Noblelift PS E12B User manual

1
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.

6

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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

9
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.

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1-3 Appearance and specifications

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Type sheet for industrial truck acc. to VDI 2198
General data
1.2 Manufacturer`s type designation PS E12N
3600
1.3
Power (battery ,diesel, petrol, gas,
manual)
Battery
1.4 Operator type Pedestrian
1.5 Load Capacity / rated load Q(t) 1.2
1.6 Load centre distance c(mm) 600
1.8
Load
distance ,centre of drive axle
to fork
x(mm) 760
1.9 Wheelbase Y(mm) 1147
Weight
2.1 Service weight kg 585
2.2
Axle loading, laden front/rear kg 560 / 1225
2.3
Axle loading, unladen front/rear kg 440 / 145
Tires, chassis
3.1
Tires Polyurethane (PU)
3.2
Tire size, front  x w
(mm)
Φ210 x 70
3.3
Tire size, rear  x w
(mm)
Φ84 x 93
3.4
Additional wheels(dimensions)  x w
(mm)
Φ100 x 50
3.5
Wheels, number
front/rear(x=driven wheels)
1x + 1 / 2
3.6
Track, front b10 (mm) 550
3.7
Track, rear b11 (mm) 400 / 515
Dimensions
4.2
Lowered mast height h1 (mm) 2280
4.3
Free Lift height h2 (mm) -
4.4
Lift height h3 (mm) 3514
4.5
Extended mast height h4 (mm) 4037
4.9
Height of tiller in drive position
min./ max.
h14 (mm) 710 / 1150
4.15
Height, lowered h13 (mm) 86
4.19
Overall length l1 (mm) 1710
4.20
Length to face of forks l2 (mm) 560
4.21
Overall width b1 (mm) 800
4.22
Fork dimensions s/e/l (mm)
60 / 180 / 1150
4.25
Width across forks b5 (mm) 570 / 685
4.32
Ground clearance,
centre of
wheelbase
m2 (mm) 26
4.33
Aisle width for pallets 1000X1200
crossways
Ast (mm) 2197
4.34
Aisle width for palle
ts 800X1200
lengthways
Ast (mm) 2145
4.35
Turning radius Wa (mm) 1350
Perfor
mance
5.1
Travel speed, laden/ unladen Km/h 4.5 / 4.7
5.2
Lift speed, laden/ unladen m/s 0.12 / 0.19
5.3
Lowering speed, laden/ unladen m/s 0.13 / 0.11

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5.8
Max. gradeability, laden/ unladen % 5 / 10
5.10
Service brake
Electromagnetic
Electric
6.1
Drive motor rating S2 60min kW 0.65
6.2
Lift motor rating at S3 7.5% kW 2.2
6.3
Battery acc. to DIN 43531/35/36
A, B, C, no no
6.4
Battery voltage, nominal capacity
K5
V/Ah 24 / 60
6.5
Battery weight kg 19
6.6
Energy consumption acc: to VDI
cycle
Kwh/h 0.8
Oth
er
8.1
Type of drive control AC- speed control
8.4
Sound level at driver’s ear acc. to
EN 12053
dB(A) <70
Type Lowered mast height
h1(mm)
Free Lift height
h2(mm)
Lift height
h3(mm)
Extended mast height
h4(mm)
One stage
mast
1930 1514 1514 1930
2330 1914 1914 2330
Two stage
mast
1930 - 2814 3337
2080 - 3114 3637
2280 - 3514 4037

