PARTS MANUAL

ELECTRIC FORKLIFT
MODEL: EVX 15-20 MAX

PART NO : PMEVX15-20MAX-02 JAN 2021

FRAME ASSEMBLY
 FRAME ASSEMBLY

ITEM
PART NUMBER DESCRIPTION QTY. REMARKS
NO.
1 MH799201121 FRAME WELD'T 1

2 MH799215039 SIDE COVER RIGHT SIDE 1

3 MH799215023 SIDE COVER LEFT SIDE 1

4 MH992791515 SPRING WASHER 8 M6

5 MH992275212 HEX. HEAD BOLT 8 M6x12LG.

6 MH799201131-06 THICK PLATE 1 562x120x8mm

7 MH992785644 PLAIN WASHER 4 M12

8 MH992276377 HEX. HEAD BOLT 4 M6x30LG.

MH796412512 Seat Assy 1

MH799215042 FRP Battery Top Cover 1

MH16940 Seat Belt 1

PARTS FOR EVX20MAX MODEL WITH SIDE EXTRACTER BATTERY

S/n Part No Description Qty

MH799264053
1 COUNTERWEIGHT COVER 1
MH799264028
2 LH SIDE COVER EVX 20 SE 1
MH799264012
3 RH SIDE COVER EVX 20 SE 1
MH799264032
4 Battery HOOD EVX 20 SE 1
MH799215144
5 SIDE COVER BRACKET -EVX 15-2 4
MH799215164
6 LH SIDE COVER VER. BKT -EVX 15-20 2
MH799215179
7 RH SIDE COVER VER. BKT -EVX 15-20 2
MH799251804
8 SIDE FRP COVER LOCK HINGH LH 1
MH799251814
9 IDE FRP LOCK HINGH RH 1
DRIVE AXLE ASSEMBLY
 DRIVE AXLE ASSEMBLY

ITEM NO. PART NUMBER DESCRIPTION QTY. REMARKS

1 MH40497 Gear Box + AXLE 1
1A MH40495 GEAR BOX 1
1B MH40496 DRIVE AXLE 1
1C GASKET 1
2 *MH40493 DRIVE MOTOR(CFR) 1
3 MH992186484 HEX. HEAD BOLT 5 M14x155LG.
4 MH992791555 SPRING WASHER 5 M14
5 MH992781654 PLAIN WASHER 5 M14
6 MH015492400 O-RING 1
*MH40942 AC Traction Motor (PM) 1
MH42480 Encoder Hall Effect 1
MHENCHE469 Encoder Probe Type 1 64 Pulse
TEER AXLE ASSEMBLY
ITE
PART
M DESCRIPTION QTY REMARKS
NUMBER
NO.
MH7992030
1 STEER AXLE WELD'T FINISHED 1
81
MH7982071
2 BUSH FOR STEERING KNUCKLE 4
33
STEER CYLINDER Sundaram (Sim
3 *MH42494 1
MH42033)
MH9927915
4 SPRING WASHER M12 4
45
MH9921754
5 HEX. HEAD BOLT 4 M12x70 LG.
27
MH7992031
6 STEER KNUCKLE L.H 1
02
MH7992030
7 STEER KNUCKLE R.H. 1
92
MH7982071
8 STEERING KNUCKLE PIN 2
43
MH7982071
9 THRUST BEARING 2
74
MH9925735
10 GRUB SCREW 2 M16x40LG.
01
MH9927630
11 LOCK NUT 2 M16x1.5P
17
MH7992031
12 CONNECTING LINK ASSEMBLY 4
14
13 MH17265 HEADED PIN 4
MH9927856
14 PLAIN WASHER 16 M14
54
MH9928262
15 SPLIT PIN 4 Ø3x20LG.
20
MH2381830
16 EXPANSION PLUG 2
0
MH9921712
17 HEX. HEAD BOLT 2 M6x20 LG.
16
MH7982071
18 REAR WHEEL HUB 2
22
 MH7982071
19 TRAIL WHEEL BOLT 10
54
MH7982071
20 TRAIL WHEEL NUT 10
64
MH9933611
21 OUTER TAPER ROLLER BEARING 2
37
MH9933611
22 INNER TAPER ROLLER BEARING 2
40
MH9934321
23 OIL SEAL 2
35
MH7853243
24 GREASE NIPPLE 4
00
MH797903013 Bushing trail axle 2

MH799209448 Hose Kit Stear Axle 1

ITEM PART REMARKS
DESCRIPTION QTY.
NO. NUMBER
25 MH014984900 SLOTTED NUT 2 1 1/4" UNF
26 MH015420400 SPLIT PIN 2
27 MH514008300 HUB CAP 2
28 MH993791106 GREASE NI[PPLE 8 M6
29 MH09186 BUSH 8
COUNTERWEIGHT ASSEMBLY
 COUNTERWEIGHT ASSEMBLY

ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.
COUNTERWEIGHT
1 MH799204031 1
ASSEMBLY
2 MH992176621 HEX. HEAD BOLT 2 M20x180 LG.

