V-08

THREE 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

Big Lift LLC MANUAL NO. BL-V08-1015 - 11-29-2016

www.bigjoeforklifts.com
 WARNING

Do not operate this truck unless you have been autho- Do not overload truck. Check nameplate for capacity
rized and trained to do so, and have read all warnings and load center information.
and instructions in Operator’s Manual and on this
When using forks, space forks as far apart as load will
truck.
permit. Before lifting, be sure load is centered, forks
Do not operate this truck until you have checked its are completely under load, and load is as far back as
condition. Give special attention to tires, horn, battery, possible against load backrest.
controller, lift system (including forks or attachments,
Do not handle unstable or loosely stacked loads. Use
chains, cables and limit switches), brakes, steering
special care when handling long, high or wide loads, to
mechanism, guards and safety devices.
avoid losing the load, striking bystanders, or tipping
Operate truck only from designated operating position. the truck.
Never place any part of your body into the mast struc-
Do not handle loads which are higher than the load
ture or between the mast and the truck. Do not carry
backrest or load backrest extension unless load is
passengers. Keep feet clear of truck and wear foot
secured so that no part of it could fall backward.
protection.
Elevate forks or other lifting mechanism only to pick up
Observe applicable traffic regulations. Yield right of
or stack a load. Watch out for obstructions, especially
way to pedestrians. Slow down and sound horn at
overhead.
cross aisles and wherever vision is obstructed.
Do not lift personnel except on a securely attached
Start, stop, travel, steer and brake smoothly. Slow
specially designed work platform. USE EXTREME
down for turns and on uneven or slippery surfaces that
CARE WHEN LIFTING PERSONNEL. Make sure
could cause truck to slide or overturn. Use special
mast is vertical, place truck controls in neutral and
care when traveling without load as the risk of overturn
apply brakes. Lift and lower smoothly. Remain in oper-
may be greater.
ating position or immediate vicinity as long as person-
Travel with lifting mechanism as low as possible. nel are on the work platform. Never transport
Always look in direction of travel. Keep a clear view, personnel on forks or work platform.
and when load interferes with visibility, travel with load
Do not allow anyone to stand or pass under load or lift-
trailing.
ing mechanism.
Use special care when operating on ramps travel
When leaving truck, neutralize travel control, fully
slowly, and do not angle or turn. Travel with load
lower lifting mechanism and set brake. When leaving
downhill.
truck unattended, also shut off power.
 TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION ............................................................1-1 5-1.2 STEERING CONTROL INSTALLATION ... 5-3
1-1 INTRODUCTION ................................................1-1 5-2 COMPARTMENT COVERS............................... 5-3
1-2 GENERAL DESCRIPTION .................................1-1 5-2.1 COVER REMOVAL ................................... 5-3
1-3 SAFETY FEATURES..........................................1-1 5-2.2 COVER INSTALLATION ........................... 5-3
5-3 FLOOR BOARD ................................................. 5-3
5-3.1 REMOVAL ................................................. 5-3
2 OPERATION ...............................................................2-1 5-3.2 INSTALLATION ......................................... 5-3
2-1 GENERAL...........................................................2-1 5-4 STEERING MOTOR .......................................... 5-4
2-2 OPERATING PRECAUTIONS............................2-1 5-4.1 MOTOR REMOVAL .................................. 5-4
2-3 BEFORE OPERATION.......................................2-2 5-4.2 MOTOR INSTALLATION .......................... 5-5
2-4 GENERAL CONTROL OPERATION..................2-4 5-5 STEERING HANDLE ......................................... 5-6
2-4.1 INSTRUMENT PANEL...............................2-4 5-5.1 REMOVAL ................................................. 5-6
2-4.1.1 LED INDICATORS ...............................2-4 5-5.2 INSTALLATION ......................................... 5-6
2-4.2 HORN SWITCH .........................................2-4
2-4.3 KEY SWITCH.............................................2-4
2-4.4 SHIFT LEVER ............................................2-4 6 BRAKE SERVICING ................................................... 6-1
2-4.5 STEERING WHEEL ...................................2-4 6-1 BRAKES............................................................. 6-1
2-4.6 ACCELERATOR PEDAL ...........................2-4 6-2 ELECTRICAL BRAKE........................................ 6-1
2-4.7 EMERGENCY DISCONNECT SWITCH ....2-4 6-2.1 BRAKE ASSEMBLY REPLACEMENT ...... 6-1
2-4.8 LIFT CONTROL LEVER ............................2-4 6-3 HYDRAULIC BRAKE ......................................... 6-1
2-4.9 TILT CONTROL LEVER ............................2-4 6-3.1 MASTER CYLINDER REMOVAL.............. 6-1
2-4.9.1 SIDE SHIFT CONTROL LEVER ..........2-4 6-3.2 MASTER CYLINDER INSTALLATION...... 6-1
2-4.10 BRAKE PEDAL ..........................................2-5 6-3.3 BLEEDING THE BRAKES ........................ 6-1
2-5 SEAT ADJUSTMENT .........................................2-5 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEELS.. 7-1
2-6 PREPARING FOR OPERATION........................2-6 7-1 TRANSMISSION................................................ 7-1
2-7 DURING BREAK-IN............................................2-6 7-2 DRIVE WHEEL .................................................. 7-2
2-8 STARTING THE TRUCK ....................................2-6 7-3 LOAD WHEEL.................................................... 7-2
2-9 DRIVING AND STOPPING PROCEDURES ......2-6 7-3.1 REMOVAL ................................................. 7-2
2-9.1 TRAVEL .....................................................2-6 7-3.2 INSTALLATION ......................................... 7-2
2-9.2 DECREASING SPEED ..............................2-6 7-4 CASTER............................................................. 7-2
2-9.3 STEERING.................................................2-6
2-9.4 STOPPING AND PARKING.......................2-6
2-9.5 LOADING AND UNLOADING ....................2-6 8 ELEVATION SYSTEM SERVICING ........................... 8-1
2-9.6 STACKING.................................................2-6 8-1 GENERAL .......................................................... 8-1
2-9.7 UN-STACKING ..........................................2-7 8-2 LIFT CHAIN WEAR INSPECTION..................... 8-1
2-10 PARKING............................................................2-7 8-3 LIFT CHAIN LENGTH ADJUSTMENT............... 8-1
8-4 LIFT CHAIN REPLACEMENT............................ 8-2
8-5 LIFT CYLINDER................................................. 8-2
3 PLANNED MAINTENANCE ........................................3-1
3-1 GENERAL...........................................................3-1
3-2 MONTHLY AND QUARTERLY CHECKS...........3-1 9 HYDRAULIC SYSTEM SERVICING........................... 9-1
3-3 BATTERY CARE ...............................................3-1 9-1 LINES AND FITTINGS....................................... 9-1
3-3.1 GENERAL ..................................................3-1 9-2 HYDRAULIC PUMP ........................................... 9-1
3-3.2 SAFETY RULES ........................................3-2 9-2.1 REMOVAL ................................................. 9-1
3-3.3 BATTERY CARE AND CHARGING...........3-2 9-2.2 INSTALLATION ......................................... 9-1
3-3.4 BATTERY CLEANING ...............................3-2 9-3 HYDRAULIC RESERVOIR ................................ 9-3
3-3.5 MAINTENANCE FREE BATTERIES .........3-2 9-4 CONTROL VALVE ............................................. 9-4
3-4 CHARGING BATTERIES ...................................3-3 9-4.1 REMOVAL ................................................. 9-4
3-5 BATTERY REMOVAL.........................................3-4 9-4.2 INSTALLATION ......................................... 9-5
3-6 LUBRICATION....................................................3-4 9-5 TILT CYLINDER................................................. 9-5
3-7 LIFT CHAIN MAINTENANCE .............................3-4 9-5.1 REMOVAL ................................................. 9-5
9-5.2 REPAIR ..................................................... 9-5
9-5.3 INSTALLATION ......................................... 9-6
4 TROUBLESHOOTING ................................................4-1 9-6 LIFT CYLINDER................................................. 9-7
4-1 GENERAL...........................................................4-1 9-6.1 FREE LIFT CYLINDER ............................. 9-7
4-2 CONTROLLER TROUBLESHOOTING ..............4-4 9-6.1.1 REMOVAL ........................................... 9-7
4-2.1 ZAPI HANDSET .........................................4-4 9-6.1.2 REPAIR ............................................. 9-10
4-2.1 FAULT DETECTION ..................................4-4
4-2.2.1 GENERAL ............................................4-4 9-6.1.3 INSTALLATION ................................. 9-11
4-2.2.2 LOGBOOK ACCESS............................4-4 9-6.2 SECONDARY CYLINDER....................... 9-11
9-6.2.1 REMOVAL ......................................... 9-11
4-2.3 TESTING TRUCK OPERATION ................4-4
4-2-4 FACTORY SETTINGS ...............................4-5 9-6.2.2 REPAIR ............................................. 9-11
9-6.2.3 INSTALLATION ................................. 9-12
5 STEERING, COVERS AND FLOORBOARDS............5-1
5-1 CONTROL HANDLE...........................................5-1
5-1.1 STEERING CONTROL REMOVAL............5-1

BL-V08-1015 - 11-29-2016 1
 TABLE OF CONTENTS - CONTINUED

Section Page Section Page

10 ELECTRICAL COMPONENTS ................................. 10-1 10-2.1 REMOVAL ............................................... 10-2
10-1 CONTROL HANDLE ........................................ 10-1 10-2.2 INSTALLATION ....................................... 10-2
10-1.1 COVER.................................................... 10-1 10-3 DRIVE MOTOR ................................................ 10-2
10-1.1.1 REMOVAL ......................................... 10-1 10-3.1 REMOVAL ............................................... 10-2
10-1.1.2 INSTALLATION ................................. 10-1 10-3.2 INSTALLATION ....................................... 10-2
10-1.2 KEY SWITCH .......................................... 10-2 10-4 PUMP MOTOR................................................. 10-3
10-1.2.1 REMOVAL ......................................... 10-2 10-5 ACCELERATOR............................................... 10-3
10-5.1 REMOVAL ............................................... 10-3
10-1.2.2 INSTALLATION ................................. 10-2 10-5.2 INSTALLATION ....................................... 10-4
10-1.3 HORN SWITCH....................................... 10-2 10-6 ELECTRICAL CONTROL PANEL .................... 10-4
10-1.3.1 REMOVAL ......................................... 10-2 10-6.1 MAINTENANCE....................................... 10-4
10-1.3.2 INSTALLATION ................................. 10-2 10-6.2 CLEANING............................................... 10-4
10-1.4 FORWARD/REVERSE SWITCH............. 10-2 10-6.3 CONTROLLER REMOVAL...................... 10-4
10-1.4.1 REMOVAL ......................................... 10-2 10-6.4 CONTROLLER INSTALLATION.............. 10-4
10-1.4.2 INSTALLATION ................................. 10-2
10-1.5 INSTRUMENT PANEL ............................ 10-2 11 OPTIONAL EQUIPMENT .......................................... 11-1
10-1.5.1 REMOVAL ......................................... 10-2
10-1.5.2 INSTALLATION ................................. 10-2 12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1
10-2 EMERGENCY DISCONNECT SWITCH .......... 10-2

1-2 BL-V08-1015 - 11-29-2016

 SECTION 1
DESCRIPTION

1-1. INTRODUCTION.
MODEL NO. SERIAL NO.
This publication describes the 24 volt three wheel V-08
lift truck manufactured by Big Lift LLC. Included are MAX CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/ MM

operating instructions, planned maintenance instruc-

tions, lubrication procedures, corrective maintenance ALT CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/ MM

procedures and a complete parts list with part location TRUCK WT LESS BATTERY LB/ KG BATTERY MIN WT LB/ KG

illustrations.
TRUCK WT WITH BATTERY LB/ KG BATTERY MAX WT LB/ KG
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of TRUCK BATTERY
CERTIFIED VOLTAGE
TYPE TYPE
A.N.S.I. B56.1 Part II. By following these requirements
and the recommendations contained in this manual, COMPLIES WITH THE APPLICABLE REQUIRE-

you will receive many years of dependable service MENTS OF ANSI B56.1 AND OSHA STANDARDS

from your V series lift truck. U.S. PATENT NO. 4,444,284

AUSTRALIAN PATENT NO. 537,987

BIG LIFT LLC

R6209 WISCONSIN DELLS, WISCONSIN 53965
1-2. GENERAL DESCRIPTION.
Figure 1-1 Name Plate
The V-08 lift truck is a TRIMAST model with a 157 inch
lift. It lifts and transports payloads up to 2200 pounds 1-3. SAFETY FEATURES.
on adjustable forks.
The V-08 series lift truck is designed engineered to
The three wheel counterbalanced design features a provide maximum safety for operator and payload.
small turning radius. Some of the safety features incorporated into the
The forward and reverse motion is controlled by a design are:
small shift lever next to the steering wheel. Stopping is • Deadman switch to shut off power and apply brake
controlled by the brake pedal. Control levers to the when operator leaves seat.
right of the operator control the Lift, Lower, and Tilt. An • High speed limit switch to restrict speed when lift
optional lever is available to control side motion of the carriage is raised above the preset limit.
forks. The battery powered lift truck is quiet and with- • All control functions automatically return to “OFF”
out exhaust fumes. when released.
The reversible AC motor propels the truck in forward • Emergency disconnect switch within operator's
or reverse direction throughout the available speed reach.
range. The V-08 series lift truck can be driven with • Separately fused control circuits and power circuits.
forks raised or lowered; however, the speed is • Readily accessible horn button in steering wheel.
restricted when the mast is raised above a preset limit. • Lift carriage backrest to help stabilize the load.
The model number will be found on the name plate • Handle on the front left pillar of overhead guard to
(Figure 1-1) along with the serial number, lifting capac- provide a firm hand hold for operator.
ity, and load center. Figure 1-2 shows the locations of • Relief valve maintains hydraulic pressure within pre-
the truck’s main components. scribed limits.
• High visibility color scheme of truck provides visual
alert of truck’s presence.
• Instrument panel and display.

BL-V08-1015 - 11-29-2016 1-1

 R7291

Figure 1-2 V-08 Series Lift Truck

ITEM COMPONENT ITEM COMPONENT

1 Seat 6 Fork
2 Operating Panel 7 Front Wheel
3 Chassis 8 Battery
4 Mast 9 Caster
5 Load backrest 10 Drive Wheel

1-2 BL-V08-1015 - 11-29-2016

 SECTION 2
OPERATION

2-1. GENERAL. • Be certain that the lifting mechanism is operating

This section gives detailed operating instructions for smoothly throughout its entire height, both empty
the V-08 series lift truck. The instructions are divided and loaded.
into the various phases of operations, such as operat- • Be sure that mast is vertical - do not operate on a
ing lift, driving, and stopping. Routine precautions are side slope.
included for safe operation.
• Be sure the truck has a firm and level footing.
2-2. OPERATING PRECAUTIONS. • Avoid overhead wires and obstructions.

WARNING: Improper operation of the lift truck may • Check for obstructions when raising or lowering the
result in operator injury, or load and/or lift lift carriage.
truck damage. Observe the following • Do not handle unstable or loosely stacked loads.
precautions when operating the V-08 Use special care when handling long, high, or wide
series lift truck. loads to avoid tipping, loss of load, or striking
bystanders.
The following safety precautions must be adhered to
at all times. • Center and carry the load as far back as possible
toward the lift carriage back rest. The center-of-grav-
• Do not operate this truck unless you have been ity of the load must not exceed the load center listed
trained and authorized to do so. on the nameplate. See Figure 2-1 for load center
• All warnings and instructions must be read and limitations.
understood before using the equipment. • Pick up loads on both forks. Do not pick up on only
• Equipment must not be altered in any way. one fork.
• Equipment must be inspected by a qualified person • When traveling, always lower the load as far as pos-
on a regular basis. sible.
• Do not exceed the rated capacity. Overloading may • When stacking pallets in racks and it is necessary to
result in damage to the hydraulic system and struc- move the load in a raised position, use caution.
tural components. Operate truck smoothly.

R3814

Figure 2-1 Load Center

BL-V08-1015 - 11-29-2016 2-1

• Observe applicable traffic regulations. Yield right of Figure 2-2 shows a sample format for an Operator
way to pedestrians. Slow down and sound horn at Checklist, which can be modified as necessary to fit
cross aisles and wherever vision is obstructed. your operation.
• Operate truck only from designated operation posi- WARNING: Periodic maintenance of this truck by a
tion. Never place any part of your body between the QUALIFIED TECHNICIAN is required.
mast uprights. Do not carry passengers.
CAUTION: A QUALIFIED SERVICE TECHNICIAN
• Do not allow anyone to stand or pass under load or
should check the truck monthly for
lifting mechanism.
proper lubrication, proper fluid levels,
• When leaving truck, neutralize travel control. Fully brake maintenance, motor maintenance
lower lifting mechanism and set parking brake. and other areas specified in the SEC-
When leaving truck unattended, turn off key switch, TION 3.
remove key and disengage the emergency stop
switch. WARNING: If the truck is found to be unsafe and in
need of repair, or contributes to an
2-3. BEFORE OPERATION unsafe condition, report it immediately to
the designated authority. Do not operate
Table 2-1 covers important inspection points on the it until it has been restored to a safe
V-08 Series lift truck which should be checked prior to operating condition. Do not make any
operation. Depending on use, some trucks may unauthorized repairs or adjustments. All
require additional checks. service must be performed by a qualified
maintenance technician.

Table 2-1 Operator Checks

ITEM PROCEDURE ITEM PROCEDURE
Transmissions Check for signs of fluid leakage. Travel controls Check that the accelerator oper-
and hydraulic ates in all speed ranges in for-
systems. ward and reverse.
Forks Check for cracks and damage; Wheels Check front drive wheels for
and, that they are properly cracks or damage. Move truck
secured. to check load for freedom of
Chains, cables Check that they are in place, rotation.
and hoses secured correctly, functioning Hydraulic Check operation of lift, tilt and
properly and free of binding or controls side shift to their maximum
damage. positions.
Guards and load Check that safety guards are in Brakes Check that brakes actuate when
backrest place, properly secured and not the brake pedal is depressed.
damaged. Parking brake Check that the electric brake on
Safety signs Check that warning labels, the drive motor engages when
nameplate, etc., are in good the emergency disconnect
condition and legible. switch is pressed.
Horn Check that horn sounds when Battery charge Check the instrument panel bat-
operated. tery indicator.
Steering Check for binding or looseness
when steering.

2-2 BL-V08-1015 - 11-29-2016

 Electric Truck
Big Joe Manufacturing Company Daily Operator Check-Off List

Date Operator

Truck No. Model No.

Dept. Shift
Hour Meter
Reading Drive Hoist

Check O.K. ( ) Need Maintenance

Tires
Load Wheels
Horn
Lift Lower Control
Attachment Operation
Forward & Reverse Controls

Steering
Brakes
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.

R6479

Figure 2-2 Sample of Operator Check List

BL-V08-1015 - 11-29-2016 2-3

2-4. GENERAL CONTROL OPERATION. 2-4.3. Key Switch

2-4.1. Instrument Panel The key switch (13, Figure 2-4) has two positions, ON
and OFF. Be sure the shift lever is in the neutral posi-
The instrument panel contains the following displays tion and the acceleration pedal is released before the
and controls: key switch is turned on.
2-4.1.1. LED Indicators Removing the key prevents the truck from being used
by unauthorized personnel.
There are six indicators:
2-4.4. Shift Lever
Hourmeter: Normally off. Blinks when The shift lever (14, Figure 2-4) controls forward and
the Hourmeter is working. reverse travel.

Speed Reduction: Normally off. Appears 2-4.5. Steering Wheel

when maximum speed and acceleration The steering wheel (15, Figure 2-4) is operated in the
are reduced. conventional manner. The rear wheels steer the truck
Maintenance: Normally off. Appears causing the rear of the truck to swing out when a turn
when programmed maintenance. Also is made.
appears along with relative code when 2-4.6. Accelerator Pedal
an alarm occurs.
As the accelerator pedal (16, Figure 2-4) is slowly
Alarms: Displays the corresponding pressed, the drive motors start turning and the truck
code when an alarm occurs. To attract will start to move. According to the force applied to the
attention, the Red LED will start blinking pedal, the speed increases.
when an alarm occurs.Refer to SEC-
TION 4 for fault codes. 2-4.7. Emergency Disconnect Switch

Battery Indicator: The battery state of This switch (17, Figure 2-4) is used to cut off the main
charge is indicated by ten notches. power to the truck in case of an emergency. The brake
Each notch represents 10% of the bat- will apply when the this switch is depressed.
tery change. As the battery becomes 2-4.8. Lift Control Lever
discharged, the notches turn off pro-
gressively. This lever (18, Figure 2-4) is used to lift the forks. Pull-
ing the lever back will raise the forks. Pushing it for-
ward will lower the forks. The speed of the tilt can be
controlled by the pressure on the lever. Motor speed or
accelerator pedal has not affect the lowering speed.

