Nissan Procedures Service Manual

Maruboshi Europe B.V. NISSAN FORKLIFT - OWNER’S MANUAL

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A Word to NISSAN FORKLIFT Operators

This booklet describes operating procedures, daily cares and simple maintenance for safe usage of your NISSAN FORKLIFT. We urge you to read this booklet carefully before operating the lift truck to familiarize yourself with safety instructions. These instructions will not only reduce mechanical troubles of your lift truck, but may also save your life.

If you encounter any problems with your NISSAN FORKLIFT truck, contact the authorized NISSAN FORKLIFT dealer in your area and request a complete check-up. The dealership will insure that your Lift Truck is serviced in accordance with the latest factory approved methods.

All information, specifications and illustrations in this manual are on a basis of the latest data obtainable at the time of the publication. Nissan reserves the right to make changes or improvements at any time without notice.

Throughout this manual we have used the symbol the word WARNING. This is used to indicate the presence of a hazard which may cause the possibility of a personal injury or other damage and must be followed precisely.

CAUTION. This is also used throughout the manual to indicate the presence of a hazard that could cause possible minor injury to yourself or components and the procedures must be followed carefully.

followed by

Contents

Name of Components ......................................................................... 2

Safety Rules ........................................................................................ 3

Positioning of Warning, Caution and Instruction Labels................... 13

Instruments and Controls .................................................................. 20

Starting and Operating ...................................................................... 27

Loading and Unloading ..................................................................... 35

Other Handling and Operations ........................................................ 35

Daily Care.......................................................................................... 43

Maintenance...................................................................................... 55

Putting Forklift in Storage.................................................................. 68

Load Chart......................................................................................... 70

Identification Numbers....................................................................... 71

Specifications .................................................................................... 72

Side shift (Optional attachment)........................................................ 84

Cabin (Option) ................................................................................... 94

Index................................................................................................ 100

TOKYO, JAPAN

This Operator’s Manual has been prepared on the assumption that your truck is fully equipped (including all optional equipment). Thus if you have any questions regarding equipment, please contact your authorized NISSAN FORKLIFT dealer.

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NAME OF COMPONENTS

Mast

Lift cylinder

Backrest

Fork

Overhead guard

Steering wheel

Operator’s seat

Joystick lever

Counterweight

Top panel

Rear tire

Tilt cylinder

Front tire

MOM1826

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SAFETY RULES

The forklift shall be operated in accordance with the conditions of the operator’s license, and the applicable provisions of the laws and regulations of your country.

Operator must be trained and authorized to drive the lift truck, and must understand safety technics and rules for lift truck operation.

Before installing hook-on attachments, be sure to read the installation manual issued by the attachment manufacturer to assure correct and proper installation. Contact your NISSAN FORKLIFT dealer for the revised load capacity figures.

When warning and caution labels are damaged so they cannot be read or have peeled off, they should be immediately replaced with new labels to ensure that they are constantly maintained in a legible condition. The warning and caution labels are available at your nearest NISSAN FORKLIFT dealer.

Inspect the lift truck before operating. Do not operate lift truck if it is

in need of repair. If it is in need of repair, tag the lift truck, remove the key, and report the condition to the proper authority. Do not attempt repair unless you are trained and authorized for repairing.

MOM0015

The working clothes worn by the operator shall be such that sleeves and cuffs fit snugly so as to prevent them from getting caught on forklift levers, etc., and safety glasses, ear muffs, dust mask and safety shoes should also be worn.

Do not remove overhead guard or backrest unless specifically authorized.

Make sure that forward-reverse lever is set in neutral and hand brake is applied before starting the engine. Do not start or operate the lift truck if you are not in designated

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operator’s position.

Before starting the engine, make sure that the seat belt is secure.

D01/D02 models do not have creeping phenomena.

Do not allow anyone on any part of the lift truck while moving or lifting.

