BATTERY OPERATED

PALLET TRUCK

SERVICE MANUAL
&
SPARE PARTS LIST

MODEL :- MXBPT20SP CAPACITY : 2000KGS

SR. NO .:- 2012/12/0117 & 18 LIFT HIGHT : 300mm

BOPT
A DESPATCH & UNLOADING

1. Unless specified in the Purchase order, the BOPT shall be dispatched suitably packed
for protecting paint and instrument panel and dispatched by road through the
company’s regular transporter.

2. Under special instruction, the cruiser is packed and anchored to pallets.

3. Loading, for dispatch, will be our responsibility. On receipt of the cruiser at site, please
check and ensure that there is no physical damage to the equipment.

4. While unloading the equipment from the transporting vehicle, please ensure to use
slings with rated capacity higher than the gross weight of the cruiser in packed
condition.

5. Slings MUST be hooked ONLY at specified positions. These positions are indicated
and marked with a figure of ‘HOOK’. Improper sling position or improper slinging
could cause damage to the equipment.

B. ORDERING OF SPARES

1. When ordering for spare, please specify the following in your Purchase Order.

• Equipment Name
• Model Number
• Equipment Serial No.
• Part name / Description
• Part Number
• Quantity required
• Delivery period / time
• Mode of dispatch

This would avoid ambiguity and help us serve you better.

BOPT

2
1.0.0 GENERAL INSTRUCTIONS

1.1.0 Important

1.1.1 All designated operators of this equipment must read, understand and familiarize
themselves with the content of this manual before operating the equipment.

1.1.2 No modification or alteration to the equipment or its part may be done, either
temporarily or as a permanent measure, without the written consent of the
manufacture, M/s. MHE Next Pvt. Ltd. Any violation of this requirement would
void the warranty on the equipment.

1.2.0 Responsibility

1.2.1 The equipment should be handled with care and always driven in a responsible
manner.

1.2.2 Follow all safety norms, in vogue, when operating the equipment.

1.2.3 Not adhering to correct operating procedures or maintenance and carrying out
repairs to the equipment through person not qualified or trained by the company
may result in damage to the equipment. When necessary, call for our technical
assistance.

1.2.4 Check the equipment and its functioning, everyday, prior to starting your work.
Do not operate the equipment if any defect is noted. Report the defect to your
superior.

1.2.5 Always ensure that the specification label is on the equipment and is legible. Note
the rated capacity of the equipment and NEVER overload the equipment.

Caution!
This is mobile equipment and is venerable while in motion on uneven ground
surfaces, gradients and sharp turns. Any damage may impart steering and/or drive
movements.

BOPT

3
1.3.0 Working Area

1.3.1 The equipment is designed for working on even, fairly smooth and hard surface
only. The ground surface should be capable of withstanding the 1.5 times the
weight of the equipment (1400 Kgs) plus the maximum load rated capacity of the
equipment.

1.3.2 Take care and exercise caution in areas with protrusions from racks, shelf or wall
which could possible cause damage to the equipment.

1.3.3 Presence of other living being should not be permitted within the path or in the area
where material is being moved, lifted and unloaded / stacked.

1.4.0 Operating the equipment

1.4.1 Do not operate the equipment unless you are familiar with the controls and
operating procedure and are confident of handling the equipment.

1.4.2 Only authorized and trained personnel should operate / drive the equipment.

1.4.3 Do not carry passengers. The equipment is not designed for this.

1.4.4 Observe applicable traffic regulations even within the factory. Slow down and
sound horn at intersections and at areas where visions is obstructed.

1.4.5 Never exceed the rated capacity of the equipment. The capacity is mentioned on
the nameplate.

1.4.6 Avoid driving around corners at high speed, both when laden and unlade. The
equipment behaves differently under these conditions.

1.4.7 Do not take fast turns on inclines; this will increase the possibility of the equipment
overturning.

1.4.8 Asses swing clearance when turning near walls, racks, pillars or any other
obstruction.

1.4.9 Ensure safe distance from edge of loading ramps. Observe caution at marked risk
areas. When working with loading ramps, ensure that the ramp is secure and rated
for the weight being moved. Always drive slowly over ramps.