2-4.9. Tilt Control Lever

This lever (19, Figure 2-4) is used to tilt the mast. Pull-
ing the lever back will tilt the mast backwards. Pushing
it forward will tilt the mast forward. The speed of the tilt
can be controlled by the pressure on the lever. The tilt
lock mechanism built in the hydraulic control valve
R7298 does not allow the mast to tilt forward with the key
switch off.
Figure 2-3 Steering Column Tilt Lever
2-4.9.1. Side Shift Control Lever
2-4.2. Horn Switch If equipped, this lever (20, Figure 2-4) is used to side
Press button (12, Figure 2-4) to sound the horn. shift the forks. The speed of the side shift can be con-
trolled by the pressure on the lever.

2-4 BL-V08-1015 - 11-29-2016

 R7292

Figure 2-4 Controls

2-4.10.Brake Pedal
Press the brake pedal (21, Figure 2-4) to slow or stop
with the hydraulic brakes on the load wheel. The brake
light will come on when pedal is depressed.

2-5. SEAT ADJUSTMENT.

Before operating the truck, adjust the operator’s seat
and make sure it is securely locked. The seat is
unlocked by turning adjusting lock (2, Figure 2-5)
counterclockwise. Lever (1) is used to adjust the lean
of the seat. Lever (3) is used to adjust the position of R7299

the seat.
Figure 2-5 Seat Adjustment

BL-V08-1015 - 11-29-2016 2-5

2-6. PREPARING FOR OPERATION. 2-9.3. Steering.
Preparing the truck for operation after delivery or The steer wheel is located at the rear of the truck
transport: causing the rear to swing out when turning. Slow down
and move toward the side being turned.
1. Check that the equipment is complete.
2. Check the hydraulic oil level. Refer to SECTION 2-9.4. Stopping and Parking.
3.
1. Slow down and press the brake pedal to stop the
3. Install the batteries if necessary. Refer to SEC- truck.
TION 3. 2. Place the shift lever in neutral.
4. Charge the batteries. Refer to SECTION 3. 3. Tilt the forks until parallel with the floor.
5. Visually inspect the entire truck (in particularly
4. Lower the forks to the ground.
wheels and forks) for obvious damage.
5. Turn off the key switch and remove the key.
2-7. DURING BREAK-IN.
2-9.5. Loading and Unloading.
Operating the truck under light load conditions is rec-
1. Place the truck in front of the load.
ommended. Limited load is 70 to 80% of the rated
load. During the first 100 hours of operation observe 2. Adjust the forks sideways to maintain proper bal-
the following: ance of the load.
1. Prevent the new batteries from over-discharging. 3. The pallet should be evenly positioned across
both forks.
2. Perform preventive maintenance services care-
fully and completely. 4. Insert the forks into the pallet a far as possible.
3. Avoid sudden stops, starts or turns. 5. To raise the load from the ground:
4. Perform oil changes and lubrication earlier than a. Slightly lift the load.
specified. b. Be sure the load is stable.

2-8. STARTING THE TRUCK. c. Tilt the forks back to level the load.

1. Place the shift lever in neutral. 6. When handling bulky loads which restrict your
vision, operate the truck in reverse except when
2. Hold the steering wheel with the left hand and turn climbing grades.
on key switch with the right hand.
3. Slightly lift and tilt the forks. 2-9.6. Stacking.
1. Slowly approach the deposit area.
2-9. DRIVING AND STOPPING PROCEDURES.
2. Stop the truck when right in front of the area.
2-9.1. Travel. 3. Check the condition of the deposit area.
1. Place the shift lever in forward or reverse. 4. Tilt the mast forward until forks are horizontal.
2. Slowly step on the accelerator pedal until the 5. Raise the forks until they are a little higher than
desired speed is obtained. the deposit area.

WARNING: Do not step on the accelerator pedal and 6. Move forward to place the load directly over the
the brake pedal at the same time. desired area and stop the truck.
7. Make sure your load is just over the desired area
2-9.2. Decreasing Speed. and slowly lower the load into position. Make sure
1. Slowly release the accelerator pedal. The truck the load is securely stacked.
will decelerate. 8. Disengage forks from the load using necessary lift
and tilt operation and then back the truck up.
9. After making sure the fork tips are clear of the
load, lower the forks and tilt backwards.

2-6 BL-V08-1015 - 11-29-2016

2-9.7. Un-stacking. 7. Check around the truck to insure that the path of
travel is unobstructed and back away slowly.
1. Slowly approach the load to be retrieved.
8. Lower the forks and tilt backwards.
2. Stop truck when right in front of the load.
3. Check the condition of the load. 2-10.PARKING.
4. Tilt the mast forward until forks are horizontal. When finished with moving loads, return the truck to its
5. Raise the forks up to the position of the pallet or maintenance or storage area. Turn off the key switch.
skid. Charge batteries as necessary. Refer to battery care
6. Make sure the forks are positioned properly for instructions, SECTION 3.
the pallet. Slowly move forward to insert the forks
into the pallet as far as possible and then stop the
truck.

BL-V08-1015 - 11-29-2016 2-7

 NOTES

2-8 BL-V08-1015 - 11-29-2016

 SECTION 3
PLANNED MAINTENANCE

3-1. GENERAL. CAUTION: Gases produced by a battery can be

Planned maintenance consists of periodic visual and explosive. Do not smoke, use an open
operational checks, parts inspection, lubrication, and flame, create an arc or sparks in the
scheduled maintenance designed to prevent or dis- vicinity of the battery. Ventilate an
cover malfunctions and defective parts. The operator enclosed area well when charging.
performs the checks in SECTION 2, and refers any CAUTION: Batteries contain sulfuric acid which may
required servicing to a qualified maintenance techni- cause severe burns. Avoid contact with
cian who performs the scheduled maintenance and eyes, skin or clothing. In case of contact,
any required servicing. flush immediately and thoroughly with
clean water. Obtain medical attention
3-2. MONTHLY AND QUARTERLY CHECKS. when eyes are affected. A baking soda
Table 3-1 is a monthly and quarterly inspection and solution (one pound to one gallon of
service chart based on normal usage of equipment water) applied to spilled acid until bub-
eight hours per day, five days per week. If the lift truck bling stops, neutralizes the acid for safe
is used in excess of forty hours per week, the fre- handing and disposal.
quency of inspection and service should be increased
Leakage voltage from battery terminals to battery case
accordingly. These procedures must be performed by
can cause misleading trouble symptoms with the truck
a qualified service technician or your Big Lift LLC Ser-
electrical system. Since components of the truck elec-
vice Representative.
trical system are insulated from truck frame, leakage
voltage will not normally affect truck operation unless a
3-3. BATTERY CARE.
short circuit or breakdown of circuit wire insulation to
3-3.1. General truck frame occurs.

The V-08 series lift trucks may be equipped with main- A voltage check from battery connector terminal to
tenance free batteries. battery case should indicate near zero volts. Typically,
however, the sum of the voltages at both terminals will
The care and maintenance of the battery is very equal battery volts. This leakage voltage will discharge
important to obtain efficient truck operation and maxi- the battery. As battery cleanliness deteriorates, the
mum battery life. usable charge of the battery decreases due to this self
discharge.
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 wheel for wear or damage.
Monthly Inspect wiring for loose connections and damaged insulation.
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-V08-1015 - 11-29-2016 3-1

Although a leakage voltage reading of zero volts may 2. Battery terminals should be checked and cleaned
not be possible, a cleaner battery will have more of corrosion regularly. Good battery terminal con-
usable charge for truck operation and not affect opera- tact is essential not only for operation, but also for
tion of electronic devices on the unit. proper charging of the battery.

3-3.2. Safety Rules 3. The charging requirements will vary depending on

the use of the truck. The battery should be given
• Wear protective clothing, such as rubber apron, an equalizing charge on a weekly basis. This
gloves, boots and goggles when performing any charge should normally be an additional three
maintenance on batteries. Do not allow electrolyte to hours at the finish rate.
come in contact with eyes, skin, clothing or floor. If
4. Make certain battery used meets weight and size
electrolyte comes in contact with eyes, flush immedi-
requirements of truck. NEVER operate truck with
ately and thoroughly with clean water. Obtain medi-
an undersized battery.
cal attention immediately. Should electrolyte be
spilled on skin, rinse promptly with clean water and 3-3.4. Battery Cleaning
wash with soap. A baking soda solution (one pound
to one gallon of water) will neutralize acid spilled on Always keep vent plugs tightly in place when cleaning
clothing, floor or any other surface. Apply solution battery. When properly watered and charged, the bat-
until bubbing stops and rinse with clean water. tery will remain clean and dry. All that is necessary is
to brush or blow off any dust or dirt that may accumu-
• Do not bring any type of flame, spark, etc., near the late on them. However, if electrolyte is spilled or over-
battery. Gas formed while the battery is charging, is flows from a cell, it should be neutralized with a
highly explosive. This gas remains in cell long after solution of baking soda and water, brushing the soda
charging has stopped. solution beneath the connectors and removing grime
• Do not lay metallic or conductive objects on battery. from the covers. Then rinse the battery with cool water
Arcing will result. from a low pressure supply to remove the soda and
loosen dirt. If batteries stay wet consistently, they may
• Do not touch non-insulated parts of DC output con-
be either overcharged or over filled. This condition
nector or battery terminals to avoid possible electri-
should be investigated and corrected.
cal shock.
• De-energize all AC and DC power connections 3-3.5. MAINTENANCE FREE BATTERIES
before servicing battery. Some trucks may be equipped with maintenance free
• Do not charge a frozen battery. batteries. These batteries are completely sealed, will
not require any watering and have a full 80% dis-
• Do not use charger if it has been dropped or other- charge available.
wise damaged.
Sealed Maintenance Free batteries contain a pressure
3-3.3. Battery Care and Charging release valve and under normal operating conditions
do not require any special ventilation.
CAUTION: Never smoke or bring open flame near
the battery. Gas formed during charging CAUTION: Do not try to open this battery or remove
is highly explosive and can cause seri- the pressure release valve.
ous injury.
Only under severe overcharging, such as connected
1. Charge the battery only in areas designated for to an improperly sized charger, will any significant
that use. amount of gasses be released from the battery. Also,
being a valve regulated battery, it never requires
watering.

3-2 BL-V08-1015 - 11-29-2016

3-4. CHARGING BATTERIES
Charging requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
placing a battery on charge.
Proceed as follows:
1. Park truck at charging station with carriage low-
ered and turn the key switch off.
2. Check the condition of the AC cord and battery
cables. If there are any cuts in the cable, any
exposed wires, loose plugs or connectors, DO R7300
NOT attempt to charge the batteries. Contact
appropriate personnel for repairs to be made. Figure 3-1 Battery Connector
3. Disconnect the battery connector (Figure 3-1) 4. Connect the charger to the appropriate power
from the truck and connect the batteries to the supply.
charger. Make sure connectors are mated prop- 5. Follow the instructions for the charger being used.
erly.

BL-V08-1015 - 11-29-2016 3-3

3-5. BATTERY REMOVAL 3-6. LUBRICATION.
1. Park truck with carriage lowered and turn the key Refer to Table 3-2 for the recommended types of
switch off. grease and oil. Table 3-3 in conjunction with
2. Disconnect the battery connector from the truck. Figure 3-4 identifies the items requiring lubrication.

3. Position the optional battery removal carriage 3-7. LIFT CHAIN MAINTENANCE.
along side the truck. Engage the interlock (3, Fig-
ure 3-2) by lowering the carriage. Fully raise and lower lift carriage while observing
chains as they move over chain sheaves. Ensure
chain is aligned and tracking properly and all links are
pivoting freely. With lift carriage fully lowered, spray or
brush on a film of SAE 30 or 40 engine oil.
Table 3-2 Recommended Lubricants
(See Table 3-3 for Application)
No. 1 Transmission oil—EP SAE 80W-90
Transmission 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
R7301 Hydraulic oil-Heavy duty with a viscosity of
100 SUS foam suppressing agent and
Figure 3-2 Aligning interlock rust and oxidation inhibitors (Note)
4. Slide the battery onto the battery removal car-
riage. No. 4 SAE 30 or 40 Engine lubricating oil
5. Raise the battery removal carriage to release the No. 5 DOT3 Brake Fluid
interlock and move away from the truck (Figure 3- NOTE: USED ON COLD CONDITIONED TRUCKS
3).

R7302

Figure 3-3 Battery Removal

3-4 BL-V08-1015 - 11-29-2016

 R7303

Figure 3-4 Lubrication Diagram

Table 3-3 Lubrication Chart
FIG 3-2 LOCATION METHOD OF TYPE APPLICATION
INDEX APPLICATION (Table OF
NO. 3-3) LUBRICANT
1 Inner & Outer Mast Brush No. 2 Full length of channel where rollers
operate.
2 Lift Chain Brush or Spray No. 4 See Paragraph 3-7.
3 Lift Carriage Brush No. 2 Light coating where forks slide.
4 Brake Reservoir Can No. 5 Fill reservoir with brake fluid to
level between seams of reser-
voir.
5 Hydraulic Reservoir Can No. 3 With lift carriage fully lowered, fill
Capacity-1 quarts reservoir with hydraulic oil to
level on dip stick.
6 Transmission Can No. 1 Fill to level plug.
Capacity 2 pints

BL-V08-1015 - 11-29-2016 3-5

 NOTES

3-6 BL-V08-1015 - 11-29-2016

 SECTION 4
TROUBLESHOOTING

4-1. GENERAL ate: Truck Does Not Operate Forward or Reverse:

Use Table 4-1 as a guide to determine possible Trouble With Braking: Trouble With Lifting Or Lower-
causes of trouble. The table is divided into five main ing, and Miscellaneous malfunctions.
categories: Truck and Hydraulic System Will Not Oper-
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- a. Emergency disconnect switch Bypass keyswitch to determine if it
tem operate. (6, Figure 12-5 or 31, Figure 12- is malfunctioning.
9) defective.
b. Battery dead or disconnected. Check battery connections and
check battery voltage.
c. Keyswitch (22, Figure 12-8 or Bypass keyswitch to determine if it
22, Figure 12-9) defective. 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 a. Check all wiring. A loose con- Tighten all loose connections
reverse. All other functions oper- nection may be the cause of before further troubleshooting.
ate normally. malfunction.
b. Defective controller (13, Figure Check for proper operation and
12-15). replace if necessary.
d. Defective accelerator (2, Figure Check and replace accelerator if
12-4). defective.
Truck travels forward but not in Defective accelerator (2, Figure Check and replace accelerator if
reverse. 12-4). defective.
Truck travels reverse but not in Defective accelerator (2, Figure Check and replace accelerator if
forward. 12-4). defective.
Truck travels forward and in Defective accelerator (2, Figure Check and replace accelerator if
reverse at lower speeds; will not 12-4). defective.
travel at high speed.
TROUBLE WITH BRAKING
Insufficient brake force. a. Low brake fluid in reservoir (1, Check and refill.
Figure 12-20).
b. Air in brake lines Bleed air
c. Uneven wear or contact of Replace.
brake linings.
Brake drags or grabs. a. No free play of brake pedal. Adjust
b. Clogged master cylinder return Clean
port.
c. Clogged brake lines Clean.

BL-V08-1015 - 11-29-2016 4-1

 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH HYDRAULIC
PUMP
No oil from hydraulic pump a. Oil level too low. Identify oil leak and fill reservoir.
b. Clogged suction pipe or filter Clean oil line and reservoir. If oil is
(16, Figure 12-19). dirty, change.
Low discharge pressure on a. Worn pump. Replace
hydraulic pump b. Relief valve out of adjustment. Readjust to specified pressure
using pressure gauge.
c. Air in hydraulic pump a. Retighten suction lines.
b. Add oil to hydraulic reservoir.
Noisy hydraulic pump a. Cavitation due to crushed suc- Adjust or replace crushed line and
tion line or clogged filter (16, Fig- clean filter.
ure 12-19).
b. Air being sucked from loose Retighten.
suction joint.
c. Cavitation due to too high oil Replace with oil having proper vis-
viscosity 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 not Lose of pressure --adjust screw Readjust and tighten.
steady or too low. Faulty control valve. Replace
Forks tilt forward when control Worn or damaged tilt section. Replace valve
lever is used while engine is off.
Mast is unstable when tilting for- Malfunctioning tilt relief valve Replace valve
ward
Valve is not returning to neutral a. Damage or distorted return Replace valve
position. spring
b. Dirt exists between valve body Clean.
and spool.
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

4-2 BL-V08-1015 - 11-29-2016

 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH LIFTING
SYSTEM - Continued
Lift carriage moves up and down a. Faulty lift cylinder Repair
sluggishly b. Too much accumulated dirt Clean
c. Insufficient lubrication. Apply grease on contact surfaces
of sliding parts.

Forks lift unevenly. Lift chains out of adjustment Adjust lift chains
Lift rollers do not rotate a. Grease stiffened or dirt accu- Clean and lubricate lift rollers
mulated on lift roller and mast
sliding surfaces
b. Improperly adjusted lift rollers. Adjust
Excessive mast noise a. Insufficient lubrication Lubricate
b. Improperly adjusted lift rollers, Adjust.
side rollers.
Insufficient lift power or no lift a. Worn hydraulic pump. Replace
movement. b. Worn lift cylinder seals resulting Repair cylinder
in excessive internal leakage.
c. Worn control valve Replace
d. Leaking hydraulic lines Tighten and inspect for damage
e. Oil temperature too high. Oil Change hydraulic oil or stop oper-
viscosity is too low. ation until oil cools. Find out the
reasons for high oil temperature
and eliminate the trouble.
f. Load larger than capacity. Refer to nameplate on side of
mast for maximum load capacity.

BL-V08-1015 - 11-29-2016 4-3

4-2. CONTROLLER TROUBLESHOOTING The microprocessor in the controller records the last
five Alarms that have occurred. Items remembered rel-
4-2.1. Zapi Handset ative to each Alarm are:
A Zapi Handset Figure 4-1 is available that is designed • The alarm code
specifically for use with either the traction or steering
controller. It serves multiple functions of reading diag- • The times that each alarm occurs consecutively
nostic data, testing truck operation, setting options, • The Hour Meter value when the latest event of every
adjustments and parameter changes of the controller. alarm occurred
The Zapi Handset is available through your Big Lift
This function permits a deeper diagnosis of problems
LLC dealer. If you require dealer location information,
as the recent history can be revisited.
contact Big Lift LLC.
Remove the rubber plug from the CNC connector of 4-2.2.2. Logbook Access
either the traction or the steering controller and plug in To view either the traction or steering alarm logbook
the Zapi Handset connector. proceed as follows:
1. Connect the Zapi Handset to either the traction or
steering controller, refer to paragraph 4-2.1.
2. Press the ENTER button (3, Figure 4-1) to enter
the MAIN MENU.
3. Press the ROLL down button (2) or the ROLL up
button (1) until ALARMS menu appears on the
display.
4. Press the ENTER button (3) to enter the ALARMS
menu.
5. Press the ROLL up button (1) to view the alarms.
Pressing the ROLL down button (2) returns to the
most recent alarm.

If an alarm has not occurred, the display will show

ALARM NULL.

Refer to Table 4-3 and Table 4-4 for suggestions

covering a wide range of possible faults.
6. Press the OUT button (4) to exit the alarms.

The display will ask: “CLEAR LOGBOOK?” Press

the ENTER button (3) for Yes or OUT button (4)
for No.
R6624
7. Press the OUT button (4) again to return to Open-
Figure 4-1 Zapi Handset ing Zapi Menu.
4-2.2. Fault Detection. 4-2.3. Testing Truck Operation.
4-2.2.1. General The Zapi Handset can be used to test certain truck
operations as follows:
Alarm codes are displayed on the instrument panel
(23, Figure 12-9). Refer to Table 4-3 and Table 4-4 for 1. Connect the Zapi Handset to either the traction or
suggestions covering a wide range of possible faults. steering controller, refer to paragraph 4-2.1.
2. Press the ENTER button (3, Figure 4-1) to enter
the MAIN MENU.
3. Press the ROLL down button (2) or the ROLL up
button (1) to find the TESTER display.

