NICHIYU NTF200P 56 Series User manual

OPERATOR'S MANUAL
ELECTRIC LIFT TRUCK
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
NTF200P
NTF360P
56 SERIES
ELECTRIC FORKLIFT TRUCK

OPERATORʼS
MANUAL
ELECTRIC
LIFTTRUCKS
OPERATORʼS
MANUAL
ELECTRIC FORKLIFT TRUCK

DANGER
WARNING
CAUTION
NOTE
Indicates an extremely hazardous situation which, if not avoid-
ed, will result in death or serious injury.
You shall observe this instruction.
Indicates a potentially hazardous situation which, if not avoid-
ed, could result in death or serious injury.
You shall observe this instruction.
Indicates a potentially hazardous situation which, if not avoid-
ed, may result in minor or moderate injury.
You shall observe this instruction.
Indicates suggestions, tips and hints related to the safety of a
operator and maintain of a tractor.
¡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 tractor. Keep this manual after reading.
¡If you have any questions, please feel free to contact your local NICHIYU dealer.
and are very important for you and others for safety. Follow these
instructions.
INTRODUCTION
CAUTION
The operator should read and understand
the safe operation contained in this manual.

CONTENTS
zSAFETY OPERATION ............................................................................... 1
Information for safety operation .......................................................................... 1
xPARTS NAME AND FUNCTION ............................................................ 4
Name of parts ..................................................................................................... 4
Driving system .................................................................................................... 4
Indicator panel .................................................................................................... 5
Operation ............................................................................................................ 6
cDRIVING AND OPERATION .................................................................... 8
Preparation of start ............................................................................................. 8
Traveling ............................................................................................................. 9
vBATTERY AND CHARGER .................................................................... 11
Battery .............................................................................................................. 11
Precautions for charging the battery ................................................................ 14
Charger ............................................................................................................. 16
Charging method .............................................................................................. 17
Level of electrolyte and specific gravity ............................................................ 21
b INSPECTION PRIOR TO OPERATION
......................................................... 23
Check points and contents................................................................................ 23
Inspection procedure ........................................................................................ 23
n INSPECTION OF AFTER OPERATION
........................................................ 26
Inspection after working .................................................................................... 26
mPERIODIC SERVICING ........................................................................... 27
Precautions of maintenance ............................................................................. 27
Weekly (50-hour) servicing ............................................................................... 29
Monthly (200-hour) servicing ............................................................................ 31
Lubrication points and recommended oil .......................................................... 32
Every three-month (600-hour) servicing ........................................................... 32
Semiannually (1200-hour) servicing ................................................................. 33
Replacing parts and trouble shooting ............................................................... 33
,QUICK FAULT FINDING AND PARTS CHANGING ..................... 34
.PERIODICAL REPLACING PARTS .................................................... 36
⁄00 SPECIFICATIONS...................................................................................... 37

1
SAFETY OPERATION
■Information for safety operation
1
CAUTION
Only a trained and authorized operator shall
operate the tractor.
CAUTION
The operator is recommended to wear a hel-
met, safety shoes and working clothes.
WARNING
Do not operate the tractor while taking
drugs and/or alcohol; otherwise, an acci-
dent may occur which can cause serious
injury or death.
CAUTION
Do not use a tractor in the following circum-
stances.
qWhere the temperature is less than –10°C
or more than 40°C.
wWhere the explosive gas (thinner, gaso-
line etc.) may exist.
CAUTION
Keep the operator's compartment clean at all
times.
CAUTION
Do not operate the tractor with greasy or wet
hands.
CAUTION
Do not modify the tractor.
CAUTION
Carry out the daily inspection before operation.
CAUTION
Prior to handling, confirm the weight of a load.
¡Modifications and additions shall not be performed
without the written approval of NICHIYU. Contact
NICHIYU
’ s qualified facility for details.
¡Do not install any parts blocking visibility from oper-
ating position.
¡Prohibit to draw over the rated drawbar pull.

2
1SAFETY OPERATION
CAUTION
Refrain from a sudden start, quick braking and
quick turn.
CAUTION
Be careful about the condition of road surface,
and not couple while the tractor is leaned and
is on and incline.
CAUTION
When turning, be sure to confirm safety
around the truck, and travel slowly.
CAUTION
Do not either run sideways or change the
direction along the inclined surface.
CAUTION
Do not run over an obstacle on the road.

