Control Wiring Layout

Maintenance Instructions

Daily check Annual check

1. Check the brake, the horn and the safety buttons.
1. A thorough overhaul of the equipment should be made
once a year. Lubricate as per instructions.
2. Check that the batteries are fully charged and that the
acid level is correct in each cell. Refer to the battery
2. Clean and adjust the drive motor, pump motor and the
section in this manual for more details.
electrical system.
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.
be straightened to prevent breakdowns.

4. Change the oil in the hydraulic system to ensure smooth

Weekly check and efficient functioning
1. Lubricate as per instructions.
5. Check for the proper functioning of the pump unit and
the hydraulic seals. These should be replaced if they
2. Clean the machine completely. Special attention should be
are weak or damaged
paid to wheels and axles as threads, rags and the like
may block one or more wheels. 6. Check that all the bearings are functioning smoothly.
3. Check the acid level and charging condition of the battery. 7. Lubricate the machine as at assembly
4. Check the tyres for wear. Replace when worn out.

Additional Maintenance Instructions

Monthly check
Drive and pump motor
1. Lubricate as per instructions. Carbon brushes must be inspected for wear every 6 months
or at intervals of 500 hours of operation.
2. Tighten any loose connections, including cable and wire
connections and fitting bolts. Drive wheel
When a new drive wheel has been fitted, the wheel nuts
3. Check for brush wear in the drive and pump motor and should be tightened after 300 hours of operation at a
grind away possible irregularities so that a good contact tightening torque of 25.5 - 30Nm.
is maintained.

Lubrication Instructions
Location Description Lubricant Frequency

A Pivot bushings SAE 10 motor oil Monthly

B Wheel bearings Standard, Sealed, No lube required
Castors Grease nipple Monthly
C Channel surface Automotive chassis grease Yearly
Sl.No. Part No. Qty Description Sl.No. Part No. Qty Description D Hydraulic pump Hydrol - 68 Yearly
E Gear box SAE – 40 Yearly
70.0064 1 Control Wiring 21 70.7754 1 Logic (Controller) F Steering wheel Automotive chassis grease Monthly
1 70.7773 1 Harness Auxillary Relay 22 70.7345 1 Traction Contactor
2 70.7799 1 Harness Horn Microswitch G Lifting chain SAE – 30 Motor oil Quarter yearly
23 70.7420 1 Key Switch
3 70.7788 1 Harness Brake Microswitch 24 70.8043 1 Auxillary Relay
4 70.7786 1 Harness 25 70.7961 1 Charger Plug
5 70.7776 1 Main Harness 26 70.9621 1 Horn
6 70.7889 1 Harness BDI 27 20.2079 1 Electro Magnetic Brake
71.0221 1 Harness Fuel Guage 28 70.7431 1 Microswitch Salami
7 70.7775 1 Harness Charger Plug 29 70.7361 1 Pump Contactor
8 70.7781 1 Harness Salami Microswitch 30 70.8065 1 Battery Discharge Indicator (Optional)
9 70.7780 1 Harness Salami 70.8211 1 Battery Fuel Guage (Optional)
10 70.7774 1 Harness Key Switch 31 70.8044 1 Glass Fuse Lubrication of the Lifting chain (for stackers only)
11 70.7770 1 HarnessEMC 32 70.7472 1 Glass Fuse The lifting chain has been lubricated. Lubrication is required every six months. However if the machine is working in dust filled rooms or salt
12 70.7772 1 Harness -VE 33 70.7431 2 Salami Microswitch 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.
13 70.7777 1 Harness EMB 34 71.0217 1 SS Harness 2
14 70.7779 1 Harness Horn 35 71.0216 1 SS Harness 1 * Ensure that all contaminated grease is evacuated as new grease is pumped in.
15 70.8039 2 Diode 36 71.0218 1 SS Harness 3
16 70.8040 1 Capacitor 37 70.7438 1 Mast Limit Switch All lubrication and change of oil should be carried out by a service engineer in connection with the regular service. Regular service is
17 71.0219 1 Electronic Throttle 38 70.7418 1 Microswitch Stabiliser recommended at intervals of no more than 6 months.
18 70.7431 1 Brake Microswitch 39 70.7440 1 Magnetic Valve Recommended frequencies are for normal operating conditions. In corrosive conditions increase lubrication accordingly.
19 70.7403 1 Microswitch Safety
20 70.7431 1 Microswitch Horn

