Kelvin Mini Series Manual
A:UK Headquarters | Waterend Farm | Epping Road | Ongar | Essex | CM5 0DE |
Company Reg Number 08189288 | Vat Reg 260080637 |
KELVIN Mini series electric counterbalance forklift
Maintenance Instruction Manual
Preface
Dear Customer
To make sure you operate this product correctly and safely, before using it, please read these instructions
carefully and keep this document for reference.
The operator must use, operate and maintain the forklift according to the data in the instruction manual. The
use of the equipment for any other purpose is not compliant operation and may result in personal injury and
the loss of a forklift or other property. The user of the device must comply with the maximum loading capacity
limitation specified on the nameplate or load chart to ensure that the forklift is used for the regulated purpose
and to eliminate the danger of life and health of the user or a third party. In addition, equipment operators
must strictly abide by accident prevention regulations, technical safety regulations and maintenance and
repair guidelines. The operator of the machine must ensure that they carefully read and fully understand
the contents of this instruction manual.
If you do not follow this instruction manual, our company's quality guarantee automatically expires. If the
customer or a third party arbitrarily makes non-standard operations to the equipment, or Kelvin Engineering
will not assume any responsibility for the resulting losses.
Special declarations:
1) This product is strictly not to be used in potentially explosive environment.
2) The environmental requirements for the normal use of this product: no more than 1500 meters elevation,
5Ԩ~40Ԩtemperature range and no more than 90% humidity. If it needs to be used in cold storage or other
special environments for a long time, special modifications are required and please contact our technical
department.
Contents
Chapter 1 Safe Regulations 1
Chapter 2 Warning, Nameplate And Symbols 3
Chapter 3 Forklift Introduction 4
1. Forklift suitable occasion 4
2. Forklift forbidden occasions 4
3. Technical specifications 4
4. Capacity chart 8
5. Safety Signs 8
Chapter 4 Main Components And Control Devices 9
Chapter 5 Driving 10
1. Start 10
2. Braking 10
3. Steering 11
4. Parking 11
Chapter 6 Attachments 12
Chapter 7 Cargo Transportation 13
Chapter 8 Battery And Charger 15
1. Replace battery 15
2. Charge 15
3. Battery maintenance 16
4. Motor Maintenance 17
5. Electromagnetic brake maintenance 17
Chapter 9 Fault Analysis 18
Chapter 10 Maintenance 20
1. Maintenance Safety Rule 21
2. User can complete the maintenance work 21
3. Forklift Cleaning 22
4. Maintenance sheet 22
5. Lubrication parts table 24
6. Lube and grease 24
Chapter 11 Forklift Transport And Storage 26
1. Lifting forklift 26
2. Towing and transport faulty forklift 26
3. Forklift storage 26
4. Precautions for reusing the forklift after storage 26
Chapter 12 Product Warranty And After-Sales Service 27
1
Chapter 1 Safe Regulations
Safe Regulation Overview
Before using the forklift, all safety switches and equipment should be inspected beforehand to ensure that these
safety facilities are in good condition.
Inspection of all warnings and design parameters signs on the vehicle.
The battery must be securely fixed in the battery box.
Do not use the forklift if the machine is damaged or has faults which will affect the safe use.
When the forklift is being repaired or adjusted, it should be carried out by a professional.
1. The forklift can have free lift at certain operation height
2. Operator responsibility
Operators of the forklift must be fully trained and have completed a driver training course.
Observe this manual and local safety regulations, rules, and traffic rules.
Do not operate the forklift with oily hands or feet.
The cab should always be clean. Do not put tools or other objects to avoid affecting operation of the controls or
pedals.
3. Workplace
It can only run on a flat and hard ground such as concrete or asphalt ground. Do not work in oily areas to avoid
slipping.
Make sure that the ground can bear the total weight of the stacking forklift, which is the weight of the forklift itself,
the weight of the load, and the weight of the operator.
4. Driving and guidance during working
Do not suddenly brake and turn at high speed.