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1-4 Safety notice
The safety section includes the following subsections: general, personal safety, maintenance
safety, compressed air hazards, hydraulic oil hazards, mechanical hazards, electrical hazards, and fire
and burn hazards. Under each heading are listed the precautions you should take to ensure that you
stay safe while working on the vehicle.
Readers are responsible for reading thoroughly, understanding and implementing all the
following preventive measures. Please also note that the safety instructions listed below are not only
for the safety of the reader, but also for the people around him. Therefore, for your own personal
safety and the safety of those around you, please read the following instructions carefully:
General
safety instructions
Be familiar with the safety instructions immediately visible on the vehicle. These include
warning signs, stickers, engravings, etc. Before operating, lubricating or repairing the vehicle, please
write down and read them (see the section "Description of Safety Devices and Warning Labels" in the
"Operation Manual").
Ensure that all safety rules, regulations and instructions are followed when performing
maintenance. Please pay special attention to the danger warnings in this manual, which will inform
you of potentially dangerous situations.
Do not assume that you can perform the steps outlined in this manual based on your previous
maintenance experience with similar models. Different models have different weights and
specifications, so close attention should be paid to avoid dangerous situations, injuries and/or
component damage.
Personal safety
Do not operate or maintain the vehicle without authorization or training. Do not operate or
maintain the vehicle after drinking alcohol or drugs that damage your judgment.
If you have any diseases or conditions that restrict physical activity, do not operate or maintain
the vehicle.
Work clothes
If you are wearing loose clothes or your hair is very long and it is not handled in a safe state,
please do not operate the vehicle or perform maintenance. Both may be caught by moving parts and
cause serious injury.
Wear proper protective equipment when you are performing maintenance tasks. Protective
equipment may include hard hats, glasses/visors, ear protectors, gloves and protective shoes.
Wear a mask when polishing the car body, and wear an air breathing device when spraying
paint.
Wear welder's gloves, welding mask/goggles, apron and other suitable welding clothing when
welding.

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Maintain safety
Pre-maintenance
Ensure that the vehicle is in a clean, open environment and not affected by traffic and other
people.
Ensure that the vehicle is parked safely and that the vehicle does not move suddenly. Place
wooden props in front of and behind the wheels and make sure the parking brake is properly
engaged.
Ensure that the vehicle is empty and unoccupied, the fork is lowered, all hydraulic controllers
are in the neutral position, and the key is switched to OFF. Before servicing or repairing the vehicle,
attach a "no operation" or similar warning label to the start switch or control 器上。 On the device.
Make sure the tool is in good condition.
Installation and removal
Before installing the vehicle, make sure that the working environment is clean, tidy and dry.
When using steps, ladders or walkways for installation or removal, please face the vehicle.
Use these steps and grab the handle to install or remove parts. When you cannot use these
steps, use ladders, scaffolds, work platforms or cranes to safely perform maintenance operations。
Hoist
Check the weight of each component before removal. Some parts of this vehicle are very heavy
and may cause serious injury.
When removing any components, use proper lifting procedures
To avoid back injuries, use a hoist when lifting parts weighing 23 kg (50 lb) or more. Ensure that
all chains, hooks, slings, etc. are in good condition and have the correct capacity. Make sure that
the hook is positioned correctly. During the lifting operation, the eye bolts should not be loaded
sideways.
Assembly/disassembly
Ensure that the assembly/disassembly work site is kept clean, tidy and dry, and keep hand tools
clean.
When tightening/loosening bolts and nuts, please use a wrench of appropriate size and always
pull it toward your body. Using the wrong wrench size or pushing away from the body to
loosen/tighten the bolts or nuts may cause accidents due to the sliding of the handle.
If two or more people are working, use signs or signals to communicate so that the work is done
in an agile way, as if the work was done by one person.
Reinstall all fasteners using the same parts. If you need to replace any fasteners, please use
high-quality fasteners and be careful not to use metric system fasteners mixed with imperial
fasteners。
Compressed air hazards
When cleaning, please wear a protective mask, protective clothing and protective shoes. When
cleaning, the maximum air pressure must be lower than 205 kPa (30 psi).

