Nakanishi KOLEC FX15WT, Instruction Manual

Page 1: ...ual Nakanishi Metal Works Co Ltd Before operation inspection and maintenance of this forklift be sure to read this instruction manual to understand the contents thoroughly Keep this instruction manual in place where you can quickly access it FX15WT ...

Page 2: ...alanced forklift Before using this forklift please read this instruction manual to understand the instructions given in the manual thoroughly Keep this instruction manual in place where you can access it anytime If you have uncertainty during use of the forklift or if a trouble occurs with this forklift this instruction manual serves as a help We hope you use this forklift safely for a long period...

Page 3: ...receipt of this forklift Startup Traveling Raising lowering the fork and tiling the mast backward Loading unloading cargo Safety devices At end of work Charging Battery maintenance 5 Inspection and Maintenance Preoperational inspection Monthly inspection Voluntary inspection Periodic replacement parts Troubleshooting Electric circuit diagram 6 Transportation 7 Disposal 47 49 52 54 Table of content...

Page 4: ...names 2 Accessories Tilt operation switch Pinch accident prevention switch Horn button Lift operation switch Travel knob Speed change switch Battery discharge meter Hour meter Emergency stop button Steering handle Battery cover Drive wheel front Load wheel rear Mast Chain Cylinder Backrest Fork ...

Page 5: ...ry capacity 5HR Battery charger Drive motor Drive control Hydraulic motor Hydraulic control 2 mm mm Unladen Under load No load mm mm kg mm mm mm s mm s km h km h Unit Model Lifting speed Driving speed Laden Remarks FX15WT 1 500 500 35 2 500 5 60 140 3 2 mm mm mm mm mm kg mm 890 Minimum upper stroke end Maximum lower stroke end Overall height 3 8 1 380 2 430 2 200 AC motor control Automatic battery...

Page 6: ...g and transfer operations using the fork etc on a rigid flat floor in a building Manufacturer model and serial No of this forklift are indicated at the following position of the vehicle body When you issue a repair order be sure to inform us of the model and serial No of your machine Temperature Humidity Ambient conditions The following are basic instructions that you should learn about use of thi...

Page 7: ...activated to limit the flow rate to prevent abrupt fall of the fork When slinging the vehicle body sling hooks can be attached to the eyeholes Using the eyeholes enables sling work to be securely conducted This forklift is equipped with the following safety devices and additional protection devices During operation of the forklift these devices must not be removed Pressing the emergency stop butto...

Page 8: ...ls If any of the warning labels is difficult to read due to stain or damage replace it with a new one so that the warning labels are kept readable Warning label Allowable load curve Operation handle side of Mast Front of battery cover WARNING WARNING Take care when stcking No overloading The load capacity and lifting height should be within the rated WARNING WARNING ...

Page 9: ...o read and understand the contents of the instruction manual causes improper handling of the forklift which may result in accidents involving serious injury and burns Before start of work make a work plan and notify it to people around the forklift operating area If the forklift is operated without preparation of a work plan or without notification of the work plan to surrounding people the forkli...

Page 10: ...erson who has not been familiarized with operation of this forklift may operate the forklift resulting in an accident If the forklift is used in a fault or abnormal condition it may result in collision cargo fall or forklift overturn accidents because the forklift cannot be normally operated due to the fault If a fault or abnormality is found with the forklift repair it immediately When lowering t...

Page 11: ...tention during operation of the forklift causing operation error or operation delay which may result in a collision accident etc Be sure to wear protective cap and safety shoes Otherwise if a cargo fall it may collide with or pinch your feet If the forklift overturns you may suffer serious injury If you operate the forklift with wet hands or hands stained with oil the hands slip which may result i...

Page 12: ...ate the forklift before getting familiarized with it operation error or operation delay may occur resulting in a collision accident etc If you operate the forklift at any position other than the position that enables all operations immediately normal operating position operation error or operation delay may occur resulting in a collision accident etc 9 Before operation be familiarized with this fo...