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JUN-2010 JUN-2010 Page 5
 Control Wiring
Hood, Panels & Control Panels

Part Part Number Qty. Description

1 50.1423 1 Cover
2 50.4206 1 Cover battery
3 99.9902 8 Screw
4 50.3517 1 Bracket cover
5 50.0020 1 Cover
6 50.5018 2 J Clamp
7 86.8601 2 Screw
8 70.8065 1 BDI Connection For Battery Fuel Guage
9 70.7420 1 Switch with key
10 70.7486 1 Main Switch
11 81.8121 10 Bolt
12 50.3993 1 Bracket
13 82.0041 2 Side Cover
14 90.9037 4 Bolt

Tiller Arm and Control Panel Part Part Number Qty. Description

60.0008 1 Tiller arm installation

1 60.0002 1 Tiller arm
2 60.1492 1 Panel
3 60.1493 1 Push Button
4 60.4134 1 Bracket
5 60.2192 1 Cap
6 81.8192 10 Bolt
7 81.8158 2 Bolt
8 60.3451 1 Bracket-Micro Switch
9 60.5131 2 Spring-Horn
10 70.7431 3 Micro Switch
11 86.8678 4 Screw
12 60.3452 1 Bracket-Micro Switch
13 83.8334 6 Washer NOTE FOR WIRING :
14 60.3373 2 Axle
A ---> -VE JUNCTION
15 60.5129 1 Gas Spring B,C ---> KEY SWITCH OR +VE JUNCION
16 60.2960 1 Spacer D ---> BRAKE MICROSWITCH JUNCTION NOTE FOR CONNECTORS :
17 60.4112 1 Axle
18 60.7492 2 Horn Switch CABLES ARE VIEWED FROM CABLE ENTRY
Colour Code Colour Description SIDE
19 60.1402 1 Rubber Pad
20 60.2959 1 Spacer 1WAY CONNECTOR
01 Red Key Switch
21 60.3375 1 Spacer 2WAY CONNECTOR
02 Blue B-VE
22 60.3376 1 Bolt 03 Brown Contactor Reverse 4WAY CONNECTOR
23 60.3374 1 Spacer 04 Pink Contactor Forward
05 Yellow & Green Brake Microswitch 6WAY CONNECTOR
24 60.0001 1 Throttle Frame
06 Orange Safety Reverse
25 70.7722 1 Accelerator 07 White & Black Reverse 9WAY CONNECTOR
26 60.7433 2 Toggle Switch 08 White Forward
27 60.2974 1 Plate 09 Black Wiper (0-5V)
10 Blue & White BDI (O/P -VE) 8WAY CONNECTOR
28 86.8622 2 Screw
11 Green Main Switch
29 70.7403 1 Micro Switch 12 Brown & Green BDI (I/P +VE)
30 83.8333 4 Plain Washer 13 White & Green Lowering Valve 16WAY CONNECTOR
31 81.8183 2 Bolt 14 Red & Green Pump Contactor
32 99.9925 2 Screw 15 Yellow & Red Horn
16 Red & White Salami Input
33 81.8159 2 Bolt 17 Green & Black Charger
34 86.8698 4 Screw
35 84.8444 4 Nut
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 Electrical Components
Battery
Part Part No. Qty. Description

