v-15, v-18, v20

Big Lift LLC MANUAL NO. BL-V-0217 - 12-16-2021www.bigjoeforklifts.com

V-15, V-18, V20THREE WHEEL,

COUNTERBALANCED LIFT TRUCK

Operation

Maintenance

Repair Parts List

NOTE:For the most current parts information and service updates, please refer to the Big Joe

Support site at www.bigjoesupport.com

WARNING

Do not operate this truck unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator’s Manual and on thistruck.

Do not operate this truck until you have checked itscondition. Give special attention to tires, horn, battery,controller, lift system (including forks or attachments,chains, cables and limit switches), brakes, steeringmechanism, guards and safety devices.

Operate truck only from designated operating position.Never place any part of your body into the mast struc-ture or between the mast and the truck. Do not carrypassengers. Keep feet clear of truck and wear footprotection.

Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be greater.

Travel with lifting mechanism as low as possible.Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with loadtrailing.

Use special care when operating on ramps travelslowly, and do not angle or turn. Travel with loaddownhill.

Do not overload truck. Check data plate for capacityand load center information.

Space forks as far apart as load will permit. Before lift-ing, be sure load is centered, forks are completelyunder load, and load is as far back as possible againstload backrest.

Do not handle unstable or loosely stacked loads. Usespecial care when handling long, high or wide loads, toavoid losing the load, striking bystanders, or tippingthe truck.

Do not handle loads which are higher than the loadbackrest or load backrest extension unless load issecured so that no part of it could fall backward.

Elevate forks or other lifting mechanism only to pick upor stack a load. Watch out for obstructions, especiallyoverhead.

Do not lift personnel except on a specially designedwork platform securely attached . USE EXTREMECARE WHEN LIFTING PERSONNEL. Make suremast is vertical, place truck controls in neutral andapply brakes. Lift and lower smoothly. Remain in oper-ating position as long as personnel are on the workplatform. Never transport personnel on forks or workplatform.

Do not allow anyone to stand or pass under load or lift-ing mechanism.

When leaving the truck, neutralize travel control, fullylower lifting mechanism and set brake. When leavingtruck unattended, also shut off power.

TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION............................................................1-11-1. INTRODUCTION. .........................................1-11-2. GENERAL DESCRIPTION. ..........................1-11-3. SAFETY FEATURES....................................1-1

2 OPERATION ...............................................................2-12-1. GENERAL.....................................................2-12-2. OPERATING PRECAUTIONS......................2-12-3. BEFORE OPERATION.................................2-22-4. GENERAL CONTROL OPERATION. ...........2-42-4.1. PARKING BRAKE ........................................2-42-4.2. SHIFT LEVER ..............................................2-42-4.3. BRAKE PEDAL.............................................2-42-4.4. ACCELERATOR PEDAL..............................2-42-4.5. STEERING WHEEL .....................................2-42-4.6. TURN SIGNAL/LIGHT SWITCH...................2-52-4.7. KEY SWITCH ...............................................2-52-4.8. STEERING COLUMN TILT LEVER .............2-52-4.9. CAUTION LIGHT SWITCH...........................2-52-4.10. INSTRUMENT PANEL .................................2-52-5. SEAT ADJUSTMENT. ..................................2-72-6. PREPARING FOR OPERATION..................2-72-7. DURING BRAKE-IN......................................2-72-8. STARTING THE TRUCK. .............................2-72-9. DRIVING AND STOPPING PROCEDURES.2-72-9.1. TRAVEL........................................................2-72-9.2. DECREASING SPEED.................................2-72-9.3. STEERING. ..................................................2-72-9.4. STOPPING AND PARKING. ........................2-72-9.5. LOADING AND UNLOADING. .....................2-72-9.6. STACKING. ..................................................2-82-9.7. UN-STACKING.............................................2-82-10. PARKING......................................................2-8

3 PLANNED MAINTENANCE ........................................3-13-1. GENERAL.....................................................3-13-2. MONTHLY AND QUARTERLY CHECKS.....3-13-3. BATTERY CARE. ........................................3-13-3.1. GENERAL ....................................................3-13-3.2. SAFETY RULES...........................................3-23-3.3. BATTERY CARE AND CHARGING .............3-23-3.4. BATTERY CLEANING..................................3-23-3.5. MAINTENANCE FREE BATTERY ...............3-23-4. CHARGING BATTERY.................................3-33-5. BATTERY REMOVAL...................................3-43-6. LUBRICATION..............................................3-43-7. LIFT CHAIN MAINTENANCE. ......................3-4

4 TROUBLESHOOTING ................................................4-14-1. GENERAL.....................................................4-14-2. CONTROLLER TROUBLESHOOTING ........4-44-2.1. PROGRAMMABLE PARAMETERS .............4-44-2.2. FAULT DETECTION. ...................................4-44-2.3. DIAGNOSTICS AND

TROUBLESHOOTING .................................4-4

5 STEERING SYSTEM.................................................. 5-15-1. STEERING COLUMN .................................. 5-15-1.1. COVER REMOVAL...................................... 5-15-1.2. COVER INSTALLATION.............................. 5-15-1.3. STEERING COLUMN REMOVAL ............... 5-25-1.4. STEERING COLUMN INSTALLATION ....... 5-35-2. COUNTERWEIGHT REMOVAL................... 5-35-3. COUNTERWEIGHT INSTALLATION........... 5-35-4. STEERING AXLE REMOVAL. ..................... 5-35-5. STEERING AXLE INSTALLATION. ............. 5-4

6 BRAKE SERVICING................................................... 6-16-1. BRAKES....................................................... 6-16-2. HAND BRAKES. .......................................... 6-16-2.1. REMOVAL ................................................... 6-16-2.2. INSTALLATION ........................................... 6-26-3. FOOT BRAKE. ............................................. 6-26-3.1. MASTER CYLINDER REMOVAL ................ 6-26-3.2. MASTER CYLINDER INSTALLATION ........ 6-26-3.3. BLEEDING THE BRAKES ........................... 6-2

7 TRANSMISSION, DRIVE WHEELS, REAR WHEELS 7-17-1. STEERING WHEEL ..................................... 7-17-2. DRIVE WHEEL. ........................................... 7-27-3. TRANSMISSION.......................................... 7-2

8 ELEVATION SYSTEM SERVICING ........................... 8-18-1. GENERAL. ................................................... 8-18-2. LIFT CHAIN WEAR INSPECTION. .............. 8-18-3. LIFT CHAIN LENGTH ADJUSTMENT. ........ 8-18-4. LIFT CHAIN REPLACEMENT...................... 8-28-5. LIFT CYLINDERS. ....................................... 8-3

9 HYDRAULIC SYSTEM SERVICING........................... 9-19-1. LINES AND FITTINGS................................. 9-19-2. HYDRAULIC RESERVOIR .......................... 9-19-3. HYDRAULIC PUMP REMOVAL................... 9-29-4. HYDRAULIC PUMP INSTALLATION........... 9-39-5. STEERING PUMP. ...................................... 9-39-5.1. REMOVAL ................................................... 9-39-5.2. INSTALLATION. .......................................... 9-39-6. STEERING AXLE......................................... 9-39-7. CONTROL VALVE ....................................... 9-49-7.1. REMOVAL ................................................... 9-49-7.2. INSTALLATION ........................................... 9-49-8. TILT CYLINDER........................................... 9-69-8.1. REMOVAL ................................................... 9-69-8.2. REPAIR........................................................ 9-69-8.3. INSTALLATION ........................................... 9-79-9. LIFT CYLINDER (TELESCOPIC)................. 9-89-9.1. FREE LIFT CYLINDER................................ 9-89-9.2. SECONDARY LIFT CYLINDER................. 9-129-10. LIFT CYLINDER

(WIDE ANGLE TELESCOPIC) .................. 9-139-11. LIFT CYLINDER

(WIDE ANGLE TELESCOPIC) .................. 9-14

BL-V-0217 - 12-16-2021 i

TABLE OF CONTENTS

Section Page Section Page

9-12. LIFT CYLINDER (TRIMAST)...................... 9-189-12.1. FREE LIFT CYLINDER.............................. 9-189-12.2. SECONDARY LIFT CYLINDER................. 9-22

10 ELECTRICAL COMPONENTS ................................. 10-110-1. DASH ......................................................... 10-110-1.1. REMOVAL ................................................. 10-110-1.2. INSTALLATION ......................................... 10-110-2. FLASHER................................................... 10-210-2.1. REMOVAL ................................................. 10-210-2.2. INSTALLATION ......................................... 10-210-3. PARKING BRAKE SWITCH....................... 10-210-3.1. REMOVAL ................................................. 10-210-3.2. INSTALLATION ......................................... 10-210-4. KEY SWITCH............................................. 10-210-4.1. REMOVAL ................................................ 10-210-4.2. INSTALLATION ......................................... 10-210-5. DIRECTION AND LIGHT SWITCHES ....... 10-210-5.1. REMOVAL ................................................ 10-210-5.2. INSTALLATION ......................................... 10-2

10-6. DRIVE MOTOR ..........................................10-210-6.1. REMOVAL..................................................10-210-6.2. INSTALLATION..........................................10-310-7. PUMP MOTOR. ..........................................10-310-8. ACCELERATOR.........................................10-310-8.1. REMOVAL..................................................10-310-8.2. INSTALLATION..........................................10-310-9. DC CONVERTER.......................................10-310-9.1. REMOVAL..................................................10-310-9.2. INSTALLATION..........................................10-310-10. FUSE BOX..................................................10-310-11. ELECTRICAL CONTROL PANEL ..............10-310-11.1. MAINTENANCE .........................................10-310-11.2. CLEANING .................................................10-410-11.3. CONTROLLER REMOVAL. .......................10-410-11.4. CONTROLLER INSTALLATION. ...............10-4

11 OPTIONAL EQUIPMENT..........................................11-1

12 ILLUSTRATED PARTS BREAKDOWN ....................12-1

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 NAME PLATE ...................................................... 1-11-2 V SERIES LIFT TRUCK....................................... 1-22-1 LOAD CENTER.................................................... 2-12-2 SAMPLE OF OPERATOR CHECK LIST ............. 2-32-3 CONTROLS ......................................................... 2-42-4 STEERING COLUMN TILT LEVER..................... 2-52-5 INSTRUMENT PANEL......................................... 2-62-6 SEAT ADJUSTMENT........................................... 2-73-1 BATTERY ACCESS............................................. 3-33-2 BATTERY CONNECTOR ................................... 3-33-3 BATTERY REMOVAL.......................................... 3-43-4 LUBRICATION DIAGRAM ................................... 3-55-1 STEERING SYSTEM........................................... 5-15-2 STEERING COLUMN .......................................... 5-25-3 FRAME AND COUNTERWEIGHT....................... 5-45-4 REAR STEERING................................................ 5-56-1 STEERING AND BRAKE CONTROLS................ 6-16-2 BRAKE PEDAL .................................................... 6-37-1 REAR STEERING................................................ 7-17-2 DRIVE .................................................................. 7-28-1 CHAIN ASSEMBLY.............................................. 8-18-2 CHAIN ASSEMBLY.............................................. 8-29-1 BATTERY ACCESS............................................. 9-19-2 HYDRAULIC SYSTEM......................................... 9-29-3 HYDRAULIC RESERVOIR .................................. 9-49-4 VALVE CONTROL LEVERS................................ 9-59-5 HYDRAULIC TILT (TELESCOPIC SHOWN) ....... 9-69-6 TILT CYLINDER................................................... 9-79-7 HYDRAULIC LIFT (TELESCOPIC)...................... 9-89-8 ELEVATION SYSTEM (TELESCOPIC) ............... 9-99-9 HYDRAULIC LIFT (TELESCOPIC).................... 9-109-10 ELEVATION SYSTEM (TELESCOPIC) ............. 9-11

9-11 HYDRAULIC LIFT(WIDE ANGLE TELESCOPIC)........................... 9-14

9-12 ELEVATION SYSTEM (WIDE ANGLE TELESCOPIC)........................... 9-15

9-13 HYDRAULIC LIFT (WIDE ANGLE TELESCOPIC)........................... 9-16

9-14 ELEVATION SYSTEM (WIDE ANGLE TELESCOPIC)........................... 9-17

9-15 HYDRAULIC LIFT (TRIMAST) ........................... 9-189-16 ELEVATION SYSTEM (TRIMAST) .................... 9-199-17 HYDRAULIC LIFT (TRIMAST) ........................... 9-209-18 ELEVATION SYSTEM (TRIMAST) .................... 9-2110-1 OPERATOR COMPARTMENT .......................... 10-110-2 FUSE BOX ......................................................... 10-312-1 FRAME AND COUNTERWEIGHT ..................... 12-212-2 OVERHEAD GUARD ......................................... 12-312-3 OVERHEAD GUARD ......................................... 12-412-4 OPERATOR’S COMPARTMENT....................... 12-612-5 BACK COVER.................................................... 12-812-6 STEERING AND BRAKE CONTROLS ............ 12-1012-7 HAND BRAKE .................................................. 12-1212-8 BRAKE PEDAL................................................. 12-1312-9 STEERING COLUMN....................................... 12-1412-10 CONTROL VALVE MOUNTING....................... 12-1612-11 DRIVE .............................................................. 12-1812-12 FRONT WHEEL ............................................... 12-1912-13 TRANSMISSION .............................................. 12-2012-14 REAR STEERING ............................................ 12-2112-15 STEERING AXLE............................................. 12-2212-16 BACK TIRE ASSEMBLY .................................. 12-2312-17 CONTROL PANEL ........................................... 12-2412-18 WIRING HARNESS.......................................... 12-25

ii BL-V-0217 - 12-16-2021

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

Figure Page Figure Page

12-19 WIRING CABLES ............................................. 12-2612-20 HYDRAULIC SYSTEM ..................................... 12-2812-21 HYDRAULIC RESERVOIR............................... 12-3012-22 ELEVATION SYSTEM (TELESCOPIC) ........... 12-3112-23 ELEVATION SYSTEM (TELESCOPIC) ........... 12-3212-24 ELEVATION SYSTEM

(WIDE ANGLE TELESCOPIC)......................... 12-3412-25 ELEVATION SYSTEM

(WIDE ANGLE TELESCOPIC)......................... 12-3512-26 ELEVATION SYSTEM (TRIMAST) .................. 12-3612-27 ELEVATION SYSTEM (TRIMAST) .................. 12-3812-28 HYDRAULIC LIFT (TELESCOPIC) .................. 12-4012-29 HYDRAULIC LIFT (TELESCOPIC) .................. 12-4212-30 HYDRAULIC LIFT

(WIDE ANGLE TELESCOPIC)......................... 12-4412-31 HYDRAULIC LIFT

(WIDE ANGLE TELESCOPIC)......................... 12-4512-32 HYDRAULIC LIFT (TRIMAST) ......................... 12-4612-33 HYDRAULIC LIFT (TRIMAST) ......................... 12-4812-34 HYDRAULIC TILT (TELESCOPIC) .................. 12-5012-35 HYDRAULIC TILT (TELESCOPIC) .................. 12-5112-36 HYDRAULIC TILT

(WIDE ANGLE TELESCOPIC)......................... 12-52

12-37 HYDRAULIC TILT (WIDE ANGLE TELESCOPIC) ........................ 12-53

12-38 HYDRAULIC TILT (TRIMAST)......................... 12-5412-39 HYDRAULIC TILT (TRIMAST)......................... 12-5512-40 LIFT CARRIAGE.............................................. 12-5612-41 LIFT CARRIAGE.............................................. 12-5712-42 LIFT CYLINDER, FULL FREE LIFT

(TELESCOPIC)................................................ 12-5812-43 LIFT CYLINDER, RIGHT SECONDARY

(TELESCOPIC)................................................ 12-6012-44 LIFT CYLINDER, RIGHT SECONDARY

(TELESCOPIC)................................................ 12-6212-45 LIFT CYLINDER, LEFT SECONDARY

(TELESCOPIC)................................................ 12-6412-46 LIFT CYLINDER, LEFT SECONDARY

(TELESCOPIC)................................................ 12-6612-47 LIFT CYLINDER

(WIDE ANGLE TELESCOPIC) ........................ 12-6812-48 LIFT CYLINDER, FULL FREE LIFT

(TRIMAST)....................................................... 12-7012-49 LIFT CYLINDER, SECONDARY (TRIMAST) .. 12-7212-50 TILT CYLINDER .............................................. 12-7412-51 LIFT CHAIN ..................................................... 12-7612-52 LIFT CHAIN ..................................................... 12-77

LIST OF TABLES

Table Page Table Page

2-1 OPERATOR CHECKS ...........................................2-23-1 MONTHLY AND QUARTERLY INSPECTION

AND SERVICE CHART .........................................3-13-2 RECOMMENDED LUBRICANTS ..........................3-43-3 LUBRICATION CHART..........................................3-5

4-1 TROUBLESHOOTING CHART ............................. 4-14-2 TROUBLESHOOTING CHART

(TRACTION SYSTEM FAULTS) ........................... 4-44-3 TROUBLESHOOTING CHART

(HYDRAULIC SYSTEM FAULTS)....................... 4-10

BL-V-0217 - 12-16-2021 iii

TABLE OF CONTENTS

NOTES

iv BL-V-0217 - 12-16-2021

SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the 48 volt three wheel Vseries lift truck distributed by Big Lift LLC. Included areoperating instructions, planned maintenance instruc-tions, lubrication procedures, corrective maintenanceprocedures and a complete parts list with part locationillustrations.

Users shall comply with all requirements indicated inapplicable OSHA standards and current edition ofA.N.S.I. B56.1 Part II. By following these requirementsand the recommendations contained in this manual,you will receive many years of dependable servicefrom your V series lift truck.

1-2. GENERAL DESCRIPTION.

The V series comes in a TRIMAST model.

The TRIMAST model has a 188 inch lift.

The V15 truck lifts and transports payloads up to 2800pounds on adjustable forks. The V18 truck lifts andtransports payloads up to 3500 pounds on adjustableforks.

The three wheel counterbalanced lift truck has thecharacter of a small turning radius.

The forward and reverse motion is controlled by a con-trol lever on the left side of the steering wheel. Stop-ping is controlled by the brake pedal. Control levers tothe right of the operator control the Lift, Lower, and Tilt.Optional levers are available to control side motion ofthe forks and additional attachments.

Two front wheel mounted reversible motors propel thelift truck in forward or reverse direction throughout theavailable speed range. The V series lift truck can bedriven with forks raised or lowered; however, thespeed is restricted when the platform is raised above apreset limit.

The model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center. Figure 1-2 shows the locations ofthe truck’s main components.

1-3. SAFETY FEATURES.

The V series lift truck is designed engineered to pro-vide maximum safety for operator and payload. Someof the safety features incorporated into the design are:

Figure 1-1 Name Plate

• Deadman switch to shut off power and apply brakewhen operator leaves seat.

• Parking brake lever to apply the brake to both frontwheels.

• High speed limit switch to restrict speed when liftcarriage is raised above the preset limit.

• All control functions automatically return to “OFF”when released.

• Emergency disconnect switch within operator'sreach.

• Separately fused control circuits and power circuits.

• Readily accessible horn button in steering wheel.

• Lift carriage backrest to help stabilize the load.

• Handle on the front left pillar of overhead guard toprovide a firm hand hold for operator.

• Steps on both sides for mounting and dismountingthe truck.

• Relief valve maintains hydraulic pressure within pre-scribed limits.

• High visibility color scheme of truck provides visualalert of truck’s presence.

• Instrument panel and display.

COMPLIES WITH THE APPLICABLE REQUIRE-COMPLIES WITH THE APPLICABLE REQUIRE-

MENTS OF ANSI B56.1 AND OSHA STANDARDSMENTS OF ANSI B56.1 AND OSHA STANDARDS

BIG LIFT LLCBIG LIFT LLC

WISCONSIN DELLS, WISCONSIN 53965WISCONSIN DELLS, WISCONSIN 53965

AUSTRALIAN PATENT NO. 537,987AUSTRALIAN PATENT NO. 537,987

U.S. PATENT NO. 4,444,284U.S. PATENT NO. 4,444,284

TRUCK

TYPE

MODEL NO. SERIAL NO.