3 MH870001204 SPECIAL WASHER 4 OD60XID26X6

4 MH08724 HEX. NUT 2 M20

5 MH992176614 HEX. HEAD BOLT 2 M20x110 LG.

6 MH799204043 COUNTERWEIGHT COVER 1

7 MH992271421 HEX. HEAD BOLT 2 M12x40LG.

8 MH992785644 PLAIN WASHER 2 M12

COWL ASSEMBLY
 COWL ASSEMBLY
ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.
1 MH799215063 STEERING COVER BACK 1
2 MH799215053 STEERING COVER FRONT 1
3 MH797905233 PARKING BRAKE 1
4 MH799215082 LH COWL COVER 1
5 MH799215012 RH COWL COVER 1
6 MH992275295 HEX. HEAD BOLT 6 M8x20 LG.
7 MH992791525 SPRING WASHER 8 M8
8 MH992781624 PLAIN WASHER 6 M8
9 MH992275377 HEX. HEAD BOLT 2 M10x30 LG.
10 MH992791535 SPRING WASHER 2 M10
11 MH992781634 PLAIN WASHER 2 M10
HEX. SOCKET HEAD CAP
12 MH992571295 2 M8x20 LG.
SCREW
13 MH992781604 PLAIN WASHER 9 M6
14 MH992275215 HEX. HEAD BOLT 9 M6x20 LG.
STEERING COLUMN ASSEMBLY
 STEERING COLUMN ASSEMBLY

ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.
1 MH799804023 STEERING COLUMN 1
2 MH799213043 STEERING COLMN. MTG. BKT. 1
3 MH42046 STEERING UNIT 1
4 *MH796415029 STEERING WHEEL 1
5 MH992781634 PLAIN WASHER 8 M10
6 MH992791535 SPRING WASHER 8 M10
7 MH992275377 HEX. HEAD BOLT 6 M10x30 LG.
8 MH13920 U' BOLT 1
9 MH992761214 HEX. NUT 2 M10
10 MH40468 COMBINATION SWITCH 1
11 MH799215104 SMALL STEERING BRKT FRONT 1
12 MH799215114 SMALL STEERING BRACKET CLAMP 1
13 MH799215134 STEERING BRACKET CLAMP 1
14 MH799215124 STEERING BRACKET FRONT 1
15 MH992791515 SPRING WASHER 4 M6
16 MH992571214 HEX. HEAD BOLT 6 M6x16 LG.
*MH42109 Steering Wheel(Dia 325) 1
MH799213034 Cowl Mounting Brkt 1
CONTROL VALVE LINKAGE ASSEMBLY
ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.

1 MH799209213 CONTROL VALVE PLATE 1

2-SPOOL CONTROL VALVE

2 MH42052 1
WALVOIL

3 MH799209224 LEVER BKT WELD'T 1

4 MH799209264 YOKE END 2

5 MH799209254 AUX CONTROL ROD 2

6 MH799209233 HOIST HANDLE WELD'T 2

7 MH500067906 ROLL PINS 2

8 MH799209244 Handle PIN 1

9 MH799209274 Yoke PIN 2

10 MH992275295 HEX. HEAD BOLT 4 M8x80 LG.

11 MH992791525 SPRING WASHER 3 M8

12 MH992826140 SPLIT PIN 4 Ø3 X 20LG.

13 MH798722214 KNOB - CONTROL VALVE TILT 1

14 MH798722224 KNOB - CONTROL VALVE HOIST 1

15 MH992781624 PLAIN WASHER 3 M8

16 MH992573176 GRUB SCREW 3 M5 X 6LG.

MH12969 LIMIT S/W 2

 BRAKE ASSEMBLY

ITEM PART
DESCRIPTION QTY. REMARKS
NO. NUMBER
1 MH799214023 BRAKE MOUNTING PLATE 1
2 MH799214033 BRAKE LEVER WELD'T 1
3 MH870001211 MAST CYL ASSY 1 7/8"
4 MH063681200 PEDAL PAD 1
5 MH60309600 RETURN SPRING 1
6 MH799214064 ROD END 1
7 *MH785577603 BRAKE PIN 1
8 MH014936900 HEX. HEAD NUT 2 3/8"-16UNF
9 MH15026400 PLAIN WASHER 4
10 MH870001359 LOCK NUT 1
11 MH992275379 HEX HEAD BOLT 1 M10 X 50LG.
12 MH992761014 HEX. NUT 1 M10
13 MH992275297 HEX HEAD BOLT 1 M8 X 30LG.
14 MH992781624 PLAIN WASHER 2
15 MH992761013 HEX. NUT 1 M8
16 MH992826232 SPLIT PIN. 1 Ø3 X 32LG
17 MH60930300 HEX HEAD BOLT 2 3/8"-16UNF- 3-1/4 LG
18 MH798205064 BUSH 1
BRAKE ASSEMBLY
• MH014607000 Rod End Pin 1

Brake Spares related to Drive Axle

1 MH4049618 Brake left 1

2 MH40449624 Brake right 1
3 MH40497021 (Brake Shoe) Liner 4
4 MH40497041 Wheel Cylinder 2
BRAKE TUBE ASSEMBLY
 BRAKE TUBE ASSEMBLY