70.0006 1 Electrical panel assembly Part Part Number Qty. Description

1 70.2124 1 Panel
2 70.7754 1 Controller 70.0055 1 Battery installation
3 70.7345 1 Contactor 1 70.7221 1 Battery
2 70.3371 1 Pawl
4 70.7361 1 Relay 3 70.8332 1 Washer
5 70.7364 1 Auxillary Relay 4 70.8685 1 Screw
6 70.1495 1 Fuse carrier 5 70.0004 1 Bracket
7 70.1494 1 Base fuse holder 6 81.8121 2 Bolt
7 50.3381 8 Bush
8 70.7473 2 Fuse 8 70.3382 4 Axle
9 70.9804 1 Copper band 9 50.1456 4 Roller
10 81.8150 3 Bolt 10 81.4208 2 Stopper
11 84.8435 3 Nut 11 81.8157 4 Bolt
12 83.8333 4 Plane Washer
12 83.8354 5 Spring Washer 13 83.8354 4 Lock Washer
13 81.8111 4 Bolt
14 83.8337 4 Spring Washer
15 84.8431 4 Nut
16 81.8127 2 Bolt
17 83.8333 2 Plain Washer
18 86.8689 4 Screw
19 87.8737 2 Bolt
20 84.8464 12 Brass Nut
21 83.8335 20 Brass Washer
22 81.8158 6 Bolt
23 70.5019 1 Cable Strut
24 70.1744 1 Heat sink compound
25 83.8334 6 Plain Washer
26 83.8353 6 Spring Washer
27 84.8457 6 Nut Operator Platform Part Part Number Qty. Description

81.0056 1 Operator platform installation

1 81.0059 1 Platform frame
2 81.1709 1 Foam Mat
Power Wiring Sl.No. Part No. Qty Description 3 81.1710 1 Rubber Mat
4 81.0057 1 Bracket-LH
70.0065 1 Power Wiring
5 81.0058 1 Bracket-RH
1 70.7756 1 Cable 1
2 70.7757 1 Cable 2 6 81.5145 12 Disc Spring
3 70.7758 1 Cable 3 7 81.8147 2 Bolt
4 70.7759 1 Cable 4 8 84.8461 2 Nyloc Nut
5 70.7760 1 Cable 5 9 83.8330 4 Washer
6 70.7761 1 Cable 6
10 83.8383 4 Washer
7 70.7762 1 Cable 7
8 70.7763 1 Cable 8 11 81.8195 4 Bolt
9 70.7764 1 Cable 9 12 81.5146 1 Torsion spring
10 70.7765 1 Cable 10 13 81.0061 1 Spring Tensioner
11 70.7766 1 Cable 11 14 87.8708 2 Bolt
12 70.7767 1 Cable 12
13 70.7768 1 Cable 13 15 83.8350 2 Washer
14 70.7769 1 Charger Plug Cable 16 08.0805 2 Pin
15 70.9804 1 Copper Band 17 81.3879 1 Axle
16 70.7505 1 Power Fuse 18 81.4101 1 Vibration isolator
17 70.7961 1 Charger Plug
19 83.8396 2 Plain Washer
18 70.7754 1 Controller
19 70.9330 1 Drive Motor 20 83.8337 2 Spring Washer
20 70.7486 1 Main Switch
21 70.7345 1 Traction Contactor
22 70.7361 1 Pump Contactor
23 70.7221 1 Battery