1.4.10 Any accident caused during operation, either to the equipment or any person,
should be promptly reported to the superior.

BOPT

4
2.0.0 OPERATING

2.1.0 Starting

2.1.1 Insert the connector half on the battery and the control to provide poser to the drive
unit and release the emergency cut-off switch.

2.1.2 Insert key in the ignition switch and switch it ‘ON’.

2.1.3 Check charge of batter. This will be indicated by a series of green LED on the
panel.

2.1.4 Move the Tiller Arm down, position, to drive position. A click sound indicates the
connecting of the main contactor.

2.1.5 The direction of movement is controlled by the F/R (forward/reverse) lever.

Turning the F/R lever clockwise, the BOPT will move forward while turning the
lever anti-clockwise, the cruiser will move in the backward direction.

2.1.6 The turning of the F/R lever releases the electro-magnetic security brake which is
normally locked when in neutral position.

2.1.7 The speed of the BOPT depends on the extent of turning of the F/R lever from its
neutral position. The speed is higher at higher displacement.

2.1.8 The forks are operated by the control lever or push button on the tiller arm. Pull the
lever towards to raise the forks and push the lever to lower the forks. In case of
push button type push the lift button to lift and push the lower button to lower the
forks

NOTE

The BOPT will not move if the F/R switch is operated without lowering the handle.
Please follow the sequence given above for proper operating of the cruiser.

2.2.0 Braking

2.2.1 Braking for slowing down, is suggested to be done by reversing the direction of the
main drive motor. The brake is to be activated by changing the position of the F/R
lever. The speed of the reversal of motor direction is controlled by the electronic
speed controller which is adjustable.

BOPT

5
2.2.3 Electro-magnetic brakes have been provided as standard braking which is activated
when the steering handle is released. The handle, on release, swings back to its
vertical position by spring action provided for this purpose and brings the BOPT to
an immediate stop.

Keeping the handle in the vertical position also acts as parking brake.

2.2.3 The electro-magnetic brake will not be released if the battery is not connected or
has run down. In these conditions the drive wheel is locked. To move the BOPT
without battery or with a run down battery the brake will have to be mechanically
released.

2.3.0 Forks

The equipment is equipped with either fixed forks as per your specified
requirement.

3.0.0 USING THE BOPT

3.1.0 Drive a loaded BOPT always with the care and avoid sudden starts and stops.

3.2.0 Placing load on the BOPT for lowering from elevated stacked position should be
done as under.

• Drive the BOPT close to the load

• Lower the fork to below the load
• Drive forward to bring the forks under the load completely.
• Lift the load to clear the load from the floor.
• Drive the BOPT to the desired place.

3.3.0 Unloading the material from the BOPT should be carried out as under,

• Move close to the unloading position

• Move the BOPT forward to bring forks over unloading position
• Lower the forks to bring load set load in position’
• Back BOPT out until clear of load

3.4.0 When climbing up or moving down ramps with load, the forks/load should always
face the climb. This is to avoid slippage of the load. Moving down the ramp
without load, the fork should be facing the descend.

BOPT

6
4.0.0 SAFETY FEATURE

4.1.0 Horn

Push button type horn provide on the operating handle to alert other about your
presence.

4.2.0 Safety Reverse

Provided on the head of the operating handle and is activated by the cover plate.
The switch safeguards the operator from getting trapped/squeezed between the
BOPT and other obstacles. On activation the BOPT direction is reversed and
moves away from the operator.

4.3.0 Emergency switch

This is a large push down switch to cut off power quickly. This is provided for use
in emergency.

4.4.0 Operator’s stand-on platform

Stand-on platform is a spring loaded mechanism designed for operator’s convenient

and comfortable driving. This will also protect the operator from hitting the rack,
wall or any other obstructions on the floor. Since the operator is standing on the
platform, chances of cruiser wheels accidentally running on the feet of the operator
is eliminated.