VOLTAGEBATTERY

TYPECERTIFIED

MAX CAP LB/MAX CAP LB/ LOAD CTR IN/LOAD CTR IN/ LIFT HGT IN/

LOAD CTR IN/LOAD CTR IN/ LIFT HGT IN/ALT CAP LB/

BATTERY MIN WT LB/BATTERY MIN WT LB/TRUCK WT LESS BATTERY LB/TRUCK WT LESS BATTERY LB/

BATTERY MAX WT LB/BATTERY MAX WT LB/TRUCK WT WITH BATTERY LB/TRUCK WT WITH BATTERY LB/

KG MM MM

MM MMKG

KGKG

KGKG

R6209

BL-V-0217 - 12-16-2021 1-1

Figure 1-2 V Series Lift Truck

R6905

ITEM COMPONENT

1 Rear light

2 Strobe light

3 Overhead guard

4 Steering wheel

5 Rear view mirror

6 Mast

7 Head light

8 Front lamp

9 Load backrest

10 Fork

11 Front drive wheel

12 Side battery cover

13 Chassis

14 Seat

15 Counter weight

16 Rear wheel

ITEM COMPONENT

1-2 BL-V-0217 - 12-16-2021

SECTION 2OPERATION

2-1. GENERAL.

This section gives detailed operating instructions forthe V series lift truck. The instructions are divided intothe various phases of operations, such as operatinglift, driving, and stopping. Routine precautions areincluded for safe operation.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the lift truck mayresult in operator injury, or load and/or lifttruck damage. Observe the followingprecautions when operating the V serieslift truck.

The following safety precautions must be adhered toat all times.

• Do not operate this truck unless you have beentrained and authorized to do so.

• All warnings and instructions must be read andunderstood before using the equipment.

• Equipment must not be altered in any way.

• Equipment must be inspected by a qualified personon a regular basis.

• Do not exceed the rated capacity. Overloading mayresult in damage to the hydraulic system and struc-tural components.

• Be certain that the lifting mechanism is operatingsmoothly throughout its entire height, both emptyand loaded.

• Be sure that mast is vertical - do not operate on aside slope.

• Be sure the truck has a firm and level footing.

• Avoid overhead wires and obstructions.

• Check for obstructions when raising or lowering thelift carriage.

• Do not handle unstable or loosely stacked loads.Use special care when handling long, high, or wideloads to avoid tipping, loss of load, or strikingbystanders.

• Center and carry the load as far back as possibletoward the lift carriage back rest. The center-of-grav-ity of the load must not exceed the load center listedon the data plate. See Figure 2-1 for load center lim-itations.

• Pick up loads on both forks. Do not pick up on onlyone fork.

• When traveling, always lower the load as far as pos-sible.

• When stacking pallets in racks and it is necessary tomove the load in a raised position, use caution.Operate truck smoothly.

Figure 2-1 Load Center

R3814

BL-V-0217 - 12-16-2021 2-1

• Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

• Operate truck only from designated operation posi-tion. Never place any part of your body between themast uprights. Do not carry passengers.

• Do not allow anyone to stand or pass under load orlifting mechanism.

• When leaving truck, neutralize travel control. Fullylower the forks and set parking brake. When leavingtruck unattended, turn off key switch, remove keyand disengage the emergency stop switch

2-3. BEFORE OPERATION

Table 2-1 covers important inspection points on the

V Series lift truck which should be checked prior tooperation. Depending on use, some trucks mayrequire additional checks

Figure 2-2 shows a sample format for an OperatorChecklist, which can be modified as necessary to fityour operation.

WARNING: Periodic maintenance of this truck by aQUALIFIED TECHNICIAN is required.

CAUTION: A QUALIFIED SERVICE TECHNICIANshould check the truck monthly forproper lubrication, proper fluid levels,brake maintenance, motor maintenanceand other areas specified in the SEC-TION 3.

WARNING: If the truck is found to be unsafe and inneed of repair, or contributes to anunsafe condition, report it immediately tothe designated authority. Do not operateit until it has been restored to a safeoperating condition. Do not make anyunauthorized repairs or adjustments. Allservice must be performed by a qualifiedmaintenance technician.

Table 2-1 Operator Checks

ITEM PROCEDURE

Transmissions and hydraulic systems.

Check for signs of fluid leakage.

Forks Check for cracks and damage; and, that they are properly secured.

Chains, cables and hoses

Check that they are in place, secured correctly, functioning properly and free of binding or damage.

Guards and load backrest

Check that safety guards are in place, properly secured and not damaged.

Safety signs Check that warning labels, data plate, etc., are in good condi-tion and legible.

Horn Check that horn sounds when operated.

Steering Check for binding or looseness when steering.

Travel controls Check that the accelerator oper-ates in all speed ranges in for-ward and reverse.

Wheels Check front drive wheels for cracks or damage. Move truck to check load for freedom of rotation.

Hydraulic controls

Check operation of lift, tilt and side shift to their maximum positions.

Brakes Check that brakes actuate when the brake pedal is depressed.

Parking brake Check that the parking brake lever engages and disengages the brakes.

Emergency Stop Switch

Check that emergency stop switch can be disengaged and reengaged.

Battery charge Check the instrument panel bat-tery indicator.

ITEM PROCEDURE

2-2 BL-V-0217 - 12-16-2021

Figure 2-2 Sample of Operator Check List

R6479

Electric TruckDaily Operator Check-Off List

Date

Big Joe Manufacturing Company

Operator

Truck No. Model No.

Dept.

Check

Tires

Load Wheels

Horn

Lift Lower Control

Need MaintenanceO.K. ( )

Shift

Hour Meter

Reading Drive Hoist

Attachment Operation

Forward & Reverse Controls

Steering

Brakes

Hydraulic Leaks, Cylinders,

Valves, Hoses, Etc.

BL-V-0217 - 12-16-2021 2-3

2-4. GENERAL CONTROL OPERATION.

2-4.1. Parking Brake

Pull up on the parking brake lever to apply brakes onthe front wheels. To release, press the button on thelever and move the lever forward.

2-4.2. Shift Lever

The shift lever controls forward, neutral and reversetravel.

2-4.3. Brake Pedal

Press the brake pedal to slow or stop. The brake lightwill come on when pedal is depressed.

2-4.4. Accelerator Pedal

As the accelerator pedal is slowly pressed, the drivemotors start turning and the truck will start to move.According to the force applied to the pedal, the speedincreases.

2-4.5. Steering Wheel

The steering wheel is operated in the conventionalmanner. The rear wheels steer the truck causing therear of the truck to swing out when a turn is made.

Figure 2-3 Controls

R6906

2-4 BL-V-0217 - 12-16-2021

2-4.6. Turn Signal/Light Switch

This combined light switch operates the turn signalsand the front lights.

2-4.6.1. Turn Signal

Move the lever forward to indicate a left turn or backto indicate a right turn.

NOTE: The lever does not automatically return to theneutral position. Reset it by hand.

2-4.6.2. Light Switch

The light switch has two positions. First position is forlow lamp only. The second position is for both the lowlamp and high lamp.

2-4.7. Key Switch

The key switch has two positions, ON and OFF. Besure the shift lever is in the neutral position and theacceleration pedal is released before the key switch isturned on.

Removing the key prevents the truck from being usedby unauthorized personnel.

NOTE: If the shift lever is not in neutral or the acceler-ation pedal is depressed, an error code may appearon display. When the correct procedure is used, theerror code should disappear.

2-4.8. Steering Column Tilt Lever

This lever is used to adjust the steering column to suitindividual operators. Move the lever counterclockwiseand adjust the steering column. Then move the leverclockwise to lock the column in place.

Figure 2-4 Steering Column Tilt Lever

2-4.9. Caution Light Switch

Use switch to turn on the caution light.

2-4.10.Instrument Panel

The instrument panel contains the following displaysand controls:

2-4.10.1. LED Indicators

There are six indicators:

2-4.10.2. Control Buttons

There are six control buttons:

R6908

Power Indicator: Indicates power supply is OK.

Error Indicator: Indicates improper operation.

Low Battery Warning: Indicates battery capacity is lower than 20% and a buzzer sounds.

Parking Brake Warning: Indicates con-troller temperature is out of range.

Parking Brake Indicator: Indicates parking brake is engaged.

Seat Belt Indicator: Indicates the seat belt is not secured.

Enter Button: Used to enter changes.

Roll Up Button: Used to change high-lighted digit on the instrument panel dis-play.

Roll Down Button: Used to change highlighted digit on the instrument panel display.

Set Up Button: Used to shift the high-light to the previous digit on the instru-ment panel display.

Set Down Button: Used to shift the high-light to the following digit on the instru-ment panel display.

Out Button: Used to cancel changes.

BL-V-0217 - 12-16-2021 2-5

Figure 2-5 Instrument Panel

2-4.10.3. Display LED

When the key switch is turned on, the system will self-diagnose and the LED will display battery capacity. Ablank LED indicates a dead battery. The batteryshould be charged when the low battery warning indi-cator is on. Refer to SECTION 3 for charging the bat-tery.

When traveling, the LED will display the truck speed.

When a controller detects a fault, the LED will show afault code. Refer to SECTION 4 for fault codes.

2-4.10.4. Auxiliary Control Lever

If equipped, the function of this lever depends on theauxiliary attachment.

2-4.10.5. Side Shift Control Lever

If equipped, this lever is used to side shift the forks.The speed of the side shift can be controlled by thepressure on the lever.

2-4.10.6. Tilt Control Lever

This lever is used to tilt the mast. Pulling the leverback will tilt the mast backwards. Pushing it forwardwill tilt the mast forward. The speed of the tilt can becontrolled by the pressure on the lever.

2-4.10.7. Lift Control Lever

This lever is used to lift the forks. Pulling the lever backwill raise the forks. Pushing it forward will lower theforks. The speed of the tilt can be controlled by thepressure on the lever. Motor speed or acceleratorpedal has not affect the lowering speed.

2-4.10.8. Emergency Disconnect Switch

This switch is used to cut off the main power to thetruck in case of an emergency

R6909

2-6 BL-V-0217 - 12-16-2021

2-5. SEAT ADJUSTMENT.

Before operating the truck, adjust the operator’s seatand make sure it is securely locked. The seat isunlocked by turning adjusting lock (2, Figure 2-6)counterclockwise. Lever (1) is used to adjust the leanof the seat. Lever (3) is used to adjust the position ofthe seat.

Figure 2-6 Seat Adjustment

2-6. PREPARING FOR OPERATION.

Preparing the truck for operation after delivery ortransport:

1. Check that the equipment is complete.

2. Check the hydraulic oil level. Refer to SECTION3.

3. Install the battery if necessary. Refer to SECTION3.

4. Charge the battery. Refer to SECTION 3.

5. Visually inspect the entire truck (in particularlywheels and forks) for obvious damage.

2-7. DURING BRAKE-IN.

Operating the truck under light load conditions is rec-ommended. Limited load is 70 to 80% of the ratedload. During the first 100 hours of operation observethe following:

1. Prevent the new battery from over-discharging.

2. Perform preventive maintenance services care-fully and completely.

3. Avoid sudden stops, starts or turns.

4. Perform oil changes and lubrication earlier thanspecified.

2-8. STARTING THE TRUCK.

1. Place the shift lever in neutral.

2. Hold the steering wheel with the left hand and turnon key switch with the right hand.

3. Slightly lift and tilt the forks.

4. Press the brake pedal and release the parkingbrake.

2-9. DRIVING AND STOPPING PROCEDURES.

2-9.1. Travel.

1. Place the shift lever in forward or reverse.

2. Slowly step on the accelerator pedal until thedesired speed is obtained.

WARNING: Do not step on the accelerator pedal andthe brake pedal at the same time.

2-9.2. Decreasing Speed.

1. Slowly release the accelerator pedal. The truckwill decelerate.

2-9.3. Steering.

The steer wheels are located at the rear of the truckcausing the rear to swing out when turning. Slow downand move toward the side being turned.

2-9.4. Stopping and Parking.

1. Slow down and press the brake pedal to stop thetruck.

2. Place the shift lever in neutral.

3. Apply the parking brake.

4. Tilt the forks until parallel with the floor.

5. Lower the forks to the ground.

6. Turn off the key switch and remove the key.

2-9.5. Loading and Unloading.

1. Place the truck in front of the load.

2. Adjust the forks sideways to maintain proper bal-ance of the load.

3. The pallet should be evenly positioned acrossboth forks.

4. Insert the forks into the pallet a far as possible.

5. To raise the load from the ground:

a. Slightly lift the load.

b. Be sure the load is stable.

c. Tilt the forks back to level the load.

R6977

BL-V-0217 - 12-16-2021 2-7

6. When handling bulky loads which restrict yourvision, operate the truck in reverse except whenclimbing grades.

2-9.6. Stacking.

1. Slowly approach the deposit area.

2. Stop the truck is right in front of the area.

3. Check the condition of the deposit area.

4. Tilt the mast forward until forks are horizontal.

5. Raise the forks until they are a little higher thanthe deposit area.

6. Move forward to place the load directly over thedesired area and stop the truck.

7. Make sure you load is just over the desired areaand slowly lower the load into position. Make surethe load is securely stacked.

8. Disengage forks from the load using necessary liftand tilt operation and then back the truck up.

9. After making sure the fork tips are clear of theload, lower the forks and tilt backwards.

2-9.7. Un-stacking.

1. Slowly approach the load to be retrieved.

2. Stop the truck is right in front of the load.

3. Check the condition of the load.

4. Tilt the mast forward until forks are horizontal.

5. Raise the forks up to the position of the pallet orskid.

6. Make sure the forks are positioned properly forthe pallet. Slowly move forward to insert the forksinto the pallet as far as possible and then stop thetruck.

7. Check around the truck to insure that the path oftravel is unobstructed and back away slowly.

8. Lower the forks and tilt backwards.

2-10.PARKING.

When finished with moving loads, return the truck to itsmaintenance or storage area. Turn off the key switch.Charge battery as necessary. Refer to battery manu-facturer for care instructions.

2-8 BL-V-0217 - 12-16-2021

SECTION 3PLANNED MAINTENANCE

3-1. GENERAL.

Planned maintenance consists of periodic visual andoperational checks, parts inspection, lubrication, andscheduled maintenance designed to prevent or dis-cover malfunctions and defective parts. The operatorperforms the checks in SECTION 2, and refers anyrequired servicing to a qualified maintenance techni-cian who performs the scheduled maintenance andany required servicing.

3-2. MONTHLY AND QUARTERLY CHECKS.

Table 3-1 iis a monthly and quarterly inspection andservice chart based on normal usage of equipmenteight hours per day, five days per week. If the lift truckis used in excess of forty hours per week, the fre-quency of inspection and service should be increasedaccordingly. These procedures must be performed bya qualified service technician or your Big Lift LLC Ser-vice Representative.

3-3. BATTERY CARE.

3-3.1. General

The V series lift trucks may be equipped with a mainte-nance free battery.

The care and maintenance of the battery is veryimportant to obtain efficient truck operation and maxi-mum battery life.

CAUTION: Gases produced by a battery can beexplosive. Do not smoke, use an openflame, create an arc or sparks in thevicinity of the battery. Ventilate anenclosed area well when charging.

CAUTION: Batteries contain sulfuric acid which maycause severe burns. Avoid contact witheyes, skin or clothing. In case of contact,flush immediately and thoroughly withclean water. Obtain medical attentionwhen eyes are affected. A baking sodasolution (one pound to one gallon ofwater) applied to spilled acid until bub-bling stops, neutralizes the acid for safehandling and disposal.

Leakage voltage from battery terminals to battery casecan cause misleading trouble symptoms with the truckelectrical system. Since components of the truck elec-trical system are insulated from truck frame, leakagevoltage will not normally affect truck operation unless ashort circuit or breakdown of circuit wire insulation totruck frame occurs.

A voltage check from battery connector terminal tobattery case should indicate near zero volts. Typically,however, the sum of the voltages at both terminals willequal battery volts. This leakage voltage will dischargethe battery. As battery cleanliness deteriorates, theusable charge of the battery decreases due to this selfdischarge

Table 3-1 Monthly and Quarterly Inspection and Service Chart

VISUAL CHECKS

INTERVAL INSPECTION OR SERVICE

Monthly Check electrical brakes for proper operation.

Monthly Check rear steering wheels for wear or damage.

Monthly Inspect wiring for loose connections and damaged insulation.

Monthly Check deadman brake switch for proper operation.

Monthly Check lift chain tension, lubrication & operation (see paragraph 3-7.)

Quarterly Check lift cylinder for leakage.

Quarterly Check for excessive jerking of steering when stopping or starting.

Semi-annually Inspect for chain wear (See SECTION 8)

BL-V-0217 - 12-16-2021 3-1

Although a leakage voltage reading of zero volts maynot be possible, a cleaner battery will have moreusable charge for truck operation and not affect opera-tion of electronic devices on the unit.

3-3.2. Safety Rules

• Wear protective clothing, such as rubber apron,gloves, boots and goggles when performing anymaintenance on battery. Do not allow electrolyte tocome in contact with eyes, skin, clothing or floor. Ifelectrolyte comes in contact with eyes, flush immedi-ately and thoroughly with clean water. Obtain medi-cal attention immediately. Should electrolyte bespilled on skin, rinse promptly with clean water andwash with soap. A baking soda solution (one poundto one gallon of water) will neutralize acid spilled onclothing, floor or any other surface. Apply solutionuntil bubbling stops and rinse with clean water.

• Do not bring any type of flame, spark, etc., near thebattery. Gas formed while the battery is charging, ishighly explosive. This gas remains in cell long aftercharging has stopped.

• Do not lay metallic or conductive objects on battery.Arcing will result

• Do not touch non-insulated parts of DC output con-nector or battery terminals to avoid possible electri-cal shock.

• De-energize all AC and DC power connectionsbefore servicing battery.

• Do not charge a frozen battery.

• Do not use charger if it has been dropped or other-wise damaged.

3-3.3. Battery Care and Charging

CAUTION: Never smoke or bring open flame nearthe battery. Gas formed during chargingis highly explosive and can cause seri-ous injury.

1. Charge the battery only in areas designated forthat use.

2. Make certain battery used meets weight and sizerequirements of truck. NEVER operate truck withan undersized battery.

3. For more information please see

Battery Manufacturers Recommendations

3-2 BL-V-0217 - 12-16-2021

3-4. CHARGING BATTERY

Charging requirements will vary depending on depth ofdischarge and temperature. Follow safety rules whenplacing a battery on charge.

Proceed as follows:

1. Park truck at charging station with carriage low-ered and turn the key switch off.

2. Apply the parking brake.

3. Pull up on latch and free catch.

Figure 3-1 Battery Access

4. Using hand hold (3), lift up the hood and seatassembly to expose the battery. The hood andseat assembly can be lifted up with little effort withthe aid of the installed gas shock.

5. Check the condition of the AC cord and batterycables. If there are any cuts in the cable, anyexposed wires, loose plugs or connectors, DONOT attempt to charge the battery. Contactappropriate personnel for repairs to be made..

6. Disconnect the battery connector (Figure 3-2)from the truck and connect the battery to the char-ger. Make sure connectors are mated properly.

Figure 3-2 Battery Connector

7. Connect the charger to the appropriate powersupply.R6922

R6966

BL-V-0217 - 12-16-2021 3-3

3-5. BATTERY REMOVAL

1. Park truck with carriage lowered, apply the park-ing brake and turn the key switch off. Pull up onlatch and free catch.

2. Using hand, lift up the hood and seat assembly toexpose the battery. The hood and seat assemblycan be lifted up with little effort with the aid of theinstalled gas shock.

3. Disconnect the battery connector from the truck.

4. Using a suitable lifting device remove the battery(Figure 3-3).

Figure 3-3 Battery Removal

NOTE: The steering wheel and other equipmentshould not be bumped when removing thebattery.

3-6. LUBRICATION.

Refer to Table 3-2 for the recommended types ofgrease and oil. Table 3-3 in conjunction with Figure 3-4 identifies the items requiring lubrication.

3-7. LIFT CHAIN MAINTENANCE.

Fully raise and lower lift carriage while observingchains as they move over chain sheaves. Ensurechain is aligned and tracking properly and all links arepivoting freely. With lift carriage fully lowered, spray orbrush on a film of SAE 30 or 40 engine oil.

Table 3-2 Recommended Lubricants(See Table 3-3 for Application)

R6967

No. 1 Transmission oil—EP SAE 80W-90Transmission oil—EP SAE 10W-30 (Note)

No. 2 Grease—Lithium base, general purpose.