SR. NO. PART NO. DESCRIPTION QTY REMARKS

1 MH870001211 MASTER CYLINDER 1
2 MH870001394 BANJO ADAPTOR 1
3 MH08782 BRAKE HOSE 1
4 *MH013370100 TEE 1
5 MH799214043 LH BRAKE TUBE 1
6 MH799214059 RH BRAKE TUBE 1
*MH09947 Brake TEE Fitting
DIFFERENTIAL ASSY
Reduction Assy
 1、Differential assy
S. No Part No. Part Name Qty M/C Remark

GB/T276-1994 Deep Groove ball

1-1 2 MH4049501
(6211) bearing

1-2 GB6170-86 M10 Nut 12 MH4049502

1-3 10113-50141 Anti-loose plate 6 MH4049503

Case, cross joint

1-4 15413-52031 1 MH4049504
(L.H.)

20113-53181 2 MH4049505

20113-52181 2 MH4049506
1-5 Washer
20113-51181 2 MH4049507

20113-50181 2 MH4049508

1-6 WH-DC25-01-05 Gear, side 2 MH4049509

1-7 15413-52051 Shaft, pinion Ⅱ 1 MH4049510

1-8 15413-52081 Washer 4 MH4049511

 15413-52091 4 MH4049512

15413-52101 4 MH4049513

1-9 15413-52072 Gear, pinion 4 MH4049514

1-10 15413-52041 Shaft, pinion Ⅰ 1 MH4049515

Case, cross joint

1-11 15413-52021 1 MH4049516
(R.H.)

1-12 GB119-76 (B6×25) Taper pin 1 MH4049517

1-13 181N3-52001 Ring Gear 1 MH4049518

1-14 15413-52011 Bolt for ring gear 12 MH4049519

S. No Part No. Part Name Qty M/C Remark

2、Reduction assy

15413-22021 Bolt for bearing

2 4 MH4049520
(M14×1.5-88) cap

3 10113-50131 Anti-loose plate 2 MH4049521

4 15413-22011a Bearing cap 2 MH4049522

5 WH-DC25-01-01 Housing 1 MH4049523

6 GB119-86 (B10×25) Taper pin 2 MH4049524

GB/T276-1994 Deep groove ball

7 3 MH4049525
(6305) bearing
8 181N3-22001 Dual gear 1 MH4049526

9 181E3-22021 Pinion 1 MH4049527

10 WH-DC25-01-02 Housing 1 MH4049528

GB5783-86
11 Hex head screw 2 MH4049529
(M12×50)

12 GB93-87 (12) Spring washer 8 MH4049530

Deep groove ball

13 GB/T276-1994 (6206) 2 MH4049531
bearing

GB5783-86
14 Hex head screw 4 MH4049532
(M10×25)

15 GB93-87 (10) Spring washer 6 MH4049533

16 WH-DC25-01-03 Retainer 1 MH4049534

GB1235-76
17 O ring 1 MH4049535
(80×3.1)

GB/T276-1994 (6208- Deep groove ball

18 2 MH4049536
2RS) bearing

19 181E3-22001 Input pinion 1 MH4049537

GB1235-76
20 O ring 2 MH4049538
(25×2.4)

21 177H3-22051a Shaft 1 MH4049539

 GB/T276-1994 Deep groove ball
22 1 MH4049540
(6307) bearing

23 WH-DC25-01-04 Lock washer 1 MH4049541

GB5783-86
24 Hex head screw 2 MH4049542
(M10×16)

GB5783-86
25 Hex head screw 6 MH4049543
(M12×100)
1 MH4049618 Brake left 1
2 MH40449624 Brake right 1
3 MH40497021 (Brake Shoe) Liner 4
4 MH40497041 Wheel Cylinder 2

PUMP & MOTOR ASSEMBLY

870001754
 DC HYD MOTOR & PUMP ASSEMBLY
ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.
DC PUMP MOTOR
1 MH 40519 1
8KW/48V
HYDRAULIC PUMP
2 MH 17747 1
Dowty
3 MH 992785634 PLAIN WASHER 2 M10

4 MH 992791535 SPRING WASHER 2 M10

HEX. SOCKET HEAD
5 MH 992571377 2 M10 X 30LG.
CAP SCREW
6 MH 992785634 PLAIN WASHER 2 M10

7 MH 992791535 SPRING WASHER 2 M10

8 MH 992275376 HEX HEAD BOLT 1 M10 X 25LG.

Carbon Brush Hoist

9 MH17552A009 4
DC Motor
 AC HYD MOTOR & PUMP ASSEMBLY

ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.
AC PUMP MOTOR 10KW
1 MH42180 1
48V (PM)
2 MH17571 HYDRAULIC PUMP DOWTY 1