This is an optional feature and is provided at an additional cost.

BOPT

7
5.0.0. BATTERY INDICATOR

Battery indicator with pump lock out is provided on the cruiser to protect the
battery from complete discharge. The limit for critical discharge is 80%. For
maintenance free battery the allowed discharge is 70%.

The pump motor is cut off when the battery has discharged to the set limit. The
indicator has a field of LED displays in Green and Red. The numbers of green light
indicate the extent of discharge while the single red lights indicate that the battery
has reached its critical discharge limit.

6.0.0 BATTERY

6.1.0 The battery is the only energy source of the equipment. The performance of the
equipment depends directly on the state and performance of the battery. It is,
therefore, a MUST that the battery is maintained as per procedures specified by the
manufacture. The battery need to be fully charged before start of work every day.

6.2.0 The following routine checks are recommended for better battery life and
performance of the equipment.

6.2.1 After every normal shift the battery should be placed on charge. An uninterrupted
charging time of eleven hours is recommended unless stated otherwise by the
battery manufacture.

6.2.2 A battery log book should be maintained. Specific gravity readings before and after
charging should be posted regularly. The level of distilled water shields the life of a
battery and its performance is directly dependent on the operating conditions. The
achieve a long life of the battery it is suggested that the following points be taken
care of,

• Keep the battery clean any all times. This will prevent current leakage and
corrosion.

• Add distilled water at regular intervals. Enough water should be added to

bring the electrolyte about 25mm (1”) about the plates.

• Charge the battery correctly. An overcharged battery will damage the

plates. One the other hand a discharged battery has detrimental effects on
the contactors, motor and resistors. An equalizing charge is necessary at
least once at month.
As illustrated above a fully charged battery gives a specific gravity reading of 1.250
esp. should never be allowed to fall below 1.130.

BOPT

8
 Temperature Correction

The specific gravity of the dilute sculpture acid varies with the temperature and in
quoting values it is necessary to use standard temperature i.e. 270C as reference.
When recording specific gravities it is necessary also to record the temperature of
the electrolyte so that the Specific gravity figures can be corrected for 270C. The
correction can be made by using the following rule.

For each 100C above 270C add 0.007 and for each 100C below 270C subtract
0.007 from the hydrometer reading.

This correction is equivalent to 0.007 for every degree centigrade, e.g., if the
hydrometer reading is 1.240 and the temperature of the electrolyte is 370C the
equivalent specific gravity at 270C is 1.240 plus 0.007=1.247.

6.3.0 CHARGING

1. Disconnect the battery connection after switching ‘OFF’ the key switch and
then remove the battery cover. This permits air circulation which checks
temperature rise and allows the battery to gas freely.

2. Connect the charger and Battery plugs.

3. Set the charger switch as desired to NORMAL or EQUILISING CHARGING.

4. After a truck has been used continuously for one shift, the Battery gets
discharged and should be put on charged without much delay. Now, if the
truck has to be used again through the next shift, the interval between two
shifts is utilized for replacing the discharged battery by a fully charged one.
Replace the weak battery by a fully charged one.

The general procedure adopted for replacing the battery is described blow

• Battery is placed on rollers so for removing the battery the battery can be
pulled out by hand on pallet truck legs or battery removing trolley.
• Turn off the key switch and remove the battery socket.
• Remove the side cover of the battery compartment.
• Pull the battery outside (keeping the pallet truck/ trolley near the opening,
matching the chassis level) on to the legs.
• Reverse the procedure to put the battery in the battery compartment.
• Avoid removing Battery Cover when aligning to prevent accidental short
circuit while transporting.

BOPT

9
7.0.0 CONTROLLER

7.1.0 The equipment is fitted with a ‘PGDT’ SET 425 controller. The Controller does not
have any user serviceable part.

7.2.0 It attempt to open the controller is likely to damage the same and will also void the
warranty on the controller.

7.3.0 It is, however, recommended that the exterior of the controller is periodically
cleaned. The controller’s diagnostic history may be checked if a hand held
programmer is available. The fault detection circuitry should be checked when the
equipment is serviced.