3
1
SAFETY OPERATION
CAUTION
When leaving the truck, remove the key.
¡Refrain from parking on an incline. If parking on an
incline should unavoidably be obliged, be sure to
apply buffer-stops.
CAUTION
When coupling the trailer, approach slowly.
CAUTION
When turning, the trailers draw near to the
inside. So make large turn considerably.
CAUTION
Refrain, from turning and quick braking on an
incline as it is dangerous.
CAUTION
When the truck is damaged, immediately repair
and never operate the truck until the repair is
finished.

■Name of parts
■Driving system
2
PARTS NAME AND FUNCTION
4
qIndicator panel
wParking brake lever
eHead lamps
rFront hood
tTurn signal lamps
yFront axle
uRear axle
iRearview mirror
oSteering wheel
!0 Center hood cover
!1 Seat
!2 Battery
!3 Stop, Tail & back lamps
!4 Coupler
q w e r t y u i o !0 !1
qParking brake lever
wSteering wheel knob
eSteering wheel
rHorn button
tFloor plate
yHour meter (Option)
uSwitch for turn signal lamp
iBrake pedal
oAccelerator pedal
!00 Directional switch
!1 Indicator panel

5
■Indicator panel
qSave energy switch
The switch adjusts peak current flowing to the traction
motor. When turning the switch clockwise, starting
power and gradeability are reduced.
This results the soft acceleration and save the battery
energy consumption.
When turning the switch to the left end (“P” position),
the acceleration and gradeability are maximum.
The forcible by-pass circuit can activate at this “P”
position only.
When starting is difficult, set this switch to “P” (click is
heard) and depress the accelerator pedal fully. After
three to five seconds, the by-pass contactor is activat-
ed and the tractor start moving.
When turning the switch to the right end (“SE” posi-
tion), the acceleration becomes soft.
wHour meter (Option)
The hour meter indicates the operational integrating
hour. it is useful to know the operational hour efficiency
and periodical inspection for the better management
and schedule of materials handling.
eBattery capacity indicator
The battery capacity indicator measures the state of
charge of the battery. when the key switch is turned
on, the five green lamps will light, one at a time from
left to right to indicate the state of charge of the bat-
tery. With fully charged battery, all five will light. As the
battery energy is used, the lights will go out one at a
time from right to left. When red light begins to flash,
battery needs to be recharged.
2
PARTS NAME AND FUNCTION
q w e r yt
BATTERY 48V
qSave energy switch
wHour meter (Option)
eBattery capacity indicator
rParking lamp (red)
tSwitch for head lamp and tail lamp
yKey switch

6
rParking lamp (red)
The parking lamp indicates parking brake applied. The
parking lamp warns against starting while parking
brake is applied.
tSwitch for head lamp and tail lamp
Switch position :
Tilt up : Turn on the head lamps and the tail
lamps.
Neutral : All lamps are turned off.
Tilt down : Turn on the tail lamps.
yKey switch
OFF : This is the position to insert or remove a key.
ON :
Preparation for operation is completed by turning
the key switch clockwise, and at the same time,
the opreration lamp (green) on the battery
capacity indicator is put on.
■Operation
qParking brake lever
Pull the parking brake lever fully when parking. Push
the parking brake lever forward when releasing the
parking brake.
2PARTS NAME AND FUNCTION
CAUTION
Turn off the key switch while stopping opera-
tion or charging the battery.
OFF ON
q w e r t y u i
qParking brake lever
wSteering wheel knob
eSteering wheel
rHorn button
tSwitch for turn signal lamp
yBrake pedal
uAccelerator pedal
iDirectional switch
when parking

