VOLTAS

FORKLIFTS

SPARE PARTS CATALOGUE

VOLTAS DIESEL FORKLIFT TRUCK
MODEL: DVX-405-FC

PART NO: VALID FOR TRUCK NO:

DVX 405 FC
VOLTAS
FORKLIFTS

USER INFORMATION
To verify this manual is correct for this truck compare the
model with the nameplate on the truck.
Refer to table of contents for nameplate location and
information. If the model in this manual does not agree with
the information on the nameplate contact your nearest
VOLTAS OFFICE.

SPECIAL NOTE
This part manual contains complete and accurate
information available at the time of publication for the
components and systems listed. VOLTAS reserves the right
to make changes to its product at any time and the
possibility exists that latter changes are not included in this
manual. If your forklift truck is equipped with special options
that are not covered in this part manual, you should contact
your local VOLTAS OFFICE for additional information.

DVX 405 FC 1-2

VOLTAS
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EXPLANATION OF MODEL

D V X 405 FC BCD HVM 2360

FUEL MANUFACTURER TYPE CAPACITY FLUID COUPLING TYRES MAST MAST-HEIGHT

FUEL: D DIESEL

MANUFACTURER: V VOLTAS LIMITED

TYPE: X NEW SERIES

CAPACITY : 405 4000 KG

TRANSMISSION: FC FLUID COUPLING

TYRES: PNEUMATIC
BEARCAT
PD PNEUMATIC DUAL
BCD BEARCAT DUAL

MAST: HVM SIMPLEX - HVM MAST

HVD TRIPLEX - HVT MAST
HI-LO SIMPLEX - HILO MAST

MAST-HEIGHT: 2360 HEIGHT IN mm

DVX 405 FC 1-3

VOLTAS
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CONTENTS

DESCRIPTION PAGE
NUMBER

GENERAL PARTS……………………………………………………………………….. 1-08

EQUALISER BAR ASSEMBLY………………………………………………………….1-10
EXHAUST SYSTEM…………………………………………………………………….. 1-12
FUEL TANK ASSEMBLY……………………………………………………………….. 1-14
HARDWARE FOR FUEL TANK MOUNTING………………………………………… 1-14
ACCELERATOR ASSEMBLY…………………………………………………………. 1-16
STARTING BATTERY………………………………………………………………… 1-18
INSTRUMENT PANEL ASSEMBLY…………………………………………………… 1-20
WIRING DIAGRAM (GENERAL)………………………………………………………. 1-22
FLUID COUPLING ASSEMBLY…………………………………………………………1-24
CLUTCH PEDAL & LINKAGE………………………………………………………….. 1-26
CLUTCH PEDAL & LINKAGE………………………………………………………….. 1-28
TRANSMISSION ASSEMBLY…………………………………………………………. 1-32
ENGINE TO FLUID COUPLING - TRANSMISSION…………………………………. 1-34
DIFFERENTIAL, RING GEAR & PINION ASSEMBLY………………………………. 1-36
HARDWARE FOR CROWN WHEEL MOUNTING ON
DIFFERENTIAL CASE (not shown) ……………………………………………………
HYDRAULIC WHEEL BRAKES…………………………………………………………1-38
HARDWARE FOR MOUNTING OF BRAKE,
BACK PLATE (not shown) ……………………………………………………………..
BRAKE MAST CYLINDER……………………………………………………………… 1-40
BRAKE TUBE ASSEMBLY…………………………………………………………….. 1-42
HYDRAULIC WHEEL CYLINDER…………………………………………………….. 1-44
DRIVE AXILE ASSEMBLY ………………………………………………………………1-47
BRAKE PEDAL AND LINKAGE……………………………………………………….. 1-49
PARKING BRAKE INSTALLATION…………………………………………………… 1-51
STEER AXLE ASSEMBLY……………………………………………………………… 1-53
STEER AXLE ASSEMBLY……………………………………………………………… 1-55
STEERING SYSTEM …………………………………………………………………… 1-57
STEERING UNIT (DANFOSS) ………………………………………………………… 1-59
PRIORITY VALVE ( DANFOSS)……………………………………………………….. 1-61
MAIN HYDRAULIC PUMP DRIVE ASSEMBLY
(SIMPSON S4 ENGINE) ……………………………………………………………….. 1-63
HYDRAULIC PUMP ASSEMBLY (785202800) ………………………………………1-65
TILT CYLINDER ASSEMBLY (WIPRO)……………………………………………… 1-67
TILT CYLINDER L .H. ASSEMBLY……………………………………………….. 1-69
STEER CYLINDER ASSEMBLY………………………………………………………. 1-71
HIGH VISIBILITY MAST ASSEMBLY…………………………………………………. 1-73

DVX 405 FC 1-4

VOLTAS
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CONTENTS

DESCRIPTION PAGE
NUMBER

HIGH VISIBILITY MAST ASSEMBLY…………………………………………………. 1-75

HYDRAULIC SYSTEM………………………………………………………………….. 1-77
HYDRAULIC SYSTEM………………………………………………………………….. 1-79
HYDRAULIC SYSTEM………………………………………………………………….. 1-81
HYDRAULIC TANK ASSEMBLY………………………………………………………. 1-83
HARDWARE FOR HYDRAULIC TANK……………………………………………….. 1-83
FUEL LINE DIAGRAM (SIMPSON S4 ENGINE) ……………………………………. 1-85
AIR INTAKE SYSTEM………………………………………………………………….. 1-87
CANOPY INSTALLATION……………………………………………………………… 1-89
COUNTERWEIGHT INSTALLATION…………………………………………………. 1-91
WHEELS AND TYRES (BEAR CAT) …………………………………………………. 1-93
PARTS ORDERING INSTRUCTIONS………………………………………………… 1-95
TRAINING CALENDAR…………………………………………………………………. 1-96
ADDERSSES-VOLTAS LIMITED…………………………………………………….. 1-97

DVX 405 FC 1-5

VOLTAS
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PARTS INFORMATION
This Parts Manual contains complete and accurate parts
replacement information available at the time of publication
for the components and systems installed on a standard
forklift truck and some commonly ordered options. However,
Voltas reserves the right to make changes to its product at
any time and the possibility exists that later changes are not
included here. Please contact your local Voltas Offices if you
need additional parts information

ATTACHMENT
If your forklift truck was ordered with special attachments
that are not covered in this Standard Parts Manual, you
should contact your local Voltas Offices for Attachment Part
Manuals.

DVX 405 FC 1-6

VOLTAS
FORKLIFTS

13

12

21

19

10

20

16

11 7
14

15

4
18
1
6

GENERAL TRUCK

DVX 405 FC 1-7

VOLTAS
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GENERAL PARTS

ITEM NO. PART NO. DESCRIPTION QTY.

1 797301011 MAIN FRAME 1

2 13455 ENGINE - SIMPSONS S4 1
3 05176 GEAR BOX ASSLY 1
4 796416078 DRIVE WHEEL AND TYRE (BEARCAT) 2
5 796403000 STEER AXLE ASSEMBLY 1
6 796416028 TRAIL WHEEL AND TYRE (BEAR CAT) 2
796425028 TRAIL WHEEL AND TYRE (PNEUMATIC)
7 796414069 TILT CYLINDER ASSLY RH (WIPRO) 1
796414099 TILT CYLINDER ASSLY RH (VOLTAS) 1
8 796414052 TILT CYLINDER ASSLY LH (WIPRO) 1
796414089 TILT CYLINDER ASSLY LH (VOLTAS) 1
9 796407091 RADIATOR 1
10 796413000 CANOPY ASSLY 1
11 796417011 COUNTER WEIGHT 1
12 797319012 STATIONARY WELDMENT 1
13 797319062 ELEVATING WELDMENT 1
14 797320078 CARRIAGE ASSEMBLY 1
15 796620503 FORK 2
16 796410078 EXHAUST SYSTEM 1
17 796606392 2 SPOOL CONTROL VALVE INSTLN 1
18 796412112 ENGINE HOOD 1
19 796418538 INSTRUMENT PANEL ASSLY 1
20 796412512 SEAT ASSLY 1
21 796415029 STEERING WHEEL 1
22 796418042 BATTERY BRACKET 1
785211802 12 VOLT BATTERY 1

ITEMS NOT SHOWN

10136 RADIATOR UPPER HOSE 1

066328800 RADIATOR LOWER HOSE 1
796407052 RADIATOR PIPE OUTLET (TOP) 1
796412523 GAS SPRING 1

DVX 405 FC 1-8

VOLTAS
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EQUALISER BAR ASSEMBLY

DVX 405 FC 1-9

VOLTAS
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EQUALISER BAR ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1 796407511 EQUALISER BAR RH 1

