Yale MP22 1

Part no.
: 550127938 Overhaul: 1 (05/2018)
Technical information for Yale service

centres
This manual is intended solely for the specialized technicians of

the Yale service network.
MP16 - MP18
A428.....
MP20 - MP22
INTRODUCTION SERVICE
IMPORTANT
The Service Manuals are updated regularly, but may not contain the most recent product design modifica-
tions. The updated technical information is in any case available from your nearest authorised Hyster®
dealer. The Service Manuals provide the guidelines for correct maintenance and are designed for use by
appropriately trained technicians. Incorrect maintenance or non-compliance with the instructions contained
in this manual could cause damage to property or injury and even death to people.
We therefore recommend that you read this manual carefully and keep it in a good condition so it is always
decipherable and complete.
This manual does not replace the use and maintenance manual, it is a supplement to it.
Product support group
2
SERVICE INTRODUCTION
SECTIONS
This handbook is composed of the following sections:
Section 1: Presentation
Section 2: Installation and settings
Section 3: Diagnostics and measurements
Section 4: Electrical system
Section 5: Hydraulic system
Section 6: Mechanics
Section 7: Reduction gear
Section 8: Braking system
Section 9: Standard maintenance
Use the sections index with the numbered black bands to go quickly to the desired section.
SYMBOLS
Signals a danger that can cause accidents to people or damage to the machine.
Signals danger due to high temperatures.
Signals important notes or information to take into particular consideration.
Signals disposal/recycling of harmful substances under the protection of current legislation.
INSTALLATION PROCEDURES
For the installation procedures, carry out the reverse procedure to disassembly, observing any notes and
information given for the truck to function properly.
3
GENERAL SAFETY RULES

PERSONAL SAFETY
• Always wear the personal protective equipment in situations requiring it.
• Pay particular attention to the risk of getting crushed due to moving parts, oscillations, material not
properly secured when performing lifting operations or moving loads.
• Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbut-
toned jackets or tops with open zippers that can get caught up in moving parts.
• Never do any cleaning, lubrication or maintenance work with the battery connected.
• Using compressed air to clean the parts, protect yourself with goggles that have side protection. The
maximum air pressure must not exceed 1 bar.
SAFETY AT THE WORKPLACE

• Make sure that all the work tools are perfectly efficient and ready for use. Keep the work surfaces clean
and clear of debris that can come into contact with parts of the machine and cause damage.
• Make sure you keep sparks, naked lights and cigarettes away from fuels or flammable materials such
as the gas of the batteries and fuels.
• Make sure that the work area is ventilated, well illuminated, dry and clean. Remove any puddles of
water or oil stains.
• Make sure that the equipment, devices or lifting machinery used is able to sustain the load in a stable
manner.
• Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable
and non-toxic trade solvents.
• When working outside the garage, move the machine preferably onto the level and block it. If working
on a slope is inevitable, block the machine beforehand and move it onto a level area as soon as pos-
sible with a certain margin of safety.
• Disconnect the batteries and label all the controls to signal that work is in progress. Block the machine
and every attachment that has to be raised.
• Never perform any servicing on the machine with persons at the controls, unless they are accredited
operators and help with the operation to be performed.
• When towing use solely the prescribed coupling points and check that the pins and/or bolts are firmly
secured before pulling. Lift and handle all the heavy parts with lifting equipment of adequate capacity.
Use the lifting eyebolts intended for this purpose. Make sure no one is near the load to be lifted.
• Avoid twisting chains or metal ropes.
• Do not trust bent or damaged chains or ropes: do not use them for lifting or pulling. Always wear the
safety gloves to handle them.
• Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away
into a closed metal container.
• Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.
• When welding is necessary, you must use appropriate safety protection: dark goggles, hard hat, overalls,
gloves, safety footwear. Dark goggles must be worn also by those who are not doing the work if they
remain nearby during the welding.
4
• Before using the batteries, make sure that both ends of the cables are connected to the terminals as
prescribed: (+) with (+) and (-) with (-).
• Do not short-circuit the terminals.
• The gas released when charging is highly flammable. When charging, leave the battery compartment
uncovered for more effective ventilation and take off the plugs.
• Never check the battery charge with "jumpers" obtained by putting metal items on the terminals.
• Before taking any action, check that no elements are shorted.
• Always disconnect the battery before working on the electrical system.
• For battery chargers and similar equipment, use solely auxiliary power sources with an effective ground
connection to avoid any electric shocks.
• Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.
• Having to check the system pressure, use the specific instruments.
BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE

• Keep a record of all the suspension elements used, stating the characteristics of the suspension ele-
ments and the data given on the identification plate .
• Never leave belts, cords or suspension elements in use whose identification plate has been lost.
• Always use belts, ropes or suspension elements of suitable dimensions. Concerning the suspension
elements, take into consideration the lifting angle and any unbalancing of the load.
• The bells on the suspension elements must be sized in proportion to the hook of the overhead travelling
crane and anyhow must be free to move easily.
• Always rest the load in the race of the hook.
• Never load the tip of the hook.
• When lifting, avoid sudden operations that can jerk on the ropes and belts.
• Never do any lifting with the ropes and belts twisted.
• Knots are not permissible. Always protect the ropes and belts when they come into contact with sharp
edges.
• When moving with no load, to prevent impact and accidental hooking, hang the hooks in the bells and
close the safety ones.
Using suspension elements under conditions of unbalanced load

If lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting elements:
• Slings with 2 booms, consider them as corresponding to 1 boom.
• Slings with 3 and 4 booms, consider them as corresponding to 2 booms.
Tips for maintenance
Periodically examine the belts, ropes and suspension elements according to current legislation to define
their state of service.
Change them in the following cases:
• When the components show: deformation, cracks, hollows, cuts or abrasions.
• When the wear of the components exceeds 10% of the original dimensions.
• When the sling shows signs of overloading.
5
Belt capacity table
Colour
purple 1000 2000 1400 800

green 2000 4000 2800 1600
yellow 3000 6000 4200 2400
grey 4000 8000 5600 3200
red 5000 10000 7000 4000
brown 6000 12000 8400 4800
Working load blue 8000 16000 11200 6400
capacity (kg)
orange 10000 20000 14000 8000
orange 12000 24000 16800 9600
orange 15000 30000 21000 12000
orange 20000 40000 28000 16000
orange 25000 50000 35000 20000
orange 30000 60000 42000 24000
Coefficient 1 2 1.4 0.8
Rope capacity table
Track
Colour
(mm)
black 35 500 1000 700 400

purple 50 1000 2000 1400 800
black 50 1500 3000 2100 1200
green 60 2000 4000 2800 1600
Working load yellow 75 3000 6000 4200 2400
capacity (kg) grey 120 4000 8000 5600 3200
red 150 5000 10000 7000 4000
brown 180 6000 12000 8400 4800
blue 240 8000 16000 11200 6400
orange 300 10000 20000 14000 8000
Coefficient 1 2 1.4 0.8
6
Suspension element capacity table
Colour
purple 1000 1400 2100 2100

green 2000 2800 4200 4200
Working load
yellow 3000 3800 6300 6300
capacity (kg)
grey 4000 5600 8400 8400
red 5000 6600 9800 10500
Coefficient 1 1.4 2.1 2.1
Working load capacity: the working load capacity is calculated with an angle at the
centre of 90°
7
TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

Before disassembling the various parts
and nuts and bolts, read the following Nominal TORQUE SETTING Nm
carefully. diameter
Class 8 Class 10
To make the threaded matings secure, LOCTITE 270 is M3 4 5.2
used for tightening the screws.
M4 7 9.15
If it is not possible to unscrew the bolts because this
M5 12.14 14.8
product has been used, avoid applying extensions to
the tools, instead slightly heat the area (at most 50°C) M6 17.2 20.9
so as to eliminate the LOCTITE 270 effect. M8 31.8 38.1
In the cases described, reapply LOCTITE 270 during M10 50.5 60.3
installation in a moderate quantity (30% of the mating M12 74.2 88.5
surface). M14 101.2 120.8
The torque setting used for tightening the threaded M16 138.2 164.9
couplings is extremely important to make the coupling
M18 176.6 203.5
secure and the machine safe.
M20 225.4 259.7
M22 278.8 321.2
The tables on this page give the classes of bolts normally
used with the relevant torque settings. M24 324.8 374.2
M27 422.3 486.5
M30 516.1 594.7
TORQUE SETTING Nm
Pre-load N Class 5.8 Class 8.8 Class 10.9
M4 0.7 7 3 2400 1.92 1.44 3.07 2.3 4.17 3.13

M5 0.8 8 4 3880 3.88 2.91 6.2 4.65 8.43 6.33
M6 1 10 5 5490 6.58 4.94 10.5 7.9 14.3 10.8
M8 1.25 13 6 9990 16 12 25.6 19.2 34.8 26.1
M8 1 13 6 10700 17.1 12.8 27.4 20.5 37.3 27.9
M10 1.5 16 8 15825 31.7 23.8 51 38 69 52
M10 1.25 16 8 16700 33.4 25.1 53 40.1 73 55
M12 1.75 18 10 23025 55 41.4 88 66 120 90
M12 1.25 18 10 25150 60 45.3 96 72 130 98
M14 2 21 12 31400 88 66 140 105 190 145
M14 1.5 21 12 34125 96 72 155 115 210 155
M16 2 24 14 42850 135 105 220 165 300 225
M16 1.5 24 14 45600 145 110 235 175 320 240
M20 2.5 30 17 66875 270 200 430 320 580 435
M20 1.5 30 17 74250 295 225 475 355 650 485
= with lubricant
8
CORRECT METHOD FOR APPLYING FEMALE FITTINGS

To assure a reliable seal between female fittings and the adapters in this manual, it is necessary to observe
the following procedure, which differs from the one for assembling rigid pipes.
Female fittings without a gasket (metal/metal joint)
Screw on the nut by hand and then, with the aid of a wrench, tighten by another quarter turn.
Female fittings with O-ring
Screw on the nut by hand and then, with the aid of a wrench, tighten by another half turn.
In every case make sure that the pipe is properly aligned before tightening the nut on the adapter.
TORQUE SETTINGS
METRIC REVOLVING FEMALE REVOLVING FEMALE jic 37°

Torque setting Nm Torque setting Nm
Outside
UNF UNF
diameter Size
thread Nominal torque min / max thread Nominal torque min / max
of the pipe
M 12x1.5 6 20 15 -25 7/16-20 -4 15 9 - 21
M 14x1.5 8 38 30 - 45 1/2-20 -5 20 13 - 27
8 9/16-18 -6 30 18 - 42
M 16x1.5 45 38 - 52
10 3/4-16 -8 50 30 - 70
10 7/8-14 -10 69 44 - 94
M 18x1.5 51 43 - 85
12 1.1/16-12 -12 98 63 - 133
M 20x1.5 12 58 50 - 65 1.3/16-12 -14 118 73 - 163
14 1.5/16-12 -16 140 90 - 190
M 22x1.5 74 60 - 88
15 1.5/8-12 -20 210 135 - 285
M 24x1.5 16 74 60 - 88 1.7/8-12 -24 290 200 - 380
M 26x1.5 18 105 85 - 125 2.1/2-12 -32 450 300 - 600
20
M 30x2 135 115 - 155
22
25
M 36x2 166 140 - 192
28
M 42x2 30 240 210 - 270
M 45x2 35 290 255 - 325
38
M 52x2 330 280 - 380
42
BSP REVOLVING FEMALE ORFS REVOLVING FEMALE

Torque setting Nm Torque setting Nm
UNF UNF
Size
thread Nominal torque max thread Nominal torque max.
G1/4 20 15 - 25 9/16-18 -4 14 16
G3/8 34 27 - 41 11/16-16 -6 24 27
G1/2 60 42 - 76 13/16-16 -8 43 47
G5/8 69 44 - 94 1-14 -10 60 68
G3/4 115 95 - 135 1.3/16-12 -12 90 95
G1 140 115 - 165 1.3/16-12 -14 90 95
G1.1/4 210 140 - 280 1.7/16-12 -16 125 135
G1.1/2 290 215 - 365 1.11/16-12 -20 170 190
G2 400 300 - 500 2-12 -24 200 225
2-1/2-20 -32 460 490
The values given in the tables refer to galvanized steel fittings. Fittings of other materials
have other values.
9
INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS

Inspection of pipes and fittings
When even just one of the following conditions arises the pipe must immediately be disconnected and
replaced:
• a shift of the connector on the pipe;
• the presence of damage, cuts or abrasions on the surface layer;
• hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
• the presence of cracks, damage or bad corrosion on the connector;
• the presence of leaks along the pipe or at the connector;
• the presence of permanent creases, compression, flattening or twists in the pipe;
• the presence of blisters, softening, wear of the external coat.
Pre-installation inspection
Before installing a flexible hose it is necessary to inspect the pipes carefully. First check that the type, size,
reference code and length are correct, then check there is no debris, blockages, bubbles, peeling of the
outer layer or any other visible defects.
Installation
Avoid twisting the pipe, which could cause it to burst under pressure.
There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assem-
bled pipe decreases considerably when below the minimum radius of curvature.
The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly
greater length than the requirement in order to compensate for these changes.
10
SECTION CONTENTS
Presentation 1
Installation and settings 2
Diagnostics and measurements 3
Electrical system 4
Hydraulic system 5
Mechanics 6
Reduction gear 6
7
Braking system 6
8
Standard maintenance 7
9
11
12
SERVICE PRESENTATION
PRESENTATION
TRUCK PRESENTATION�� 2
VIEWS OF THE TRUCK�� 3
TRUCK IDENTIFICATION DATA AND LOAD CAPACITIES�� 4
TRUCK IDENTIFICATION DATA PLATE�� 4
MAST SERIAL NUMBER STAMP�� 4
LOCATION OF DOCUMENTATION�� 5
GENERAL SPECIFICATIONS�� 6
1
PRESENTATION SERVICE
TRUCK PRESENTATION
The new range of pedestrian tiller operated pallet trucks has a nominal load capacity of from 1600 kg to
2200 kg.
These trucks are electric vehicles on which a battery provides sufficient current for driving and lifting. The
battery is in the compartment on the fork frame and is raised/lowered together with the movement of the
forks. The battery compartment also acts as a load rack and helps keep the load blocked.
The tiller is used to select the various functions, among which steering, selecting the drive mode, braking,
directing the truck and controlling the speed, lifting and lowering of the forks.
2
VIEWS OF THE TRUCK
3
TRUCK AND LOAD IDENTIFICATION DATA

