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ELECTRIC LIFT TRUCK OPERATOR'S MANUAL 70 SERIES RB10D ( F ) RB15D ( F ) WARNING 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.
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ELECTRIC LIFT TRUCKS OPERATOR’S OPERATOR’S MANUAL MANUAL...
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¡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 your local NICHIYU dealer. are very important for you and others for safety. Follow these instructions.
CONTENTS AFE OPERATION INSPECTION PRIOR TO OPERATION ......1 ..63 Safety decals and name plates .
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To know about specification of forklift To know about procedure of countermeasure for break down ⁄1 SPECIFICATIONS (P81) , QUICK FAULT FINDING [P77] ⁄2 COLD STORAGE TYPE FORKLIFT TRUCK (P83) To know about safe operation To know about periodical inspection and maintenance z SAFE OPERATION (P1) b INSPECTION PRIOR TO OPERATION...
If you find that decals and name plates are removed and/or unreadable, contact your local CAUTION NICHIYU dealer for replacement. s Indication of direction This model has two different chassis type of the “drive-front type” and the “fork-front type”.
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SAFE OPERATION s Decals and Name Plates !0 0 0 0 (Illustration shows the drive-front type.) CAUTION 9. Do not make a sudden start,stop or turn. 10. Do not operate or park on an incline. 1. Only a trained and authorized operator shall operate this truck. 11.
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SAFE OPERATION 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. 6977F 24700-04610 GASES produced by this battery can be explosive. Cigarettes, flames or sparks could cause battery to explode. Make sure batteries are stored and charged in a well–ventilayed area.
40°C. w Where the explosive gas (thinner, gaso- line etc.) may exist. When using a forklift truck in the following area, consult your local NICHIYU dealer before operation. q Where the explosive materials such as gunpowder are exist.
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SAFE OPERATION NICHIYU forklift truck is equipped with an over- head guard, safety strap and protection guard. CAUTION ¡Do not operate the forklift truck if these items are not installed correctly. ¡Pay attention for overhead area because the over- head guard cannot endure for any kinds of impact.
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CAUTION ¡Do not operate the forklift truck until it is repaired completely. ¡Contact to your local Nichiyu dealer for repair the forklift truck. Do not overload. Failure to observe the rated capacity can cause the forklift truck to CAUTION turnover.
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SAFE OPERATION Make sure that the load is palletized securely in a proper shape. If the load is unstable, it can CAUTION easily shift and fall on someone. Look all around the forklift truck before moving. CAUTION ¡Make sure that the accelerator grip is in the neutral position before turning on the key switch.
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SAFE OPERATION Always look in the direction of travel. CAUTION ¡Always be aware of people near your forklift truck. Do not proceed near them until they are aware of you. Be aware of tail swing. CAUTION ¡Always make sure that the tail swing are is clear before turning.
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SAFE OPERATION Always check road surface, and stay away from soft or uneven ground to avoid turning over. CAUTION Avoid slippery surface. CAUTION ¡Water, sand, gravel, ice or mud can cause a turnover. ¡Do not go into a flooded or water covered area. Keep enough clearance.
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SAFE OPERATION Do not push or drag the load. CAUTION ¡Do not lift the load by the tip of the fork. ¡Misuse can damage the load as well as the forklift truck. Do not drag any loads with rope by the forklift truck.
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SAFE OPERATION Travel carefully on slope with a loaded forklift truck. CAUTION ¡When traveling up or down with a loaded forklift truck, keep the load upgrade to maintain control. ¡Travel with plugging brake if necessary. Make sure the fork or the load is not touched on the ground when going up or down a slope.
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SAFE OPERATION Do not put legs or arms out of the chassis while operating. CAUTION ¡They may be hit while operation if put out of the chassis. ¡Do not put any parts of your body out- side the operator’s compartment of the WARNING forklift truck.
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SAFE OPERATION Do not drop any items from the operator’s com- partment. CAUTION Do not jump on or off the forklift truck. CAUTION ¡Getting on or off the forklift truck after stopping com- pletely. ¡Do not grab the steering handle or the accelerator grip when getting on or off.
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¡Improper spreading of forks can cause unstable or off-center loading. ¡Consult to your local Nichiyu dealer for adjustment of the fork spread. Travel carefully when handling with a long or wide load.
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SAFE OPERATION When parking the forklift truck which requires repairing, a warning or “out-of order” sign shall CAUTION be placed on the forklift truck and remove the key. ¡When the fork cannot lower because of the fault, place a large sign or marker on the fork. This proce- dures will caution other forklift trucks and pedestri- ans.