4-4 BL-V08-1015 - 11-29-2016

4. Press the ENTER button (3) to enter the TESTER 2. Press the ENTER button (3, Figure 4-1) to enter
function. the MAIN MENU.
3. Press the ROLL down button (1) or the ROLL up
The first switch to be tested is shown on the dis- button (2) to find the PARAMETER CHANGE dis-
play. play.
5. To verify various switch functions, press the ROLL 4. Press the ENTER button (3) to view the parame-
down button (2) or the ROLL up button (1) to ters.
locate the switch on the display and then operate
that function to verify operation 5. Press the ROLL down button (2) or the ROLL up
button (1) to find the parameter to be checked.
6. Press the OUT button (6) to exit the tests. The
display will show TESTER. 6. Press the SET up button (5) or the SET down but-
ton (6) until the factory setting is reached.
7. Press the OUT button (6) again to return to Open-
ing Zapi Menu. 7. Press the OUT button (4) to exit the parameters.
The confirmation request appears.
4-2.4. Factory Settings 8. Press ENTER button (3) to accept the changes or
Parameter setting are not to be changed from factory press OUT button (6) to refuse the changes.
settings. To verify the parameter settings proceed as 9. Press the OUT button (6) again to return to Open-
follows and refer to Table 4-2: ing Zapi Menu.
1. Connect the Zapi Handset to either the traction or
steering controller, refer to paragraph 4-2.1.

BL-V08-1015 - 11-29-2016 4-5

 Table 4-2 Parameter Adjustments
Code Parameter Factory Code Parameter Factory
Setting Setting
0 ACCELER. DELAY LEVEL = 1 145 SET BATTERY TYPE 24 V
11 RELEASE BRAKING LEVEL = 8 140 ADJUST BATTERY 24.3 V
12 INVERS. BRAKING LEVEL = 8 249 THROTTLE 0 ZONE 9%
13 PEDAL BRAKING LEVEL = 9 252 THROTTLE X POINT 54%
14 SPEED LIMIT BRK LEVEL = 2 253 THROTTLE Y POINT 25%
28 BRAKE CUTBACK LEVEL = 5 159 ADJUSTMENT #01 LEVEL = 5
30 MAX SPEED FORW 172 Hz 158 ADJUSTMENT #02 LEVEL = 5
31 MAX SPEED BACK 172 Hz 248 LOAD HM FROM MDI OFF
20 CUTBACK SPEED 100% 242 CHECK UP DONE OFF
22 CUTBACK SPEED 2 100% 243 CHECK UP TYPE NONE
23 CUTBACK SPEED 3 100% 159 ADJUSTMENT #01 106%
29 CURVE CUTBACK 60% 158 ADJUSTMENT #02 103%
248 HS CUTBACK 26% 141 SET TEMPERATURE 22 C
245 FREQUENCY CREEP 1.20 Hz 139 AUX FUNCTION 1 LEVEL = 15
63 MAXIMUM CURRENT LEVEL = 9 247 AC TYPE 0 ON
246 INCHING SPEED 0 Hz 53 COMPENSATION ON
251 INCHING TIME LEVEL = 0 241 SLIP CONTROL ON
56 AUXILIARY TIME 0.4 244 DC-LINL COMPENS. ON
246 TILLER SWITCH HANDLE 244 SAT FREQUENCY 100 Hz
149 SET INPUT #1 LEVEL = 0 14 BRAKING MODUL. 100 Hz
148 SET INPUT #2 PRESENT 254 MINIMUM VOLTAGE 3%
147 SET INPUT #3 PRESENT 250 BOOST AT LO FREQ 24%
146 SET INPUT #4 OPTION #1 250 BOOST AT HI FREQ 45%
125 HOUR COUNTER RUNNING 241 BOOST CORNER FRE 50 Hz
121 BATTERY CHECK LEVEL = 0 249 BRAKING BOOSTER 0%
251 HYDRO KEY ON OFF 252 MOTOR RESISTANCE LEVEL = 0
247 STOP ON RAMP OFF 254 SLIP COEFFICIENT LEVEL = 0
119 AUX OUTPUT #1 BRAKE 251 MAXSLIP RESET 0.60 Hz
241 PEDAL BRAKING NONE 247 N\MAXSLIP 0 10.0 Hz
100 QUICK INVERSION BELLY 248 MAXSLIP 1 10.0 Hz
82 AUX VOLTAGE #1 68% 241 FREQSLIP 1 50 Hz
252 DISPLAY TYPE LEVEL = 4 242 MAXSLIP 2 13.0 Hz
254 EPS PRESENT 243 FREQSLIP 2 100 Hz
242 360 DEGREE ON 242 MAXSLIP 3 13.0 Hz
244 QUICK INV. LOGIC OPTION #2 243 FERQSLIP 3 130 Hz
91 OPTION 09 OPTION #1 245 MAXSLIP 4 13.0 Hz
84 MODEL TYPE 2 246 FREQSLIP 4 140 Hz
248 SET POT BRK MIN 0.0 V 93 OPTION 07 LEVEL = 1
250 SET POT BRK MAX 2.1 V 92 OPTION 08 LEVEL =6
249 MOTOR OVERTEMP 120  94 OPTION 06 LEVEL = 6
244 SET MOT TEMP. 35 C

4-6 BL-V08-1015 - 11-29-2016

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller)
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
One Blink Alarms
8 WATCH DOG This alarm occurs when the embed- Verify the motor is connected and
ded WATCH DOG protection is not there is continuity of the three motor
able to either cut off the power stage phases. If the alarm occurs perma-
when not triggered or it is not able to nently, replace the controller.
activate the power stage when trig-
gered.
13 EEPROM KO This alarm occurs due to a HW or SW Try to execute a CLEAR EEPROM
defect of the non-volatile embedded operation. This consists of entering
memory supporting the controller ALARMS in the MAIN MENU. Push
regulations. at the same time the two right side
buttons to enter the hidden ZAPI
MENU. Roll up and down until the
CLEAR EEPROM appears on the
handset display. Push the Enter But-
ton two times. Switch the key off and
on to check the result. If the alarm
occurs permanently, replace the
controller.
19 LOGIC FAILURE #1 This alarm signals that an overvolt- Normally the overvoltage occurs due
age/undervoltage protection opera- to the regenerative braking energy
tion has occurred. increasing the battery voltage; the
under voltage of the logic supply,
can be due to a depletion in the key
voltage. First, check for the failure
mode. Then contact the Big Lift LLC
Service Representative to look for a
countermeasure.

This alarm may occur for a HW fail-

ure. Replace the Controller.
18 LOGIC FAILURE #2 This alarm occurs when the circuit, to Replace the Controller.
compensate for the dead times of
the sine waves, is failed.
17 LOGIC FAILURE #3 This alarm occurs when the circuit, to Replace the Controller.
limit via HW the current peak in the
controller is active.
99 CHECK UP NEEDED This is just a warning to perform pro- It is just enough to turn the CHECK
grammed maintenance. UP DONE option to level ON after
the maintenance is executed.

BL-V08-1015 - 11-29-2016 4-7

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Two Blink Alarms
79 INCORRECT START This is just a warning for an incorrect The possible reasons for this alarm
starting sequence. are (use the readings in the TES-
TER to facilitate the troubleshoot-
ing):

1. A travel demand active at key on

2. The tiller switch active at key on
3. The H&S input active at key on
4. The Quick inversion active at key
on
A failure in the logic is possible too.
When all of the above conditions
checked OK, replace the controller.

80 FORW+BACK This alarm occurs when both the Check the wiring of the Fwd and Bwd
travel demands (Fwd and Bwd) are travel demand inputs (use the read-
active at the same time. ings in the TESTER to facilitate the
troubleshooting).

A failure in the logic is possible too.

When you verified the travel
demand switches are working prop-
erly and the wiring is right, replace
the controller.
71 HANDBRAKE This alarm occurs when the operator Check the emergency brake switch
tries to travel with the emergency and its wiring to CNA#13 The emer-
brake active. gency brake switch must be con-
nected between CAN#13 and GND.
When it is closed to GND, the emer-
gency brake is considered active. A
failure in the logic is possible too.
Replace the controller.
90 LIFT+LOWER This alarm occurs when both a lifting If the MDI-PRC is absent, check only
request and a lowering request are the of the main lifting/lowering pair
active at the same time. (CNB#8 and CNB#9); if the MDI-
PRC is present check the wiring of
the aux lift/lowering pair (CNA#14
and CNA#15). (Use the readings in
the TESTER to facilitate the trouble-
shooting).

A failure in the logic is also possible.

When you have verified the lifting/
lowering switches and the wiring is
right, replace the controller.

4-8 BL-V08-1015 - 11-29-2016

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Two Blink Alarms - Continued
91 LIFT LOW ACTIVE This is just a warning when a lifting/ The possible reasons for this alarm
lowering request is active at key-on. are (use the readings in the TES-
TER to facilitate the troubleshoot-
ing):
• When MDI-PRC is absent: at least
one between LIFTING SWITCH
(CNB#9) or DESCENT SWITCH
(CNB#8) active at key on.
• When vehicle TYPE is Level=1: at
least one between: LIFTING
SWITCH (CNB#9) or DESCENT
SWICH (CNB#8), DIGITAL
INPUT#1 (CNA#14) or DIGITAL
INPUT#2 (CNA#15) active at key
on.
• When vehicle TYPE is Level=2: at
least one between: LIFTING
SWITCH (CNB#9) or DESCENT
SWICH (CNB#8) active at key on.
• When vehicle TYPE is Level=3: at
least one between LIFTING
SWITCH (CNB#9) or DECENT
SWITCH (CNB#8) active at key-on.
A failure in the logic is possible too.
When all of the above conditions were
checked and nothing was found,
replace the controller.
Three Blink Alarms
60 CAPACITOR In working condition, a resistance The possibilities:
CHARGE connected between the key and the
Rail Capacitors, keeps the Rail 1. Another device, connected in
Capacitors charged before the Main parallel with the Rail Capacitors,
Contactor closes. When the voltage has a failure.
on the Rail Capacitors (measured on
the phase V) is low and does not 2. At least a motor phase is not con-
increase when the main contactor is nected to the controller or bro-
opened, this alarm occurs. ken.
3. A Power failure or a Logic Failure
occurred in the controller.
Replace the controller.

BL-V08-1015 - 11-29-2016 4-9

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Three Blink Alarms - Continued
31 VMN HIGH Before the main contactor is turned There are two possibilities:
on, the SW turns on the bottom side 1. A motor phase is not connected
Power Mosfets and expects the to the controller or broken.
phase V voltage to fall to GND
value. If the phase V remains high, 2. A Power Failure (e.g. a Bottom
this alarm occurs. side Power Mosfet opened) or a
Logic Failure occurred in the con-
troller. In this case, replace the
controller.
30 VMN LOW Before the main contactor is turned If the problem occurs before the Main
on, the SW turns on the top side Contactor closes, a power failure
Power Mosfets and expects the occurred (e.g. a bottom side Power
phase V voltage to increase toward Mosfet short circuited or a top side
the rail capacitor value. If the phase Power Mosfet is broken) or a Logic
V does not increase, this alarm Failure occurred in the controller.
occurs.
The alarm may occur when the initial If the problem occurs when the opera-
diagnosis is overcome, and the main tor turns a moving vehicle, the prob-
contractor is expected to be closed. lem is the Battery positive is not
Then when the operator tries to connected to the +Batt terminal of
move the vehicle, but the +Batt ter- the controller (check the continuity
minal of the controller is lower volt- of the main contactor).
age than the Battery voltage, this
alarm occurs (Main Contractor has If the problem occurs permanently,
lost the contact although it is replace the controller.
closed).
Four Blink Alarms
78 VACC NOT OK A test is made at key-on and after 20 Check the mechanical calibration and
sec that both the travel demands are the functionality of the potentiome-
disactive. This alarm occurs if the ter.
ACCELERATOR reading in the
TESTER menu is higher than 1.0V
(meaning the wiper of the potenti-
ometer is higher than 2Vdc).

4-10 BL-V08-1015 - 11-29-2016

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Three Blink Alarms - Continued
86 PEDAL WIRE KO The SW continuously checks for the Check the voltage on NPOT
connection of the two supply ends of (CNB#11) and the potentiometer
the potentiometer in the accelerator. connections.
The test consists of the voltage drop
on a sense diode, connected
between MPOT (CNB#11) and GND
and cascaded with the potentiome-
ter: if the potentiometer gets discon-
nected on PPOT or NPOT, no
current flow in this sense diode and
the voltage on the MPOT connection
collapses down. When the NPOT
voltage is less than 0.3V this alarm
occurs. This alarm also occurs when
the NPOT voltage is higher than 2
VDC (to detect the condition of a
broken sense diode).
55 PROGRAM LIFT The SW continuously matches the Check the Main Lifting/Lowering pair
LEVER potentiometer connected to CNA#18 (CNB#8 and CNB#9) and the volt-
with the Main Lifting/Lowering pair age on the potentiometer con-
request (CNB# and CNB#8). When nected to CNA#18. (Use the
the vehicle TYPE is set 2, the alarm readings LIFTING SWITCH,
occur in the following conditions: DESCENT SWITCH and LIFTING
1. If both the Main Lifting and Main CONTROL in the TESTER to facili-
Lowering request are disactive tate the troubleshooting).
and the potentiometer voltage is
higher than 60 mV over either the
MIN LIFT or the MIN LOWER
setting.
2. If the Main Lifting request is
active and the potentiometer volt-
age is higher than 200 mV over
the MAX LIFT setting.
3. If the Main Lowering request is
active and the potentiometer volt-
age is higher than 200 mV over
the MAX LOWER setting.
4. If the MIN LIFT setting is higher
than the MAX LIFT setting.
When the vehicle TYPE is set at 3,
the alarm occurs in the following
conditions:
1. If the Main Lowering request is
higher that the MIN LOWER.
2. If the MIN LOWER setting is
higher that the MAX LOWER

BL-V08-1015 - 11-29-2016 4-11

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Five Blink Alarms
70 ENCODER ERROR Two consecutive readings of the Check both the electric and the
encoder speed are too drastic. It is mechanical encoder functionality.
not possible for the encoder to Frequently one of the two sensor
change its speed a lot in a short bearing rings slips inside its seat
period. An encoder failure has causing this alarm. Also, the elec-
occurred (e.g. one or two channels tronic noise on the sensor bearing
of the encoder are corrupted or dis- can be a cause of the alarm.
connected).
53 STBY I HIGH This diagnosis is executed only when If the alarm occurs permanently,
the main contactor is opened and replace the controller.
asked to be closed (e.g. at key on or
when the main contactor is opened
and a new motion request turn
active). Then the outputs of the Cur-
rent amplifiers must be in a narrow
window close to 2.5 Vdc (from 2.26
V to 2.74 V).
Otherwise this STBY I HIGH alarm
occurs.
49 I=0 EVER This test is carried out when the motor If everything is OK for the motor, the
is running, and it verifies that the problem could be in the related cir-
current feedback sensor is not con- cuit.
stantly stuck at 0.
Six Blink Alarms
76 COIL SHORTED This alarm occurs when there is an Check the coils of main contactor
overload on one of the following (CNA#1), electromechanical brake
connections: CNA#1, CNA#3, (CNA#3), pump contactor (CNA#4),
CNA#4 or CNA#6. Typically the and aux valve (CNA#6).
problem is due to a short circuit of
one of the coils connected to these
outputs. After the overload has been
removed, the alarm automatically
resets by releasing and then
enabling a travel demand.
75 CONTACTOR This alarm occurs when the voltage Check that coils of the main contactor
DRIVER on the main contactor is smaller (CNA#1) are not short circuited. If
than expected. The main contactor not, replace the controller.
has a null voltage when supplied.
38 CINTACTOR OPEN The main contactor coil has been There are two possibilities:
driven by the logic board, but the 1. The wires to the coil are inter-
contactor does not close. rupted or not well connected.
2. The contact of the contactor is
defective.

4-12 BL-V08-1015 - 11-29-2016

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Six Blink Alarms - Continued
37 CONTACTOR The controller check if the MV contact It is suggested to check the contactor,
CLOSED is closed when the coil isn’t driven, if it is mechanically stuck or burnt
trying to discharge the capacitor closed.
bank. If they don’t discharge, the
fault condition is entered.
74 DRIVER SHORTED This alarm occurs when the voltage Replace the controller.
on the main contactor is higher than
expected. This means that the main
contactor coil has a high voltage
although it is not supplied.
16 AUX OUPUT KO This alarm occurs when the feedfor- Replace the controller because the
ward PWM generated by the con- driver of the Electromechanical
troller to supply the Brake has a failure.
Electromechanical Brake are not
matched in between. The diagnosis
is made only when the Tiller Switch
is active.
1. When the feedforward PWM is
less than 10% of the battery volt-
age, the Actual voltage on the
Electromechanical Brake is
expected low. If it higher than 14
V it means the Electromechanical
Brake never brakes the truck
(probably the Driver of the Elec-
tromechanical Brake is short cir-
cuited) and this alarm occurs.
2. When the feedback PWM is
higher than 70% of the battery
voltage on the Electromechanical
Brake is expected high. If it is
lower that 14V it means the Elec-
tromechanical Brake always gets
the trucked braked (probably the
Driver of the Electromechanical
Brake is opened) and this alarm
occurs
Seven Blink Alarms
61 HIGH TEMPERA- This alarm occurs when the tempera- Improve the air cooling of the control-
TURE ture of the base plate is higher than ler.
78C up to 100C. At 100C the cur-
rent is limited to 0 Amps.

BL-V08-1015 - 11-29-2016 4-13

 Table 4-3 Troubleshooting Chart (Traction/Lift Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Seven Blink Alarms - Continued
65 MOTOR TEMPERAT This is just a warning and will not Check the thermal sensor inside the
effect the vehicle performance. It motor (use the MOTOR TEMPERA-
occurs when the temperature of the TURE reading in the TESTER
motor winding overtakes the menu). If the senor is OK, improve
MOTOR OVERTEMP setting. the air cooling of the motor.
73 THERMIC SENS KO When the output of the thermal sen- It is necessary to replace the control-
sor on the base plate is higher than ler.
4.95V or lower than 0.1V, the sensor
is assumed defective and this alarm
occurs.
Eight Blink Alarms
67 CAN BUS KO This alarm occurs if the controller 1. First check the wiring.
does not receive any message from 2. If OK, try to disconnect one to
the CAN Bus line. one the module connected to the
CAN Bus and check if this alarm
disappears.
3. Replace the controller.
No Blink Alarms
1 WRONG CONFIG This alarm occurs the first time a con- The AC TYPE 0 setting must be fac-
troller is switched on when the non tory adjusted and so the alarm
volatile eeprom memory is not initial- should never happen. Ask for the
ized yet. Then it is necessary to assistance of a Big Lift LLC Service
specify if the controller is AC-0 or Representative when this alarm
AC-1 type (see AC TYPE 0 in the occurs.
hidden hardware setting Zapi
menu). If the alarm is present, by
switching off the key the AC TYPE 0
setting will be automatically turned
On (and the controller is specified to
be an AC-0). The AC TYPE 0 setting
can be changed only when a
WRONG CONFIG alarm is present.
If it is not present, it is necessary to
clear the eeprom memory if the
WRONG CONFIG alarm occurs.
94 CURRENT SENS KO This alarm occurs when the proce- The maximum current set-up is fac-
dure for the maximum current set-up tory adjusted and so this alarm
is in progress. should never happen. Ask for the
assistance of a Big Lift LLC Service
Representative when this alarm
occurs.

4-14 BL-V08-1015 - 11-29-2016

 Table 4-4 Troubleshooting Chart (Steering Controller)
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
One Blink Alarms
246 MICRO SLAVE KO In stepper motor application, this Replace the controller.
alarm occurs if the main uC is
detecting a direction of the stepper
motor not matched with the one that
the slave uC is detecting.

In the closed loop application, this

alarm occurs if the main uC is
detecting a direction of the steering
error not matched with the one that
the slave uC is detecting.

Furthermore, this alarm occurs if the

main uC is detecting no steering lim-
itation while the slave uC is detect-
ing a steering limitation.
221 MICRO SLAVE #4 This alarm occurs in one of the follow- Replace the controller.
ing:

(Open loop application only) If the

slave uC detects the stator voltage
phasor rotates in the opposite direc-
tion respect to the sign of the step-
per motor speed.

(Closed loop application only) if the

slave uC detects the stator voltage
phasor rotates in the opposite direc-
tion respect to the commanded posi-
tion.
250 MICRO SLAVE It occurs when the information on the Replace the controller.
status bus between the main uC and
the slave uC is frozen to the 0xFF
value (the slave uC does not update
the status bus configuration).
212 MICRO SLAVE #8 This alarm occurs when the encoder Replace the controller.
counting of the main uC is not
matched with the encoder counting
of the slave uC.
99 INPUT ERROR #1 This alarm occurs when the voltage When the safety contacts are open,
on CNA#4 (lower potential terminal the voltage on CNA#4 is expected to
of the safety contacts) is higher than be close to 0 VDC. Only a harness
12V. mistake may connect NK1 to a
higher than
12 V.