TRUCK IDENTIFICATION DATA PLATE
The truck identification data plate is located in the battery

compartment.
• Manufacturer's name • Max. battery weight

• Model • Min. battery weight
• Serial number • Battery voltage
• Weight without battery • Nominal load capacity
• Year of manufacture • Persons on board
TRUCK SERIAL NUMBER
The truck serial number is stamped on top of

the frame.
4
DATA POSITION
The truck documentation is located in the battery

compartment.
5
GENERAL SPECIFICATIONS
MP18 - MP20
1 - Running
2 - Braking
6
1.2 Model P 1.6
MP16 P 1.8
MP18
1.3 Propulsion: battery, diesel, LPG, petrol, electric Battery Battery
CHARACTERISTICS
1.4 Steering: tiller, pedestrian, standing, sitting tiller tiller

1.5 Load capacity, load Q (t) 1.6 1.8
1.6 Centre of gravity c (mm) 600 600
1.8 Load distance from the load wheel axle(2) x (mm) 955 955
1.9 Wheelbase (WB) (2) y (mm) 1368 1368
2.1 Unladen weight (1) (3) kg 545 545
WEIGHTS
2.2 Load per axle when loaded (front/rear) kg 841 / 1304 893 / 1452
2.3 Load per axle when unladen (front/rear) kg 425 / 120 425 / 120
3.1 Tyres: full rubber, polyurethane, vulkollan (front/rear) polyur. polyur.
WHEELS AND CHASSIS
3.2 Tyre size, front ø (mmxmm) 250 x 75 250 x 75

3.3 Tyre size, rear ø (mmxmm) 85 x 110 85 x 110
3.4 Additional wheels (size) ø (mmxmm) 100 x 40 100 x 40
3.5 Wheels: quantity, (x= traction) (front/rear) 1x+2 / 2 1x+2 / 2
3.6 Front track width b10 (mm) 461 461
3.7 Rear track width b11 (mm) 390 390
4.4 Lifting h3 (mm) 130 130
4.9 Height of tiller in operating position (min/max) h14 (mm) 744 / 1221 744 / 1221
4.15 Lowered forks height h13 (mm) 83 83
4.19 Total length (2)
l1 (mm) 1734 1734
4.20 Length of the forks at the heel (2) l2 (mm) 578 578
DIMENSIONS
4.21 Overall width b1/b2 (mm) 712 712

4.22 Fork size s/e/l (mm) 64 / 172 / 1156 64 / 172 / 1156
4.25 Outer fork gauge b5 (mm) 560 560
4.32 Ground clearance at wheelbase centre m2 (mm) 21 21
4.33 Load dimension b 12 × l 6 crossways b12 × l6 (mm) - -
4.34.1 Working aisle width with 1000 x 1200 pallet (2) Ast (mm) 2337 2337
4.35 Turning radius (2)
Wa (mm) 1535 1535
5.1 Travel speed with/without load km/h 6/6 6/6
5,1,1 Travel speed with/without load............... km/h 6/6 6/6
PERFORMANCE
5.2 Fork lifting speed with/without load m/s 0.04 / 0.05 0.04 / 0.05
5.3 Fork lowering speed with/without load m/s 0.09 / 0.04 0.09 / 0.04
5.7 Gradient, with/without load % 10 / 15 10 / 15
5.8 Maximum gradeability with/without load % 14.5 / 20 14.5 / 20
5.10 Service brakes electromagnetic electromagnetic
6.1 Traction motor, S2 60 minutes kW 1.25 1.25
ELECTRIC MOTORS
6.2 Lift motor, SR 15% rating kW 1.2 1.2

6.3 BS battery, DIN 43531/35/36 A,B,C, no (4) Din 43535 B Din 43535 B
6.4 Battery voltage/nominal capacity (1) V/Ah 24 / 250 24 / 250
6.5 Battery weight (1) (3) kg 212 212
kWh/h at number
6.6 Energy consumption per VDI cycle 0.384 0.384
of cycles
Upd. Drive/lift
data mech.
8.1 Type of control AC ~ Mosfet AC ~ Mosfet
10.7 Noise level at driver's position dB (A) < 70 < 70
(1) On P1.6 P1.8 available batteries 150Ah,210Ah. (2) See “batteries table”
On P2.0 available batteries 150Ah, 210Ah, 250Ah, 315Ah. (3) These values can vary by +/- 5%
On P2.2 available batteries 210Ah, 250Ah, 315Ah. (4) The 150Ah battery is not DIN 43635 B
7
MP20L - MP22
1 - Running
2 - Braking
8
1.2 Model MP20
P 2.0 MP22
P 2.2
1.3 Propulsion: battery, diesel, LPG, petrol, electric Battery Battery
CHARACTERISTICS
1.4 Steering: tiller, pedestrian, standing, sitting tiller tiller

1.5 Load capacity, load Q (t) 2.0 2.2
1.6 Centre of gravity c (mm) 600 600
1.8 Load distance from the load wheel axle(2) x (mm) 955 955
1.9 Wheelbase (WB) (2) y (mm) 1440 1440
2.1 Unladen weight (1) (3) kg 632 632
WEIGHTS
2.2 Load per axle when loaded (front/rear) kg 983 / 1452 983 / 1452
2.3 Load per axle when unladen (front/rear) kg 489 / 143 489 / 143
3.1 Tyres: full rubber, polyurethane, vulkollan (front/rear) polyur. polyur.
WHEELS AND CHASSIS
3.2 Tyre size, front ø (mmxmm) 250 x 75 250 x 75

3.3 Tyre size, rear ø (mmxmm) 85 x 110 85 x 110
3.4 Additional wheels (size) ø (mmxmm) 100 x 40 100 x 40
3.5 Wheels: quantity, (x= traction) (front/rear) 1x+2 / 2 1x+2 / 2
3.6 Front track width b10 (mm) 461 461
3.7 Rear track width b11 (mm) 390 390
4.4 Lifting h3 (mm) 130 130
4.9 Height of tiller in operating position (min/max) h14 (mm) 744 / 1221 744 / 1221
4.15 Lowered forks height h13 (mm) 83 83
4.19 Total length (2)
l1 (mm) 1806 1806
4.20 Length of the forks at the heel (2) l2 (mm) 650 650
DIMENSIONS
4.21 Overall width b1/b2 (mm) 712 712

4.22 Fork size s/e/l (mm) 64 / 172 / 1156 64 / 172 / 1156
4.25 Outer fork gauge b5 (mm) 560 560
4.32 Ground clearance at wheelbase centre m2 (mm) 21 21
4.33 Load dimension b 12 × l 6 crossways b12 × l6 (mm) - -
4.35 Turning radius (2)
Wa (mm) 1607 1607
5.1 Travel speed with/without load km/h 6/6 6/6
5,1,1 Travel speed with/without load............... km/h 6/6 6/6
PERFORMANCE
5.2 Fork lifting speed with/without load m/s 0.04 / 0.05 0.04 / 0.05
5.3 Fork lowering speed with/without load m/s 0.09 / 0.04 0.09 / 0.04
5.7 Gradient with/without load % 10 / 15 10 / 15
5.8 Maximum gradeability with/without load % 14.5 / 20 14.5 / 20
5.10 Service brakes electromagnetic electromagnetic
6.1 Traction motor, S2 60 minutes kW 1.25 1.25
ELECTICAL MOTORS
6.2 Lift motor, SR 15% rating kW 1.2 1.2

6.3 BS battery, DIN 43531/35/36 A,B,C, no (4) Din 43535 B Din 43535 B
6.4 Battery voltage/nominal capacity (1) V/Ah 24 / 375 24 / 375
6.5 Battery weight (1) (3) kg 288 288
kWh/h at number
6.6 Energy consumption per VDI cycle 0.384 0.384
of cycles
Upd. Drive/lift
data mech.
8.1 Type of control AC ~ Mosfet AC ~ Mosfet
10.7 Noise level at driver's position dB (A) < 70 < 70
(1) On P1.6 P1.8 available batteries 150Ah,210Ah. (2) See “batteries table”
On P2.0 available batteries 150Ah, 210Ah, 250Ah, 315Ah. (3) These values can vary by +/- 5%
On P2.2 available batteries 210Ah, 250Ah, 315Ah.
(4) The 150Ah battery is not DIN 43635 B
9
10
SERVICE INSTALLATION AND SETTINGS
INSTALLATION AND SETTINGS

BEFORE INSTALLATION�� 2
WEIGHT TABLE�� 2
MACHINE ASSEMBLY�� 3
LIST OF MATERIALS RECEIVED FROM THE DEALER�� 3
UNLOADING THE TRUCK�� 4
OIL TOP UP�� 5
BATTERY INSTALLATION�� 6
WITH SIDE REMOVAL�� 7
BATTERY CABLE CONNECTION�� 8
LIST AND DESCRIPTION OF ADJUSTMENTS AND SETTINGS TO BE CARRIED OUT�� 9
CHECKING THE CONDITIONS OF USE OF THE TRUCK�� 9
1
INSTALLATION AND SETTINGS SERVICE
BEFORE INSTALLATION
Make sure in advance that all the tools required to unload the truck are available (bridge crane, lift truck,
lifting slings, etc.). Before handover of the truck to the customer it is very important to check the suitability
of the place where the truck is to be used.
WEIGHT TABLE
Weight (exclud- Battery voltage/ Battery
Fork length Overall weight
Model ing battery) capacity weight
mm kg V/Ah kg kg
800 x 520
305 24 / 150 144 449
800 x 560
313 24 / 210-250 212 525
800 x 670
1006 x 520
316 24 / 150 144 460
1006 x 560
324 24 / 210-250 212 536
1006 x 670
1156 x 520
325 24 / 150 144 469
P 1.6 1156 x 560
333 24 / 210-250 212 545
1156 x 670
1400 x 520
339 24 / 150 144 483
1400 x 560
347 24 / 210-250 212 559
1400 x 670
1600 x 520
350 24 / 150 144 494
1600 x 560
358 24 / 210-250 212 570
1600 x 670
800 x 520
305 24 / 150 144 449
800 x 560
313 24 / 210-250 212 525
800 x 670
1006 x 520
316 24 / 150 144 460
1006 x 560
324 24 / 210-250 212 536
1006 x 670
1156 x 520
325 24 / 150 144 469
P 1.8 1156 x 560
333 24 / 210-250 212 545
1156 x 670
1400 x 520
339 24 / 150 144 483
1400 x 560
347 24 / 210-250 212 559
1400 x 670
1600 x 520
350 24 / 150 144 494
1600 x 560
358 24 / 210-250 212 570
1600 x 670
800 x 520 314 24 / 150 144 458
800 x 560 322 24 / 210-250 212 534
800 x 670 333 24 / 310-375 288 621
1006 x 520 325 24 / 150 144 469
1006 x 560 333 24 / 210-250 212 545
1006 x 670 344 24 / 310-375 288 632
1156 x 520 334 24 / 150 144 478
P 2.0 1156 x 560 342 24 / 210-250 212 554
1156 x 670 353 24 / 310-375 288 641
1400 x 520 348 24 / 150 144 492
1400 x 560 356 24 / 210-250 212 568
1400 x 670 367 24 / 310-375 288 655
1600 x 520 359 24 / 150 144 503
1600 x 560 367 24 / 210-250 212 579
1600 x 670 378 24 / 310-375 288 666
800 x 520
322 24 / 210-250 212 534
800 x 560
333 24 / 310-375 288 621
800 x 670
1006 x 520
333 24 / 210-250 212 545
1006 x 560
344 24 / 310-375 288 632
1006 x 670
1156 x 520
342 24 / 210-250 212 554
P 2.2 1156 x 560
353 24 / 310-375 288 641
1156 x 670
1400 x 520
356 24 / 210-250 212 568
1400 x 560
367 24 / 310-375 288 655
1400 x 670
1600 x 520
367 24 / 210-250 212 579
1600 x 560
378 24 / 310-375 288 666
1600 x 670
2
MACHINE ASSEMBLY
LIST OF MATERIALS RECEIVED FROM THE DEALER
5
6
The materials received from the dealer may vary according to whether or not optional accessories are
included.
Ref. Description
1 Truck
2 Batter extension plug (with lateral extraction)
3 External battery charger (optional)
4 Battery
5 Top up bottle for battery electrolyte
6 Rollerway for side battery removal (optional)
3
TRUCK UNLOADING
Equipment and tools
fork lift truck bridge crane 2 lifting slings

load capacity load capacity load capacity
1000 kg 1000 kg 1000 kg
Procedure
Before starting work, ensure that you are wearing suitable
protective clothing.
Phase 1
FORKLIFT TRUCK
Pick up the pallet using the lift truck, raise it and carry it to a safe place,
away from the transit areas of other vehicles and pedestrians.
Phase 2
BRIDGE CRANE - 2 LIFTING SLINGS
Remove the packaging.
Attach the two lifting slings to the lifting attachments on the truck base
(fig.1).
Fig. 1
Ensure that the bridge crane is positioned vertically above
the truck to be lifted.
Attach the lifting slings to the bridge crane, lift the truck off the pallet and
slowly lower it to the ground.
4
TOPPING UP THE OIL RESERVOIR

If required top up the oil in the hydraulic oil reservoir. Before proceeding, make sure that the forks are fully
lowered.
Equipment and tools
B
funnel oil resistant gloves
socket wrench Fig. 1