PART NAME AND FUNCTION ■Name of parts Drive-front type Fork-front type q Mast o Overhead guard q Mast !1 Emergency button w Wire !0 Safety strap w Wire !2 Accelerator grip e Lift cylinder !1 Steering wheel e Lift cylinder !3 Safety guard r Turn signal lamp !2 Steering post...
1.0 second. checking screen, the normal screen is shown immediately. MODE LOAD 0000 Contact to your local Nichiyu dealer if the error code is displayed. CAUTION AM 10:30 s Mode setting buttons If traveling or hydraulic operation is done while showing the NOTE setting screen, the normal screen is displayed immediately.
PART NAME AND FUNCTION ■Function of display This forklift has the self-diagnosis function. q Battery discharge indicator The battery discharge indicator shows the discharged condition of the battery. Do not over-discharge. The battery life can be shorted by over-dis- CAUTION charging.
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PART NAME AND FUNCTION e Weight gauge, traveling speed monitor MODE When the forklift truck is stopped, the loading weight is km/h indicated. When traveling, the traveling speed is indi- cated. AM 10:30 r Clock, hour meter, odometer, lifting MODE height monitor This area shows one of the clock, hour meter, odome- ter or lifting height which is selected.
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PART NAME AND FUNCTION ™Loading weight indicator (weight gauge) ¡The indicated weight on the screen is for ref- erence only. CAUTION ¡The indicated value is not accurate after low- ering or some time later after stopping the hydraulic operation. To get the accurate weight, raise the fork about 500mm above the floor and stop.
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PART NAME AND FUNCTION y Service (spanner) icon MODE This icon warns the fault of the forklift truck to an oper- ator. If a fault is detected, this icon flashes and the presumed defective part is shown on the display with beeping sound.
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PART NAME AND FUNCTION !2 Safety monitor (for chain slacking / table side) MODE When the lift chain of the table side is slacked, the monitor icon is flashed and the lowering and traveling functions are interlocked. AM 10:30 Raise the fork a little to get recover the chain. !3 Safety monitor (for chain slacking / mast MODE side) (for 3-stage mast only)
PART NAME AND FUNCTION ■Various kinds of mode selection z Travel mode setting x Meter mode setting c Display brightness adjustment v Neutral regeneration setting b Time setting If traveling or hydraulic operation is done while setting, the display is returned to the normal CAUTION screen immediately.
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PART NAME AND FUNCTION c Display brightness adjust screen Display brightness adjustment screen The brightness of the screen can be adjusted on this MODE BRIGHT screen. Make sure that “BRIGHT” and the number are dis- played on the screen. Press E or F button to adjust the brightness of the Brightness is flashing screen.
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PART NAME AND FUNCTION b How to set the time Normal screen When the M button is pressed for more than 3 sec- MODE onds, the time setting screen is displayed. LOAD To return to the normal screen, press M again. 0000 AM 10:30 More than...
PART NAME AND FUNCTION ■Operating equipment q Safety strap w Turn signal switch e Horn button r Emergency button t Accelerator grip y Safety guard u Lift button i Lower button o Pallet lock cancel switch !0 Key switch !1 Steering wheel !2 Glove compartment !3 Brake pedal (Illustration shows the drive-front type)
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PART NAME AND FUNCTION w Turn signal switch Turn signal switch Use the turn signal lamp when turning. ¡When the switch is turned to the right, the right hand side lamp is flashed. ¡When the switch is turned to the left, the left hand side lamp is flashed.
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PART NAME AND FUNCTION y Safety guard The safety guard shall be closed while operation. If the guard is opened when the lifting height is more than NOTE the pre-stop height and the pallet lock device is disen- gaged, the warning buzzer is beeped. Safety guard u Lift button Lift button...
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PART NAME AND FUNCTION If the pallet does not have the lower board With lower boards (such as the skid-type pallet), the pallet locking CAUTION device does not activated. Make sure that the pallet locking device is activated properly before use the forklift truck. If the forklift truck detects the error, the truck does not NOTE move.
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PART NAME AND FUNCTION !3 Brake pedal Brake pedal The brake is released and the electrical travel circuit is connected by depressing the brake pedal. The brake is applied and the electrical travel circuit is Applied disconnected by releasing the brake pedal. (Deadman brake system) Released Knob for emergency lowering...
DRIVING AND OPERATION Do not operate the forklift truck prior to daily inspection. CAUTION Inspect the forklift truck before you operate it to be sure that it is properly maintained and in a good working order. ■Preparation of start 1) Set the safety strap and close the safety guard. If the safety guard is not closed completely, the forklift NOTE truck does not move.