It should be driven slowly on a slope/gradient, keep the goods in the lowest position. It should be forwards or
reverse on a slope and not advised to turn the body of the machine or lift the forks on the slope/ gradient.
Do not steer, load or unload on a ramp, otherwise the truck may tip over.
If the road is slippery, it should be driven slowly to prevent the forklift from overturning.
In addition to loading and unloading cargo, the forks should fall no more than 200mm above the ground during
driving. Do not lift goods at the same time.
Keep a safe distance from vehicles, people, and objects in front of you.
Before entering the elevator, you need to make sure the elevator can bear all the weight.
2
5ɿLoading and Unloading goods
Only when unloading goods or taking cargo, you can lift the forks and keep a distance with the surrounding
people. Do NOT lift the forks during the driving process and ensure that the height of the forks from the ground does
not exceed 200mm.
※When loading and unloading goods, the forks should be accurately inserted into the pallet so that the centre of
the goods gravity is consistent with the centre of the forklift.
※When carrying an unbalanced cargo, it can easily fall, and the forklift may tip over.
※When lifting the goods, do NOT touch the gantry to prevent pinching.
※The cargo can only be loaded and unloaded within the maximum allowed weight and load centre of the forklift.
Please refer to the load curve for details.
When loading and unloading heavy and over-heavy goods, you need to be very careful. For larger cargo loads,
forklifts should be equipped with backrest.
Do not drive or tilt the mast when lifting goods.
6ɿParking precautions
After the forklift stops, the forks should be at the lowest point and the machine should be placed in brake.
The forklift is not allowed to park on a slope.
The forklift should be parked at appointed locations.
The forklift is not allowed to park at an emergency exit.
After parking the forklift, you need to turn off the machine and take the key away.
7ɿBattery loading and unloading
You need to be careful when loading and unloading batteries and their plugs. Read the instructions carefully first
and get to know the battery section for details.
Wear protective eyewear when replacing or charging the battery.
8ɿMaintenance
Maintenance can prevent accidents, please refer to the chapter about maintenance.
All replacement spare parts should be parts approved by Kelvin Engineering Ltd. The maintenance or modification
of the forklift which will affect the safety or functions is not permitted.
3
Chapter 2 Warning, Nameplate and Symbols
The Battery forklift has the following symbols:
(Please read the related content on the labels)
1. Lifting and lowering control.
2. Safety marks nameplate.
3. Load chart label.
4. Lifting point.
4
Chapter 3 Forklift Introduction
Kelvin Mini series battery counterbalance forklift is powered by electric energy. It uses a foot accelerator to control
speed and the steering wheel to control steering. We adopt a 24V electronic system, and steplessly adjust its speed
with an integrated circuit controller to ensure available stable speed and acceleration during the running process.
The forks are lifted by an advanced electric hydraulic pump through manual multi-way valves.
1.Forklifts purpose
The main purpose of the forklift is to carry the cargo placed on the pallet and stack it at a certain height.
2.Forklift not to be used.
The forklift is not to be used in following areas:
Sites that can cause fire or explosion, such as slippery areas.
Using as tow tractor for other vehicles.
Using to transport or lift people.
Working on grass or sand.
Hanging the wire rope directly on the forks to hang the goods.
Using the forks to push cargo or other vehicles.
Using the forks to open and close other truck’s door.
3.Technical specifications
3.1 standard basic technical specifications
Item Forklift Model
Kelvin Mini 10 Kelvin Mini 15
Rated Capacity (kg) 1000 1500
Standard Lifting Height h3(mm) 3000 3000
Overall Length
ʤ
Inc. forks
ʥ
l1(mm) 2330 2450
Overall Height
ʤ
Mast lowered/extended
ʥ
h1(mm) 1995/3530 1995/3500
Overall width b1(mm)
912 912
Min. Ground Clearance of Forks m1(mm)
90 50
Turning Radius Wa (mm) 1255 1380
Travel Speed (load/unload
ʥ
(km/h) 6/7 6/7
Gradeability (load/unload
ʥ
(%) 8/10 8/10
Service Weight
ʤ
Inc. battery
ʥ
(kg) 1700 1970
Tires Type
ʤ
Front/rear
ʥ
PU wheels PU wheels
Drive MotorʤPower/typeʥ1.5kw/AC 2.3kw/AC
Lift MotorʤPower/typeʥ2.0kw/DC 3.5kw/DC
5
3.2 Environmental Requirement
Ambient temperature: The forklift truck is suitable for 5 Ԩto 40 Ԩin the working environment.