BL-V08-1015 - 11-29-2016 4-15

 Table 4-4 Troubleshooting Chart (Steering Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
One Blink Alarms - Continued
6 SERIAL ERR #1 Main uC and Slave uC communicate Replace the controller.
via a local serial interface. This
alarm occurs when the slave uC
does not receive the communica-
tion from the main uC through the
serial interface.
227 SLAVE COM. Main uC and Slave uC communicate Replace the controller.
ERROR via a local serial interface. This
alarm occurs when the main uC
does not receive the communica-
tion from the slave uC through this
serial interface.
226 NO SYNC Every 16 msec, inside the code cycle, Replace the controller.
the main uC rises and then lowers
an input for the slave uC (SYNC).
When the slave uC detects no edge
for more than 100 msec on this
input, this alarm occurs. This is just
a watch dog function: when the main
uC does not execute the code cycle
it does not update the SYNC signal
and the slave uC cuts off the steer
and traction.
253 KM CLOSED This alarm occurs at key on if the This alarm occurs if the connection
slave uC detects the safety contact, CNA#5 (K1) is around a voltage of
of the main uC, is closed prior to 12 Vdc when switching on the key.
being commanded. In fact, when the safety contacts are
open, K1 is expected to be con-
nected to a battery voltage (not 12
V). Search for a harness problem or
replace the controller.
251 KM OPEN This alarm occurs if the slave uC Replace the controller.
detects the safety contact, of the
main uC, is open when expected to
be closed.
254 KS CLOSED This alarm occurs if the main uC This alarm occurs if the connection
detects the safety contact, of the CNA#4 (NK1) is around a voltage of
slave uC to be closed prior to being 12 Vdc when switching on the key.
commanded. In fact, when the safety contacts are
open to a minus battery voltage (not
12 V). Search for a harness problem
or replace the controller.
252 KS OPEN This alarm occurs if the main uC Replace the controller.
detects the safety contact, of the
slave uC, is open when expected to
be closed.

4-16 BL-V08-1015 - 11-29-2016

 Table 4-4 Troubleshooting Chart (Steering Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
One Blink Alarms - Continued
218 CLOCK PAL NOT OK The main uC send an analog signal Replace the controller.
towards the salve uC to reset the
slave uC on demand. When the
slave uC detects this analog signal
external to a window from 2.2 to 2.8
and not in the range to generate the
reset on demand, the slave uC
raises this alarm.
Two Blink Alarms
70 HIGH CURRECT This alarm occurs if the circuit to limit Check that the motor is suited to work
via hardware the current in the with the EPS-AC0 (not oversized).
motor is either always active at key Otherwise, replace the controller.
on or repeatedly active when the
motor is turning.
73 POWER FAILURE #1 This alarm occurs when the current in Check that the power is OK. Check
the phase W of the motor is zero the battery positive arrives to the
and the motor is commanded for controller. Check the continuity of
moving. the wire in the phase W of the motor.
Otherwise replace the controller.
72 POWER FAILURE #2 This alarm occurs when the current in Check that the power is OK. Check
the phase U of the motor is zero and the battery positive arrives to the
the motor is commanded for moving. controller. Check the continuity of
the wire in the phase U of the motor.
Otherwise replace the controller.
71 POWER FAILURE #3 This alarm occurs when the current in Check that the power fuse is OK.
the phase V of the motor is zero and Check the battery positive arrives to
the motor is commanded for moving. the controller. Check the continuity
of the wire in the [phase V of the
motor. Otherwise replace the con-
troller.
19 LOGIC FAILURE #1 This alarm occurs when the real volt- Replace the controller.
age between phases W and U of the
motor is different from the desired.
18 LOGIC FAILURE #2 This alarm occurs when the real volt- Replace the controller.
age between phases X and V of the
motor is different from the desired.
48 MAIN CONT. OPEN This alarm occurs only when the set- Find, on the traction controller, the
ting CAN BUS is PRESENT. Then reason for keeping the main contac-
the EPS-AC0 waits for a via CAN tor open.
information that the traction control-
ler has closed the main contactor. If
this information lacks more than 1.5
secs, this alarm occurs.

BL-V08-1015 - 11-29-2016 4-17

 Table 4-4 Troubleshooting Chart (Steering Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Two Blink Alarms - Continued
247 CAN BUS KO This alarm occurs only when the set- Check the CAN Bus communication
ting CAN BUS is PRESENT. Then system and analyze the frames from
the eps-ac0 must receive the event the traction controller to the steer
messages from the traction control- controllers.
ler. If these messages lack more
than about 1 sec, this alarm occurs.
220 MOTOR LOCKED This alarm occurs if the current in the Search for a mechanical problem
steering motor stays close to the locking the motor. To make easier
maximum current longer than 1 sec. fault detecting, set DEBUG OUT-
PUT to level 11.
Three Blink Alarms
243 D LINE SENSOR KO This alarm occurs when the mean Check continuity of the stepper motor
voltage on the Direct line of the step- connections. In particular the resis-
per motor (connection CNA#9) is not tance between CNA#9 and the
null: the voltage on every stepper minus battery (with the stepper
motor line is a sine wave with null motor at rest) is expected to be very
mean voltage. low (close to 30 ohms)
242 Q LINE SENSOR KO This alarm occurs when the mean Check continuity of the stepper motor
voltage on the Quadrature line of the connections. In particular the resis-
stepper motor (connection CNA#8) tance between CNA#8 and the
is not null: the voltage on every step- minus battery (with the stepper
per motor line is a sine wave with motor at rest) is expected to be very
null mean voltage. low (close to 30 ohms).
248 S.P OUT OF RANGE This alarm occurs for a fault on the Check the connections of the poten-
command potentiometer (CPOC1 tiometer. This alarm occurs when
on CNA#9, CPOC2 on CNA#8). one connection of the command
When a single command pot is cho- potentiometer is broken.
sen, the alarm occurs if its wiper
(CPOC1) range is from 0.8 Vdc to
4.2 Vdc. When the twin pot is cho-
sen, the alarm occurs if the sum of
the two wiper voltages
(CPOC1+CPOC2) range is from 4.5
Vdc to 5.5 Vdc.
249 F.B OUT OF RANGE This alarm occurs for a fault on the Check the connections of the feed-
feedback potentiometer (CPOT on back potentiometer. This alarm
CNB#6). It occurs if CPOT exits the occurs when one connection of the
range of 0.3 Vdc to 4.7 Vdc. feedback potentiometer is broken.

4-18 BL-V08-1015 - 11-29-2016

 Table 4-4 Troubleshooting Chart (Steering Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Three Blink Alarms - Continued
228 POSITION ERROR This alarm occurs for an error in the Check the potentiometer connected to
redundant test of the feedback sen- CNB#6 is working correctly. If toggle
sors. switches are connected to CNA#2
and CNA#3, verify that they are work-
ing correctly and setting AUX FUNC-
TION 11 is correct. Also the sensor
bearing in the motor (encoder). The
sensor bearing has two rings: one
connected to the rotor safety; the
other is connected to the motor frame.
Check these two rings are strictly con-
nected to their structure without slip.
84 STEER SEBSOR KO This alarm occurs if the command Change the twin pot.
potentiometer (CPOC1 on CNA#9 or
CPOC2 on CNA#8) changes with a
jerk larger than MAX SP SLOPE.
This alarm is used to catch a discon-
tinuity in the voltages of the com-
mand potentiometer.
223 JERKING FB POT This alarm occur if the feedback Change the feedback potentiometer.
potentiometrer (CPOT on CNB#6)
changes with a jerk larger than 0.3 V
in 16 msec. This alarm is used to
catch a discontinuity in the voltages
of the feedback potentiometer.
222 FB POT LOCKED In application with a feedback potenti- In application with the feedback with
ometer, this alarm occurs if the feed- the feedback potentiometrer, verify
back potentiometer (CPOT on the feedback potentiometer is not
CNB#6) does not change (or mechanically loosened.
changes in the opposite direction) its
value even if commanded to Check there is not a mechanical block
change. of the steered wheel. Be sure the
wiper has not reached its own elec-
In application with toggle switches trical limit because of too much
with ENCODER CONTROL to off, angle of the steered wheel. Besides,
this alarm occurs if the feedback this alarm may occur at the installa-
encoder counting does not change tion when the motor rotates in the
its value even if commanded to wrong direction from the command.
change.
219 STEPER MOTOR This alarm occurs if the frequency and Replace the controller.
MISM the amplitude of the voltages from
the stepper motor lines are mis-
matched. In normal condition when
the amplitude of the stepper motor
lines increase, the frequency of the
stepper motor lines must increase
too.

BL-V08-1015 - 11-29-2016 4-19

 Table 4-4 Troubleshooting Chart (Steering Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Three Blink Alarms - Continued
241 ENCODER ERROR It occurs when ENCODER CONTROL This condition occurs several times
is set ON and the real frequency due to either, a mismatch between
does not follow the commanded fre- the Encoder resolution used in the
quency. SW and the real encoder resolution,
or a wrong connection between th4e
two encoder channels. In this latest
case exchange in between the two
encoder channels.
83 BAD ENCODER This alarm occurs in applications with Swap in between the two encoder
SIGN toggle switches when the applied channels (CNB#7 with CNB#8).
frequency (FREQUENCY) and the
motor speed (ENC SPEED) have
opposite sign.
Four Blink Alarms
13 EEPROM KO This occurs if a test to write and read Replace the controller.
one location in EEPROM fails. The
SW expects to read the written
value. It can also occur when the
hour counter gives different values
between the three redundant loca-
tion in which it is recorded. It also
occurs when the busy bit of the
EEPROM does not rise within 12
msec.
244 GAIN EEPROM KO The parameter to compensate for the Replace the controller.
gain of the current amplifiers
(ADJUSTMENT #03 and ADJUST-
MENT #4) are recorded in a non-vol-
atile memory (eeprom) with a
redundant handling. In fact every
adjustment is recorded in three
eeprom locations. If the values in
these three locations are different,
this alarm occurs.
225 CURRENT GAIN This alarm occurs when the parame- Replace the controller.
ters to compensate for the gain of
the current amplifiers (ADJUST-
MENT #03 and ADJUSTMENT #04)
have the default values.
Five Blink Alarms
61 HIGH TEMPERA- This alarm occurs if the temperature Improve the cooling of the controller;
TURE of the controller base plate over- otherwise replace the controller.
takes 75 degrees.

4-20 BL-V08-1015 - 11-29-2016

 Table 4-4 Troubleshooting Chart (Steering Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
Five Blink Alarms - Continued
65 MOTOR TEMPERA- This alarm occurs only when DIAG Check that the thermal sensor in the
TURE MOTOR TEMP is on and the ther- motor is working correctly. If it is,
mal sensor inside the motor mea- improve the cooling of the motor.
sures a temperature higher than 150
degrees. It also occurs when trying
to acquire the motor resistance with
a temperature in the motor higher
than 150 degrees (still with DIAG
MOTOR TEMP to ON).
Six Blink Alarms
53 STBY I HIGH This alarm occurs two ways: Replace the controller.
1. In the initial rest state after key
on, if the outputs of the current
amplifiers are not comprised in
the window 2.2 to 2.8 Vdc.
2. After the initial diagnosis this
alarm occurs when the output of
the current amplifiers at rest have
a drift larger than ±0.15 V.
32 VMN NOT OK This alarm occurs in the initial rest Replace the controller.
state after key on if the output of the
motor voltage amplifiers are not in
the window from 2.2 to 2.8 Vdc.
17 LOGIC FAILURE #3 This alarm occurs in the rest state if Replace the controller.
the output of the voltage amplifier of
phase Vu-Vw have a drift larger than
±0.25 V.
16 LOGIC FAILUREE #4 This alarm occurs in the rest state if Replace the controller.
the output of the voltage amplifier of
the phase Vw-Vv have a drift larger
than ±0.25 V.
Thirty-two Blink Alarms
245 DATA ACQUISITION This alarm occurs when acquiring the Recycle the key.
motor resistance or when adjusting
the parameters to compensate for
the gain of the current amplifiers
(maximum current factory adjusted).
No Blink Alarms (Warning)
85 STEER HAZARD This is just a warning to inform that
the steering controller is limiting the
angle in the steering direction. No
speed reduction occurs on the trac-
tion

BL-V08-1015 - 11-29-2016 4-21

 Table 4-4 Troubleshooting Chart (Steering Controller) - Continued
ERROR ERROR TEXT POSSIBLE CAUSE FAULT CLEARANCE
No Blink Alarms - Continued
237 WAITING DATA This warning occurs only if CAN BUS
is PRESENT. At the eps-ac0 asks to
the traction controller to send a list
of parameters via CAN Bus. From
the request until the parameters are
correctly received, this warning
occurs. The steer is not activated
yet, and the safety relays remain
open when this warning is present.

239 WAITING FOR TRAC At key-on the eps-ac0 needs an

assent from the traction controller to
close the safety contacts and to turn
on operational mode. Until this
assent is not received, this warning
occurs. The steer is not activated yet
and the safety relays remain open
when this warning is present.
238 EPS NOT ALIGNED This is a real alarm that cuts off the
traction. It occurs at the initial align-
ment if the straight-ahead condition
is not matched within 6 sec.
Throughout this 6 secs delay, the
steer is not activated yet, the safety
relays are open and the traction is
stopped.

4-22 BL-V08-1015 - 11-29-2016

 SECTION 5
STEERING, COVERS AND FLOORBOARDS

5-1. CONTROL HANDLE 2. Remove six screws (14) and six lock washers (15)
and six flat washers (16). Separate cover (13) and
5-1.1. Steering Control Removal. cover (12).
1. Press the emergency power disconnect switch (6, 3. Tag and disconnect harness (17) from compo-
Figure 12-5 or 31, Figure 12-9) and turn off key nents on cover (12) and remove cover (12).
switch (22, Figure 12-8 or 22, Figure 12-9).

R7251

Figure 5-1 Control Handle (Sheet 1)

BL-V08-1015 - 11-29-2016 5-1

 R7252

Figure 5-2 Control Handle (Sheet 2)

5-2 BL-V08-1015 - 11-29-2016

4. Tag and disconnect harness (17) from harness 13. Engage the emergency power disconnect switch
(23, Figure 5-1). (6, Figure 12-5 or 31, Figure 12-9) and turn on
5. Remove button plug, nut (7), handle (6) and pad key switch (22, Figure 12-8 or 22, Figure 12-9).
(13).
5-2. COMPARTMENT COVERS
6. Remove four screws (9), four flat washers (10)
and plate (8) from handle (6). 5-2.1. Cover Removal.
7. Remove four screws (11), four flat washers (12) 1. Press the emergency power disconnect switch (6,
and block (14) and remove potentiometer (22) Figure 12-5 or 31, Figure 12-9) and turn off key
from control arm. switch (22, Figure 12-8 or 22, Figure 12-9).
8. Remove screw (16), nut (15) and upper bearing 2. Remove two screws (7, Figure 5-3) securing
(17). cover (10) to cover (9).
9. Remove four screws (24), four lock washers (25) 3. Remove two screws (11), two lock washers (4),
and remove potentiometer (22) from bearing seat two flat washers (5) securing cover (10) to the
(21). truck frame and remove the cover.
10. Loosen screw (19) and remove shaft (18) from 4. Remove two screws (11), two lock washers (4),
potentiometer (22). two flat washers (5) securing cover (9) to the truck
11. Remove retaining ring (20) and lower bearing (17) frame and remove the cover.
from shaft (18).
5-2.2. Cover Installation.
5-1.2. Steering Control Installation. 1. Position cover (9, Figure 5-3) on the truck frame
1. Install lower bearing (17, Figure 5-1) and retaining and secure with two screws (11), two lock wash-
ring (20) on shaft (18). ers (4) and two flat washers (5).
2. Install shaft (18) on potentiometer (22) and secure 2. Position cover (10) on the truck frame and secure
with screw (19). with two screws (11), two lock washers (4) and
two flat washers (5).
3. Position potentiometer (22) on bearing seat (21)
and secure with four screws (11), and four lock 3. Securing cover (10) to cover (9) with two screws
washers (12). (7).
4. Install upper bearing (17), nut (15) and screw 4. Engage the emergency power disconnect switch
(16). (6, Figure 12-5 or 31, Figure 12-9) and turn on
key switch (22, Figure 12-8 or 22, Figure 12-9).
5. Position potentiometer (22) on control arm.
6. Install block (14) and secure with four screws (11) 5-3. FLOOR BOARD
and four lock washers (12).
7. Install plate (8) on handle (6) and secure with four 5-3.1. Removal.
screws (9) and flat washers (10). 1. Press the emergency power disconnect switch (6,
8. Install pad (13) and handle (6), engaging bracket Figure 12-5 or 31, Figure 12-9) and turn off key
(8) with block (14). switch (22, Figure 12-8 or 22, Figure 12-9).

9. Secure handle (6) with nut (7) and install the but- 2. Remove two screws (7, Figure 5-3) securing floor-
ton plug. board (1) to the truck frame.

10. Reconnect harness (23) to harness (17, Figure 5- 3. Lift up on floor board (1) and disconnect harness
2). (1, Figure 12-16) from accelerator (2, Figure 5-3)
and using rods (8), move the floor board out of the
11. Reconnect harness (17) to components on cover way.
(12).
12. Install cover (12) and cover (13) and secure with 5-3.2. Installation.
six screws (14), six lock washers (15) and six flat 1. Position floor board (1, Figure 5-3) on the truck
washers (16). frame.
2. Lift up on floor board (1) and disconnect harness
(1, Figure 12-16) to accelerator (2, Figure 5-3).

BL-V08-1015 - 11-29-2016 5-3

 R7249

Figure 5-3 Covers

3. Secure floor board (1) with two screws (7). 2. Remove the compartment cover as described in
4. Engage the emergency power disconnect switch paragraph 5-2.1.
(6, Figure 12-5 or 31, Figure 12-9) and turn on
3. Disconnect harness (1, Figure 12-16) and cables
key switch (22, Figure 12-8 or 22, Figure 12-9).
(10 and 11, Figure 12-17) from the steering motor.
5-4. STEERING MOTOR 4. Remove three screws (25, Figure 5-4) and coder
(24) from steering motor (26).
5-4.1. Motor Removal.
5. Remove five screws (28) and five lock washers
1. Press the emergency power disconnect switch (6, (29) from under the vehicle.
Figure 12-5 or 31, Figure 12-9) and turn off key 6. Remove the steering motor from the top of the
switch (22, Figure 12-8 or 22, Figure 12-9). vehicle.

5-4 BL-V08-1015 - 11-29-2016

5-4.2. Motor Installation. 4. Reconnect harness (1, Figure 12-16) and cables
(10 and 11, Figure 12-17) to the steering motor.
1. Position the steering motor in the top of the motor
compartment. 5. Install the compartment cover as described in
paragraph 5-2.2.
2. Secure the motor with five screws (28, Figure 5-4)
and five lock washers (29) from under the vehicle. 6. Engage the emergency power disconnect switch
(6, Figure 12-5 or 31, Figure 12-9) and turn on
3. Secure the coder (24) to steering motor (26) with
key switch (22, Figure 12-8 or 22, Figure 12-9).
three screws (25).

R7255

Figure 5-4 Transmission, Motor & Brake Assembly

BL-V08-1015 - 11-29-2016 5-5

5-5. STEERING HANDLE 5-5.2. Installation.

5-5.1. Removal. 1. Lift steering handle (1, Figure 5-2) and secure
with four screws (2, Figure 5-5), four lock washers
1. Turn off key switch (22, Figure 12-8 or 22, Figure (4), eight flat washers (3).
12-9) and disconnect the batteries.
2. Install the floor board as described in paragraph
2. Remove the floor board as described in para- 5-3.2.
graph 5-3.1.
3. Engage the emergency power disconnect switch
3. Remove four screws (2, Figure 5-5), four lock (22, Figure 12-8 or 22, Figure 12-9) and turn on
washers (4), eight flat washers (3) and steering key switch (22, Figure 12-8 or 22, Figure 12-9).
handle (1, Figure 5-2).