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 Part Part Number Qty. Description
Suspension Unit Mast assembly and Chain Wheel - FFTL Masts
20.0052 1 Drive unit & installation
1 20.4132 1 Transmission suspension
2 20.0002 4 Guide pin
3 20.3368 2 Side rail
4 20.5132 4 Spring
5 20.2191 1 Angle rail Part Part No. Qty. Description
6 20.4133 1 Bracket 40.0025C 1 Mast installation (Lift 3600 - 6000 mm)
7 81.8189 6 Bolt
1 40.0049 4 Side guide
8 20.3805 1 Steering column
9 83.8337 6 Spring Washer 2 40.0004 4 Side guide
10 81.8130 6 Bolt 3 90.3457 8 Shim (0.5mm)
11 81.8127 4 Bolt 4 90.3458 8 Shim (1.0mm)
12 87.8719 6 Bolt
5 40.3836 8 Shim (1.5mm)
13 83.8381 10 Spring Washer
14 83.8343 9 Plain Washer 6 40.0032C 1 Inner mast (Lift 3600 - 6000 mm)
15 20.3369 2 Spacer 7 40.0028C 1 Intermediate mast (Lift 3600 - 6000 mm)
16 20.3370 1 Stopper plate 8 40.0026C 1 Outer mast (Lift 3600 - 6000 mm)
17 81.8131 2 Bolt
9 81.8114 16 Bolt
18 87.8724 3 Bolt
19 87.8793 1 Bolt 10 83.8390 12 Washer
11 83.8381 16 Lock washer
Part Part Number Qty. Description 12 83.8355 10 Lock washer
13 83.8351 10 Washer
20.0065 1 Drive unit assembly
14 40.0003 8 Roller assembly
01 90.9321 1 Motor
15 40.4820 8 Roller
02 20.0013 1 Brake assembly
16 61.6150 8 Bearing
03 20.2078 1 Brake pad
17 01.0124 8 Lock ring
04 20.2079 1 Brake coil
Drive Unit 05 20.2077 4 Carbon brush
18 01.0125 8 Lock ring
19 40.0023 1 Chain wheel assembly
06 87.8789 3 Bolt
20 40.3809 2 Chain wheel
07 83.8354 3 Spring Washer
21 81.8194 8 Bolt
08 21.0005 1 Drive wheel (5 Holes)
22 86.8636 4 Screw
08 21.0005C1 1 Drive wheel (6 Holes)
23 83.8344 4 Washer
09 83.8355 6 Spring Washer
24 40.3808 2 Axle
10 81.8176 6 Bolt
25 08.0837 4 Pin-Dowel
11 61.6123 1 Flange bearing
26 40.3386 2 Chain Adjuster
12 20.9334 1 Armature
27 40.3387 2 Axle
13 20.9335 1 Rocker assy
28 08.0864 4 Cotter pin
29 40.3838 1 Chain Adjuster
30 40.8252C 1 Chain (Lift 3600 - 6000 mm)
Load Wheel & Support wheel 31 40.8253C 1 Chain (Lift 3600 - 6000 mm)
Part Part No. Qty. Description
32 84.8459 8 Nut
1 50.0003 2 Load wheel unit 33 84.8461 3 Nut
2 50.0002 4 Load wheel unit 34 81.8114 2 Bolt
3 50.1536 4 Load wheel 35 30.3456 1 Clamp
4 61.6101 8 Bearing
36 40.2937 2 Clamp
5 50.3208 4 Axle
37 40.3835 1 Axle
6 50.3207 4 Bushing
38 08.0864 2 Cotter pin
7 50.3209 4 Pin
8 08.0808 12 Pin 39 81.8115 2 Bolt
9 50.2408 4 Side member 40 83.8343 2 Nut
10 20.0007 2 Support wheel unit 41 84.8463 2 Washer
11 20.0005 1 Bracket 42 40.0002 1 Chain wheel assembly
12 20.0006 1 Support wheel unit 43 40.3829 1 Spacer
13 20.1535 1 Support wheel 44 40.3828 1 Chain wheel
14 61.6101 2 Bearing 45 61.6107 2 Bearing
15 20.3377 1 Bushing 46 01.0130 1 Lock ring
16 20.3378 2 Spacer
47 40.0035 1 Cross Head
17 81.8179 1 Bolt
48 81.8132 1 Bolt
18 84.8405 1 Nut
49 84.8483 1 Nut
19 81.8194 4 Bolt
20 83.8383 4 Lock washer Note: *Please Specify Roller Diameter
21 83.8330 4 Washer