2 796407521 EQUALISER BAR LH 1
3 056918300 RUBBER VIB. SUPP. CASTING 2
4 056917800 RUBBER MOUNTS 4
5 785315400 HEX HD SCREW 4
6 032658800 NYLOCK NUT 4
7 056917500 SPECIAL WASHER 4
8 056917700 RUBBER WASHER 4
9 785202200 HEX HD SCREW 6
10 061278200 LOCK WASHER 6
11 057091500 HEX HD SCREW 4
12 014937400 NUT 4
13 992785644 WASHER M 12 4
14 992211257 HEX HD SCREW 8
15 061278200 LOCK WASHER 8
16 796407542 CROSS MEMBER 1
17 055485100 HEX. HD. SCREW 4
18 061278200 LOCK WASHER 4
19 016247600 DOWEL PIN 2

DVX 405 FC 1 - 10
VOLTAS
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EXHAUST SYSTEM

DVX 405 FC 1 - 11
VOLTAS
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EXHAUST SYSTEM

ITEM NO PART NO DESCRIPTION QTY

1 785782600 CAP - EXHAUST MUFFLER 1

2 785782700 VERTICAL EXHAUST MUFFLER 1
3 796410023 EXHAUST MESH ASSEMBLY 1
4 796410069 EXHAUST PIPE WELD' T 1
5 796410013 EXHAUST PIPE BELLOW 1
6 10242 GASKET 2
7 785205100 CLAMP 1
8 992271376 HEX SCREW M10 4
9 992761014 HEX NUT M10 4
10 992791535 SPRING WASHER 4

DVX 405 FC 1 - 12
VOLTAS
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FUEL TANK ASSEMBLY

DVX 405 FC 1 - 13
VOLTAS
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FUEL TANK ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1 785202301 HOSE OVERFLOW (INJECTOR TO TANK) 1

2 870001084 FUEL TANK CAP ASSLY 1
3 785200400 SENSING UNIT 1
4 014875600 ROUND HEAD SCREW 6
016107400 LEAD WASHER 6
015832900 CUP WASHER 6
5 785202301 FUEL HOSE TANK TO ENGINE LIFT PUMP 1
785202301 FUEL HOSE TO PREFILTER 1
6 785215000 FUEL SUCTION STRAINER SCREW 1
7 870001173 SUCTION LINE FITTING 1
8 796421011 FUEL TANK WELDMENT 1
9 785791700 DRAIN PLUG 1
10 785200804 ADAPTOR 1
11 785200803 COPPER WASHER 6
12 785200802 CAP NUT 1
13 785202301 HOSE OVERFLOW (FUEL PUMP TO TANK) 1

HARDWARE FOR FUEL TANK MOUNTING

014936900 HEX NUT 2

015029000 SPRING WASHER 2
055486800 HEX HD. SCREW 2
061278000 FLAT WASHER 2

DVX 405 FC 1 - 14
VOLTAS
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ACCELERATOR PEDAL AND LINKAGE

DVX 405 FC 1 - 15
VOLTAS
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ACCELERATOR ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1 016103500 FLAT WASHER 1

2 015417900 COTTER PIN 7
3 10190 ACCELERATOR ROD 1
4 797315019 ACCELERATOR LINKAGE ROD 1
5 10194 THROTTLE CROSS SHAFT 1
6 014633200 HEX HD. BOLT 2
7 014936500 HEX NUT 2
8 015026200 WASHER 2
9 063688800 ACCLERATOR PEDAL 1
10 785763100 BALL JOINT 1
11 014939500 HEX NUT 1
12 13464 THROTTLE CROSS SHAFT BKT. WELD' T 1
13 065795400 THROTTLE CONTROL CROSS SHAFT 2

DVX 405 FC 1 - 16
VOLTAS
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STARTING BATTERY

DVX 405 FC 1 - 17
VOLTAS
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STARTING BATTERY

ITEM NO. PART NO. DESCRIPTION QTY.

1 796418042 BATTERY BRACKET 1

2 785211802 BATTERY 12 V 1
3 07519 BATTERY CABLE +VE 1
4 07520 BATTERY CABLE -VE 1

DVX 405 FC 1 - 18
VOLTAS
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7 8 9 10 11
12 13

6 5 4 3 2

INSTRUMENT PANEL

DVX 405 FC 1 - 19
VOLTAS
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INSTRUMENT PANEL ASSEMBLY

ITEM NO PART NO DESCRIPTION QTY

1 796418511 HOUSING - INSTRUMENT PANEL 1

2 08962 IGNITION SWITCH 1
3 785786800 PUSH BUTTON 1
4 79Z2924D1 INDICATOR LAMP - RED (TRANSMISSION) 1
5 09091 INDICATOR LAMP - RED (BATTERY CHARGE) 1
6 13175 LIGHT SWITCH (PIANO TYPE) 1
7 79Z2924D3 INDICATOR LAMP - GREEN 2
8 785207900 OIL PRESSURE GAUGE 1
9 785761600 FUEL GAUGE 1
10 785358400 ELECTRONIC HOUR METER 1
11 785761600 AMMETER 1
12 785207800 TEMPERATURE GAUGE 1
13 79Z2924D3 INDICATOR LAMP - GREEN 2

PARTS NOT SHOWN

796418543 BASE - INSTRUMENT PANEL 1

785208500 ADAPTOR FOR PRESSURE SWITCH 1
08714 SENSOR FOR TEMPERATURE GAUGE 1
785369400 PR. SENDING LINE WELDMENT (SHORT) 1
785209000 ADAPTOR FOR PRESSURE SENDING LINE 1
785369500 PR. SENDING LINE WELDMENT (LONG) 1
015029000 LOCK WASHER FOR 3/8"° 2
060930300 HEX. HD. SCREW 2
785208200 CLAMP, CHOKE CABLE 1
785794700 FLAT WASHER I.D. = 22.5 ° 2
992275214 HEX SCREW M6 X 16LG 8
992791515 SPRING WASHER M6 8
026258600 CHOKE CABLE 1
10217 CHOKE CABLE CLAMP 1
11408 PRESS SWITCH - HOBBS 1

DVX 405 FC 1 - 20
VOLTAS
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WIRING DIAGRAM WITH ALTERNATOR

DVX 405 FC 1 - 21
VOLTAS
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WIRING DIAGRAM (GENERAL)

ITEM NO PART NO DESCRIPTION QTY

1 512476400 HORN 1
2 785207900 OIL PRESSURE GAUGE 1
3 785761600 FUEL GAUGE 1
4 785358400 ELECTRONIC HOUR METER 1
5 785208000 AMMETER 1
6 785207800 WATER TEMPERATURE GAUGE 1
7 08962 IGNITION SWITCH 1
8 11408 PRESSURE SWITCH (H- SWITCH) 1
785208500 ADAPTOR FOR PRESSURE SWITCH 1
9 08714 SENSOR FOR TEMPERATURE GAUGE 1
(T-SWITCH)
10 09796 FUSE BOX 1
09718 FUSE 30 AMP 2
10205 FUSE MOUNTING PLATE 1
09716 FUSE 10 AMP 2
11 796418023 HEAD LIGHT (TAIL LIGHT) 3
12 796418053 INDICATOR LIGHT-FRONT 2*
13 796418063 INDICATOR LIGHT-REAR 2*
14 13174 PILOT LAMP 1*
15 795119154 DIRECTION INDICATOR LEVER 1*
16 07840 FLASHER 1*
17 796418554 WIRE HARNESS 1

Item no.s are for reference only. Not shown in wiring diagram

· These items are not illustrated in circuit diagram as they are optional items.

DVX 405 FC 1 - 22
VOLTAS
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FLUID COUPLING ASSEMBLY

DVX 405 FC 1 - 23
VOLTAS
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FLUID COUPLING ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1 062232800 HEX. HD. SCREW 18

061277900 WASHER 18
2 510628800 IMPELLER 1
3 023666000 RETAINING WASHER 1*
4 016172900 RUBBER ELEMENT 1*
015968900 GARTER SPRING 1*
5 023665900 BACKING WASHER 1*
6 016368300 BUSHING 1*
7 012334900 NOSE PIECE 1*
8 023344800 INTERNAL SNAP RING 1*
9 023411300 COMPRESSION SPRING 8*
10 500494904 RING GASKET 1
11 510622800 RUNNER 1
12 059716300 HEX. HD. SCREW 8
061277900 WASHER 8
13 012783900 MATING RING 1*
14 016349300 BUSHING 1*
15 870000924 EXPANSION PLUG 1
16 016132300 MATING RING WASHER 1
17 510624800 HEADED PIN 1*
18 03557 HUB FOR FLUID COUPLING 1
19 09070 LOCK PLATE FOR RUNNER 4

* Not serviced separately. Order service kit P.No. 10236 - S4

DVX 405 FC 1 - 24
VOLTAS
FORKLIFTS

CLUTCH PEDAL AND LINKAGE

DVX 405 FC 1 - 25
VOLTAS
FORKLIFTS

CLUTCH PEDAL & LINKAGE

ITEM NO. PART NO. DESCRIPTION QTY.