R7250

Figure 5-5 Seat and Steering Controls

5-6 BL-V08-1015 - 11-29-2016

 SECTION 6
BRAKE SERVICING

6-1. BRAKES. 3. Remove the floor board as described in para-

graph 5-3.1.
There are two brake systems: electrical brake on drive
motor and hydraulic brakes on load wheels. The Elec- 4. Loosen clamp (23, Figure 6-2) and remove hose
trical brake is spring applied and electrically released (22) from master cylinder (16).
acting as parking brake. The hydraulic brake is applied 5. Disconnect tubes (27 and 28) from master cylin-
by the brake pedal and is used to slow and stop the der.
truck.
6. Remove cotter pin (18) and clevis pin (17) from
the end of the master cylinder.
6-2. ELECTRICAL BRAKE.
7. Remove two bolts (19), two lock washers (9), two
6-2.1. Brake Assembly Replacement flat washers (8) and master cylinder from the
1. Press the emergency power disconnect switch (6, mounting bracket (1).
Figure 12-5 or 31, Figure 12-9) and turn off key
6-3.2. Master Cylinder Installation
switch (22, Figure 12-8 or 22, Figure 12-9).
1. Position the master cylinder on the mounting
2. Block load wheels.
bracket (1, Figure 6-2) and install two screws (19),
3. Remove the compartment cover as described in two lock washers (9) and two flat washers (8).
paragraph Figure 5-3.
2. Line up the end of the master cylinder with hole in
4. Disconnect electric brake from harness (1, Figure pedal (11) and install clevis pin (17) and cotter pin
12-16). (18).
5. Remove the three screws(1, Figure 6-1) and 3. Reconnect tubes (27 and 28) to master cylinder.
brake (3).
4. Reconnect hose (22) to master cylinder (16) and
6. Place the new brake into position and secure with secure with clamp (23).
the mounting screws.
5. Bleed the brakes as described in paragraph 6-3.3.
7. Reconnect electric brake to harness (1, Figure
6. Reinstall rubber floor as described in paragraph
12-16).
5-3.2.
8. Engage the emergency power disconnect switch
7. Engage the emergency power disconnect switch
(6, Figure 12-5 or 31, Figure 12-9) and turn on
(6, Figure 12-5 or 31, Figure 12-9) and turn on
key switch (22, Figure 12-8 or 22, Figure 12-9).
key switch (22, Figure 12-8 or 22, Figure 12-9).
9. Remove load wheel blocks and check operation.
8. Removing the blocking from the wheels.
6-3. HYDRAULIC BRAKE. 6-3.3. Bleeding the Brakes
6-3.1. Master Cylinder Removal There are 3 holes on the brake booster of reduction
gear box. Loosen the air bleed plug to let the air out of
1. Block wheels to prevent movement.
brake oil tube. Then tighten the plug.
2. Press the emergency power disconnect switch (6,
Figure 12-5 or 31, Figure 12-9) and turn off key
switch (22, Figure 12-8 or 22, Figure 12-9).

BL-V08-1015 - 11-29-2016 6-1

 R7255

Figure 6-1 Transmission, Motor & Brake Assembly

6-2 BL-V08-1015 - 11-29-2016

 R7253

Figure 6-2 Brake Pedal

BL-V08-1015 - 11-29-2016 6-3

6-4 BL-V08-1015 - 11-29-2016
 SECTION 7
TRANSMISSION, DRIVE WHEEL, LOAD WHEELS

7-1. Transmission. 3. Remove the steering motor as described in para-

graph 5-4.1.
1. Press the emergency power disconnect switch (6,
Figure 12-5 or 31, Figure 12-9) and turn off key 4. Remove the drive motor as described in para-
switch (22, Figure 12-8 or 22, Figure 12-9). graph 10-3.
2. Remove the compartment cover as described in 5. Raise the vehicle off the ground to provide clear-
paragraph 5-2.1. ance for transmission (12, Figure 7-1) out the bot-
tom. Securely block the vehicle to prevent
movement.

R7255

Figure 7-1 Transmission, Motor & Brake Assembly

BL-V08-1015 - 11-29-2016 7-1

6. Support the transmission (12) and remove six 4. Remove three screws (11, Figure 7-2), flat wash-
screws (17), six washers (18) and flat washers ers (10), lock washers (9) and cover (8).
(19). 5. Remove six screws (16), lock washer (15) to free
7. Lower the transmission (12) out the bottom of the load wheel (1) from brake (2).
vehicle. 6. Remove nut (7), washer (6) and load wheel (1).
8. Install new drive assembly (12) by reversing the 7. Remove seal (4) from load wheel (1).
steps above.
8. Remove bearings (5) from load wheel (1).
7-2. DRIVE WHEEL. 9. Inspect bearings (5) and replace if necessary.
1. Press the emergency power disconnect switch (6, 7-3.2. Installation
Figure 12-5 or 31, Figure 12-9) and turn off key
switch (22, Figure 12-8 or 22, Figure 12-9). 1. Pack bearings (5, Figure 7-2) with grease.
2. Jack up the vehicle to gain access to the drive 2. Reassemble bearings (5) in wheel (1).
wheel; then securely block the vehicle to prevent 3. Install seal (4) in load wheel (1).
movement.
4. Position load wheel (1) in the axle and install
3. Remove the five mounting nuts (2, Figure 7-1) washer (6) and nut (7). Tighten nut (6) until there
and five lock washers (21). is a slight drag on load wheel (1). Secure nut (7)
4. Remove drive wheel (13). with tab on washer (6).
5. Install new drive wheel in reverse order of 5. Install cover (8) and secure with three screws
removal. (11), flat washers (10), lock washers (9).
6. Remove the blocking from under the vehicle and
7-3. LOAD WHEEL. lower it to the ground.

7-3.1. Removal 7. Engage the emergency power disconnect switch

(6, Figure 12-5 or 31, Figure 12-9) and turn on
1. Press the emergency power disconnect switch (6, key switch (22, Figure 12-8 or 22, Figure 12-9).
Figure 12-5 or 31, Figure 12-9) and turn off key
8. .
switch (22, Figure 12-8 or 22, Figure 12-9).
2. Block the drive wheel to prevent the vehicle from 7-4. Caster.
rolling.
Casters provide additional stability. Installation of the
3. Jack up the vehicle to raise the load wheels off casters is shown in Figure 12-1 and repair parts are
the floor. Securely block the vehicle in the raised shown in Figure 12-3.
position by positioning supports under the frame.

7-2 BL-V08-1015 - 11-29-2016

 R7270

Figure 7-2 Load Wheel and Tilt Mounting

BL-V08-1015 - 11-29-2016 7-3

 NOTES

7-4 BL-V08-1015 - 11-29-2016

 SECTION 8
ELEVATION SYSTEM SERVICING

8-1. GENERAL. 8. Engage the emergency power disconnect switch

The elevation system includes the outer mast, inner (6, Figure 12-5 or 31, Figure 12-9) and turn on
mast, lift linkage, lift chains, lift cylinder and ram head. key switch (22, Figure 12-8 or 22, Figure 12-9).
9. Test chain by operating carriage. If slack is still
8-2. LIFT CHAIN WEAR INSPECTION. apparent, repeat above procedure.
The lift chain should be replaced when it is worn
enough to increase it’s length by 3% or more. On Tele-
cospic trucks, Both chains should be replaced at the
same time. To make this determination proceed as fol-
lows.
Using a section of chain that sees the most frequent
operation over the chain sheaves, isolate a vertical
portion under tension from the weight of carriage and
forks.
Measure the distance between pin centers on 20 verti-
cal links. If the section measures 12.88” or more, the
chain should be replaced.
New chain anchor pins should be installed when
chains are replaced. Never replace a partial section of
chain 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.
2. Press the emergency power disconnect switch (6,
Figure 12-5 or 31, Figure 12-9) and turn off key
switch (22, Figure 12-8 or 22, Figure 12-9).

WARNING: Before attempting any adjustment, make

certain power is disconnected.

3. Loosen jam nut (2, Figure 8-1), located the above

either the mast or the bracket to allow for adjust-
ment of middle jam nut.
4. Break the lower jam nuts (2) free from the middle
jam nuts (2).
5. Take up slack in both lift chains with middle jam
nuts (2).
6. Align adjusting screws (1) so the clevis pins (4)
are parallel to the mast.

CAUTION: At least 3 full threads must be present

below lower nuts (2) after adjustment.

7. Tighten jam nuts securely while maintaining align- R7282

ment of clevis pins (4).

Figure 8-1 Chain Assembly

BL-V08-1015 - 11-29-2016 8-1

8-4. LIFT CHAIN REPLACEMENT. 6. Remove chain from sheave.
1. With the lift truck wheels securely blocked, raise 7. Position new chain on the sheave.
the forks approximately three feet from floor and 8. Secure chain to anchor (6) at the fork frame with
position blocks or strong supports under the lift clevis pin (4), washer (8) and cotter pin (3).
carriage.
9. Connect the opposite end of chain to adjusting
2. Lower lift carriage onto the support. Check that screw (1) at the mast with clevis pin (4), washer
arrangement is secure before proceeding. (8) and cotter pin (3).
3. Press the emergency power disconnect switch (6, 10. Adjust the chains according to paragraph 8-3.
Figure 12-5 or 31, Figure 12-9) and turn off key
11. Engage the emergency power disconnect switch
switch (22, Figure 12-8 or 22, Figure 12-9).
(6, Figure 12-5 or 31, Figure 12-9) and turn on
WARNING: Before attempting any replacement, key switch (22, Figure 12-8 or 22, Figure 12-9).
make certain power is disconnected.
8-5. LIFT CYLINDER.
4. Remove cotter pin (3, Figure 8-1), washer (8) and
clevis pin (4) connecting chain (5) to adjusting NOTE: Removal and repair of the lift cylinder is cov-
screw (1) at the lift mast. ered in SECTION 9.
5. Remove cotter pin (3), washer (8) and clevis pin
(4) connecting chain (5) to anchor (6) at the fork
frame.

8-2 BL-V08-1015 - 11-29-2016

 SECTION 9
HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS 12. Install all covers removed in steps 4. thru 5.

WARNING: When forks are raised, pressure exists in 9-2. HYDRAULIC PUMP.
the hydraulic system lines and fittings. To
ensure release of pressure, forks must 9-2.1. Removal
be fully lowered and the batteries discon-
nected before performing any mainte- CAUTION: Hydraulic oil can damage parts. Wipe off
nance on the hydraulic system. any oil immediately. Provide a container
under the line or fitting before discon-
NOTE: Leaking hydraulic fittings may be remedied by necting.
simply tightening fittings. If this does not rem-
edy the leak, the fittings or line must be 1. Lower forks fully.
replaced. 2. Press the emergency power disconnect switch (6,
Figure 12-5 or 31, Figure 12-9) and turn off key
1. Lower forks fully. switch (22, Figure 12-8 or 22, Figure 12-9).
2. Press the emergency power disconnect switch (6,
3. Remove the floor board as described in para-
Figure 12-5 or 31, Figure 12-9) and turn off key
graph 5-3.1.
switch (22, Figure 12-8 or 22, Figure 12-9).
4. Disconnect the cables (4 and 5, Figure 12-17)
3. Remove the floor board as described in para- from the pump motor.
graph 5-3.1.
5. Disconnect hoses (2 and 3, Figure 9-1) from
4. Remove two screws (10, Figure 9-3) and cover pump (23).
plate (39).
6. Remove fittings (4 and 6) from the pump.
5. Remove four screws (10) and cover (11).
7. Remove four bolts (11, Figure 9-2), four lock
CAUTION: Hydraulic oil can damage parts. Wipe off washers (12) and the pump from reservoir (1).
any oil immediately. Provide a container
under the line or fitting before discon- 9-2.2. Installation.
necting. 1. Install the pump on reservoir (1, Figure 9-2) and
secure with four bolts (11) and four lock washers
6. Refer to Figure 9-1 and remove leaking line or fit-
(12).
ting and replace it with a new line or fitting.
2. Install fittings (4 and 6, Figure 9-1) with new O-
7. Check level of hydraulic oil. If required, add
rings (5) on the pump.
hydraulic oil to bring to proper level. Use hydraulic
oil listed in Table 3-2. 3. Reconnect hoses (2 and 3) to the pump.
8. Engage the emergency power disconnect switch 4. Add hydraulic oil to bring to proper level. Use
(6, Figure 12-5 or 31, Figure 12-9) and turn on hydraulic oil listed in Table 3-2.
key switch (22, Figure 12-8 or 22, Figure 12-9). 5. Reinstall dipstick (10).
9. Operate all hydraulic levers to refill the cylinders 6. Reconnect cables (4 and 5, Figure 12-17) to the
and lines with hydraulic oil. pump motor.
10. Check level of hydraulic oil. If required, add 7. Install the floor board as described in paragraph
hydraulic oil to bring to proper level. Use hydraulic 5-3.2.
oil listed in Table 3-2.
8. Engage the emergency power disconnect switch
11. Install the floor board as described in paragraph (6, Figure 12-5 or 31, Figure 12-9) and turn on
5-3.2. key switch (22, Figure 12-8 or 22, Figure 12-9).

BL-V08-1015 - 11-29-2016 9-1

 R7263

Figure 9-1 Hydraulic System

9-2 BL-V08-1015 - 11-29-2016

9-3. HYDRAULIC RESERVOIR 6. Remove ten bolts (4), ten lock washers (5), ten
flat washers (8), horn (13) and cover (5).
CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container 7. Remove all traces of gasket (4) from the reservoir.
under the line or fitting before discon- 8. Remove, clean and reinstall magnet (14).
necting. 9. Install cover (9) with new gasket (7) and secure
1. Lower forks fully. with ten bolts (4), ten lock washers (5), ten flat
washers (8) and horn (13).
2. Press the emergency power disconnect switch (6,
Figure 12-5 or 31, Figure 12-9) and turn off key 10. Install plug (3) with new washer (2).
switch (22, Figure 12-8 or 22, Figure 12-9). 11. Add hydraulic oil to bring to proper level. Use
3. Remove the pump as described in paragraph 9- hydraulic oil listed in Table 3-2.
2.1. 12. Reinstall dipstick (10).
4. Remove dipstick (10, Figure 9-2) from the reser- 13. Install the pump as described in paragraph 9-2.2.
voir 14. Engage the emergency power disconnect switch
5. Remove plug (3) and washer (2) and drain the (6, Figure 12-5 or 31, Figure 12-9) and turn on
reservoir. key switch (22, Figure 12-8 or 22, Figure 12-9).

R7268

Figure 9-2 Reservoir

BL-V08-1015 - 11-29-2016 9-3

9-4. CONTROL VALVE 1. Lower forks fully.
2. Press the emergency power disconnect switch (6,
9-4.1. Removal
Figure 12-5 or 31, Figure 12-9) and turn off key
WARNING: When forks are raised, pressure exists in switch (22, Figure 12-8 or 22, Figure 12-9).
the hydraulic system lines and fittings. To 3. Remove the floor board as described in para-
ensure release of pressure, forks must graph 5-3.1.
be fully lowered and the batteries discon-
4. Remove two screws (10, Figure 9-3) and cover
nected before performing any mainte-
plate (39).
nance on the hydraulic system.
5. Remove four screws (10) and cover (11).

R7254

Figure 9-3 Control Valve Mounting

9-4 BL-V08-1015 - 11-29-2016

CAUTION: Hydraulic oil can damage parts. Wipe off 12. Engage the emergency power disconnect switch
any oil immediately. Provide a container (6, Figure 12-5 or 31, Figure 12-9) and turn on
under the line or fitting before discon- key switch (22, Figure 12-8 or 22, Figure 12-9).
necting. 13. Operate all hydraulic levers to refill the cylinders
6. Tag and disconnect hoses from valve (1). and lines with hydraulic oil.

7. Remove covers (30) from switches (36). 14. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
8. Tag and disconnect electrical leads from each oil listed in Table 3-2.
switch (36).
9. Remove four screws (7), four lock washers (8), 9-5. TILT CYLINDER
four flat washers (9), and mounting plate (6) with
valve (1) from frame (1, Figure 12-1). 9-5.1. Removal
10. Remove cotter pins (31, Figure 9-3) and clevis WARNING: Mast must be supported by a hoist
pins (32) and free link (22) from spools of valve before removing tilt cylinders.
(1).
1. Raise the forks to approximately three feet. Tilt
11. Remove three screws (3), three lock washers (4), the mast all the way forward.
three flat washers (5), valve (1) and shock
absorber (37) from mounting plate (6). 2. Secure mast with a hoist.
12. Remove screws (27), lock washers (28), flat 3. Remove the floor board as described in para-
washers (29) and bracket (26) from each spool of graph 5-3.1.
valve (1).
NOTE: Leaking hydraulic fittings may be remedied by
9-4.2. Installation simply tightening fittings. If this does not rem-
edy the leak, the fittings or line must be
1. Position brackets (26, Figure 9-3) on each spool replaced.
of valve (1) and secure with screws (27), lock
washers (28), and flat washers (29). 4. Tag and disconnect hoses from the tilt cylinder.
2. Position valve (1) on mounting plate (6) and 5. Remove bolt (21, Figure 9-4), lock washer (22)
secure with three screws (3), three lock washers and pin (20) from the mast.
(4), three flat washers (5), and shock absorber 6. Pull tilt control back to free tilt cylinder from the
(37). mast.
3. Connect spools of valve (1) with clevis pins (32) 7. Support cylinder (17) and remove bolt (21), lock
and cotter pins (31). washer (22) and pin (20).
4. Adjust switches (36) so that the switch opens and 8. Remove the cylinder.
closes when the controls levers are moved.
5. Position mounting plate (6) with valve (1) on 9-5.2. Repair
frame (1, Figure 12-1) and secure with four WARNING: To prevent cylinder damage, use proper
screws (7, Figure 9-3), four lock washers (8), four pipe vise. The cylinder will be distorted if
flat washers (9). the vise is tightened too much.
6. Reconnect electrical leads to each switch (36).
1. Secure the cylinder assembly in a vise.
7. Install covers (30) on switches (36).
2. Remove nut (6, Figure 9-5), lock washer (5), bolt
8. Reconnect hoses to valve (1). (4) and clevis end (1) from piston rod (14).
9. Install cover (11) and secure with four bolts (10). 3. Remove snap rings (3) and bearing (2) from clevis
10. Install cover plate (39) and secure with two end (1).
screws (10). 4. Using spanner wrench, unthread gland nut (11)
11. Install the floor board as described in paragraph from cylinder body (17).
5-3.2.

BL-V08-1015 - 11-29-2016 9-5

 R7270

Figure 9-4 Hydraulic Tilt

5. Remove dust seal (7), O-ring (8), snap ring (9), 2. Reconnect hoses to the tilt cylinder.
seal (10), bearing (12) and O-ring (13) from gland 3. Move the tilt control forward to extend the mount-
nut (11). ing bracket on the mast.
6. Pull piston rod (14) from cylinder body (17). 4. Install pin (20) and secure with bolt (21) and lock
7. Remove seals (16) and wear ring (15) from the washer (22).
piston rod (14). 5. Remove the hoist from the mast.
NOTE: Before reassembling the cylinder, it is recom- 6. Check level of hydraulic oil. If required, add
mended that packing kit items (7, 8, 10, 13, hydraulic oil to bring to proper level. Use hydraulic
and 16) be replaced. oil listed in Table 3-2.

8. Reassemble the cylinder in reverse order of dis- 7. Install the floor board as described in paragraph
assembly. 5-3.2.
8. Operate all hydraulic levers to refill the cylinders
9-5.3. Installation and lines with hydraulic oil.
1. Position the tilt cylinder in the frame and install pin 9. Check level of hydraulic oil. If required, add
(20, Figure 9-4) and secure with bolt (21) and lock hydraulic oil to bring to proper level. Use hydraulic
washer (22). oil listed in Table 3-2.

9-6 BL-V08-1015 - 11-29-2016

 R7290

Figure 9-5 Tilt Cylinder

9-6. LIFT CYLINDER WARNING: Before attempting any replacement,

make certain power is disconnected.
9-6.1. Free Lift Cylinder
CAUTION: Hydraulic oil can damage parts. Wipe off
9-6.1.1. Removal any oil immediately. Provide a container
under the line or fitting before discon-
1. With the lift truck wheels securely blocked, raise necting.
the forks approximately three feet from floor and
position blocks or strong supports under the lift 4. Remove the lift chain as described in paragraph
carriage. 8-4.
2. Lower lift carriage onto the support. Check that 5. Disconnect the tube (9, Figure 9-6) from lift cylin-
arrangement is secure before proceeding. der (8, Figure 9-7).
3. Press the emergency power disconnect switch (6, 6. Manually push the cylinder rod down as far as
possible.
Figure 12-5 or 31, Figure 12-9) and turn off key
switch (22, Figure 12-8 or 22, Figure 12-9). 7. Remove screw (32), flat washers (19), bracket (4)
and ram head (5) from cylinder (8).