The truck will not move if the select lever is in the F (forward) or R (reverse) position unless you depress the accelerator pedal. When depressing the accelerator pedal, be sure to visually confirm the position of the forward-reverse lever. When starting on slopes, be sure to apply the parking brake to hold the truck and then start, even if the slopes are gentle. Avoid rapid acceleration (especially during high loading).

Do not allow anyone to stand or ride on the forks, pallet, etc.

MOM1631 MOM1632

Do not allow anyone to stand or walk under the elevated portion of the forks whether it is empty or loaded.

Keep hands, feet and other parts of your body inside the operator’s compartment all the times.

Never put any part of your body into the mast structure or between the mast and the truck.

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MOM1633 MOM1677 MOM1634

Space forks as far apart as the load will permit.

Always carry loads low with the mast tilted to the backmost position, never forward. Do not elevate loads except during stacking.

Maintain a careful lookout for people and obstructions, and watch the path of travel. Watch clearances, especially overhead and tail swing. When visibility is obstructed, use extreme caution. Yield right of way to pedestrians.

If the load obstructs the front view, drive the lift truck in reverse.

Do not place load higher than the backrest of the lift truck. A load placed higher than the backrest may drop towards the operator and is very dangerous. If such a load must be handled, securely fasten the load using suitable ropes or holddown bands.

Do not overload lift truck. Check the load chart for load weight and load center information. Always pick up loads as close to weight center as possible to avoid offcenter loading.

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the tires so as prevent the forklift from moving while it is parked in the elevator. Do not carry out work in the elevator.

MOM1635 MOM0019

Avoid sudden starts, stops or turns. Slow down for turns and on uneven or slippery surfaces that could cause lift truck to overturn or slide.

Use special care when traveling without load as risk of lateral overturn may be greater than when traveling with load.

When moving the forklift in elevators, check to make sure the elevator is capable of withstanding the truck weight or the truck weight plus load weight. Be sure to apply stoppers under

Precautions relating to driving onto freight cars and trailers Check freight cars and trailers to make sure they will not move. The ramp for driving the forklift onto a freight car or trailer shall have sufficient strength to withstand the weight of forklift and its load, and the forces exerted by the bouncing of the truck. The ramp shall be anchored so that it is prevented from shifting. Use the utmost care when driving on and off a freight car or trailer.

Before entering trucks or trailers, be certain the brakes on the truck

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or trailer are applied and the wheel chocks are in place or trailer is locked to the loading dock.

MOM1636 MOM1637

Before driving over a dockboard or bridge plate, be certain that it is properly secured. Drive carefully and slowly across the dockboard or bridge. Never exceed its rated capacity.

Use special care when operating on slopes. Travel slowly and do not angle across or turn.

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MOM0016 MOM0017 MOM0018

Use care when traveling on gradients. When traveling on gradients with a load, always drive forward on upward slopes and in reverse on downward slopes. Drive slowly on slopes. Drive in the reverse direction on upward slopes when without a load, and drive forward on downward slopes.

Use the brake pedal and engine brake together when driving downhill so as to maximize the effectiveness of the engine brake.

Do not traverse and turn around on slopes. Since driving on slopes causes the center of gravity to shift towards the lowest point, the forklift is likely to lose its balance.

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ered, forward-reverse lever is in neutral, hand brake is applied and key switch is turned off. Avoid parking lift truck on a slope.

Fuel is highly flammable. It must be handled with the utmost care, in accordance with the safe handling requirements of fuels and the applicable safety provisions of laws and regulations of your country.

MOM1638 MOM1639

When ascending or descending slopes, drive the lift truck with the load facing upgrade.

Do not handle unstable or loosely stacked loads. When handling long, high or wide loads, use special care to ensure stability and carefully watch the surrounding conditions.

When approaching cross aisles, slow down, and sound horn if visibility is obstructed.

Before leaving the lift truck, be sure that forks or attachments are low-

When filling the tank with fuel, make sure the truck is properly parked. Turn off the key switch and remove it. When fuel is spilled, wipe the area clean with a cloth. The cloth shall be disposed of in accordance with the requirements of safe handling of fuels, environmental requirements, and the applicable provisions of the laws and regulations of your country.

