NICHIYU FBRF14 75 Series User manual

OPERATOR'S MANUAL
ELECTRIC LIFT TRUCK
FBRF14
FBRF16
FBRF20
75 SERIES
Unsafe use of this lift truck may cause serious injury or
death. Operators and maintenance personnel must read this
manual and be sure that they understand its contents before
operating, inspecting or carrying out maintenance on this lift
truck. This manual should be kept near the lift truck for
reference and periodically reviewed by all operators and
maintenance personnel who come in contact with it.
WARNING

OPERATOR’S
MANUAL
ELECTRIC
LIFT TRUCKS
OPERATOR’S
MANUAL

INTRODUCTION
●This operator's manual provides for the proper operation, easy maintenance and periodical
inspection.
●Prior to operation, read this manual carefully for safe and efficient operation.
●Specifications and equipment in this manual are subject to change without any notice by the
manufacturer for further improvement and modifications.
●Make sure these important instructions in this manual are available for the operator on each
delivery or transfer of lift truck. Keep this manual after reading.
●If you have any questions, please feel free to contact NICHIYU local dealer.
and are very important for you and others for safety. Follow these
instructions.
DANGER
Indicates an exteremely hazardous situation which, if not
avoided, will result in death or serious injury.
You must follow this instruction.
WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
You must follow this instruction.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
You must follow this instruction.
NOTE Indicates suggestions, tips and hints related to the safety of a
operator and maintenance of a truck.
CAUTION
The operator must read and understand the instruction of safe
operation contained in this manual.

[1]SAFE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Decals and name plates. . . . . . . . . . . . . . . . . . . . . . . . . . 1
Information for safe operation . . . . . . . . . . . . . . . . . . . . . 4
[2]PART NAME AND FUNCTION . . . . . . . . . . . . . . . 18
Name of part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Driving equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Indicator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Indication of display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Function of display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Various kinds of mode selection. . . . . . . . . . . . . . . . . . . 25
Operating equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
[3]DRIVING AND OPERATION . . . . . . . . . . . . . . . . . . 34
Preparation of start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Stacking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Picking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
[4]BATTERY AND CHARGER . . . . . . . . . . . . . . . . . . 39
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Precautions for charging the battery . . . . . . . . . . . . . . . 43
Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
How to charge the battery (By stationary charger). . . . . 48
Exchanging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Level of electrolyte and specific gravity . . . . . . . . . . . . . 54
[5]INSPECTION PRIOR TO OPERATION . . . . . . . . 56
Check point and contents. . . . . . . . . . . . . . . . . . . . . . . . 56
Inspection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
[6]INSPECTION AFTER OPERATION . . . . . . . . . . . 60
Inspection after working . . . . . . . . . . . . . . . . . . . . . . . . . 60
[7]PERIODIC SERVICING . . . . . . . . . . . . . . . . . . . . . . 61
Precautions of maintenance. . . . . . . . . . . . . . . . . . . . . . 61
Weekly (50-hour) servicing. . . . . . . . . . . . . . . . . . . . . . . 64
Monthly (200-hour) servicing . . . . . . . . . . . . . . . . . . . . . 66
Lubrication points and recommended oil . . . . . . . . . . . . 67
Every three-month (600-hour) servicing. . . . . . . . . . . . . 68
Semiannually (1200-hour) servicing. . . . . . . . . . . . . . . . 68
Replacing parts and trouble shooting. . . . . . . . . . . . . . . 69
[8]QUICK FAULT FINDING . . . . . . . . . . . . . . . . . . . . . 70
[9]PERIODICAL REPLACING PARTS . . . . . . . . . . . 72
[10]STABILITY OF FORKLIFT TRUCK . . . . . . . . . . . 73
Load center and load chart . . . . . . . . . . . . . . . . . . . . . . 73
Stability of the forklift truck . . . . . . . . . . . . . . . . . . . . . . . 74
[11]SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
[12]
COLD STORAGE TYPE FORKLIFT TRUCK . . . . 77
Protection from rust and corrosion . . . . . . . . . . . . . . . . . 78
Protection from low temperature . . . . . . . . . . . . . . . . . . 78
[13]SIDE SHIFT ATTACHMENT . . . . . . . . . . . . . . . . . . 79
Side shift attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Part name and function . . . . . . . . . . . . . . . . . . . . . . . . . 81
Materials handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Periodical inspection and service . . . . . . . . . . . . . . . . . 85
Periodical replacing parts . . . . . . . . . . . . . . . . . . . . . . . 87
[14]AOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
CONTENTS