1 014671800 HEX. HD. SCREW 1

2 014936900 HEX. NUT 1
3 016548400 YOKE END 1
4 065376300 CLUTCH PEDAL LEVER 1
5 063681200 PEDAL PAD 1
6 062143700 HEX. HD. SCREW 1
014936600 HEX. NUT 1
015028900 LOCK WASHER 1
7 064597100 PIVOT PIN 1
8 062077800 ROLL PIN 1
9 504101300 BELLCRANK SUPPORT 1
10 055485100 HEX. HD. SCREW 2
014937200 HEX. NUT 2
061278200 WASHER 2
11 796412274 BRACKET-BELLCRANK SUPPORT 1
12 506949300 LEVER 1
13 023031500 YOKE PIN 2
992816049 COTTER PIN 2
14 016549200 YOKE END 1
15 014973100 HEX. JAM NUT 2
16 797315029 ROD 1
17 014599100 YOKE END 1
18 011775900 BUSHING 1
19 796412283 BELL CRANK ASSEMBLY 1
20 796412294 YOKE PIN 1
992816049 COTTER PIN 1
21 09641 YOKE END 1
22 014973100 HEX. JAM NUT 1
23 060309600 SPRING 1
24 796412303 ROD-CLUTCH ASSLY 1
25 014972700 HEX. JAM NUT 1
26 015628700 LUBE FITTING 1

DVX 405 FC 1 - 26
VOLTAS
FORKLIFTS

CLUTCH PEDAL AND LINKAGE

DVX 405 FC 1 - 27
VOLTAS
FORKLIFTS

CLUTCH PEDAL & LINKAGE

ITEM NO. PART NO. DESCRIPTION QTY.

27 063541000 PEDAL SHAFT 1

992816068 COTTER PIN 1
870001234 SHIM WASHER A/R
28 021848800 YOKE PIN 1
992816049 COTTER PIN 1

DVX 405 FC 1 - 28
VOLTAS
FORKLIFTS

TRANSMISSION ASSEMBLY

TRANSMISSION ASSEMBLY

DVX 405 FC 1 - 29
VOLTAS
FORKLIFTS

TRANSMISSION ASSEMBLY
ITEM NO. PART NO. DESCRIPTION QTY.
3 03045 TRANSMISSION HOUSING ASSY. 1
4 08528 CLUTCH COVER ASSY. 1
- 08529 CLUTCH DISC. 1
5 08498 CLUTCH RELEASE BEARING SLEEVE 1
- 08530 CLUTCH RELEASE BEARING 1
6 - VENT COVER 1
- 062151100 SPRING WASHER 4
- 015026000 HEX. LOCK NUT 4
7 7857793300 SPACER 1
8 08527 BEARING SUPPORT CAP 1
- 062232800 INTERNAL CIRCLIP 5
9 992831567 EXTERNAL CIRCLIP 1
10 993312107 'O' RING 1
11 08526 DRIVE PINION SHAFT 1
12 022641200 DUAL GEAR 2
13 015953900 SPRING 1
14 014964200 DUST BOOT 1
15 016483600 LEVER KNOB 1
16 0645937 GEAR SHIFT LEVER ASSY. 1
- 785204500 GEAR SHIFT LEVER SHAFT 1
- 016474600 GEAR SHIFT LEVER 1
- 015716600 PIN 1
17 016243300 RETAINING KEY 1
18 064976000 SHIFT LEVER & SUPPORT ASSY. 1
- 015236400 LEVER SUPPORT 1
- 057048200 HEX. SCREW 3/8” UNC 4
19 05382 INTER – LOCK ASSY. 1
20 015957800 SPRING FOLLOWER 2
21 015835800 SPRING FOLLOWER 2
22 01968 BALL 4

DVX 405 FC 1 - 30
VOLTAS
FORKLIFTS

TRANSMISSION ASSEMBLY
ITEM NO. PART NO. DESCRIPTION QTY.
23 01968 LEVER 1
- 060305300 HEX SCREW 3/8” UNC 1
- 014936900 HEX NUT 3/8” UNC 1
24 - LUBE FITTING 1
- 016348700 BUSHING 2
26 062236500 HEX SCREW 3/8” UNC 2
27 019848200 LUBRICANT HOSE 1
- 056716800 ADAPTOR 1
28 018478100 GREECE CUP 1
- 018479700 SPL. ELBOW 1
29 018896700 R. H. GEAR SHIFTER BAR 1
30 015445000 GEAR SHIFTER BAR CAP 2
31 018896800 L. H. GEAR SHIFTER BAR 1
32 015720700 INTERLOCKING PIN 2
33 012717300 GEAR SHIFTER FORK 2
34 014669400 SET SCREW 5/16” UNC 2
35 015848800 CLUTCH THROW OUT SHAFT 1
36 015949400 RELEASE BEARING RETURN SPRING 1
37 015848700 CLUTCH THROW OUT SHAFT 1
38 054586100 BALL BEARING 4
39 785325100 SNAP RING 4
40 785324900 INTERMEDIATE SHAFT 2
41 - SNAP RING -
42 785204000 OIL LEVEL PLUG 1
43 785204100 MAGNETIC DRAIN PLUG 1
44 09094 DIFFERENTIAL RING GEAR & PINION 1
- 015139400 DIFFERENTIAL BEARING 2
- 015818800 DIFFERENTIAL BEARING RETAINER 2
- 015416100 COTTER PIN 2
45 993361060 PINION BEARING 1

DVX 405 FC 1 - 31
VOLTAS
FORKLIFTS

TRANSMISSION ASSEMBLY
ITEM NO. PART NO. DESCRIPTION QTY.
46 03903 SHIM WASHER 0.075” THICK + AR
- 03904 SHIM WASHER 0.070” THICK + AR
- 03905 SHIM WASHER 0.065” THICK + AR
- 03906 SHIM WASHER 0.060” THICK + AR
- 03907 SHIM WASHER 0.055” THICK + AR
- 03908 SHIM WASHER 0.050" THICK + AR
- 015173060 SHIM WASHER 0.100” THICK + AR
- 015173070 SHIM WASHER 0.105” THICK + AR
- 015173080 SHIM WASHER 0.110” THICK + AR
47 08871 GEAR SPACER 1
48 08858 LOW GEAR (42 TEETH) 1
49 9095 KEY 1
50 08859 HIGH GEAR (33 TEETH) 1
51 992831591 SNAP RING 1
52 993361178 PINION BEARING 1
53 056262200 KEYED WASHER 1
54 993396018 BEARING LOCK WASHER 1
55 993395018 BEARING LOCK NUT 2
56 015534600 INTERMEDIATE GEAR 2
57 785325200 SNAP RING 2
58 015630100 BREATHER 1

* ITEM NO. 18 CONSISTS OF (1) 064593700, (2) 016483600,

(3) 014196200 (4) 016246600 AND (5) 015236400.
** SERVICED UNDER PART NO. 064593700
+ AR MEANS “AS REQUIRED”

DVX 405 FC 1 - 32
VOLTAS
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ENGINE TO FLUID COUPLING TRANSMISSION

CONNECTION
(SIMPSON S4 ENGINE)

DVX 405 FC 1 - 33
VOLTAS
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ENGINE TO FLUID COUPLING - TRANSMISSION

ITEM NO. PART NO. DESCRIPTION QTY.

1 07545 STARTER RING 1

3 11279 FLY WHEEL 1
785214200 LOCK WASHER 3
4 08809 SEALING WASHER 6
992285421 HEX. BOLT 6
5 015493500 'O' RING 1
6 785776601 CIRCLIP 1
7 992835607 CIRCLIP 1
8 993311066 BALL BEARING 2
9 03557 HUB FOR FLUID COUPLING 1
10 08140 INNER SPACER 1
11 016241000 KEY 1
12 500494904 RING GASKET 1
13 08522 DRIVE PLATE 1
14 01133 FLUID COUPLING ASSLY 1
15 015029000 LOCK WASHER 12
055486800 HEX. BOLT 9
062236500 HEX. BOLT 3
16 785791700 PIPE PLUG 2

ITEMS NOT SHOWN

014970100 NUT 1
016139600 PLATE WASHER 1

DVX 405 FC 1 - 34
VOLTAS
FORKLIFTS

DIFFERENTIAL, RING GEAR & PINION ASSEMBLY

DVX 405 FC 1 - 35
VOLTAS
FORKLIFTS

DIFFERENTIAL, RING GEAR & PINION ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

016873800 DIFFERENTIAL WITHOUT RING GEAR

& PINION 1
1 870000943 BEVEL PINION 4
2 025607600 PINION THRUST WASHER 4
3 11241 RING GEAR AND PINION ASSLY 1SET
4 033422600 HEX. HD. SCREW 12
5 870000962 DIFFERENTIAL CASE SHORT 1
870000971 DIFFERENTIAL CASE LONG 1
6 025607500 SIDE GEAR THRUST WASHER 2
7 870000933 DIFFERENTIAL SPIDER 1
8 016113600 SPACER 1
9 870000952 BEVEL GEAR 1

HARDWARE FOR CROWN WHEEL MOUNTING

ON DIFFERENTIAL CASE (not shown)

515412100 HEX. HD. SCREW 12

992785644 WASHER 12
032228900 BAIL WIRE 1

DVX 405 FC 1 - 36
VOLTAS
FORKLIFTS

HYDRAULIC WHEEL BRAKES

DVX 405 FC 1 - 37
VOLTAS
FORKLIFTS

HYDRAULIC WHEEL BRAKES

ITEM NO. PART NO. DESCRIPTION QTY.

