Battery 2. Connect the battery to the charger.

3. Switch on the charger, then the POWER ON lamp will light and
The battery is the energy source of the equipment and the performance of POWER LED will come ON. Power Wiring
the functions is highly dependent upon the condition of the battery. It is 4. The charger will run a self test program - all the LED’s will come ON
therefore of vital importance to the operation of the equipment that the one by one and go OFF.
battery is maintained according to the instructions of the battery manufacturer. 5. After ensuring that the AC input supply is healthy, the charger will
The battery should be fully charged every day at the start of work. The check whether the battery voltage lies within 1.2V / cell and 2.90V/cell,
following routine checks are recommended for a better life of the battery. If so, Charging will comence and CHARGING LED will come ON.
Electrolyte level
6. During charging, LED display is illuminated it indicates the % rated
Check at least once a week that the electrolyte level is at the correct level. charging current and the charging begins with constant current mode.
The electrolyte specific gravity at 25° C is shown below for the corresponding 7. “80% CHARGED” Amber LED will come on when the battery voltage
state of discharge has reached 2.40V / cell. At this point the constant current mode will
Remaining battery Specific gravity change to taper mode. The charge controller will taper battery current
capacity in g /cm3 while the voltage builds up naturally. The finishing current will be 40%
100 % 1.290 of starting current at 2.7V / cell.
75 % 1.240 8. The controller evaluates the state of the charge in the post gassing
50 % 1.180 period by the dv/dt method. When the voltage is found to be constant
20 % 1.150 within a specified window for a period of time, the controller terminates
the charging.
Refilling 9. In the charged condition “ CHARGED” LED will illuminate.
Only distilled water should be used for refilling. Refilling should be 10. The charging is now complete. The charger should be switched
undertaken only after the charging has been completed. This is because OFF before disconnecting the battery.
the electrolyte tends to expand during charging and will other wise run over. 11. If the battery is fully charged and is not required for immediate
Cleaning service, leave the battery connected to the charger with the switch ON.
The charger wil deliver Refreshing charge at regular itervals (10
The battery surface must be kept clean. Remove any spilled electrolyte with minutes for every 6 hours) to maintain the battery in a fully charged
the cloth with dissolved soda or ammonia and rinse with water. No dust and condition.
dirt must be allowed to deposit on the battery surface. They may carry so- The CHARGING LED flashes to indicate that the charger is performing
called leak currents between the poles of the element. REFRESH charging.
Battery Poles
Maintain clean battery surface and remove any sulphate deposits by grinding. HF1 Charger
Such deposits may result in considerable loss of voltage. Grease the poles Operator controls and Indications
with acid-free grease and always ensure that the cable terminals are tightened
securely to the battery poles. Power on Switch
This switch isolates the power to the control circuit.
Battery Charger LED Descriptions
The battery charger is for charging traction batteries only. The charger is Charging / Refreshing
electronically protected against over current, short circuit and reverse battery Charging - This green LED will come ON after 3 seconds delay.Charging
connection. The charging profile is constant current followed by a forced has now started.
taper with dv/dt sensing to evaluate the 100 % charged condition.
Technical information Refreshing - This green LED flashes to indicate that the charger is
Input Voltage/Frequency 230 V +10 %/-15 %, 50 Hz performing REFRESHING charge.
Charging Time 8 Hrs for a 80 % discharged 80% Charged / Override
C-5 Battery 80% charged - The yellow LED will come ON when the battery is
Battery operating temp. 0° to 40 ° C approximately 80% charged.
Relative Humidity 90 % This LED will also on when battery received 7 hours voltage did not
Installation and Commissioning reach 2.40V/cell within this period, the charger switched to taper mode.
Receiving Charger Override - The yellow LED flashes. This indicates that the battery is not
When received, the charger should be unpacked and checked for any accepting chare or that the HF1 charger and the battery Ah capacity is
transit damage. Check/tighten the mounting bolts of the main transformer not matched.
Location of Charger Charged / Equalising
Install the charger in a cool, dry, well ventilated location away from corrosive Charged - Green LED comes fully charged.
fumes and steamy atmospheres. Allow 200mm free space on all sides for Equalising - Flashing Green LED indicate charger in equalising
proper ventilation. mode.
DC Fault / Over temperature
LMP1 Charger 1. No battery connected or battery connector not matched properly or
battery voltage does not fall within 1.80V/cell and 2.90V/cell
Operator controls and Indications 2. The same DC fault indication will come on when battery
Rocer Switch connected in reverse or if the outputs DC fuse blow.
This switch isolates the power to the control circuit. Over temperature - The yellow will be ON if the charger is over the
LED Indications limits.
There are two sets of LEDs. AC Fault
CHARGER STATUS : This indicates the charging status. The Red LED will come ON if
AMPS : This set of 5 LED’s Indicates the % rated Charging current. The mains AC supply below 170V AC or above 265V AC.
Charger Status LED’s The charger will stop charging automatically when the AC supply in
Power ON between limits.