To know about safe operation
[1]SAFE OPERATION [P1-]
[10]STABILITY OF FORKLIFT TRUCK [P73-]
To know about specification of forklift
[11]SPECIFICATIONS [P75-]
[12]
COLD STORAGE TYPE FORKLIFT TRUCK [P77-]
[14]AOS [P88-]
OPTIONS
To know about procedure of operation
[2]PART NAME AND FUNCTION [P18-]
[3]DRIVING AND OPERATION [P34-]
[13]SIDE SHIFT ATTACHMENT [P79-]
To know about battery and charger
[4]BATTERY AND CHARGER [P39-]
To know about periodical inspection and maintenance
[7]PERIODIC SERVICING [P61-]
[5]INSPECTION PRIOR TO OPERATION [P56-]
[6]INSPECTION AFTER OPERATION [P60-]
[9]PERIODICAL REPLACING PARTS [P72-]
To know about procedure of
countermeasure for break down
[8]QUICK FAULT FINDING [P70-]
1
2
3
4
5
6
7
8
9
10
11
12
13
14

1
SAFE OPERATION
1
1
Decals and name plates
►Indication of direction (Right side / Left side)
The following illustration shows the direction of this
forklift truck from the operator's compartment.
►Decals and Name Plates
CAUTION
Decals and name plates are installed on the
forklift truck to give information about possible
hazards.
CAUTION
If you find that the decals and name plates
are removed and/or unreadable, contact your
NICHIYU local dealer for replacement.
Rear Front
Right
Left
3
2
1
4
5
6
6
7

SAFE OPERATION
2
1
1
3[for Std.]
[for CHINA]
24700-04610
6
4
2
CAUTION
Always depress floor switch while traveling.
Plugging brake dose not work
when release your foot from floor switch.
24700-04670
5
LUBRICATION
MAST
HOSE PULLEY
: GREASE
G
: GEAR OIL
: HYDRAULIC OIL
HO
GO
: REFINED WATER
W
: MACHINE OIL
MO
200HOUR
600HOUR
1200HOUR
: LUBRICATION
: REPLACE
25HOUR
: CHECK AND ADJUSTMENT
50002-18330
FORK SUPPORT SHAFT LIFT CHAIN
HYDRAULIC OIL TANK
OIL FILTER
BATTERY
STEERING GEAR
DRIVE GEAR
G
HO HO
G
GW
GOGO
MO
MO
7
1
MODEL
MAXIMUM
LOAD/LC
LIFT HEIGHT
SERIAL NO. MFG. YEAR
VOLTAGE
SERVICE WEIGHT
W/O BATTERY
BATTERY WEIGHT
50006-91500
kg /
kg /
kg
kg
MIN.
mm
mm
V
kg
MAX.
mm
LOAD CHART
LIFT HEIGHT
LOAD CENTER mm
CAPACITY kg
50007-92420㧔㧕
MADE IN JAPAN

SAFE OPERATION
3
1
8 9
Fire hazards !
1. Always charge the battery in well ventilated area.
2. DO NOT use equipment that is liable to produce
sparkes, in this area.
11
PRECAUTIONS FOR BATTERY EXTEND/RETRACT
BATTERY EXTEND
1. Be sure to retract the mast completery.
2. Depress the battery lock pedal to the end of its stroke.
3. Push the reach lever slowly to extend the mast and
battery.
4. Release the reach lever and lock pedal after extended
the battery to the appropriate position for maintenance.
BATTERY RETRACT
1. Be sure to set hoses on the guide properly.
2. Depress the battery lock pedal to the end of its stroke.
3. Pull the reach lever slowly to retract the mast and
battery.
4. Be sure to keep the hoses and battery cables on their
appropriate position.
5. Release the reach lever and lock pedal after retracted
the battery completery.
6. Be sure to check the lock lever to return its proper
position.
All check and maintenance of the battery should be done
on the flat floor, after extended the battery and disconnect
the battery plug.
13
PRECAUTIONS FOR SAFETY OPERATION
1. Do not overload.
Observe allowable load.
2. Prior to operation, check performance of brake.
3. Do not make a sudden start and brake or
turn quickly.
4. Do not make a sudden valve lever operation at
a high lift.
5. Do not run sideways or handle on an incline.
6. When the red lamp of battery capacity indicator
turns on, charge battery.
7. Check electrolyte every week and replenish
water.
8. Be sure to use the prescribed fuses.
12
This is to certify that this is a new fork lift truck
which has been manufactured for exportation by
as stated in the certificate issued by them.
14
10
9
8
10
11
13
14
12