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DRIVING AND OPERATION 2) Make sure that the accelerator grip is in a neutral position. ¡If turning on the key switch with pressing the lift or NOTE lower button, the error is detected, Release the lift and lower buttons and turn on the key switch again. ¡If turning on the key switch with turning the accelerator grip, the error is detected.
DRIVING AND OPERATION ■Traveling Brake pedal 1) Start Applied Depress the foot switch and turn the accelerator grip gradually. Then the truck starts to move. Traveling direction Released Turn the grip to forward Turn the grip to backward Drive-front type Drive side Fork side [Drive-front type]...
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DRIVING AND OPERATION 4) Stopping Release the accelerator grip. Then release the brake pedal to stop. Do not stop suddenly. Sudden stop can cause falling loads or CAUTION turnover the forklift truck. 5) Parking ¡When parking the forklift truck, lower the fork to the floor.
DRIVING AND OPERATION ■Stacking operation Illustrations on this page show the drive-front type fork- lift truck. If your truck is the fork-front type, the operat- ing direction is opposite. ¡Check following matters before operating the forklift truck. CAUTION ¡Make sure that the operating area is clear. When stacking a load, observe following procedures.
DRIVING AND OPERATION ■Picking operation Illustrations on this page show the drive-front type fork- lift truck. If your truck is the fork-front type, the operat- ing direction is opposite. When picking a load, observe following procedures. q Slow down the travel speed. w Stop in front of the picking place.
DRIVING AND OPERATION ■Safety tips for picking a load Make sure following things before operation. ¡Pallets or loads are not overhanged from CAUTION shelves. ¡No obstacles are stayed on the aisle. ¡No damage on the pallet. ¡Pallet is securely locked on the fork. When picking the load, q Wear the hard hat and safety strap.
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DRIVING AND OPERATION y Stop lifting when matching the height of the fork and the shelf. u Turn off the key switch. i Face to the fork side. o Raise the operator guard fully. Safety guard !0 Pick items from the shelf and put them on the pallet on the fork.
Tighten all bolts securely after adjustment. Screw Bolt Pallet lock lever ¡When changing the fork position, the pallet lock lever is also required to change the CAUTION position. ¡Contact to your local Nichiyu dealer to adjust the fork position.
DRIVING AND OPERATION ■Fork spread adjustment The fork spread can be adjusted by change of the four spacer's conbination and by loosening the fitting bolts. Tighten all bolts securely after adjustment. APPLICABLE TRUCKS RB10-70 : 415AD0762~ RB15-70 : 416AD0290~ Spacer Spacer Parts Number L (mm)
BATTERY AND CHARGER ■Battery ¡This section explains NICHIYU’s genuine bat- tery and charger. CAUTION ¡When the lift truck is equipped with another type battery and/or charger, please follow the instructions provided by that manufacturer. s Keep away from fire (Explosive gas) ¡Never allow open flame to come near...
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BATTERY AND CHARGER s Do not over-discharge Do not use the forklift truck until no longer run, it will shorten the battery life. CAUTION ¡When the battery discharge indicator shows empty, charge the battery as soon as possible. s Keep clean ¡Keep the upper surface of the battery clean.
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Do not wash the battery on the forklift truck. It causes damage to the truck. CAUTION s Abnormal battery If the battery shows the following situation, contact NICHIYU’s qualified service facility or CAUTION battery manufacturer. ¡The battery stinks. ¡The electrolyte is muddy.
CAUTION ¡Keep the battery away from open flames or ignitions. s Do not dispose of used batteries. Please contact NICHIYU’s qualified service facil- ity or the battery manufacturer for disposal. CAUTION ■Precautions for charging the battery...
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BATTERY AND CHARGER s Open the top cover ¡While charging the battery, the hydrogen gas is produced and need to open the top cover CAUTION to diffuse. ¡When the top cover is closed, the charging function does not start. (Built-in charger) s Check cable and plug Prior to charging, check the condition of the cable and plug.
BATTERY AND CHARGER ■Charger Use the same value of a fuse for replacement. If you need to replace the fuse for the charger, CAUTION disconnect all input and output plugs first. The supplied voltage should be stabilized with- in ±10% of the rated input voltage. CAUTION The charger should be used within 0°C to + 40°C ambient temperature.
BATTERY AND CHARGER ■How to charge the battery (By stationary charger) s Stationary charger Charging plug Battery plug Stationary charger s Control panel (Controller) CHECK lamp (red) AUTO lamp (red) MI-CON. CHARGER 点検 AUTO button for charge CHECK 自動 AUTO EQUAL lamp (red) 均等 ...