16
Hydraulic oil hazards
Please carefully follow the instructions below to carry out safety tips on hydraulic system
maintenance.
De-oiling under pressure, even if the pinhole size leaks, it can penetrate body tissues, causing
serious injury and possibly death. Wear gloves, goggles, and make sure your arms and legs are
completely covered. Release all pressure from the hydraulic system before disconnecting or removing
any pipes, fittings or related items, and wait for the system to cool down when it is just running.
Do not touch the pressurized hose with your hands, and do not bend or hit the hose.
Never use your hands to check the pinhole for leaks; this is the most common method of oil
injection related injuries! Use cardboard or other solid surfaces instead.
When removing the filler cap, vents and plugs, put a rag on the port to prevent being sprayed or
splashed by liquid under pressure.
Prepare a container to catch any hydraulic fluid that may flow out of the hose/port.
Make sure that all raised components are properly locked.
When reinstalling the lines, make sure to tighten them to the correct torque.
Ensure that all clamps and guards are installed correctly to avoid vibration or friction with other
parts during operation.
Mechanical hazard
If any rotating parts are damaged and any other parts are touched during operation, do not
operate the machine. Before reuse, check the balance of any damaged or altered high-speed rotating
parts.
When working under the vehicle, properly support the equipment and installation components.
Don't expect the hydraulic cylinder to remain installed. If the moving lever or the hydraulic line
breaks, any accessories may fall.
Upon impact, debris or other debris will fly away from the object. Before striking an object,
make sure that flying debris will not harm anyone.
Electrical hazard
Do not damage the wiring during the disassembly operation. When reinstalling the wiring, please
ensure that the installation method is correct.
Do not connect the wiring to lines containing oil.
When checking, charging or servicing the battery, do not smoke or expose the battery to sparks or
flames. Keep chains and metal tools away from the top of the battery.
Electrolyte is an acid that may cause personal injury if it comes in contact with skin or eyes。
Risk of fire and burns
To avoid burns, please pay attention to the hot parts on the machine just stopped and the hot
oil in the pipes and tanks.
All hydraulic fluids, most lubricants and some coolant mixtures are flammable. If the pipe is
loose or damaged, a fire may occur.
Store all hydraulic oil and lubricants in appropriately labeled containers away from

17
unauthorized personnel.
Store all oily wipes or other flammable materials in a protective container in a safe place.
Do not weld or flame cut pipes or pipes that contain flammable fuel. Before welding or flame
cutting, clean them thoroughly with a non-flammable solvent.
Remove all residual flammable materials from the vehicle。
1-5 maintenance
The following describes the key items and replaceable parts to be checked during maintenance
intervals.
Note: Except for the daily inspection by the vehicle driver, all maintenance and repairs should be
carried out by qualified and authorized engineers.
Note: Careless handling of waste oil will not only harm the environment but also human health.
Waste oil should always be placed in a container and disposed of by authorized personnel at
designated locations.
Check if necessary
item Inspection standards and methods
Gear rack roller Measure the distance from the bottom of the inner main frame to the bottom
of the carriage bearing,
Make the inner door frame upright, and then adjust the extrusion of the roller。
Power module Before touching any electrical components, the power module must be fully
discharged。
Fuse box Check whether the fuse has any removed components and replace it if
necessary.
10 A: Key switch
150 A: main fuse
Wheel bolts Check whether the wheel bolts and nuts are fixed as follows:
Drive tightening torque: 50 Nm
Drive axle gear box Check the gearbox for lubricating oil
Refill the lubricating oil into the plug opening to check the housing level。
Check every 10 service hours or once a day
item Inspection standards and methods
Walk around Check for loose parts and fasteners。
Check whether the indicator on the dashboard is abnormal.
Check whether the horn and other alarms are operating normally.
Check whether the mast and lifting chain are worn out, and whether the
pins/rollers are abnormal.
Check the shelf, front fork and accessories for damage and abnormality.
Check whether the tires, valves and wheels are abnormal.

18
Check the hydraulic system for oil leakage and damage.
Check whether the drive is leaking.
Door frame Lubricate the beam where the rollers are located。
Tires Check the tires for wear, cuts, grooves and contamination。
Check every 500 service hours or 3 months
item Inspection standards and methods
Crosshead roller Check whether the crosshead roller guard and retainer are damaged。
Doorframe, chain Check whether the lifting cylinder is operating normally.
Check whether the fork is operating normally.
Use a brush to lubricate all chains and check whether their anchor points are
abnormal。
Steering shaft Lubrication of steering shaft accessories。
control panel Clean the control panel.
Maximum allowable air pressure: 205 kPa (29.7 psi)
accelerator Check the tightness of the accelerator switch mounting bracket, and repair as
needed.
Check for loose wiring and fix it if necessary.
Hydraulic oil Check the hydraulic oil level and refill as needed。
Check every 1,000 service hours or 6 months
item Inspection standards and methods
Drive and hydraulic
pump motor
Remove dust and check the area of the drive motor and electrical components.
Maximum allowable air pressure: 205 kPa (29.7 psi)
Hydraulic return
filter
Replace the oil return filter in the hydraulic oil tank.
Tires Check tires for wear, cuts, grooves, contamination, etc.
Check the wheel components for cracks, wear, damage, corrosion, etc.
Standard torque of driving wheel: 50 N·m
Lifting chain Perform lifting chain wear test by measuring the wear of chain links and pins。
Check every 2,000 service hours or once a year
item Inspection standards and methods
Hydraulic system Replace hydraulic oil and filter。
Basic maintenance Under normal circumstances, regular inspections are carried out at least every
12 months. If you work for a long time or under a heavy load, perform regular
inspections for 6 months.
If you find any of the following conditions, please replace:
Healing of cracks on forks, welding, brackets, etc.