13 mm
Procedure
Fig. 2
Move the carriage to a safe place, away from areas of
transit of other vehicles and all pedestrians. Set the key
switch to OFF and disconnect the battery.
Phase 1
D
SOCKET WRENCH SIZE 13 mm C
Use the socket wrench to unscrew and remove the motor cover fixing
nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then
on the right-hand side to trip the locking clips (ref.B fig.1).
Phase 2
OIL PROTECTING GLOVES - FUNNEL
Unscrew the reservoir cap (ref.C fig.2), place the funnel in the filler hole
and top up the oil level.
Take the oil level in the tank to between the MIN and MAX values (ref.D
fig.2).
At the end of the operation screw the tank cap back on.
5
INSTALLATION OF THE BATTERY

Equipment and tools
bridge crane hexagonal "T"

load capacity spreader bar section spanner
1000 kg 6 mm
Procedure Fig. 1
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.
A
Phase 1
T-HANDLE HEX KEY SIZE 6 mm Fig. 2
Raise the cover of the battery compartment
Using the T-handle hex key, unscrew the battery bracket fixing screw
(ref.A fig.1) and remove the battery bracket.
Phase 2
BRIDGE CRANE - SPREADER BAR
Attach the spreader bar to the bridge crane.
Attach the spreader bar to the battery, lift the battery using the bridge
crane and position it over the battery compartment.
Lower the battery very carefully into the battery compartment (fig.2).
Unhook the spreader bar from the battery.
Phase 3
T-HANDLE HEX KEY SIZE 6 mm
Fit the battery catch back in place. Using the T-handle hex key screw in
the battery bracket fixing screw.
6
WITH LATERAL REMOVAL

Equipment and tools
bridge crane
load capacity spreader bar rollerway
1000 kg
Procedure
Move the truck to a safe place, away from the transit areas
of other vehicles and pedestrians.
Fig. 1
Phase 1
ROLLERWAY
Position the rollerway alongside the battery compartment and adjust the
height so that the top of rollerway is aligned with the bottom of the bat-
tery compartment.
Phase 2
Attach the spreader bar to the bridge crane.
Attach the spreader bar to the battery; lift the battery using the bridge
crane and place it on the rollerway (fig.1).
Detach the spreader bar from the battery and push it very carefully into
the truck compartment to trip the battery catch.
Phase 3
Connect the battery leads to the plug.
7
CONNECTION OF CABLES TO BATTERY

The positive battery terminal is identified with the redmarking or the symbol + , while the negative pole is
identified with bluemarking or the symbol .
The battery connector cables are in turn marked with a red tag for the connection to the positive pole and
a blue tag for the connection to the negative pole.
After connecting the clamps to the battery poles, apply some Vaseline grease to prevent
the risk of oxidation.
_ Tag coloured BLUE

Connection of the cable to
the negative terminal
Tag coloured RED

+ Connect lead to positive
terminal
Negative terminal
coloured BLUE
Positive terminal
_
coloured RED
8
LIST OF THE SETTINGS AND ADJUSTMENTS TO BE CARRIED OUT

After assembling all the machine's components as described in the previous pages, the following operations
must be carried out in the sequence given:
• Checking the conditions of use of the truck
VERIFY THE TRUCK USE CONDITIONS

In order to safeguard the safety of people and goods, before undertaking the following
operations, one should first check:
• The type of load to be moved
• The general conditions of the warehouse, aisles and flooring
Having carried out these assessments verify whether the conditions given are compatible with the perfor-
mance levels set:
• maximum traction speed

• traction acceleration
• reduction of traction speed
• maximum fork lifting/lowering speed
• braking
If necessary, reduce truck performance by using the programmer to customize the truck configuration pa-
rameters (see "TRUCK FUNCTIONS“ section “ELECTRICAL SYSTEM”).
In order not to jeopardize the carriage's safety, the configuration parameter customisation
can only be carried out by exclusively reducing factory values.
Parameter values in excess of those introduced at the factory are not allowed.
9
10
SERVICE DIAGNOSTICS AND MEASUREMENTS
DIAGNOSTICS AND
MEASUREMENTS
DESCRIPTION OF MODULE CONNECTORS�� 2
COMBI MODULE�� 2
MENU�� 4
MONITOR MENU�� 4
DTC CODE.................................................................................................................................................................14
LED BLINKS..............................................................................................................................................................14
COMBI CONTROLLER ALARMS - NODE 30�� 16
TILLER BOARD ALARMS - NODE 60�� 25
ELECTRICAL COMPONENT MEASUREMENTS�� 27
SOLENOID VALVE COILS�� 27
ELECTROMAGNETIC BRAKE COILS�� 27
MOTORS�� 28
1
DIAGNOSTICS AND MEASUREMENTS SERVICE
DESCRIPTION OF MODULE CONNECTORS

COMBI MODULE
A1 - +24V logic power supply from key switch

A2 – Optional buzzer negative
A3 – Down solenoid valve negative
A4 – Pump contactor coil negative
A5 – Electromagnetic brake coil negative
A6 – Main contactor coil negative
A7 - Encoder power supply negative
A8 - Motor temperature sensor input
A9 – Tiller digital input (+24V)
A10 – Not utilized
A11 – Steering system optional sensor input
2

A13 – +24V coil power supply output
A14 – Lifting block optional sensor input
A19 - Not utilized
A20 – Horn negative
A21 – Can bypass termination pin 34
A22 – Belly Switch digital input
A23 – Can High
A25 – 12V MDI output
A26 – 5V output
A28 – Serial line transmission
A29 – Serial line reception
A30 - Not utilized
A31 – CH A encoder input
A32 – CH B encoder input
A34 – Can bypass termination pin 21
A35 – Can Low
3
MENU
The main input and output signals can be measured in real time using the MONITOR function of the pro-
grammer. The programmer acts as a multimeter capable of reading voltage, current and temperature.
Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to
functions directly connected to the analog/digital inputs of the module.
The following list shows the relative measurements:
MONITOR MENU
MAIN MENU MONITOR  System Controller Information
LEVEL 4
TRUCK SERIES
Not used
MODEL
Controller model number
CONTROLLER SERIAL Nu
Controller serial number
CONTROLLER MFG DATE

Date of manufacture of the controller. The first two digits indicate the year, the last three digits indicate the day.
HARDWARE VERSION
Hardware version
OS VERSION
Latest version of the operating system installed
BUILD NUMBER
First version of the operating system installed
START MANAGER VERSION

Version of the Start Manager installed on the controller
PARAM BLOCK VERSION

Version of the Parameter Block installed on the controller
VCL APP VERSION

Version of the programming language software installed
VEHICLE SERIAL NUMBER

Not used
4
MAIN MENU MONITOR  Software Enabled Features
PARAMETER
BUZZER OPTION
Shows whether this option is active on the truck
CHARGER PRESENT
BEVERAGE TRUCK ENABLING

STEER REDUCTION OPTION

ADVANCES TURTLE OPTION

TURTLE ACTIVATION A
LIFT FUNCTION 0-NORM

PERFORMANCE MODE
MAIN MENU MONITOR  Charger Messages
LEVEL 4
CHARGER STATE OF CHARGE
Shows the battery charger status
CHARGER ERROR CODES

CHARGER EVENTS
CHARGER HOURMETER
5
MAIN MENU MONITOR  Throttle Inputs
LEVEL 4
RAW CAN THROTTLE
Numeric status level of traction control butterfly rotation
MAPPED CAN THROTTLE

Percentage status level of traction control butterfly rotation
RAW REDUNDANT THROTTLE

Not used
MAPPED REDUNDANT THROTTLE

Not used
MAIN MENU MONITOR  Tiller Switch Inputs
LEVEL 4
NEUTRAL SWITCH
Traction control throttle level: ON if in rest position
EMER REV SWITCH

Emergency reverse button selection
SNAIL SWITCH
"Snail" mode button selection
HORN SWITCH
Horn button selection
FORK LIFT SWITCH

Slow fork lifting button selection
FORK LOWER SWITCH

Slow fork lowering button selection
MAST LIFT SWITCH

Slow fork lifting button selection
MAST LOWER SWITCH

Forks lowering button selection
6
MAIN MENU MONITOR  Maintenance Timers
LEVEL 4
TOTAL HOURS LEFT
Number of key-on operating hours remaining before servicing
TRACTION HOURS LEFT

Number of traction hours remaining before servicing
PUMP HOURS LEFT

Number of hydraulic pump operating hours remaining before servicing
MAIN MENU MONITOR  Inputs
LEVEL 4
THROTTLE COMMAND
Angular displacement of the traction control butterfly
MAPPED THROTTLE
Angular displacement of the traction control butterfly evaluated after mapping
THROTTLE POT
Not used
BRAKE COMMAND
Not used
MAPPED BRAKE
Not used
POT2 RAW
Not used
MAPPED HYD THROTTLE

Not used
PUMP THROTTLE
Not used
PD THROTTLE
Not used
STEER POT
Not used
STEER ANGLE (DEG)

Not used
7
INTERLOCK
Tiller status level: ON during activation
EMER REV
Emergency direction reversal level: ON during direction reversal
ANALOG 1
Not used
ANALOG 2
Thermal sensor voltage sensor measured on input A8
SWITCH 1
Not used
SWITCH 2
Not used
SWITCH 3
Status level of the tiller measured on input A9
SWITCH 4
Not used
SWITCH 5
Optional steering sensor status level
SWITCH 6
Not used
SWITCH 7
Belly switch status level measured on input A22
SWITCH 8
Not used
DRIVER 1 INPUT
See the parameter main menu monitor / Outputs / Driver 1 PWM
DRIVER 2 INPUT
DRIVER 3 INPUT
DRIVER 4 INPUT
8
PD INPUT
See the parameter main menu monitor / Outputs / PD PWM
DIGOUT6 INPUT
See the parameter main menu monitor / Outputs / Digital Out 6
DIGOUT7 INPUT
See the parameter main menu monitor / Outputs / Digital Out 7
SWITCH 16
Status level of the optional lifting block sensor on input A14
MAIN MENU MONITOR  Outputs
LEVEL 4
ANALOG OUT
Not used
DIGITAL OUT 6
Not used
DIGITAL OUT 7
Status level of the horn control signal on output A20
DRIVER 1 PWM
Percentage level of main contactor coil control on output A6
DRIVER 2 PWM
Percentage level of electromagnetic brake control on output A5
DRIVER 3 PWM
Percentage level of hydraulic pump contactor coil control on output A4
DRIVER 4 PWM
Percentage level of forks down solenoid valve control on output A3
PD PWM
Percentage level of optional buzzer control on output A2
PUMP PWM
Percentage level of control on output A4
PD CURRENT
Current measured on output A2
PUMP CURRENT
Current measured on output A4
9
5 VOLTS
Voltage measured on output A26
12 VOLTS
Voltage measured on output A25
EXT SUPPLY CURRENT

Current measured on outputs A25 - A26
POT LOW
Not used
MAIN MENU MONITOR  Battery
LEVEL 4
BDI
Battery charge percentage level
CAPACITOR VOLTAGE
Voltage at internal capacitor bank, measured at terminal B+ of the controller
KEY SWITCH VOLTAGE

Key switch voltage measured at input A1
INSULATION RESISTANCE
Not used
MAIN MENU MONITOR  Motor
LEVEL 4
MOTOR RPM
Motor speed
TEMPERATURE
Motor temperature read by thermal sensor
MOTORSPEED A
Rpm of phase A of the motor encoder
MOTORSPEED B
Rpm of phase B of the motor encoder
10
MAIN MENU MONITOR  Controller
LEVEL 4
CURRENT (RMS)
Controller current draw
MODULATION DEPTH
Voltage percentage applied to the motor
FREQUENCY
Rotation frequency applied to the motor
TEMPERATURE
Controller internal temperature
MAIN STATE
Status of the main contactor
0 = open
1 = pre-charging
2 = welding check
3 = closing delay
4 = no check
5 = closed (with parameter Main Enable > ON)
6 = delay
7 = arc check
8 = opening delay
9 = error
10 = closed (with parameter Main Enable > OFF)
REGEN
ON during all phases of current regeneration
VCL ERROR MODULE

Software runtime error (code 68); information on the cause/s of the error are saved in the parameters VCL Error
Module and VCL Error.
VCL ERROR
Software runtime error (code 68); information on the cause/s of the error are saved in the parameters VCL Error
Module and VCL Error.
11
MAIN MENU MONITOR  Cutbacks
LEVEL 4
MOTOR TEMP CUTBACK
Percentage of cutback during motor temperature reduction stage
CONTROLLER TEMP CUTBACK

Percentage of cutback during controller temperature reduction stage
UNDERVOLTAGE CUTBACK
Percentage of cutback during under-voltage reduction stage
OVERVOLTAGE CUTBACK
Percentage of cutback during over-voltage reduction stage
MAIN MENU MONITOR  Vehicle
LEVEL 4
VEHICLE SPEED
Speed of the truck
VEHICLE ODOMETER
Distance travelled in forward drive
VEHICLE ACCELERATION
Acceleration of the truck
TIME TO SPEED 1
Time required to reach 0 km/h from a speed value pre-defined in the software
TIME TO SPEED 2
Time required to reach 0 km/h from a speed value pre-defined in the software
TIME BETWEEN SPEEDS

Time taken to get from Speed 1 to Speed 2
TIME TO DIST 1
Time taken to cover a pre-defined distance in the software
TIME TO DIST 2
TIME TO DIST 3
BRAKING DISTANCE CAPTURE

Distance travelled during all phases of the braking action
12
DISTANCE SINCE STOP

Total distance travelled by the truck, calculated as the sum of distances travelled in both directions. This value is
reset to zero each time the truck is stopped.
DISTANCE FINE
Net distance travelled by the truck calculated as the sum of the distances travelled in the direction the operator is
facing (positive value) and in the opposite direction (negative value).
MAIN MENU MONITOR  CAN Status
LEVEL 4
CAN NODE ID
Displays the Can node of the controller
CONTROLLER TEMP CUTBACK