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BATTERY AND CHARGER s Normal (Daily charge) This charge returns the battery to a fully charged con- dition after operating the forklift truck. q Move the forklift truck to designated charging area. w Turn off the key switch and remove the key. e Release the latch and open the top cover.
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BATTERY AND CHARGER Then both “AUTO” and “EQUAL” lamps turn on. MI-CON. CHARGER If “AUTO” and “EQUAL” lamps do not turn on, make sure NOTE CHECK the charger’s cable is connected correctly. AUTO EQUAL STOP TEST i Push the “AUTO” button. Automatic charge is started.
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BATTERY AND CHARGER s Balancing charge Specific gravity of electrolyte in each cell becomes unbalanced after a certain time of charge. In this case, charge the battery for a little bit longer than a normal charge in order to equalize all cells. Manual balancing charge Start the balancing charge.
BATTERY AND CHARGER ■How to charge the battery (By built-in charger) [option] s Built-in charger Charger panel Receptacle Charging plug Power supply plug s Charger panel “AUTO” lamp “AUTO” button for normal charging “EQUAL” lamp “EQUAL” button for equalize charging s Normal (Daily) charge This charge recovers the battery to a full-charged con- dition after operating the forklift truck.
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BATTERY AND CHARGER e Release the latch and open the top cover. Top cover ¡While charging the battery, the hydrogen gas is produced and need to open the top cover CAUTION to diffuse. ¡When the top cover is closed, the charging Latch function does not start.
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BATTERY AND CHARGER u Push “AUTO” button. The automatic charge is started. The “AUTO” lamp stays on and the “EQUAL” lamp is disappeared. i When charging is completed, the “AUTO” lamp is flashed. o Push the “AUTO” button again to turn off the “AUTO”...
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BATTERY AND CHARGER s Balancing charge Specific gravity of electrolyte in each cell becomes unbalanced after a certain time of the charge. In this case, charge the battery for a bit longer than a normal charge in order to equalize all cells. Automatic balancing charge In the case of the built-in charger, the controller selects the “EQUAL”...
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BATTERY AND CHARGER s Supplementary charging When one charge is not enough to finish the daily work, a supplementary charge should be done during a break time. The procedure of the charge is the same as with a nor- mal charge. When the ambient temperature is low, the auto- matic supplementary charge function may be CAUTION...
BATTERY AND CHARGER ■Level of electrolyte and specific gravity s Electrolyte level If the battery is used when the electrolyte level is low, the battery will become overheated causing it to have a shorter life. ¡When the battery level sensor which is mounted on the side of the battery case shows the red flashing, the electrolyte level is too low.
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BATTERY AND CHARGER r After replenishing to all cells, close all vent caps completely. t Clean the top of cells by wet cloth. ¡Do not replenish water over the maximum level. CAUTION ¡Overfilling will cause the electrolyte to over- flow while charging resulting in damage to the forklift truck.
BATTERY AND CHARGER ■Exchanging battery ¡When an exchange of a battery is required, the discharged battery should be charged as CAUTION soon as possible. ¡Exchange the battery on the flat floor with following procedure. Top cover Stopper q Turn off the key switch. w Release the latch and open the top cover.
BATTERY AND CHARGER ■Exchanging battery (for optional side loading type) ¡When an exchange of a battery is required, the discharged battery should be charged as CAUTION soon as possible. ¡Exchange the battery on the flat floor with following procedure. q Turn off the key switch. Top cover w Release the latch and open the top cover.
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BATTERY AND CHARGER y Pull the pin and open the side cover. u Release the battery stopper. Battery stopper i Pull the battery out on the table slowly. If pulling the battery strongly, the battery stand may be disengaged or pinched fingers. CAUTION o Hang the battery with slings and exchange.
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BATTERY AND CHARGER ¡connect the battery plug securely. Battery plug ¡Close the top cover and secure by the latch. s Battery carrier (option) The battery carrier is available as option. It is useful for easy transfer of the battery. The battery carrier has the adjuster of the height of the roller base.
At the beginning of each shift, check your forklift truck to make sure it is in safe operating condition. If faults are found, contact NICHIYU’s qualified facility. ¡Do not operate the forklift truck until finish- ing repairs and inspections.
INSPECTION PRIOR TO OPERATION ■Inspection procedure q Safety monitor MODE Make sure the [OK] sign is displayed on the screen for a few seconds after turning on the key switch. w Turn signal lamps and horn Switch for turn signal lamp Check operation of lights and horn.
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INSPECTION PRIOR TO OPERATION u Hydraulic piping Make sure no oil leaking is found on all hydraulic pip- ing. i Hydraulic oil level Level gauge After lowering the fork to the bottom completely, check the hydraulic oil level by the gauge. [RB10] If within the range, the oil level is normal.