SAFE OPERATION
4
1
1
Information for safe operation
CAUTION
Only a trained and authorized operator shall
operate the forklift truck.
CAUTION
The operator is recommended to wear a helmet,
safety shoes and working clothes.
CAUTION
Do not use a forklift truck in the following cir-
cumstances.
1. Where the temperature is less than –10°C
(except cold-storage use forklift truck) or
more than 40°C.
2. Where the explosive gas (thinner, gasoline
etc.) may exist.
When using a forklift truck in the following area,
consult NICHIYU local dealer before operation.
1. Where the explosive materials such as gun-
powder are exist.
2. The dusty place.
CAUTION
NICHIYU forklift trucks are equipped with an
overhead guard and load backrest extension.
●These designed features are incorporated to protect
the operator from falling loads.
●Make sure they are in place and in good condition.
●Precautions still should be exercised by the operator
for possible falling objects or impacts.
WARNING
Do not operate forklift truck while taking
drugs and/or alcohol; otherwise, an acci-
dent may occur which can cause serious
injury or death.
●Observe the safety regulations and workplace rules.
CAUTION
●Keep the operator's compartment clean at all
times.
●Do not place tools or components in and
around the operator's compartment.
●Doing so may prevent proper operation of the steer-
ing wheel, levers and pedals.
CAUTION
Do not operate the forklift truck with greasy or
wet hands.
●Doing so may result in hazardous operation of the
forklift truck caused by slippery hands or feet.

SAFE OPERATION
5
1
WARNING
Do not overload. Failure to observe the
rated capacity can cause the forklift truck
to tip over.
●Refer to the load chart and make sure that the
weight and the load center are within the capacity of
your forklift truck before handling. If the attachment
is installed on the forklift truck, the maximum capac-
ity should be reduced. Read the instruction manual
of the attachment before operation.
CAUTION
Before handling a load, check the weight and
the center of gravity of the load.
CAUTION
●Be sure to carry out the daily inspection and
the periodic inspection.
●
Do not use a forklift truck that is not inspected.
●Before starting operation, prepare a work
plan and have an important meeting regard-
ing safety.
CAUTION
●Do not modify the forklift truck.
●Do not operate a forklift truck that is equipped
with an overhead guard or a load backrest
extension.
●Always pay attention to possible falling
objects or impacts during cargo handling
operation.
●Modifications and additions shall not be performed
without the written approval of NICHIYU. Contact
NICHIYU local dealer for details.
●Do not install any parts blocking visibility from oper-
ating position.
CAUTION
●Stop operation and report immediately for any
damage or faults on the forklift truck.
●Do not operate the forklift truck until it is
repaired completely.
●Repair and adjustment must be performed by a qual-
ified person.
●If the modification cannot be repaired, contact
NICHIYU local dealer.
CAUTION
Use a pallet of the proper size that has suffi-
cient strength for the load.

SAFE OPERATION
6
1
1
CAUTION
Before operation, make sure that the load is
palletized securely in a proper shape. If a load
is unstable, it can easily shift and fall on some-
one.
CAUTION
Before starting, make sure that no persons or
objects are around the forklift trucks.
CAUTION
Stop temporarily at intersections, entrances
or areas where visibility is restricted, and then
make sure no one is coming from the right or
left blind corners.
●If you cannot see where you are going, don't move!
Travel slowly around corners.
●Sound the horn at cross aisles and other areas
where you cannot see clearly or where visibility is
restricted.
CAUTION
●Travel in forward if backward visibility is
blocked.
●When transporting a large load, travel in for-
ward or have an assistant perform guidance
in the direction of travel.
CAUTION
Make sure no person is around the forklift truck
when traveling in forward. Look around behind
the forklift truck and sound the horn before
moving.
●If the load blocks your view, or when you travel down
a grade with a load, drive forward. Always look in the
direction of travel. A look-out helper may be required
if your visibility is obstructed.

SAFE OPERATION
7
1
CAUTION
Always look in the direction of travel!
●Always be aware of people near your forklift truck.
Do not proceed near them until they are aware of
you.
CAUTION
Be aware of tail swing.
●Rear wheel steering of the forklift truck causes large
tail swing.
●Always make sure that the tail swing area is clear
before turning.
●When turning in aisles, especially narrow aisles,
keep as far away as possible from stock and racks.
Be extra cautious near people.
●Failure to observe the tail swing area when making a
turn can injure or kill someone.
CAUTION
In a narrow space, have an assistant perform
guidance in the direction of travel, and operate
the forklift truck following the guidance of the
assistant.
CAUTION
Do not make a sudden start, stop or turn.
●Doing so can cause the load to fall.
●Doing so can cause the forklift truck to tip over.

SAFE OPERATION
8
1
1
CAUTION
Do not go over obstacles, curbs, ditches, ridges
and railroad trucks.
●Avoid bumps, holes, spill spots and loose materials
that may cause the forklift truck to swerve or tip. If
unavoidable, slow down, and proceed with caution.
CAUTION
●Do not operate on soft surfaces or dirt.
●Always check road surface, and stay away
from soft or uneven ground to avoid a tip
over.
CAUTION
Avoid slippery surface.
●Water, sand, gravel, ice or mud can cause a tipover.
If unavoidable, slow down.
●Do not go into a flooded or water covered area.
CAUTION
Keep enough clearance.
●Serious accidents can be caused by hitting pipes
and beams near the ceiling with mast or overhead
guard. Make sure there is enough clearance for ceil-
ing and height limit of the entrance.
CAUTION
When another truck is approaching from the
opposite side direction, slow down and main-
tain a sufficient distance from the front, rear,
right and left sides of the truck. Do not pass a
forklift that is traveling in the same direction.