No. 3 Hydraulic oil-Heavy duty with a viscosity of 150 SUS foam suppressing agent and rust and oxidation inhibitors

Hydraulic oil-Heavy duty with a viscosity of 100 SUS foam suppressing agent and rust and oxidation inhibitors (Note)

No. 4 SAE 30 or 40 Engine lubricating oil

No. 5 DOT3 Brake Fluid

NOTE: USED ON COLD CONDITIONED TRUCKS

3-4 BL-V-0217 - 12-16-2021

Figure 3-4 Lubrication Diagram

Table 3-3 Lubrication Chart

FIG 3-2 INDEX

NO.

LOCATION METHOD OF APPLICATION

TYPE (Table 3-3)

APPLICATION OF

LUBRICANT

1 Lift Chain Spray No. 4 See Paragraph 3-7.

2 Inner & Outer Mast Spray No. 2 Full length of channel where rollers operate.

3 Lift Carriage Spray No. 2 Light coating where forks slide.

4 TransmissionCapacity 2 pints

Can No. 1 Fill to level plug.

5 Hydraulic ReservoirCapacity-1 quarts

Can No. 3 With lift carriage fully lowered, fill reservoir with hydraulic oil to level on dip stick.

6 Brake Reservoir Can No. 5 Fill reservoir with brake fluid to level between seams of reser-voir.

R6968

BL-V-0217 - 12-16-2021 3-5

NOTES

3-6 BL-V-0217 - 12-16-2021

SECTION 4TROUBLESHOOTING

4-1. GENERAL

Use Table 4-1 as a guide to determine possiblecauses of trouble. The table is divided into five maincategories: Truck and Hydraulic System Will Not Oper-

ate: Truck Does Not Operate Forward or Reverse:Trouble With Braking: Trouble With Lifting Or Lower-ing, and Miscellaneous malfunctions.

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK AND HYDRAULIC SYSTEM WILL NOT OPERATE

Truck will not travel nor will lift sys-tem operate.

a. Emergency disconnect switch defective.

Bypass keyswitch to determine if it is malfunctioning.

b. Battery dead or disconnected. Check battery connections and check battery voltage.

c. Key switch defective. Bypass keyswitch to determine if it is malfunctioning.

d. Defective wiring. Check for open circuit. Repair as required.

TRUCK DOES NOT OPERATE FORWARD OR REVERSE

Truck does not travel forward or reverse. All other functions oper-ate normally.

a. Check all wiring. A loose con-nection may be the cause of malfunction.

Tighten all loose connections before further troubleshooting.

b. Defective controller. Check for proper operation and replace if necessary.

d. Defective accelerator. Check and replace accelerator if defective.

Truck travels forward but not in reverse.

Defective accelerator. Check and replace accelerator if defective.

Truck travels reverse but not in forward.


Truck travels forward and in reverse at lower speeds; will not travel at high speed.


TROUBLE WITH BRAKING

Insufficient brake force. a. Low brake fluid in reservoir. Check and refill.

b. Air in brake lines Bleed air

c. Uneven wear or contact of brake linings.

Replace.

Brake drags or grabs. a. No free play of brake pedal. Adjust

b. Clogged master cylinder return port.

Clean

c. Clogged brake lines Clean.

Table 4-1 Troubleshooting Chart - Continued

BL-V-0217 - 12-16-2021 4-1


TROUBLE WITH HYDRAULIC PUMP

No oil from hydraulic pump a. Oil level too low. Identify and repair oil leak and fill reservoir.

b. Clogged suction pipe or filter . Clean oil line and reservoir. If oil is dirty, change.

Low discharge pressure on hydraulic pump

a. Worn pump. Replace

b. Relief valve out of adjustment. Readjust to specified pressure using pressure gauge.

c. Air in hydraulic pump a. Re tighten suction lines.

b. Add oil to hydraulic reservoir.

Noisy hydraulic pump a. Cavitation due to crushed suc-tion line or clogged filter .

Adjust or replace damaged line and clean breather.

b. Air being sucked from loose suction joint.

Re tighten.

c. Cavitation due to too high oil viscosity

Replace with oil having proper vis-cosity for temperature.

d. Bubbles in hydraulic oil. Determine cause of bubbles and remedy.

Oil leaking from pump Faulty oil seal on pump Replace pump.

TROUBLE WITH CONTROL VALVE

Pressure of relief valve is bad or out of adjustment.

Loose of pressure --adjust screw Readjust and tighten.

Faulty control valve. Replace

Fork drift forward when key is off. Worn or damaged tilt section. Replace valve

Valve is not returning to neutral position.

a. Damage or distorted return spring

Replace valve

b. Dirt exists between valve body and spool.

Clean.

Leakage Faulty control valve Replace valve

TROUBLE WITH LIFTING SYSTEM

Mast tilts by itself a. Faulty tilt cylinder Repair tilt cylinder

b. Faulty control valve Replace valve

Lift carriage moves up and down sluggishly

a. Faulty lift cylinder Repair

b. Too much accumulated dirt Clean

c. Insufficient lubrication. Apply dry moly lube on contact surfaces of sliding parts.

4-2 BL-V-0217 - 12-16-2021

Table 4-1 Troubleshooting Chart - Continued


TROUBLE WITH LIFTING SYSTEM - Continued

Forks lift unevenly. Lift chains out of adjustment Adjust lift chains

Lift rollers do not rotate a. Grease stiffened or dirt accu-mulated on lift roller and mast sliding surfaces

Clean and lubricate lift rollers

b. Improperly adjusted lift rollers. Adjust

Excessive mast noise a. Insufficient lubrication Lubricate

b. Improperly adjusted lift rollers, side rollers.

Adjust.

Insufficient lift power or no lift movement.

a. Worn hydraulic pump. Replace

b. Worn lift cylinder seals resulting in excessive internal leakage.

Repair cylinder

c. Worn control valve Replace

d. Leaking hydraulic lines Tighten and inspect for damage

e. Oil temperature too high. Oil viscosity is too low.

Change hydraulic oil or stop oper-ation until oil cools. Find out the reasons for high oil temperature and eliminate the trouble.

f. Load larger than capacity. Refer to data plate on side of mast for maximum load capacity.

BL-V-0217 - 12-16-2021 4-3

4-2. CONTROLLER TROUBLESHOOTING

4-2.1. Programmable Parameters

The controller has a number of parameters that can be programmed using "Parameter Change" on the instrument panel LED. These programmable parameters allow the vehicle's performance characteristics to be customized to fit the needs of individual vehicles or vehicle applications.

Use the buttons on the instrument panel LED to change the following programmable parameters:o Accel Delay

• Release Braking

• Inverse Braking

• Pedal Braking

• Speed Limit Brk.

• Brake Cutback

• Max Speed Forw

• Cutback Speed 1

• Curve Cutback

• Frequency Creep

• Maximum Current

4-2.2. Fault Detection.

During normal operation with no faults present, theinstrument panel LED will display the truck speed. Ifthe controller detects a fault the LED will display a faultcode until the fault is corrected.

4-2.3. Diagnostics and Troubleshooting.

For suggestions about possible causes of the varioustraction system faults, refer to Table 4-2 Troubleshoot-ing Chart. For suggestions about possible causes ofthe various hydraulic system faults, refer to Table 4-3Troubleshooting Chart.

The following 4-step process is generally used fordiagnosing and troubleshooting an inoperative vehicleusing the programmer:

1. Visually inspect the vehicle for obvious problems:

2. Diagnose the problem:

3. Test the circuitry.

4. Correct the problem.

Repeat the last three steps as necessary until thevehicle is operational.

Refer to the Table 4-2 and Table 4-3 for sugges-tions covering a wide range of possible faults.

Table 4-2 Troubleshooting Chart (Traction System Faults)

DASHLED

CODE

ALARM (SEE PARAGRAPH

4-2.3.1.)

DESCRIPTION FAULT CLEARANCE

8 WATCH DOG ALARM: The watchdog alarm has been triggered

1. If the alarm is present in Init status, remove the cause of the alarm.

2. If the alarm has occurred in stby or running mode, it is necessary to remove cause of the alarm and to acti-vate a traction request.

17 LOGIC FAILURE #3 ALARM: failure in over-load protection hw circuit

Remove cause of the alarm and activate a traction request.

18 LOGIC FAILURE #2 ALARM: failure in U, V, W voltage feed-back circuit

Remove cause of the alarm and activate a traction request.

19 LOGIC FAILURE #1 ALARM: An overvoltage or under volt-age condition has been detected

Recycle the key switch

30 VMN LOW ALARM: Wrong voltage on motor power outputs; failure in the power section or in the mosfet driver circuit or in the motor


2. If the alarm has occurred in stby or running mode, it is necessary to remove the cause of the alarm and activate a traction request.

4-4 BL-V-0217 - 12-16-2021

Table 4-2 Programmable Parameters (Traction System Faults) - Continued

DASHLED

CODE


4-2.3.1.)


31 VMN HIGH ALARM: Wrong voltage on motor poweroutputs; failure in the power section or in

the mosfet driver circuit or in the motor

1. If the alarm is present in Init status,remove the cause of the alarm.


53 STBY 1 HIGH ALARM: Wrong voltage in the currentsensor feedback circuit



60 CAP CHARGE ALARM: power capacitor voltage doesnot increase when key is turned ON; fail-

ure in the power section, or in the logic PCB, or in the driver PBC, or in the motor

Remove cause of the alarm.

74 DRIVER SHORTED ALARM: Line contactor coil driver is shorted.



75 CONTACTOR DRIVER ALARM: Line contactor coil driver is open (not able to drive the coil to the correct voltage).

Remove the cause of the alarm and activate a traction request.

76 COIL SHORTED ALARM:

1. Init mode, the LC and EB coil driver protection circuit is damaged.

2. Stby or running mode, short on LC coil or EB coil.



37 CONTACTOR CLOSED ALARM: Line contactor is stuck. Remove the cause of the alarm within a timeout; if the timeout is elapsed, it is necessary to remove the cause of the alarm and activate a traction request.

BL-V-0217 - 12-16-2021 4-5


DASHLED

CODE


4-2.3.1.)


38 CONTACTOR OPEN ALARM: Line contactor does not pull-in. Remove the cause of the alarm within a timeout; if the timeout is elapsed, it is necessary to recycle the key.

82 ENCODER ERROR ALARM: Motor speed sensor (encoder) does not work properly.

Recycle the key.

84 STEER SENSOR KO ALARM: Steering pot signal out of range.

Remove the cause of the alarm.

86 PEDAL WIRE KO ALARM: Fault in accelerator negative (NPOT) input circuit.

Remove the cause of the alarm and activate a traction request.

245 WRONG SET BATTERY

ALARM: The battery voltage does not correspond to programmed SET BATTERY.


246 SLAVE KO ALARM: Master µC detects a slave µC malfunction


247 MASTER KO ALARM: Slave µC detects a master µC malfunction or a mismatch between input status and Master commands (via canbus).

Recycle key.

250 INPUT MISMATCH ALARM: Slave µC detects a mismatch between input status and input status transmitted via canbus by Master µC.

Recycle key.

253 AUX OUTPUT KO ALARM: EB coil driver shorted or open. 1. If the alarm is present in Init status, remove the cause of the alarm.


13 EEPROM KO Warning: Eeprom fault, controller will use default parameters.

Remove the cause of the warning.

61 HIGH TEMPERATURE Warning: Master or slave or both temperature higher than 75C.


65 MOTOR TEMPERA-TURE

Warning: Right or left or both temperature high.


66 BATTERY LOW Warning: Battery charge level below 20%


78 VACC NOT OK Warning: Accelerator signal (CPOT) voltage higher than VACC MIN +1V while the traction enable switch is open.


79 INCORRECT START Warning: Wrong traction sequence. Remove the cause of the warning.

4-6 BL-V-0217 - 12-16-2021

4-2.3.1. Traction related alarms

WATCH DOG

It is a self-diagnosing test within the logic betweenMaster and Slave µcontrollers. This alarm could alsobe caused by currblinds Master-Slave communica-tion. So, before replacing the controller, check the can-bus.

LOGIC FAILURE #3

Fault in the hardware section of the logic board whichmanages the hardware current protection. Replace thelogic board.

LOGIC FAILURE #2

Fault in the hardware section of the logic board whichmanages the phase's voltage feedback. Replace thelogic board.

LOGIC FAILURE #1

This a hardware current ggered. Two possible rea-sons:

1. A real under voltage/overvoltage situation hap-pened.

2. Fault in the hardware section of the logic boardwhich manages the over voltage prote3ction.Replace the logic board.

VMN LOW, VMN HIGH

The test is carried out during initial diagnosis and instandby. Possible causes:

1. Problem with the motor connections or the motorpower circuit; check if the 3 phases are correctlyconnected; check if there's a dispersion of themotor to truck frame.

2. Fault in the inverter power section, replace thecontroller.

STBY 1 HIGH

The µCs verify if the feedback of current sensorsdevice output is within the zero current window. Possi-ble causes of the alarm:

1. Current sensor failure.

2. Failure in the logic card: first replace the logiccard; if the defect persists, replace the power unit.

CAPACITOR CHARGE

Follows the charging capacitor system: When the keyis switched ON, the inverter tries to charge the capaci-tor through a power resistance, and check if thecapacitor are charged within a time-out. If they do notcharge, an alarm is signaled; the main contact is notclosed.

Possible reasons:

1. The charging resistance is opened.

2. The charging circuit has a failure.

3. There is a problem in the power section.


DASHLED

CODE


4-2.3.1.)


80 FORWARD+BACK-WARD

Warning: Forward and reverse input are both active.


249 THERMIAC SENSOR KO

Warning: Master or slave temperature sensor is out of range.


251 WAITING FOR NODE #4

Warning: Master µC signal that slave µC is in alarm status.


251 WAITING FOR NODE #3

Warning: Slave µC signal that master µC is in alarm status.


241 NO CAN MESSAGE #4 ALARM: Master has lost can communi-cation with the slave.


247 NO CAN MESSAGE #4 ALARM: Slave has lost can communica-tion with the master.


BL-V-0217 - 12-16-2021 4-7

MAIN CONTACTOR ALAMS:

COIL SHORTED

When the key is switched ON the µController checksthe LC coil driver short-circuit protection hardware. If itdoes not react in a correct way to the µC stimulus, thealarm is signaled. Replace the logic board. When thefault occurs while the LC is closed, the alarm signals ashort-circuit across LC coil. Check if there are externalshort-circuit and if the ohmic value of the MC coil iscorrect; otherwise replace the logic.

DRIVER SHORTED

When the key is switched ON the µC checks the LCcoil driver is not shorted; if it is, this alarm is signaled.Preliminary, check if there is an external short or lowimpedance pull-down between NLC (C26) and -BATT.If no external causes can be found, replace the con-troller.

CONTACTOR DRIVER

When the initial diagnosis is finished, the traction logiccloses the LC and checks the voltage on the Drain ofthe driver. If this is not low, the driver is not able toclose an alarm is signaled. Replace the logic.

CONTACTOR OPEN

The main contactor. coil has been driven by the logicboard, but the contactor. does not close. Two possiblereasons:

1. The wires to the coil are interrupted or not wellconnected.

2. The contactor is not properly working (does notpull-in).

CONTACTOR CLOSED

Before driving the LC coil, the controller checks if theLC contact is stuck. The controller drives the bridge fora while, trying to discharge the capacitor bank. If theydon't discharge, the fault condition is entered. It is sug-gested to check the contactor if it is mechanicallystuck.

ENCODER ERROR

This alarm is signaled by the following condition: thefrequency supplied to the motor is higher than 20 Hz,and the signal feedback from the encoder has a jumphigher than 20 Hz in few tens millisecond. This condi-tion clearly shows a malfunctioning of the encoder sig-nal. It is suggested to preliminary check the encoderwiring; if no fault is found in the wiring it is necessary toreplace the encoder.

STEER SENSOR KO

This is an alarm which indicates an out of range steer-ing potentiometer signal. The fault condition is enteredin the following two conditions:

1. The "Set steer 0 pos" (straight wheels progranna-tion) parameter is wrong (lower than "Set steermin" or higher than "Set steer max").

2. The feedback signal of the steering potentiometeris outside the window defined by "Set steer min"and "Set steer max" parameters.

In the first case, repeat the steering potentiometeracquisition. In the second case, check the steeringpotentiometer and its wiring. Eventually, repeat thesteering potentiometer acquisition.

PEDAL WIRE KO

This alarm is signaled if a fault is detected in the accel-erator unit wiring (NPOT or PPOT cable is interrupted.

WRONG SET BATTERY

When the key is turned ON, the controller checks thebattery voltage and compares it with the "SET BAT-TERY" parameter setting. If the actual value is 20%higher or lower than nominal value, the fault conditionis entered. Replace the battery with a correct battery.

SLAVE KO

Slave and Master µCs perform a cross-check in orderto verify their functionality. If the MASTER detectsSLAVE µC malfunctioning, it brings the controller in asafe status opening the power bridge and the LineContactor.

MASTER KO

Slave and Master µCs perform a cross-check in orderto verify their functionality. There are two conditionsunder which slave enters this fault condition:

1. The SLAVE µC receives incoherent can messagefrom the MASTER µC.

2. The SLAVE µC compares the inputs status andthe related MASTER operations, and find they arenot coherent.

In both cases, the SLAVE brings the controller to asafe status opening the power bridge and the LineContactor

4-8 BL-V-0217 - 12-16-2021

INPUT MISMATCH

Safety related inputs (Fw direction, Rev direction,accelerator enable, seat switch) are input to bothmicro controllers by independent hw circuit. The two

µCs read these input and compare by exchangingrelated status on the canbus. If the SLAVE µC finds amismatch between its inputs and MASTER inputs, itbrings the controller to a safe status opening thepower bridge and the Line Contractor.

AUX OUTPUT KO

The µP checks the driver of the electromechanicalbrake coil. If the status of he driver output does notcorrespond to the signal coming from the µP, the alarmis signaled. It is suggested to preliminary check if thereis an external short or low impedance pull downbetween NAUX (C31) and -BATT. If no external causecan be found, replace the logic card.

EEPROM KO

Fault in the area of memory in which the adjustmentparameters are stored; this alarm does not inhibit truckoperation, but the controller sill use default parame-ters. If the defect persists when the key is switchedOFF and ON, replace the logic. If the alarm disap-pears, remember that the parameters stored previ-ously have been cancelled and replaced by the defaultvalues.

HIGH TEMPERATURE

Master or Slave or both temperatures are greater than

75 C. The maximum current is reduced proportionallyto the temperature increase. At 100 C the max currentof both inverter is reduced to zero. If the alarm is sig-naled when he controller is cold:

1. Thermal sensor failure.

2. Failure in the logic card.

MOTOR TEMPERATURE

This warning is signaled if right or left or both motortemperature switches open (digital sensor) or if theanalog signals overtake the cut off level. If it happenswhen the motor is cold, check wiring. If all is ok,replace the logic board.

BATTERY LOW

If the "battery check option is ON, a battery dischargealgorithm is carried out. When the charge level is 20%,this alarm is signaled and the current i reduced to halfof the programmed level.

VACC NOT OK

The test is made in standby. This alarm indicates thatthe accelerator voltage is 1V greater than the mini-mum value programmed by the PROGRAM VACC

function. Possible causes:

1. The potentiometer is not correctly calibrated.

2. The potentiometer is defective.

INCORRECT START

This alarm signals an incorrect starting sequence.Possible causes:

1. Fw ore Rev or Enable micro switch failure.

2. Error in sequence made by the operator.

3. Incorrect wiring.

4. If the default persists after checking the har-ness, replace the logic.

FORW + BACK

The test is carried out continuously. An alarm is sig-naled hen a double running request is made simulta-neously. Possible causes:

1. Defective wiring.

2. Running micro switch failure.

3. Incorrect operation.

4. If the defect persists, replace the logic.

THERMIC SENSOR KO

The range of inverter temperature sensor is alwayschecked and a warning is signaled if it is out of range.When this alarm is signaled, the maximum current ofthe controller is reduced to 0.

WAITING FOR NODE #4

The Slave has detected a failure, the Master cannotclose the main contactor because of the alarm statusof the Slave (Which the Master knows by the CAN-BUS line). The failure must be looked for in the Salvecontroller, use the remote console to get connection tothe Slave µC.