When filling the tank with fuel or recharging the battery, stop the engine and place the lift truck only in designated area with good ventilation. Keep away from arcs, sparks, flames or lit cigarettes.

Do not breathe exhaust gases: they contain colorless and odorless carbon monoxide. Carbon monoxide is a dangerous gas and can cause unconsciousness or death.

Do not run the engine in closed spaces or poorly ventilated rooms such as a garage or refrigerator, etc.

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IN CASE OF TIP-OVER

Be extremely careful to prevent the lift truck from tipping over during operation. Slow down the lift truck sufficiently when turning a corner or tight curve. The following precautions should be closely observed to ensure safe

operation of the lift truck as well as to protect personnel against injury.

If the forklift is equipped with a seat belt, always make sure that your seat belt is securely fastened and the top panel latch is in the locked position.

MOM0137C

If the lift truck begins to tip, DO NOT ATTEMPT TO JUMP CLEAR. The lift truck will fall faster than you can jump. Brace your feet and hold yourself inside the operator compartment by holding onto the steering wheel with both hands.

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Tilt the mast back to the maximum without load. Check the approach angle, departure angle, and ramp breakover angle to make sure the underside of the forklift will not contact the load carrying platform or the ground. When using a gangway, make sure the planks are capable of supporting the truck weight. Drive forklift on and off the carrier slowly. When winching the forklift onto a load carrying platform, be sure to attach the cable to the traction pin. Do not ride on the forklift while it is being winched. Be sure to use lashing points and firmly secure the truck to the load carrying platform. When hoisting the forklift, be sure to use the lifting points. Turn off the key switch and remove it.

APPROACH ANGLE, DEPARTURE ANGLE AND GANGWAY

MOM0020 MOM0021

MOM0022

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MOM0023

MOM1641

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POSITIONING OF WARNING, CAUTION AND INSTRUCTION LABELS

Carry out the daily checks as per “Daily care” on page 46, and the applicable provisions of laws and regulations of your country.

When replacing NISSAN FORKLIFT truck parts (including lubricants), be sure to use NISSAN FORKLIFT genuine parts or the equivalents guaranteed by Nissan Motor Co., Ltd. Any irregularities arising from the use of parts other than those specified above shall not be covered under warranty.

MOM0062A

Used parts and materials such as engine oil, long-life coolant, paint, rag, battery fluid, and batteries shall be disposed of as per the applicable provisions of the laws and regulations of your country. Also consult with your nearest NISSAN FORKLIFT dealer.

WARNING AND CAUTION LABELS

WARNING:

+ The warning and caution labels are affixed

to the designated locations of the forklift as shown in the figure below. Before operating the truck, be sure to make note of the details given in the labels so as to ensure proper and safe operation.

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FIGURE INDICATING THE POSITIONING OF WARNING AND CAUTION LABELS

MOM1598

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MOM1562A

WARNING:

+ This truck has no creeping phenomena.

+ The truck will not move if the forward-

reverse lever is in the F or R position unless you depress the accelerator pedal. When depressing the accelerator pedal, be sure to visually confirm the position of the forward-reverse lever.

+ When starting on slopes, be sure to

apply the parking brake to hold the truck and then start, even if the slopes are gentle.

+ Avoid rapid acceleration (especially dur-

ing high loading).

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WARNING:

Operation precautions

+ This label contains instructions on how

to operate the forklift safely and avoid accidents. Therefore, be sure to take careful note of the instructions before operating the forklift.

MOM1809

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IN CASE OF TIP-OVER

operation of the lift truck as well as to protect personnel against injury.

If the forklift is equipped with a seat belt, always make sure that your seat belt is securely fastened and the top panel latch is in the locked position.

MOM0137B

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MOM0004A MOM0005C MOM0009

WARNING:

Do not stand on or below forks.

+ Riding on forks is strictly prohibited.