08549 L.H. BRAKE ASSEMBLY 1

08550 R.H. BRAKE ASSEMBLY 1
1 065044000 CYLINDER SPACER PLATE & LEVER GUIDE 2
2 057456800 SPRING 2
3 023187000 SPRING RETAINER 4
4 506071800 ANTI RATTLE ROD 2
5 507337800 ADJUSTING PAWL KIT 1
6 065040100 R.H. CONTROL LEVER & LINK 1
065040200 L.H. CONTROL LEVER & LINK 1
7 065092100 PUSH ROD 2
8 870001339 R.H. WHEEL CYLINDER 1
870001303 L.H. WHEEL CYLINDER 1
HEX. HD. SCREW 2
015026400 LOCK WASHER 2
9 511667400 BRAKE SHOE AND LINING 2
10 065041000 BRAKE SHOE RETURN SPRING 1
11 511666401 R.H. BACKING PLATE 1
511666402 L.H. BACKING PLATE 1
12 023411600 RETAINING SPRING 1
13 014936900 HEX NUT 2
14 061278200 HARDENED WASHER 2
15 507337802 SPRING WASHER 2

HARDWARE FOR MOUNTING OF BRAKE BACK PLATE (not shown)

060305600 HEX. SCREW 8

061278100 WASHER 8

DVX 405 FC 1 - 38
VOLTAS
FORKLIFTS

BRAKE MASTER CYLINDER

DVX 405 FC 1 - 39
VOLTAS
FORKLIFTS

BRAKE MASTER CYLINDER

ITEM NO. PART NO. DESCRIPTION QTY.

1 870001211 MASTER CYLINDER ASSEMBLY 1

2 870004099 BACK SEAL 1*
870004139 VALVE 1*
870004079 CIRCLIP 1*
870004119 CUP SEAL 1*
870004059 DUST COVER 1*
870004089 RETAINING WASHER 1*
4 870004109 PISTON 1*
5 870004129 SPRING 1
6 870001394 BANJO 1
7 870001369 BANJO WASHER 1*
8 870001344 BANJO BOLT 1
9 08995 STOP LIGHT SWITCH WITH WASHER 1
10 870004169 FILLER CAP 1
11 870004179 GASKET (FILLER CAP) 1*

ITEMS NOT SHOWN

870001379 WASHER 1*
870004059 PUSH ROD 1
870001224 ROD END 1
870001359 LOCK NUT 1
870004149 VALVE SEAT 1*
870004159 BODY MASTER CYLINDER 1
870001659 KIT MASTER CYLINDER
870002609 KIT MASTER CYLINDER 1

* Order kit Master Cylinder 870002609 only.

DVX 405 FC 1 - 40
VOLTAS
FORKLIFTS

BRAKE TUBE ASSEMBLY DIAGRAM

DVX 405 FC 1 - 41
VOLTAS
FORKLIFTS

BRAKE TUBE ASSEMBLY

ITEM NO PART NO DESCRIPTION QTY.

1 870001211 MASTER CYLINDER 1

2 870001394 BANJO ADAPTOR 1
3 785766401 FLEXIBLE HOSE 1
4 013370100 TEE 1
5 507305400 L.H. BRAKE TUBE 1
6 506363300 R.H. BRAKE TUBE 1

DVX 405 FC 1 - 42
VOLTAS
FORKLIFTS

HYDRAULIC WHEEL CYLINDER

DVX 405 FC 1 - 43
VOLTAS
FORKLIFTS

HYDRAULIC WHEEL CYLINDER

ITEM NO PART NO DESCRIPTION QTY

870001339 R.H. WHEEL CYLINDER 1

870001303 L.H. WHEEL CYLINDER 1
1 870001989 BOOT 2*
2 870001999 PISTON 2
3 870002009 PISTON CUP 2*
4 870002019 FILLER CUP 2
5 870002029 SPRING 1
6 015489300 GASKET 1
7 013389600 INLET FITTING 1
8 015489100 GASKET 1
9 014788400 INLET FITTING BOLT 1
10 014788300 BLEEDER SCREW 1

* Not serviced separately. Order Repair Kit P.No. 061378000

DVX 405 FC 1 - 44
VOLTAS
FORKLIFTS

DVX 405 FC 1 - 45
VOLTAS
FORKLIFTS

DRIVE AXLE ASSEMBLY (FOR DUAL TYRES)

ITEM NO. PART NO. DESCRIPTION QTY.

1 797302029 LONG DRIVE SHAFT 1

2 015416400 COTTER PIN 2
3 015818800 BEARING RETAINER 2
4 015139400 DIFFERENTIAL BEARING 2
5 09094 DIFFERENTIAL ASSEMBLY 1
6 797302019 DRIVE AXLE HOUSING 1
797308029 SLEEVE 2
785204100 PIPE PLUG 1
785204700 PIPE PLUG 1
785204000 PIPE PLUG 1
015630100 AIR VENT 1
7 797302039 SHORT DRIVE SHAFT 1
8 07667 SPACER RING 2
9 059074900 HEX.HD.SCREW 7/16” –14 UNC X 1”Ig SAE 12
Gr -5
10 07576 HUB & BRAKE DRUM 8 HOLES 12
056663400 TYRE , TUBE & FLAB GROUP 7.00X12 4
056663500 TYRE 4
056663600 TUBE ORDER 056663400 4
056663700 FLAB 4
OR
785765901 CUSHION (Non Pneumatic) Tyre 7.00 X 12

12 785231102 RIM ASSEMBLY (PNEUMATIC /BEARCAT) 4

13 791340034 WHEEL STUD 24
08724 WHEEL NUT 24
08725 SPRING WASHER 24
14 057699900 HEX. HD SCREW 5/8”unc X 2 ½ Ig SAE Gr-5 16
15 785256600 LOCKING BLOCK 2
16 992372212 FIL .HD.SCREW M16 X 12 Ig 2
015028800 LOCKWASHER FOR ¼” DIA. 2
17 870002234 WESH PLUG 2
18 00205 WHEEL NUT 2
19 993361146 WHEEL BEARING 4
20 07565 HUB FLANGE 8 HOLES 2

DVX 405 FC 1 - 46
VOLTAS
FORKLIFTS

DRIVE AXLE ASSEMBLY ( FOR DUAL TYRE )

ITEM NO. PART NO. DESCRIPTION QTY.

21 785295700 SPL.HD.SCREW –M12x1.5-30.5 Ig 20

785764100 HEX.NUT M12 x 1.25 20
992791545 FLAT WASHER 20
785760700 HEX. SCREW M10x1.5-16 Ig 8
22 500753100 ADAPTOR RING & BOLT ASSEMBLY 2
062760100 ADAPTOR PLATE 2
791340034 WHEEL BOLT 12
24 09608 OIL SEAL 2
25 055485000 HEX.HD.SCREW ½ “ –13x 1 ¼” Ig SAE Gr-5 8*
059694600 HEX.HD.SCREW ½ “ –13x 1 ¼” Ig SAE Gr-5 2*
059117400 PEDESTAL CAP SCREW 4*

DVX 405 FC 1 - 47
VOLTAS
FORKLIFTS

BRAKE PADEL AND LINKAGE

DVX 405 FC 1 - 48
VOLTAS
FORKLIFTS

BRAKE PEDAL AND LINKAGE

ITEM NO PART NO DESCRIPTION QTY

1 063541000 BRAKE PEDAL SHAFT 1

2 021848800 YOKE PIN 2
3 015416100 COTTER PIN 2
4 014671800 HEX. HD. SCREW 1
5 014936900 HEX. NUT 1
6 015628700 LUBE FITTING 3
7 065376200 BRAKE PEDAL LEVER 1
8 063681200 PEDAL PAD 2
9 062143700 HEX. HD. SCREW 2
014936600 HEX. NUT 2
015028900 WASHER 2
10 063541300 SUPPORT PLATE 1
11 060930300 HEX. HD. SCREW 2
12 870001211 MASTER CYLINDER 1
13 870001359 HEX. JAM NUT 1
14 870001224 ROD END 1
15 058941300 HEX HD. SCREW 1
16 502383100 RETAINER 1
17 014607000 ROD END PIN 1
992816069 COTTER PIN 1
18 07605 LOCKING PIN 1
19 063542700 BELL CRANK 1
20 063681000 CONNECTING ROD 1
21 060309600 PEDAL RETURN SPRING 1