WAITING FOR NODE #3

The Master µC has detected a fault condition, theSlave is aware of this thanks to canbus communica-tion; it cannot drive the motor until the Master hasresolved it problem. The fault has to be looked for inthe Master.

NO CAN MESSAGE #4

Master (node #3) signals that it has lost can communi-cation with the Slave (node #4). This fault could bedetermined by a problem in the truck canbus line or byan internal problem in the controller logic card. It issuggested to preliminary check canbus connection

BL-V-0217 - 12-16-2021 4-9

NO CAN MESSAGE #3

Slave (node #4) signals that it has lost can communi-cation with the Master (node #3). This fault could be

determined by a problem in the truck canbus line or byan internal problem in the controller logic card. It issuggested to preliminary check canbus connection.

Table 4-3 Troubleshooting Chart (Hydraulic System Faults)

4-2.3.2. Pump related alarms

PUMP VMN LOW

The pump chopper power output is feedback to the

µC. If this feedback voltage is not coherent with theapplied PWM, this fault condition is signaled. Therecould be many causes:

1. Failure in the pump chopper power section.

2. Failure in the pump chopper driving section

3. Failure in the pump chopper voltage feedback cir-cuit.

4. Dispersion in the pump motor to truck frame.

PUMP STBY I HIGH

The pump chopper current sensor feedback is out ofthe zero-current window while no PWM is applied tothe pump chopper. The most likely cause is a failure inthe current sensor.

PUMP TEMPERATURE

Pump chopper temperature is higher than 75 C, maxi-mum current is proportionally reduced. If the alarm ispresent when the controller is cold, there is a failure inthe temperature sensor or in the feedback circuit.

PUMP

This is a warning in the MASTER controller, whichinform that the SLAVE is in a pump chopper relatedfault condition.

DASHLED

CODE

ALARM DESCRIPTION FAULT CLEARANCE

28 PUMP VMN LOW ALARM: Wrong voltage of pump chop-per, the motor voltage feedback is not coherent with the applied PWM.


2. If the alarm has occurred in stby or running mode, it is necessary to remove cause of the alarm and to acti-vate a function request.

56 PUMP STBY 1 HIGH ALARM: In stby condition (no OWM applied to pump chopper) the pump current sensor feedback is out of he zero current window.


2. If the alarm has occurred in stby or running mode, it is necessary to remove cause of the alarm and to acti-vate a function request.

242Slave

PUMP TEMPERAT Warning: The pump chopper tempera-ture is higher than 75C.

Remove cause of the warning.

242Master

PUMP Warning: Master controller signals that slave µC has detected a fault in the pump chopper.


243 PUMP INC. START Warning: Pump incorrect start sequence Remove cause of the warning.

244 PUMP VACC MOTOR Warning: Pump accelerator voltage is 1V greater than the minimum value programmed


4-10 BL-V-0217 - 12-16-2021

SECTION 5STEERING SYSTEM

5-1. STEERING COLUMN

5-1.1. Cover Removal.

1. Turn off key switch and disconnect the battery.

2. Remove four screw, four lock washers, four flatwashers and cover.

3. Disconnect harness from key switch.

4. Remove tilt handle from axis.

5. Remove four bolts, four lock washers, four flatwashers, four bushings and cover.

6. Remove four grommets from steering column(10)

5-1.2. Cover Installation.

1. Install four grommets on steering column.

2. Position cover on steering column and securewith four bolts, four lock washers, four flat wash-ers, and four bushings

Figure 5-1 Steering System

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BL-V-0217 - 12-16-2021 5-1

3. Install tilt handle .

4. Reconnect harness to key switch.

5. Position cover on the steering column and securewith four screws, four lock washers, four flatwashers .

6. Reconnect the battery and turn on key switch.

5-1.3. Steering Column Removal


2. Remove the covers from the steering column asdescribed in paragraph 5-1.1.

3. Remove the dash as described in paragraph 10-1.

4. Remove rubber floor mat.

5. Lift up floor board and disconnect harness ( fromaccelerator and move floor board out of the way.

6. Remove the directional switch and light switch asdescribed in paragraph 10-5.

7. Disconnect harness from harness.

8. Remove bolt and lock washer.

Figure 5-2 Steering Column

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5-2 BL-V-0217 - 12-16-2021

9. Spread top of universal shaft and free it fromsteering shaft.

10. Attach a suitable lifting device to the steeringwheel and remove four nuts, four lock washers,eight flat washers (8), shock absorber, fourscrews and steering column. Refer to Figure 5-2for disassembly.

11. Remove steering pump as described in paragraph9-5.

12. Remove four nuts, four lock washers, eight flatwashers (20), four screws and housing. Refer toFigure 5-2 for disassembly.

5-1.4. Steering Column Installation

1. Position housing on its mounting bracket andsecure with four nuts, four lock washers, eight flatwashers, and four screws.

2. Install steering pump as described in paragraph9-5.

3. Attach a suitable lifting device to the steeringwheel and position on its mounting bracket.Secure with four screws, four lock washers, eightflat washers, shock absorber, and four nuts

4. Position top of universal shaft on steering shaftand secure with bolt and lock washer.

5. Reconnect harness to harness.

6. Install the directional switch and light switch asdescribed in paragraph 10-5.

7. Reconnect harness from accelerator and installfloor board.

8. Install rubber floor mat.


10. Install the covers from the steering column asdescribed in paragraph 5-1.2.


5-2. COUNTERWEIGHT REMOVAL.


2. Remove two screws on top of the rear cover.

3. Remove two bolts , two lock washers, two flatwashers and rubber cover.

4. Attach a suitable lifting device to counterweight.

5. Remove three bolts, three lock washers and threeflat washers.

6. Remove counterweight.

5-3. COUNTERWEIGHT INSTALLATION.

1. Using a suitable lifting device, position counter-weight on frame.

2. Secure counterweight with three bolts, three lockwashers and three flat washers.

3. Position rubber cover on frame and secure withtwo bolts, two lock washers and two flat washers.

4. Position cover on frame and secure with twoscrews.

5. Reconnect the battery and turn on key switch

5-4. STEERING AXLE REMOVAL.


2. Remove the counterweight as described in para-graph 5-2.

3. Remove covers and loosen, but do not removenuts.

4. Raise the rear of the truck off the ground to pro-vide clearance for steering axle removal. Securelyblock the truck to prevent movement.

5. Remove nuts and rear wheels.

6. Disconnect hoses from steering axle.

7. Remove rubber shield from potentiometer.

8. Disconnect harness from potentiometer.

9. Remove two screws, two lock washers, two flatwashers and potentiometer from bracket.

10. Remove potentiometer shaft from axle.

11. Remove two screws, two lock washers, two flatwashers and bracket from axle.

BL-V-0217 - 12-16-2021 5-3

Figure 5-3 Frame and Counterweight

12. Attach a suitable lifting device to axle and removefive screws, five lock washers , five flat washersand axle.

5-5. STEERING AXLE INSTALLATION.

1. Using a suitable lifting device position axle on itsmounting bracket. Secure with five screws, fivelock washers, and five flat washers.

2. Install bracket on axle and secure with twoscrews, two lock washers and two flat washers.

3. Install potentiometer shaft on axle.

4. Install potentiometer from bracket and secure withtwo screws, two lock washers and two flat wash-ers.

5. Reconnect harness to potentiometer.

6. Install rubber shield on potentiometer.

7. Reconnect hose to steering axle.

8. Install rear wheels and secure with nuts.

9. Remove the blocking and lower the truck to theground.

10. Reinstall covers.

11. Reinstall the counterweight as described in para-graph 5-3.


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5-4 BL-V-0217 - 12-16-2021

Figure 5-4 Rear Steering

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BL-V-0217 - 12-16-2021 5-5

5-6

NOTES

BL-V-0217 - 12-16-2021

SECTION 6BRAKE SERVICING

6-1. BRAKES.

There are two types of brakes: hand brake and footbrake. The hand brake uses two cables to apply thetwo Parking brake. The foot brake use a master cylin-der to apply the same brakes.

6-2. HAND BRAKES.

6-2.1. Removal

1. Block wheels to prevent movement.




5. Lift up floor board and disconnect harness fromaccelerator and move floor board out of the way.

6. Release the hand brake to remove tension fromthe cables.

7. Disconnect harness from harness.

8. Remove safety switch from hand brake.

Figure 6-1 Steering and Brake Controls

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BL-V-0217 - 12-16-2021 6-1

9. Disconnect the two cables from the bottom of thehand brake.

10. Remove the two nuts, two lock washers, four flatwashers, two screws and hand brake from frame.

6-2.2. Installation

1. Position hand brake on frame and secure with twoscrews, two lock washers, four flat washers, andtwo nuts.

2. Reconnect the two cables to the bottom of thehand brake.

3. Install safety switch on hand brake and adjust soit closes when the brake is engaged.

4. Reconnect harness to harness

5. Engage the hand brake and remove the blockingfrom under the truck. The force of hand brakelever can be adjusted with. Turn the screw clock-wise to increase pull force. Turn the screw coun-terclockwise to decrease the pull force.

6. Reconnect harness to accelerator and install floorboard.

7. Reinstall rubber floor mat.

8. Install the dash as described in paragraph 10-1.


6-3. FOOT BRAKE.

6-3.1. Master Cylinder Removal

1. Block wheels to prevent movement.

2. 2.Turn off key switch and disconnect the battery.

3. 3.Remove the dash as described in paragraph10-1.


5. Lift up floor board and disconnect harness fromaccelerator and move floor board out of the way.

6. Loosen clamp and remove hose

7. from master cylinder.

8. Disconnect hoses from master cylinder.

9. Remove cotter pin and clevis pin from the end ofthe master cylinder.

10. Remove two nuts, two lock washers, four flatwashers, two screws and master cylinder from themounting bracket on frame..

6-3.2. Master Cylinder Installation

1. Position the master cylinder on the mountingbracket on frame and install two screws, two lockwashers, four flat washers, and two nuts.

2. Line up the end of the master cylinder with hole inpedal and install clevis pin and cotter pin.

3. Reconnect hoses to master cylinder.

4. Reconnect hose to master cylinder and securewith clamp (10).

5. Bleed the brakes as described in paragraph 6-3.3.

6. Reconnect harness to accelerator and install floorboard.

7. Reinstall rubber floor mat.

8. Install the dash as described in paragraph.


10. Removing the blocking from the wheels

6-3.3. Bleeding the Brakes

There are 3 holes on the brake booster of reductiongear box. Loosen the air bleed plug to let the air out ofbrake oil tube. Then tighten the plug.

6-2 BL-V-0217 - 12-16-2021

Figure 6-2 Brake Pedal

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NOTES

6-4 BL-V-0217 - 12-16-2021

SECTION 7TRANSMISSION, DRIVE WHEELS, REAR WHEELS

7-1. STEERING WHEEL


2. Remove covers and loosen, but do not remove,nuts.

3. Securely block the front wheels to prevent move-ment.

4. Raise the rear of the truck off the ground to pro-vide clearance for wheel removal. Block the truckto prevent accidental lowering.

5. Remove nuts and rear wheels.

6. Release the air pressure in the tire.

7. Remove and replace the tire.

8. Install front wheel in reverse order of removal.

9. Torque nuts (11) to 89-119 ft-lb (121-162 Nm).


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BL-V-0217 - 12-16-2021 7-1

7-2. DRIVE WHEEL.


2. Remove covers and loosen, but do not remove,nuts.

3. Securely block the rear wheels to prevent move-ment.

4. Raise the side of the truck off the ground to pro-vide clearance for wheel removal. Block the truckto prevent accidental lowering.

5. Remove nuts and wheel.

6. Remove and replace the tire.

7. Install front wheel in reverse order of removal.

8. Torque nuts (13) to 102 ft-lb (140 Nm).

7-3. TRANSMISSION.

1. Remove the drive wheel as described in para-graph 7-2.

2. Remove the drive motor as described in para-graph 10-6.1.

3. Remove five bolts, five lock washers and five flatwashers.

4. 4.Support transmission and remove two bolts,bolt, three lock washers and three flat washers.

5. 5.Remove transmission.

6. 6.Refer to Figure 12-13 for disassembly.

7. Support transmission and install two bolts, bolt,three lock washers and three flat washers.

8. 2.Install five bolts, five lock washers and five flatwashers.

9. 3.Install the drive motor as described in para-graph 10-6.2.

10. Install the drive wheel as described in paragraph7-2.

Figure 7-2 Drive

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SECTION 8ELEVATION SYSTEM SERVICING

8-1. GENERAL.

The elevation system includes the outer mast, innermast, lift linkage, lift chains, lift cylinder and ram head

8-2. LIFT CHAIN WEAR INSPECTION.

The lift chain should be replaced when it is wornenough to increase it's length by 3% or more. On Tele-cospic trucks, Both chains should be replaced at thesame time. To make this determination proceed as fol-lows.

Using a section of chain that sees the most frequentoperation over the chain sheaves, isolate a verticalportion under tension from the weight of carriage andforks.

Measure the distance between pin centers on 20 verti-cal links. If the section measures 12.88" or more, thechain should be replaced.

New chain anchor pins should be installed whenchains are replaced. Never replace a partial section ofchain and never repair chain. Refer to paragraph 8-4.when installing new chain.

8-3. LIFT CHAIN LENGTH ADJUSTMENT.

1. Fully lower the lift carriage.


3. WARNING: Before attempting any adjustment,make certain power is disconnected.

4. Loosen jam nuts, located the above either themast or the bracket to allow for adjustment of mid-dle jam nut.

5. Break the lower jam nuts free from the middle jamnuts.

6. Take up slack in both lift chains with middle jamnuts.

7. Align anchors so the clevis pins are parallel to themast.

8. CAUTION:At least 3 full threads must be presentbelow lower nuts after adjustment.

9. Tighten jam nuts securely while maintaining align-ment of clevis pins.


11. Test chain by operating carriage. If slack is stillapparent, repeat above procedure.

Figure 8-1 Chain Assembly

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BL-V-0217 - 12-16-2021 8-1

8-4. LIFT CHAIN REPLACEMENT.

1. With the lift truck wheels securely blocked, raisethe forks approximately three feet from floor andposition blocks or strong supports under the liftcarriage.

2. Lower lift carriage onto the support. Check thatarrangement is secure before proceeding.


WARNING: Beforeattemptinganyreplacement, makecertain power is disconnected.

4. Remove cotter pin and clevis pin connectingchain to adjusting screw at the lift mast.

5. Remove cotter pin and clevis pin connectingchain to anchor at the lift carriage.

6. Remove chain from sheave.

7. Position new chain on the sheave.

8. Secure chain to anchor at lift carriage with clevispin and cotter pin.

9. Connect the opposite end of chain to adjustingscrew at the mast with clevis pin and cotter pin.

10. Adjust the chains according to paragraph 8-3.


8-5. LIFT CYLINDERS.

NOTE: Removal and repair of lift cylinders are cov-ered in SECTION 9.

Figure 8-2 Chain Assembly

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8-2 BL-V-0217 - 12-16-2021

SECTION 9HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS

WARNING: When forks are raised, pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the battery discon-nected before performing any mainte-nance on the hydraulic system.

NOTE: Leaking hydraulic fittings may be remedied bysimply tightening fittings. If this does not rem-edy the leak, the fittings or line must bereplaced.

1. Lower forks fully.


3. Remove the rubber floor mat.

4. Lift up on floor board and disconnect harnessfrom accelerator and move the floor board out ofthe way.

5. Remove two screws and cover.


Figure 9-1 Battery Access

7. Using hand hold, lift up the hood and seat assem-bly to expose the battery. The hood and seatassembly can be lifted up with little effort with theaid of the installed gas shock.

8. Remove bolt and cover.

9. Remove four bolts and cover.

CAUTION: Hydraulic oil can damage parts. Wipe offany oil immediately. Provide a containerunder the line or fitting before discon-necting

10. Refer to Figure 9-2 and remove leaking line or fit-ting and replace it with a new line or fitting.

11. Check level of hydraulic oil. If required, addhydraulic oil to bring to proper level. Use hydraulicoil listed in Table 3-2.


13. Operate all hydraulic levers to refill the cylindersand lines with hydraulic oil.

14. Turn the steering wheel back and forth to refillsteering axle and lines with hydraulic oil.


16. Install all covers removed in steps 3. thru 9.

9-2. HYDRAULIC RESERVOIR

CAUTION: Hydraulic oil can damage parts. Wipe offany oil immediately. Provide a containerunder the line or fitting before discon-necting.




4. Using hand hold (3), lift up the hood and seatassembly to expose the battery. The hood andseat assembly can be lifted up with little effort withthe aid of the installed gas shock.


6. Remove dipstick and cap from the reservoir

7. Remove plug and drain the reservoir.

8. Remove ten bolts, ten lock washers, ten flatwashers and cover.

9. Remove all traces of gasket from the reservoir.

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BL-V-0217 - 12-16-2021 9-1

Figure 9-2 Hydraulic System

10. Remove and clean filter.

11. Install filter in the reservoir.

12. Install cover with new gasket and secure with tenbolts, ten lock washers, and ten flat washers.

13. Add hydraulic oil to bring to proper level. Usehydraulic oil listed in Table 3-2.

14. Reinstall dipstick and cap.

15. Install cover and secure with bolt.


17. Lower hood and seat assembly and secure withcatch.

9-3. HYDRAULIC PUMP REMOVAL.






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9-2 BL-V-0217 - 12-16-2021

5. Remove dipstick and cap from the reservoir.

6. Remove plug and drain the reservoir.

7. Loosen clip and disconnect hose from fitting.

8. Disconnect hose from fitting .

9. Remove two bolts, two lock washers, two flatwashers and pump from motor.

10. Remove fittings from the pump.

9-4. HYDRAULIC PUMP INSTALLATION.

1. Install fittings with new O- rings (18 and 19) onpump.

2. Install pump on motor and secure with two bolts,two lock washers and two flat washers.

3. Reconnect hose to fitting.

4. Reconnect hose to fitting and secure with clip.

5. Reinstall plug and drain the reservoir.

6. Add hydraulic oil to bring to proper level. Usehydraulic oil listed in Table 3-2.

7. Reinstall dipstick and cap.

8. Reconnect harness from accelerator and lower itinto position.

9. Reinstall the rubber floor mat.


9-5. STEERING PUMP.

9-5.1. Removal





4. Lift up on floor board and disconnect harnessfromaccelerator and move the floor board out of theway.

5. Tag and disconnect hoses from steering pump.

6. Remove two elbows and two elbows fromsteering pump.

7. Loosen clip and remove return hose from fitting.

8. Remove fitting and seal from steering pump.

9. Remove four bolts, four lock washers, four flatwashers and steering pump from housing.

9-5.2. Installation.

1. Position steering pump on housing and securewith four bolts, four lock washers and four flatwashers.

2. Install fitting and seal on steering pump.

3. Install fitting and seal on steering pump.

4. Connect return hose to fitting and secure with clip.

5. Install two elbows and two elbows on steeringpump.

6. Reconnect hoses from steering pump.



9. Turn the steering wheel back and forth to refillsteering axle and lines with hydraulic oil.



12. 12. Reinstall the rubber floor mat.

9-6. STEERING AXLE.

NOTE: Removal of the steering axle is covered inSECTION 5.

BL-V-0217 - 12-16-2021 9-3

Figure 9-3 Hydraulic Reservoir

9-7. CONTROL VALVE

9-7.1. Removal

WARNING: When forks are raised, pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the battery discon-nected before performing any mainte-nance on the hydraulic system.




4. Lift up on floor board (15) and disconnect harnessfrom accelerator and move the floor board out ofthe way.

5. Remove four bolts and cover.


6. Tag and disconnect hoses from valve.

7. Remove covers from switches.

8. Tag and disconnect electrical leads from eachswitch.

9. Remove four screws, four lock washers, four flatwashers, and mounting plate with valve fromframe.

10. Remove cotter pins and clevis pins and free linkfrom spools of valve.

11. Remove three screws, three lock washers, threeflat washers, valve and shock absorber frommounting plate.

12. Remove screws, lock washers, flat washers andbracket from each spool of valve.

9-7.2. Installation

1. Position brackets on each spool of valve andsecure with screws, lock washers, and flat wash-ers.

2. Position valve on mounting plate and secure withthree screws, three lock washers, three flat wash-ers, valve and shock absorber from mountingplate.