Furthermore, do not stand immediately below the forks. Otherwise, serious accidents can occur if the forks should move abruptly and the load placed on the forks unexpectedly falls down. In the worst cases, these accidents can be fatal.

WARNING:

Be sure to keep your hands, feet, and body away when operating the mast or closing the top panel. Otherwise, parts of the body are liable to become caught between the moving and fixed sections of the masts or top panel and injury may be incurred.

WARNING:

Handling of radiator cap

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MOM0062B MOM1599 MOM1600

WARNING:

+ Diluted sulfuric acid and lead are used in

the battery.

+ Used battery fluid, and batteries shall be

disposed of as per the applicable provisions of the laws and regulations of your country.

+ Also consult with your nearest NISSAN

FORKLIFT dealer.

WARNING:

+ As soon as the top panel is opened

while the engine is operating, the engine will stop.

+ The engine cannot be started while the

top panel is open.

WARNING:

Pay attention to the position of the pedal.

+ The labels indicate the positions of ped-

als for the operation of forklift.

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INSTRUMENTS AND CONTROLS

MOM1601C

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METERS, GAUGES, INDICATOR AND WARNING LAMPS

Fuel meter

With the ignition switch ON, the fuel meter indicates the approximate amount of fuel in the tank. Always top up the fuel tank.

Water temperature meter

When the ignition switch is set at ON, the water temperature meter operates and pointer indicates coolant temperature. During ordinary operation, the pointer will remain about the center range of the gauge. If the pointer indicates “H” position and remains there for more than a few minutes, stop the Lift Truck and cool the engine at idling speed. After stopping the engine, check the coolant level and fan belt deflection.

Hour meter

The hour meter operates when the ignition switch is in the ON position. The dial of the hour meter advances one number when the ignition switch remains in the ON position for an hour. Consequently, the number of the hour meter indicates total operating period of hour.

Cooling water level warning lamp (Option)

This lamp comes on when the ignition switch is turned to START. If the lamp comes on while the forklift is in operation, it indicates that the coolant in the radiator reservoir tank has dropped below the MIN. level.

Add coolant to the MAX. level.

Air cleaner plugging indicator lamp (Option)

This lamp comes on when the air cleaner is clogged. If the lamp comes on while driving, clean the air cleaner immediately.

Torque converter oil temperature warning lamp

Under normal operating conditions, the warning lamp turns on when the key switch is turned to the START position and turns off when the engine starts. The lamp will turn on during engine operation whenever the torque converter oil temperature exceeds the normal level.

NOTE:

Immediately stop the engine whenever the warning lamp turns on during operation. Check the oil level and replenish if required. If the lamp remains lit after oil

replenishment, contact your nearest NISSAN FORKLIFT dealer to have the torque converter inspected and serviced.

(Refer to “Automatic transmission oil level” on Page 50 for the inspection and oil replenishment procedure).

Fuel level warning lamp

If the remaining fuel drops below the specified level when the key switch is turned ON, the fuel warning lamp will come on.

When the fuel warning light illuminates, add fuel up to the specified level as soon as possible.

Emergency seat belt warning lamp

The seat belt warning lamp comes on when the seat belt is not fastened with the key switch turned ON.

Fasten the seat belt.

Parking brake warning lamp

The parking brake warning lamp comes on when the parking brake is applied with the key switch turned ON.

+ Drive the vehicle with the parking brake

released.

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+ Make sure that the parking brake is

released during operation. Failure to do this may cause premature wear of braking parts, overheat the brake system and result in poor braking performance.

Oil pressure warning lamp

This lamp glows red when the ignition switch turns ON and oil pressure is not built effectively in the engine lubricating system. If the lamp glows under ordinary operating conditions, stop the engine immediately and check the engine lubrication system.

Charge warning lamp

With the ignition switch ON, the warning lamp glows red when the alternator is not supplying current to the electrical system. After the engine starts, the lamp should go out, indicating that the alternator is operating properly. If the lamp glows or flickers occasionally during normal operating, the alternator and electrical system should be checked.