DVX 405 FC 1 - 49
VOLTAS
FORKLIFTS

PARKING BRAKE INSTALLATION

DVX 405 FC 1 - 50
VOLTAS
FORKLIFTS

PARKING BRAKE INSTALLATION

ITEM NO PART NO DESCRIPTION QTY

1 063542700 BELL CRANK 1

2 785534000 YOKE END 1
3 785577603 YOKE PIN 1
4 992781634 BLACK WASHER 1
5 992826140 SPLIT PIN 1
6 05213 CABLE MOUNTING BRACKET 1
7 992275295 HEX. SCREW 1
8 785540200 CABLE 1
10 05224 SPACER 2
11 05229 BRAKE CABLE SUPPORT BKT. 2
12 870000191 HAND LEVER ASSLY 1
13 992171303 HEX. HD. BOLT 2
992171304 HEX. HD. BOLT 2
14 992761013 HEX. NUT M8 4
15 992791525 SPRING WASHER 4

DVX 405 FC 1 - 51
VOLTAS
FORKLIFTS

STEER AXLE ASSEMBLY

DVX 405 FC 1 - 52
VOLTAS
FORKLIFTS

STEER AXLE ASSEMBLY

ITEM NO PART NO DESCRIPTION QTY

1 11286 STEER CYLINDER ASSLY (WIPRO) 1

2 08971 STEER KNUCKLE LH 1
3 08966 WELD' T TRAIL AXLE 1
4 08977 CONNECTOR LINK 4
5 019383600 THRUST BEARING 2
6 09182 STEER KNUCKLE RH 1
7 785282300 STEER WHEEL HUB 2
8 796416028 REAR WHEEL ASSEMBLY (BEAR CAT) 2
796425028 REAR WHEEL ASSEMBLY (PNEUMATIC) 2
9 992275504 HEX. SCREW 4
10 992791565 SPRING WASHER 4
11 12205 BUSH 2
12 08973 SPECIAL WASHER 4
13 992826225 SPLIT PIN 6
14 09185 YOKE PIN 2
15 992781654 M.S. WASHER 8
16 08978 SPACER 2
17 066616800 STEERING KNUCLE PIN 2
18 785201300 BUSH FOR STEER KNUCKLE 4
19 023818300 EXPANSION PLUG 4
20 09186 BUSH 8
21 016136300 SPECIAL THRUST WASHER 2
22 056142200 GRUB SCREW 2
23 014971100 LOCK NUT 2
24 785324300 NIPPLE 4
25 08980 CLAMP SCREW 2
26 992763017 LOCK NUT 2
27 993791106 GREASE NIPPLE 4
28 016167300 OIL SEAL 2
29 514008300 HUB CAP TRAIL WHEEL 2
30 014984900 SLOTTED NUT 2
31 015420400 COTTER PIN 2
32 993361140 INNER BEARING 2

DVX 405 FC 1 - 53
VOLTAS
FORKLIFTS

STEER AXLE ASSEMBLY

DVX 405 FC 1 - 54
VOLTAS
FORKLIFTS

STEER AXLE ASSEMBLY

ITEM NO PART NO DESCRIPTION QTY

33 993361137 OUTER BEARING 2

34 785770701 TRAIL WHEEL BOLT 12
35 12195 TRAIL WHEEL NUT 12
36 785293700 TRAIL RIM STUD 12
37 785764100 HEX NUT 12
38 992791545 SPRING WASHER 12
39 796403014 YOKE PIN 2

ITEMS NOT SHOWN

016344800 BUSH 2

DVX 405 FC 1 - 55
VOLTAS
FORKLIFTS

STEERING SYSTEM
(7964014000)

DVX 405 FC 1 - 56
VOLTAS
FORKLIFTS

STEERING SYSTEM
(796404000)

ITEM NO. PART NO. DESCRIPTION QTY.

1 796415029 STEERING WHEEL 1
2 795119154 DIRECTION INDICATOR LEVER 1
3 020184500 RUBBER PAD 1
4 13920 U - BOLT 1
5 08933 STEERING COLUMN ASSEMBLY 1
6 796404019 STEERING MTG. BKT. 1
7 785372600 SPACER 4
8 992275377 HEX. HEAD SCREW 4
9 992275376 HEX. HEAD SCREW 2
10 992761114 HEX. NUT 2
11 992763014 LOCK NUT 2
12 992781634 PLAIN WASHER 8
13 992791535 SPRING WASHER 4

DVX 405 FC 1 - 57
VOLTAS
FORKLIFTS

STEERING UNIT
(13465 DANFOSS)

DVX 405 FC 1 - 58
VOLTAS
FORKLIFTS

STEERING UNIT
(13465 DANFOSS)

ITEM NO PART NO DESCRIPTION QTY

1 633B9002 DUST SEAL RING 1
2 - HOUSING 1
3 689X1031 BALL E8, 5 1
4 150-0304 THREAD BUSHING 1
5 633B1205 O – RING 1
6 633B9007 KIN – RING 1
7 150-4262 BEARING ASSEMBLY 1
8 150-0310 RING 1
9 150-0305 CROSS PIN 1
10 150-0435 SPACER 1
11 150-0442 CARDAN SHAFT 1
12 150-4209 SPRING 1
13 633B1202 O – RING 1
14 150-0301 DISTRIBUTOR PLATE 1
15 150-4251 GEAR WHEEL SET 1
16 633B1173 O – RING 2
17 150-0328 END COVER 1
18 684X2481 WASHER 7
19 682L3058 ROLLED PIN 1
20 150-0321 SCREW WITH BORE 1
21 681X1578 SCREW 6
22 150A0000 NAME PLATE 1
23 681Z1011 DRIVE SCREW 2
24 150-4272 COMPLETE RELIEF VALVE 1
26 150-4268 COMPLETE DUAL SHOCK VALVE 2
27 689X1005 BALL E3, 16 IN 2
29 150-4080 ROLLED PIN 2

SEAL KIT 13465-80 COMPRISES ITEM NOS. 1, 5, 6, 13, 16 & 18.

DVX 405 FC 1 - 59
VOLTAS
FORKLIFTS

DANFOSS PRIORITY VALVE

DVX 405 FC 1 - 60
VOLTAS
FORKLIFTS

DANFOSS PRIORITY VALVE

ITEM NO PART NO DESCRIPTION QTY

1 152B0353 LS PLUG 1
2 663X1088 SPRING 1
3 633L3061 SEAL RING 2
4 152B0385 LS ORIFICE SCREW 1
5 - HOUSING 1
6 - SPOOL 1
7 152B0380 PP ORIFICE SCREW 1
8 152-0413 PP PLUG 1
9 152A0000 NAME PLATE 1
10 681Z1011 DRIVE SCREW 2
11 150-0442 CARDAN SHAFT 1
12 152B000 SET OF SEAL 1

DVX 405 FC 1 - 61
VOLTAS
FORKLIFTS

HYDRAULIC PUMP DRIVE ASSEMBLY

( SIMPSON S4 ENGINE )

DVX 405 FC 1 - 62
VOLTAS
FORKLIFTS

MAIN HYDRAULIC PUMP DRIVE ASSEMBLY

(SIMPSON S4 ENGINE)

ITEM NO. PART NO. DESCRIPTION QTY.

1 785202800 MAIN HYDRAULIC PUMP 1

2 055486800 HEX. SCREW 2
3 796407542 CROSS MEMBER 1
4 508592400 END PIECE 1
5 508591400 END PIECE 1
6 508593400 FLEXIBLE COUPLING 1
7 065577200 SOCKET HD. SCREW 3
8 992791130 LOCK WASHER 6
9 08797 SPACER 1
10 785249900 HEX. SCREW 1
11 061943400 SPL. STEEL WASHER 1
12 11038 FAN BELT 1
13 - PULLEY (A PART OF ENGINE) 1

DVX 405 FC 1 - 63
VOLTAS
FORKLIFTS

HYDRAULIC PUMP
(785202800)

DVX 405 FC 1 - 64
VOLTAS
FORKLIFTS

HYDRAULIC PUMP
(785202800)

ITEM NO PART NO DESCRIPTION QTY

785202800 Hydraulic Pump Assembly 1
1 785312800 Pump Body 1
2 785312900 Hex. Hd .Screw 4
3 785313100 COVER 1
4 785313200 Pressure Plate Spring 1
5 785313300 Pressure Plate 1
6 785313400 ‘O’ Ring Sealing 2+
7 786313500 Ring 1+
8 785313600 Rotor 1+
9 785313700 Vane Kit (12 vanes) 1
10 785313800 Pin 1
11 785313900 Bearing 1
12 785314100 Seal 1
13 785314200 Shaft 1
14 785314300 Key 1
15 785314400 Bearing 1
16 78514500 Snap Ring 1

1. SEAL KIT PART NO. 922732.

2. CARTRIDGE KIT PART NO. 78532700. COMPRISES

ITEM NOS. 4, 7, 8 & 10.