CAUTION

The SET 425 controller is inherently a high power device. When the working
around any battery powered vehicle, proper safety precautions should be taken.
• proper training,
• wearing eye protection,
• avoiding loose clothing and jewellery, and
• Using insulated wrenches.

7.4.0 CLEANING

Although the ‘PGDT’ SET 425 controllers requires virtually no maintenance if

equipment is properly operated, the following minor maintenance is recommended
in certain applications.

• Remove power by disconnecting the battery.

• Remove the dirt or corrosion from the bus bar area. The controller should
be wiped clean with a moist rag. Allow it to dry before reconnecting the
battery.

• Make sure the connections to the bus bar are right. Use two well insulated
wrenches for this task in order to avoid stressing the bus bars.

BOPT

10
7.5.0 TESTING THE FAULT DETECTION CIRCUIT

Specific material handling directives require periodic testing of the controller’s fault
detection circuitry. It is recommended that such time the vehicle is serviced, the M-
fault detection circuitry be checked as follows.

1. Put the vehicle up on block to get the drive wheel(s) off the ground,
disconnect the battery, and make sure the key switch is off.

2. Using an inline fuse holder fitted with a 10-amp fuse and alligator clips,
connect the controller’s M- and B- terminals.

3. Turn the key switch on, release the brake, and apply the throttle. The
motor should not operate, and the direction contactors should not pull in.

4. Leave the key switch on and remove the inline fuse wire. The vehicle
start should not continue to remain off.

Cycle the key switch off and on, release the brake, and apply the throttle. The
vehicle should now operate normally.

8.0.0 MAINTENANCE INSTRUCTION

8.1.0 Daily Check

8.1.1 Check functioning of the Horn, Brake and safety switch

8.1.2 Check charge of battery and ensure it is full. Ensure electrolyte level on every cell
is above minimum specified level.

8.1.3 Check level of hydraulic oil and operate the carriage and check for any leakage in
the system.

8.2.0 WEEKLY CHECKS

8.2.1 Lubricate all moving parts

8.2.2 Clean the equipment thoroughly. Special attention need to be given to wheels for
imbedded and wrapped on materials, undercarriage, and castors.

8.2.3 Check electrical system, clean by air or brush. Clean and dry contactors.

8.2.4 Check motor and clean. Check brush for wear.

8.2.5 Check movement of guide, wear on roller and grease.

BOPT

11
8.3.0 MONTHLY CHECK

8.3.1 Complete service of the parts and lubricate as directed.

8.3.2 Tighten all bolts, fasteners, electrical connections. Check for performance of all
safety devices.

8.3.3 Check setting and stretch on lift chains and adjust as necessary.

8.3.4 Check wear on wheels and condition of bearings.

8.4.0 ANNUAL CHECK

8.4.1 Do a complete overhaul of the equipment.

8.4.2 Check fork, mast etc. for alignment and correct as necessary.

8.4.3 Clean and flush hydraulic tank and distribution system and refill with fresh oil.
Check for leakage and replace seals as necessary.

8.4.4 Check motor brush and change if necessary

BOPT

12
 RECOMMENDED LUBRICANTS

GRASE: -

ESSO BEACON-2

CASTROL PETROLEUM CASTRDE ASELM

BHARAT PETROLEUM BHARAT UNIVEX “A”

HYDRAULIC OIL: -

TELLUS-68

ENCLO-68

BOPT

13
BOPT

14
 DRIVE UNIT

BOPT

15
BOPT

16
SPARE PARTS LIST

BOPT

17
 1150

Specifications
Equipment STACKER
Rated Capacity W Kgs 2000
Forks Length mm 1150
680