3 MH992785634 PLAIN WASHER 2 M10

4 MH992791535 SPRING WASHER 2 M10

HEX. SOCKET HEAD CAP
5 MH992571377 2 M10 X 30LG.
SCREW
6 MH992785634 PLAIN WASHER 2 M10

7 MH992791535 SPRING WASHER 2 M10

8 MH992275376 HEX HEAD BOLT 1 M10 X 25LG.

 36

35

34

40

39 39

37
41
32 41

31 27 27
25 26 26
25
30

24 28 29 33 23
19
38
18 20
42

22 18
5 6 4
21
7

6 9

44
10
17
16
11

21 14
13
8
8 15

43
3

12

1 1
 HYDRAULIC CIRCUIT

ITEM
PART NUMBER DESCRIPTION QTY. REMARKS
NO.
1 MH993750109 STRAIGHT ADAPTOR 2
2 MH799209063 HYDRUALIC BRAKE TUBE 2
3 MH993811160 HOSE (1600 LG.) 2 1/4" R1
4 MH11193 STRAIGHT ADAPTOR 2
5 MH11332 STRAIGHT ADAPTOR 1
6 MH993750612 90 DEG. SWIVEL ELBOW 3
7 MH799209184 HOSE (600 LG.) 1 3/8" R3
8 MH993728140 HOSE CLAMP 2
9 MH11304 STRAIGHT ADAPTOR 2
10 MH799209174 HOSE (1100 LG.) 1 1/2" R2
11 MH799209194 HOSE (500 LG.) 1 1/2" R2
12 MH799209033 HYRAULIC TANK 1
13 MH799806123 RETURN LINE FILTER 1
14 MH003338400 BARE HOSE 1 3/4" R3
15 MH799806114 BARE HOSE 1 1" R3
16 MH797006444 STRAIGHT ADAPTOR 1
17 MH42098 STRAIGHT ADAPTOR 1
18 MH00896 STRAIGHT ADAPTOR 2
19 MH08311 STRAIGHT ADAPTOR 2
20 MH44Z487D5 TEE FITTING 2
21 MH993728130 HOSE CLAMP 2
22 MH42111 90 DEG. ELBOW 1
23 MH993811055 HOSE (550 LG.) 2 1/4" R1
24 MH993811075 HOSE (750 LG.) 2 1/4" R1
25 MH870001109 90 DEG. SWIVEL ELBOW 4
26 MH00888 90 DEG. SWIVEL ELBOW 2
27 MH40680 90 DEG. ELBOW 1
28 MH17563 HOSE ASSY 3/4 UNF 90 D BEND 1
29 MH12698 HOSE 1
30 MH12619 TEE FITTING 1
31 MH12319 MANIFOLD 1
32 MH12648 STRAIGHT ADAPTOR 1
33 MH799201204 HOSE (550 LG.) 1 1/2" R2
34 MH14557 HOSE 1
35 12519 STRAIGHT FITTING 1

HYDRAULIC CIRCUIT

ITEM QTY
PART NUMBER DESCRIPTION REMARKS
NO. .
36 MH18319 HOSE 1
37 MH42086 90 DEG. SWIVEL ELBOW 1
38 MH42052 2 SPOOL CONTROL VALVE 1
39 **MH16208 SIDE CYLINDER 2
40 ***MH16201 CENTER CYLINDER 1
41 *MH40504 TILT CYLINDER 2
42 MH42046 STEERING UNIT 1
43 MH42180 PUMP MOTOR 10KW 48V (PM) 1
44 MH17571 HYDRAULIC PUMP 1
*MH42443 Tilt Cyl ( HVT ) Sundaram 1
*MH42031 Tilt Cyl(HVT ) DC12398 2
**MH42482 Side Lift Cyl RAM type 2
***MH42238 Centre Cyl Dantal 1
1
REAR TYRE ASSEMBLY
 REAR TYRE & RIM ASSY(MH79820422)

ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.
1 MH798204032 Spilt RIM 4.33”*8” 2

2 MH798204054 TYRE ASSEMBLY 18x7-8 2

FRONT TYRE ASSEMBLY
 FRONT TYRE & RIM ASSY(MH799212063)

ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.
FRONT RIM for 21” press on
1 MH799212033 2
Type
TYRE PRESS ON 21x7x15
2 MH799212044 2
Press on Type
TILT CYLINDER ASSEMBLY
 TILT CYLINDER ASSEMBLY

ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO
1 MH40503 TILT CYLINDER 1 HVM

MH42031 TILT CYLINDER 1 HVT

2 MH501900300 ROD END 1

3 MH509816101 Pin TILT CYL. (common) 1

4 MH502658100 PIN RETAINER 2

5 MH992791535 SPRING WASHER FOR M10 2

3/8" X 5/16"
6 MH55486700 HEX. HEAD BOLT 1
LG. GR-5
7 MH796414049 Rear PIN-TILT CYLINDER 1

8 MH992275374 HEX. HEAD BOLT 1 M10x16 LG.

3/4" X 3 1/4"
9 MH63894200 HEX. HEAD BOLT 1
LG. GR-5
10 MH14939500 HEX NUT 1 ¾” x 10 UNC
 HVM MAST ASSEMBLY

ITEM
PART NO. DESCRIPTION QTY. REMARKS
NO.