If the forklift needs to be used for a long time in the environment of great changes in temperature or humidity,
special equipment must be installed. Kelvin Engineering Limited's permission must be obtained.
6
3.3 Hydraulic schematic diagram
Spare parts name aboveʁ
1.Pump station or gear pump
2. Multi-way valve
3. Block valve
4. Lift cylinder
5. Tilting cylinder
7
3.4 Electrical schematic diagram
8
4. Capacity chart
5.Safety signs
Do NOT Stand on or off Caution nipping hand
Lifting position No access to the back of the mast
9
Chapter 4 Main Components and Control Devices
1. Overhead guard 2. Brake fluid injection port 3. Headlight switch 4. driver seat
5. Pedal horn switch 6. Counterweight 7. Driving boxes 8. Folder 9. USB Power Interface
10. Emergency Stop Switch 11. Driving direction switch 12.Lifting handle 13. Brake pedal 14. Tilt the handle
15.Fork 16. Accelerator 17.Cup holder 18.Instrument 19. Key switch 20.steering wheel 21.Mast
10
Chapter 5 Driving
1.Start
Please proceed in the following order, otherwise the truck will not operate normally:
1.1 Make sure the power connector is plugged in firmly.
1.2 Turning on emergency stop switch
1.3 Turn the key switch to the open position.
1.4 Make sure the battery has enough power.
Note:
For a long time of low power operation of the forklift, the battery life will be drastically reduced. Do not start
the forklift until the battery is charged.
1.4 Turn the driving switch to the desired direction.
1.5 Lightly step on the accelerator pedal, and the forklift can travel.
1.6 Push forward and pull up the lifting handle, the mast descends and lifts respectively, push forward and pull
backward the tilt handle, and the mast tilts forward and backward, respectively. The speed is controlled by the tilt
angle of the handle, the greater the angle, the faster the speed.
Note:
Do not suddenly stop when lowering the forks and lowering the fork.
Warningʄ
Non-operable forklifts with serious functional defects that endanger safety. Before working every day, you should
check the following security features firstly:
The horn function is normal.
Manipulation function is in good condition.
The brake function is normal.
The hydraulic function is normal.
2. Braking
2.1 When the accelerator pedal is released, the electromagnetic brake at the rear end of the forklift drive motor
starts to brake and the forklift can be stopped smoothly.
2.2 If you need to reduce the braking distance, you can use the brake pedal to control the braking distance.
2.3 Forklift parking.
Stop the truck by releasing the accelerator and switch the driving direction back to neutral.
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2.4 The maximum noise value of the ear of the forklift truck is not more than 80dB (A). The test method is according
to JB/T3300; the vibration is not more than 0.4m/s2. The uneven road surface will increase the noise and vibration.
3. Steering
3.1 Steering is controlled by the steering wheel. The forklift is a speed-following type electric steering. The faster
the steering wheel rotates, the faster the steering wheel turns. When the steering wheel is reversed, the steering
wheel also reverses.
3.2 When the forklift encounters an obstacle, it should not be forced to pass and should pass by the obstacle.
Warningʄ
Do not allow wheels to slip.
If the operator's hands or shoes are stained with oil, it is easy to operate error and cause the forklift to lose control,
so you should clean your hands and shoes before driving.
4. Parking
4.1 Release the accelerator.
4.2 Make direction switch to the middle.
4.3 Reduce the fork to the lowest position so that there is no system pressure in the hydraulic system.
4.4 Turn off the key switch.
4.5 Press the emergency stop switch.
Warningʄ
Do not allow unauthorised driving.
If you leave, take the key with you.