Page 13: ...ng in a collision accident Operate the forklift in a place where cargos materials and equipment are arranged in well ordered conditions If the forklift is operated in a disordered place it may collide with scattered articles Also the operator may pay attention to scattered articles which induce operation delay resulting in collision and cargo fall accidents Use caution about strength of the floor ...

Page 14: ... become unstable resulting in a collision accident Run the forklift with the handle placed forward except for a case where you insert the fork into a pallet or push a pallet by inserting the fork 11 When operating the forklift on a floor that is slippery due to dew etc reduce the operating speed to a safe speed If the forklift slips on the floor it may collide with a person resulting in serious in...

Page 15: ...t a person If the forklift is rapidly stopped the cargo may fall and hit a person Also rapidly stopping the forklift may cause collision with surrounding people and vehicles If the forklift is rapidly turned it may become out of control resulting in collision and the cargo may fall and hit a person If you run the forklift while looking aside it may cause operation delay resulting in collision with...

Page 16: ...orklift may fall During travel on a platform keep a margin from the edge of the platform 13 If the fork is raised during travel the forklift becomes unstable and may overturn and the cargo may fall If the traveling direction is changed on a slope the forklift becomes unstable and may overturn If the forklift overturns the forklift or dropped cargo may collide with a person resulting in serious inj...

Page 17: ...e to ensure safety When a guide is allocated a guide sign should be discussed in advance If work starts without discussion about a guide sign the worker may confuse the sign causing collision and fall accidents If the forklift runs to the back toward the fork with cargo being stacked to a height that blocks operator s view the operator cannot see the area at the front of the cargo and fails to avo...

Page 18: ...mum allowable load weight of this forklift will be reduced Overloading the forklift beyond the maximum allowable load weight causes the forklift to overturn If the forklift overturns the forklift and dropped cargo may collide with a person resulting in serious injury During loading into a truck or container if the truck or container unexpectedly starts the forklift may fall Before loading the fork...

Page 19: ...and may overturn Also the cargo may fall If such a case the forklift and dropped cargo may collide with a person resulting in serious injury If cargo is stacked under uneven load condition the pallet may be inclined when it is raised causing the cargo to fall If the cargo falls it may collide with a person resulting in injury The surface of fork is slippery If cargo is directly put on the fork the...

Page 20: ...y overturn if the forklift or fork unexpectedly moves resulting in injury Do not raise the fork with a person riding the fork or pallet The person may fall and suffer serious injury If a cargo is pried with the fork the forklift and cargo move unexpectedly and may collide with a person resulting in injury 17 Do not lower the fork rapidly Do not enter the area under the fork Do not step on the fork...

Page 21: ...ft at an elevated position it may accidentally collide with a person resulting in injury Also it causes collision with other vehicles If the forklift is parked on a slope it may unexpectedly move and collide with a building and surrounding object resulting in damage to these objects Also it may collision with a person 18 If you conduct loading unloading work with the forklift placed on a slope the...

Page 22: ...use fire around the forklift while the battery is charged Also do not work with sparks around the forklift Otherwise hydrogen gas may catch a spark resulting in explosion and fire Battery charging should be conducted in a well ventilated place If the battery is charged in a place with poor ventilation hydrogen gas generated from the battery is retained during charging which may cause explosion and...

Page 23: ...diately wash the eye with a large amount of water and take doctor s diagnosis Never attempt to lick or drink it Such an action may result in death If you disconnect the cable from the outlet during battery charging hydrogen gas generated during charging may catch a spark resulting in explosion Loose connection of the cable to the battery terminals or using the battery with corrosion of the battery...

Page 24: ...ng in an accident involving injury to the operator and surrounding persons When cleaning the forklift wipe it with rags etc Washing the forklift with water causes water intrusion into the vehicle body which may result in a trouble of the control circuit A trouble of the control circuit causes operation failure and erroneous operation which may result in a collision accident etc If the forklift is ...