Displays the NMT Can
0= initialization
4=stopped
5= operative
127=pre-operation
13
DTC CODE
The status codes inform the operator of any malfunctioning and incorrect use of the truck.
The status codes are numeric codes that indicate failure or malfunctioning. If, during operation, the truck
is used incorrectly or there is a fault, the key symbol will flash and the status code number will appear
on the LCD screen. If the numeric status code appears, the truck must be checked and repaired by an
authorized engineer.
The causes of each status code are detailed in this manual. This manual also provides detailed trouble-
shooting procedures for the following systems or nodes:
NODE 30: TRACTION CONTROLLER
NODE 60: TILLER CARD
NODE 12: BATTERY CHARGER
The error codes are composed of 5 digits: the first two digits indicate the affected node, the last three
indicate the number of the alarm.
Examples:
30001 – Lift Coil = Alarm Coil3 Open/Short on Combi controller
60058 – Snail = Snail redundant fault alarm on tiller board
12044 – Charger = Charger Fault alarm on optional battery charger
LED BLINKS
The module is equipped with a two-colour status LED (red and yellow) which, in the event of a fault, will
flash the corresponding error code. The red LED flashes once to indicate that the system is about to signal
first digit of the error code, then the yellow LED will emit the number of flashes corresponding to this first
digit. The red LED now flashes twice to indicate that the system is about to signal second digit of the error
code, then the yellow LED will emit the number of flashes corresponding to this second digit.
DTC CODE MDI TXT DTC TXT LED BLINKS

30001 LiftCoil Coil3 Open/short 33
30003 Lwr Coil Coil4 Open/short 34
Coil 1 open/short
30033 MainCoil 31
Main open/short
Coil2 open/short 32
30035 Brake Embrake Open/short 32
embrake failed to set 92
30037 AlrmCoil Coil7 Open/short 27
PD Open/short 35
30039 AlrmCoil
Coil6 Open/Short 26
Thumb Sw Throttle Wiper high 41
30052
Start Up Analog HPD fault 67
30060 Mtr Curr Controller overcurrent 12
30061 Mtr Open motor open 37
Encoder fault 36
30062 Encoder
Encoder LOS 93
30067 MainCont Main contactor welded 38
30068 MainCont Main contactor DNC 39
30069 PreCharg Precharge failed 14
OverHeat Motor temp hot cutback 28
30080
MtTmpSns Motor temp sensor do not display 29
30082 OverHeat overtemp cutback 22
30083 OverHeat Severe overtemp 16
14
DTC CODE MDI TXT DTC TXT LED BLINKS

Severe Undervoltage 17
30086 Low Batt Undervoltage Cutback 23
Severe Undervoltage Shutdown
Overvoltage 18
30087 OverVolt
Overvoltage Cutback 24
external supply out of range
30090 12&5Vout
5v supply failure 25
Current sensor fault 13
30099 CTRLLR
OS general 71
CAN Startup failure 51
30106 CAN Comm
PDO Timeout
HPD Sequencing fault 47
30201 Startup interlock fault 58
EMR HPD 47
30227 Stalled Stall detected 73
30231 Maintremnd Maintenance reminder
EEPROM Failure 46
30232 Software
VCL runtime error 68
Parameter change fault 49
30247 Parametr
motor characterization fault 87
30248 Low Temp Severe undertemp 15
EMR cutback shutdown
60050 EmerRev
Parity belly fault 59
60058 Snail Snail redundant fault 63
60099 CtrlCard Rema tiller fault 53
60210 EmerRev BB sequencing fault 61
60211 Start Up KSI Interlock SRO 62
12044 Charger Charger fault 54
12113 Charger Charger CAN fault 55
15
COMBI CONTROLLER ALARMS - Node 30
ALARM troubleshooting
DTC CODE MDI TXT • Carry out a visual inspection of all the connectors paired with the error code.
Restart the truck and check whether the error code is still present.
30001 LiftCoil CAUSE A
Description: • Disconnect the connectors TS11 and TS12 from the contactor coil and switch
on the truck.
The Combi controller has detected a • Measure the voltage between the connector TS11 and B(-). If the voltage is not
problem on the pump contactor coil. 24 ± 2.5 V DC, check wire 239.
Possible causes: • Disconnect the connector CPS01 from the Combi controller and measure the
resistance between pin 4 and connector TS11. If the resistance is > 1 ohm, check
A. Short circuit or open circuit in the wire W028.
coil wire harness • Measure the voltage between the connector TS12 and B(+) holding down the fork
B. Short circuit or open circuit in the lifting button. If the voltage is not 24 ± 2.5 V DC proceed with cause C.
coil windings CAUSE B
C. Combi controller faulty • Measure the resistance between the two contacts of the contactor coil; if the
resistance is not equal to 55 ± 5.25 ohms, replace the pump contactor.
CAUSE C
• If no trouble is found, replace the controller.
DTC CODE MDI TXT •
Carry out a visual inspection of all the connectors paired with the error code.
30003 LwrCoil CAUSE A
Description: • Disconnect the connector CRS05 from the down valve coil located on the hydraulic
pump and switch on the truck.
The Combi controller has detected • Measure the voltage between connector CRS05 pin 1 and B(-), if the voltage is
a problem on the fork down valve. not equal to 24 ± 2.5 V DC, check wire W239-D.
Possible causes: • Disconnect the connector CPS01 from the Combi controller and measure the
continuity between CRS05 pin 2 and CPS01 pin 3; if the resistance is > 1 ohm,
A. Short circuit or open circuit in the check wire W801.
coil wire harness • Measure the voltage between the connector CRS05 pin 2 and B(+) holding down
B. Short circuit or open circuit in the the fork lifting button. If the voltage is not 24 ± 2.5 V DC proceed with cause C.
coil windings CAUSE B
C. Combi controller faulty • Measure the resistance between the two contacts of the valve coil; if the resist-
ance is not equal to 19 ± 2.0 ohms, replace the down valve coil.
CAUSE C
DTC CODE MDI TXT
• Carry out a visual inspection of all the connectors paired with the error code.
30033 MainCoil Restart the truck and check whether the error code is still present.
CAUSE A
Description:
• With the key in the ON position, disconnect the connector TS07 from the contactor
The Combi controller has detected coil and measure the voltage between the connector TS07 and B(-); if the voltage
a problem in the main contactor coil. is not equal to 24 ± 2.5 V DC, check wire W239-B.
• With the key in the OFF position, disconnect the connector CPS01 from the
Possible causes: Combi controller and connector TS08 (negative) of the contactor coil. Measure
A. Short circuit or open circuit in the the resistance between the connector TS08 and the connector CPS01 pin 6; if
coil wire harness the resistance is > 1 ohm, check wire 075.
B. Short circuit or open circuit in the CAUSE B
coil windings • With the key OFF, measure the resistance between the contacts of the main contac-
tor coil; if the resistance is not equal to 30 ± 3 ohms, replace the main contactor.
C. Combi controller faulty CAUSE C
• If no trouble is found, replace the Combi controller.
16
DTC CODE MDI TXT • Carry out a visual inspection of all the connectors paired with the error code.
30035 Brake
CAUSE A
Description: • With the key in the ON position, disconnect the connector CPS01 from the Combi
controller and measure the voltage between pin 1 of the connector CPS01 and B (-).
The Combi controller has detected
Note the value of the voltage, reconnect the connector CPS01, switch the truck off
a problem in the electromagnetic and back on again. Disconnect the connector CRP04-A from the electromagnetic
brake coil. brake and measure the voltage between pin 1 of the connector CRP04-A and B
(-). If the two voltages measured are not equal, check wire 239.
Possible causes:
CAUSE B
A. Short circuit or open circuit in the • Measure the resistance between pin 1 and pin 2 of connector CRP04-A; if the
coil wire harness resistance is not equal to 23 ± 2.3 ohms, replace the brake coil.
B. Short circuit or open circuit in the CAUSE C
coil windings • If no trouble is found, replace the Combi controller.
C. Combi controller faulty
30037 AlrmCoil CAUSE A
Description: • With the key in the ON position, disconnect the connector TS09 and measure
the voltage between TS09 and B(-). If the voltage is not equal to 24 ± 2.5 V DC,
The Combi controller has detected check wire 239.
an issue with the electronic horn. • Disconnect the connector CPS01 from the Combi controller. Measure the resist-
ance between pin 20 of the connector CPS01 and connector TS09. If the resist-
Possible causes: ance is > 1 ohm, check wire 045.
A. Short circuit or open circuit in the CAUSE B
horn wire harness • With the key in the ON position and holding down the horn button, measure the
B. Problem inside the horn. continuity between the connector TS09 and B(-); if there is continuity, replace
the horn.
CAUSE C
30039 MainCoil
CAUSE A
Description: • With the key in the ON position, disconnect the connector CPS13 from the optional
The Combi controller has detected buzzer and measure the voltage between pin 1 and B (-). If the voltage is not
equal to 24 ± 2.5 V DC, check wire 010.
an issue with the optional buzzer.
• Disconnect the connector CPS01 from the Combi controller. Measure the resist-
Possible causes: ance between pin 2 of the connector CPS01 and pin 2 of connector CPS13. If the
resistance is > 1 ohm, check wire 728.
A. Short circuit or open circuit in the
CAUSE B
optional buzzer wire harness.
• With the key in the ON position and the optional buzzer working, measure the
B. Problem inside the optional buzz- continuity between pin 2 of the connector CPS13 and B(-); if there is continuity,
er. replace the optional buzzer.
17
DTC CODE MDI TXT
30052 Thumb Sw,
Start Up •
Description: CAUSE A
Voltage on pin 16 of the Combi Con- • Perform the correct ignition and start-up procedure.
troller too high. CAUSE B
Possible causes: • Check for a short circuit on pin 16 of the connector CPS01.
A. Incorrect start-up sequence. CAUSE C
B. Short circuit on pin 16 of the con-
nector CPS01.
C. Problem inside the Combi control-
ler
DTC CODE MDI TXT • Check the conditions of the battery and its state of charge.
30060 Mtr Curr Restart the truck and check whether the error code is still present.
The Combi controller has detected • Check the three phases are correctly tightened on the traction motor and Combi
controller.
overcurrent on one of the phases of
• Check the wire harness continuity.
the traction motor.
CAUSE B
Possible causes: • Check whether there is continuity between phases U and V of the traction motor.
A. External short-circuit on connec- If there is not, then replace the traction motor.
tions of phases U, V or W to the • Check whether there is continuity between phases U and W of the traction motor.
motor If there is not, then replace the traction motor.
• Check whether there is continuity between phases W and V of the traction motor.
B. Problem inside the motor. If there is not, then replace the traction motor.
• If no trouble is found, replace the Combi controller
Check the conditions of the battery and its state of charge.
•
30061 Mtr Open Restart the truck and check whether the error code is still present.
The Combi controller has detected • Check the three phases are correctly tightened on the traction motor and Combi
controller.
an open circuit on one of the phases
• Check the wire harness continuity.
of the motor.
CAUSE B
Possible causes: • Check whether there is continuity between phases U and V of the traction motor.
A. Open circuit on connections of If there is not, then replace the traction motor.
phases U, V or W to the motor • Check whether there is continuity between phases U and W of the traction motor.
If there is not, then replace the traction motor.
B. Problem inside the motor.
• Check whether there is continuity between phases W and V of the traction motor.
C. Combi controller faulty If there is not, then replace the traction motor.
CAUSE C
18
30062 Encoder CAUSE A
Description: • Disconnect the connector CPS03 of the traction motor encoder and measure
the voltage between pin 1 and B(-). If the voltage is not equal to 5 ± 0.5 V DC,
The Combi controller has detected check wire 250.
a problem with the encoder of the • Measure the voltage between pin 1 and pin 4 of encoder connector CPS03; if the
traction motor. voltage is not equal to 5 ± 0.5 V DC, check the continuity of wire 102.
• Disconnect the connector CPS01 from the Combi controller and measure the re-
Possible causes: sistance between pin 32 of the connector CPS01 and pin 3 of connector CPS03.
A. Short circuit or open circuit in the If the resistance is > 1 ohm, check wire 578.
motor encoder wire harness • Measure the resistance between pin 31 of the connector CPS01 and pin 2 of
B. Problem inside the encoder. connector CPS03; if the resistance is > 1 ohm, check wire 577.
CAUSE B
• With the battery connected and the traction motor running, compare
the Motor>MotorSpeed A and Motor>MotorSpeedB parameters with the
Controller>Frequency parameter to check the state of the encoder.
CAUSE C
• If no trouble is found, replace the Combi controller
DTC CODE MDI TXT
30067 MainCont Restart the truck and check whether the error code is still present.
• With the key in the ON position, disconnect the connector TS07 from the main
The Combi controller has detected contactor coil and measure the voltage between TS07 and B(-); if the voltage is
that the main contactor is jammed not 24 ± 2.5 V DC, check wire 239.
closed or its contacts are soldered. • Disconnect the connector CPS01 from the Combi controller and the connector
TS08 from the main contactor coil. Measure the continuity between TS08 and pin
Possible causes: 6 of the controller CPS01. If there is no continuity, check wire 075.
A. Short circuit or open circuit in the CAUSE B
main contactor coil wire harness. • With the key in the OFF position, measure the voltage B(+) and B(-) on the Combi
B. Main contactor contacts soldered. controller, if the voltage is 24 ± 2.5 V DC, replace the main contactor.
DTC CODE MDI TXT
30068 MainCont •
The controller has detected that the • With the key in the ON position, disconnect the connector TS07 from the main
main contactor is not closed or is contactor coil and measure the voltage between TS07 and B(-); if the voltage is
jammed open. not 24 ± 2.5 V DC, check wire 239.
• Disconnect the connector CPS01 from the Combi controller and the connector
Possible causes: TS08 from the main contactor coil. Measure the continuity between TS08 and pin
A. Short circuit or open circuit in the 6 of the controller CPS01. If there is no continuity, check wire 075.
main contactor coil wire harness. CAUSE B
• With the tiller in its working position, measure the voltage between terminals B(+)
B. Contactor contacts blocked. and B(-) on the Combi controller. Press the Snail button while measuring the volt-
C. Combi controller faulty age. If no voltage is measured between B(+) and B(-), replace the main contactor.
CAUSE C
19
DTC CODE MDI TXT
•
30069 PreCharge Restart the truck and check whether the error code is still present.
CAUSE A
Description: • Repair or replace the connector or the wire harness paired with the error code.
The Combi controller has detected CAUSE B
an error in charging the capacitor • Disconnect the battery and discharge the capacitor. Reconnect the battery, if
bank. the alarm is still present, check the capacitor voltage and battery voltage on the
Monitor menu. If the voltage of the capacitor and battery are equal, check the
Possible causes: battery charge status.
A- Problem with the Combi controller • If the voltage of the capacitor and battery are not equal, measure the voltage
connections between the terminal of the traction controller B(+) and B(-); if the pre-charge volt-
age is identical to the battery voltage, check for external charges or short circuits.
B- Combi controller faulty
DTC CODE MDI TXT
30080 OverHeat, Mt- Restart the truck and check whether the error code is still present.
TempSns CAUSE A
Description: • Repair or replace the connector or the wire harness paired with the error code.
The motor temperature has reached • Reduce truck use and allow the controller to cool for at least 15 minutes. The
system restarts on reaching temperatures below 115°C for the traction motor
or exceeded the threshold tempera- and 85°C for the traction controller. If the error does not reoccur, we suggest you
ture reread the information on truck use and load capacity.
• If the alarm persists, disconnect the connectors CPS01 and CPS02. Measure the
Possible causes:
resistance between pin 8 of CPS01 and pin 1 of CPS02. If the resistance is > 1
A. Short circuit or open circuit in the ohm, check the continuity of wire 367.
traction motor temperature sensor • Measure the resistance between pin 2 of the connector CPS02 and terminal B(-) on
wire harness. the Combi controller. If the resistance is > 1 ohm, check the continuity of wire 101.
B. Combi controller faulty CAUSE B
DTC CODE MDI TXT
30082 OverHeat •
Description:
CAUSE A
: The Combi controller is operating in • Return the temperature to below the maximum limit of 85°C, release all the tiller
high temperature conditions (above controls, remove all loads from the truck, switch off the truck, wait a few minutes,
85°C) then switch it on again. Check the load handled and reduce truck use. See whether
the error code reappears.
Possible causes: CAUSE B
A. Truck overloaded. • Check that the module is installed correctly.
B. Combi controller incorrectly in- CAUSE C
stalled. • If no trouble is found, replace the controller.
20
ALARM breakdown search