DVX 405 FC 1 - 65
VOLTAS
FORKLIFTS

TILT CYLINDER R.H.(ALT-1)

( 796414069 ) - WIPRO
DVX 405 FC 1 - 66
VOLTAS
FORKLIFTS

TILT CYLINDER R. H. (ALT-1)

(796414069)

ITEM NO PART NO DESCRIPTION QTY

01 P3899A - 01 PISTON 1
02 P3899A - 02 PISTON ROD 1
03 P3899A – 03 TUBE 1
04 P3899A – 04 H. E. COVER 1
05 P3899A – 05 BUSH 1
06 P3899A – 06 SNAP RING - 1 1
07 P3899A – 07 SNAP RING – 2 1
08 P3899A – 08 HEX. SOC. SET SCREW 1
09 P3899A – 09 PISTON SEAL 1
10 P3899A – 10 ROD SEAL 1
11 P3899A – 11 WIPER 1
12 P3899A – 12 O – RING (PISTON SEAL) 1
13 P3899A – 13 O – RING (PISTON ROD) 1
14 P3899A – 14 O – RING (HEC) 1
15 P3899A – 15 LOCKING EASHER 1
16 P3899A – 16 O – RING (PLUG) 2
17 P3899A – 17 PROTECTION COVER 1
18 P3899A – 18 PROTECTION PLUG 2

SEAL KIT PART NO. P3899A - 80

ITEMS NOT SHOWN

501900300 ROD END 1

063894200 HEX. SCREW ¾” x 3 ¼” LG GR – 5 1
014939500 NYLOCK NUT 1
509816101 HEX. SCREW 1
502658100 PIN RETAINER (FRONT) 1
015026400 LOCK WASHER FOR 3/8” 2
504169100 TILT CYLINDER PIN (REAR) 1
504168100 PIN RETAINER (REAR) 0

DVX 405 FC 1 - 67
VOLTAS
FORKLIFTS

TILT CYLINDER L. H. (ALT-1)

(796414052)

DVX 405 FC 1 - 68
VOLTAS
FORKLIFTS

TILT CYLINDER L. H. (ALT-1)

(796414052)

ITEM NO PART NO DESCRIPTION QTY

01 P3898A - 01 PISTON 1
02 P3898A - 02 PISTON ROD 1
03 P3898A - 03 TUBE S/A 1
04 P3898A - 04 H. E. COVER 1
05 P3898A - 05 BUSH 1
06 P3898A - 06 SNAP RING – 1 1
07 P3898A - 07 SNAP RING – 2 1
08 P3898A - 08 HEX. SOC. SET SCREW 1
09 P3898A - 09 PISTON SEAL 1
10 P3898A - 10 ROD SEAL 1
11 P3898A - 11 WIPER 1
12 P3898A - 12 O – RING (PISTON SEAL) 1
13 P3898A - 13 O – RING (PISTON ROD) 1
14 P3898A - 14 O – RING (HEC) 1
15 P3898A - 15 LOCKING EASHER 1
16 P3898A - 16 O – RING (PLUG) 2
17 P3898A - 17 PROTECTION COVER 1
18 P3898A - 18 PROTECTION PLUG 2

SEAL KIT PART NO. P3898A - 80

ITEMS NOT SHOWN

501900300 ROD END 1

063894200 HEX. SCREW ¾” x 3 ¼” LG GR – 5 1
014939500 NYLOCK NUT 1
509816101 HEX. SCREW 1
502658100 PIN RETAINER (FRONT) 1
015026400 LOCK WASHER FOR 3/8” 2
504169100 TILT CYLINDER PIN (REAR) 1
504168100 PIN RETAINER (REAR) 0

DVX 405 FC 1 - 69
 STEERING CYLINDER ASSEMBLY
(11286)

DVX 405 FC
FORKLIFTS
VOLTAS

1 - 70
VOLTAS
FORKLIFTS

STEER CYLINDER ASSEMBLY

(11286)

ITEM NO PART NO DESCRIPTION QTY

1 P3323D-01 PISTON 1
2 P3323D-02 PISTON ROD 1
3 P3323D-03 TUBE S / A 1
3A P3323D-03A TUBE -
4 P3323D-04 H.E. COVER 2
5 P3323D-05 PROTECTION PLUG 2
6 P3323D-06 HEX. SOC. GRUB SCREW 1
7 P3323D-07 CH. ALLOY STEEL BALL 1
8 P3323D-08 PISTON SEAL 1
9 P3323D-09 PISTON BEARING 1
10 P3323D-10 ROD SEAL 2
11 P3323D-11 ROD BEARING 2
12 P3323D-12 WIPER 2
13 P3323D-13 'O' RING (PISTON) 1
14 P3323D-14 'O' RING (PISTON SEAL) 1
15 P3323D-15 'O' RING (H.E. COVER) 2
16 P3323D-16 PROTECTION CAP 4
17 P3323D-17 SPACER 2

Seal Kit (P. No. 13227) consists of Item Nos. 8,9,10,11,12,13,14 & 15

DVX 405 FC 1 - 71
VOLTAS
FORKLIFTS

DVX 405 FC 1 - 72
VOLTAS
FORKLIFTS

HIGH VISIBILITY MAST ASSEMBLY

ITEM NO PART NO DESCRIPTION QTY

1 797319012 STATIONARY WELD'T 1

2 797319062 ELEVATING WELD'T 1
3 870001754 INTEGRAL BEARING 4
4 785269000 FLOW REGULATOR 1
5 12319 MANIFOLD 1
6 508623301 CHAIN SHEAVE 2
7 501989903 RETAINING RING 2
8 500353903 BEARING 2
9 060379000 RETAINING RING 2
10 060733200 HEX. SCREW 2
11 785209100 BARBED ELEBOW 2
12 992826072 SPLIT PIN 4
13 785769001 NYLOC NUT 2
14 014937500 HEX NUT 2
15 870002989 ROD END 2
16 870002974 PIN 2
17 993463092 'O' RING 3
19 993765270 ELBOW 3
20 992275385 HEX. SCREW 2
21 992761014 LOCK NUT 2
22 992791535 SPRING WASHER 8
23 504562100 WEAR PLUG ASSLY 4
24 014973300 JAM NUT 4
25 11274 SPL. GRUB SCREW 2
26 870000904 SPL. GRUB SCREW 2
27 12343 SPECIAL WASHER 2
28 992275379 HEX. SCREW 2
29 992275376 HEX. SCREW 4
30 12245 SPACER, MAST CYLINDER 2
31 12036 CYLINDER CLAMP 2
32 992571223 SOC. HEAD SCREW 4
33 992821555 CYLINDER PIN 2

DVX 405 FC 1 - 73
VOLTAS
FORKLIFTS

DVX 405 FC 1 - 74
VOLTAS
FORKLIFTS

HIGH VISIBILITY MAST ASSEMBLY

ITEM NO PART NO DESCRIPTION QTY

34 512926300 TRUNNION BUSHING 2

35 785324300 LUBE FITTING 2
36 508990100 TILT PIVOT BUSHING 2
37 502313100 RETAINER WEAR STRIP 2
38 502314100 WEAR STRIP 2
39 055486700 HEX. SCREW 2
40 061278000 FLAT WASHER 2
41 992791515 SPRING WASHER 4
42 992275221 HEX. SCREW 4
43 512505100 LOCK PLATE 4
44 060313900 CIRCLIP 4
45 00888 ADAPTOR 2
46 993463064 'O' RING 2
47 10135 HOIST CHAIN 2
48 797319052 HOIST CYLINDER 2

DVX 405 FC 1 - 75
 VOLTAS
FORKLIFTS
63 65
21 63 65
54
17 18 13
17 18 58
EF
P T
L R
7 15 51 52 64
5
14 43
59 60 46 61 62
28 71 64
48
53
28 78 49 66
55 41 42
75 76
15 15 50 56 47 77

43
29 44
26 31
57

39
10 40 10 25
9 2 9 16
6
38
3 1 4 72 73 24
9 10 68
74 ,73 74 ,73
32
10 9
74 ,73 74 ,73

71 6 19
4 72 73
71

20
12
8
12 21 23
22
11 12
36 37
35
32 28 70

HYDRAULIC SYSTEM
(797306018)

DVX 405 FC 1 - 76
VOLTAS
FORKLIFTS

HYDRAULIC SYSTEM
(797306018)