Page 25: ...an the genuine fuse results in overcurrent causing burnout of parts fire and electric shock Be sure to use the specified genuine fuse Before handling the fork or other equipment that may fall take fall preventive measures by using a safety column safety block etc If the equipment falls it may collide with a person resulting in serious injury When jacking up the forklift observe the basic safety in...

Page 26: ...th of the ramp If there is no margin in these items the forklift may fall and collide with a person resulting in injury To dispose of the battery order the distributor of the battery If the battery is left without disposal a person may touch the battery electrolyte and get burns because the battery electrolyte contains dilute sulfuric acid To sling the forklift be sure to hook it by the specified ...

Page 27: ...stable Accordingly when the center of gravity of cargo exceeds a certain distance load center from the root of the fork the maximum allowable load weight of the forklift will be reduced For the maximum allowable load weight by the distance of center of gravity of cargo refer to the graph below If the center of gravity of the cargo is at 500 mm or farther distance from the root of the fork the maxi...

Page 28: ... knob and fasten the bracket Charge the battery Battery charge procedure is described on p 38 When lowering the fork from the traveling position to the operating position hold the fork and lower it carefully If you handle the fork roughly your hand may get pinched with the fork resulting in injury such as bone fracture and bruise Fork 25 Check for damage to the forklift in transportation Also chec...

Page 29: ...y is left in the switch an authorized person or a person who has not been familiarized with operation of this forklift may operate the forklift resulting in an accident Conduct preoperational inspection before using the forklift every day If the inspection is omitted a failure of the forklift can be ignored during use resulting in an accident Details of the inspection are described on p 46 To oper...

Page 30: ...rom the floor When a cargo is loaded tilt the mast backward to stabilize the cargo Turn the handle to the traveling position If the handle position is low or high the brake is activated so that the forklift does not run If the traveling knob attached to the steering handle is turned to the front toward the operator s position the forklift travels forward Turning the traveling knob widely increases...

Page 31: ...brake is activated so that the forklift does not run If the traveling knob attached to the steering handle is slowly turned toward the fork the forklift travels backward Turning the traveling knob widely increases the traveling speed Once the traveling knob is released it will return to the neutral position The traveling knob is attached to both sides of the steering handle 28 Reducing the traveli...

Page 32: ...osition Be sure to lower the traveling speed before the stop procedure Turning the handle swings the forklift Increasing the handle turn angle reduces the swing radius If you turn the handle steeply during travel the traveling speed automatically lowers When the forklift travels forward toward the handle the relation between the handle turn direction and the forklift swing operation is as shown be...

Page 33: ...f an entrance exit so that the mast does not collide with the entrance exit If the mast is extended during travel the risk of collision with entrance exit or beams will be enhanced If the mast of the forklift collides with an entrance exit etc the forklift may overturn and the cargo may fall The forklift and dropped cargo may collide with a person resulting in serious injury If the traveling direc...

Page 34: ...ll Before loading the forklift into a truck or container make sure that the truck is securely parked with parking blocks etc If you run the forklift with the fork placed forward the handle may become unstable resulting in a collision accident Run the forklift with the handle placed forward except for a case where you insert the fork into a pallet or push a pallet by inserting the fork Tilt the mas...

Page 35: ...tral position When the fork reaches the upper stroke end immediately stop the raising operation Before raising the fork be sure to stop the forklift If you turn the switch on the right side of the handle toward you the fork is raised Returning the switch to the neutral position stops the fork raising operation Once the switch is released it will return to the neutral position When the fork reaches...

Page 36: ... the following procedure is recommended Move the forklift slowly so that the fork is inserted into the pallet by three fourths of the fork length Raise the fork by 5 to 10 cm and make sure that cargo can be stabled loaded Raise the cargo by 5 to 10 cm and move the forklift slowly to a position that enables cargo lowering operation Move the forklift slowly so that the root of the fork is inserted i...