Put the Rocker switch ON. The POWER ON LED will come ON and all the PCB Fault
other LED’s will come ON and go OFF. This is a SELF TEST for the PCB. This LED will come ON in case of electronics failure or if Sl.No. Part No. Qty Description Sl.No. Part No. Qty Description
Charging / Refreshing AC voltage is below 150V ac.
The GREEN LED will come ON after 3 seconds delay. Charging has now Operation
started. The set of 5 LED’s indicates the CHARGING CURRENT. The The charger has two modes of operations Normal mode and 70.0065 1 Power wiring 12 70.7767 1 Cable 12
Charger will charge even if the battery is deeply discharged (1.2V/cell). If Equalising mode.
no battery or wrong voltage battery or very deeply discharged battery 1 70.7756 1 Cable 1 13 70.7768 1 Cable 13
Normal mode
(below 1.2V/cell) is connected charging will not start. Refreshing LED will 1. Put switch in normal condition. 2 70.7757 1 Cable 2 14 70.7769 1 Charger Plug Cable
flash when charger is delivering a refreshing charge at periodic intervals. 2. Connect charger charging plug to vehicle battery plug.
3 70.7758 1 Cable 3 15 70.9804 1 Copper Band
80% Charged / DC Fault 3. Put the MCB on front panal charging to vehicle battery plug.
The AMBER LED will come ON when the battery voltage reaches 2.4V / 4. Charging will start after5-8 secs. In this time a self check will be 4 70.7759 1 Cable 4 16 70.7505 1 Power Fuse
cell. done. 17 70.7961 1 Charger Plug
This means the battery is approximately 80% charged. The charge 5. Charging will end with the green LED ON. 5 70.7760 1 Cable 5
controller will now start tapering the battery current. This LED will flash Equalising mode 6 70.7761 1 Cable 6 18 70.7754 1 Controller
(DC FAULT) if battery voltage is below 1.2V / cell or wrong polarity. 1. Put switch in equalising position. 19 70.9330 1 Drive Motor
Charged / Override 2. Charging will start and complete. Green LED will come ON. then 7 70.7762 1 Cable 7
The RED LED will come ON when the battery is 100% charged. The LMP equalising will start. 8 70.7763 1 Cable 8 20 70.7486 1 Main Switch
will automatically stop the charging. The battery is now ready for use. 3. Green LED will be flashing when equalising is in progress. 21 70.7345 1 Traction Contactor
This RED LED will Flash (OVERRIDE) if 100% charged condition is not 9 70.7764 1 Cable 9
Maintenance 22 70.7361 1 Pump Contactor
reached within the 6 hours after 80% CHARGED is reached. This 1. Put it in safe, ventilative, clean and no drenching place. 10 70.7765 1 Cable 10
indicates that the battery is not accepting charge (Please check with 2. Don’t open the case when charging. 23 70.7245 1 Battery
battery manefacturer) or the LMP charger and the battery are not 11 70.7766 1 Cable 11
3. Don’t open the case except professionl workers.
matched. 4. Packaged putting when long time not used.
Description of Operation 5. During recharging, super-voltage or sub-voltage, i.e. voltage range
1. Ensure that the battery is suitably matched to the charger output is out of 185V~255V for 220V,323V~437V for 380V. In protection
specification. status, fault light would signal the user. Charging would auto-
continue when voltage was back in the working range.
Page 4 JUN-2010 JUN-2010 For prompt service, please mention the correct part numbers in all your enquiries. Page 13
 Electrical Components
Maintenance Instructions
Part Part No. Qty. Description
Daily check Annual check
70.0006 1 Electrical panel assembly
1 70.2124 1 Panel 1. Check the brake, the horn and the safety buttons.
1. A thorough overhaul of the equipment should be made
2 70.7754 1 Controller once a year. Lubricate as per instructions.
2. Check that the batteries are fully charged and that the
3 70.7345 1 Contactor
acid level is correct in each cell. Refer to the battery
4 70.7361 1 Relay 2. Clean and adjust the drive motor, pump motor and the
section in this manual for more details.
electrical system.
5 70.7364 1 Auxillary Relay
6 70.1495 1 Fuse carrier 3. Lift the carriage to its top position to check that there is
3. Check for any bends in the forks or frame. These should
enough hydraulic oil in the system.
7 70.1494 1 Base fuse holder be straightened to prevent breakdowns.
8 70.7473 2 Fuse
4. Change the oil in the hydraulic system to ensure smooth
9 70.9804 1 Copper band Weekly check and efficient functioning
10 81.8150 3 Bolt
1. Lubricate as per instructions.
11 84.8435 3 Nut 5. Check for the proper functioning of the pump unit and
12 83.8354 5 Spring Washer the hydraulic seals. These should be replaced if they
2. Clean the machine completely. Special attention should be
are weak or damaged
13 81.8111 4 Bolt paid to wheels and axles as threads, rags and the like
14 83.8337 4 Spring Washer may block one or more wheels. 6. Check that all the bearings are functioning smoothly.
15 84.8431 4 Nut
3. Check the acid level and charging condition of the battery. 7. Lubricate the machine as at assembly
16 81.8127 2 Bolt
17 83.8333 2 Plain Washer 4. Check the tyres for wear. Replace when worn out.
18 86.8689 4 Screw
Additional Maintenance Instructions
19 87.8737 2 Bolt
Monthly check
20 84.8464 12 Brass Nut
Drive and pump motor
21 83.8335 20 Brass Washer 1. Lubricate as per instructions.
Carbon brushes must be inspected for wear every 6 months
22 81.8158 6 Bolt
or at intervals of 500 hours of operation.
23 70.5019 1 Cable Strut 2. Tighten any loose connections, including cable and wire
connections and fitting bolts.
24 70.1744 1 Heat sink compound Drive wheel
25 83.8334 6 Plain Washer 3. Check for brush wear in the drive and pump motor and When a new drive wheel has been fitted, the wheel nuts
26 83.8353 6 Spring Washer grind away possible irregularities so that a good contact should be tightened after 300 hours of operation at a
is maintained. tightening torque of 25.5 - 30Nm.
27 84.8457 6 Nut