DTC CODE MDI TXT
•
30083 OverHeat Restart the truck and check whether the error code is still present.
CAUSE A
Description:
• Return the temperature to below the maximum limit of 95°C, release all the tiller
The Combi controller is operating controls, remove all loads from the truck, switch off the truck, wait a few minutes,
in too high temperature conditions then switch it on again. Check the load handled and reduce truck use. See whether
(above 95°C) the error code reappears.
CAUSE B
Possible causes:
• Check that the module is installed correctly.
A. Truck overloaded. CAUSE C
B. Combi controller incorrectly in- • If no trouble is found, replace the controller.
stalled.

DTC CODE MDI TXT
30086 Low Batt
Description: Restart the truck and check whether the error code is still present.
CAUSE A
The Combi controller has detected
a low voltage condition on the bank • Repair or replace the connector or the wire harness paired with the error code
of capacitors • Measure the voltage between B(-) and B(+); if the voltage is not equal to 25 ±
0.5V DC, charge the battery.
A. Low battery charge, battery resist- • Measure the voltage between terminal B(+) and B(-) of the Combi controller, if the
ance too high. pre-charge voltage is not equal to the battery voltage, check the cable B(+). Check
the cable continuity, check the tightening of the connector on the controller. Check
B. Error in the Combi controller wire the state of the fuses FU1 and FU2. Check the main contactor works properly.
harness. CAUSE C
C. Combi controller faulty • If no trouble is found, replace the controller.

DTC CODE MDI TXT
30087 OverVolt Restart the truck and check whether the error code is still present.
The Combi controller has detected • Repair or replace the connector or the wire harness paired with the error code
a high voltage condition on the bank • Measure the voltage between terminals B(-) and B(+) of the Combi controller; if
the voltage is higher than 26V DC, check that the battery voltage is 24V and that
of capacitors
it is correctly connected to the truck.
A. Voltage on the Combi controller • Measure the voltage between terminal B(+) and B(-) of the Combi controller, if
terminals too high. the pre-charge voltage is not equal to the battery voltage, check the cable B(+).
Check the cable continuity, check the tightening of the connector on the controller.
B. Error in the Combi controller wire Check the state of the fuses FU1 and FU2.
harness. CAUSE C
C. Combi controller faulty • If no trouble is found, replace the Combi controller.
21

30090 12&5Volt CAUSE A
Description: • With the key in the ON position, disconnect the connector CRS07 from the MDI
display: switch the truck off and on. If the alarm is no longer present continue
The traction controller has detected with Cause B.
a fault in the 5/12 Volt output power • With the key in the ON position, disconnect the connector CPS03 from the trac-
supply. tion motor encoder: switch the truck off and on. If the alarm is no longer present
continue with Cause C.
Possible causes: • If the alarm persists, measure the supply voltages of the encoder and MDI on the
A. Fault in the wire harnesses Combi controller referring to the wiring diagram.
B. Fault in the MDI display CAUSE B
C. Fault in the traction motor encoder • If the fault disappears on disconnecting the MDI display and reappears on recon-
necting it, replace the MDI display module.
D. Combi controller faulty CAUSE C
• If the fault disappears on disconnecting the traction motor encoder and reappears
on reconnecting it, replace the encoder sensor.
CAUSE D

DTC CODE MDI TXT
30099 CTRLLR
Description: Restart the truck and check whether the error code is still present.
The Combi controller has detected CAUSE A
an issue with the values of the trac- • Check the wire harnesses of the traction motor phases: check for a short-circuit
tion motor currents. or low impedance on the phases U, V and W.
• Check the motor parameters are correct.
A. Dispersion of current from phases • If no fault is found in the wiring or the parameters but the alarm persists, then the
U, V or W to the truck chassis problem lies in the module.
(short circuit of motor stator)
B. Combi controller faulty.

DTC CODE MDI TXT
30106 CAN Comm
Description:
The tiller board fails to communi-
cate with the Combi controller via • Carry out a visual inspection of all the connectors paired with the error code.
CANbus. Restart the truck and check whether the error code is still present.
Possible causes: • Check the wiring harness between the Combi controller (pin 23 and pin 35) and
the tiller board (CRS 18 connector pin 4 and pin 3).
A. CANbus communication error – • Check that the connectors are clean.
no reception of the message via
CAN
B. Error in the tiller board wiring har-
ness – short circuit or open circuit
on pins 23 and 35 of the Combi
controller.
22

DTC CODE MDI TXT
30201 Startup •
Description:
CAUSE A
Incorrect start-up and firing se- • Follow the correct start up sequence
quence sequence.
CAUSE B
Possible causes: • Check the tiller wiring and the electrical panel wiring
A. Incorrect start-up sequence • Check condition of pushbutton connectors, clean if necessary.
B. Wire harness or connectors or • Check that all the tiller controls have been released.
push buttons damaged

DTC CODE MDI TXT
• Make sure there is nothing obstructing the transmission and the wheels.
30227 Stalled • Carry out a visual inspection of all the connectors paired with the fault code. Restart
Description: the truck and check whether the error code is still present.
• Make sure the electromagnetic brake is raised when a request is made for traction
The Combi controller has detected and that it lets the motor turn freely.
the traction motor is stalled.
•
Possible causes: CAUSE A
A. Encoder wire harness damaged • Check the encoder connections: check the continuity of wires 250, 577, 578 and
102. Check the condition of the connector CPS03.
B. Motor encoder damaged
CAUSE B
C. Traction motor faulty • With the battery connected and the traction motor running, compare
D. Combi controller faulty the Motor>MotorSpeed A and Motor>MotorSpeedB parameters with the
Controller>Frequency parameter to check the state of the encoder.
CAUSE C
• Check continuity of the 3 traction motor phases. If two phases do not have con-
tinuity, replace the traction motor.
CAUSE D

DTC CODE MDI TXT
30231 Maintremnd
Description:
Warning that you need to perform • Perform regular maintenance.
regular maintenance. • Reset the regular maintenance counters.
Possible causes:
A. Time interval until regular mainte-
nance is due.
23

DTC CODE MDI TXT
30232 Software
Description: • If this error occurs after editing parameters or installing new software, restore
The Combi controller has detected a conditions existing prior to the error.
problem with the controller software • Download and install the correct software; use the standard parameter configura-
or parameter settings. tion.
• Turn off and restart the truck.
Possible causes:
• If no fault is found and the alarm persists, then the problem lies in the module
A. Incorrect installation of new soft-
ware
B- Incorrect changes to the configu-
ration of the parameters

DTC CODE MDI TXT
30247 Parameter
Description:
The Combi controller has detected • Switch the truck off and on: check whether the error is still present.
a fault in the configuration of the • Restore the original configuration of the parameters.
parameters
Possible causes:
A. Incorrect configuration of the
parameters

DTC CODE MDI TXT
30248 Low Temp
Description:
CAUSE A
The Combi controller is operating in • Bring the temperature to above the lower limit of -30°C, release all tiller controls,
low temperature conditions (below turn off and restart the truck.
-30°C). CAUSE B
Possible causes: • If no fault is found and the alarm persists, then the problem lies in the module.
A. Operating temperature too low

B. Fault with the temperature sensor
in the controller
24
TILLER BOARD ALARMS - Node 60

DTC CODE MDI TXT
60050 EmerRev
Description:
The tiller board has detected an
incorrect start-up sequence or a • Release all the tiller controls
problem with the belly switch. • Check that the Belly button is released
• Switch the truck off and on: check whether the problem is still present.
Possible causes:
A. Incorrect start-up sequence
B- After an emergency reversing
manoeuvre, some of the inputs
may not have returned to neutral
position.

DTC CODE MDI TXT
60058 Snail
Description: • Carry out a visual inspection of all the connectors paired with the error code.
The tiller board sends the Snail but- Restart the truck and check whether the error code is still present.
ton signal via Can but the signal is CAUSE A
not present on pin 7 of connector X1 • Check the continuity of the wire from pin 7 of connector X1.
of the tiller board. CAUSE B
• Check for 24 V on pin 7 of connector X1 when the Snail button is active.
Possible causes:
A. Fault in the wiring harness of the
signal on pin 7 of connector X1.
B. Tiller board faulty

DTC CODE MDI TXT
60099 CtrlCard • Carry out a visual inspection of all the connectors paired with the error code.
Description: • Check that all the tiller controls are released.
Issue with the tiller board • Switch the truck off and on and check whether the problem is still present.
Possible causes:
A. Tiller board faulty

DTC CODE MDI TXT
60210 EmerRev
CAUSE A
Description:
• Release all the tiller controls. Do not activate the Belly button with the tiller in the
The tiller board has detected the rest position.
Belly button is active with the tiller in CAUSE B
the rest position. • Check the operation of the Belly button.
Possible causes:
A- Incorrect start-up sequence
B- Belly button shorted.
25

DTC CODE MDI TXT
60211 Start Up • Carry out a visual inspection of all the connectors paired with the error code.
Description:
CAUSE A
The tiller board has detected an error • Perform the correct truck start-up procedure. Do not switch on the truck with the
in the truck start-up phase. tiller in the operating position.
• Check the state of the tiller sensor.
A. Switching on the truck with the
tiller in the operating position
B. Tiller sensor short circuited
26
ELECTRICAL COMPONENT MEASUREMENTS

SOLENOID VALVE COILS
Ref. solenoid valve Value measured (Ohm)
1 Q1 27
ELECTROMAGNETIC BRAKE COILS
Traction wheel electro-