1 MH799206532 STATIONARY WELDMENT 1

2 MH799206492 ELEVATING WELDMENT 1

SIDE LIFT CYL RAM DC 6040 Sim

3 *MH16200 2
MH16018( Wipro)

MH42498 LIFT CYL (Sundaram make)

4 - -

5 MH785769001 NYLOCK NUT 2

6 MH10135 CARRIAGE LIFTING CHAIN . (118 LINKS) 2

8 - -

9 MH500353903 BEARING 2

10 MH992821555 HARDENED CYL PIN 2

11 - -

12 MH992175382 HEX HEAD SCREW M10*45LG 2

13 MH799226854 CYL CLAMP 2

14 MH508623301 CHAIN SHEEVE COMMON 2

15 MH12319 MANIFOLD 1

16 MH13614 FLOW REGULATOR( 2 HOLE) 1

17 - -

18 - -

19 MH799229438 HOSES & FIITINGS 1

 MH785324300 NIPPLE 2

20 MH512505100 LOCK PLATE 4

21 MH799227072 CARRIGE ASSY 1

22 MH504562101 WEAR PLUG W/Disc 4

MH42084 INTEGRAL BEARING EQV MH870001754 4

23 ELBOW 1

24 MH799226284 BUSHING 4

Mh799217123 Phos bronze bush for mast

HVT 2125 MAST ASSEMBLY
 HVT 2125 MAST ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY. REMARKS

1 MH799206422 STATIONARY WELDMENT 1
2 MH799206252 SECONDARY WELDMENT 1
PRIMARY ELEVATING
3 MH799206232 1
WELDMENT
4 *MH870001754 INTEGRAL BEARING 8
5 MH42482 SIDE HOIST CYL. ASSLY 2
6 MH42238 Central Cyl Dantal DC12756. 1
7 MH17295 SHEAVE Chain 4
8 MH500353903 BEARING 4
9 MH797930614 SHEAVE SUPPORT WELDMENT 1
10 MH17321 HOSE SHEAVE 1
11 MH12521 BUSHING 1
12 MH42086 90 DEG ELBOW 1
13 MH12139 MANIFOLD 1
14 **MH799206103 MAST BUSHING 2
15 MH12698 HOSE 1
16 MH17563 HOSE ASSY LH 1
17 MH12519 STRAIGHT FITTING 1
18 MH799206564 HOSE TAKE-UP BRACKET 1
19 MH797930584 CYL. CLAMP 2
20 MH014937500 NYLOCK NUT 4
21 MH060379000 EXT. CIRCLIP 4
22 MH00888 90 DEG. SWIVEL ELBOW 2
23 MH12619 TEE FITTING 1
24 MH721552700 90 DEG ELBOW 1
25 MH12648 STRAIGHT FITTING 1
26 MH10106 FLOW REGULATOR 4 HOLES 2
27 MH14557 HOSE 1
28 MH18319 HOSE 1
29 MH508990100 TILT PIVOT BUSHING 2
M12x100
30 MH992275433 HEX. HD. SCREW 2
LG.
M10x30
31 MH992275377 HEX SCREW 2
LG.
M10x30
32 MH992275370 HEX. HD. BOLT 2
LG.
 33 MH992791535 SPRING WASHER 7 M10
34 MH992761115 HEX. HD. NUT 6 M10
M10x65
35 MH992176386 HEX. HD. BOLT 2
LG.

HVT 2125 MAST ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY. REMARKS

36 MH504562101 WEAR PLUG 8
37 MH504560100 DISC - WEAR PLUG 8
38 MH992573419 GRUB SCREW 8 M12 X 35 LG.
39 MH992761015 HEX NUT 8 1/2"
40 MH785324300 LUBE FITTING 2
41 MH992551288 SOC. HD. SCREW 1 5/8" UNFx7/8" LG.
42 MH785769001 NYLOCK NUT 4
43 MH513837100 SPHERICAL WASHER 1
44 MH992246170 HEX. HD. SCREW 1 3/8" UNCx1 1/4" LG.
45 MH11493 SPACER 3
46 MH13344 CHAIN ASSY. 2 76 LINKS
47 MH515924419 Pre Lifting Chain 103link
48 MH40680 90 DEG. ELBOW 1
Integral bearing eqv
*MH42084 1
MH870001754
**MH799217123 Phos Bronze Bush for Mast 2
MH504560100 Sheave Chain (Common) 3
MH799209608 Hoses & Fitting Kit HVT2125 1
8
4
1

2
 HVT 2700 MAST ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY. REMARKS

MH799206612
1 STATIONARY WELDMENT 1
MH799206652
2 SECONDARY WELDMENT 1
MH799206662 PRIMARY ELEVATING
3 1
WELDMENT
4 *MH870001754 INTEGRAL BEARING 8
MH14635/