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 Carriage Part Part No. Qty. Description
Mast assembly and Chain Wheel - FFL Masts
90.0025 1 Carriage Installation
1 90.0016 1 Carriage
2 41.0027 4 Roller assembly
3 40.4819 4 Roller*
4 61.6150 4 Bearing*
5 01.0124 4 Lock ring
6 01.0125 4 Lock ring
7 90.4821 2 Eccentric pin
8 84.8466 2 Nut
9 84.8459 6 Nut
10 40.0004 4 Side guide
11 40.3457 4 Shim (0.5 mm)
12 40.3458 4 Shim (1.0 mm)
13 81.8178 8 Bolt
14 83.8344 8 Washer
15 84.8460 8 Lock nut
16 40.3386 2 Chain adjuster
17 82.8299 1 Chain link
18 84.8463 3 Nut
19 81.8154 2 Bolt
20 40.3387 2 Axle
21 08.0864 2 Cotter pin

Part Part No. Qty. Description Adjustable Carriage ( for - W versions)

40.0025C 1 Mast installation (Lift 2850 - 3350 mm)
1 40.0002 4 Side guide
2 40.0004 4 Side guide Part Part No. Qty. Description
3 90.3457 8 Shim (0.5mm)
1 90.0020 1 Carriage installation
4 90.3458 8 Shim (1.0mm)
2 90.0021 2 Straddle
5 40.3836 8 Shim (1.5mm)
3 90.4821 2 Eccentric Pin
6 40.0045C 1 Inner mast (Lift 2850 - 3350 mm)
4 41.0027 4 Roller assembly
7 41.0045C 1 Outer mast (Lift 2850 - 3350 mm)
5 40.4819 4 Roller*
8 41.5331 1 Cross Head
6 61.6150 4 Bearing*
9 87.8706 8 Bolt
7 01.0124 4 Lock ring
10 83.8332 12 Washer 8 01.0125 4 Lock ring
11 83.8381 16 Lock washer 9 40.0004 4 Side guide
12 83.8330 10 Washer 10 40.3457 4 Shim (0.5mm)
13 83.8343 8 Washer 11 40.3458 4 Shim (1.0mm)
14 41.0027 8 Roller assembly* 12 81.8178 8 Bolt
15 40.4819 8 Roller* 13 84.8466 2 Lock nut
16 61.6150 8 Bearing* 14 84.8460 8 Lock nut
17 01.0124 8 Lock ring 15 84.8459 6 Nut
18 01.0125 8 Lock ring 16 40.3386 2 Chain adjuster
19 81.8194 8 Bolt 17 08.0864 4 Cotter pin
20 81.8142 1 Bolt 18 40.3387 2 Axle
21 83.8396 1 Washer 19 81.8154 2 Bolt
22 86.8636 4 Screw 20 84.8463 2 Nut
23 40.3386 2 Chain Adjuster 21 82.8299 2 Chain link
24 40.3387 2 Axle
25 08.0864 4 Pin-Dowel
Note: *Please Specify Roller Diameter
26 40.8252 1 Chain (Lift 2450 mm-3350 mm)
27 41.0036 2 Chain Wheel Assembly
28 40.4787 2 Chain Wheel
29 41.5333 1 Clamp
30 40.2937 2 Clamp
31 81.8168 8 Bolt
Note: *Please Specify Roller Diameter 32 81.8172 2 Bolt