7
wSteering wheel knob eSteering wheel
When steering the wheel, grasp the steering wheel
by the right hand and the left hand are put on the
steering wheel lightly.
rHorn button
Horn button is equipped on the left side of the post for
steering wheel. Horn sounds by pushing button.
tSwitch for turn signal lamp
Lamp at either right or left hand side is put on when
the switch is either pushed or pulled. Move the switch
by finger lightly.
yBrake pedal and uAccelerator pedal
Depress the accelerator pedal gently. The travel
speed is adjusted by depressing angle of the pedal.
iDirectional switch
When the switch is pushed forward, truck is ready to
go forward. When it is pulled, truck is ready to go
backward.
Seat
Operator restraint type seat is equipped as standard.
It is adjustable for the best position to forward or back-
ward.
Adjust the seat for proper operating position. The
operator
’ s manual can be stored in the box behind the
back of the seat.
Adjustable position of the seat
Forward : 60mm
Backward : 60mm
2
PARTS NAME AND FUNCTION
Left
Right
Forward
Backward
Neutral
CAUTION
Do not depress accelerator pedal before turn-
ing on key switch and putting directional
switch either direction.
Adjust lever
Reclining knob
(option)
Forward
(60mm)
Backward
(60mm)

3
DRIVING AND OPERATION
■Preparation of start
1) Check the directional switch is in the neu-
tral position and the parking brake is
applied.
2) Turn on the key switch
Grasp the steering wheel knob and then turn on the
key switch.
3) Operation of the directional lever
Operate the directional lever to the moving direction.
Forward : Push the lever forward.
Backward : Pull the lever backward.
4) Release the parking brake
Depress the brake pedal.
Push the parking brake lever forward fully to release
the parking brake.
Grasp the steering wheel knob by the left hand, put
the right hand lightly on the steering wheel.
8
CAUTION
¡Do not operate the tractor prior to daily
inspection.
¡Be sure to confirm safety around the tractor
when operating.
Forward
Backward
Neutral

9
■Traveling
1) Start
Release the brake pedal and depress the accelera-
tor pedal gradually, then the tractor will begin to
move.
Acceleration varies in accordance with the
depressing of the accelerator pedal.
2) Slow down
Reducing depression of accelerator pedal slows
down travel speed.
3) Traveling with stipulated speed
Observe an appropriate stipulated travel speed in
the working place when the truck operates at facto-
ry or indoor.
4) Turning
When turning corner, slow down and turn the
steering wheel and taking care the trailers not to hit
the corner and so on. When towing the trailer, tak-
ing enough care the turning.
5) Stop
Slow down and apply the brake slowly.
6) Towing
Approach to the trailer, confirming the position of
couplers, so as to be in one line and connect the
couplers between the tractor and the trailer.
Confirm that the individual loads on the trailers are
put on securely and drawbar pins are inserted into
the coupling devices securely.
Start to drive slowly so as to decrease the loose-
ness of coupling device and drive at constant
speed. On turning at a corner, slow down before-
hand and make a large turn. On arriving the desti-
nation, loosening depression of accel pedal and
brake gradually. Avoid a sudden brake so as not to
hit the trailers each other and fall down the cargo
from the trailers.
3
DRIVING AND OPERATION
CAUTION
Slow down at the next areas.
¡At a corner
¡Approaching to load or pallet.
¡Approaching to loading area.
¡Narrow aisle area.
¡On a rough floor.
CAUTION
Do not apply brake suddenly.

10
7) Parking
When parking the tractor,
¡When getting off the tractor, correctly apply the
parking brake lever.
¡Do not park the tractor on a slope.
3DRIVING AND OPERATION
CAUTION
Remove the key swith when operator leaves
truck.

■Battery
sKeep away from fire (Explosive gas)
sPay attention to an electric shock
sConnect correctly
sKeep tools away
4
BATTERY AND CHARGER
11
CAUTION
¡This section explains NICHIYU's genuine
battery (GS made) and charger.
¡When the lift truck is equipped with another
type battery and/or charger, please follow the
instructions provided by that manufacturer.
WARNING
¡Never allow open flame to come near
the battery.
¡Explosive gas is always present within
the battery.
¡Smoking, flames, or sparks will result
in battery explosions.
CAUTION
Do not make a short circuit.
The battery has high voltage and power.
CAUTION
When servicing the battery, wear the safety
goggles, rubber gloves and boots.
CAUTION
Do not swap the positive and negative terminals.
¡It can cause sparking, burning
and/or explosion.
WARNING
Keep tools away from terminals to avoid
sparks or shorting.