Glow plug indicator lamp (Diesel engine)

This lamp goes on when the ignition switch is ON, and goes out when the glow plugs have been preheated.

If the lamp remains lit after the glow plugs

are preheated, this indicates an abnormality in the glow system.

Have the system checked at your nearest NISSAN FORKLIFT dealer or other competent service shop.

Fuel filter (water accumulation) warning lamp (Diesel engine)

Under normal operating conditions, the warning lamp turns on when the key switch is moved to the START position and turns off when the engine starts.

The lamp will turn on during engine operation whenever the accumulated water in the fuel filter exceeds the specified level.

When the lamp turns on during operation, drain the water from the fuel filter as soon as possible.

(Refer to the fuel filter draining procedure on Page 57.)

Continued operation with the warning lamp on can result in fuel pump seizure.

Joystick warning lamp

With the key switch turned ON, the joystick warning lamp comes on when the electrically controlled joystick system is malfunctioning.

WARNING:

If the warning lamp comes on, suspend cargo handling operations and have thesystem checked and repaired by the nearest NISSAN FORKLIFT dealer.

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SWITCHES

Key (ignition) switch

Horn button

Lighting switch & tirn signal switch

Engine idling control knob

Backup operation lamp (OPT)

MOM1828

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the OFF position once, then turn it to the START position.

Lighting switch & turn signal switch

Horn button

OFF

START

Pushing the button in the center of the steering wheel will sound the horn, regardless of key position.

MOM1603

Key switch

The key switch controls the engine ignition system and most of electrical equipments and has three positions. The key can be inserted or withdrawn only when the key is in the OFF position.

To turn on the ignition system as well as other electrical circuits, turn the key to ON position. The start position allows to start engine. After the engine has started, by releasing the key, it will automatically spring back to the ON position.

This key switch incorporates an anti-restart function. When restarting, return the key to

MOM1604

Lighting switch

The switch controls the headlamps and tail lamps.

The lighting switch operates independently of the key switch.

Turn the switch knob clockwise. The lamps corresponding with the marked position will come on. For details concerning lamp operation, refer to the table.

Turn signal switch

Push the switch lever forward when turning left, and pull it backward when turning right.

The switch lever will automatically return to its

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original position after the lift truck has turned to the left or right. If it does not, return it by hand.

Switch lever

position

Passing lamp

Turn to 1st step

Turn to 2nd step

Turn to the right or left

Without combination lamp (Standard) With combination lamp (Optional)

Headlamp Tail lamp

Comes on

Comes on — Comes on —

——

Comes on Comes on Comes on —

— — — Comes on

Turn signal

The turn signal lever can be moved even in vehicles not equipped with a combination lamp.

lamp

Headlamp Tail lamp

Comes on Goes out —

Turn signal

lamp

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pended. Failure to do so can result in a dead battery.

FAST

SLOW

MOM1605 MOM1606

Engine idling control knob (For diesel engines: cold climate specifications are optional)

The control is located on the meter panel. Turning the knob clockwise will increase the

engine idling speed. Turning the knob counterclockwise will slow

down the engine idling speed. It is used to warm up the engine at starting.

Backup operation switch (Optional)

The rear operating lights are used for nighttime operation and operation in poorly lit areas. The rear operating light switch controls these lights.

The light switch is a button type. When this switch is pushed, the back operation lamp comes on. When it is pushed again, the lamp goes out.

+ The backup operation switch works in-

dependently of the key switch ON and OFF positions.

+ Be sure to turn off the rear operating

lights by pushing the knob in whenever the engine is stopped or operation sus-

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STARTING AND OPERATING

Forward-Reverse lever (OPT)

Hand brake

Neutral-position lamp

Inching brake pedal

Forward-Reverse lever

Accelerator pedal

Brake pedal

MOM1827

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OFF

START

MOM1609

Gasoline engine starting (Including LPG vehicles)

The engine is equipped with a fully automatic choke. Follow the procedure outlined below to start the engine.

On LPG models, open the discharge valve and then start the engine.