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 Mast assembly and Chain Wheel - MONO Masts Mast assembly and Chain Wheel - FFTL Masts
Part Part No. Qty. Description
Part Part No. Qty. Description
1 40.0016 1 Mast assembly 40.0025C 1 Mast installation (Lift 3600 - 6000 mm)
2 87.8705 1 Bolt
1 40.0002 4 Side guide
3 81.8177 8 Bolt
2 40.0004 4 Side guide
4 83.8330 8 Washer
5 83.8355 8 Lock Washer 3 90.3457 8 Shim (0.5mm)
6 41.0036 2 Chain wheel assembly 4 90.3458 8 Shim (1.0mm)
7 41.4787 1 Chain wheel 5 40.3836 8 Shim (1.5mm)
8 61.6150 2 Bearing 6 41.0046C 1 Inner mast (Lift 3600 - 6000 mm)
9 01.0124 2 Lock ring 7 41.0045C 1 Intermediate mast (Lift 3600 - 6000 mm)
10 01.0125 2 Lock ring
8 41.0044C 1 Outer mast (Lift 3600 - 6000 mm)
11 41.5331 1 Cross Head
9 87.8706 8 Bolt
12 81.8172 2 Bolt
13 41.5333 1 Clamp 10 83.8332 12 Washer
14 83.8396 1 Washer 11 83.8381 16 Lock washer
15 83.8343 1 Washer 12 83.8330 10 Washer
16 40.3386 2 Cotter pin 13 83.8343 8 Washer
17 81.8148 1 Bolt 14 41.0028 8 Roller assembly*
18 40.3387 2 Axle 15 40.4820 8 Roller*
19 08.0864 4 Cotter pin 16 61.6150 8 Bearing*
20 40.8252C 1 Chain (Lift 1600 mm ) 17 01.0124 8 Lock ring
18 01.0125 8 Lock ring
19 40.0023 1 Chain wheel assembly
Mast assembly and Chain Wheel - TELESCOPIC & FFL Masts 20 40.3809 2 Chain wheel
Part Part No. Qty. Description 21 81.8177 8 Bolt
40.0018C 1 Mast installation (Lift 2450 - 4800 mm) 22 86.8636 4 Screw
40.0048C 1 Mast installation (Lift 2850 - 3350 mm) 23 83.8344 4 Washer
1 41.0009C 1 Outer mast (Lift 2450 - 4800 mm) 24 40.3808 2 Axle
2 41.0008C 1 Inner mast (Lift 2450 - 4800 mm) 25 08.0837 4 Pin-Dowel
2 40.0045C 1 Inner mast (Lift 2850 - 3350 mm)
26 40.3386 2 Chain Adjuster
3 40.0023 2 Chain wheel assembly
4 40.3809 1 Chain wheel 27 40.3387 2 Axle
5 61.6105 1 Bearing 28 08.0864 4 Cotter pin
6 01.0124 1 Lock ring 29 41.0036 2 Chain Wheel Assembly
7 83.8344 2 Washer 30 40.8252C 1 Chain (Lift 3600 - 6000 mm)
8 40.3808 1 Axle
31 40.4787 2 Chain Wheel
9 08.0837 4 Pin - Dowel
10 40.3386 2 Chain adjuster 32 84.8459 12 Nut
11 84.8459 6 Nut 33 41.5331 1 Cross Head
12 40.8252 1 Chain (Lift 2450 - 4800 mm) 34 81.8172 2 Bolt
13 40.0049 2 Side guide 35 41.5333 1 Clamp
14 40.3457 4 Shim (0.5mm)
36 40.2937 2 Clamp
15 40.3458 4 Shim (1.0mm)
16 86.8636 4 Screw 37 83.8396 1 Washer
17 81.8114 16 Bolt 38 81.8142 1 Bolt
18 83.8381 8 Lock washer 39 87.8774 2 Bolt
19 83.8390 16 Washer 40 81.8168 8 Bolt
20 81.8194 8 Bolt
41 81.8142 1 Bolt
21 83.8355 8 Lock washer
22 83.8351 8 Washer
23 40.1469 2 Guide piece
24 83.8343 4 Lock washer Note: *Please Specify Roller Diameter
25 81.8113 4 Bolt
26 40.0004 2 Side guide
27 01.0125 4 Lock ring
28 41.0027 4 Roller assembly*
29 40.4819 4 Roller*
30 61.6150 4 Bearing*
31 01.0124 4 Lock ring
32 40.2937 2 Clamp
33 40.3387 2 Axle
34 08.0864 4 Cotter pin

Note: *Please Specify Roller Diameter

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