magnetic brake
Coil Value measured (Ohm)
Electromagnetic
17.9
brake
27
MOTORI
Per misurare l’isolamento del motore scollegare i cavi delle fasi (U,V, W). Collegare un puntale del tester
alla fase U e l’altro puntale sulla carrozzeria. Il valore di resistenza ( ) indicato dal tester deve essere
infinito ( ). In caso contrario il motore non è isolato e il modulo relativo al motore interessato diagnostica
l’allarme “capacitor charge”.
Ripetere l’operazione per le altre due fasi (V,W).
28
SERVICE ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
WIRING DIAGRAMS �� 2
ELECTRICAL COMPONENTS�� 8
KEY TO ELECTRICAL COMPONENTS�� 8
TILLER BOARD�� 10
CONTROLS�� 12
KEY TO TILLER CONTROLS AND MAIN PANEL�� 12
DISPLAY (BATTERY CHARGE LEVEL INDICATOR)�� 14
BATTERY CHARGE LEVEL INDICATOR�� 15
MAINTENANCE AND WARNINGS INDICATOR�� 15
TRUCK FUNCTIONS�� 16
FORWARD/REVERSE TRACTION�� 16
CONTROLS�� 16
CONFIGURATION PARAMETERS�� 17
SPEED AND ACCELERATION�� 17
SPEED REDUCTION AND TRACTION LOCKOUT.�� 17
MODE SELECTION....................................................................................................................................................17
BRAKING.�� 18
EMERGENCY REVERSE MANOEUVRE.�� 18
SNAIL FUNCTION�� 19
STEERING SYSTEM�� 20
CONTROLS�� 20
SPEED REDUCTION OPTION..................................................................................................................................20
SPEED REDUCTION WITH TRACTION WHEEL STEERED....................................................................................20
FORK LIFTING/LOWERING�� 21
CONFIGURATION PARAMETERS�� 21
LIFTING LOCKOUT WITH LOW BATTERY�� 22
TIMED LIFTING LOCKOUT�� 22
END POINT SLOWDOWN LIFTING/LOWERING FORKS�� 22
LIFTING WITH INTELLIGENT LIFT OPTION.............................................................................................................22
ACCESS TO PARAMETERS VIA THE CONSOLE......................................................................................................23
MENU SEARCH AND PARAMETER MODIFICATION PROCEDURE................................................................................23
ALARM DISPLAY PROCEDURE...............................................................................................................................25
BOOKMARK..............................................................................................................................................................26
STANDARD CONFIGURATION OF MODULE PARAMETERS�� 27
MODULE PARAMETER DESCRIPTION....................................................................................................................29
MODULE: INTRODUCTION.......................................................................................................................................35
MODULE REPLACEMENT..........................................................................................................................................37
REMOVAL OF ELECTRICAL COMPONENTS...............................................................................................................39
REPLACEMENT OF THE GENERAL EMERGENCY SWITCH.................................................................................39
DISPLAY REPLACEMENT..........................................................................................................................................40
REPLACEMENT OF THE KEY SWITCH...................................................................................................................41
REPLACEMENT OF THE HORN...............................................................................................................................42
FUSE REPLACEMENT...............................................................................................................................................43
TILLER BOARD REPLACEMENT..............................................................................................................................44
REPLACEMENT OF TILLER BUTTONS.......................................................................................................................45
REPLACEMENT OF THE TILLER CONTROL SPRINGS...........................................................................................46
REPLACEMENT OF THE TILLER ENABLE SENSOR..................................................................................................48
REPLACEMENT OF OPTIONAL STEERING SENSOR.................................................................................................50
1
GENERAL NOTES
THIS WIRING DIAGRAM SHOWS ALL THE OPTIONS. YOUR MODEL MIGHT YOUR MODEL DOES NOT HAVE ALL THE OPTIONS SHOWN IN THIS ALL THE WIRES HAVE A CIRCUIT MARKED ON THE SURFACE ID
NOT HAVE ALL THE OPTIONS INDICATED WIRING DIAGRAM. REFER TO THE WIRING DIAGRAM FOR EACH
ALL THE WIRES ARE WHITE UNLESS OTHERWISE SPECIFIED
CONFIGURATION TO DETERMINE THE EXACT CONTENT.
REFER TO THE INSTRUCTIONS TO IDENTIFY THE CORRECT CONNECTION ALL THE WIRES ARE BLACK UNLESS OTHERWISE SPECIFIED
OF ALL THE OPTIONS CIRCUIT IDENTIFICATION COLOURS APPROX. 900 DEDICATED FOR CAN-LO BUSS - GREEN WIRE
RED RED CIRCUIT BATTERY LEVEL APPROX. 901 DEDICATED FOR CAN-HU BUSS, YELLOW WIRE
REFER TO THE WIRING DIAGRAM OF EACH CONFIGURATION TO
DETERMINE THE EXACT CONTENT WIRES 900 AND 901 MUST BE TWISTED
GRN GREEN - GREEN GROUND SIGNAL AND CAN BUS
COMMiniCATION CIRCUIT CIRCUITS 101-104 ARE LOW CURRENT GROUND
ALL COMPONENTS ARE SHOWN IN THEIR NORMAL POSITION. ALL
SWITCHES ARE SHOWN IN THEIR STATIC POSITION BLK BLACK - HIGH CURRENT (HIGHER THAN THE AMPERAGE OF CIRCUITS WITH THE FOLLOWING IDENTIFICATION NUMBERS ARE USED
THE LINE FUSES ON CIRCUITS WITH BATTERY LEVEL VOLTAGE
REVERSE AND DIRECTIONAL DRIVE WITH FORKS - CIRCUITS 10, 35, 79 AND 239
YEL YELLOW - CAN/BuS HI CIRCUIT COMMUNICATION
ALL TERMINALS NOT USED MUST BE FIXED TO A MAIN WIRE HARNESS ORN CIRCUTS 33 CIRCUITS AT 12 VOLTS 1S A
ORANGE - 5 VOLT CIRCUITS
CIRCUTS 250 CIRCUITS AT 5 VOLTS 1S A
PNK PINK - 12 VOLT CIRCUITS
THE FOLLOWING CIRCUIT IDENTIFICATION NUMBERS ARE USED FOR
WHT WHITE - ALL THE OTHER CIRCUITS THE GROUND SIGNALS
-101 TO 104
DIAGRAM / ELECTRICAL SYMBOLS GENERAL ABBREVIATIONS

REF-DES PREFIX “CPS” REF-DES PREFIX “CRP” ALTERNATING CURRENT - AC HEATER - HTR
CONNECTOR PLUG SOCKET CONNECTOR TERMINAL PIN
AMPERES - A HYDRAULIC - HYD
BATTERY - BATT LEFT HAND - LH
REF-DES PREFIX “CPP” REF-DES PREFIX “CRP”
CONNECTOR PLUG PIN CONNECTOR SOCKET BDI - BATTERY LIGHT - LGT
DISPLAY INDICATOR MOTOR - MTR
(CXX #) THE CONNECTORS IN BRACKETS MIGHT NOT BE LABELLED
CIRCUIT - CKT NEGATIVE - NEG
REF-DES PREFIX “TS” REF-DES PREFIX “TP” CONNECTOR - CONN OUTPUT- OUP
TERMINAL SOCKET TERMINAL PLUG
CONTACTOR - K PRESSURE - PRESS
CONNECTOR BLADE CONTROLLER - CNTLR PROXIMITY - PROX
FEMALE CYLINDRICAL DIAGNOSTICS - DGS RIGHT HAND - RH
MALE CYLINDRICAL CONNECTOR
CONNECTOR
DIODE - D SENSOR - SEN
INSULATED CONNECTOR INSULATED BLADE DIRECT CURRENT - DC SIGNAL - SIG
RING DISCONNECT - DISC STEERING - STEER
DISPLAY - DISP SWITCH - SW
SPADE
DRIVE - DR TEMPERATURE - TEMP
DOUBLE-SIDED SPADE EXAMPLE - EX TRACTION - TRAC
FUSE - FU TRANSDUCER - XDCR
DOUBLE-SIDED CONNECTOR GROUND - GND VOLTS - V
WIRE HARNESS - HRN
INSULATED DOUBLE-SIDED CONNECTOR
NOTE COUPLING CIRCUIT NODE
CABLE CABLE W / ELECTRIC CORD OPTIONS

BIPOLAR
REPRESENTS M BIPOLAR ELECTRIC CORD
FOR THE OPERATION OF THE TRUCK OPTIONS, FOLLOW THESE INSTRUCTIONS:
OPTION A - BRAKING INHIBITION OPTION: NOT AVAILABLE IN THE EMEA

VERSION
OPTION B - 20 AMP CHARGER

DISCONNECT THE INTERLOCK KEY SWITCH CRS 01-A 8 CPP 01-A CONNECT
THE LEADS OF THE CHARGER (NOT LABELLED CPP 01-8) AT THE KEY SWITCH
CRS 01-A.
CONNECT TO THE PORT AND TO THE LEADS OF THE CHARGER.
DOES NOT REQUIRE CAN COMMUNICATION.
30 AMP CHARGER OPTION: NOT AVAILABLE IN THE EMEA VERSION
OPTION C- CONNECT CPP 01-A TO THE INTERLOCK SELECTOR CRS 01-A

CONNECT THE PORT CABLES TO THE CHARGER
CONNECT THE MAIN WIRE HARNESS CPS 12 OPTIONS TO CRP 12
SUB-WIRE HARNESS CRP 12, LOCATED AT THE LOWER END OF THE CONTROL
PANEL. CONNECT THE SUB-WIRE HARNESS OPTIONS CRS 15 TO THE CAN
BUSS PORT OF THE CHARGER
OPTION D - BEVERAGE OPTION: NOT AVAILABLE FOR THE EMEA VERSION
OPTION E- THE FOLLOWING OPTIONS USE A SUB-WIRE HARNESS

THAT CONNECTS TO THE TRUCK'S MAIN WIRE HARNESS. FOR PROPER
FUNCTIONALITY OF THE FOLLOWING OPTIONS, THE SUB-WIRE HARNESS
MUST CONNECT TO CPS 12 ON THE MAIN WIRE HARNESS, LOCATED AT THE
LOWER END OF THE CONTROL PANEL.
CAN BUSS PORT CHARGER
THIS OPTION ALSO USES THE SUB-WIRE HARNESS OPTION.
REFER TO NOTE C.
BACK UP ALARM
OPTIONS INCLUDE LIGHT OR BUZZER. CONNECT THE AVAILABLE OPTION TO
CPS 15 ON THE SUB-WIRE HARNESS OPTIONS
LIFTING INTERLOCK SENSOR

THE PROXIMITY SENSOR MUST BE POSITIONED ON THE LOWER RIGHT
CORNER OF THE CONTROL PANEL. CONNECT THE PROXIMITY SENSOR TO
CRP 14 ON THE SUB-WIRE HARNESS OPTIONS.
. .
OPTION F- TO USE THE KEYPAD OPTION, DISCONNECT AND DISCARD THE
CONNECTORS OF THE SELECTOR TS04 AND TS05. CONNECT THE TABS OF
THE KEYPAD WIRE HARNESS TERMINAL TP 14-B AND TP 15-B TO THE WIRE
HARNESS TERMINAL SOCKETS TS 14-A AND TS 15-A. CONNECT CPS 17 TO
THE KEYPAD CONNECTOR. CONNECT TS13 TO THE MAIN CONTACTOR AND
TS 16 TO B- OF THE CONTROL DEVICE
OPTION G- AUTO-LIFTING SENSOR: NOT AVAILABLE IN THE EMEA VERSION
OPTION H- MULTI-CAN BAR BOARD OPTION FOR THE EUROPEAN, MIDDLE

EAST AND AFRICAN MARKET
OPTION J- OPTION RESERVED FOR EMEA COUNTRIES

TS15-A AND TS14-A WILL BE DIRECTLY CONNECTED TO THE SELECTOR. NO
JUMPER WIRE W010-B AND W079-B WILL BE CONNECTED TO THE SELECTOR

O P T I O N R ES E RV E D F O R E M EA
COUNTRIES
MAIN WIRE HARNESS OPTIONS

IN THE SCHEMATIC SECTION OF THE ELECTRICAL SYSTEM
THE CONNECTOR CPS 12 / OPTIONS
IS LOCATED ON THE RIGHT-HAND SIDE
OF THE DRAWING
THE CONNECTION IS LOCATED NEAR

THE MOTOR PHASE WIRES
AND THE MDU POSITION
ELECTRICAL SYSTEM SERVICE
ELECTRICAL COMPONENTS
IDENTIFICATION OF ELECTRICAL COMPONENTS
Ref. Description
1 Main contactor - emergency button

2 Battery charge level indicator (display)
3 Power fuse - 175 A
4 Key switch
5 Electronic control
6 Electromagnetic brake
7 Traction motor
8 Pump motor
9 Pump contactor
10 Horn
11 Battery charger socket
12 Battery charger
8
1 2 3
10
11
4
9
12
9
TILLER DIAGRAM
Ref. Description
1 Rapid reverse microswitch

2 Micro slow progress enabling with vertical tiller
3 Tiller control cable connection connector
4 Unused connector
5 Unused connector
6 Lifting ON/OFF button connector
7 Lowering ON/OFF button connector
8 Lifting ON/OFF button connector
9 Lowering ON/OFF button connector
10 Unused connector
11 Connector not used
14 Horn microswitch
10
14
13
12
11
10
4
5
11
CONTROLS
IDENTIFICATION OF TILLER CONTROLS AND MAIN PANEL
4 5 5 4
2
3
12
Ref. Description
1 Quick reverse button

2 acoustic buzzer button
3 Forward reverse traction throttle
4 Fork lowering button
5 Fork lifting button
6 Slow travel enabling button with tiller in rest position
7 Emergency button
8 Keyswitch
13
DISPLAY (BATTERY CHARGE LEVEL INDICATOR)
2 3 4
Ref. Description
1 Total operating hours and alarms indicator

2 Green LED - hour meter ON
3 Yellow LED - battery low
4 Red LED - alarm and maintenance warning
On starting the truck (key-on) the MDI performs a number of tests, and each element will illuminate for one
second. On completion of the tests, the display will show the total truck operating hours for a few seconds,
followed by the battery charge status. The green operating LED will illuminate.
14
When the tiller is lowered or a traction command is given, the total number of traction hours are displayed
for a few seconds.
When a lifting or lowering command is given, the total operating hours of the truck pump appear on the
display for a few seconds.
BATTERY CHARGE LEVEL INDICATOR

The battery charge status is indicated on the display.
When the battery charge state reaches 20% the fork lifting is inhibited.
The "battery low" indicator LED illuminates.
To reset the low battery charge indicator, recharge the battery. When
the charge level reaches 75%% the "battery low" indicator is reset
and fork lifting is enabled.
ALARM AND MAINTENANCE WARNING INDICATOR

The MDI provides an indication of the truck's alarm status. When an
alarm signal is generated, the red LED will start flashing.
The display shows the error code that generated the alarm identified
by a number (see “DIAGNOSTICS” section).
On reaching the number of hours of operation after which maintenance

is required, the red LED lights up. After carrying out the necessary
maintenance, reset the parameters MAIN MENU PROGRAM / display
functions / maintenance timers / reset total maintenance - reset trac-
tion maintenance - reset pump maintenance (see “DESCRIPTION OF
MODULE PARAMETERS”).
15
TRUCK FUNCTIONS
TRACTION FORWARD/REVERSE
IMPLEMENTATION CONTROLS
To command forward traction, rotate the throttle backwards; to command reverse traction, rotate
the throttle forwards.
The drive direction is acquired via two hall effect sensors, one for forward travel and the other for
reverse travel.
Devices involved Status
Keyswitch ON
Emergency switch ON
Tiller tilt sensor ON*
Forward reverse traction throttle forward/reverse rotation
* OFF when the "snail" button is pressed
16
CONFIGURATION PARAMETERS
main menu program