ITEM NO PART NO DESCRIPTION QTY

1 870000028 TILT LOCK VALVE 1

2 796406043 TUBE LH 1
3 796406053 TUBE RH 1
4 870000234 CONNECTOR 2
5 12319 MANIFOLD 1
6 993832692 H.P. HOSE 1
7 03284 HOSE 2
8 13391 2 SPOOL CONTROL VALVE - 1
9 785759401 ELBOW 4
10 993463041 'O' RING 4
11 785759402 HYDRAULIC FITTING 90° 1
12 993463075 ‘O’ RING 3
13 10987 HOIST CYLINDER ASSLY 2
14 785209100 90° FITTING 2
15 990711139 HOSE 3
16 785264500 90° SPECIAL ELBOW 1
17 797306029 RIGHT ANGLE ELBOW 2
18 993463064 'O' RING 2
19 993832650 HOSE 2
20 785757500 ELBOW 1
21 059803200 90° ELBOW (SWIVEL) 2
22 09391 PLUG (TEST PRESS) 1
23 785303100 ST. ADAPATOR 1
24 14886 RETURN LINE FILTER 1
25 07240 RT. ANGLE ELBOW 1
26 993832846 H.P. HOSE 1
27 870001299 HEX. BOLT 1
28 993463092 'O' RING 4
29 785756605 HOSE 1
30 44Z12D13 HOSE CLIP 1
31 11286 STEERING CYLINDER ASSLY 1
32 44Z12D8 HOSE CLIP 3
33 785756601 HYDRAULIC HOSE 0
34 785397900 90° ELBOW 0
35 785756602 HYDRAULIC HOSE 1
36 993766809 90° BARBED ELBOW 1
37 993463092 'O' RING 2

DVX 405 FC 1 - 77
 VOLTAS
FORKLIFTS

63 65
21 63 65
54
17 18 13
17 18 58
EF
P T
L R
7 15 51 52 64
5
14 43
59 60 46 61 62
28 71 64
48
53
28 78 49 66
55 41 42
75 76
15 15 50 56 47 77

43
29 44
26 31
57

39
10 40 10 25
9 2 9 16
6
38
3 1 4 72 73 24
9 10 68
74 ,73 74 ,73
32
10 9
74 ,73 74 ,73

71 6 19
4 72 73
71

20
12
8
12 21 23
22
11 12
36 37
35
32 28 70

HYDRAULIC SYSTEM
(797306018)

DVX 405 FC 1 - 78
VOLTAS
FORKLIFTS

HYDRAULIC SYSTEM
(797306018)

ITEM NO PART NO DESCRIPTION QTY

38 796406591 HYDRAULIC TANK ASSLY 1

39 796414052 L.H. TILT CYLINDER (ALT-1 / ALT-2) 1
796414089 L.H. TILT CYLINDER (VOLTAS) 1
40 796414069 R.H. TILT CYLINDER (ALT-1 / ALT-2) 1
796414099 R.H. TILT CYLINDER (VOLTAS) 1
41 993750109 ST. ADAPTOR 2
42 993463046 'O' RING 2
43 09465 HOSE 2
44 993728160 HOSE CLIP 1
45 993728140 HOSE CLIP 1
46 992781634 BLACK WASHER 2
47 992791525 SPRING WASHER 1
48 992571379 SOC. HEAD SCREW 2
49 992791535 SPRING WASHER 2
50 796406014 SPECIAL FITTING 1
51 794707119 HOSE 1
52 11332 ST. ADAPTOR 1
53 993764089 ELBOW 1
54 11660 STEERING UNIT 1
55 785258600 HYDRAULIC ADAPTOR 1
56 993728160 HOSE CLIP 1
57 798622029 HOSE 1
58 794707119 H.P. HOSE 1
59 08744 TEE 1
60 993728112 HOSE CLIP 5
61 11193 ST. ADAPTOR 2
62 993750609 90° SWIVEL ELBOE 2
63 11333 ST. ADAPTOR 2
64 795020119 DOWTY WASHER 3
65 795020129 DOWTY WASHER 2
66 11672 STRG. HOSE CLAMP BKT. 2
67 993750609 RT. ANGLE ELBOW 9/16” 2
68 993764805 RT. ANGLE ELBOW 1
69 11305 ST. ADAPTOR 1
70 059803200 90° ELBOW 1 1/16” 1
71 93832675 HOSE 2

DVX 405 FC 1 - 79
 VOLTAS
FORKLIFTS

63 65
21 63 65
54
17 18 13
17 18 58
EF
P T
L R
7 15 51 52 64
5
14 43
59 60 46 61 62
28 71 64
48
53
28 78 49 66
55 41 42
75 76
15 15 50 56 47 77

43
29 44
26 31
57

39
10 40 10 25
9 2 9 16
6
38
3 1 4 72 73 24
9 10 68
74 ,73 74 ,73
32
10 9
74 ,73 74 ,73

71 6 19
4 72 73
71

20
12
8
12 21 23
22
11 12
36 37
35
32 28 70

HYDRAULIC SYSTEM
(797306018)

DVX 405 FC 1 - 80
VOLTAS
FORKLIFTS

HYDRAULIC SYSTEM
(797306018)

ITEM NO PART NO DESCRIPTION QTY

72 870000224 90° MALE ELBOW LONG 2

73 870000243 WASHER 6
74 870000214 CONNECTOR MALE TO MALE 4
75 992271297 HEX. SCREW M8 x 30 1
76 992761013 HEX. NUT M8 1
77 992781624 WASHER M8 1
78 993765270 RIGHT ANGLE ELBOW 1
79 721552700 ELBOW 90° 2

DVX 405 FC 1 - 81
VOLTAS
FORKLIFTS

HYDRAULIC TANK ASSEMBLY

DVX 405 FC 1 - 82
VOLTAS
FORKLIFTS

HYDRAULIC TANK ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1 785767200 HYD. TANK WELD' T 1

2 00792 SUCTION STRAINER 1
3 785382800 AIR BREATHER ASSLY 1
4 870000533 DIP STICK 1

HARDWARE FOR HYDRAULIC TANK

014936900 HEX NUT 2

015029000 SPRING WASHER 2
055486800 HEX HD. SCREW 2
061278000 FLAT WASHER 2
992275376 HEX SCREW M10 3
992761114 HEX NUT M10 3

DVX 405 FC 1 - 83
VOLTAS
FORKLIFTS

FUEL LINE DIAGRAM

( SIMPSON S4 ENGINE )

DVX 405 FC 1 - 84
VOLTAS
FORKLIFTS

FUEL LINE DIAGRAM (SIMPSON S4 ENGINE)

ITEM NO. PART NO. DESCRIPTION QTY.

1 785202301 FUEL LINE (TANK TO ENGINE SUCTION) 1

2 785202301 FUEL LINE (ENGINE OUTLET TO FILTER) 1
3 785202301 FUEL LINE(FILTER TO FUEL INJECTOR PUMP) 1
4 785202301 FUEL LINE (OVERFLOW FUEL PUMP TO TANK) 1
5 785216100 DUAL FILTER 1
785216101 FILTER ELEMENT (PRELIMINARY FILTER) 1
785216102 FILTER ELEMENT (PAPER ELEMENT) 1
6 796421011 FUEL TANK 1
7 785750900 JUNCTION BLOCK WELDMENT 1
785761700 PLATE 1
8 10187 BANJO CONNECTION 1
9 785200803 WASHER 4
10 785215000 HEX. HOLLOW SCREW 1
11 10209 FUEL LINE (OVERFLOW - INJECTOR TO TANK) 1

ITEMS NOT SHOWN

10933 PLUG FOR FUEL FILTER 1

785252781 PERFORATED 2
785252701 NYLON BUTTON 2

DVX 405 FC 1 - 85
VOLTAS
FORKLIFTS

AIR INTAKE ASSEMBLY

(SIMPSON S4 ENGINE)

DVX 405 FC 1 - 86
VOLTAS
FORKLIFTS

AIR INTAKE SYSTEM

ITEM NO PART NO DESCRIPTION QTY

1 10197 AIR INTAKE FILTER 1

2 10206 AIR FILTER MTG. BKT. 1
3 11473 HOSE 1
4 11934 AIR CLEANER SUPPORT BKT. 1
5 992271416 HEX. SCREW 6
6 992761015 NUT 4
7 992781644 PLAIN WASHER 6
8 992791545 SPRING WASHER 6
9 993728180 HOSE CLAMP 2

ITEMS NOT SHOWN

10237 FILTER ELEMENT ( OUTER ) 1

10238 FILTER ELEMENT ( INNER ) 1
10239 VACCUM INDICATOR 1

DVX 405 FC 1 - 87
VOLTAS
FORKLIFTS

CANOPY INSTALLATION

DVX 405 FC 1 - 88
VOLTAS
FORKLIFTS

CANOPY INSTALLATION

ITEM NO PART NO DESCRIPTION QTY

1 796413011 CANOPY WELDMENT 1

2 992175433 BOLT M12 X 100 2
3 992175389 BOLT M12 X 80 2
4 992781684 BLACK WASHER M20 6
5 992785644 GALVANISED WASHER M12 6
6 992791545 SPRING WASHER M12 4
7 992761215 NUT M12 2

DVX 405 FC 1 - 89
VOLTAS
FORKLIFTS

COUNTERWEIGHT INSTALLATION

DVX 405 FC 1 - 90
VOLTAS
FORKLIFTS

COUNTERWEIGHT INSTALLATION

ITEM NO PART NO DESCRIPTION QTY

1 796417011 COUNTERWEIGHT 1
2 07608 SPL. BOLT 2
3 870001204 SPL. WASHER 2

ITEM NOT SHOWN

796417033 TOW SHACKLE 1

DVX 405 FC 1 - 91
VOLTAS
FORKLIFTS

WHEELS & TYRES ( SOLID CUSHION )

DVX 405 FC 1 - 92
VOLTAS
FORKLIFTS

WHEELS AND TYRES (BEAR CAT)

ITEM NO. PART NO. DESCRIPTION QTY.