Page 37: ...ide with a person resulting in serious injury If a long object is stacked the forklift becomes unstable and may overturn Also the cargo may fall If such a case the forklift and dropped cargo may collide with a person resulting in serious injury If you enter the area under the fork you may hit by a dropped cargo or lowered fork resulting in serious injury 34 To unload cargo from the forklift the fo...

Page 38: ...f fork is slippery If cargo is directly put on the fork the cargo will slip and fall and it may collide with a person resulting in injury Be sure to use a pallet to stack cargo If cargo is stacked under uneven load condition the pallet may be inclined when it is raised causing the cargo to fall If the cargo falls it may collide with a person resulting in injury When adjusting the fork width handle...

Page 39: ...ted at the top of the vehicle body Pressing this button turns OFF the power supply Use this button in case of emergency only When the handle is at the traveling position pressing the pinch accident prevention switch moves the forklift backward toward the fork Even if the pinch accident prevention switch is pressed while the forklift is moving backward the forklift does not move forward The pinch a...

Page 40: ... person If the key switch is not turned OFF a person may accidentally touch the operating part without noticing that the forklift is ready to start In this case the forklift unexpectedly starts running resulting in a collision accident etc Restore the fork to the lower stroke end If the fork is left at an elevated position it may accidentally collide with a person resulting in injury Also it cause...

Page 41: ...tion becomes lower than a half level after the battery is fully charged and conduct the normal charging at the interval of the relevant number of days While the battery is charged hydrogen gas is generated from the battery Battery charging should be conducted in a well ventilated place where hydrogen gas will not remain and free from exposure to rain To charge the battery indoors use through cauti...

Page 42: ...supply switch Charge cable Power supply cable Before charging Check the residual charge level 1 Turn ON the key switch 2 位置で充電内容を確認して下さい 0 1 2 1 Charge the battery immediately Overheating of charger Check the residual charge level with the battery discharge meter on the vehicle body To check the residual charge level follow the procedure below The lamp of the battery discharge meter lights Check t...

Page 43: ... cable to the charger Install the charger in a well ventilated place where no flammable is present around it Do not put the charger in a place where it is exposed to moisture or rain Provide at least 1 m distance between the forklift and the charger Connect the power supply cable to the charger and connect the power supply cable to the outlet 40 Disconnect the battery plug from the plug of the veh...

Page 44: ... the charger will restart charging at elapse of 24 hours After completion of charging disconnect the charge plug of the charger from the battery plug and connect the battery plug to the plug of the vehicle body Turning ON the power supply switch of the charger starts charging The ON indicator lamp at the left top of the charger lights After approx 10 seconds the indicator lamp and information disp...

Page 45: ... equalizing charging is manually executed equalizing charging will not be automatically conducted afterwards If the daily normal charging is not enough conduct supplementary charging in an intermission lunch break etc The Info Key change switch provides the following functions The number of seconds for which the Info Key switch is pressed is displayed on the information display window If you press...

Page 46: ...ttery electrolyte runs short replenish purified water battery replenisher as required Do not replenish water tap water etc other than purified water Check for looseness of the terminals Remove the cap at the top of the battery and look into the filling port When the electrolyte level reaches the bottom of the basket in the filling port it is the normal level Replenish purified water until it reach...

Page 47: ...battery electrolyte and charge status is shown in the table below You can find out a fault inside the battery by comparing specific gravity of battery electrolyte between before charging and after charging The above table applies to a case where battery electrolyte is 20 C When battery electrolyte is at a lower temperature indication of charge status becomes lower 75 4 to 6 hours 1 21 or more Char...