Width mm 680

830
Overall Length mm 1950
200

Width mm 830

BOPT
D imensions
Height mm 1450
Ground Clearance mm 30

Heights
Lowered mm 90
mm 300

T R1700
Lifted

PU Wheels

18
Load Wheel mm Ø83X70

W heels
Drive Wheel mm Ø230X70

Lift Motor DC KW 2.2

9 00

Drive Motor AC KW 1.5

1450

D rive
Battery V/AH 24/210
300

90

BATTERY OPERATED MHE NEXT ENGINEERING PVT. LIMITED

MHE
STACKER Plot No : 76, Sector 19, Goodwill Harmony, Shop No: 4,
NXT Airoli, Navi Mumbai -400 708, Tel/Fax : +91 22 27792500
Customised Handling Solutions
E mail - info@mhenext.com. Web : www.mhenext.com
 TANDEM WHEEL ASSLY.
PART NO-70000061

06 BLB00001 BALL BEARING 8

05 70000067 TANDEM WHEEL PIN 2
04 DSP00007 SPRING PIN 8
03 70000066 TANDEM WHEEL BRACKET 2
02 70000064 TANDEM WHEEL(PU) 4
01 70000061 TANDEM WHEEL ASSLY. 2
SR. PART No. DESCRIPTION QTY.
NO

5
2 1

BOPT

19
 CARRIAGE PLATE ASSLY.
PART NO-70000613
03 70000054 MAST ROLLER PIN 2
02 70000613 CARRIAGE PLATE ASSLY. 2
01 10000026 MAST ROLLER 2
SR. PART No. DESCRIPTION QTY.
NO

BOPT

20
 7

4 2

8
8

D R IV E U N IT A S S L Y .
P A R T N O -7 0 0 0 0 0 6 8
08 B 5081017 A LLE N H E A D B O LT( M 10x35L) 2
07 B 5031650 H E X H E A D B O L T (M 1 6 x 1 0 0 L ) 2
06 B 5081010 A LLE N H E A D B O LT( M 10x20L) 4
05 70000073 D R IV E M T G . B K T . 2
04 70000072 D R I V E U N I T G U ID E R O D 2
03 70000071 S P R IN G D R IV E U N IT 2
02 70000070 S P R IN G T E N S IO N E R 2
01 70000069 D R I V E U N I T G U ID E A S S L Y . 2
SR. P A R T N o. D E S C R IP T IO N Q TY.
NO

BOPT

21
STEERING COLUMN ASSLY.
PART NO-70000079

BOPT

22
 4 9
7
6 8
10
11

2 3

CASTO R W HEEL ASSLY.

P A R T N O -7 0 0 0 0 0 7 4
11 H 5200410 N YLO C K N U T M 10 8
10 B8880410 S P R IN G W A S H E R M 1 0 8
09 B5081015 A LLE N H E A D B O LT( M 10x30L) 8
08 700000077 H O U S IN G B E A R IN G 2
07 TRB00002 T A P E R R O L L E R B E A R IN G 2
06 THB00001 T H R U S T B E A R IN G 2
05 70000076 BRA CKET CASTO R 2
04 B5200116 H EX N UT M 16 4
03 70000075 C A S T O R W H E E L P IN 2
02 BLB00001 B A L L B E A R IN G 4
01 70000074 CASTO R W HEEL PU 2
SR. PART No. D E S C R IP T IO N Q TY.
NO

BOPT

23
 11
12 13 13
8

BOPT
4 9 10 1 2 7 6 5 3

13 13 GRD00004 GUIDE RING Ø40xØ45x15THK 2

12 12 WPS00015 WIPER SEAL Ø40xØ48x7THK 1
11 11 PTS00011 SEAL OIL ID40xOD50x9THK 1
10 10 ORN00069 O RING Ø47.35X1.78THK 1
13 GAUGEx300L

24
9 9 WLK13300 LOCKING WIRE 1
8 8 ECP00009 CIRCLIP EXT Ø25 1
7 7 70000050 SPACER Ø40 Ø40xØ48x30 1
6 6 70000154 PISTON Ø40 Ø40xØ50x52 1
5 5 70000049 RETAINER SEAL Ø25xØ48x5 1
4 4 70000048 WIPER SEAL HOUSING Ø63X82 L 1
3 3 70000045 BOTTOM END Ø63x49 1
2 2 70000153 ASSLY WELDED CYLINDER 50 HONEDx2240 1
1 1 70000152 SHAFT JACK Ø40x2280 1
PARTS
SR.NO. ITEM DESCRIPTION SIZE QTY
NO. NO.

