=J/s) Energy (J = N·m)
kiloJ
oule (kJ)
×0.948 = Btu ×1.055 = kJ
J
oule (J)
×0.239 = calorie ×4.19 = J
(J=N·m) Velocity and Acceleration
meter per sec
2
(m/s
2
×3.28
)
= ft/s
2
×
0.305
= m/s
2
meter per sec (m/s)
×
3.28
= ft/s
×
0.305
= m/s
kilometer per hour (km/h)
×0.62 = mph ×1.61 = km/h
Horse Power/Torque
BHP ×5252 R.P.M. = TQ (lb·ft) TQ Z R.P.M. 5252 = B.H.P.
Temperature
°C = (°F–32) ÷ 1.8 °F= (°C Z 1.8) + 32
Flow Rate
liter/min (dm3×
0.264
/min)
= US gal/minZ3.785 = l/min
Note : ( ) Non–SI Unit
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2. SPECIFICATION
2.1 LOCATION OF COMPONENTS
1. Multifunction tiller 8. Drive motor cover
2. Dis
charge indicator and charging
indicating LED 9. Lift Cylinder
3. Emergency Button 10. Drive wheel
4. Main cover 11 Castors
5. Fork chassis 12 Safety (belly) button
6. Load Wheels 13 Drive control switch
7. Charging cable
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CONTROL HANDLE
12 Safety (belly) button 15 Lifting button
13 Drive control switch 16 Lowing button
14 Horn button
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2.2 SPECIFICATION SHEET
2.2.1 Technical Features
Type sheet for industrial truck acc. to VDI 2198
Distinguishing mark
1.2 Manufacturer`s type designation EPT15
1.3 Drive electric
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) 946
1.9 Wheelbase y (mm) 1293
Weight
2.1 Service weight kg 190 200
2.2 Axle loading, laden front/rear kg 510/1180 560/1140
2.3 Axle loading, unladen front/rear kg 150/40 160/40
Tyres, chassis
3.1 Tires Polyurethane (PU)
3.2 Tire size,front ∅x w (mm) ∅220×70
3.3 Tire size,rear ∅x w (mm) ∅80×70 ∅80×93
3.4 Additional wheels(dimensions) ∅x w (mm) ∅50×30
3.5 Wheels,number front/rear(x=driven wheels) 1x +2/ 4 1x +2/ 2
3.6 Tread, front b10 340(mm)
3.7 Tread, rear b11 380(mm)
Dimensions
4.4 Lift h3 115(mm)
4.9 Height of tiller in drive position min./ max. h14 800 / 1170(mm)
4.15 Height, lowered h13 85(mm) 80
4.19 Overall length l1 1648(mm) 1718
4.20 Length to face of forks l2 498(mm)
4.21 Overall width b1 560(mm) 705
4.22 Fork dimensions s/e/l (mm) 48/160/1150 48/160/1200
4.25 Distance between fork- arms b5 540(mm) 685
4.32 Ground clearance, centre of wheelbase m2 37(mm) 32
4.34 Aisle width for pallets 800X1200
lengthways
Ast (mm) 1950
4.35 Turning radius Wa (mm) 1445
Performance data
5.1 Travel speed, laden/ unladen km/h 4.2 / 4.6
5.2 Lift speed, laden/ unladen mm/s 30 / 53
5.3
Lowering speed, laden/ unladen
mm/s 49 / 36
5.8
Max. gradeability, laden/ unladen
% 4 / 10
5.10 Service brake electromagnetic
Electric- engine
6.1
Drive motor rating S2 60min
kW 0.45
6.2 Lift motor rating at S3 10% kW 0.8
6.3 Battery acc. to DIN 43531/ 35/ 36 A, B, C, no no
6.4
Battery voltage, nominal capacity K5
V/ Ah 2x12V / 64
6.5 Battery weight kg 48 kg
6.6 Energy consumption acc. to VDI cycle kWh/h 0,39
Other
8.1 Type of drive control MOSFET Control
8.4 Sound level at driver`s ear acc. to EN 12053 dB(A) 69
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2.3 LUBRICATION
Hydraulic oil
Hydraulic oil must have anti-wear qualities at least. It is not advisable to mix oils of
different brands or types, as the may not contain the same required additives or be of
comparable viscosities.
Name: Thickened hydraulic oil.
ISO Viscosity Grade
#40
#30
Characteristics
unit
Viscosity
At 40O
mm
C
2
57
/s
48
At 50O
40
C
30
Viscosity index ≥150 ≥150
Flash point, Cleveland open cup
O
≥160
C ≥160
Pour point, Max
O
≤-35
C ≤-35
Density at 15O
kg/m
C
3
861.5
Copper corrosion(100
O
degreeC, 3h) ≤1 ≤1
Foaming (93.5
O
ml / mlC) ≤30/0 ≤30/0
Vickers vane pump test, loss of mass (on vanes after 100h) mg ≤100 15.3
Diameter of wear spot, 1200 r/min, 294N, 30min, 75
O
mmC ≤0.5 ≤0.5
The oil for gear box
Name: Extreme pressure lithium-based grease, 1#.
Characteristics unit
Worked Penetration, 0.1mm 310--340
Dropping point, O≥170C
Extreme pressure (Timken OK) N ≥177
Similar viscosity (-10
O
C, 10s
-1
Pa.s
) ≤250
Corrosion preventive properties (52
O
GradeC, 48h) 1
Wire points oil (100
O
%C, 24h) ≤10
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3 ELECTRIC SYSTEM
3.1 ELECTRIC DIAGRAM
WIRING DIAGRAM
Electric diagram EPT 15
Fuses EPT 15
FU1 : 10A
FU2 : 0.5A
FU01 : 60A
FU02 : 60A
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No. Code Description Qty.
1 GB Battery, 12V/64Ah 2
2 S Emergency button ,S100/80 1
3 FU01,FU02 Fuse, 60A 2
4 Mt Motor for traction, DC24V 1
5 Mp Motor for lift, DC24V 1
6 YB Brake, DC24V 1
7 Et Controller, Curtis 1212-2501 1
8 FU1 Fuse,10A 1
9 P Battery Indicator, CURTIS 906 T24BNBO 1
10 LED Trouble light 1
11 HA Buzzer, HYD-4216W 24VDC 1
12 VD diode,1N5408 2
13 KMp Contactor for lift 1
14 SU Micro switch ,WS1-Z5-W200R200 1
15 YV Valve, DC24V 1
16 SA Inductive Sensor, NBN5-FT-E2 1
17 U Charger, 24V/8A 1
18 XW Power cord 1
19 HL Charging indicator 1
20 Kr Protect module ,BD-W-115 1
21 S1,S2,S3,S4 Micro switch ,SS-5GL2 4
22 BE Accelerator, BD-126 1
23 K Relay,ARP12F-1C 24VDC 1
24 FU2 Fuse, 0.5A 1
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CONNECTION DIAGRAM
EPT
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