MH16206
5 SIDE HOIST CYL. ASSLY 2

MH15995
6 Central Cyl 1
7 MH17295 SHEAVE Chain 4
8 MH500353903 BEARING 4
9 MH797930614 SHEAVE SUPPORT WELDMENT 1
10 MH17321 HOSE SHEAVE 1
11 MH12521 BUSHING 1
12 MH42086 90 DEG ELBOW 1
13 MH12139 MANIFOLD 1
14 **MH799206103 MAST BUSHING 2
15 MH12698 HOSE 1
16 MH17563 HOSE ASSY LH 1
17 MH12519 STRAIGHT FITTING 1
18 MH799206564 HOSE TAKE-UP BRACKET 1
19 MH797930584 CYL. CLAMP 2
20 MH014937500 NYLOCK NUT 4
21 MH060379000 EXT. CIRCLIP 4
22 MH00888 90 DEG. SWIVEL ELBOW 2
23 MH12619 TEE FITTING 1
24 MH721552700 90 DEG ELBOW 1
25 MH12648 STRAIGHT FITTING 1
26 MH10106 FLOW REGULATOR 4 HOLES 2
27 MH14557 HOSE 1
28 MH18319 HOSE 1
29 MH508990100 TILT PIVOT BUSHING 2
 M12x100
30 MH992275433 HEX. HD. SCREW 2
LG.
M10x30
31 MH992275377 HEX SCREW 2
LG.
M10x30
32 MH992275370 HEX. HD. BOLT 2
LG.
33 MH992791535 SPRING WASHER 7 M10
34 MH992761115 HEX. HD. NUT 6 M10
M10x65
35 MH992176386 HEX. HD. BOLT 2
LG.
 HVT 2700 MAST ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY. REMARKS

36 MH504562101 WEAR PLUG 8
37 MH504560100 DISC - WEAR PLUG 8
38 MH992573419 GRUB SCREW 8 M12 X 35 LG.
39 MH992761015 HEX NUT 8 1/2"
40 MH785324300 LUBE FITTING 2
41 MH992551288 SOC. HD. SCREW 1 5/8" UNFx7/8" LG.
42 MH785769001 NYLOCK NUT 4
43 MH513837100 SPHERICAL WASHER 1
44 MH992246170 HEX. HD. SCREW 1 3/8" UNCx1 1/4" LG.
45 MH11493 SPACER 3
46 MH13344 CHAIN ASSY. 2 76 LINKS
47 MH515924419 Pre Lifting Chain 103link
48 MH40680 90 DEG. ELBOW 1
Integral bearing eqv
*MH42084 1
MH870001754
**MH799217123 Phos Bronze Bush for Mast 2
MH504560100 Sheave Chain (Common) 3
MH799209448
Hoses Kit 1

8
4
1

2
 CARRIAGE ASSEMBLY

ITEM
PART NUMBER DESCRIPTION QTY. REMARKS
NO.
1 MH799207112 CARRIAGE WELD'T 1
2 MH870001754 INTEGRAL BEARING 4
3 MH504562101 WEAR PLUG 4
4 MH504560100 DISC - WEAR PLUG 4
5 MH992573419 GRUB SCREW 4 M12x35 LG.
6 MH992761015 HEX NUT 4 1/2"
7 MH60313900 CIRCLIP (EXTERNAL) 4
8 MH11132 FORK 2 40x100x1070
9 MH799820042 LOAD BACK REST 1
10 MH992175420 HEX.BOLT 4 M12x35 LG.
11 MH992791545 SPRING WASHER 4 M12
COMPONENT LAYOUT FOR EVX20MAX FULLY AC
HEATSINK SIZE=204X235X43

PUMP CONTROLLER
+ +
1234-5271

4 3
2 1 +
+
POWER WIRING DIAGRAM FOR EVX20MAX FULLY AC

HEATSINK SIZE=204X235X43

+ +

PUMP CONTROLLER
1234-5271
+
+
r. No. Part No Item Description Qty Unit

1 MH470435421 Traction controller -1234SE

1232SE-5421+1232SE-5321
2 MH799208172 Controller2TACAC 1 No

3 MH470335321 Pump Controller -1232SE-

4 MH799208143 Main Wiring Harness AC+AC 1 No

5 MH799208063 Canopy Wiring Harness 1 No

MH61069525

6 Control panel wiring harness

7 MH799208153 Power Cable Set AC+AC 1 Set

FNR & Combination Switch

8 MH40468 (Honeywell) 1 No

9 MH512476400 12V DC Horn 1 No

10 MH18557 48V DC Reverse Horn 1 No

11 MH18555 48V DC LED Flasher 1 No

12 MH797016020 12V DC Head Light 2 No

13 MH10332 12V DC Signal & Parking light 2 No

14 MH42389/MH42388 Rear Indicator Light -RH/LH 2

15 MH016051600 ON - OFF Key Switch - 48V, 5A 1 No

16 MH17840701-0003 1 No
SPY Glass ( BDI)
POWER & CONTROL WIRING DIAGRAM FOR EVX20 MAX FULLY AC

FROM J1-19 OF 1236

TRACTION CONTROLLER
STEER I/P CN2-6

LIFT CN1-13 GREEN+YELLOW

CN2-1

TILT CN1-9 YELLOW

CN1-10 WHITE
SHIFT

CN1-7 GREY

INTERLOCK

CN3-6
MOTOR
TEMP
SENSOR CN3-5

CN5 LENGTH 0.5 MTRS.

 GRAY - IVS SW D
RED - IVS 12V E
RED - RED +5V C
WHITE - APS 0-5V A
BLACK - APS B- B
ACCLERATOR PEDAL - FP-FCV
LENGTH 0.5 MTRS.