3. Connect spools of valve with clevis pins and cot-ter pins.

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9-4 BL-V-0217 - 12-16-2021

4. Adjust switches so that the switch opens andcloses when the controls levers are moved.

5. Position mounting plate with valve on frame andsecure with four screws, four lock washers, fourflat washers.

6. Reconnect electrical leads to each switch.

7. Install covers on switches.

8. Reconnect hoses to valve.

9. Install cover and secure with four bolts.

10. Reconnect harness from accelerator and lowerfloor board into position.






Figure 9-4 Valve Control Levers

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BL-V-0217 - 12-16-2021 9-5

9-8. TILT CYLINDER

9-8.1. Removal

WARNING: Mast must be supported by a hoistbefore removing tilt cylinders.

1. Raise the forks to approximately three feet. Tiltthe mast all the way forward.

2. Secure mast with a hoist.


4. Lift up on floor board (15) and disconnect harnessfrom accelerator and move the floor board out ofthe way.

5. Remove bolt, lock washer and pin.

6. Pull tilt control back to free tilt cylinder from themast.

NOTE: Leaking hydraulic fittings may be remedied bysimply tightening fittings. If this does not rem-edy the leak, the fittings or line must bereplaced.

7. Tag and disconnect hoses from the tilt cylinder.

8. Support cylinder and remove bolt, lock washerand pin.

9. Remove the cylinder.

9-8.2. Repair

WARNING: To prevent cylinder damage, use properpipe vise. The cylinder will be distorted ifthe vise is tightened too much.

1. Secure the cylinder assembly in a vise.

2. Remove nut, lock washer, bolt and clevis endfrom piston rod.

3. Remove snap rings and bearing from clevis end.

4. Using spanner wrench, unthread gland nut fromcylinder body.

5. Remove dust seal, O-ring, snap ring, seal, bear-ing and O-ring from gland nut.

Figure 9-5 Hydraulic Tilt (Telescopic Shown)

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9-6 BL-V-0217 - 12-16-2021

6. Pull piston rod (14) from cylinder body.

7. Remove seals (16) and wear ring from the piston.

NOTE: Before reassembling the cylinder, it is recom-mended that packing kit items be replaced.

8. Reassemble the cylinder in reverse order for dis-assembly.

9-8.3. Installation

1. Position the tilt cylinder in the frame and install pinand secure with bolt and lock washer.

2. Reconnect hoses to the tilt cylinder

3. Move the tilt control forward to extend the mount-ing bracket on the mast.

4. Install pin and secure with bolt and lock washer.

5. Remove the hoist from the mast.

6. Reconnect harness from accelerator and lowerfloor board into position.





Figure 9-6 Tilt Cylinder

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BL-V-0217 - 12-16-2021 9-7

9-9. LIFT CYLINDER (TRIMAST)

9-9.1. Free Lift Cylinder




WARNING: Before attempting any replacement,make certain power is disconnected

CAUTION: Hydraulic oil can damage parts. Wipe offany oil immediately. Provide a containerunder the line or fitting before discon-necting relieve the hydraulic pressure

4. Remove the lift chain as described in paragraph8-4.

5. Disconnect the hose from tube.

6. Remove tube from lift cylinder.

7. Manually push the cylinder rod down as far aspossible.

8. Remove screw, lock washer, flat washer, bracketand ram head from cylinder.

Figure 9-7 Hydraulic Lift (TRIMAST)

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9-8 BL-V-0217 - 12-16-2021

WARNING: Support lift cylinder before performingthe following steps to prevent cylinderfrom falling.

9. Remove two bolts, two lock washers, and two flatwashers.

10. Raise lift cylinder assembly up and out of truck.

11. Position the cylinder in the mast and secure withtwo bolts , two lock washers and two flat washers.

12. Install ram head and bracket on top of cylinderand secure with screw, lock washer, flat washer.

13. Install the lift chain as described in paragraph 8-4.

14. Connect tube to cylinder.

15. Reconnect the hose to tube.

16. Fill the hydraulic reservoir. Use hydraulic oil listedin Table 3-2.


18. Reconnect the battery and turn on key switch

19. Operate lift levers to refill the cylinder and lineswith hydraulic oil.



Figure 9-8 Elevation System (TRIMAST)

R6961

BL-V-0217 - 12-16-2021 9-9




WARNING: Before attempting any replacement,make certain power is disconnected.


4. Remove the lift chain as described in paragraph8-4.

5. Disconnect the hose from tube.

6. Remove tube from lift cylinder.

7. Manually push the cylinder rod down as far aspossible.

8. Remove screw, lock washer, flat washer, bracketand ram head from cylinder.

Figure 9-9 Hydraulic Lift (TRIMAST)

USED ON TRUCKS SERIAL NUMBERS F211504 AND HIGHER

R6995

9-10 BL-V-0217 - 12-16-2021


9. Remove two bolts, two lock washers, and two flatwashers.

10. Raise lift cylinder assembly up and out of truck.

11. Refer to Figure 12-48 for disassembly.

12. Position the cylinder in the mast and secure withtwo bolts, two lock washers and two flat washers.

13. Install ram head and bracket on top of cylinderand secure with screw lock washer, flat washer.


15. Connect tube to cylinder.

16. Reconnect the hose to tube.

17. Fill the hydraulic reservoir. Use hydraulic oil listedin Table 3-2.



20. Operate lift levers to refill the cylinder and lineswith hydraulic oil.




USED ON TRUCKS SERIAL NUMBERS F211504 AND HIGHER

R6992

BL-V-0217 - 12-16-2021 9-11

9-9.2. Secondary Lift Cylinder

1. With the lift truck wheels securely blocked, raisethe forks approximately three feet from floor andposition blocks or strong supports under mast.

2. Lower the mast onto the support. Check thatarrangement is secure before proceeding.


WARNING: Before attempting any replacement, makecertain power is disconnected.


4. 4.Remove the lift chain as described in paragraph8-4.

5. Left Cylinder: Disconnect the hose from threeway fitting. Remove three way fitting from lift cylin-der.

Right Cylinder: Disconnect the hose from lift cyl-inder. Remove nipple.

6. Remove bolt, lock washer and flat washer fromthe cylinder being removed.

7. Using another lift truck or suitable jack, raise mastup far enough to remove pressure on sec- ondarycylinders.


8. Remove screw lock washer, shim , bracket andclip from securing the cylinder being removed.

9. Raise the lift cylinder up and out of truck.

10. Refer to Figure 12-49 for disassembly.

11. Position the cylinder in the mast and secure withscrew, lock washer, shim, bracket and clip.

12. Lower mast onto the secondary cylinder andinstall bolt, lock washer and flat washer.

13. Left Cylinder: Reinstall nipple and reconnect thehose.

Right Cylinder: Reinstall three way fitting andreconnect the hoses.




17. Operate lift levers to refill the cylinders and lineswith hydraulic oil.



9-12 BL-V-0217 - 12-16-2021

SECTION 10ELECTRICAL COMPONENTS

10-1.DASH

10-1.1.Removal

1. Remove screws and right dash from the firewall.

2. Disconnect harness from instrument panel.

3. Remove screws and left dash from firewall.

4. Disconnect harness from warning light switch.

5. If necessary, remove four nuts, two clamps andinstrument panel from right dash.

6. If necessary, remove warning light switch from theleft dash.

10-1.2.Installation

1. If removed, install new warning light switch in theleft dash.

2. If removed, new instrument panel in right dashand secure with two clamps and four nuts,

3. Reconnect harness to warning light switch

4. Position left dash on firewall and secure withscrews.

Figure 10-1 Operator Compartment

R6938

BL-V-0217 - 12-16-2021 10-1

5. Reconnect harness to instrument panel.

6. Position right dash on firewall and secure withscrews.

10-2.FLASHER

10-2.1.Removal

1. Remove the dash as described in paragraph 10-1.1.

2. Disconnect harness from flasher.

3. Remove one nut, bolt, lock washer, flat washerand flasher.

10-2.2.Installation

1. Install flasher and secure with bolt, lock washer ,flat washer and nut.

2. Reconnect harness to flasher.

3. Install the dash as described in paragraph 10-1.2.

10-3.PARKING BRAKE SWITCH

10-3.1.Removal

1. Remove the dash as described in paragraph 10-1.1.

2. Disconnect harness from switch.

3. Disengage the parking brake lever and removeswitch.

10-3.2.Installation

1. Install switch on its bracket on parking brake.

2. Adjust switch so that engages when parkingbrake lever is engaged.

3. Reconnect harness to switch.

4. Install the dash as described in paragraph 10-1.2.

10-4.KEY SWITCH

10-4.1. Removal


2. Disconnect harness from key switch.

3. Remove key switch from cover.

10-4.2.Installation

1. Install key switch on cover.

2. Reconnect harness to from key switch.

3. Install the covers on the steering column asdescribed in paragraph 5-1.2.

10-5.DIRECTION AND LIGHT SWITCHES

10-5.1. Removal


2. Disconnect harness from directional switch andlight switch.

3. Remove four screws, light switch and directionalswitch.

10-5.2.Installation

1. Position light switch and directional switch on thesteering column and secure with four screws.

2. Reconnect harness to directional switch and lightswitch.

3. Install the covers on the steering column asdescribed in paragraph 5-1.2.

10-6.DRIVE MOTOR

10-6.1.Removal


2. Lift up floor board and disconnect harness fromaccelerator and move the floor board out of theway.

3. Disconnect cables from drive motor.

4. Remove the drive wheel as described in para-graph 7-2.

5. Support drive motor and remove two bolts, onebolt three lock washers, three flat washers andmotor.

6. 6.Remove O-ring from motor

10-2 BL-V-0217 - 12-16-2021

10-6.2.Installation

1. IInstall new O-ring on motor.

2. Lower drive motor into place and secure with twobolts, one bolt, three lock washers and three flatwashers.

3. Install the drive wheel as described in paragraph7-2.

4. Reconnect cables to drive motor.



10-7.PUMP MOTOR.

The pump motor is replaceable but not repairable.Refer to paragraph 9-3.

10-8.ACCELERATOR

10-8.1.Removal



3. Remove two nuts, two lock washers, four flatwashers, two bolts, and accelerator from floorboard.

10-8.2.Installation

1. Position accelerator on floor board and securewith two bolts, four flat washers, two lock washersand two nuts.



10-9.DC CONVERTER

10-9.1.Removal

1. Unhook the seat latch and lift up the hood andseat assembly.


3. Disconnect harness from converter.

4. Remove three screws, three lock washers, threeflat washers and converter.

10-9.2.Installation

5. Install converter and secure with three screws,three lock washers and three flat washers.

6. 2.Reconnect harness to converter.

7. 3.Lower the hood and seat assembly and securewith the seat latch.

10-10.FUSE BOX

The first is a 15A control circuit fuse2nd, 3rd and 4th are 15A light and beeper circuit fuses5th and 6th are spare 15A fuses.

Figure 10-2 Fuse Box

10-11.ELECTRICAL CONTROL PANEL

10-11.1.Maintenance

NOTE: Erratic operation of the truck may be causedby defective controller components. Beforeremoving the electrical panel, perform trou-bleshooting procedures per SECTION 4, todetermine corrective action to be taken.

There are two controllers: the smaller one controls thepump motor, the larger one controls the drive. Thereare no user-serviceable parts inside the controllers. Noattempt should be made to open the controllers. Open-ing the controllers may damage it and will void thewarranty.

The controllers are programmed at the factory specifi-cally for the truck model on which it is equipped. It isimportant to replace the controllers with the correctpreprogrammed unit to assure proper performancesettings intended for that particular truck. See Figure12-17 for the preprogrammed controller numbers.

It is recommended that the controller exterior becleaned periodically, and if a hand held programmer isavailable, this periodic cleaning provides a goodopportunity to check the controller's diagnostic historyfile. It is also recommended that the controller's fault

R6976

BL-V-0217 - 12-16-2021 10-3

detection circuitry be checked whenever the vehicle isserviced

10-11.2.Cleaning



3. Remove two bolt, two lock washers, two flatwashers and rubber cover.

4. Remove any dirt or corrosion from the bus bararea. The controller should be wiped clean with amoist rag. Allow it to dry before reconnecting thebattery.

10-11.3.Controller Removal.



3. Remove two bolts, two lock washers, two flatwashers and rubber cover.

4. Tag and disconnect harness from controller.

5. Tag and disconnect remaining leads from the con-troller. Refer to Figure 12-19.

6. Remove mounting screws, lock washers andremove controller and heat sink.

10-11.4.Controller Installation.

1. Position controller on plate and secure with origi-nal screws and lock washers.

2. Reconnect harness to controller.

3. Reconnect remaining leads to the controller.Referto Figure 12-19.

4. Install rubber cover (13, Figure 12-14) and securewith two bolts (16), two lock washers (2) and twoflat washers (3).

5. Install cover (12, Figure 12-1) and secure with twoscrews (11).

6. Reconnect the battery and turn on key switch (25,Figure 12-6).

10-4 BL-V-0217 - 12-16-2021

SECTION 11OPTIONAL EQUIPMENT

BL-V-0217 - 12-16-2021 11-1

NOTES

11-2 BL-V-0217 - 12-16-2021

SECTION 12ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the V series Lift Truck.

BL-V-0217 - 12-16-2021 12-1

Figure 12-1 Frame and Counterweight

R6936 - DF_0001

12-2 BL-V-0217 - 12-16-2021

Frame and Counterweight

Pos. Part Number DescriptionQty.

Reqd.Notes

1 0000-000255-00 BOLT M8×20 7

2 0000-000159-00 LOCKWASHER Φ8 17

3 0000-000176-00 FLATWASHER Φ8 17

4 3218-110004-00 LEFT BRAKE CABLE HOLDER 1

5 3218-110003-00 RIGHT BRAKE CABLE HOLDER 1

6 3218-111000-00 FRAME 1 Used on V-16 and V-18

6a 3215-111000-00 FRAME 1 Used on V-15

6b 3220-111000-00 FRAME 1 Used on V-20

7 0000-000853-00 BOLT M24×70 3

8 0000-000250-00 LOCKWASHER Φ24 3

9 0000-000539-00 FLATWASHER Φ24 3

10 3218-130000-00 COUNTER WEIGHT 1 Used on V-18

10a 3220-130000-00 COUNTER WEIGHT 1 Used on V-20

10b 3215-130000-00 COUNTER WEIGHT 1 Used on V-15

11 1220-150008-00 SCREW 2

12 3218-200001-00 CAP 1

13 0000-000242-00 BOLT M8×16 7

14 3218-110002-00 BRACKET CABLE 3

15 3218-600500-00 HORN 1

16 3218-110011-00 PLATE 1

17 0000-000326-00 SCREW M6×12 2Used up to serial number

F24130051

17a 0000-001381-00 SCREW M6×12 2Used from serial number

F24130052

18 0000-000277-00 BOLT M8×25 3

19 3218-113000-0A GAS SPRING BRACKET 1

20 3218-110007-00 SHOCK ABSORBER 4

21 3218-110005-00 SHOCK ABSORBER 6

22 0000-000451-00 BOLT M20×60 2

23 0000-000854-00 NUT M20 2

24 3218-100002-LS SAFETY GUARD I 4

25 0000-000259-00 BOLT M6×16 12

26 0000-000380-00 FLAT WASHER Φ6 12

27 0000-000056-00 LOCK WASHER Φ6 12

28 3218-100003-LS SAFETY GUARD II 2

BL-V-0217 - 12-16-2021 12-3

Figure 12-2 Overhead Guard - Used up to 11-26-2012

R6937 - DF_0002

12-4 BL-V-0217 - 12-16-2021

Overhead Guard - Used up to 11-26-2012


Reqd.Notes

1 0000-000548-00 BOLT M16×70 4

2 0000-000220-00 FLATWASHER Φ16 4

3 0000-000191-00 LOCKWASHER Φ16 2

4 0000-000232-00 NUT M16 4

5 3215-121000-00 OVERHEAD GUARD 1 Used up to 11-26-2012 on V-15

5a 3218-121000-00 OVERHEAD GUARD 1Used up to 11-26-2012

on V-16 and V-18

5b 3220-121000-00 OVERHEAD GUARD 1 Used up to 11-26-2012 on V-20

6 0000-000087-00 SCREW M12×25 4

7 0000-000060-00 LOCKWASHER Φ12 4

8 0000-000373-00 FLATWASHER Φ12 4

9 0000-000855-00 BOLT M6×55 4

10 0000-000437-00 FLATWASHER Φ6 10

11 0000-000056-00 LOCKWASHER Φ6 6

12 0000-000166-00 NUT M6 4

13 3115-122000-00 LEFT HEAD LIGHT BRACKET 1

14 0000-000617-00 SCREW M4×20 2

15 0000-000122-00 LOCKWASHER Φ4 2

16 0000-000852-00 SCREW M5×65 4

17 3218-120003-0A REAR VIEW MIRROR BRACKET 1

18 0000-000139-00 NUT M4 2

19 0000-000259-00 BOLT M6×16 2

20 0000-000482-00 NUT M16 2

21 3218-120001-00 WASHER 2

22 3125-122000-00 REAR VIEW MIRROR 1

23 3218-622000-00 HEAD LIGHT HARNESS L 1

24 3218-623000-00 HEAD LIGHT HARNESS R 1

25 3130-680100-00 HEAD LIGHT 2 LED

26 3115-123000-00 RIGHT HEAD LIGHT BRACKET 1

27 3218-600400-00 WARNING LIGHT 1

28 3130-680200-00 REAR LIGHT UNIT 2 LED

29 3218-624000-00 REAR LIGHT HARNESS R 1

30 3218-625000-00 REAR LIGHT HARNESS L 1

31 3125-210001-00 WASHER 2

32 0000-000702-00 FLATWASHER Φ4 2

BL-V-0217 - 12-16-2021 12-5

Figure 12-3 Overhead Guard - Used from 11-27-2012 to F24150012

R7004

12-6 BL-V-0217 - 12-16-2021

P

Overhead Guard - Used from 11-27-2012 up to F24150012

os. Part Number DescriptionQty.