BL-V08-1015 - 11-29-2016 9-7

WARNING: Support lift cylinder before performing 8. Remove two bolts (15), two lock washers (16) and
the following steps to prevent cylinder two flat washers (17).
from falling. 9. Raise lift cylinder assembly (8) up and out of
truck.

R7273

Figure 9-6 Hydraulic Pipes

9-8 BL-V08-1015 - 11-29-2016

 R7272

Figure 9-7 Elevation System

BL-V08-1015 - 11-29-2016 9-9

9-6.1.2. Repair 4. Pull out piston rod (6).

WARNING: To prevent damage, use proper pipe 5. Remove back up ring (7) from piston rod (6).
clamp vise. The cylinder will be distorted 6. Coat all parts with hydraulic oil (Table 3-2).
if the vise is tightened too much. 7. Install back up (7) on piston rod (6).
1. Secure the lift cylinder in a vise, clamping lightly 8. Insert rod (6) in cylinder tube (8).
at the base of the cylinder. 9. Install wiper ring (1), collar (2), packing (3) and O-
2. Remove gland nut (4, Figure 9-8). ring (5) on gland nut (4).
3. Remove wiper ring (1), collar (2), packing (3) and 10. Install gland nut (4) in cylinder tube (8).
O-ring (5) from gland nut (4).

R7284

Figure 9-8 Free Lift Cylinder

9-10 BL-V08-1015 - 11-29-2016

9-6.1.3. Installation CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
1. Position the cylinder in the mast and secure with
under the line or fitting before discon-
two bolts (15, Figure 9-7), two lock washers (16), necting.
two flat washers (17).
4. Disconnect the tube (3, Figure 9-6) from the cylin-
2. Install ram head (5) and bracket (4) on top of cyl- der being removed.
inder (8) and secure with screw (32) and washers
(19). 5. Remove connector (13) and washer (1) from the
cylinder being removed.
3. Install the lift chain as described in paragraph 8-4.
4. Reconnect the tube (9, Figure 9-6) to the bottom WARNING: Support lift cylinder before performing
of the lift cylinder. the following steps to prevent cylinder
from falling.
5. Lift inner mast (14) and remove blocking
6. Remove two bolt (1), lock washer (2) and flat
6. Fill the hydraulic reservoir. Use hydraulic oil listed
washers (3) from the top of the cylinder.
in Table 3-2.
7. Remove with two bolts (24), two lock washers (2),
7. Engage the emergency power disconnect switch two flat washers (33), shim (27), support (28),
(6, Figure 12-5 or 31, Figure 12-9) and turn on clamp (29) and two nuts (31).
key switch (22, Figure 12-8 or 22, Figure 12-9).
8. Raise lift cylinder assembly (30) up and out of
8. Operate lift levers to refill the cylinder and lines
truck.
with hydraulic oil.
9. Check level of hydraulic oil. If required, add 9-6.2.2. Repair
hydraulic oil to bring to proper level. Use hydraulic
WARNING: To prevent damage, use proper pipe
oil listed in Table 3-2.
clamp vise. The cylinder will be distorted
10. Adjust the chains according to paragraph 8-3. if the vise is tightened too much.
9-6.2. Secondary Cylinder 1. Secure the lift cylinder in a vise, clamping lightly
at the base of the cylinder.
9-6.2.1. Removal
2. Remove gland nut (3).
1. With the lift truck wheels securely blocked, raise
the forks approximately three feet from floor and 3. Remove wiper ring (1), packing (2) and O-rings (4
position blocks or strong supports under the inner and 13) from gland nut (3).
mast. 4. Pull out piston rod (5).
2. Lower mast onto the support. Check that arrange- 5. Remove ring (8), retaining ring (7) and bushing (6)
ment is secure before proceeding. from rod (5).
3. Press the emergency power disconnect switch (6,
6. Coat all parts with hydraulic oil (Table 3-2).
Figure 12-5 or 31, Figure 12-9) and turn off key
switch (22, Figure 12-8 or 22, Figure 12-9). 7. Install ring (8), retaining ring (7) and bushing (6)
on rod (5).
WARNING: Before attempting any replacement,
make certain power is disconnected. 8. Insert rod (5) in cylinder tube (9).
9. Install wiper ring (1), packing (2) and O-rings (4
and 13) on gland nut (3).
10. Install gland nut (3) in cylinder tube (9).

BL-V08-1015 - 11-29-2016 9-11

 R7285

Figure 9-9 Secondary Lift Cylinder

9-6.2.3. Installation 5. Fill the hydraulic reservoir. Use hydraulic oil listed
in Table 3-2.
1. Position the cylinder in the mast (25, Figure 9-7)
and secure with two bolts (24), two lock washers 6. Engage the emergency power disconnect switch
(2), flat washers (33), shim (27), support (28), (6, Figure 12-5 or 31, Figure 12-9) and turn on
clamp (29) an two nuts (31). key switch (22, Figure 12-8 or 22, Figure 12-9).
2. Lift middle mast (22) and remove blocking. Lower 7. Operate lift levers to refill the cylinder and lines
the mast onto the lift cylinder. with hydraulic oil.
3. Install bolt (1), lock washer (2) and flat washers 8. Check level of hydraulic oil. If required, add
(3). hydraulic oil to bring to proper level. Use hydraulic
4. Install connector (13, Figure 9-6) and washer (1) oil listed in Table 3-2.
in the bottom of the lift cylinder. Reconnect the
9. Adjust the chains according to paragraph 8-3.
tube (3) to connector (13).

9-12 BL-V08-1015 - 11-29-2016

 SECTION 10
ELECTRICAL COMPONENTS

10-1.CONTROL HANDLE 3. Tag and disconnect harness (17) from compo-

nents on cover (12) and remove cover (12).
10-1.1.Cover
10-1.1.2. Installation
10-1.1.1. Removal
1. Reconnect harness (17, Figure 10-1) to compo-
1. Press the emergency power disconnect switch (6, nents on cover (12).
Figure 12-5 or 31, Figure 12-9) and turn off key
2. Install cover (12) and cover (13) and secure with
switch (22, Figure 12-8 or 22, Figure 12-9).
six screws (14) and six lock washers (15) and six
2. Remove six screws (14) and six lock washers (15) flat washers (16).
and six flat washers (16). Separate cover (13) and
3. Engage the emergency power disconnect switch
cover (12).
(6, Figure 12-5 or 31, Figure 12-9) and turn on
key switch (22, Figure 12-8 or 22, Figure 12-9).

R7252 Used up to 05-14-2015 R8049 Used from 05-15-2015

Figure 10-1 Control Handle Assembly

BL-V08-1015 - 11-29-2016 10-1

10-1.2.Key Switch 2. Install the covers from the control handle as
described in paragraph 10-1.1.2.
10-1.2.1. Removal
1. Remove the covers from the control handle as 10-2.EMERGENCY DISCONNECT SWITCH
described in paragraph 10-1.1.1.
10-2.1.Removal
2. Remove key switch (22, Figure 12-8 or 22, Figure
12-9) from cover (12). 1. Remove the covers as described in paragraph 5-
2.1.
10-1.2.2. Installation 2. Disconnect harness (1, Figure 12-16) from switch
1. Install key switch (22, Figure 12-8 or 22, Figure (6, Figure 12-5 or 31, Figure 12-9).
12-9) on cover (12). 3. Remove switch (6) from the frame.
2. Install the covers from the control handle as
10-2.2.Installation
described in paragraph 10-1.1.2.
1. Install switch (6, Figure 12-5 or 31, Figure 12-9)
10-1.3.Horn Switch on the frame.
10-1.3.1. Removal 2. Reconnect harness (1, Figure 12-16) to the
switch.
1. Remove the covers from the control handle as
described in paragraph 10-1.1.1. 3. Install the covers as described in paragraph 5-2.2.
2. Remove horn (20, Figure 10-1) from cover (12). 10-3.DRIVE MOTOR
10-1.3.2. Installation
10-3.1.Removal
1. Install horn (20, Figure 10-1) on cover (12).
1. Press the emergency power disconnect switch (6,
2. Install the covers from the control handle as Figure 12-5 or 31, Figure 12-9) and turn off key
described in paragraph 10-1.1.2. switch (22, Figure 12-8 or 22, Figure 12-9).

10-1.4.Forward/Reverse Switch 2. Remove the compartment cover as described in

paragraph 5-2.1.
10-1.4.1. Removal 3. Remove the steering motor as described in para-
1. Remove the covers from the control handle as graph 5-4.1.
described in paragraph 10-1.1.1. 4. Remove the electronic brake as described in
2. Remove forward/reverse (18, Figure 10-1) from paragraph 6-2.1..
cover (12). 5. Tag and disconnect the cables from the drive
motor.
10-1.4.2. Installation
6. Remove six screws (14, Figure 10-2), six lock
1. Install forward/reverse switch (18, Figure 10-1) on washers (15) and six flat washers (16).
cover (12).
7. Remove the drive motor (4) from the frame.
2. Install the covers from the control handle as
described in paragraph 10-1.1.2. 8. Remove the gear, retaining ring (5), O-ring (9),
sleeve (8), bearing (7) and ring (6) from the shaft
10-1.5.Instrument Panel of drive motor (4).

10-1.5.1. Removal 10-3.2.Installation

1. Remove the covers from the control handle as 1. Install the gear, retaining ring (5), O-ring (9),
described in paragraph 10-1.1.1. sleeve (8), bearing (7) and ring (6) on the shaft of
2. Remove instrument panel (23, Figure 10-1) from drive motor (4).
cover (12). 2. Position the drive motor (4) on the frame being
sure the gear aligns with the transmission.
10-1.5.2. Installation
3. Secure with the six screws (14, Figure 10-2), six
1. Install instrument panel (23, Figure 10-1) on cover lock washers (15) and six flat washers (16).
(12).

10-2 BL-V08-1015 - 11-29-2016

4. Reconnect the cables to the drive motor. 7. Install the compartment cover as described in
5. Install the electronic brake as described in para- paragraph 5-2.2.
graph 6-2.1.. 8. Engage the emergency power disconnect switch
6. Reinstall the steering motor as described in para- (6, Figure 12-5 or 31, Figure 12-9) and turn on
graph 5-4.2. key switch (22, Figure 12-8 or 22, Figure 12-9).

R7255

Figure 10-2 Transmission, Motor & Brake Assembly

10-4.PUMP MOTOR. 10-5.ACCELERATOR

The pump motor is replaceable but not repairable. 10-5.1.Removal
Refer to paragraph 9-4.
1. Remove the floor board as described in para-
graph 5-3.1.

BL-V08-1015 - 11-29-2016 10-3

2. Remove two nuts (6, Figure 12-4), two lock wash- 10-6.2.Cleaning
ers (4), four flat washers (5), two bolts (2), and
1. Press the emergency power disconnect switch (6,
accelerator (2) from floor board (1).
Figure 12-5 or 31, Figure 12-9) and turn off key
10-5.2.Installation switch (22, Figure 12-8 or 22, Figure 12-9).

1. Position accelerator (2, Figure 12-4) on floor 2. Remove the compartment cover as described in
board (1) and secure with two bolts (2), four flat paragraph 5-2.1.
washers (5), two lock washers (4) and two nuts 3. Remove any dirt or corrosion from the bus bar
(6). area. The controller should be wiped clean with a
1. Install the floor board as described in paragraph moist rag. Allow it to dry before reconnecting the
5-3.2. battery.

10-6.3.Controller Removal.
10-6.ELECTRICAL CONTROL PANEL
1. Press the emergency power disconnect switch (6,
10-6.1.Maintenance Figure 12-5 or 31, Figure 12-9) and turn off key
switch (22, Figure 12-8 or 22, Figure 12-9).
NOTE: Erratic operation of the truck may be caused
by defective controller components. Before 2. Remove the compartment cover as described in
removing the electrical panel, perform trou- paragraph 5-2.1.
bleshooting procedures per SECTION 4, to 3. Tag and disconnect harness (1, Figure 12-16)
determine corrective action to be taken. from controller (14 or 18, Figure 12-15).

There are two controllers: one for the traction and the 4. Tag and disconnect remaining leads from the con-
second for the power steering. There are no user-ser- troller. Refer to Figure 12-17.
viceable parts inside the controllers. No attempt 5. Remove mounting screws, lock washers and
should be made to open the controllers. Opening the remove controller (14 or 18, Figure 12-15).
controllers may damage it and will void the war-
ranty. 10-6.4.Controller Installation.

The controllers are programmed at the factory specifi- 1. Position controller (14 or 18, Figure 12-15) on
cally for the truck model on which it is equipped. It is plate (1) and secure with original screws and lock
important to replace the controllers with the correct washers.
preprogrammed unit to assure proper performance 2. Reconnect harness (1, Figure 12-16) to controller
settings intended for that particular truck. See Figure (14 or 18, Figure 12-15).
12-15 for the preprogrammed controller numbers. 3. Reconnect remaining leads to the controller.
It is recommended that the controller exterior be Refer to Figure 12-17.
cleaned periodically, and if a hand held programmer is 4. Install the compartment cover as described in
available, this periodic cleaning provides a good paragraph 5-2.2.
opportunity to check the controller’s diagnostic history
file. It is also recommended that the controller’s fault 5. Engage the emergency power disconnect switch
detection circuitry be checked whenever the vehicle is (6, Figure 12-5 or 31, Figure 12-9) and turn on
serviced. key switch (22, Figure 12-8 or 22, Figure 12-9).

10-4 BL-V08-1015 - 11-29-2016

 SECTION 11
OPTIONAL EQUIPMENT

BL-V08-1015 - 11-29-2016 11-1

 NOTES

11-2 BL-V08-1015 - 11-29-2016

 SECTION 12
ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the V-08 Lift Truck.

BL-V08-1015 - 11-29-2016 12-1

 R7247

Figure 12-1 Frame and Counterweight - Used up to 05-14-2015

12-2 BL-V08-1015 - 11-29-2016

 FRAME AND COUNTERWEIGHT - USED UP TO 05-14-2015

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-110000-00 FRAME 1 Used up to 09-09-2014

Used from 09-10-2014

1a 3712-110000-0A FRAME 1
to 05-14-2015

2 3712-100005-00 PLATE 1

3 0000-000242-00 BOLT, M8 X 16 5

4 0000-000159-00 WASHER, LOCK, M8 2

5 0000-000540-00 WASHER, FLAT, M8 2

6 3712-100001-00 CLAMP 2

7 0000-000352-00 BOLT, M14 X 1.5 X 60 4

8 0000-000233-00 WASHER, LOCK, M14 4

9 0000-001004-00 WASHER, FLAT, M14 4

10 3712-100006-00 BUSHING 4

11 3712-100003-00 PLATE 1

12 3218-210001-00 BUMPER PAD 3

13 2140-140000-0A CASTER ASSEMBLY 2

14 0000-000324-00 SCREW, M10 X 30 8

15 0000-000063-00 WASHER, LOCK, M10 8

16 0000-000547-00 WASHER, FLAT, M10 8

17 3712-100007-00 SHIM AR

18 3316-814000-00 ROLLER 11

19 0000-000368-00 SCREW, M8 X 12 4

20 3712-100002-00 PLATE 1

21 3712-120003-00 COUNTERWEIGHT 1

22 3712-120004-00 COUNTERWEIGHT 1

23 3712-120001-00 COUNTERWEIGHT 1

24 3712-120002-00 COUNTERWEIGHT 1

BL-V08-1015 - 11-29-2016 12-3

 R7247

Figure 12-1 Frame and Counterweight - Continued - Used up to 05-14-2015

12-4 BL-V08-1015 - 11-29-2016

 FRAME AND COUNTERWEIGHT - CONTINUED - USED UP TO 05-14-2015

Qty.
Pos. Part Number Description Notes
Reqd.
25 0000-000374-00 SCREW, M12 X 30 10

26 0000-000060-00 WASHER, LOCK, M12 14

27 0000-000554-00 WASHER, FLAT, M12 18

31 3712-405000-00 ALARM BUZZER 1

BL-V08-1015 - 11-29-2016 12-5

 R8046

Figure 12-2 Frame and Counterweight - Used from 05-15-2015

12-6 BL-V08-1015 - 11-29-2016

 FRAME AND COUNTERWEIGHT - USED FROM 05-15-2015

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-110000-C0 FRAME 1

2 3712-100005-00 PLATE 1

3 0000-000242-00 BOLT M8×16 5

4 0000-000159-00 LOCKWASHER Φ8 2

5 0000-000540-00 FLATWASHER Φ8 2

6 3712-100001-00 BEARING COVER 2

7 0000-000352-00 BOLT M14×1.5×60 4

8 0000-000233-00 LOCKWASHER Φ14 4

9 0000-001004-00 FLATWASHER Φ14 4

10 3712-100006-00 BUSHING 4

11 3712-100003-00 PLATE 1

12 3218-210001-00 SHOCK PAD 3

13 2140-140000-0A CASTER ASSEMBLY 2

14 0000-000324-00 SCREW M10×30 8

15 0000-000063-00 LOCKWASHER Φ10 8

16 0000-000547-00 FLATWASHER Φ10 8

17 3712-100007-00 WASHER A.R. As Required

18 3316-814000-00 ROLLER 11

19 0000-000368-00 SCREW M8×12 4

20 3712-100002-00 PLATE 1

21 3712-120003-00 COUNTER WEIGHT 1

22 3712-120004-00 COUNTER WEIGHT 1

23 3712-120001-00 COUNTER WEIGHT 1

24 3712-120002-00 COUNTER WEIGHT 1

25 0000-000374-00 SCREW M12×30 6

26 0000-000060-00 LOCKWASHER Φ12 6

27 0000-000554-00 FLATWASHER Φ12 6

28 3712-405000-00 ALARM BUZZER 1

BL-V08-1015 - 11-29-2016 12-7

 R7248

Figure 12-3 Caster Assembly

12-8 BL-V08-1015 - 11-29-2016

 CASTER ASSEMBLY

Qty.
Pos. Part Number Description Notes
Reqd.
— 2140-140000-0A CASTER ASSEMBLY 2

1 0000-000093-00 NUT, M27 X 1.5 1

2 0000-000094-00 WASHER, M27 1

3 1220-140001-00 SNAP RING 1

4 0000-000420-00 BEARING 1

5 2140-140002-0A BEARING BLOCK 1

6 0000-000421-00 BEARING 1

7 2140-140004-00 SPRING 2

8 2140-141000-00 YOKE 1

9 0000-000242-00 BOLT, M8 X 16 2

10 0000-000159-00 WASHER, LOCK, M8 2

11 2140-142000-00 PIN 1

12 2140-145000-00 SHAFT 1

13 2140-140003-00 SHAFT 2

14 2140-143000-00 YOKE 1

15 2140-144002-00 WHEEL 1

16 0000-000424-00 BEARING 2

BL-V08-1015 - 11-29-2016 12-9

 R7249

Figure 12-4 Covers

12-10 BL-V08-1015 - 11-29-2016

 COVERS

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-131000-00 FLOOR BOARD 1

2 3218-680000-00 ACCELERATOR 1

3 0000-000277-00 BOLT, M8 X 25 2

4 0000-000159-00 WASHER, LOCK, M8 6

5 0000-000540-00 WASHER, FLAT, M8 8

6 0000-000550-00 NUT, M8 10

7 0000-000368-00 SCREW, M8 X 12 6

8 3218-240001-00 ROD 2

9 3712-140000-00 SIDE DOOR, LEFT 1

10 3712-150000-00 SIDE DOOR, RIGHT 1

11 0000-000255-00 BOLT, M8 X 20 4

BL-V08-1015 - 11-29-2016 12-11

 R7250

Figure 12-5 Seat and Steering Controls

12-12 BL-V08-1015 - 11-29-2016

 SEAT AND STEERING CONTROLS

Qty.
Pos. Part Number Description Notes
Reqd.
1 3218-212000-10 SEAT, SC1 1

2 0000-000255-00 BOLT, M8 X 20 8

3 0000-000540-00 WASHER, FLAT, M8 28

4 0000-000159-00 WASHER, LOCK, M8 16

5 0000-000550-00 NUT, M8 20

6 3218-604000-00 EMERG. DISCONNECT SWITCH 1 Used up to 05-14-2015

7 3218-212001-00 SEAT BELT 1

8 3125-600200-00 SEAT SWITCH 1

BL-V08-1015 - 11-29-2016 12-13

 R7251

Figure 12-6 Control Handle Assembly (Sheet 1) - Used up to serial number 224150054