LIFT JACK ASSLY.

PART NO-70000151
 DESCRIPTION MAKE QTY.
2
1 OIL TANK 70000102 01
2 2 LIFT JACK 70000151 01

3 PRESSURE LINE 14R210BN10BN80 01

4 HOSE TO JACK Ø10 STEEL PIPE 02

5 PUMP MOTOR 10000222 01

6 PUMP 10000216 01

4 4

BOPT
3

25
5

6
M 1

HYDRAULIC CIRCUIT
BOPT
 2

Serial
Part No Description Quantity Note
No
1 70000079 Handle Column assly. 1
2 10000027 Drive motor 1
3 10000028 Drive motor gear box 1
4 10000029 Drive wheel 1

BOPT

26
 6
1 5

D E T A IL S :- 2 0
D R IV E M O T O R A S S L Y .
P A R T N O -7 0 0 0 0 0 6 8

06 10000302 M a g n e tic B ra k e 1
05 10000300 E n c o d e r d riv e m o to r 1
04 10000299 D riv e w h e e l 1
03 10000298 D riv e m o to r g e a r b o x 1
02 10000233 D riv e m o to r 1
01 70000554 H a n d le C o lu m n a s s ly . 1
SR. PAR T N o. D E S C R IP T IO N Q TY.
NO

BOPT

27
 7 10
1
4

5
9

8 6
2

HANDLE ASSLY.
(PART NO: 10000203)

Serial
Part No Description Quantity Note
No
1 10000204 Handle Cover 1
2 10000205 Accelerator Knob 1
3 10000206 Accelerator Assly. 1
4 10000207 Push Button switch 1
5 10000208 Handle Cover back side 1
6 10000209 Belly Cover 1
7 10000210 Belly Cover Spring 1
8 10000211 Accelerator retainer spring 2
9 10000212 Horn Cover 1
10 10000213 Micro Switch 4

BOPT

28
 PUMP CONTACTOR
(PART NO: 10000045)

* KSW 180B, 24V *

SR.NO PART NO. PART NAME QTY.

1 10000046 FIXED CONTACT (NOT SHOW) 01
2 10000047 MOVING CONTACT (NOT SHOW) 01

BOPT

29
 LINE CONTACTOR
(PART NO: 10000047)

* KSW 80B, 24V CO *

SR.NO PART NO. PART NAME QTY.

1 10000048 FIXED CONTACT (NOT SHOW) 01
2 10000049 MOVING CONTACT (NOT SHOW) 01

BOPT

30
CIRCUIT DIAGRAM FOR SET 425

BOPT

31
 BOPT CIRCUIT DIAGRAM LIST

SR. DESCRIPTION PART NO QTY.

NO
1. CONTROLLER ACT 425 S 10000051 01
2. PUMP CONTACTOR 10000045 01
3. E- CUT OFF SWICH 10000052 01
4. FUSE 250A 10000053 01
5. CONTROL FUSE -10AH 10000054 01
6. LINE CONTACTOR 10000048 01
7. BATTERY SOCKET 10000055 01
8. MICRO SWITCH 10000056 01
9. BDI 10000057 01
10. HORN 24V 10000058 01

BOPT

32
DIAGNOSTIC & TROUBLESHOOTING : -

BOPT

33
BOPT

34
 SEAFTY ACCESSORISE

1
2

SAFETY ACCESSORIES
SR.NO DESCRIPTION PART NO. Qty.
1. BATTERY SOCKET 10000055 01
2. HORN 24 DC 10000058 01
3. EMERGENCY CUTT-OFF S/W 10000052 01
4. KEY SWITCH 10000059 01

BOPT

35