12
sDo not over-discharge
sKeep clean
sWear safty clothes
sBe careful the electrolyte
4BATTERY AND CHARGER
CAUTION
Do not use the forklift truck until no longer run,
it will shorten the battery life.
¡When the battery discharge indica-
tor shows empty, charge the bat-
tery as soon as possible.
¡Electrolyte of the battery is sulfuric acid.
WARNING
¡Keep the upper surface of the battery
clean.
¡Do not use a dry cloth when cleaning,
as it may produce static electricity.
WARNING
Clean the battery before charging.
CAUTION
Wear safety goggles, rubber gloves and boots
to protect yourself.
WARNING
Be careful the electrolyte does not touch
the skin.

13
sEmergency first aid
sClose vent caps securely
sWashing
sAbnormal battery
sDo not disassemble the battery.
4
BATTERY AND CHARGER
CAUTION
The battery contains sulfuric acid which caus-
es severe burns if touched.
If an accident occurs, receive emergency first
aid and consult your physician immediately.
¡Spilled on skin:
Wash down with water for 10 to 15 minutes.
¡Splashed in eye:
Wash down with water for 10 to 15 minutes.
¡Swallowed:
Drink large amounts of milk or water.
¡Splashed on clothes:
Take off clothes immediately.
If you do not follow these instructions, you will
be seriously injured or killed.
CAUTION
Make sure all vent caps are closed securely.
Failure to close the caps can cause leaking of
electrolyte.
CAUTION
If the battery shows the following situation,
contact NICHIYU's qualified service facility or
battery manufacturer.
¡The battery stinks.
¡The electrolyte is muddy.
¡The electrolyte decreases fast.
¡The temperature of electrolyte is too high.
CAUTION
Do not drain the electrolyte, disassemble and
repair the battery.
CAUTION
Do not wash the battery on the forklift truck. It
causes damage to the truck.

14
sStorage
sDo not dispose of used batteries.
■Precautions for charging the battery
sCheck electrolyte level
¡Failure to keep proper level of the electrolyte can
cause overheating or burning of the battery and
electrical components of the forklift truck.
¡Check electrolyte level once a week.If the level is
low, add distilled water to the specific level.
sDo not over-charge.
sPay attention to an electric shock
¡ The charger has high voltage and power when working.
sCharge in well-ventilated areas.
4BATTERY AND CHARGER
CAUTION
Please contact NICHIYU's qualified service
facility or the battery manufacturer for disposal.
CAUTION
Do not use the forklift truck if the electrolyte
level is low.
CAUTION
Do not over-charge the battery.
CAUTION
Do not touch the terminal or transformer when
charging.
DANGER
¡Charge batteries only in approved and
well-ventilated areas.
¡Explosive gas comes out of the battery
while charging.If you use the local sup-
ply charger, follow its manufacturer's
instruction.
CAUTION
¡When storing the battery, store in a well-ven-
tilated and dry place.
¡
Keep the battery away from open flames or ignitions.

15
sCheck cable and plug
sCheck specific gravity
sInterruption of charge
sKinds of charge
™There are three kinds of charge.These charges are
a normal charge, a balancing charge and a supple-
mentary charge.
™Charging time depends on the discharging condition
and capacity of the battery.
™Generally, 8 to 10 hours are required to charge the
battery fully.
4
BATTERY AND CHARGER
CAUTION
Prior to charging, check the condition of the
cable and plug.
CAUTION
Do not charge the battery if cable or plug is
damaged.
CAUTION
¡When interrupting the charge, push the
STOP button of the charger before discon-
necting plugs.
¡Failure to observe this instruction can cause
a hazardous electrical shock or explosion of
the battery by sparking.
ApplicationClassification
After daily operation or
when the “ E” segment
of the battery discharge
indicator is lit.
Normal
charge
Every two weeks
(Check electrolyte level
and specific gravity )
Blancing
charge
In a recess
Supplementary
charge
Carry out the blancing
charge before storing
the battery for an
extended time. (Peri-
odical charge for
every 15 to 30 days
during storage is re-
comended.)
Charge for
storage
CAUTION
Measure the specific gravity of all cells before
charge.