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INSPECTION PRIOR TO OPERATION !1 Wheels Check all tires for damages or abnormal wearing. !2 Wheel fitting bolts Make sure all fitting bolts are tightened securely. Load wheel Drive wheel !3 Charging battery Measure the specific gravity of the electrolyte of the battery.
INSPECTION OF AFTER OPERATION ■Inspection after working At the end of each shift, clean the forklift truck and inspect the following items. ¡Any damage or oil leakage. ¡Apply grease if required. Refer to [Lubrication points and recommended oil] ¡Raise the lift carriage to the maximum lifting height several times if your normal operation did not require to do so.
PERIODIC SERVICING Periodic inspections and maintenance are nec- essary to keep your NICHIYU forklift truck run- CAUTION ning safely and smoothly. Hours shown in the maintenance schedule are based on eight hours operation per day and 200-hour operation per month.
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PERIODIC SERVICING s Precautions of maintenance ¡Smoking shall be prohibited. ¡Wear safeguard (helmet, shoes, glasses, CAUTION gloves and boots) and suitable clothes. ¡Wipe off spilt oil at once. ¡When lubricating, remove grease and dust off nipples and fittings with a brush or a cloth before lubrication.
PERIODIC SERVICING s Jacking up Do not go under the forklift truck while it is being jacked up. WARNING Failure to observe this warning can cause seriously injury or death if the forklift truck falls on you. ¡Before jacking up the forklift truck, make sure no one is around and no load is on the CAUTION forklift truck.
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PERIODIC SERVICING s Check the level of electrolyte Refer to [Level of electrolyte and specific gravity]. Appropriate level ¡After completing the replenishment, securely close the vent caps. CAUTION ¡Do not replenish the water over the maximum level. Proper level of Lowest level of electrolyte electrolyte...
If an adjustment or replacement Terminal plug Damage, Loosening, Dirt parts is required, contact to your Receptacle, plug for charger Damage, Looseness Key switch Function Battery, local Nichiyu dealer. Charger, Contactors Contacts and Function Electric system Micro switches Function EPS motor Brush, Commutator condition...
PERIODIC SERVICING ■Every three-month (600-hour) servicing Perform following service in addition to the monthly (200-hour) maintenance schedule. If an adjustment or replacement parts are required, contact to your local Nichiyu dealer. Check points Contents When surface roughness of the Contactors contact tip is excessively, replace it.
PERIODIC SERVICING ¡Inspection of brushes of the power steering motor Brush Raise up the whirl spring and then pull out the carbon brush to check the length. If the brush is worn more than the wearing limit, replace all brushes at the same time. Wearing limit of carbon brushes.
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PERIODIC SERVICING s Replacing fuses of charger for three phases power supply Be sure to disconnect the A.C. plug. CAUTION Fuses Replacing procedure Tighten screws securely Loosen the mounting screws, and replace fuses. Insufficient tightening of the screws may cause of poor contact and can cause overheating or fire.
Fuse is normal?, The lead wires are not Lamps do not turn on Contact to your local Nichiyu dealer. damaged?, The bulb is not burnt? If you have any other problems or you cannot fix even following above procedure, contact to your local Nichiyu dealer.
Therefore, Nichiyu strongly recommends to replace these parts in every period even if it looks no problem. The periodical replacement of these parts is not cov- ered by warranty.
STABILITY OF FORKLIFT TRUCK As shown in the following illustration, the forklift truck is balanced on its load wheel with the maximum rated capacity load on the forks. Therefore, careful attention should be paid to the load center. If the load weight and/or gravity exceed the rated capacity or load center, the drive and caster wheels are lifted and the forklift truck tips over.
COLD STORAGE TYPE FORKLIFT TRUCK The NICHIYU electric forklift trucks for Cold Storage Application are designed to operate in the cold storage area. This forklift truck is designed for –35°C class cold storage area. ¡The indoor and outdoor operations should...
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RB10/15-70 SERIES OPERATOR’S MANUAL Reproduction prohibited First printing : February 2006 Second edition : July 2008 Issued by : Nippon Yusoki Co., Ltd. Overseas Division PBC.1003-050...
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Printed in Japan Pub No. OP-06-012-R1 50/1003 1-1, 2-Chome, Higashikotari, Nagaokakyo-shi, Kyoto 617-8585 JAPAN Copy rights Tel: +81-(0)75-956-8622 Fax: +81-(0)75-955-0480 URL: http://www.nichiyunet.co.jp/en...
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