1. Pull the hand brake lever up as far as possible. Move the forward-reverse lever to the neutral position.

NOTE:

When the forward-reverse lever is in the F or R position, it is not possible to start the engine.

2. Press the accelerator pedal fully to the floor board (one-time only) and slowly release it. If the engine is warm at starting, it is not necessary to press the accelerator pedal.

3. Remove your foot from the accelerator pedal. Turn the starter to start the engine.

NOTE:

Do not operate the starter for more than ten seconds. If the engine fails to start within ten seconds, release the starter and wait for ten seconds before attempting to start the engine again. This allows the battery time to recover.

4. After starting the engine, allow it time to warm up. Allow the engine to idle for one minute after starting. Then, press the accelerator pedal lightly and release it. If the surrounding temperature is high, lightly pressing and releasing the accelerator pedal will reduce engine speed and permit quiet warming up. This also results in fuel savings.

NOTE:

+ The engine is cold immediately after

starting. Do not intermittently race the engine or run the engine at high speeds immediately after starting.

+ Do not move the key to the START

position when the engine is running. Damage to the starter motor will result.

+ Engine speed is high immediately after

starting. Exercise caution when moving the vehicle or handling cargo.

WARNING:

+ Inspect the condition of LPG hose con-

nections and check for gas leaks from LPG hoses and pipes before starting engine.

+ In the event of LP gas leakage or some

other abnormal occurence, close the discharge valve immediately. Have your LP gas system checked at an authorized service facility.

Stopping

Gasoline engine To stop the engine, turn the ignition key to the

OFF position, then engine will stop.

LPG model

WARNING:

Carefully follow the below procedures when turning the engine off after LPG operation:

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(1)Completely close the discharge valve

(red).

(2)Race the engine until it stops.

(3)Make sure that all of the remaining LPG

(in the piping and other receptacles) has been used. After the engine stops, turn the key switch to the OFF position.

+ After completion of operation and be-

fore storing the vehicle for an extended period, check the engine for gas leakage. Refer to “LPG cylinder replacement” on Page 60.

+ In the event of gas leakage, an accident,

or some other abnormal occurrence, immediately and completely close the discharge valve (colored red). Have your LP Gas system checked at an authorized service facility.

OFF

START

MOM1610

DIESEL ENGINE Starting

1. Pull the hand brake lever up as far as possible. Move the forward-reverse lever to the neutral position.

NOTE:

When the forward-reverse lever is in the F or R position, it is not possible to start the engine.

2. When the key switch is set to the ON position, the glow plug indicator lamp on the combination meter goes on, indicating that engine preheating has started. Keep the key switch in the ON position till

the glow plug indicator lamp goes out (indicates completion of preheating).

Engine preheating is controlled automatically corresponding to the engine coolant temperature, atmospheric air temperature and so forth, and the glow plug indicator lamp goes out when the engine is preheated to the specified temperature.

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FAST

SLOW

MOM1611 MOM1829

3. When the glow plug indicator lamp has gone out, turn the key switch to the START position while depressing fully the accelerator pedal, until the engine starts.

4. After the engine has started, release the accelerator pedal gradually, and turn the engine control knob clockwise until the engine runs smoothly.

When restarting, return the key to the OFF position once, then turn it to the START position.

Stopping

To stop the engine, turn the ignition key to the OFF position, then engine will stop.

FORWARD

REVERSE

Forward-reverse lever

This lever is used to change the direction of the lift truck, forward and reverse.

If the lever is pushed forward, the lift truck moves forward; if pulled backward, the lift truck moves backward. The midpoint between the forward and reverse positions is the neutral position. The engine must be started with the lever set in the neutral position.

Lever in forward position:

When moving the lift truck forward.

Lever in reverse position:

When moving the lift truck backward.

MOM1812

Lever in neutral position:

When starting the engine and parking the lift truck. (The neutral position lamp comes on.)

CAUTION:

Before changing the direction of travel, depress the brake pedal to stop the forklift completely and place the change lever in the Forward or Reverse position as desired.

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