Page 48: ...e cable results in damage to the electric circuit Also the battery may generate heat and you may get burns Loose connection of the cable to the battery terminals or using the battery with corrosion of the battery terminals causes the battery to emit sparks and generate heat and you may get burns Battery electrolyte contains dilute sulfuric acid When checking the battery electrolyte level and reple...

Page 49: ...mast backward Setting the mast vertical Safety device Maintenance If the battery charge level is insufficient charge the battery Press the horn button to make sure that the horn sounds Turning the switch toward the front resets the mast to the vertical form 46 Turning the switch toward the operator tilts the mast backward Turning the switch toward the front lowers the fork Turning the switch towar...

Page 50: ...he specified fuses are attached Check for looseness 3 Magnet switch Check for contact seizure or short circuit 4 Electromagnetic brake Measurement Measure the clearance Maintenance Replace the brake as required 5 Drive unit 4 Battery 1 Check the battery electrolyte volume 2 Terminal Check for looseness Maintenance Apply grease to the terminal 47 The forklift should undergo voluntary inspection at ...

Page 51: ...clearance is 1 0 mm or more replace the brake 48 Battery discharge meter Fork operating device Raising the fork Lowering the fork Tilt operating device Tiling the mast backward Tiling the mast forward Safety device Check the battery charge level Maintenance If the battery charge level is insufficient charge the battery Turning the switch toward the operator raises the fork Turning the switch towar...

Page 52: ...r than the genuine fuse results in overcurrent causing burnout of parts fire and electric shock Be sure to use the specified genuine fuse Replace the following parts and consumables periodically The replacement intervals vary depending on the forklift operation time Replace these parts and consumables at the following intervals as standard The following standard intervals are based on the assumpti...

Page 53: ... A drain port is located at the bottom of the tank Hydraulic oil inspection filling port During inspection of hydraulic oil lower the mast to the lower stroke end and set the mast vertical The hydraulic oil tank becomes hot during operation of the forklift or immediately after startup If you touch the hydraulic oil tank you may get burns CAUTION ...

Page 54: ...llide with the forklift and floor resulting in damage to these objects The hydraulic oil tank becomes hot during operation of the forklift or immediately after startup If you touch the hydraulic oil tank you may get burns If repair work is conducted without a work leader incorrect work procedure etc may cause fall of parts and equipment Also incorrect connection of the electric circuit may cause t...

Page 55: ...e company Please contact our authorized service company Please contact our authorized service company Reduce the cargo weight so that it does not exceed the maximum allowable load Replace the fuse To be replaced after the cause of trouble is eliminated The emergency stop button has been pressed The fork does not smoothly move Reduce the cargo weight so that it does not exceed the maximum allowable...

Page 56: ... the hydraulic oil Specified oil ISO VG32 Replace the fuse To be replaced after the cause of trouble is eliminated Replace the fuse To be replaced after the cause of trouble is eliminated Reduce the cargo weight so that it does not exceed the maximum allowable load Oil leak from the hydraulic circuit The fork lowers under its own weight Fork movement is unstable The forklift cannot travel Transfer...

Page 57: ...5 Inspection and Maintenance 54 Electric circuit diagram ⓐ ⓑ Ⓒ ⓓⓔ ⓕ ⓖ ⓗ ...

Page 58: ...5 Inspection and Maintenance 55 ⓐ ⓑ Ⓒ ⓓⓔ ⓕ ⓖ ⓗ ...

Page 59: ...of the mast to fasten the mast by pulling the rope from the front and back When applying rope to the mast be sure to hook the rope onto the part indicated by the sling position mark To load the forklift into a truck by running the forklift use through caution about gradient of the work site and length width and strength of the ramp Sling position mark indicated on the vehicle body When lifting the...

Page 60: ...r sling work use appropriate sling gear If forklift is lifted at any position other the specified position the forklift may fall and collide with a person resulting in serious injury To move the forklift via a ramp during loading unloading work use through caution about gradient of the work site and length width and strength of the ramp If there is no margin in these items the forklift may fall an...