ALL POWER CABLE 25Sqmm LAPP

 4 3
2 1

4 3
2 1

4 3
2 1

4 3
2 1

DIAGNOSTICS AND TROUBLESHOOTING

The 1236/38 controller detects a wide variety of faults or error conditions. Faults can be
detected by the operating system or by the VCL code. This section describes the faults detected
by the operating system. Faults detected by VCL code (faults 51–67 in Table 5) cannot be
defined here as they will vary from application to application. Refer to the appropriate OEM
documentation for information on these faults.
DIAGNOSTICS

Diagnostics information can be obtained in either of two ways: (1) by reading the
display on a 1311 programmer or (2) by observing the fault codes issued by the Status
LEDs. See Table 4 for a summary of LED display formats. The 1311 programmer will display all
faults that are currently set as well as a history of the faults that have been set since the history
log was last cleared. The 1311 displays the faults by name. The pair of LEDs built into the
controller (one red, one yellow) produce flash codes displaying all the currently set faults in a
repeating cycle. Each code consists of two digits. The red LED flashes once to indicate that the
first digit of the code will follow; the yellow LED then flashes the appropriate number of times
for the first digit. The red LED flashes twice to indicate that the second digit of the code will
follow; the yellow LED flashes the appropriate number of times for the second digit.

Example: Battery Under voltage (code 23).

In the Fault menu of the 1311 programmer, the words

The numerical codes used by the yellow LED are listed in the troubleshooting chart (Table 5),
which also lists possible fault causes and describes the conditions that set and clear each fault.
Summary of LED display formats

The two LEDs have four different display modes, indicating the type of information they are
providing.

TROUBLESHOOTING – 1236

The troubleshooting chart, Table 5, provides the following information on all the controller
faults:
• fault code

• fault name as displayed on the programmer’s LCD

• the effect of the fault

• possible causes of the fault

• fault set conditions

• fault clear conditions.

Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off KSI and
turn it back on to see if the fault clears. If not, shut off KSI and remove the 35-pin connector.
Check the connector for corrosion or damage, clean it if necessary, and re-insert it.
MAINTENANCE
There are no user serviceable parts in the Curtis 1236/38 controller. No attempt

should be made to open, repair, or otherwise modify the controller. Doing so may damage the
controller and will void the warranty. It is recommended that the controller and connections be
kept clean and dry and that the controller’s diagnostics history file be checked and cleared
periodically.

CLEANING
Periodically cleaning the controller exterior will help protect it against corrosion and
possible electrical control problems created by dirt, grime, and chemicals that are
part of the operating environment and that normally exist in battery

powered systems.

When working around any battery powered system, proper safety precautions should be
taken. These include, but are not limited to: proper training, wearing eye protection, and
avoiding loose clothing and jewelry.

Use the following cleaning procedure for routine maintenance. Never use a high pressure
washer to clean the controller.

1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load (such as a contactor coil)
across the controller’s B+ and B- terminals.

3. Remove any dirt or corrosion from the power and signal connector areas. The controller
should be wiped clean with a moist rag. Dry it before reconnecting the battery.

4. Make sure the connections are tight. Refer to Section 2, page 6, for maximum tightening
torque specifications for the battery and motor connections.

DIAGNOSTIC HISTORY

The 1311 programmer can be used to access the controller’s diagnostic history file. The
programmer will read out all the faults the controller has experienced since the last time the
diagnostic history file was cleared. Faults such as contactor faults may be the result of loose
wires; contactor wiring should be carefully checked. Faults such as overtemperature may be
caused by operator habits or by overloading.

After a problem has been diagnosed and corrected, it is a good idea to clear the diagnostic
history file. This allows the controller to accumulate a new file of faults. By checking the new
diagnostic history file at a later date, you can readily determine whether the problem was
indeed fixed.
COMPONENT LAYOUT EVX20MAX AC/DC

+ +

PUMP CONTROLLER
1253-4802

4 3
2 1
+
+
 ELECTRICAL SPARES EVX20MAX AC/DC

Sr.
No. Item Description Part no Qty

1 Traction Controller – 1234SE MH470435421 1No

Pump Controller - 1253 -4802

2 DC, 48V, 600A MH17724701 1No

3 Battery Charger MH17264 1No

4 MAIN1 Fuse 250A MH29221 1No

5 MAIN2 Fuse 355A MH14290A0002 1No

6 Pump Contactor SU80, 48V MH13223696 1No

7 MAIN2 Contactor SU60, 48V MH13222745 1No

8 Control Panel harness MH61069395 1No

Accelerator Assy with

9 Potentiometer 18140800-0003 1No

10 Battery connector MH17840701-003 2No

11 Cooling fan for controller(24V) Mh14290A0001 2No

POWER WIRING DIAGRAM EVX20MAX AC /DC

ARM.

+ +

PUMP CONTROLLER
1253-4802
+
+
 Sr. Part No Item Description Qty Unit
No.