12-14 BL-V08-1015 - 11-29-2016

 CONTROL HANDLE ASSEMBLY (SHEET 1) - USED UP TO SERIAL NUMBER 224150054

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-211000-00 HANDLE, UPPER 1

2 0000-000015-00 SCREW, M8 X 10 2

3 0000-000063-00 WASHER, LOCK, M10 2

4 0000-000030-00 SCREW, M10 X 16 2

5 CK11-311000-00 HANDLE BALL 1

6 CK11-310002-00 STEERING WHEEL 1

7 0000-000951-00 NUT, M10 X 1.5 1

8 3316-311202-00 PLATE 1

9 0000-000646-00 SCREW, M4 X 10 4

10 0000-000702-00 WASHER, FLAT, M4 4

11 0000-000035-00 BOLT, M5 X 20 4

12 0000-000206-00 WASHER, LOCK, M5 4

13 3316-311204-00 ADJUSTMENT PAD 1

14 3316-311203-00 DAMPING BLOCK 1

15 3316-311205-00 NUT 1

16 0000-000939-00 SCREW, M3 X 6 1

17 0000-000937-00 BEARING 2

18 3316-311201-00 AXLE 1

19 0000-000416-00 SCREW, M4 X 8 1

20 0000-000941-00 RETAINING RING 1

21 3316-311206-00 BEARING SEAT 1

22 CK11-560002-00 MOTOR 1

23 3712-420004-00 WIRE HARNESS 1

24 0000-000004-00 SCREW M5 X 12 4

25 0000-000206-00 LOCKWASHER Φ5 4

BL-V08-1015 - 11-29-2016 12-15

 R8047

Figure 12-7 Control Handle Assembly (Sheet 1) - Used from serial number 224150055

12-16 BL-V08-1015 - 11-29-2016

 CONTROL HANDLE ASSEMBLY (SHEET 1) - USED FROM SERIAL NUMBER 224150055

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-211000-C0 HANDLE-UPPER 1

2 0000-000015-00 SCREW M6×10 2

3 0000-000063-00 LOCKWASHER Φ10 2

4 0000-000030-00 SCREW M10×16 2

5 CK11-311000-00 HANDLE-BALL 1

6 CK11-310002-00 STEERING WHEEL 1

7 0000-000951-00 NUT M10×1.5 1

8 3316-311202-00 PLATE 1

9 0000-000646-00 SCREW M4×10 4

10 0000-000702-00 FLATWASHER Φ4 4

11 0000-000035-00 BOLT M5×20 4

12 0000-000206-00 LOCKWASHER Ø5 4

13 3316-311204-00 ADJUSTMENT PAD 1

14 3316-311203-00 DAMPING BLOCK 1

15 3316-311205-00 NUT 1

16 0000-000939-00 SCREW M3×6 1

17 0000-000937-00 BEARING 61803 2

18 3316-311201-00 AXLE 1

19 0000-000416-00 SCREW M4×8 1

20 0000-000941-00 RETAINER RING Ø26 1

21 3316-311206-00 BEARING SEAT 1

22 CK11-560002-00 MOTOR 1

23 3712-420004-00 WIRE HARNESS 1

24 0000-000004-00 SCREW M5×12 4

25 0000-000206-00 LOCKWASHER Ø5 4

26 3712-210006-C0 BAFFLE 1

27 0000-000077-00 SCREW M6×12 2

28 0000-000056-00 LOCKWASHER Φ6 2

BL-V08-1015 - 11-29-2016 12-17

 R8048

Figure 12-8 Control Handle Assembly (Sheet 2) - Used up to serial number 224150054

12-18 BL-V08-1015 - 11-29-2016

 CONTROL HANDLE ASSEMBLY (SHEET 2) - USED UP TO SERIAL NUMBER 224150054

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-212000-00 HANDLE, LOWER 1

2 3712-210001-00 BOLT 1

3 0000-000413-00 NUT, M8 1

4 0000-000293-00 RETAINING RING 2

5 0000-001105-00 BUSHING 2

6 3712-210002-00 PIN 1

7 0000-000386-00 SCREW, M6 X 20 3

8 0000-000056-00 WASHER, LOCK, M6 3

9 0000-000544-00 WASHER, FLAT, M6 3

10 3712-213000-00 GAS SPRING 1

11 3218-330017-A0 SCREW 1

12 3712-210004-00 COVER, UPPER 1

13 3712-210005-00 COVER, LOWER 1

14 0000-000378-00 SCREW, M4 X 16 6

15 0000-000122-00 WASHER, LOCK, M4 6

16 0000-000702-00 WASHER, FLAT, M4 6

17 3712-420002-00 CONTROL HARNESS 1

18 3712-402000-00 FORWARD/REVERSE SWITCH 1

19 3712-420007-0A WIRE HARNESS 1

20 3712-401000-00 HORN SWITCH 1

21 3712-420008-00 WIRE HARNESS 1

22 3712-420005-00 KEY SWITCH 1

23 3425-301000-00 INSTRUMENT PANEL GAUGE 1

BL-V08-1015 - 11-29-2016 12-19

 R8049

Figure 12-9 Control Handle Assembly (Sheet 2) - Used from serial number 224150055

12-20 BL-V08-1015 - 11-29-2016

 CONTROL HANDLE ASSEMBLY (SHEET 2) - USED FROM SERIAL NUMBER 224150055

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-212000-C0 HANDLE-LOWER 1

2 3712-210001-00 BOLT 1

3 0000-000413-00 NUT M8 1

4 0000-000293-00 RETAINER RING Ø20 2

5 0000-001105-00 BUSHING 2

6 3712-210002-00 PIN 1

7 0000-000386-00 SCREW M6×20 3

8 0000-000056-00 LOCKWASHER Φ6 8

9 0000-000544-00 FLATWASHER Φ6 7

10 3712-213000-C0 GAS SPRING 1

11 3218-330017-A0 SCREW 1

12 3712-210004-C0 COVER-UPPERI 1

13 3712-210005-C0 COVER-UPPERII 1

14 0000-001029-00 SCREW M4×12 8

15 0000-000122-00 LOCKWASHER Φ4 6

16 0000-000702-00 FLATWASHER Φ4 6

17 3712-420002-C0 BEND WIRE HARNESS 1

18 3712-402000-00 FORWARD/REVERSE SWITCH 1

19 3712-420007-0A WIRE HARNESS 1

20 3712-401000-00 HORN SWITCH 1

21 3712-420008-00 WIRE HARNESS 1

22 2212-520002-00 KEY SWITCH 1

23 CK11-560001-00 METER 1

24 3712-210007-C0 PLATE 1

BL-V08-1015 - 11-29-2016 12-21

 R8049

Figure 12-9 Control Handle Assembly (Sheet 2) - Used from serial number 224150055 - Continued

12-22 BL-V08-1015 - 11-29-2016

 CONTROL HANDLE ASSEMBLY (SHEET 2) - USED FROM SERIAL NUMBER 224150055 - CONTINUED

Qty.
Pos. Part Number Description Notes
Reqd.
25 0000-000077-00 SCREW M6×12 2

26 0000-000055-00 SCREW M6×16 4

27 3712-210008-C0 SPACER 1

28 1220-560001-00 INCHING SWITCH 1

29 0000-001353-00 SCREW M2×10 2

30 3712-210009-C0 LOCK 1

31 3218-604000-00 EMERG. DISCONNECT SWITCH 1

32 CK10-520008-00 METER WIRE HARNESS 1

BL-V08-1015 - 11-29-2016 12-23

 R7253

Figure 12-10 Brake Pedal

12-24 BL-V08-1015 - 11-29-2016

 BRAKE PEDAL

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-171000-00 BRAKE BRACKET 1

2 0000-000008-00 SCREW, M10 X 20 3

3 0000-000063-00 WASHER, LOCK, M10 4

4 0000-000547-00 WASHER, FLAT, M10 4

5 0000-000277-00 BOLT, M8 X 25 1

6 0000-000550-00 NUT, M8 1

7 3316-410003-00 BOLT, M10 X 125 1

8 0000-000540-00 WASHER, FLAT, M8 2

9 0000-000159-00 WASHER, LOCK, M8 2

10 0000-000553-00 NUT, M10 1

11 3712-172000-00 BRAKE PEDAL 1

12 3125-310005-00 PEDAL COVER 1

13 3316-410001-00 SPRING 1

14 3316-410002-00 BUSHING 1

15 3316-410004-00 BEARING 2

16 3125-314000-00 MASTER CYLINDER 1

17 0000-000952-00 PIN, 8 X 30 1

18 0000-000376-00 COTTER PIN, 2.5 X 20 1

19 0000-000242-00 BOLT, M8 X 16 1

20 3218-310006-00 RESERVOIR BRACKET 2

21 3218-315000-00 BRAKE RESERVOIR 1

22 3218-310001-00 HOSE 1

23 0000-000468-00 CLAMP, M10-16 2

BL-V08-1015 - 11-29-2016 12-25

 R7253

Figure 12-10 Brake Pedal - Continued

12-26 BL-V08-1015 - 11-29-2016

 BRAKE PEDAL - COUTINUED

Qty.
Pos. Part Number Description Notes
Reqd.
24 0000-000264-00 BOLT, M6 X 12 2

25 0000-000056-00 WASHER, LOCK, M6 2

26 0000-000380-00 WASHER, FLAT, M6 2

27 3712-173000-00 TUBE, LEFT 1

28 3712-174000-0A TUBE, RIGHT 1

BL-V08-1015 - 11-29-2016 12-27

 R7254

Figure 12-11 Control Valve Mounting

12-28 BL-V08-1015 - 11-29-2016

 CONTROL VALVE MOUNTING

Qty.
Pos. Part Number Description Notes
Reqd.
1 3218-730000-10 CONTROL VALVE, TWO SPOOL 1

1a 3218-730000-20 CONTROL VALVE, THREE SPOOL 1

2 3218-330001-00 PIN 1

3 0000-000306-00 BOLT, M10 X 25 3

4 0000-000063-00 WASHER, LOCK, M10 3

5 0000-000007-00 WASHER, FLAT, M10 3

6 3712-221000-00 MOUNTING PLATE 1

7 0000-000109-00 SCREW, M8 X 16 4

8 0000-000159-00 WASHER, LOCK, M8 8

9 0000-000176-00 WASHER, FLAT, M8 8

10 0000-000368-00 SCREW, M8 X 10 6

11 3218-330005-00 COVER 1

12 0000-000242-00 BOLT, M8 X 16 4

13 3218-330002-00 MOUNTING BRACKET 1

14 3218-330006-00 KNOB, LIFT 1

15 3218-330007-00 KNOB, TILT 1

16 3712-222000-00 CONTROL LEVER, LIFT 1

17 3712-223000-00 CONTROL LEVER, TILT 1

18 0000-000740-00 NUT, M8 1

19 3218-330003-00 MOUNTING BRACKET 1

20 3218-336100-00 CONTROL VALVE ROD 3

21 0000-000552-00 NUT, M8 3

22 3218-336001-00 LINK 3

23 0000-000296-00 PIN Φ2×20 3

24 0000-000460-00 PIN Φ8×25 3

25 3218-330004-00 BUSHING 6

BL-V08-1015 - 11-29-2016 12-29

 R7254

Figure 12-11 Control Valve Mounting - Continued

12-30 BL-V08-1015 - 11-29-2016

 CONTROL VALVE MOUNTING - CONTINUED

Qty.
Pos. Part Number Description Notes
Reqd.
26 3218-337000-00 BRACKET 4

27 0000-000264-00 BOLT, M6 X 12 8

28 0000-000056-00 WASHER, LOCK, M6 8

29 0000-000123-00 WASHER, FLAT, M6 8

30 3218-605001-00 RUBBER COVER 4

31 0000-000295-00 PIN, 1.2 X 12 3

32 0000-000238-00 PIN. M5 X 18 3

33 3712-224000-00 CONTROL LEVER, SIDE 1

34 3218-330008-00 KNOB, SIDE 1

35 3125-636000-00 SWITCH HARNESS 1

36 3218-605000-00 SWITCH 4

37 3218-600006-00 SHOCK ABSORBER 3

38 3218-332002-00 COLLAR AR

39 3712-226000-00 COVER PLATE 1

BL-V08-1015 - 11-29-2016 12-31

 R7255

Figure 12-12 Transmission, Motor & Brake Assembly - Up to Serial number F24140131

12-32 BL-V08-1015 - 11-29-2016

 TRANSMISSION, MOTOR & BRAKE ASSEMBLY - UP TO SERIAL NUMBER F24140131

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000027-00 SCREW, M6 X 55 3

2 1120-210002-00 BRAKE LINING 1

3 1120-210000-00 BRAKE ASSEMBLY 1

4 1221-220000-00 DRIVE MOTOR 1

5 0000-000293-00 RETAINING RING, M20 1

6 0000-000849-00 RETAINING RING 1

7 0000-000879-00 BEARING 1

8 1221-200001-00 BEARING SLEEVE 1

9 0000-000409-00 O-RING, M63 X 3.55 1

10 1221-230000-00 BEARING 1

11 1221-200003-00 GEAR 1 Order with Item 27

12 4230-210000-00 TRANSMISSION 1

13 1120-200001-00 DRIVING WHEEL 1

14 0000-000154-00 SCREW, M8 X 35 6

15 0000-000159-00 WASHER, LOCK, M8 6

16 0000-000176-00 WASHER, FLAT, M8 6

17 0000-000155-00 SCREW, M10 X 40 6

18 0000-000063-00 WASHER, LOCK, M10 6

19 0000-000007-00 WASHER, FLAT, M10 6

20 0000-000869-00 BOLT, M8 X 40 8

21 0000-000025-00 WASHER, LOCK, M12 5

22 0000-000157-00 NUT, M12 X 1.25 5

BL-V08-1015 - 11-29-2016 12-33

 R7255

Figure 12-12 Transmission, Motor & Brake Assembly - Up to Serial number F24140131 - Continued

12-34 BL-V08-1015 - 11-29-2016

 TRANSMISSION, MOTOR & BRAKE ASSEMBLY - UP TO SERIAL NUMBER F24140131 - CONTINUED

Qty.
Pos. Part Number Description Notes
Reqd.
23 0000-000013-00 GREASE FITTING 1

24 3712-403000-00 CODER 1

25 0000-000208-00 SCREW, M4 X 25 3

26 1221-240000-00 STEERING MOTOR 1

27 1221-200004-00 GEAR 1 Order with Item 11

28 0000-000151-00 SCREW, M6 X 25 5

29 0000-000056-00 WASHER, LOCK, M6 5

30 1221-200005-00 WASHER 1

31 1280-520008-10 POSITION SWITCH 1

BL-V08-1015 - 11-29-2016 12-35

 R8050

Figure 12-13 Transmission, Motor & Brake Assembly - From Serial number F24140132

12-36 BL-V08-1015 - 11-29-2016

 TRANSMISSION, MOTOR & BRAKE ASSEMBLY - FROM SERIAL NUMBER F24140132

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-001129-10 SCREW M5×45 3

2 CK10-250001-10 BRAKE LINING 1

3 CK10-250000-10 BRAKE ASSEMBLY 1

4 CK10-220000-10 DRIVING MOTOR 1

5 0000-000293-00 RETAINER RING Ø20 3

6 0000-000849-00 ELASTIC COLLAR Ø47 1

7 CK10-220002-10 BALL BEARING 1

8 CK10-220003-10 HUB FOR ENDSHIELD 1

9 CK10-220004-10 O-RING Ø64.5×3.0 1

10 1221-230000-00 BEARING 1

11 1221-200003-00 GEAR 1

12 4230-210000-00 GEAR CASE ASSEMBLY 1

13 1120-200001-00 DRIVING WHEEL 1

14 0000-000154-00 SCREW M8×35 6

15 0000-000159-00 LOCKWASHER Ø8 6

16 0000-000176-00 FLATWASHER Ø8 6

17 0000-000155-00 SCREW M10×40 6

18 0000-000063-00 LOCKWASHER Ø10 6

19 0000-000007-00 FLATWASHER Ø10 6

20 0000-000869-00 BOLT M8×40 8

21 0000-000025-00 WASHER Ø12 5

22 0000-001131-10 NUT M12×1.5 5

Used up to serial num-

23 1221-240000-00 STEERING MOTOR 1
ber F24150002

Used from serial num-

23a 1221-240000-0A STEERING MOTOR 1
ber F24150003

24 1221-200004-00 GEAR 1

25 1221-200005-00 WASHER 1

BL-V08-1015 - 11-29-2016 12-37

 R8050

Figure 12-13 Transmission, Motor & Brake Assembly - From Serial number F24140132 - Continued

12-38 BL-V08-1015 - 11-29-2016

 TRANSMISSION, MOTOR & BRAKE ASSEMBLY - FROM SERIAL NUMBER F24140132 - CONTINUED

Qty.
Pos. Part Number Description Notes
Reqd.
26 0000-000386-00 SCREW M6×20 1

27 0000-000151-00 SCREW M6×25 5

28 0000-000056-00 LOCKWASHER Ø6 5

29 CK10-220005-10 KB-SENSOR 1

30 0000-000013-00 GREASE FITTING M8 1

31 0000-000226-00 KEY 6×6×16 1

32 0000-000204-00 KEY 3×5×13 1

33 0000-000436-00 NUT M12×1.5 1

34 CK10-220001-10 SHAFT SEAL Ø25×40×7 1

35 3712-403000-00 CODER 1

36 1280-520009-10 SWITCH WIRE HARNESSII 1

37 0000-000208-00 SCREW M4×25 3

38 1221-240001-0A BRUSH,STEERING MOTOR 4

BL-V08-1015 - 11-29-2016 12-39

 R7256

Figure 12-14 Drive Motor - Used up to serial number F24140131

12-40 BL-V08-1015 - 11-29-2016

 DRIVE MOTOR - USED UP TO SERIAL NUMBER F24140131

Qty.
Pos. Part Number Description Notes
Reqd.
— 1221-220000-00 DRIVE MOTOR 1

1 0000-000293-00 RETAINING RING, M20 2

2 0000-000226-00 KEY, 6 X 6 X 16 1

3 0000-000048-00 SCREW, M6 X 180 4

4 1220-230001-00 BEARING 1

5 0000-000056-00 WASHER, LOCK, M6 2

6 0000-000618-00 SCREW, M6 X 12 2

7 0000-000204-00 KEY, 3 X 5 X 13 1

8 0000-000436-00 NUT, M12 X 1.5 1

9 1220-230002-00 TERMINAL BLOCK 1

BL-V08-1015 - 11-29-2016 12-41

 R7258

Figure 12-15 Electrical Panel - Used up to serial number 224150054

12-42 BL-V08-1015 - 11-29-2016

 ELECTRICAL PANEL - USED UP TO SERIAL NUMBER 224150054

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-440001-00 CONTROL PANEL 1

2 1120-540001-00-B FUSE HOLDER 1

3 1120-540002-00 FUSE, 200A 1

4 3712-440002-00 WASHER A.R. As Required

5 0000-000196-00 NUT, M8 2

6 0000-000074-00 SCREW, M6 X 20 2

7 1120-500005-10 CONTACTOR 1

8 0000-000380-00 WASHER, FLAT, M6 6

9 0000-000056-00 WASHER, LOCK, M6 6

10 0000-000077-00 SCREW, M6 X 12 2

11 1120-530006-00 BUSS BAR, COPPER 1

12 CK11-510002-00 BUSS BAR, COPPER 1

13 1220-500011-E0 CONTROLLER, TRACTION 1

Used up to serial number

14 4230-560002-00-70 CONTROLLER 1
F24140131

Used from serial number

14a 4230-560002-00-80 CONTROLLER 1
F24140132 to 224150054

15 0000-000004-00 SCREW, M5 X 12 4

16 0000-000206-00 WASHER, LOCK, M5 4

17 0000-000390-00 WASHER, FLAT, M5 4

18 1280-560002-10-20 CONTROLLER, STEERING 1

19 0000-000032-00 SCREW, M6 X 25 4

20 0000-000321-00 SCREW, M8 X 20 4

21 0000-000159-00 WASHER, LOCK, M8 4

22 0000-000540-00 WASHER, FLAT, M8 4

23 3316-730003-00 GROUND RESISTANCE LINE 1

BL-V08-1015 - 11-29-2016 12-43

 R8221

Figure 12-16 Electrical Panel - Used from serial number 224150055

12-44 BL-V08-1015 - 11-29-2016

 ELECTRICAL PANEL - USED FROM SERIAL NUMBER 224150055

Qty.
Pos. Part Number Description Notes
Reqd.

