Noblelift PS E12B User manual

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WARNING
Do not use the pallet 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.
Service & Maintenance Manual
Electric Pallet Truck
PSL-type Stacker（PS E12B / PS E12N）

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Content
1-1 How to use this manual ........................................................................................................................................... 5
1-1-1 Build this manual .......................................................................................................................................... 5
1-1-2 Warning label definition ............................................................................................................................... 5
1-2 vocabulary ............................................................................................................................................................... 7
1-3 Appearance and specifications .............................................................................................................................. 11
1-4 Safety notice .......................................................................................................................................................... 14
1-5 maintenance .......................................................................................................................................................... 17
1-6 lubricating oil ......................................................................................................................................................... 19
1-6-1 Lubricant specifications .............................................................................................................................. 19
1-6-2 Hydraulic oil（HYDO） ........................................................................................................................... 19
1-7 Disassembly/assembly instructions ....................................................................................................................... 19
1-8 Standard torque ..................................................................................................................................................... 25
1-8-1 Standard torque of bolts and nuts.............................................................................................................. 25
1-8-2 Standard torque for fastening accessories ................................................................................................. 27
2 electronic system ................................................................................................................................................... 29
2-1 Overview ................................................................................................................................................................ 29
2-1-1 Communication protocol ............................................................................................................................ 30
2-2 lithium battery ....................................................................................................................................................... 31
2-2-1 Appearance and specifications ................................................................................................................... 31
2-2-2 Analysis and explanation of lithium battery fault ....................................................................................... 32
2-2-3 Removal and installation of lithium battery ............................................................................................... 34
2-3 Emergency switch .................................................................................................................................................. 34
2-3-1 Appearance and Specifications................................................................................................................... 34
2-3-2 function ...................................................................................................................................................... 34
2-4 Controller and associated equipment ................................................................................................................... 36
2-4-1 appearance ................................................................................................................................................. 36
2-4-2 Features ...................................................................................................................................................... 36
2-4-3 test .............................................................................................................................................................. 37
2-4-4 Removal and installation ............................................................................................................................ 38
2-5 Miscellaneous load ................................................................................................................................................ 38
2-5-1 fuse .......................................................................................................................................................... 38
2-5-2 horn ......................................................................................................................................................... 39
2-6 Handle the head .................................................................................................................................................... 40
2-6-1 appearance ................................................................................................................................................. 40
2-6-2 function ...................................................................................................................................................... 40
2-6-3 Handle head detection ............................................................................................................................... 40
2-6-4 Removal and installation ............................................................................................................................ 41
2-6-5 Handle proximity switch removed and installed ........................................................................................ 41
2-6-6 Handle air spring removed and installed .................................................................................................... 41
2-6-7 Handle removed and installed .................................................................................................................... 41
2-7 CURTIS Handheld programmer ........................................................................................................................... 42
2-7-1 Operation precautions and connection to the vehicle controller： .......................................................... 42