Max Speed TM2 Max Speed
Max Accel TM2 Walk Accel
MODULE
Max Decel TM2 Max Decel
Neutral Braking TM2 Neutral Braking
Max Braking TM2 Max Braking
Speed Red3 (Steer)
For the regulation values of each individual parameter see the paragraph "CONFIGURA-
TION OF STANDARD MODULEparameters".
For the description of each individual parameters see " MODULE PARAMETER DESCRIP-
TION".
SPEED AND ACCELERATION

The maximum traction speed and acceleration in operating Mode 1 and Mode 2 can be set via the pro-
grammer.
Setting maximum forward/reverse traction speed
main menu program / traction / mode 1 / max speed
Setting acceleration
main menu program / traction / mode 1 / walk accel
The same settings can be applied to the Mode 2 operating mode by going to the following menu:
main menu program / traction / mode 2
SPEED REDUCTION AND TRACTION LOCKOUT

When the traction motor reaches a temperature of 115°C the current supplied
to the motor is limited, leading to a reduction in performance and hence truck speed. If the temperature
reaches 140°C, the motor lockout is tripped.
MODE SELECTION:
There are 3 selectable traction modes:
1- Mode 1: Used to save battery, with limited performance.
2- Mode 2: average performance.
3- Mode 3 (default): maximum performance, cannot be changed by the programmer.
Procedure for selecting traction mode:

• The tiller must be in the rest position, the brake on and the key switch off (OFF).
• Press and hold the horn button while switching on the truck (key switch ON).
• When the horn sounds, release the button on the tiller.
• Select the preferred mode using the fork lifting/lowering buttons.
• The horn emits a sound according to the selected mode, one sound for mode 1, two for mode 2 and
three for mode 3.
• Lower the tiller to confirm the selected mode that will be saved by the truck.
17
BRAKING
The truck is equipped with four braking systems:
• Release braking.
• Braking on direction reversal.
• Emergency braking.
• Parking braking.
Truck braking will be performed in different ways according to which of the above systems is implemented.
For further information on the braking systems see "BRAKING SYSTEMS" “BRAKING SYSTEM” section.
BRAKING SYSTEMS WHEN DOES IT COME INTO OPERATION?
Release braking Traction control throttle release
Braking on direction reversal Inversion of the direction of motion through the traction control throttle
Through operation of the emergency braking button

Emergency braking
A warning has been triggered that requires immediate traction stop-
page.
Stationary handbrake The machine is stationary and no traction control is activated
With the programmer it is possible to set the deceleration ramps for release braking, emergency braking
and direction reversal braking.
Setting the deceleration ramp for release braking

main menu program / traction / normal mode / neutral braking
Setting the deceleration ramp for emergency braking
main menu program / traction / normal mode / max braking
Setting the deceleration ramp for direction reversal braking
main menu program / traction / normal mode / max decel
EMERGENCY REVERSE MANOEUVRE

The emergency reverse manoeuvre is a safety function
that is applied in the event that the operator, when driving
forwards (direction of the traction wheel), hits an object.
In this event, pressing the reverse button causes the truck
to immediately reverse, thereby preventing the operator
from being crushed.
The emergency reverse procedure is activated with the
truck in forward drive, the tiller in the driving position (tiller emergency reverse
sensor active) and the "BELLY SWITCH" button pressed. function activation
button
18
SNAIL FUNCTION
The "snail" function enables traction even when the tiller is in the rest position (tiller sensor not active). This
allows the operator to drive the truck even when there is not enough room to lower the tiller. The "snail"
function is activated by pressing the button on the tiller head. Once the "snail" button is pressed, the trac-
tion request is performed by the potentiometric throttle.
tiller sensor potentiometric throttle (accelerator)
snail function activa-

tion button
19
STEERING
IMPLEMENTATION CONTROLS
To steer to the right or to the left rotate the steering tiller in the corresponding direction.
Devices involved status
Keyswitch ON
Emergency switch ON
Tiller tilt sensor ON
tiller rotation right/left
SPEED REDUCTION OPTION (optional sensor)

Speed reduction according to the steering angle is optional.
It is activated via the Steer Reduction Option and is managed via the Speed Red 3 (Steer) param-
eter and occurs with a steering angle greater than 15°.
SPEED REDUCTION WITH TRACTION WHEEL STEERED

This optional function reduces the maximum traction speed on exceeding a steering angle of 15°.
Above this value speed limitation trips and this can be set via the programmer. This feature is only
available if the Steer Reduction Option is active.
Speed setting for steering angle exceeding 15°

main menu program / traction / speed reduction / speed red3 (Steer)
20
FORK LIFTING/LOWERING
CONTROLS
D C A B
To lift the forks, press the on/off button “A” or “C”.

To lower the forks, press the on/off button "B" or “D”.
Devices involved status
Keyswitch ON
Emergency switch ON
ON/OFF button for lifting/
Fork lifting/lowering
lowering activated
Tiller tilt sensor ON*
* Only where the forks are being lowered (OFF if the "snail" button is pressed)
CONFIGURATION PARAMETERS
main menu program

Quick Lift Window
Quick Lift Re-Enable Time
Initial Lift Interval
Full Lift Interval
Lift run time
BDI Warning Enable
Lift Delay Time Valve 1-2
Lowering Delay Time Valve 1-2
For the settings of each single parameter, see the "STANDARD CONFIGURATION OF
MODULE PARAMETERS" subsection. For a description of each single parameter, see the
"DESCRIPTION OF MODULE PARAMETERS" subsection.
21
LIFTING LOCKOUT WITH LOW BATTERY

When the level of the battery charge drops below 20% fork lifting is inhibited. To restore
initial operating conditions the battery must be recharged.
When the battery charge reaches 75% the “battery low” indicator is reset and normal fork operation is restored.
Lifting lockout due to low battery may be disabled via the programmer.
Enabling/disablinglifting lockout with battery low (with optional MDI)
main menu program / display functions / bdi warning enable > off: disabled, on: enabled
The level of battery charge at which the “battery low” condition is activated can be modified using the pro-
grammer.
Battery low level

main menu program / display functions / warning bdi
TIMED LIFTING LOCKOUT

On pressing a “lift” button, P5, the forks start to rise and continue to rise for the maximum time that can be
set using the programmer.
Setting the maximum fork lift run time.

main menu program / hydraulic functions / lift run time
Once this time period has elapsed, to continue lifting, you must first press a “lower” button
and then press the “lift” button again.
END POINT SLOWDOWN LIFTING/LOWERING FORKS

When lifting, the forks rise to their maximum height without slowing down,
the motion stopping when the cylinder reaches its mechanical end-of-stroke position.
During lowering, the forks reach their lowest position without slowing down, the motion
stopping at the mechanical travel limit.
When there is the optional sensor, the lifting limit stop will be managed by the sensor.
LIFTING WITH SMART LIFT™ OPTION

The forklifts can be equipped with the optional SMART LIFT™. On trucks equipped with this function, you
can enable and disable the option by simultaneously pressing the lifting and lowering buttons on the left
or right sides. To activate the function, select the lifting and lowering functions simultaneously. Activation
of the horn confirms that the function is active. To deactivate the function, select the lifting and lowering
functions simultaneously. Double activation of the horn confirms that the function is active. To start lifting,
briefly press the lift button. The truck then lifts up to a programmed height. Verify that there are no obstacles
in the vicinity of the truck and load. Lifting will stop when you start driving forwards. The lifting function can
be interrupted by pressing the lowering button.
22
ACCESS TO CONFIGURATION PARAMETERS VIA THE CONSOLE

Before connecting the console to the module, turn the keyswitch to “OFF”.
Once the truck is switched on (key-on), the console will start to load the data from the controller. On
completion of the operation the list of menus will be displayed.
MENU SEARCH PROCEDURE AND PARAMETER MODIFICATION
Program
Monitor
Faults
Opening screen.
Functions
Controller Information
Programmer Setup
Press the “Up” or “Down” key on the naviga-

tion keypad to move to the desired menu.
Press the “Right” key on the navigation key-

pad to access the submenus and parameters.
Program
Interlock Timeout 60s
Buzzer Option 0 The list of parameters is displayed together
with the relative values and unit of measure-
�� ment.
Monitor
Faults

tion keypad to move to the desired parameter.
Press “Plus” or “Minus” on the edit keypad to
increase/decrease the value.
23
Program
Interlock Timeout 100s Edited parameter settings are immediately
Buzzer Option 0 updated on the truck controller.
��
For each parameter the user can also access
Monitor a specific screen giving detailed information.
Faults
Press the “Right” key on the navigation

keypad to access the details.
Program
Interlock Timeout
The specific screen for the parameter will be
100s displayed.
min max
0 120
Press “Plus” or “Minus” on the edit keypad to

increase/decrease the value.
Press the “Left” key on the navigation keypad
to return to the previous menus.
The parameter value increases/decreases one unit at a time. To increase/

decrease the value by 10, 100 or 1000 at a time, hold pressed respectively the
keys 1, 2 or 3 of the numeric keypad on the console and press the “Plus” or
“Minus” of the edit keypad.
+10 00
+100 +10
Caution. The modified parameters are updated immediately on the controller

and the initial values restore function cannot be used.
24
ALARM DISPLAY PROCEDURE
Program
Monitor
Faults
Functions Opening screen.
Controller Information
Programmer Setup

tion keypad to move to the "Faults" menu.

pad to access the menu.
The following options are displayed:

Program System Faults
Monitor Display a list of all the alarm conditions cur-
rently active on the truck.
Faults
Fault History
System Faults Display a list of all the alarm conditions that
Fault History have occurred up to the present time.
Clear Fault History
Clear Fault History
Resets the alarm history.

tion keypad to move to the desired option.

pad to select the option.
25
Monitor
Faults
Scroll down to “Clear Fault History” using the
System Faults navigation keypad.
Fault History
Clear Fault History
Functions

pad.
You are about to clear

Fault History
A prompt will appear asking you to confirm
Continue? that you wish to clear the fault history.
YES (+) NO (-)
Press "Plus" or "Minus" on the editing keypad

to confirm or cancel the modification.
BOOKMARKS
The user can save up to 3 bookmarks; these enable the user to return
directly to selected menu sections without having to navigate through all
the previous menus. To save a bookmark, hold one of the 3 bookmark
keys (Fig.1) pressed for 4 seconds until the confirmation screen appears.
From now own the user can return to the selected menu section simply Fig 1
by pressing the corresponding bookmark
key.
26
STANDARD CONFIGURATION OF MODULE PARAMETERS

It is advisable to retain the factory settings seeing as they have been designed to achieve
the best compromise between performance and part wear and tear. It is however possible
to customise the performance to suit the customer's requirements, the characteristics
of the warehouse and the materials to be moved, but no parameters must be changed if
this jeopardises the safety of the truck.
MAIN MENU PROGRAM
MAIN MENU PROGRAM 
MAIN MENU PROGRAM  Truck Options
MAIN MENU PROGRAM  Emergency Reverse
MAIN MENU PROGRAM  Hydraulic Functions
MAIN MENU PROGRAM  Traction
MAIN MENU PROGRAM  Traction  Speed Reduction
MAIN MENU PROGRAM  Traction  Mode 1
MAIN MENU PROGRAM  Traction  Mode 2
MAIN MENU PROGRAM  Display Functions
MAIN MENU PROGRAM  Display Functions  Maintenance Timers
MAIN MENU PROGRAM  Display Functions  Hour Meter Preset
MAIN MENU PROGRAM
PARAMETER PARAMETER PARAMETER

value
MENU LEV.2 MENU LEV.3 LEV.4
INTERLOCK TIMEOUT 120 sec
BUZZER DEAD BAND 70 rpm
TRUCK OPTIONS BUZZER OPTION 0
I: CHARGER PRESENT 0
I: BEVERAGE TRUCK ENABLE 0
I: STEER REDUCTION OPTION 0
I: ADVANCED TURTLE OPTION 0
I: TURTLE ACTIVATION ALARM 0
I: LIFT FUNCTION 0-NORMAL,
3
1-QUICK, 2-AUTO, 3-EU STD
EMERGENCY REVERSE EM Type 1

EM Time Limit 10 sec
EM Beep Enable 1
HYDRAULIC FUNCTIONS 803 LOCKOUT ENABLE 0
QUICK LIFT WINDOW 0.5 sec
QUICK LIFT RE-ENABLE TIME 0.4 sec
INITIAL LIFT INTERVAL 0.6 sec
FULL LIFT INTERVAL 2 sec
LIFT RUN TIME 4.3 sec
LIFT DELAY TIME VALVE 1-2 0.3 sec
LOWERING DELAY TIME VALVE
0.3 sec
1-2
27
MAIN MENU PROGRAM
PARAMETER O PARAMETER O PARAMETER

level
MENU LEV.2 MENU LEV.3 LEV.4
TRACTION MAX SPEED TM2 2780 rpm
MAX ACCEL TM2 1.5 sec
MAX DECEL TM2 1 sec
NEUTRAL BRAKING TM2 1 sec
MAX BRAKING TM2 0.4 sec
SPEED REDUCTION SPEED RED 3 (STEER) 80%
MODE 1 MAX SPEED 2300 rpm
MAX ACCEL 2.5 sec
WALK ACCEL 2.4 sec
MAX DECEL 1.4 sec
NEUTRAL BRAKING 2 sec
MAX BRAKING 0.4 sec
MODE 2 MAX SPEED 2900 rpm
MAX ACCEL 2 sec
WALK ACCEL 2 sec
MAX DECEL 1 sec
NEUTRAL BRAKING 1.6 sec
MAX BRAKING 0.4 sec
DISPLAY FUNCTIONS BDI WARNING ENABLE 1
BDI WARNING 20%
MAINTENANCE TIMERS TOTAL MAINTENANCE ENABLE 1
TRACTION MAINTENANCE EN-
1
ABLE
PUMP MAINTENANCE ENABLE 1