1 1 No

2 MH799208053 Main Wiring Harness(AC/DC) 1 No

3 MH799208073 Canopy Wiring Harness 1 No

4 **MH799208073 Power Cable Set 1 No

FNR & Combination Switch

5 MH40468 (Honeywell) 1 No

6 MH512476400 12V DC Horn 1 No

7 MH18557 48V DC Reverse Horn 1 No

8 MH18555 48V DC LED Flasher 1 No

9 *MH797016020 12V DC Head Light 2 No

10 MH80124801123 Combination tail light 1 No

MH17840701-0003

11 Spy Glass( BDI) No

12 MH016051600 ON - OFF Key Switch - 48V, 5A 1 No

9 MH42324 Indicator light front 2

10 MH08995 STOP LIGHT S/W 1

11 MH797017393 BATTERY CONECTOR HANDLE 1

12 MH41005 48V 440AH 1181

1
POWER & CONTROL WIRING DIAGRAM FOR DC PUMP CONTROLLER

MAIN2
355A SW60
FUSE
CN2-6

KSI GREEN
FUSE TB1-1
YELLOW

(SS1) CN1-13 BROWN

Lift S/W

SS2 CN1-9
PINK

CN1-10
SS3 WHITE

TH-2
MAIN 2
SW60 J1
B- B+ 7 1

STATUS
LED
48/80V DC
BATTERY

12 6
M-
3 1 BLACK
4 2

J2

EVC255-(1253-4802)
GREY
J1-19 OF 1236
PUMP CONTROLLER
AC CONTROLLER J1
SERES MOTOR
1: KSI 7: SS1
2: POT HIGH 8: SS2
3: POT WIPER 9: SS3
GREEN
4: POT LOW 10:
5: INTERLOCK 11: LIFT LOCKOUT
6: STATUS LED 12: CONTACTOR
 ACCLERATOR PEDAL - FP-SCV (WIL)

GRAY - IVS SW D
RED - IVS 12V E
RED - RED +5V C
WHITE - APS 0-5V A
BLACK - APS B- B
LENGTH 0.5 MTRS.
 4 3
2 1

DIAGNOSTICS AND TROUBLESHOOTING – 1253 – pump

controller
The 1253 controller provides diagnostics information to assist technicians in
troubleshooting pump system problems. The diagnostics information can be obtained
by observing the appropriate display on the handheld programmer or the fault codes
issued by the optional Status LED. Refer to the troubleshooting chart (Table 5) for
suggestions covering a wide range of possible faults.

PROGRAMMER DIAGNOSTICS

The programmer presents complete diagnostic information in plain language. Faults are
displayed in the Faults Menu (see column 2 in the troubleshooting chart), and the status of the
controller inputs/outputs is displayed in the Monitor Menu.

Accessing the Fault History Menu provides a list of the faults that have occurred since the fault
history file was last cleared. Checking (and clearing)

the fault history file is recommended each time the vehicle is brought in for maintenance.

The following 4-step process is recommended for diagnosing and troubleshooting an

inoperative pump system: (1) visually inspect the vehicle for obvious problems; (2) diagnose the
problem, using the programmer; (3) test the circuitry with the programmer; and (4) correct the
problem. Repeat the last three steps as necessary until the pump system is operational.

Example: A vehicle that cannot perform the operation requested by Speed Select 2 is brought in
for repair.

STEP 1:
Examine the vehicle and its wiring for any obvious problems, such as broken wires or
loose connections.

STEP 2:
Connect the programmer, select the Faults Menu, and read the displayed fault
information. In this example, the display shows “No Known Faults,” indicating that the
controller has not detected anything out of the norm.

STEP 3:
Select the Monitor Menu, and observe the status of the SS2 input. In this example, the
display shows that the switch does not close when SS2 is selected, which means the problem is
either in the SS2 switch or the switch wiring.

STEP 4:
Check or replace the SS2 switch and wiring and repeat the test. If the programmer shows
the SS2 switch closing and the system now operates normally, the problem has been corrected.
 MAINTENANCE

There are no user serviceable parts in the Curtis 1253 controller. No attempt should be made
to open, repair, or otherwise modify the controller. Doing so may damage the controller and
will void the warranty. It is recommended that the controller be kept clean and dry that its fault
history file be checked and cleared periodically.

CLEANING

Periodically cleaning the controller exterior will help protect it against corrosion and possible
electrical control problems created by dirt, grime, and chemicals that are part of the operating
environment and that normally exist in battery powered systems.

When working around any battery powered system, proper safety precautions should be
taken. These include, but are not limited to: proper training, wearing eye protection, and
avoiding loose clothing and jewelry. Use the following cleaning procedure for routine
maintenance. Never use a high pressure washer to clean the controller.

1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load (such as a contactor coil)
across the controller’s B+ and B- terminals.

3. Remove any dirt or corrosion from the power and signal connector areas. The controller
should be wiped clean with a moist rag. Dry it before reconnecting the battery.

4. Make sure the connections are tight.

FAULT HISTORY

The programmer can be used to access the controller’s fault history file. The programmer will
read out all the faults that the controller has experienced since the last time the fault history

file was cleared. The faults may be intermittent faults, faults caused by loose wires, or faults
caused by operator errors. Faults such as contactor faults may be the result of loose wires;
contactor wiring should be carefully checked. Faults such as startup lockout or overtemperature
may be caused by operator habits or by overloading. After a problem has been diagnosed and
corrected, it is a good idea to clear the diagnostic history file. This allows the controller to
accumulate a new file of faults. By checking the new fault history file at a later date, you can
readily determine whether the problem was indeed fixed.