Reqd.Notes

1 0000-000299-00 BOLT M16×70 4

2 0000-000220-00 FLATWASHER Φ16 4

3 0000-000191-00 LOCKWASHER Φ16 4

4 0000-000232-00 NUT M16 4

5 3215-121000-10 OVERHEAD GUARD-L 1 Used on V-15

5a 3218-121000-10 OVERHEAD GUARD -L 1 Used on V-16 and V-18

5b 3220-121000-10 OVERHEAD GUARD -L 1 Used on V-20

6 0000-000374-00 SCREW M12×30 4

7 0000-000060-00 LOCKWASHER Φ12 4

8 0000-000373-00 FLATWASHER Φ12 4

9 0000-000855-00 BOLT M6×55 4

10 0000-000437-00 FLATWASHER Φ6 8

11 0000-000056-00 LOCKWASHER Φ6 6

12 0000-000166-00 NUT M 6 4

13 3115-122000-00 LEFT LIGHT BRACKET 1 Used up to 05-12-2013

13a 3218-120002-00 LIGHT BRACKET 2 Used from 05-13-2013

14 0000-000617-00 SCREW M4×20 2

15 0000-000122-00 LOCKWASHER Φ4 2

16 0000-000702-00 FLATWASHER Φ 2

17 3218-120003-0A REAR VIEW MIRROR BRACKET 1

18 0000-000139-00 NUT M4 2

19 0000-000259-00 BOLT M6×16 2

20 3125-210001-00 WASHER 2

21 0000-000380-00 FLATWASHER Φ6 2

22 3125-122000-00 REAR VIEW MIRROR 1



25 3130-680100-00 HEAD LIGHT 2 LED

26 3115-123000-00 RIGHT LAMP HOLDER 1 Used up to 04-20-2015

BL-V-0217 - 12-16-2021 12-7

Figure 12-3Overhead Guard - Used from 11-27-2012 - Continued to F24150012

R7004

12-8 BL-V-0217 - 12-16-2021

Overhead Guard - Used from 11-27-2012 - Continued up to F24150012


Reqd.Notes

27 3218-600400-00 WARNING LIGHT 1Used up to serial number

F24130023

27a 3218-600400-10 WARNING LIGHT 1Used from serial number

F24130024 to F24150012

28 3130-680200-00 REAR LIGHT UNIT 2LED - Used up to serial number

F2320032

28a 3218-680200-00 REAR LIGHT UNIT 2LED - Used from serial number

F2320033 to F24150012

29 3218-624000-00 BACK LIGHT HARNESS R 1

30 3218-625000-00 BACK LIGHT HARNESS L 1

31 0000-000852-00 SCREW M5×65 4

32 3215-124000-10 OVERHEAD GUARD 1 Used on V-15

32 3218-124000-10 OVERHEAD GUARD 1 Used on V-16 and V-18

32a 3220-124000-10 OVERHEAD GUARD 1 Used on V-20

33 3215-122000-10 FRONT OVERHEAD GUARD -R 1 Used on V-15

33a 3218-122000-10 FRONT OVERHEAD GUARD -R 1 Used on V-16 and V-18

33b 3220-122000-10 FRONT OVERHEAD GUARD -R 1 Used on V-20

34 3215-123000-10 BACK OVERHEAD GUARD -R 1 Used on V-15

34a 3218-123000-10 BACK OVERHEAD GUARD -R 1 Used on V-16 and V-18

34b 3220-123000-10 BACK OVERHEAD GUARD -R 1 Used on V-20

35 0000-000867-00 BOLT M16×1.5×45 8

BL-V-0217 - 12-16-2021 12-9

Figure 12-4 Overhead Guard - Used from F24150013

R8333

12-10 BL-V-0217 - 12-16-2021

P

Overhead Guard - Used from F24150013


Reqd.Notes

1 0000-000299-00 BOLT M16×70 4

2 0000-000220-00 FLAT WASHER Φ16 4

3 0000-000191-00 LOCK WASHER Φ16 4

4 0000-000232-00 NUT M16 4

5 3215-121000-10 OVERHEAD GUARD-L 1 Used on V-15

5a 3218-121000-10 OVERHEAD GUARD -L 1 Used on V-16 and V-18

5b 3220-121000-10 OVERHEAD GUARD -L 1 Used on V-20

6 0000-000374-00 SCREW M12×30 4

7 0000-000060-00 LOCK WASHER Φ12 4

8 0000-000373-00 FLAT WASHER Φ12 4

9 0000-000855-00 BOLT M6×55 4

10 0000-000437-00 FLATWASHER Φ6 8

11 0000-000056-00 LOCK WASHER Φ6 6

12 0000-000166-00 NUT M 6 4

13 3218-120002-00 LIGHT BRACKET 2

14 0000-000550-00 NUT M 8 1

15 0000-000159-00 LOCK WASHER Φ8 1

16 0000-000540-00 FLAT WASHER Φ8 1

17 3218-120003-10 REAR VIEW MIRROR BRACKET 1

18 0000-000687-00 BOLT M16×1.5×45 1

19 0000-000259-00 BOLT M6×16 2

20 3125-210001-00 WASHER 2

21 0000-000380-00 FLATWASHER Φ6 2

22 3120-101000-00 REAR VIEW MIRROR 1



25 3130-680100-00 HEAD LIGHT 2 LED

BL-V-0217 - 12-16-2021 12-11

Figure 12-4Overhead Guard - Used from F24150012 - Continued

R8333

12-12 BL-V-0217 - 12-16-2021

Overhead Guard - Used from F24150012 - Continued


Reqd.Notes

27 3218-600400-10 WARNING LIGHT 1

28 3218-680200-00 REAR LIGHT UNIT 2

29 3218-624000-00 BACK LIGHT HARNESS R 1

30 3218-625000-00 BACK LIGHT HARNESS L 1

31 0000-000852-00 SCREW M5×65 4

32 3215-124000-10 OVERHEAD GUARD 1 Used on V-15

32 3218-124000-10 OVERHEAD GUARD 1 Used on V-16 and V-18

32a 3220-124000-10 OVERHEAD GUARD 1 Used on V-20

33 3215-122000-10 FRONT OVERHEAD GUARD -R 1 Used on V-15

33a 3218-122000-10 FRONT OVERHEAD GUARD -R 1 Used on V-16 and V-18

33b 3220-122000-10 FRONT OVERHEAD GUARD -R 1 Used on V-20

34 3215-123000-10 BACK OVERHEAD GUARD -R 1 Used on V-15

34a 3218-123000-10 BACK OVERHEAD GUARD -R 1 Used on V-16 and V-18

34b 3220-123000-10 BACK OVERHEAD GUARD -R 1 Used on V-20

35 0000-001350-00 SCREW M4×12 3

36 0000-000122-00 LOCKWASHER Φ4 3

37 0000-000702-00 FLATWASHER Φ4 3

38 0000-000482-00 NUT M16 2

BL-V-0217 - 12-16-2021 12-13

12

Figure 12-5 Operator’s Compartment

R6938

-14 BL-V-0217 - 12-16-2021

Operator’s Compartment


Reqd.Notes

1 0000-000279-00 BOLT M8×35 4

2 0000-000159-00 LOCKWASHER Φ8 17

3 0000-000210-00 FLATWASHER Φ8 8

4 0000-000196-00 NUT M8 4

5 3218-300001-00 SHOCK ABSORBER 2

6 0000-000277-00 BOLT M8×25 6

7 3218-311000-00 CONSOLSE 1

8 0000-000176-00 FLATWASHER Φ8 13

9 3218-606000-00 WARNING LIGHT SWITH 1

10 3218-310008-00 CONSOLSE 1

11 3218-310007-00 CONSOLSE 1

12 3218-310010-00 COVER 1

13 3218-310009-00 CONSOLSE 1

14 1220-150008-00 SCREW 8

15 3218-241000-00 FLOOR BOARD 1 Used up to 01-02-2013

15a 3218-241000-01 FLOOR BOARD 1 Used from 01-03-2013

16 3218-240001-00 ROD 2

17 0000-000196-00 NUT M8 10

18 3218-240002-00 CUSHION 1

19 3218-680000-00 ACCELERATOR 1 Used up to 08-14-2014

20 3218-670000-00-00 DISPLAY 1

21 0000-000242-00 BOLT M8×16 5

22 3218-200003-00 PLATE-R 1

23 3218-200002-00 PLATE-L 1

24 3218-670001-00 CLIP 2

25 0000-000139-00 NUT M4 4

BL-V-0217 - 12-16-2021 12-15

Figure 12-6 Back Cover - Used up to serial number F24130051

R6939

12-16 BL-V-0217 - 12-16-2021

Back Cover - used up to serial number F24130051


Reqd.Notes

1 0000-000242-00 BOLT M8×16 2

2 0000-000159-00 LOCKWASHER Φ8 21

3 0000-001424-10 BOLT M8×12 1

4 3215-220001-00 SQUARE TUBE 2 Used on V-15

4a 3218-220002-00 SQUARE TUBE 2 Used on V-16, V-18 and V-20

5 3215-221000-00 LEFT COVER ASSEMBLY 1 Used on V-15

5a 3218-221000-00 LEFT COVER ASSEMBLY 1 Used on V-16 and V-18

5b 3220-221000-00 LEFT COVER ASSEMBLY 1 Used on V-20

6 3218-220001-00 HANDLE 4

7 3215-212000-00 GAS SPRING 1 Used on V-15

7a 3218-214000-00 GAS SPRING 1 Used on V-16, V-18 and V-20

8 3218-210001-00 SHOCK ABSORBER 2

9 3215-211000-00 COVER ASSEMBLY 1 Used on V-15

9a 3220-211000-00 COVER ASSEMBLY 1 Used on V-16 and V-18

9b 3215-211000-00 COVER ASSEMBLY 1 Used on V-20

10 0000-000196-00 NUT M8 16

11 0000-000026-00 SCREW M8×30 2

12 0000-000176-00 FLATWASHER Φ8 12

13 3218-213000-00 HINGES 2

14 0000-000151-00 SCREW M8×25 6

15 3218-212000-10 SEAT 1

16 3218-210003-10 COVER 1

17 0000-000255-00 BOLT M8×20 2

18 3215-231000-00 RIGHT COVER ASSEMBLY 1 Used on V-15

18a 3218-231000-00 RIGHT COVER ASSEMBLY 1 Used on V-16 and V-18

18b 3220-231000-00 RIGHT COVER ASSEMBLY 1 Used on V-20

19 3218-220005-00 CUSHION 4

20 3218-110100-00 LOCK 1

21 0000-000618-00 SCREW M6×12 2

22 3125-210002-00 RUBBER 1 Used up to 08-15-2011

23 0000-000210-00 FLATWASHER Φ8 11

24 0000-000278-00 BOLT M8×30 4

BL-V-0217 - 12-16-2021 12-17

12

Figure 12-6 Back Cover - used up to serial number F24130051 - Continued

R6939

-18 BL-V-0217 - 12-16-2021

Back Cover used up to serial number F24130051 - Continued


Reqd.Notes

25 3125-210001-00 WASHER 1

26 3218-604000-00 FETCH-UP SWITCH 1

27 3218-600002-00 DUST-PROOF MAT 1

28 0000-000056-00 LOCKWASHER Φ6 2

29 0000-000108-00 NUT M6 2

30 0000-001424-10 BOLT M8×12 1

31 3218-200004-00 RUBBER SLEEVE 2

32 3125-600200-10 SEAT SWITCH 1

BL-V-0217 - 12-16-2021 12-19

Figure 12-7 Back Cover - Used from serial number F24130052

R8334

12-20 BL-V-0217 - 12-16-2021

Back Cover - used from serial number F24130052


Reqd.Notes

1 0000-000242-00 BOLT M8×16 2

2 0000-000159-00 LOCKWASHER Φ8 21

3 0000-001424-10 BOLT M8×12 1

4 3215-220001-00 SQUARE TUBE 2 Used on V-15

4a 3218-220002-00 SQUARE TUBE 2 Used on V-16, V-18 and V-20

5 3215-221000-00 LEFT COVER ASSEMBLY 1 Used on V-15

5a 3218-221000-00 LEFT COVER ASSEMBLY 1 Used on V-16 and V-18

5b 3220-221000-00 LEFT COVER ASSEMBLY 1 Used on V-20

6 3218-220001-00 HANDLE 4

7 3215-212000-00 GAS SPRING 1 Used on V-15

7a 3218-214000-00 GAS SPRING 1 Used on V-16, V-18 and V-20

8 3218-210001-00 SHOCK ABSORBER 2

9 3215-211000-00 COVER ASSEMBLY 1 Used on V-15

9a 3220-211000-00 COVER ASSEMBLY 1 Used on V-16 and V-18

9b 3215-211000-00 COVER ASSEMBLY 1 Used on V-20

10 0000-000196-00 NUT M8 16

11 0000-000026-00 SCREW M8×30 2

12 0000-000176-00 FLATWASHER Φ8 12

13 3218-213000-00 HINGES 2

14 0000-000151-00 SCREW M8×25 6

15 3218-212000-10 SEAT 1

16 3218-210003-10 COVER 1

17 0000-000255-00 BOLT M8×20 2

18 3215-231000-00 RIGHT COVER ASSEMBLY 1 Used on V-15

18a 3218-231000-00 RIGHT COVER ASSEMBLY 1 Used on V-16 and V-18

18b 3220-231000-00 RIGHT COVER ASSEMBLY 1 Used on V-20

19 3218-220005-00 CUSHION 4

20 3525-210001-A0 LOCK 1

21 0000-001382-00 SCREW M4×12 2

23 0000-000210-00 FLATWASHER Φ8 11

24 0000-000278-00 BOLT M8×30 4

BL-V-0217 - 12-16-2021 12-21

Figure 12-7 Back Cover - used from serial number F24130052 - Continued

R8334

12-22 BL-V-0217 - 12-16-2021

Back Cover used from serial number F24130052 - Continued


Reqd.Notes

25 3125-210001-00 WASHER 1

26 3218-604000-00 FETCH-UP SWITCH 1

27 3218-600002-00 DUST-PROOF MAT 1

28 3525-100012-A0 LOCK II 1

29 0000-000139-00 NUT M4 2

30 0000-001424-10 BOLT M8×12 1

31 3218-200004-00 RUBBER SLEEVE 2

32 3125-600200-10 SEAT SWITCH 1

33 3218-212001-10 SEAT BELT 1

BL-V-0217 - 12-16-2021 12-23

Figure 12-8 Steering and Brake Controls

R6940

12-24 BL-V-0217 - 12-16-2021

Steering and Brake Controls


Reqd.Notes

1 0000-000054-00 NUT M10 3

2 0000-000063-00 LOCKWASHER Φ10 2

3 0000-000278-00 BOLT M8×30 2

4 0000-000159-00 LOCKWASHER Φ8 6

5 3125-634000-00 FLASHER WIRE HARNESS 1 Used up to 09-04-2012

6 3218-310006-00 BOLT M10×110 1

7 0000-000279-00 BOLT M8×35 4

8 0000-000176-00 FLATWASHER Φ8 12

9 0000-000251-00 BOLT M10×25 2

10 0000-000007-00 FLATWASHER Φ10 4

11 3218-310011-00 FIXED PLATE 2

12 3218-315000-00 BRAKE FLUID RESERVOIR 1

13 0000-000273-00 BOLT M6×20 2

14 0000-000056-00 LOCKWASHER Φ6 2

15 0000-000380-00 FLATWASHER Φ6 2

16 3218-320004-00 SHOCK ABSORBER 1

17 0000-000196-00 NUT M8 6

18 0000-000228-00 BOLT M12×25 4

19 0000-000060-00 LOCKWASHER Φ12 4

20 0000-000373-00 FLATWASHER Φ12 4

21 0000-000166-00 NUT M6 2

22 3218-600600-10 FLASHER 1 Used up to 09-04-2012

23 3125-637000-00 BRAKE SWITCH HARNESS 1

24 0000-000630-00 NUT M12 4

25 3218-609000-00 KEY LOCK 1

26 3218-605000-00 SWITCH 1

27 3125-635000-00 HAND BRAKE HARNESS 1 Used up to 09-04-2012

27a 3425-222000-00 HAND BRAKE HARNESS 1 Used from 09-05-2012

BL-V-0217 - 12-16-2021 12-25

Figure 12-9 Hand Brake

R6941

12-26 BL-V-0217 - 12-16-2021

Hand Brake


Reqd.Notes

1 3218-313100-00 HAND BRAKE LEVER 1

2 0000-000376-00 PIN Φ2.5×20 1

3 3218-313200-00 TOUCH PLATE 1

4 3218-310002-00 HAND BRAKE WIRE R 1

5 3218-310003-00 HAND BRAKE WIRE L 1

BL-V-0217 - 12-16-2021 12-27

Figure 12-10 Brake Pedal

R6942

12-28 BL-V-0217 - 12-16-2021

Brake Pedal


Reqd.Notes

1 3125-310006-00 RUBBER WASHER 1

2 3125-310005-00 BRAKE PEDAL COVER 1

3 3218-314000-00 BRAKE PEDAL 1

4 3125-310001-00 BUSHING 1

5 3125-310002-00 BUSHING 2

6 3125-310003-00 SPRING 1

7 0000-000460-00 PIN Φ8×26 1

8 0000-000296-00 PIN Φ2×20 1

9 3125-314000-00 MASTER CYLINDER 1

10 0000-000468-00 CLIP Φ10-16 2

11 3218-310001-00 BRAKE HOSE 1 To Brake Reservoir