Support wheel Lubrication Instructions

Location Description Lubricant Frequency

A Pivot bushings SAE 10 motor oil Monthly

B Wheel bearings Standard, Sealed, No lube required
Part Part Number Qty. Description Castors Grease nipple Monthly
C Channel surface Automotive chassis grease Yearly
20.0007 1 Support wheel D Hydraulic pump Hydrol - 68 Yearly
01 20.1535 1 Support Wheel E Gear box SAE – 40 Yearly
02 61.6101 2 Bearing F Suspension column SAE - 10 motor oil Monthly
03 20.3377 1 Bushing
04 20.3378 2 Spacer
05 81.8179 2 Bolt
06 84.8459 1 Nut
07 83.8330 4 Plain Washer
08 83.8355 4 Spring Washer
09 81.8177 4 Bolt Lubrication of the Lifting chain (for stackers only)
10 85.8502 1 Grease Nipple The lifting chain has been lubricated. Lubrication is required every six months. However if the machine is working in dust filled rooms or salt
11 20.0006 1 Support Wheel assembly vapor, the lifting chain should be lubricated more often. The chain should be cleaned/dried with an oilcloth and lubricated with motor oil SAE 30.
12 20.0005 1 Bracket
* Ensure that all contaminated grease is evacuated as new grease is pumped in.
All lubrication and change of oil should be carried out by a service engineer in connection with the regular service. Regular service is
recommended at intervals of no more than 6 months.
Recommended frequencies are for normal operating conditions. In corrosive conditions increase lubrication accordingly.