1 3712-440001-CA CONTROL BRACKET 1

2 1120-540001-00-B STAND 1

3 1120-540002-00 FUSE 200A 1

4 3712-440002-00 WASHER-CU 1

5 0000-000196-00 NUT M8 2

6 0000-000074-00 SCREW M6×20 4

7 1280-560003-00 CONTACTOR 1

8 0000-000380-00 FLATWASHER Ø6 6

9 0000-000056-00 LOCKWASHER Ø6 6

10 0000-000077-00 SCREW M6×12 2

11 1120-530006-00 COPPER CONDUCTOR 1

12 2110-500007-00-E0 CONTROLLER 1

13 0000-000004-00 SCREW M5×12 4

14 0000-000206-00 LOCKWASHER Φ5 4

15 0000-000390-00 FLATWASHER Φ5 4

16 1280-560002-10-90 EPS CONTROLLER 1

17 0000-000032-00 SCREW M6×25 4

18 0000-000321-00 SCREW M8×20 4

19 0000-000159-00 LOCKWASHER Φ8 4

20 0000-000540-00 FLATWASHER Φ8 4

21 3316-730003-00 GROUND RESISTANCE LINE 1

BL-V08-1015 - 11-29-2016 12-45

 R7259

Figure 12-17 Wiring Harness

12-46 BL-V08-1015 - 11-29-2016

 WIRING HARNESS

Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial num-
1 3712-420001-00 WIRE HARNESS 1
ber 224150054
Used from serial num-
1a 3712-420001-C0 WIRE HARNESS 1
ber 224150055

BL-V08-1015 - 11-29-2016 12-47

 R7260

Figure 12-18 Wiring Cables - Used up to serial number 224150054

12-48 BL-V08-1015 - 11-29-2016

 WIRING CABLES - USED UP TO SERIAL NUMBER 224150054

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-412000-00 BATTERY CABLE 1

2 3712-411000-00 POWER CABLE 1

3 3712-410005-00 STEERING CONTROLLER CABLE + 1

4 3712-410008-00 PUMP MOTOR CABLE - 1

5 3712-410009-00 PUMP MOTOR CABLE + 1

6 3712-410004-00 STEERING CONTROLLER CABLE - 1

7 3712-410003-00 DRIVE MOTOR CABLE W 1

8 3712-410001-00 DRIVE MOTOR CABLE U 1

9 3712-410002-00 DRIVE MOTOR CABLE V 1

10 3712-410007-00 STEERING MOTOR CABLE W 1

11 3712-410006-00 STEERING MOTOR CABLE U 1

12 3712-430000-0A BATTERY BOX ASSEMBLY 1

BL-V08-1015 - 11-29-2016 12-49

 R8220

Figure 12-19 Wiring Cables - Used from serial number 224150055

12-50 BL-V08-1015 - 11-29-2016

 WIRING CABLES - USED FROM SERIAL NUMBER 224150055

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-412000-00 BATTERY CABLE 1

2 3712-411000-00 POWER CABLE 1

3 3712-410005-00 STEERING CONTROLLER CABLE + 1

4 3712-410008-00 PUMP MOTOR CABLE - 1

5 3712-410009-00 PUMP MOTOR CABLE + 1

6 3712-410004-00 STEERING CONTROLLER CABLE - 1

7 3712-410003-00 DRIVE MOTOR CABLE W 1

8 3712-410001-00 DRIVE MOTOR CABLE U 1

9 3712-410002-00 DRIVE MOTOR CABLE V 1

10 3712-410007-00 STEERING MOTOR CABLE W 1

11 3712-410006-00 STEERING MOTOR CABLE U 1

12 3712-430000-0A BATTERY BOX ASSEMBLY 1

13 3712-440003-C0 CONTROLLER CABLE 1

BL-V08-1015 - 11-29-2016 12-51

 R7263

Figure 12-20 Hydraulic System

12-52 BL-V08-1015 - 11-29-2016

 HYDRAULIC SYSTEM

Qty.
Pos. Part Number Description Notes
Reqd.
1 3218-750000-A0 THREE-WAY VALVE 1

2 3712-580000-0A OIL TUBE 1

3 3712-510000-0A OIL TUBE 1

4 2707-141400-00 JOINT G1/4-M14×1.5 3

5 0000-000044-00 WASHERΦ14 8

6 2702-141600-00 JOINT G1/4-M16×1.5 2

7 3712-590000-00 JOINT 1

8 0000-000334-00 WASHERΦ24 2

9 2701-221600-00 JOINT M22×1.5-M16×1.5 1

10 0000-000639-00 O-RING 19.0×2.65 1

11 2701-201600-00 JOINT M20×1.5-M16×1.5 3

12 0000-000638-00 O-RING 17.0×2.65 3

13 3712-530000-00 OIL TUBE 2

15 3712-520000-30 OIL TUBE 1

16 0000-000322-00 SCREW M8×25 2

17 0000-000159-00 LOCKWASHER Φ8 2

18 0000-000210-00 FLATWASHER Φ8 2

19 3712-570000-00 OIL TUBE 1

20 3712-550000-00 OIL TUBE 1

21 3712-540000-0A OIL TUBE 1

22 3712-560000-00 OIL TUBE 1

23 3712-460000-00 PUMP & MOTOR ASSEMBLY 1

24 3712-420003-00 WIRE HARNESS 1

25 1220-520014-00 LINE 3

28 3712-505000-00 JOINT GOVERNOR VALVE 1

29 3712-504000-00 GOVERNOR VALVE 1

30 3712-503000-00 JOINT M20×1.5-M22×1.5 1

BL-V08-1015 - 11-29-2016 12-53

 R7265

Figure 12-21 Pump And Motor Assembly

12-54 BL-V08-1015 - 11-29-2016

 PUMP AND MOTOR ASSEMBLY

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-460001-00 VALVE BODY 1

2 3712-450002-00 PUMP 1

3 3712-460003-00 MOTOR 1

4 3712-460004-00 SEAL KIT 1

5 3712-460005-00 FILTER SCREEN 1

6 3712-460006-00 SCREW 1

7 3712-460007-00 ADAPTER 1

8 3712-460008-00 SOLENOID 1

9 3712-460009-00 CABLE 1

10 3712-460010-00 WIRE 1

11 3712-460011-00 CLAMP 1

12 3712-460012-00 FLOW CONTROL VALVE 2

13 3712-460013-00 PLUG 1

14 3712-460014-00 ELBOW 1

15 3712-460015-00 TUBE 2

16 3712-460016-00 FILTER 1

17 3712-460017-00 BRUSH 1

BL-V08-1015 - 11-29-2016 12-55

 R7268

Figure 12-22 Reservoir

12-56 BL-V08-1015 - 11-29-2016

 RESERVOIR

Qty.
Pos. Part Number Description Notes
Reqd.
1 3712-161000-0A RESERVOIR 1

2 0000-000634-00 WASHER, M18 1

3 0000-001100-00 DRAIN PLUG 1

4 0000-000255-00 BOLT, M8 X 20 17

5 0000-000159-00 WASHER, LOCK, M8 17

6 0000-000210-00 WASHER, FLAT, M8 3

7 3125-710001-00 GASKET 1

8 0000-000540-00 WASHER, FLAT, M8 12

9 3712-162000-0A RESERVOIR COVER 1

10 2125-423000-00 BREATHER, DIP STICK 1

11 3712-450016-00 BOLT, M6-1 X 16 4

12 0000-000056-00 WASHER, LOCK, M6 4

13 1120-500003-00 HORN 1

14 3218-110010-00 MAGNET 1

15 0000-000550-00 NUT, M8 2

16 3712-160001-00 CLAMP 1

BL-V08-1015 - 11-29-2016 12-57

 R7270

Figure 12-23 Load Wheel And Tilt Mounting

12-58 BL-V08-1015 - 11-29-2016

 LOAD WHEEL AND TILT MOUNTING

Qty.
Pos. Part Number Description Notes
Reqd.
1 3316-140100-00 LOAD WHEEL 2

2 3316-141000-00 BRAKE ASSEMBLY 2

3 3316-140001-00 BRAKE COVER 2

4 0000-000892-00 SEAL, B55 X 75 X 8 2

5 0000-000936-00 BEARING 4

6 0000-000928-00 WASHER, M36 2

7 0000-000927-00 NUT, M36 X 1.5 2

8 3316-140002-00 DUST COVER 2

9 0000-000122-00 WASHER, LOCK, M4 6

10 0000-000702-00 WASHER, FLAT, M4 6

11 0000-000646-00 SCREW, M4 X 10 6

12 0000-000063-00 WASHER, LOCK, M10 8

13 0000-000007-00 WASHER, FLAT, M10 8

14 0000-000070-00 SCREW, M10 X 25 8

15 0000-000159-00 WASHER, LOCK, M8 12

16 0000-000321-00 SCREW, M8 X 20 12

17 3218-810000-00 TILT CYLINDER 2

18 3712-500001-00 LIMIT BLOCK, FORWARD 2

19 3712-500002-00 LIMIT BLOCK, BACKWARD

20 3218-840000-00 SHAFT 4

21 0000-000242-00 BOLT, M8 X 16 4

22 0000-000159-00 WASHER, LOCK, M8 4

See Lift Carriage sec-

23 — LIFT CARRIAGE 1
tion

BL-V08-1015 - 11-29-2016 12-59

 R7282

Figure 12-24 Lift Chain

12-60 BL-V08-1015 - 11-29-2016

 LIFT CHAIN

Qty.
Pos. Part Number Description Notes
Reqd.
1 2125-640001-00 ADJUSTING BOLT 1

2 0000-000187-00 NUT, M16 X 1.5 3

3 0000-000188-00 COTTER PIN, M3.2 X 20 2

4 2125-640002-00 PIN 2

CHAIN I (MOUNTS ON FREE

5a 2125-651000-30-01 1
LIFT CYLINDER (55 LINKS)

CHAIN II (MOUNTS ON SECONDARY Two Chains per truck

5b 2125-652000-30-01 1
LIFT CYLINDER (85 LINKS) needed.

6 2125-640003-00 CHAIN ANCHOR 1

7 0000-000686-00 COTTER PIN, M3.2 X 32 1

8 0000-000176-00 WASHER, FLAT, M8 2

BL-V08-1015 - 11-29-2016 12-61

 R7280

Figure 12-25 Lift Carriage

12-62 BL-V08-1015 - 11-29-2016

 LIFT CARRIAGE

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000221-00 BOLT, M12 X 30 4

2 0000-000060-00 WASHER, LOCK, M12 4

3 0000-000373-00 WASHER, FLAT, M12 4

5 2125-631104-00 SCREW 4

6 2125-612007-00 SNAP RING 4

7 2125-612002-00 ROLLER ASSEMBLY 4

8 2125-612001-00 ROLLER ASSEMBLY 4

9 2125-612005-00 DUST SEAL 4

10 0000-000183-00 RETAINING RING 4

11 3712-621000-30 LIFT CARRIAGE 1

12 2125-630001-00 FORK 1

13 2125-630001-10 PIN ASSEMBLY 2

14 2125-631100-00 ROLLER ASSEMBLY 4

15 3712-622000-00 LOAD BACK REST 1

16 3712-623000-00 EXTERNAL SIDE SHIFT 1

16a 3712-623100-00 SIDE SHIFT CYLINDER 1 Not show in picture

KIT 3712-WCYG-0A SEAL KIT FOR SIDE SHIFT CYLINDER 1 Not show in picture

KIT 3712-WHK-0A SLIDER KIT 1 Not show in picture

BL-V08-1015 - 11-29-2016 12-63

 R7272

Figure 12-26 Mast

12-64 BL-V08-1015 - 11-29-2016

 MAST

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000324-00 SCREW, M10 x 30 2

2 0000-000063-00 WASHER, LOCK, M10 6

3 0000-000651-00 WASHER, FLAT, M10 2

4 2125-600007-00 BRACKET 1

5 2125-600001-30 RAM HEAD 1

6 0000-000183-00 RETAINING RING 12

7 2214-600001-00 SHEAVE 4

8 2125-420000-30-01 FREE LIFT CYLINDER 1

9 2125-612005-00 DUST SEAL 8

10 2125-612002-00 ROLLER 8

11 2126-612001-00 ROLLER ASSEMBLY 8

12 2125-612007-00 SNAP RING 8

13 2125-612004-00 SCREW 8

14 -- INNER MAST 1

15 0000-000284-00 BOLT, M12 X 30 4

16 0000-000060-00 WASHER, LOCK, M12 2

17 0000-000373-00 WASHER, FLAT, M12 2

18 0000-000517-00 BOLT, M12 X 50 1

19 0000-000427-00 WASHER, FLAT, M12 3

20 2125-600002-30 SHEAVE 1

21 2125-600003-00 BUSHING 1

22 -- MIDDLE MAST 1

BL-V08-1015 - 11-29-2016 12-65

 R7272

Figure 12-26 Mast - Continued

12-66 BL-V08-1015 - 11-29-2016

 MAST - CONTINUED

Qty.
Pos. Part Number Description Notes
Reqd.
23 2125-612000-00 ROLLER ASSEMBLY 8

24 0000-000244-00 BOLT, M10 x 30 4

25 -- OUTER MAST 1

26 0000-000026-00 SCREW, M8 X 30 2

27 2214-600005-00 SHIM A.R. As Required

28 2125-600006-30 CYLINDER SUPPORT 2

29 2125-600005-30 CLAMP 2

30 2125-410000-30-01 SECONDARY LIFT CYLINDER 2

31 0000-000425-00 NUT, M10 4

32 0000-000913-00 BOLT, M10 X 40 1

33 0000-000007-00 WASHER, FLAT, M10 4

34 2125-651000-30-01 CHAIN I 2

35 2125-652000-30-01 CHAIN II 2

36 3712-600001-30 PLATE 1

37 0000-000255-00 BOLT M8 X 20 2

38 0000-000159-00 LOCKWASHER Ø8 2

39 0000-000176-00 FLATWASHER Ø8 2

BL-V08-1015 - 11-29-2016 12-67

 R7273

Figure 12-27 Hydraulic Pipes

12-68 BL-V08-1015 - 11-29-2016

 HYDRAULIC PIPES

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000069-00 WASHER, M16 8

2 2706-161600-00 FITTING, M16 X 1.5-M16 X 1.5 2

3 2125-480000-30 TUBE ASSEMBLY 2

4 2125-400002-3A MANIFOLD 1

5 2125-450000-00 RELIEF VALVE 2

6 0000-000154-00 SCREW, M8 X 35 2

7 2702-142000-00 FITTING, G1/4-M20 X 1.5 1

8 0000-000044-00 WASHER, M14 1

9 2125-430000-3B TUBE ASSEMBLY 1

10 2125-450000-3A TUBE ASSEMBLY 1

11 2706-162000-10 FITTING, M16 X 1.5-M20 X 1.5 1

12 2125-440000-3A-01 HOSE ASSEMBLY 1

13 2701-161600-00 FITTING, M16 X 1.5-M16 X 1.5 2

14 0000-000109-00 SCREW, M8 X 16 3

15 0000-000159-00 WASHER, LOCK, M8 3

16 0000-000176-00 WASHER, FLAT, M8 3

BL-V08-1015 - 11-29-2016 12-69

 R7278

Figure 12-28 Hydraulic Side Shift

12-70 BL-V08-1015 - 11-29-2016

 HYDRAULIC SIDE SHIFT

Qty.
Pos. Part Number Description Notes
Reqd.
1 3215-860100-30 MANIFOLD 1

2 2130-440000-4A-01 TUBE ASSEMBLY 2 To Side Shifter Valve

3 3215-860200-30 TUBE ASSEMBLY 1

4 3712-631000-30-01 TUBE ASSEMBLY 2 To Main Control Valve

5 3215-864003-00 MOUNTING BLOCK 1

6 0000-000322-00 SCREW, M8 X 25 4

7 0000-000159-00 WASHER, LOCK, M8 4

8 0000-000176-00 WASHER, FLAT, M8 4

9 3215-864002-00 MOUNTING PLATE 1

10 2701-161600-00 FITTING, M16 X 1.5 X M16 X 1.5 4

11 3712-632000-30 TUBE ASSEMBLY 2

12 0000-000185-00 SCREW, M8 X 16 2

13 0000-000242-00 SCREW, M8 X 16 2

BL-V08-1015 - 11-29-2016 12-71

 R7284

Figure 12-29 Free Lift Cylinder

12-72 BL-V08-1015 - 11-29-2016

 FREE LIFT CYLINDER

Qty.
Pos. Part Number Description Notes
Reqd.
— 2125-420000-30-01 FREE LIFT CYLINDER 1

— 2125-2ZG SEAL KIT 1 Includes Pos. # 1,3 & 5

1 0000-000045-00 WIPER RING, 55 X 63 X 5-6.5 1

2 0000-000684-00 COLLAR, 55 X 65 X 3 1

3 0000-000046-00 ROD PACKING 1

4 2125-420002-30 GLAND NUT 1

5 0000-000685-00 O-RING, M65 X 3.1 1

6 2125-420001-30-01 PISTON ROD 1

7 2125-420003-30 BACK UP RING, 70 X 65 X 25 1

8 2125-421000-30-01 CYLINDER BODY 1

9 0000-000518-00 SCREW, M5 X 6 1

10 2125-410003-30 WASHER 1

BL-V08-1015 - 11-29-2016 12-73

 R7285

Figure 12-30 Secondary Lift Cylinder

12-74 BL-V08-1015 - 11-29-2016

 SECONDARY LIFT CYLINDER

Qty.
Pos. Part Number Description Notes
Reqd.
— 2125-410000-30-01 SECONDARY LIFT CYLINDER 1

— 2125-2BG SEAL KIT 1 Includes Pos. # 1,2,4 & 13

1 0000-000084-00 WIPER RING, 35 X 43 X 5-6.5 1

2 0000-000085-00 ROD PACKING, 35 X 45 X 6 1

3 2125-410004-30 GLAND NUT 1

4 0000-000519-00 O-RING, M48 X 3.1 1

5 2125-410001-30-01 PISTON ROD 1

6 2125-410005-30 BUSHING 1

7 0000-000520-00 RETAINING RING, M24 1

8 2125-410002-30 BACK UP RING 1

9 2125-411000-30-01 CYLINDER BODY 1

10 2125-410006-30 PIN 1

11 0000-000518-00 SCREW, M5 X 6 1

12 2125-410003-30 WASHER 1

13 0000-000609-00 O-RING, 52.5 X 3.1 1

BL-V08-1015 - 11-29-2016 12-75

 R7290

Figure 12-31 Tilt Cylinder

12-76 BL-V08-1015 - 11-29-2016

 TILT CYLINDER

Qty.
Pos. Part Number Description Notes
Reqd.
— 3218-810000-00 TILT CYLINDER 1

— 3215-3QG SEAL KIT 1 Includes Pos. # 8,10,13 & 16

1 58603-15T11 ROD END 1

2 3218-810008-00 BEARING 1

3 0000-000849-00 RETAINING RING, M47 1

4 0000-000850-00 BOLT, M14 X 1.5 X 45 1

5 0000-000233-00 WASHER, LOCK, M14 1

6 0000-000229-00 NUT, M14 X 1.5 1

7 3218-810002-00 DUST SEAL 1

8 3218-810006-00 O-RING 1

9 58605-15T11 SNAP RING 1

10 3218-810005-00 SEAL 1

11 58602-15T11 GLAND NUT 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 1

19 GB/T1153 GREASE FITTING 1

BL-V08-1015 - 11-29-2016 12-77

 R8051

Figure 12-32 Brake Assembly

12-78 BL-V08-1015 - 11-29-2016

 BRAKE ASSEMBLY

Qty.
Pos. Part Number Description Notes
Reqd.
1 3715-420100-00 BRAKE SHOE ASSEMBLY 2

2 3715-420001-00 LEVER,PULL 1

3 3715-420002-00 PIN 1

4 3715-420003-00 SPRING WASHER 1

5 3715-420004-00 COTTER PIN 1

6 3715-420200-00 BRAKE CYLINDER ASSEMBLY 1

7 3715-420005-00 SUPPORT PIN 2

8 0000-001052-00 BOLT M 6×10 5

9 3715-420006-00 LEVER,PUSH 1

10 3715-420007-00 RETURN SPRING, UP 2

11 3715-420008-00 RETURN SPRING, UNDER 1

12 3715-420300-00 ADJUSTER 1

13 3715-420009-00 DUST COVER 1

14 3715-420010-00 LEVER,SPRING 2

15 3715-420011-00 SPRING 2

16 3715-420012-00 SEAT,SPRING 4

17 3715-420013-00 CONNECTING PLATE 1

18 0000-000056-00 SPRING WASHER Φ6 3

19 3715-420014-00 BOLT M 8×1.25×20 2

20 3715-420015-00 SPRING WASHER 2

21 3316-141001-00 BASEPLATE 1

KIT 3715-ZDBG-00 SEAL KIT FOR PUMP CYLINDER 1

BL-V08-1015 - 11-29-2016 12-79

Big Lift LLC