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1-6 lubricating oil
The following is a detailed description of the required lubricant and the parts to be lubricated.
1-6-1 Lubricant specifications
The following lubricants are recommended for chains and connecting rods：
1-6-2 Hydraulic oil（HYDO）
The hydraulic oil should have anti-wear, anti-foam, anti-rust and anti-oxidant additives for heavy-duty
use as stated by the petroleum supplier. The ISO viscosity grade is usually No. 32.
Note: The correct hydraulic oil should be used to achieve the maximum service life and performance
of hydraulic system components. It is recommended to use the above hydraulic oils in most hydraulic
and hydraulic systems.
If the hydraulic oil becomes turbid, it means that water or air has entered the system. Water or air in
the system will cause the pump to malfunction. Drain all hydraulic oil, re-tighten all hydraulic suction
pipe clamps, then clean and refill the system.
1-7 Disassembly/assembly instructions
The disassembly/assembly part includes the following subsections: preparations before
disassembly, inspection and testing before disassembly, precautions during disassembly, precautions
after disassembly, precautions during assembly, handling of general parts, and hydraulic pipeline
accessories. Precautions to be taken to perform disassembly/assembly work correctly are listed
under each heading。
Preparation before disassembly
Remove dust and pollutants from the vehicle before sending it to a repair center. Dust or
contaminants entering the repair center may stain the components and enter them to cause damage.
Electric vehicles operate based on electrical systems. Do not let any water enter the
system.
To avoid unnecessary disassembly work, prepare the necessary tools, place the boxes for
the parts, and give priority to ensuring the cleanliness of the site
Check and test before disassembly
Before starting disassembly, be sure to record any problems. This prevents unnecessary
disassembly, loss of replacement parts, and repeated failures caused by the same problem.
item specification
1 DIN 51825 Standard grease

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To prevent malfunction, please record the malfunction and the parts required for replacement.
Also make sure to check and record the following information：
Vehicle model, serial number and business hours
The reason why the vehicle needs to be disassembled
Check the symptom, location and cause of the malfunction.
(If necessary, reproduce the same failure).
Check if any parts are inappropriate.
Check for damage or loose parts.
If possible, check the maintenance of the vehicle。
Precautions when disassembling
Disassemble
Determine the assembly method of the parts (front/rear, left/right and top/bottom connection)
to determine the disassembly sequence.
Before starting to disassemble the parts, pay attention to the connection points of the parts
and mark them with arrows to avoid incorrect placement of the parts during assembly.
Use the right tools to delete specific parts.
If you have not removed any parts, even the mounting bolts and nuts, do not use excessive
force. Check and find the reason.
Put the disassembled parts on one side in the order of disassembly, and put labels or marks
on the parts with similar appearance.
Store bolts, nuts and other common parts in an orderly manner.
Check and test during disassembly
Sometimes the cause of the failure will be discovered during the disassembly
process. Therefore, it is very important to carefully check the condition of the
friction surface and the contact parts。
During the disassembly process, measure and record the gap, deformation, projection and
other factors that may cause the failure.
Keep the gap
Ensure that the installed gaskets and washers produce the required specified clearance value
Remove press parts
Remove any dents or marks caused by hammering and polishing the area.
If you loose any press-fitted parts, please determine and eliminate the cause to avoid
problems during the assembly process。
Disassemble the bearing
Do not use force to disassemble the bearing, but use a bearing puller.