Page 12 JUN-2010 Page 5

For prompt service, please mention the correct part numbers in all your enquiries. JUN-2010
 Hood, Panels and Control Panels Mast assembly and Installation - TELESCOPIC Masts

Part Part No. Qty. Description

Part Part Number Qty. Description
40.0084 1 Mast assy & installation
01 50.1499 1 Front Cover
01 90.0002 2 Side guide
02 81.8121 10 Bolt
02 40.0004 2 Side guide
03 86.8616 4 Screw
03 40.3458 4 Shim (1.0mm)
04 50.3455 1 Cover bottom
04 40.3457 4 Shim (0.5mm)
05 87.8756 4 Bolt
05 40.4058 4 Guide piece
06 82.0037 2 Battery Stopper welded
06 40.0058 1 Outer mast (Lift Ht-2000 to 2850)
07 50.4206 1 Cover Battery
06 40.0060 1 Outer mast (Lift Ht-3100,3350 & 4500)
08 99.9902 8 Screw
06 40.0092 1 Outer mast (Lift Ht-3600 to 3900)
09 81.2109 1 Mast Shield (Lift-1600 to 4500)
06 40.0093 1 Outer mast (Lift Ht-4200)
09 81.2132 1 Mast Shield (Lift-1600 to 4500)
07 41.0018 1 Inner mast (Lift Ht-2000 to 4500)
10 83.8343 6 Plain washer
08 01.0125 4 Circlip
11 81.8168 6 Bolt
09 01.0124 4 Circlip
12 50.3474 1 Instrumental Panel
10 87.8706 4 Bolt
13 70.7486 1 Main Switch
11 81.8113 4 Bolt
14 70.7420 1 Switch with Key
12 83.8343 12 Plain washer
15 70.8065 1 BDI
13 83.8381 8 Spring washer
16 50.1751 1 Cover top
14 83.8332 4 Plain washer
17 50.5018 2 J Clamp
15 61.6150 4 Bearing
18 86.8601 2 Screw
16 40.4819 4 Roller
*
19 50.3517 1 Bracket Cover Note : Specify Roller Dia
* 17 41.0027 4
*
Roller assy
*
Page 6 For prompt service, please mention the correct part numbers in all your enquiries. JUN-2010 JUN-2010 For prompt service, please mention the correct part numbers in all your enquiries. Page 11
 Carriage Installation Tiller Arm and Control Panel
Part Part Number Qty. Description

60.0008 1 Tiller arm installation

Part Part Number Qty. Description
1 60.0002 1 Tiller arm
2 60.1492 1 Panel
91.0007 1 Carriage installation
3 60.1493 1 Push Button
01 90.0001 1 Carriage
4 60.4134 1 Bracket
02 40.0004 4 Side Guide
5 60.2192 1 Cap
03 90.3457 4 Shim (0.5mm)
6 81.8192 10 Bolt
04 90.3458 4 Shim (1.0mm)
7 81.8158 2 Bolt
05 90.4821 2 Eccentric Pin
06 40.4819 4 Roller
* 8 60.3451 1 Bracket-Micro Switch
07 61.6150 4
*
Bearing 9 60.5131 2 Spring-Horn
08 01.0124 4 Circlip
* 10 70.7431 3 Micro Switch
09 01.0125 4 Circlip 11 86.8678 4 Screw
10 84.8466 2 Nyloc Nut 12 60.3452 1 Bracket-Micro Switch
11 81.8178 8 Bolt 13 83.8334 6 Washer
12 84.8460 8 Nyloc Nut 14 60.3373 2 Axle
13 41.0027 4 Roller assembly 15 60.5129 1 Gas Spring
14 81.8154 2 Bolt
* 16 60.2960 1 Spacer
15 84.8463 2 Nyloc Nut 17 60.4112 1 Axle
16 82.8299 8 Chain Link 18 60.7492 2 Horn Switch
19 60.1402 1 Rubber Pad
Note :
Lift Chain and Mast Installation * Specify Roller dia 20 60.2959 1 Spacer
21 60.3375 1 Spacer
22 60.3376 1 Bolt
23 60.3374 1 Spacer
24 60.0001 1 Throttle Frame
Part Part Number Qty. Description 25 70.7722 1 Accelerator
26 60.7433 2 Toggle Switch
01 30.0078 1 Cylinder tube 27 60.2974 1 Plate
02 30.0079 1 Piston rod 28 86.8622 2 Screw
03 30.4068 1 Cylinder head 29 70.7403 1 Micro Switch
04 30.4069 1 Wiper 30 83.8333 4 Plain Washer
05 30.1225 1 U Sleeve 31 81.8183 2 Bolt
06 30.1256 1 Guide ring 32 99.9925 2 Screw
07 30.0089 1 Clamp
33 81.8159 2 Bolt
08 40.5144 1 Spring
34 86.8698 4 Screw
09 84.8434 2 Nut
35 84.8444 4 Nut
10 84.8463 2 Nut Nyloc Suspension
11 40.3387 2 Clevis pin
12 40.3386 2 Chain adjuster
13 40.0082 2 Chain wheel assy
14 40.4071 2 Chain wheel
15 61.6140 2 Bearing
16 01.0156 2 Circlip
Part Part Number Qty. Description
17 82.8265 2 Chain
18 40.4072 1 Cross head
01 20.0077 1 Guide Assembly
19 08.0872 2 Dowel pin
02 21.0002 1 Bracket
20 08.0873 2 Split pin
03 20.2053 4 Bush
21 84.8459 6 Nut
04 20.4131 2 Suspenssion Rod
22 30.0246 1 Cylinder Clamp
05 20.5132 4 Spring
23 83.8332 2 Plain washer
06 20.0002 4 Guide Pin
24 84.8460 2 Nut Nyloc
07 01.0130 4 Circlip
25 81.8177 8 Bolt
08 81.8177 3 Bolt
26 83.8330 8 Plain washer
09 83.8330 3 Plane Washer
27 83.8355 8 Spring washer
10 83.8355 3 Spring Washer
28 40.0052 1 Outer mast welded
29 31.0001 1 Seal kit