12
Chapter 6 Attachment
Forklifts can be equipped with different accessories to further enhance safety.
1. Load-backrest
When the height of the goods is too high, you can add a load-backrest to increase the stability of the goods.
13
Chapter 7 Cargo transportation
1. Transport
1.1 The weight of the goods should be within the permitted lifting capacity of the forklift.
1.2 When loading and unloading cargo, it should be stable and safe. Be careful with ultra-high and long goods.
1.3 When loading or unloading ultra-high cargo, the forklift should be equipped with suitable retaining shelves.
1.4 When the forklift is driving, the fork should be lowered to a height of about 200mm.
1.5 Uneven roads and tire wear can cause abnormal noise.
1.6 When turning, slow down.
1.7 Irregular objects should pay attention to safety during transportation. When turning, pay attention to space.
1.8 If the operator's frontal vision is affected, he should be asked to direct the direction.
1.9 When the upper and lower slopes are decelerated, it is prohibited to turn the head on the slope.
Warning!
When turning on a slope, the forklift is in danger of overturning.
On a downhill slope, the forklift's braking distance is extended and the braking time increases. Therefore, it should
speed down to reduce the braking time. Do not force a steep slope.
1.10 Before the forklift enters the elevator, it shall be ensured that the elevator can withstand the entire load (the
weight of the forklift, the weight of the cargo, and the weight of the operator). The forklift should first enter the
elevator and finally leave the elevator.
Warning!
Before starting the elevator, the bearing capacity of the elevator should be clearly understood to avoid accidents.
1.11 Before the forklift approaches the bridge deck, it should decelerate and maintain a certain distance from the
edge of the platform.
Danger!
The load capacity of the bridge board must be checked in advance to verify its safety to avoid overturning and falling.
When working outdoors, if the wind is too strong, stop using it to avoid accidents.
2. Loading
2.1 Decelerate and locate parking before shelves.
2.2 Raise the fork to the desired position.
2.3 Slowly drive the forklift forward so that the fork is inserted into the bottom of the pallet.
2.4 Raise the forks so that the goods rise to a certain height.
2.5 Slowly retreat the forklift to get the goods off the shelf.
2.6 Reduce the cargo to a height of about 200mm from the ground and carefully drive away.
2.7 Start slowly to speed up operation.
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Danger!
Do not lift the goods during the driving of the forklift to avoid overturning.
3. Unloading
3.1 Decelerate parking and positioning before the shelf.
3.2 Raise the fork to the desired position.
3.3 Slowly move the forklift forward so that the goods are accurately positioned on the shelf.
3.4 Lower the fork to remove the cargo.
3.5 Slowly retreat the forklift.
3.6 Lower the fork to a height of about 200mm and carefully leave it.
3.7 Slow start can accelerate operation.
Danger!
Do not lift the forks during the forklift to avoid dropping the goods.
15
Chapter 8 Battery and motor
Check that the battery is charged.
1. Replace battery
The replacement battery must be the same with the original battery model and weight. (Battery weight can affect
forklift performance and brake function)
Attention!
Do not change battery weight and size, otherwise it will affect the forklift gravity centre. The weight must be the
same with digital on the nameplate.
1.1 Dismantle low electricity battery
ʤ1ʥRemove power supply plug wire
ʤ2ʥOpen box cover
ʤ3ʥSwitch off joint between battery connector lug and cable
ʤ4ʥTake off battery with suitable battery box hook
1.2 Battery installation order
ʤ1ʥUse lifting device to lift battery and put into battery box
ʤ2ʥConnect joint between battery connector lug and cable
ʤ3ʥClose battery box
ʤ4ʥKeep key switch off
ʤ5ʥPlug the socket
2ɿCharge
2.1 No smoking or using fire
Please do not charge too much or too less, to avoid battery damage.
Max charge current is as follows:
Battery
ʤ
Ah
ʥ
Charger
ʤ
A
ʥ
300
40
ʛ
50
Dangerous!