1 796416048 WHEEL ASSLY - DRIVE 4

THE WHEEL ASSLY SET CONSISTS OF:
785231102 DRIVE RIM ASSLY 1
785765901 SOLID CUSHION TYRE 7.00 X 12 1
08724 DRIVE WHEEL NUT 6
08725 SPRING WASHER 6

2 796416028 WHEEL ASSLY - TRAIL 2

THE WHEEL ASSLY SET CONSISTS OF:
870001711 RIM ASSEMBLY 1
785765903 SOLID CUSHION TYRE 6.50 X 10 1
12195 TRAIL WHEEL NUT 6

DVX 405 FC 1 - 93
VOLTAS
FORKLIFTS

Your investment in a Voltas Forklift Truck is important to you and to Voltas. You
measure the return on that investment through the performance of these trucks and the
drivers who operate and the mechanics who service them safely and efficiently. The
following information and programs are intended to help you to achieve your investment
objectives:

SERVICE PARTS ORDERING INSTRUCTIONS

HOW TO ORDER SERVICE PARTS

In order to prevent delay, too much communication and to have your orders filled
correctly, quickly and at the least possible cost, the following is the correct procedure to
use to order replacement parts.

WHEN ORDERING PARTS

Contact your nearest Voltas Office giving them the following information:

1. Your Purchase order number.

2. Complete addresses for sending the invoice and parts.

3. Tell us how you want your parts to be sent.

4. Correct part numbers and descriptions. Use your parts manual as a reference.

5. Model and serial number of the truck.

TECHNICAL SERVICE PUBLICATIONS

To help you maintain your Voltas Forklift Trucks in a safe and useful condition, detailed
information is available. Included are Service Parts Manuals with complete replacement
parts in identification which give proper service and overhaul procedure. Additional
copies of this Operator's Manual can also be obtained from your nearest Voltas Office.

SERVICE MANUAL PART NO. : DVX30GB-BC-PM02-02

OPERATOR'S MANUAL PART NO. : DVX30GB-BC-OM-02-02

To provide instructions for safe operating and servicing Voltas Forklift Trucks, each truck
is equipped with an operators manual. It describes various operating techniques and
safety warnings to the operator. It contains a guide to safe maintenance practices and
recommended schedules for maintenance. If the operators manual is missing from any
Voltas Forklift Truck, it should be replaced. Replacement copies are available for a
nominal fee from your Voltas Office.

DVX 405 FC 1 - 94
VOLTAS
FORKLIFTS

OPERATOR TRAINING
The Operator and Maintenance program helps Forklift Truck users increase their
materials handling production and safety through correct lift truck operations, training
and motivation. The Voltas Forklift Truck program is based upon real life experience-not
theoretical concepts. We developed a "complete" program that is totally self-contained-
incorporating the most modern instructional techniques, including elements of self-study,
audio-visual support (both video and slides), and classroom study.

SERVICE TRAINING COURSES

Operators and service technicians can improve their technical ability for maintaining and
repairing Voltas Forklift Trucks and decrease repair time and cost by taking the Voltas
Service Training courses. Different types of mechanical, electric and electronic subjects
are available. Courses are available at customer locations in addition to regularly
scheduled courses which are held at Voltas Limited MHBD, 2nd Pokhran Road, Thane
(West)-400601.

COURSES AVAILABLE

1. Training Programme on Diesel & Electric Forklift Trucks

Objective : This programme has been designed to equip the customers

maintenance personnel who are responsible for daily maintenance of forklift trucks.
Key Topics : Diesel Engine Maintenance, Hydraulics, Electricals, Transmission,
Fluid coupling, Mechanical Maintenance & Safety.
Participation: All the above key topics will be presented by experts drawn from
Simpsons Koel, Vickers, Chloride, Lucas & Co-ordinated by all India Service
Manager.
Duration : 3 Days.
Venue : Voltas Technical Training Centre, Thane.

2. Crash Service Training Diesel & Electric Fork Lift Trucks - Major Fleet Owners

Objective : To impart in-depth knowledge to customers maintenance & operation

personnel at their own Plant / Site.
Key Topics : Proper Operational Practices, Overview of Mechanical assemblies,
Do's & Don’ts, Routine Maintenance, Preventive Maintenance.
Participation: This "On-The-Site" Training will be imparted by all India Service
Manager in association with branch service personnel.
Duration : 3 Days
Venue : At Customers Location Site.

DVX 405 FC 1 - 95
VOLTAS
FORKLIFTS

TRAINING CALENDAR
Material Handling Equipment Training Calendar is published every year.
This training calendar gives details of the courses scheduled for the current year, which
can be obtained from the nearest Voltas Office.

For additional information or assistance on these programs, contact or write to :

Voltas Limited,
MATERIAL HANDLING BUSINESS DIVISION ,
2nd Pokhran Road,
Thane (West)-400601.

FIRST INDIAN MANUFACTURER OF FORKLIFTS AND CRANES

TO GET THE ISO 9001.

DVX 405 FC 1 - 96
VOLTAS
FORKLIFTS

HEAD OFFICE: VOLTAS LIMITED

MATERIALS HANDLING BUSINESS DIVISION
2nd Pokharan Road, P. Box No. 72, Thane – 400 601
Tel.022-534 4390 / 534 2647 / 534 1951:
Fax.: 022-542 7564
e-mail: tmanohar@voltas.com
AHMEDABAD 380 001 KOLKATA 700 001
2nd Floor, Pushpak, Khanpur Gillander House, 8, Netaji Subhash Road,
Tel.: 079-560 1864 / 560 1864 Tel.: 033-220 7475
Fax. 079-560 1330 Fax: 033-248 2517 / 243 4345
e-mail; mhbdahm@voltas.com e-mail: mhaldar@voltas.com

BANGALORE 560 001 LUCKNOW 226 001

37, Kasturba Road, Bangalore, Saran Chambers, 5, Park Road,
Tel: 080-227 2488 / 227 3691 Tel: 0522-238 536
Fax: 080-227 0172 Fax: 0522-238 532
e-mail: mhbdblr@voltas.com e-mail: sdatta@voltas.com

CHENNAI 600 018 MUMBAI 400 033

503, Anna Salai, Voltas House, Chinchpokli,
Tel: 044-434 9118 / 9465 / 8976 Tel: 022-461 7691 / 4617690
Fax: 044-434 2178 Fax: 022-3747 990
e-mail: chemhbd@voltas.com e-mail: anil joshi@voltas.com

HYDRABAD 500 018 NEW DELHI 110 044

Voltas House, 7-2-1813 / 5A, A-43 Mohan Co-op. Ind. Estate
Sanath Nagar Mathura Road
Tel: 040-370 3820 / 3821 / 3822 Tel: 011-695 0278 / 0289 / 9042
Dir; 040-370 3806 Fax: 011-695 0022
e-mail: swaminathan@volta.com e-mail: cchakrav@voltas.com

JAMSHEDPUR 831 001 PUNE 411 003

Voltas House, P. Box No. 52, Bistupur 14, Mumbai-Pune Road, Wakade wadi.
Tel: 0657-424276 / 427651 Tel: 022-551 1429 / 1430
Fax: 0657-432 201 Fax: 022-551 2410 /2431
e-mail: skdas@voltas.com e-mail: nsshenoy@voltas.com

KOCHI 682 018 VISHAKHAPATTAM 530 016

Vidyniketan Annex, Providence Road, 50-81-72, Rajendra Nagar,
Ernakulam, Near B.V.K.College,
Tel: 0484-392 823 Tel: 0891-562 096 /754 051
Fax: 0484-395 984 Fax: 0891-754 665
e-mail: kkumar@voltas.com e-mail: voltasdivizag@eth.net
REGD. OFFICE
Voltas House, A Dr. Babasaheb Ambedkar Road, Chinchpokli
Mumbai 400 033
Tel: 022-461 7777
Fax: 022-461 0231

DVX 405 FC 1 - 97