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2-7-2 Vehicle fault reading process ................................................................................................................... 42
2-7-3 Vehicle signal detection ........................................................................................................................... 43
2-7-4 CURTIS Handheld unit menu content ......................................................................................................... 43
2-8 Troubleshooting for each fault code ...................................................................................................................... 49
3 Drive/brake system ................................................................................................................................................... 52
3-1 Overview ................................................................................................................................................................ 52
3-1-1 Component ................................................................................................................................................. 52
3-2 Drive assembly ....................................................................................................................................................... 52
3-2-1 appearance ................................................................................................................................................. 52
3-2-2 How does this work .................................................................................................................................... 52
3-2-3 Drive motor disassembly/assembly and test .............................................................................................. 54
3-2-4 Drive wheel removal/installation ............................................................................................................... 55
3-3 Service braking system .......................................................................................................................................... 55
3-3-1 Overview ..................................................................................................................................................... 55
3-3-2 How does this work .................................................................................................................................... 55
3-3-3 test .............................................................................................................................................................. 55
3-3-4 Removal/installation of electromagnetic brake ......................................................................................... 56
3-4 Troubleshooting ..................................................................................................................................................... 56
3-4-1 Drive motor ................................................................................................................................................ 56
3-4-2 Driving box .................................................................................................................................................. 58
4 The hydraulic system.............................................................................................................................................. 59
4-1 overview ................................................................................................................................................................ 59
4-1-1 component ................................................................................................................................................. 59
4-2 Pump station assembly .......................................................................................................................................... 60
4-2-1 Appearance and specifications ................................................................................................................... 60
4-2-2 test .............................................................................................................................................................. 60
4-2-3 Removal/installation of pump motor and hydraulic pump ........................................................................ 61
4-2-4 Pump motor disassembly/assembly and testing ........................................................................................ 62
4-3 Hydraulic oil tank and filter.................................................................................................................................... 63
4-3-1 appearance ................................................................................................................................................. 63
4-3-2 Replacement of hydraulic fluid and filter ................................................................................................... 63
4-4 troubleshooting ..................................................................................................................................................... 64
4-4-1 Pump motor................................................................................................................................................ 64
4-4-2 Hydraulic pump .......................................................................................................................................... 65
5 Lifting system ......................................................................................................................................................... 66
5-1 Overview ................................................................................................................................................................ 66
5-1-1 Component ................................................................................................................................................. 66
5-2 Door frame ............................................................................................................................................................. 67
5-2-1 appearance ................................................................................................................................................. 67
5-2-2 Pallet fork .................................................................................................................................................... 68
5-2-3 Chain ........................................................................................................................................................... 68
5-2-4 Lifting cylinder ............................................................................................................................................ 69
5-3 Troubleshooting ..................................................................................................................................................... 70

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6 steering system ......................................................................................................................................................... 71
6-1 Overview ................................................................................................................................................................ 71
6-1-1 appearance ................................................................................................................................................. 71
6-1-2 How does this work .................................................................................................................................... 71
7 Schematic diagram ................................................................................................................................................. 73
7-1 Hydraulic schematic ............................................................................................................................................... 73
7-2 Electrical schematic ............................................................................................................................................... 74
8 Charger ...................................................................................................................................................................... 76
8-1 Lithium battery charger ......................................................................................................................................... 76
8-1-1 Lithium battery charger introduction ...................................................................................................... 76
8-1-2 Technical parameters of lithium battery charger .................................................................................... 76
8-1-3 Lithium battery charger indicator light description ................................................................................. 77
8-1-4 Lithium battery charger maintenance ..................................................................................................... 78
8-1-5 Troubleshooting ....................................................................................................................................... 78

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1-1 How to use this manual
1-1-1 Build this manual
This service manual provides information service engineers and technicians required for vehicle
maintenance; it does not contain vehicle operating instructions.
The introductory part of this manual provides an overview of the functions of the vehicle, with
particular attention to its different components. You can find each part in the main body of this
manual, which provides more specific and detailed information, including schematic diagrams of
vehicle components, working methods, inspection contents, repair procedures, and data and
information required for repair and maintenance.
To help readers quickly and easily find the services and training information they need, these
chapters are based on The different systems included in the vehicle are classified (see the table
below).
section title
1 general
2 electronic system
3 Drive/brake system
4 Hydraulic system
5 Lift/Tilt/Assist System
6 steering system
7 Schematic diagram
8 other
9 Charger
1-1-2 Warning label definition
This manual uses the following three warning labels: "Danger", "Warning" and "Caution". Each
label is designed to show the reader the severity and nature of the potential hazards, the
consequences, and preventive measures to prevent the hazards. You will find these labels throughout
this manual. Make sure you pay attention to them carefully, as they are included for your safety.

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1-2 vocabulary
The following are the terms and descriptions used in this service manual
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.
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 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.

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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 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
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

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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
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).

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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
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.