Page 10 For prompt service, please mention the correct part numbers in all your enquiries. JUN-2010 JUN-2010 For prompt service, please mention the correct part numbers in all your enquiries. Page 7
 Drive Unit and Drive Wheel Hydraulic System

Part Part Number Qty. Description

01 10.9404 1 Cotrol valve-1

02 10.0018 1 Pump motor installation
Part Part Number Qty. Description
03 10.9124 1 PMS elbow
20.0080 1 Steering columnn installation 04 10.9166 2 Elbow
1 20.0079 1 Steering column 05 10.9164 1 Elbow
2 20.4868 1 Plumer block 06 10.9180 1 Hose
3 20.0081 1 Cross Bar 07 10.9147 1 Nipple
4 83.8396 2 Plain washer 08 10.9148 1 Banzo
5 83.8303 2 Spring washer 09 10.9562 1 Hose
6 87.8788 2 Bolt 10 10.9568 1 Pipe
7 99.9934 4 Screw 11 10.9183 1 Hose
8 20.4012 1 Spacer ring 12 10.9165 1 Nipple
9 61.6133 1 Bearing 13 10.9123 1 Lowering brake valve
10 61.6132 1 Bearing 14 10.9179 1 Nipple
11 20.3161 1 Spacer ring 15 10.9181 1 Elbow
12 83.8339 1 Lock washer 16 30.0065 1 Cylinder
13 84.8436 1 Lock nut
14 21.0008 1 Steering pivot
15 08.0809 1 Dowel pin
16 20.0018 1 Drive unit & wheel
17 83.8343 1 Washer Battery
18 83.8381 4 Spring Washer
19 81.8154 4 Bolt
20 20.1711 1 Bush
21 20.1756 1 P U Pad
Part Part Number Qty. Description

01 70.7245 1 Battery
02 70.3371 1 Pawl
03 83.8332 1 Washer
04 86.8685 1 Screw
05 70.0040 1 Bracket
06 81.8121 2 Bolt
07 50.3381 8 Bushing
08 50.3382 4 Axle
09 50.1446 4 Roller
10 50.0004 4 Battery roller assy

Drive Wheel
Load Wheel Assembly

Part Part Number Qty. Description

Part Part Number Qty. Description
50.0003 1 Load wheel assembly
20.0018 1 Drive unit assembly
1 50.0002 4 Load wheel unit
1 20.9303 1 Drive unit
2 50.1536 4 Load wheel
2 20.1533 1 Drive Wheel
3 50.6101 8 Bearing
3 20.7001 1 Brake
4 50.3208 4 Axle
4 86.8633 8 Screw
5 50.3209 4 Pin
6 50.3207 4 Bushing
7 08.0808 12 Pin
8 50.2408 4 Side member

Page 8
For prompt service, please mention the correct part numbers in all your enquiries. JUN-2010 JUN-2010 For prompt service, please mention the correct part numbers in all your enquiries. Page 9