There is Sulfuric acid in battery electrolyte, it is corrosive. If you splash the skin, please clean with water and soap
immediately, contact the doctor if splash into eyes and clean eyes with water. When checking the battery, please
wear protective glasses and gloves.
2.2 Charge preparation
You should charge the battery after using each time, the storage time shall not exceed 24 hours.
ʤ1ʥAfter parking, turn off the key switch and take it out.
ʤ2ʥOpen battery box cover, make sure the top of the battery is ventilated and open the battery ventilator cover.
16
ʤ3ʥRemove power sully socket, connect battery plug with battery socket.
ʤ4ʥOpen battery plus liquid hole cover to make it ventilated.
ʤ5ʥSwitch on AC current and start charging.
Warning!
When charging, make sure there is good ventilation. Keep an open fire and spark far away, otherwise it may lead
to an explosion.
Switch off the charge power supply before removing the socket.
2.3 During charging
Charging method and maintenance, please refer to battery manual. Use following method to judge whether
electricity is enough:
ʤ1ʥBattery electrolyte proportion keep stable more than 2-3 hours
ʤ2ʥBattery electrolyte liquid level has strong bubble
Above situation means battery electricity is full enough.
2.4 After charge
ʤ1ʥTurn off AC power supply and charger
ʤ2ʥRemove changer plug from battery plug
ʤ3ʥPlug battery power supply socket into battery body plug
ʤ4ʥClose battery cover
After full charge, the comparison table between battery temperature and electrolyte proportion is as following
Temperature°
Proportion g/cm3
-15
1.31
0
1.30
+15
1.29
S+30
1.28
+45
1.27
Please add distilled water to adjust if proportion does not conform to this table
3. Battery maintenance
ʤ1ʥMake sure full charge before using each time
ʤ2ʥAvoid full charging and discharging, otherwise will affect battery life and performance
ʤ3ʥKeep the Battery fluid plug and vent cover clean, keep the battery surface, connecting wire and screw clean
and dry. If there is sulfuric acid, clean it with cotton wool
ʤ4ʥAfter charging, check battery liquid level, add distilled water is level is low, do not add dilute sulfuric acid
ʤ5ʥCharge battery after using
ʤ6ʥCheck whether battery box have liquid at the fixed period, use plastic long thin pipe to suck out, meantime to
clean it with dry cloth
ʤ7ʥKeep good ventilation, no fire
ʤ8ʥBattery should be equalizing charged when have the following condition
a. Normal using battery (Equalizing charge every 3 months)
b. Long time no use battery
17
ʤ8ʥEqualizing charge method
a. Normally charge first
b. Stop 1 hours when full charge, then charge 1 hour with 0.05C5 (C5 means battery rated capacity)
Repeat b with times until battery has fierce bubble when switch off
ʤ9ʥWhen not using a period of time, you must charge fully
ʤ10ʥThe battery should avoid direct sunlight, keep at least 2M distance from heat source
ʤ11ʥAvoid contact with any liquids and hazardous substances, any metal impurities cannot fall into the battery.
4ɿMotor maintenance
ʤ1ʥCheck motor at the fixed period
ʤ2ʥUse 250V ohmmeter to measure the cold insulation resistance of the motor, the resistance should more than
0.5MΩ, if less than 0.5 MΩ, should do hot dry processing
ʤ3ʥCheck whether motor outgoing connecting wire is correct and firm
ʤ4ʥCheck whether commutator segment is clean, whether electric brush can slide freely in the brush box
ʤ5ʥCheck whether all fasteners are tight
ʤ6ʥCheck electric brush worn situation every 3 months and whether replace brush
ʤ7ʥDo a full maintenance of the motor each year
5. Electromagnetic brake maintenance
1) Use for a long time in a high humidity environment, should avoid rusting, clean rust if have
2) Do not touch friction surface with hand, no oil pollution, otherwise can't reach the maximum torque, please clean
and wipe friction surface
3) When using temperature is high, please install it in ventilated place, applicable ambient temperature is -
10Ԩ~40Ԩ
4) The initial torque value is low, after some using time, torque value will be stable
5) Please check regularly for all parts
This manual suits for next models
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