SAFE OPERATION
9
1
CAUTION
Do not exceed the limitation of the floor
strength.
●A forklift truck is very heavy. Check the condition of
the driving surface. Make sure the floor, bridge and/
or elevator will support the weight of the forklift truck
and the load.
CAUTION
Check that there is sufficient height and width
for the truck to pass.
CAUTION
Do not travel while the forks are in the raised
position.
●Traveling while lifting the forks can cause the unsta-
ble condition to tip the forklift truck over.
CAUTION
●Before traveling, raise the load 50 to 100 mm
above the top of the straddle legs, retract the
carriage, tilt the carriage backward and main-
tain a clear view of the path of travel.
●Raise the top of the forks 300 mm above the
ground under no load conditions.
300 mm

SAFE OPERATION
10
1
1
WARNING
Never allow anyone to walk or stand
under raised load or the forks.
CAUTION
●Do not push a load by the tip of the forks.
●Do not drag any loads with rope by the lift
carriage or load back rest.
●Do not lift the load by the tip of the forks.
●Doing so may result in damage the load as well as
the forklift truck.
WARNING
Never allow any person to ride on the
straddle legs, the forks or the pallet.
CAUTION
Never allow any person to ride on the forklift
truck other than the operator.
CAUTION
Do not use a person as a counterweight.

SAFE OPERATION
11
1
CAUTION
●When traveling near a shoulder or platform,
maintain a distance from the edges of the
shoulder or platform.
●Always keep the road surface safe, and pro-
vide clear traffic routes.
●Operate the forklift truck on level and firm
roads and floor surfaces.
●Be sure to indicate the operation area of the
forklift truck with signs so that other trucks
and persons cannot enter the area.
●The operation area of the forklift truck should
have sufficient lighting.
●Otherwise, the forklift truck may fall down. Place bar-
riers around the edges for safe operation.
CAUTION
●Travel carefully on grades when loading.
●When traveling on an incline or a slope with
a load, go up or down with the load facing
uphill.
●Travel down slowly and with the brake
applied.
●When traveling down an incline, the stopping dis-
tance will be longer.
CAUTION
Do not turn on, or angle across an incline.
●Failure to observe this rule can cause the forklift
truck to tip over.
CAUTION
Make sure that loads are securely arranged on
a pallet and the forks are properly inserted in
the pallet to avoid an off-centered load.
●Otherwise, the forklift truck may tip over and the load
can easily shift and fall down.
●If a load protrudes outside the pallet, it may contact
a post or other piled loads.
●Do not transport an unstable load.

SAFE OPERATION
12
1
1
CAUTION
Operate hydraulic control levers slowly when
loading or unloading.
WARNING
Never put any parts of your body between
the mast and the chassis.
●Always operate the key switch, steering wheel and
levers while in the operator's compartment.
●If any part of your body or your work clothes catch-
es a lever, the mast equipment may unexpectedly
move, and then your hands or feet could be pinched.
WARNING
Do not operate the forklift truck with your
body outside of the operator's compart-
ment.
●Keep your body inside the operator’s compartment.
CAUTION
Operating the forklift truck with your head, arms
or feet sticking out of the operator's compart-
ment can cause a part of your body to hit a stor-
age rack, post or other piled lords or be caught
in trucks. Always operate the forklift truck with
your body inside the operator's compartment.
CAUTION
Do not lower or stop the load suddenly.
●Doing so can cause the load to shift and fall down or
the forklift truck to tip over.

SAFE OPERATION
13
1
CAUTION
Drive into a trailer carefully.
●Make sure the trailer brakes are set and the wheels
are blocked while loading or unloading.
CAUTION
Do not travel or lift a load up or down with the
forks tilted forward.
●Tilt the fork up enough to stabilize the load.
CAUTION
Push the emergency switch to shut off the
power supply If a malfunction occurs in the
brake system, the operation equipment, etc.
while operating the forklift truck.
CAUTION
Do not operate the emergency switch when the
truck is traveling or doing hydraulic operations
EXCEPT THE EMERGENCY SITUATION .
As soon as the power supply is shut off, power
steering function do not work.
CAUTION
Do not jump on or off the forklift truck.
●When getting on or off the forklift truck, make sure
that the truck is stopped.
●When getting on or off the forklift truck, do not grasp
the steering wheel or the hydraulic lever.