12 3218-310005-00 BRAKE HOSE 1 Right

13 3218-310004-00 BRAKE HOSE 1 Left

BL-V-0217 - 12-16-2021 12-29

12

Figure 12-11 Steering Column - Used up to serial number F2313034

R6943

-30 BL-V-0217 - 12-16-2021

Steering Column - Used up to serial number F2313034


Reqd.Notes

1 3218-323000-00 STEERING WHEEL 1

2 0000-000643-00 BEARING 2

3 0000-000293-00 SHAFT SNAP RING Ø20 2

4 0000-000386-00 SCREW M6×20 4

5 0000-000056-00 LOCKWASHER Φ6 8

6 0000-000123-00 FLATWASHER Φ6 8

7 3218-320010-00 RUBBER BUSHING 4

8 3218-320009-00 CUSHION 4

9 3218-320003-00 STEERING SHAFT 1

10 3218-322000-00 STEERING COLUMN 1

11 3125-639000-00 HORN SWITCH HARNESS 1

12 3218-320008-00-B HANDLE 1

13 3218-320005-00 LOCKING SHAFT 1

14 0000-000856-00 FLATWASHER Φ11 1

15 0000-000210-00 FLATWASHER Φ8 1

16 3218-321000-00 STEERING BRACKET 1

17 0000-000054-00 NUT M10 2

18 0000-000063-00 LOCKWASHER Φ10 6

19 3218-603000-00 HORN SWITCH 1

20 3218-320014-00 STEERING BOLT 2

21 3218-320007-00 STEERING WASHER 2

22 0000-000487-00 SCREW ST4.8×32 4

23 3218-320002-00 BACK COVER 1

24 3218-320001-00 FRONT COVER 1

25 0000-000320-00 SCREW M6×35 4

26 0000-000278-00 BOLT M8×30 1

27 0000-000159-00 LOCKWASHER Φ8 2

28 3218-324000-00 STEERING COUPLING 1

29 3218-325000-00 STEERING SHAFT 1

30 0000-000462-00 BEARING 1

31 0000-000251-00 BOLT M10×25 4

32 0000-000007-00 FLATWASHER Φ10 4

BL-V-0217 - 12-16-2021 12-31

Figure 12-11Steering Column - Used up to serial number F2313034 - Continued

R6943

12-32 BL-V-0217 - 12-16-2021

Steering Column - Used up to serial number F2313034 - Continued


Reqd.Notes

33 3218-312100-00 STEERING GEAR MOUNTING PLATE 1

34 3218-740000-00 STEERING GEAR 1

35 0000-000630-00 NUT M12 1

36 3218-323030-00 HORNHOOD 1

37 3218-323020-00 HANDLE 1

38 3218-608000-00 DIRECTION SWITH 1

39 3218-607000-00 LIGHT SWITCH 1

40 0000-000077-00 SCREW M6×12 1

41 3218-320013-00 STEERING BUSHING 4

42 3218-600900-00 SWITCH 1Used from 15-01-2013

to F2313034

BL-V-0217 - 12-16-2021 12-33

12

Figure 12-12 Steering Column - Used from serial number F2313035

R8038

-34 BL-V-0217 - 12-16-2021

Steering Column - Used from serial number F2313035


Reqd.Notes

1 3218-323000-00 STEERING WHEEL 1

2 0000-000643-00 BEARING 1

3 0000-000293-00 SHAFT SNAP RING Ø20 1

4 0000-000386-00 SCREW M6×20 4

5 0000-000056-00 LOCK WASHER Φ6 8

6 0000-000123-00 FLAT WASHER Φ6 8

7 3218-320010-00 RUBBER BUSHING 4

8 3218-320009-00 CUSHION 4

9 3218-320003-0A STEERING SHAFT 1

10 3218-326100-00 STEERING COLUMN 1

11 0000-000326-00 SCREW M6×12 1

12 3218-320008-00-B HANDLE 1

13 3218-320005-0A AXIS 1

14 0000-000856-00 FLATWASHER Φ11 1

15 0000-000210-00 FLATWASHER Φ8 1

16 3218-321000-00 STEERING BRACKET 1

17 0000-000054-00 NUT M10 2

18 0000-000063-00 LOCKWASHER Φ10 6

19 3218-320013-00 STEERING BUSHING 4

20 3218-320014-00 STEERING BOLT 2

21 3218-320007-00 STEERING WASHER 2

22 0000-000487-00 SCREW ST4.8×32 4

23 3218-320002-00 BACK COVER 1

24 3218-320001-00 FRONT COVER 1

25 3218-326001-00 NUT M16X1.5 1

26 0000-000278-00 BOLT M8×30 1

27 0000-000159-00 LOCKWASHER Φ8 2

28 3218-326200-00 GIMBAL 1

29 3218-325000-00 STEERING SHAFT 1

30 0000-000462-00 BEARING 1

31 0000-000251-00 BOLT M10×25 4

32 0000-000007-00 FLATWASHER Φ10 4

BL-V-0217 - 12-16-2021 12-35

Figure 12-12 Steering Column - Used from serial number F2313035 - Continued

R8038

12-36 BL-V-0217 - 12-16-2021

Steering Column - Used from serial number F2313035 - Continued


Reqd.Notes

33 3218-312100-00 STEERING GEAR MOUNTING PLATE 1

34 3218-740000-00 STEERING GEAR 1

35 0000-000630-00 NUT M12 1

36 3218-323010-10 HORN BUTTON 1

37 3218-323020-00 HANDLE 1

38 3218-600900-00 SWITH 1

39 0000-000077-00 SCREW M6×12 1

40 0000-000863-00 BIG WASHER Φ16 1

41 3218-326002-00 CHASSIS ASSEMBLY 1

42 3218-323030-10 HORN COVER 1

43 3218-323040-00 INSULATING SLEEVE 1

44 3218-326003-00 WASHER 1

45 0000-000320-00 SCREW M6×35 4

BL-V-0217 - 12-16-2021 12-37

Figure 12-13 Control Valve Mounting

R6944

12-38 BL-V-0217 - 12-16-2021

Control Valve Mounting


Reqd.Notes

1 3218-730000-10 CONTROL VALVE (TWO SECTION) 1

1a 3218-730000-20 CONTROL VALVE (THREE SECTION) 1

1b 3218-730000-30 CONTROL VALVE (FOUR SECTION) 1

2 3218-330001-00 PIN 1

3 0000-000306-00 BOLT M10×25 3

4 0000-000063-00 LOCKWASHER Φ10 3

5 0000-000007-00 FLATWASHER Φ10 3

6 3218-331000-00 MOUNTING PLATE 1

7 0000-000255-00 BOLT M8×20 4

8 0000-000159-00 LOCKWASHER Φ8 8

9 0000-000176-00 FLATWASHER Φ8 8

10 0000-000368-00 BOLT M8×16 4

11 3218-330005-00 COVER 1

12 0000-000242-00 BOLT M8×16 4

13 3218-330002-00 HOLDER 5 1

14 3218-330006-00 KNOB-LIFT 1

15 3218-330007-00 KNOB-TILT 1

16 3218-332000-00 CONTROL LEVER,LIFT 1

17 3218-333000-00 CONTROL LEVER,TILT 1

18 0000-000740-00 NUT M8 1

19 3218-330003-00 HOLDER 6 1

20 3218-336100-00 ROD-CONTROL VALVE 4

21 0000-000552-00 NUT M8 4

22 3218-336001-00 JOINT 4

23 0000-000296-00 PIN Φ2×20 4

24 0000-000460-00 PIN Φ8×26 4

25 3218-330004-00 BUSHING 8

26 3218-337000-00 BRACKET 4

27 0000-000264-00 BOLT M6×12 8

28 0000-000056-00 LOCKWASHER Φ6 8

29 0000-000123-00 FLATWASHER Φ6 8

30 3218-605001-00 RUBBER COVER 4

BL-V-0217 - 12-16-2021 12-39

Figure 12-13 Control Valve Mounting - Continued

R6944

12-40 BL-V-0217 - 12-16-2021

Control Valve Mounting - Continued


Reqd.Notes

31 0000-000295-00 PIN Φ1.2×12 4

32 3525-330012-00 PIN 4

33 3218-334000-00 CONTROL LEVER,SWAY 1

34 3218-330008-00 KNOB-SWAY 1

35 3218-335000-00 CONTROL LEVER, ATTACHMENT 1

36 3218-330009-00 KNOB-ATTACHMENT 1

37 3125-636000-00 SWITCH HARNESS 1 Used up to 09-04-2012

37a 3218-627000-00 SWITCH HARNESS 1 Used from 09-05-2012

38 3218-605000-00 SWITCH 4

39 3218-600006-00 SHOCK ABSORBER 3

40 3218-332002-00 SLEEVE A.R. As Required

BL-V-0217 - 12-16-2021 12-41

Figure 12-14 Drive Unit

R6945

12-42 BL-V-0217 - 12-16-2021

-

-

-

Drive Unit


Reqd.Notes

1 3218-650000-00 TRACTION MOTOR 2

Used Up To Serial Number F2219008.

This Motor Use The Following Control

lers: 3218-632000-00-00 (V15), 3218-

632000-00-50 (V18), 3218-632000-

00-60 (V20) If Replacing Drive Motor

With New Motor 3218-650000-10 You

Have To Change The Controller: 3218

632000-00-10 (V15), 3218-632000-

00-30 (V18), 3218-632000-00-40

(V20)

1A 3218-650000-10 TRACTION MOTOR 2

Used From Serial Number F2219009.

This Motor Use The Following Control

lers: 3218-632000-00-10 (V15),

3218-632000-00-30 (V18),

3218-632000-00-40 (V20)

2 3218-410001-00 O-RING 2

3 3218-410000-00 GEARBOX ASSEMBLY - LEFT 1

3a 3218-430000-00 GEARBOX ASSEMBLY - RIGHT 1

4 0000-000379-00 FLATWASHER Φ14 14

5 0000-000233-00 LOCKWASHER Φ14 14

6 0000-000288-00 BOLT M14×95 10

7 0000-000445-00 BOLT M14×55 4

8 0000-000176-00 FLATWASHER Φ8 6

9 0000-000159-00 LOCKWASHER Φ8 6

10 0000-000280-00 BOLT M8×60 2

11 0000-000281-00 BOLT M8×80 4

12 3218-420000-00 DRIVE WHEEL 2 Used on V-15, V-16 and V-18

12a 3220-420000-00 DRIVE WHEEL 2 Used on V-20

13 3218-400002-00 NUT 10

14 3218-400003-00 NUT COVER 10

15 3218-400001-00 JOINT 2

16 3218-650001-00 BEARING ENCODER 2

17 3218-650002-00 GEAR 1

18 3218-650003-00 WASHER 1

19 3218-650004-00 NUT 1

BL-V-0217 - 12-16-2021 12-43

Figure 12-15 Transmission

R6946

12-44 BL-V-0217 - 12-16-2021

Transmission


Reqd.Notes

1 3218-410002-00 SNAP RING 1

2 3218-410003-00 GROOVED BALL BEARING 1

3 3218-410004-00 HELICAL GEAR 1

4 3218-410005-00 AXIAL BEARING 1

5 3218-410006-00 HOUSING COVER 1

6 3218-410007-00 CYLINDRICAL PIN 2

7 3218-410008-00 INPUT PINION 1

8 3218-410009-00 PRESSURE PIN SET 1

9 3218-410010-00 SCREW 8

10 3218-410011-00 PRESSURE DISC 1

11 3218-410012-00 INNER DISC CARRIER 1

12 3218-410013-00 CYLINDRICAL PIN 1

13 3218-410014-00 PRESSURE SPRING 3

14 3218-410015-00 FIXING PLATE 1

15 3218-410016-00 OUTER CLUTCH DISC 4

16 3218-410017-00 HEXAGON SCREW 6

17 3218-410018-00 PRESSURE DISC SET 1

18 3218-410019-00 SLOTTED NUT 1

19 3218-410020-00 CYLINDRICAL ROLLER BEARING 3

20 3218-410021-00 PLANET GEAR 3

21 3218-410022-00 INNER CLUTCH DISC 3

22 3218-410023-00 TORX-SCREW 10

23 3218-410024-00 WASHER 4

24 3218-410025-00 SCREW PLUG 2

25 3218-410026-00 SHIM RING SET 1

26 3218-410027-00 TAPER ROLLER BEARING 2

27 3218-410028-00 NILOS-RING 1

28 3218-410029-00 SEELING RING 1

29 3218-410030-00 HOUSING 1

30 3218-410031-00 BREATHER FILTER 1

31 3218-410032-00 WHEEL BOLT 5

32 3218-410033-00 NEEDLE SLEEVE 1

BL-V-0217 - 12-16-2021 12-45

Figure 12-15 Transmission - Continued

R6946

12-46 BL-V-0217 - 12-16-2021

Transmission - Continued


Reqd.Notes

33 3218-410034-00 DRIVE WHEEL AXLE 1

34 3218-410035-00 INTERNAL GEAR 1

35 3218-410036-00 SHAFT SEALING RING 1

36 3218-410037-00 SCREW PLUG WITH MAGNET 2

37 3218-410038-00 BRAKE LEVER, COMPLETE 1

38 3218-410039-00 SHAFT SEALING RING 1

39 3218-410040-00 PLANET CARRIER 1

40 3218-410041-00 FEY-RING 1

BL-V-0217 - 12-16-2021 12-47

Figure 12-16 Drive Wheel Assembly

R6950

12-48 BL-V-0217 - 12-16-2021

Drive Wheel Assembly


Reqd.Notes

1 3218-421000-00 RIM SET 1 Used on V-15, V-16 and V-18

1a 3220-421000-00 RIM SET 1 Used on V-20

2 3218-420001-10 DRIVE TIRE (FRONT) 1 Used on V-15, V-16 and V-18

2a 3218-420001-20 DRIVE TIRE - NON MARKING (FRONT) 1 Used on V-15, V-16 and V-18

2b 3220-420001-10 DRIVE TIRE (FRONT) 1 Used on V-20

2c 3220-420001-20 DRIVE TIRE - NON MARKING (FRONT) 1 Used on V-20

NOTE: Above quantities are per wheel.

BL-V-0217 - 12-16-2021 12-49


R6948

12-50 BL-V-0217 - 12-16-2021

Rear Steering


Reqd.Notes

1 0000-000055-00 SCREW M6×16 2

2 0000-000056-00 LOCKWASHER Φ6 4

3 0000-000380-00 FLATWASHER Φ6 4

4 3218-500001-00 POTENTIOMETER BRACKET 1

5 0000-000446-00 BOLT M16×50 5

6 0000-000191-00 LOCKWASHER Φ16 5

7 0000-000190-00 FLATWASHER Φ16 5

8 3218-500004-00 STUD 10

9 3218-520000-00 STEERING AXLE 1

10 3218-510000-00 REAR TIRES ASSEMBLY 2

11 3218-500003-00 NUT 20

12 3218-500006-00 SHIELD RUBBER 1

13 3218-500005-00 RUBBER 1

14 0000-000122-00 LOCKWASHER Φ4 2

15 0000-000328-00 SCREW M4×30 2

16 0000-000264-00 BOLT M6×12 2

17 3218-600800-00 POTENTIOMETER 1

18 0000-000702-00 FLATWASHER Φ4 2

19 3218-500002-00 POTENTIOMETER SHAFT 1

20 0000-000233-00 LOCKWASHER Φ14 10

21 0000-000108-00 NUT M6 1

22 3218-500007-00 NUT COVER 20

BL-V-0217 - 12-16-2021 12-51

Figure 12-18 Steering Axle

R6949

12-52 BL-V-0217 - 12-16-2021

Steering Axle


Reqd.Notes

1 3218-520001-00 NUT M39×1.5 1

2 3218-520002-00 THRUSTWASHER 1

3 3218-520003-00 O-RING D82×2.65 1

4 3218-520004-00 BUSHING 1

5 3218-520005-00 BEARING 1

6 3218-520006-00 U- RING 40×50×6 4

7 3218-520007-00 RING 45×50×12 2

8 3218-520029-00 O-RING 1

9 3218-520009-00 CYLINDER SHAFT 1

10 3218-520010-00 ROTARY BEARINGS 1

11 3218-520011-00 CYLINDER 2

12 3218-520026-00 BEARING 2

13 3218-520027-00 SEAL 65×90×12 2

14 3218-520014-00 BEARING 1

15 3218-520015-00 STEAL 90×115×12 1

16 3218-520016-00 GEAR AXLE 1

17 3218-520017-00 SHAFT 1

18 3218-520018-00 PIN A10×24 1

19 3218-520025-00 HUB 2

20 3218-520020-00 COVER 2

21 3218-520021-00 NUT M24×2 2

22 3218-520022-00 WASHER 24 2

23 3218-520023-00 PIN 5×45 2

24 3218-520024-00 BEARING 2

BL-V-0217 - 12-16-2021 12-53

Figure 12-19 Rear Tire Assembly

R8042

12-54 BL-V-0217 - 12-16-2021

P

Rear Tire Assembly


Reqd.Notes

1 3218-511000-00 RIM SET 1

2 3218-510001-10 REAR TIRE (STEERING) 1

2a 3218-510001-20 REAR TIRE (STEERING) - NON MARKING 1

NOTE: Above quantities are per wheel.

BL-V-0217 - 12-16-2021 12-55

Figure 12-20 Electrical Components

R8039

12-56 BL-V-0217 - 12-16-2021

Electrical Components


Reqd.Notes

1 3218-690002-00 FUSE 15A 2

2 3218-690001-00 FUSE 10A 4

3 3218-690000-00 FUSE BOX 1

4 3125-633000-00 FUSE BOX HARNESS 1

5 0000-000123-00 FLATWASHER Φ6 11

6 0000-000056-00 LOCKWASHER Φ6 11

7 0000-000594-00 SCREW M6×16 6

8 3218-602000-00 DCDC CONVERTER 1

9 0000-000264-00 BOLT M6×12 1

10 3218-600700-00 ALARM BUZZER 1 Used up to 03-14-2012

10a 3125-638000-00 ALARM BUZZER HARNESS 1 Used from 03-15-2012

BL-V-0217 - 12-16-2021 12-57

Figure 12-21 Control Panel

R6951

12-58 BL-V-0217 - 12-16-2021

P

r

r

r

r

r

r

Control Panel


Reqd.Notes

1 3218-630001-00 CONTROL BRACKET 1

2 0000-000380-00 FLATWASHER Φ6 12

3 0000-000056-00 LOCKWASHER Φ6 12

4 0000-000326-00 SCREW M6×12 2

5 0000-000329-00 SCREW M5×10 2

6 0000-000206-00 LOCKWASHER Φ5 2

7 0000-000390-00 FLATWASHER Φ5 2

8 3218-631000-00 CONTACTOR BRACKET 1

9 3218-634000-00 CONTACTOR 1

10 3218-630004-00 ANODE CONDUCTOR B 1

11 3218-633000-00-00 PUMP MOTOR CONTROLLER 1

12 0000-000332-00 SCREW M6×30 10

13 3218-630002-00 CATHODE CONDUCTOR 1

14 3218-632000-00-00 TRACTION MOTOR CONTROLLER 1V15 - Used up to serial numbe

F2219008

14a 3218-632000-00-10 TRACTION MOTOR CONTROLLER 1V15 - Used from serial numbe

F2219009

14b 3218-632000-00-50 TRACTION MOTOR CONTROLLER 1V18 - Used up to serial numbe

F2219008

14c 3218-632000-00-30 TRACTION MOTOR CONTROLLER 1V18 - Used from serial numbe

F2219009

14d 3218-632000-00-60 TRACTION MOTOR CONTROLLER 1V20 - Used up to serial numbe

F2219008

14e 3218-632000-00-40 TRACTION MOTOR CONTROLLER 1V20 - Used from serial numbe

F2219009

15 3218-632001-00 FUSE 400A 1

16 3218-633001-00 FUSE 300A 1

17 3316-730003-00 GROUND RESISTANCE LINE 1

BL-V-0217 - 12-16-2021 12-59

Figure 12-22 Wiring Harness

R6952

12-60 BL-V-0217 - 12-16-2021

Wiring Harness


Reqd.Notes

1 3218-621000-0C MAIN HARNESS 1

2 3525-683000-00 LIGHT RELAY 1

3 3218-600600-20 FLASHER 1 Used from 05-09-2012

4 3115-627000-00 FLASHER HARNESS 1 Used from 05-09-2012

BL-V-0217 - 12-16-2021 12-61

12

Figure 12-23 Wiring Cables

R6953

-62 BL-V-0217 - 12-16-2021

Wiring Cables


Reqd.Notes

1 3218-610700-00 BATTERY CABLE 1

2 3218-610800-00 POWER SOURCE CABLE 1

3 3215-630000-00 BATTERY BOX 1 Used on V-15

3a 3218-640000-00 BATTERY BOX 1 Used on V-16 and V-18

3b 3220-630000-00 BATTERY BOX 1 Used on V-20

4 3215-619000-00 PUMP MOTOR CABLE W 1 Used on V-15

4a 3218-619000-00 PUMP MOTOR CABLE W 1 Used on V-16 and V-18

4b 3220-619000-00 PUMP MOTOR CABLE W 1 Used on V-20

5 3215-617000-00 PUMP MOTOR CABLE U 1 Used on V-15

5a 3218-617000-00 PUMP MOTOR CABLE U 1 Used on V-16 and V-18

5b 3220-617000-00 PUMP MOTOR CABLE U 1 Used on V-20

6 3215-618000-00 PUMP MOTOR CABLE V 1 Used on V-15

6a 3218-618000-00 PUMP MOTOR CABLE V 1 Used on V-16 and V-18

6b 3220-618000-00 PUMP MOTOR CABLE V 1 Used on V-20

7 3215-612000-00 L-DRIVE MOTOR CABLE V 1 Used on V-15

7a 3218-612000-00 L-DRIVE MOTOR CABLE V 1 Used on V-16 and V-18

7b 3220-612000-00 L-DRIVE MOTOR CABLE V 1 Used on V-20

8 3215-613000-00 L-DRIVE MOTOR CABLE W 1 Used on V-15

8a 3218-613000-00 L-DRIVE MOTOR CABLE W 1 Used on V-16 and V-18

8b 3220-613000-00 L-DRIVE MOTOR CABLE W 1 Used on V-20

9 3215-611000-00 L-DRIVE MOTOR CABLE U 1 Used on V-15

9a 3218-611000-00 L-DRIVE MOTOR CABLE U 1 Used on V-16 and V-18

9b 3220-611000-00 L-DRIVE MOTOR CABLE U 1 Used on V-20

10 3215-614000-00 R-DRIVE MOTOR CABLE U 1 Used on V-15

10a 3218-614000-00 R-DRIVE MOTOR CABLE U 1 Used on V-16 and V-18

10b 3220-614000-00 R-DRIVE MOTOR CABLE U 1 Used on V-20

11 3215-615000-00 R-DRIVE MOTOR CABLE V 1 Used on V-15

11a 3218-615000-00 R-DRIVE MOTOR CABLE V 1 Used on V-16 and V-18

11b 3220-615000-00 R-DRIVE MOTOR CABLE V 1 Used on V-20

12 3215-616000-00 R-DRIVE MOTOR CABLE W 1 Used on V-15

12a 3218-616000-00 R-DRIVE MOTOR CABLE W 1 Used on V-16 and V-18

12b 3220-616000-00 R-DRIVE MOTOR CABLE W 1 Used on V-20

BL-V-0217 - 12-16-2021 12-63

12

Figure 12-24 Hydraulic System - Part 1

R6954

-64 BL-V-0217 - 12-16-2021

Hydraulic System - Part 1


Reqd.Notes

1 3218-717000-00 FORWARD HOSE ASSEMBLY 2

2 3218-716000-00 BACKWARD HOSE ASSEMBLY 2

3 3218-710500-0A THREE-WAY VALVE 1

4 0000-000322-00 SCREW M8×25 2

5 0000-000159-00 LOCKWASHER Φ8 2

6 0000-000210-00 FLATWASHER Φ8 2

7 3218-711000-00 HOSE,VALVEA2 TO THREE-WAY 1

8 2701-201600-00 CONNECTOR M20×1.5-M16×1.5 3

9 0000-000638-00 O-RING 17×2.65 5

10 3218-712000-00 HOSE,VALVEB2 TO THREE-WAY 1

11 2701-202000-00 CONNECTOR M20×1.5-M20×1.5 1

12 2701-201600-10 CONNECTOR M20×1.5-M16×1.5 1

13 3218-722000-30 OIL PIPE 1

14 3218-723000-30 SIDESHIFTER HOSE 1

15 3218-710100-00 LIFTING HOSE ASSEMBLY 1

BL-V-0217 - 12-16-2021 12-65

Figure 12-25 Hydraulic System - Part 2

R8040

12-66 BL-V-0217 - 12-16-2021

Hydraulic System - Part 2

Pos. Part Number Description Qty. Notes

1 3218-700005-00 OIL SUCTION PIPE 1

2 0000-000471-00 CLIP Φ32-40 6

3 2713-243200-00 CONNECTOR M24×1.5-Φ32 1

4 0000-000640-00 O-RING 21.2×2.65 1

5 0000-000639-00 O-RING 19×2.65 2

6 2701-222000-00 CONNECTORM22×1.5-M20×1.5 2

7 3218-713000-00 HOSE,PUMP TO REDIRECTOR 1

8 3130-733000-00 HOSE,REDIRECTOR TO VALVE 1

9 2706-202000-00 ELBOW M20×1.5-M20×1.5 2

10 0000-000510-00 WASHER Φ20 4

11 3715-720000-00 HOSE, RETURN 1

12 2713-181300-00 CONNECTOR M18×1.5-Φ13 1

13 2706-181600-00 ELBOW M18×1.5-M16×1.5 2

14 0000-000634-00 WASHER Φ18 5

15 3218-700002-00 HOSE, RETURN 1

16 3218-700003-00 STEEL TUBE, RETURN 1

17 3218-700004-00 HOSE I, RETURN 1

18 3215-712000-00 HOSE-L,REDIRECTOR TO STEERING 1 Used on V-15

18a 3218-719000-0A HOSE-L, REDIRECTOR TO STEERING 1 Used on V-16 and V-18

18b 3220-712000-00 HOSE-L, REDIRECTOR TO STEERING 1 Used on V-20

19 3215-711000-00 HOSE-R, REDIRECTOR TO STEERING 1 Used on V-15

19a 3218-718000-00 HOSE-R, REDIRECTOR TO STEERING 1 Used on V-16 and V-18

19b 3220-711000-00 HOSE-R, REDIRECTOR TO STEERING 1 Used on V-20

20 2702-141600-00 CONNECTOR G1/4-M16×1.5 2

21 0000-000044-00 WASHER Φ14 2

BL-V-0217 - 12-16-2021 12-67

Figure 12-26 Hydraulic Pump and Motor

R8043

12-68 BL-V-0217 - 12-16-2021

Hydraulic Pump and Motor


Reqd.Notes

1 3218-760000-00 GEAR PUMP 1

2 0000-000307-00 BOLT M10×1.25×30 2

3 0000-000063-00 LOCKWASHER Φ10 2

4 0000-000007-00 FLATWASHER Φ10 2

5 3218-660000-00 LIFT MOTOR 1

6 3218-660001-00 BEARING 1

7 0000-000165-00 NUT M12 4

8 0000-000060-00 LOCKWASHER Φ12 4

9 0000-000373-00 FLATWASHER Φ12 4

10 3218-600006-00 SHOCK ABSORBER 4

11 0000-000286-00 BOLT M12×60 4

BL-V-0217 - 12-16-2021 12-69

Figure 12-27 Hydraulic Reservoir

R6955

12-70 BL-V-0217 - 12-16-2021

Hydraulic Reservoir


Reqd.Notes

1 0000-001100-00 PLUG DRAIN M18×1.5 1 Used from 12-05-2012

2 0000-000634-00 WASHER Φ18 1

3 3218-110008-00 FILTER 1

4 3218-112001-00 GASKET 1

5 3218-112100-00 OIL TANK COVER 1Used up to serial number

224170007

5a 3218-112100-C0 OIL TANK COVER 1Used from serial number

224170008

6 3218-112002-00 CAP 1

7 3125-713000-00 BREATHER 1

8 0000-000259-00 BOLT M6×16 10

9 0000-000056-00 LOCKWASHER Φ6 10

10 0000-000380-00 FLATWASHER Φ6 10

11 3218-112003-0B DIPSTICK 1

12 3218-110010-00 MAGNET 2

BL-V-0217 - 12-16-2021 12-71

Figure 12-28 Elevation System Overview (TRIMAST)

R8044

12-72 BL-V-0217 - 12-16-2021

Elevation System Overview (TRIMAST)


Reqd.Notes

1 0000-000242-00 BOLT M8×16 6

2 0000-000159-00 LOCKWASHER Φ8 6

3 3218-114000-00 SHAFT 4

4 3218-810000-00 TILT CYLINDER 2

5 0000-000176-00 FLATWASHER Φ8 6

6 -- SEE LIFT CARRIAGE SECTION 1 See Lift Carriage Section

BL-V-0217 - 12-16-2021 12-73


R6991

12-74 BL-V-0217 - 12-16-2021

Elevation System (TRIMAST)


Reqd.Notes

1 0000-000244-00 BLOT M10×30 2

2 0000-000063-00 LOCKWASHER Φ10 6

3 0000-000547-00 FLATWASHER Φ10 2

4 0000-000919-00 BOLT M12×65 1

5 0000-000060-00 LOCKWASHER Φ12 5

6 0000-000554-00 FLATWASHER Φ12 3

7 K25S100007-Y DOUBLE TUBE ROUND 1

8 3215-800002-30 TUBE AXLE 1

9 3215-800001-30 PLATE 2

10 2214-600001-00 CHAIN PULLEY 4

11 0000-000613-00 BOLT M12×50 1

12 2125-600002-30 TUBING ROLLER 1

13 2125-600003-30 SLEEVE 1

14 2125-612000-00 ROLLER I 8

15 0000-000244-00 BOLT M10×30 4

16 3215-800008-30 CYLINDER BRACKET 2

17 3215-800007-30 CLIP 2

18 2214-600005-00 PAD 2

19 B3130-08025 PIN M8×25 2

20 0000-000284-00 BLOT M12×30 4

21 0000-000373-00 FLATWASHER Φ12 2

22 0000-000449-00 BOLT M16×1.5×40 1

23 0000-000191-00 LOCKWASHER Φ16 1

24 0000-000895-00 FLATWASHER Φ16 1

25 3215-800004-30 FIXED PLATE 1

26 2125-600001-30 SPROCKET BLOCK 1 Used up to 12-17-2012

26a 3215-800011-30 SPROCKET BLOCK 1 Used from 12-18-2012

27 3215-800005-30 BRACKET 1

28 0000-000242-00 BLOT M8×16 3

29 0000-000159-00 LOCKWASHER Φ8 3

30 0000-000540-00 FLATWASHER Φ8 3

31 3215-800006-30 MIDDLE TUBE ROUND 1

BL-V-0217 - 12-16-2021 12-75

Figure 12-29 Elevation System (TRIMAST) - Continued

R6991

12-76 BL-V-0217 - 12-16-2021

Elevation System (TRIMAST) - Continued


Reqd.Notes

32 3215-800003-30 TUBE AXLE 1

33 GCQ070DJ3-845 FREE LIFT CYLINDER 1

34 GCQ045DJ4-1550L LIFT CYLINDER L 1

35 3215-810000-30-05 OUTSIDE MAST 1

36 3215-820000-30-05 MIDDLE MAST 1

37 3215-840000-3A-05 INSIDE MAST 1

38 GCQ045DJ4-1550R LIFT CYLINDER R 1

39 0000-000756-00 COLLAR Ø35 4

40 LH1223×103 SECONDARY CHAIN ASSEMBLY II 2

41 LH1223×71 PRIMARY CHAIN ASSEMBLY I 2

42 0000-000427-00 FLATWASHER Φ12 1

BL-V-0217 - 12-16-2021 12-77

Figure 12-30 Hydraulic Lines (Built In Side Shift)

R6964

12-78 BL-V-0217 - 12-16-2021

Hydraulic Lines (Built In Side Shift)


Reqd.Notes

1 3215-860400-10 FLOW REGULATOR 1 Used from 04-15-2015

2 2701-202000-00 CONNECTOR M20×1.5-M20×1.5 3

3 3215-860800-30 STEEL PIPE II 1

4 3215-860600-30 THREE WAY 1

5 3215-860400-30 STEEL PIPE I 1

6 2701-222000-00 CONNECTOR M22×1.5-M20×1.5 1

7 3215-861200-30 OIL PIPE I 1

8 3215-860300-30 STEEL PIPE 1

9 3215-861300-30 OIL PIPE II 1

10 3215-861100-30-05 OIL PIPE 1

11 3215-860700-30 THREE WAY 1

12 0000-000366-00 WASHER Φ22 2

13 0000-000638-00 O-RING 17×2.65 2

14 0000-000510-00 WASHER Φ20 2

15 3215-860100-30 FOUR WAY VALVE 1

16 3215-860900-30-05 OIL PIPE 2

17 3215-860200-30 STEEL PIPE 1

18 3215-861000-30-05 OIL PIPE 2

19 3215-860500-30 STEEL PIPE 1

20 2701-222090-A0 ELBOW M22X1.5-M20X1.5 1

21 0000-000639-00 O-RING 19×2.65 1

22 0000-000109-00 SCREW M8×16 6

23 0000-000159-00 LOCKWASHER Φ8 6

24 0000-000176-00 FLATWASHER Φ8 6

25 0000-000055-00 SCREW M 6×16 3

26 0000-000056-00 LOCKWASHER Φ6 3

27 0000-000023-00 FLATWASHER Φ6 3

28 0000-000044-00 WASHER Φ14 2

29 2706-141400-00 ELBOW M14×1.5-M14×1.5 2

30 3215-861400-30 STEEL PIPE 2

31 2702-141400-00 CONNECTOR G1/4-M14×1.5 2

32 0000-000862-00 O-RING 10.6×1.80 2

BL-V-0217 - 12-16-2021 12-79

Figure 12-31 Hydraulic Lines (External Side Shift)

R6995

12-80 BL-V-0217 - 12-16-2021

Hydraulic Lines (External Side Shift)


Reqd.Notes

1 3215-860400-10 FLOW REGULATOR 1 Used from 04-15-2015

2 2701-202000-00 CONNECTOR M20×1.5-M20×1.5 3

3 3215-860800-30 STEEL PIPE II 1

4 3215-860600-30 THREE WAY 1

5 3215-860400-30 STEEL PIPE I 1

6 2701-222000-00 CONNECTOR M22×1.5-M20×1.5 1

7 3215-861200-30 OIL PIPE I 1

8 3215-860300-30 STEEL PIPE 1

9 3215-861300-30 OIL PIPE II 1

10 3215-861100-30-05 OIL PIPE 1

11 3215-860700-30 THREE WAY 1

12 0000-000366-00 WASHER Φ22 2

13 0000-000638-00 O-RING 17×2.65 2

14 0000-000510-00 WASHER Φ20 2

15 3215-860100-30 FOUR WAY VALVE 1

16 3215-860900-30-05 OIL PIPE 2

17 3215-860200-30 STEEL PIPE 1

18 3215-861000-30-05 OIL PIPE 2

19 3215-860500-30 STEEL PIPE 1

20 2701-222090-A0 ELBOW M22X1.5-M20X1.5 1

21 0000-000639-00 O-RING 19×2.65 1

22 0000-000109-00 SCREW M8×16 6

23 0000-000159-00 LOCKWASHER Φ8 6

24 0000-000176-00 FLATWASHER Φ8 6

25 0000-000055-00 SCREW M 6×16 3

26 0000-000056-00 LOCKWASHER Φ6 3

27 0000-000023-00 FLATWASHER Φ6 3

28 0000-000044-00 WASHER Φ14 2

29 2701-141400-00 CONNECTOR M14×1.5-M14×1.5 2

30 3215-861500-30 STEEL PIPE 2

31 0000-000862-00 O-RING 10.6×1.80 2

BL-V-0217 - 12-16-2021 12-81

Figure 12-32 Lift Cylinder, Full Free Lift (TRIMAST)

R6970

12-82 BL-V-0217 - 12-16-2021

Lift Cylinder, Full Free Lift (TRIMAST)


Reqd.Notes

-- GCQ070DJ3-845 FREE LIFT CYLINDER ASSEMBLY 1

-- 3215-3ZG SEAL KIT FOR CYLINDER 1Includes Pos. # 2, 6, 8,

11 & 14

1 Q070DJ3-05 ROD 1

2 FQ0045C1 LBI DUST RING 55×63×5/6.5 1

3 Q070DJ3-02 CAP 1

4 GN4810V0 SNAP RING 55×65×3 1

5 FU0694K0 RING 55×65×6 1

6 Z6003-07503 O-RING 75×3.1 1

7 Z2114-05540 BUSHING 5540 1

8 Z6053-06503 O-RING 65×3.55 1

9 GCQ055DL4-04 SNAP RING 1

10 Q070DJ3.2-00A PISTON 1

11 GS1816V0 RING 70×56×6.3 1

12 23678-52051 WEARING 70×20×2.5 1

13 GCQ085HST-03-AA VALVE COVER 1

14 Z6003-02002 O-RING 20×2.4 1

15 GCQ085HST-04 SPOOL 1

16 GCQ085HST-06 SPRING 1

17 GCQ085HST-07 SNAP RING 1

18 B6052-00022 SNAP RING Φ22 1

19 B8032-05006 SCREW M5×6 1

20 Q70B0-82141 WASHER 1

21 Q070DJ3.1-05 CYLINDER BODY 1

BL-V-0217 - 12-16-2021 12-83

Figure 12-33 Lift Cylinder, Secondary (TRIMAST)

R6972

12-84 BL-V-0217 - 12-16-2021

Lift Cylinder, Secondary (TRIMAST)


Reqd.Notes

-- GCQ045DJ4-1550L LIFT CYLINDER 1 Left side Cylinder

-- GCQ045DJ4-1550R LIFT CYLINDER 1 Right side Cylinder

-- 3215-3BG SEAL KIT FOR CYLINDER 1 Includes Pos. # 3,4,5 & 12

1 GCQ045HST4-03 SPACER Φ35.5×Φ44×L1 1

2 Z2113-03530 BUSHING 3530 1

3 Z6053-04472 O-RING 44.7×2.4 1

4 23650-52851 SEALS 35×45×6 1

5 27410-53111 DUST RING 35×47×7 1

6 GCQ045XS-01 CAP 1

7 GCQ045DJ4-05L PISTON ROD L 1 Left side Cylinder

7 GCQ045DJ4-05R PISTON ROD R 1 Right side Cylinder

8 D20B8-42381 SNAP RING 1

9 GCQ045HST-02 PISTON 1

10 GCQ045DL4-11 WEARING D45×8 1

11 23650-52861 SNAP RING 45×35×3 1

12 22580-53311 HOLE SEALS 45×35×6 1

13 Q055HST-51002 SLEEVE 1

14 D28B8-42381B SNAP RING 1

15 GCQ045DJ4.1-05L CYLINDER L 1 Left side Cylinder

15 GCQ045DJ4.1-05R CYLINDER R 1 Right side Cylinder

16 0000-000460-00 PIN Φ8×26 1

NOTE: THE QUANTITIES FOR POS. # 1-16 AND THE KIT IS PER CYLINDER.

BL-V-0217 - 12-16-2021 12-85

Figure 12-34 Tilt Cylinder

R6974

12-86 BL-V-0217 - 12-16-2021

Tilt Cylinder


Reqd.Notes

-- 3218-810000-00 2

-- 3215-3QG SEAL KIT FOR CYLINDER 1 Incl. Pos. # 8, 10, 13 & 16

1 58603-15T11 EAR 1

2 3218-810008-00 BEARING GE30ES 1

3 0000-000849-00 SEAL Φ47 1

4 0000-000850-00 BOLT M14×1.5×45 1

5 0000-000233-00 LOCKWASHER Φ14 1

6 0000-000229-00 NUT M14×1.5 1

7 3218-810002-00 DUST SEAL 1

8 3218-810006-00 O-SING 1

9 58605-15T11 SNAP RING 1

10 3218-810005-00 SEAL 1

11 58602-15T11 GUIDE RING 1

12 3218-810001-00 BEARING 1

13 3218-810003-00 O-RING 1

14 58601-15T11 PISTON ROD 1

15 58604-15T11 WEAR RING 1

16 3218-810004-00 SEAL 2

17 58607-15T11 CYLINDER BODY 1

18 3218-810007-00 BEARING 3040 1

19 0000-000588-00 GREASE CUP M10×1 1

NOTE: THE QUANTITIES FOR POS. # 1-19 AND KIT IS PER CYLINDER

BL-V-0217 - 12-16-2021 12-87

Figure 12-35 Lift Carriage

R6973

12-88 BL-V-0217 - 12-16-2021

Lift Carriage


Reqd.Notes

KIT 3215-NCYG-0A SEAL KIT FOR CYLINDER 1 For built in Side Shifter

KIT 3215-NHK-0A KIT FOR SLIDER 1 For built in Side Shifter

KIT 3215-WCYG-0A SEAL KIT FOR CYLINDER 1 For External Side Shifter

KIT 3215-WHK-0A KIT FOR SLIDER 1 For External Side Shifter

1 3218-850000-00 BAFFLE 1

2 0000-001003-00 BOLT M14×1.5×30 8

3 0000-000233-00 LOCKWASHER Φ14 8

4 0000-001004-00 FLATWASHER Φ14 8

5 2125-631100-00 ROLLER II 4

6 3215-831000-30 FORK CARRIAGE 1Used up to serial number

F2314000

6a 3215-832000-30 FORK CARRIAGE 1Used from serial number

F2314001

6b 3218-870000-40 FORK CARRIAGE W. BUILT IN SIDE SHIFT 1 Option 1 - Built in Side Shift

7 3218-870000-20 EXTERNAL SIDE SHIFTER 1 Option 2 - External S. Shift

8 3218-800001-20 FORK 42” 1

9 3218-800002-00 PIN ASSEMBLY 2

BL-V-0217 - 12-16-2021 12-89

Figure 12-36 Built In Side Shift

R8045

12-90 BL-V-0217 - 12-16-2021

Built In Side Shift


Reqd.Notes

1 3218-870001-10 BUMPERS 2

2 3218-870002-10 PLUNGER 2

3 3218-870003-10 DUST RING 2

4 3218-870004-10 COVER 2

5 3218-870005-10 RING 2

6 3218-870006-10 SEALS 2

7 0000-001179-10 BUSHES P45×40×40 2

9 3218-870008-10 SLIDER-UP 4

11 3218-871000-40 SUPPORT FRAME 1

13 3218-870011-10 HOOK-DOWN 2

14 3218-870012-10 SLIDER-DOWN 4

15 3218-870013-10 OIL CUP M6 8

16 0000-000191-00 LOCKWASHER Φ16 4

17 0000-001178-10 BOLT M16×1.5×40 4

18 0000-000060-00 LOCKWASHER Φ12 1

19 0000-000325-00 BOLT M12×20 1

20 3218-872000-10 LATERAL SHELF 1

22 3215-NCYG-0A SEAL KIT FOR CYLINDER 1

23 3215-NHK-0A KIT FOR SLIDER 1

BL-V-0217 - 12-16-2021 12-91

Figure 12-37 External Side Shift

R8335

12-92 BL-V-0217 - 12-16-2021

External Side Shift


Reqd.Notes

1 3218-870001-20 UPPER BEARING 2

2 3218-871000-20 CYLINDER ASSEMBLY 1

3 3218-870002-20 LOWER 2

4 3218-870003-20 NUT M16 4

5 3218-870004-20 LOWER HOOK 2

6 3218-870005-20 WASHER Ø16 4

7 3218-870006-20 BOLT M16×45 4

8 3218-872000-20 FRAME 1

9 3218-870007-20 ROLL PIN 2

10 3218-870008-20 FITTING 6-6 2

11 3218-870009-20 RESTRICTOR WASHER 2

12 3218-870010-20 SCREW M12×20 1

13 3218-870011-20 LOCKWASHER Ø12 1

KIT 3215-WCYG-0A01 SEAL KIT FOR CYLINDER 1

KIT 3215-WHK-0A01 KIT FOR SLIDER 1

BL-V-0217 - 12-16-2021 12-93

Figure 12-38 Lift Chain

R6975

12-94 BL-V-0217 - 12-16-2021

Lift Chain


Reqd.Notes

1 2125-640001-00 CHAIN BOLT 1 Free Lift Cylinder

1a 58502-15T01 CHAIN BOLT 1 Lift Cylinder

2 0000-000237-00 NUT M16×1.5 3 Free Lift Cylinder

2 0000-000316-00 NUT M14×1.5 3 Lift Cylinder

3 0000-000188-00 PIN Ø3.2×20 2

4 2125-640002-00 PIN 2

5 LH1223×71 CHAIN ASSEMBLY 1 Primary (Free Lift Cylinder)

5a LH1223×103 CHAIN ASSEMBLY 1 Secondary (Lift Cylinder)

6 2125-640003-00 CHAIN ANCHOR 1

7 0000-000686-00 COTTER PIN Ø3.2×20 1

8 0000-000176-00 FLAT WASHER Ø8 2

BL-V-0217 - 12-16-2021 12-95

Big Lift LLC

v-15, v-18, v20

Documents