MAINTENANCE INTERVAL 500 h
RESET TOTAL MAINTENANCE 0
RESET TRACTION
0
MAINTENANCE
RESET PUMP MAINTENANCE 0

HOUR METER PRESET 10S OF HOURS 0
REMAINING HRS IN MINS 0
PRESET TOTAL HOURMETERS 0
PRESET TRACTION
0
HOURMETERS
PRESET PUMP HOURMETERS 0
28
MODULE PARAMETER DESCRIPTION
MAIN MENU PROGRAM
PARAMETER min max

INTERLOCK TIMEOUT 0 sec 120 sec
Maximum time period the truck may remain with the tiller in the operating position without any command being
given.
BUZZER DEAD BAND 0 rpm 1000 rpm

This parameter lets you set the RPM threshold beyond which the optional alarm is activated.
NOTE: The buzzer sounds only for RPM higher than or equal to this value.
MAIN MENU PROGRAM  Truck Options
PARAMETER min max

BUZZER OPTION 0 3
This parameter lets you set the Buzzer mode:
0-Buzzer off
1-Buzzer on when driving in reverse
2-Buzzer on when driving in both directions of travel
3-Buzzer on when driving forwards
I: CHARGER PRESENT 0 1
This parameter enables the CANopen battery charger.
I: BEVERAGE TRUCK ENABLE 0 1

This optional parameter lets you set the Beverage option (not used on the EMEA version).
I: STEER REDUCTION OPTION 0 1

This optional parameter lets you enable the option to reduce cornering speed, if the sensor is fitted.
I: ADVANCED TURTLE OPTION 0 1

This optional parameter lets you enable the truck for driving at reduced speed, with the tiller in the working
position.
I: TURTLE ACTIVATION ALARM 0 1

This parameter lets you set the alarm indicating whether the Advance Turtle option is enabled or disabled.
I: LIFT FUNCTION 0-NORMAL, 1-QUICK, 2-AUTO, 3-EU STD 0 3

This parameter lets you set the lifting performance level: 0-Normal, 1- etc.
MAIN MENU PROGRAM  Emergency Reverse

PARAMETER min max
EM TYPE 0 1
This parameter lets you set emergency stopping:
0- the truck is stopped immediately
1- the truck is stopped after a delay according to the level of the EM Time Limit parameter.
29
PARAMETER min max

EM TIME LIMIT 0 30 sec
This parameter lets you define for how long the truck is to be driven backwards by pressing
the BB switch
EM BEEP ENABLE 0 1
This parameter lets you enable the buzzer, when the emergency reversing switch is pressed.
MAIN MENU PROGRAM  Hydraulic Functions

PARAMETER min max
803 LOCKOUT ENABLE 0 1
Enables/disables lifting when the battery is low (only used on US version – on the EMEA version it should be kept
OFF).
QUICK LIFT WINDOW 0 15 sec

This optional parameter defines the minimum length of time that the lifting button must remain pressed before the
Quick Lift is activated.
QUICK LIFT RE-ENABLE TIME 0 15 sec

This optional parameter defines the minimum fork lowering time before you can again perform lifting in Quick Lift
mode.
INITIAL LIFT INTERVAL 0 10 sec

This optional parameter lets you set the time for which the truck performs lifting in Quick Lift mode. The time must
be sufficient for lifting the load...
FULL LIFT INTERVAL 0 10 sec

This optional parameter lets you set the time for which the truck will perform lifting in Quick Lift mode while traction
is active.
LIFT RUN TIME 0 10 sec

Defines the maximum time for which continuous fork lifting is enabled.
LIFT DELAY TIME VALVE 1-2 0 5 sec

This parameter defines the maximum time beyond which the valve closes after the pump has stopped having raised
the forks.
LOWERING DELAY TIME VALVE 1-2 0 5 sec

This parameter defines the maximum time beyond which the valve closes after the pump has stopped having low-
ered the forks.
MAIN MENU PROGRAM  Traction
PARAMETER min max

MAX SPEED TM2 0 3500 rpm
This parameter lets you define the maximum number of revolutions per minute of the motor under full acceleration
when the truck is moving in Advance Turtle mode.
30
PARAMETER min max

MAX ACCEL TM2 0.1 5 sec
This parameter sets the time taken to go from 0 to Max Speed TM2 when the truck is moving in Advanced Turtle
mode. Higher values correspond to a slower response.
MAX DECEL TM2 0.1 5 sec

Braking time required when the traction control throttle is inverted in Advanced Turtle mode.
NEUTRAL BRAKING TM2 0.1 5 sec

Braking time required on releasing the traction control throttle in Advanced Turtle mode.
MAX BRAKING TM2 0.1 sec 5 sec

Braking time required on releasing the tiller in Advanced Turtle mode.
MAIN MENU PROGRAM  Traction  Speed Reduction

PARAMETER min max
SPEED RED 3 (STEER) 0% 100%
This parameter defines the speed reduction (expressed as a percentage) for a steering angle greater than 15°
(feature active only with the Steer Reduction Option).
MAIN MENU PROGRAM  Traction  Mode1
PARAMETER min max

MAX SPEED 0 rpm 3550 rpm
This parameter defines the maximum number of revolutions per minute of the motor under full acceleration. RPM
= desired V. * 936 Example: rpm = 2.5MPH * 963 = 2340 rpm
MAX ACCEL 0.1 sec 5 sec

Parameter not used on the EMEA version.
WALK ACCEL 0.1 sec 5 sec

Time required to accelerate from 0% to 100% of the speed with the traction control throttle fully rotated.
MAX DECEL 0.1 sec 2 sec

Braking time required when the traction control throttle is inverted.
NEUTRAL BRAKING 0.1 sec 3 sec

Braking time required on releasing the traction control throttle.
MAX BRAKING 0.1 sec 2 sec

Braking time required on releasing the tiller.
31
MAIN MENU PROGRAM  Traction  Mode2
PARAMETER min max

MAX SPEED 0 rpm 3550 rpm
This parameter defines the maximum number of revolutions under full acceleration. RPM = VDesired * 936
Example: RPM = 2.5MPH * 963 = 2340 rpm
MAX ACCEL 0.1 sec 5 sec

Parameter not used on the EMEA version.
WALK ACCEL 0.1 sec 5 sec

Time required to accelerate from 0% to 100% of the speed with the traction control throttle fully rotated.
MAX DECEL 0.1 sec 2 sec

Braking time required when the traction control throttle is inverted.
NEUTRAL BRAKING 0.1 sec 3 sec

Braking time required on releasing the traction control throttle.
MAX BRAKING 0.1 sec 2 sec

Braking time required on releasing the tiller.
MAIN MENU PROGRAM  Display Functions

PARAMETER min max
BDI WARNING ENABLE 0 1
Enables/disables fork lifting lockout and traction speed reduction to 900 rpm when the battery charge percentage
reaches the level defined by the Warning BDI parameter
WARNING BDI 0% 100%

Defines the battery charge percentage on reaching which the truck will block the lifting function and reduce the
traction speed.
MAIN MENU PROGRAM  Display Functions  Mainteinance Timers

PARAMETER min max
TOTAL MAINTENANCE ENABLE 0 1
enables/disables signalling maintenance is necessary when the number
of hours of machine key-on operation reaches the preset maximum value.
0: signalling disabled
1: signalling enabled
TRACTION MAINTENANCE ENABLE 0 1

enables/disables signalling maintenance is necessary when the number
of hours of machine traction operation reaches the preset maximum value.
32
PARAMETER min max

PUMP MAINTENANCE ENABLE 0 1
If the optional MDI is present, it enables/disables signalling maintenance is necessary when the number of operating
hours of the machine's hydraulic pump reaches the preset maximum value.
MAINTENANCE INTERVAL 10 hours 20,000 hours
Number of truck operating hours after which maintenance is required.
RESET TOTAL MAINTENANCE 0 1

When set to 1, the remaining key-on operating hours before the next maintenance interval expires are reset to the
value indicated by the parameter MENU PROGRAM / Hours Meter Functions / Maintenance Interval.
After setting to 1 following maintenance, switch the truck off and then on again.
0: maintenance not carried out
1: maintenance carried out
RESET TRACTION MAINTENANCE 0 1

When set to 1, the remaining traction operating hours before the next maintenance interval expires are reset to the
After setting to 1 following maintenance, switch the truck off and then on again.
RESET PUMP MAINTENANCE 0 1

When set to 1, the remaining pump operating hours before the next maintenance interval expires are reset to the
After setting to ON following maintenance, switch the truck off and then on again.
MAIN MENU PROGRAM  Display Functions  Hour Meter Preset

PARAMETER min max
10S OF HOURS 0 20,000
Value used to preset the operating hours count. Each unit corresponds to 10 hours (e.g. the value 23 corresponds
to 230 hours).
REMAINING HRS IN MINS 0 6.00
Value used to preset the operating hour meter, expressed in minutes (the value 360 corresponds to 6 hours).
PRESET TOTAL HOURMETER 0 1

When set to 1, the number of truck operating hours (key-on) is preset to the value defined in the parameters MENU
PROGRAM / Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of
Hours” * 10) + (“Remaining HRs in Mins” / 60)
0: presetting not performed
1: presetting performed
33
PARAMETER min max

PRESET TRACTION HOURMETER 0 1
When set to 1, the number of truck traction hours is preset to the value defined in the parameters MENU PROGRAM
/ Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10)
+ (“Remaining HRs in Mins” / 60)
PRESET PUMP HOURMETER 0 1

When set to 1, the number of truck hydraulic pump operating hours is preset to the value defined in the parameters
MENU PROGRAM / Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula:
(“10s Of Hours” * 10) + (“Remaining HRs in Mins” / 60)
34
MODULE: INTRODUCTION
The module has been designed to perform all the electrical functions normally present on the truck:
• control of the 1.2 kW AC motor
• control of the 1 kW - 1.4 kW hydraulic pump
• driver for the porportional solenoid valve
• CanBus interface
• interface with the tiller Can Bus
• Warnings
• performances
Technical specifications:
Asynchronous three phase inverter for AC motors and chopper for DC pump motors
Regenerative braking functions
Digital control via microcontroller
Voltage: ........................................................................................24V
Maximum inverter current (24V):...................................................180A (RMS) for 2’
PWM operating frequency.............................................................10 kHz
Maximum encoder frequency........................................................10 kHz
Maximum control output frequency...............................................300 Hz
Outside temperature limits............................................................-40°C to 50°C
35
The module is connected and communicates through the CANBUS network, which allows access to truck
diagnostics or programming via PC or laptop.
The connector (X30) for the interface cable kit connection ("PC TOOL") is connected to the module and
can be accessed from a compartment on the control panel.
The module is equipped with flash memory, which enables the software to be updated by connecting a PC
to the CANBUS network (Can flash).
POSITIONING OF THE "PC TOOL" CONNECTOR
connettore pc
kit cavo interfaccia

cod.580039670
36
MODULE REPLACEMENT: INSTRUCTIONS

Equipment and tools
B
resistor
fixed spanner
100 Ohm 25w
10 mm
isolated
T-handle socket Fig. 1

wrench
10 - 13 mm
Procedure
transit of other vehicles and all pedestrians. Turn the
keyswitch to OFF and disconnect the battery.
Phase 1 Fig. 2
T-HANDLE SOCKET WRENCH SIZE 13 mm
Use the T-handle socket wrench to unscrew and remove the motor cover fixing nuts (ref.A fig.1).
Remove the motor cover by pressing your hands first on the left and then on the right-hand side to trip the
locking clips (ref.B fig.1).
Phase 2
100 Ohm 25 W RESISTOR
Connect the resistence betwen the positive(B+) and negative(B-of the module(fig.2).
Wait approximately 10 seconds for the internal capacitors to lose their charge and then disconnect the
resistence.
To avoid short circuit, it is important that the resistence by isolated.
If it is not possible to have an external resistence to run down the capacitors, it will be necessary to wait at
least 90 seconds before disconnecting the power cables.
37
Phase 3
FIXED GAUGE 10 mm SPANNER
Using the open ended spanner, unscrew and remove the power cable retaining screws.
Disconnect the module connection connector.
Earmark the power cables for reassembly and disconnect them.
Phase 4
10 mm T-HANDLE SOCKET WRENCH
Using the T-handle hex socket wrench unscrew and remove the nuts securing the module and remove the
washers.
Remove the module including the heat sink and procede with the replacement.
CONFIGURATION
ADAPTER - PROGRAMMER
Connect the adapter to the “PC CONSOLE" connector.
Connect the USB connector of the interface cable to the USB port on the PC.
Connect the battery and switch on the truck (starter key to ON). Start the PC Console program.
ACQUISITION OF OPERATING HOURS

The truck operating hours are saved in the display memory.
After replacing the controller, on switching on the truck make a note of the operating hours shown on the
display (value H: e.g. 138.9). Perform the operation H / 10. The result will be in the format XX.YY (e.g. 13.89).
Procedure
With the truck switched off (keyswitch OFF), connect the programmer.
Switch on the truck (keyswitch ON) and select the parameter main menu program / display functions / hour
meter preset / 10s of hours.
Set the parameter to the value XX (e.g.13).
Select the parameter main menu program / display functions / hour meter preset / remaining hrs in mins.
Set the parameter to the value YY·6 (e.g. 89·6=534).
Select the parameter main menu program / display functions / hour meter preset / preset total hourmeters.
Set the parameter to “ON”.
Switch off the truck (Keyswitch OFF) and switch it back on again ( Keyswitch ON).
At this point the module will make the necessary modifications to the monitor menu parameters regarding
maintenance hours and will reset the parameter preset total hourmeters to “OFF“.
38
ELECTRICAL COMPONENT DISMANTLING

REPLACEMENT OF THE GENERAL EMERGENCY SWITCH
Equipment and tools
B
T-handle socket
medium Phillips
wrench
screwdriver
13 mm
Procedure Fig. 1

protective clothing. Fig. 2
Move the carriage to a safe place, away from areas of tran-
sit of other vehicles and all pedestrians. Lower the forks
to the ground, turn the keyswitch to OFF and disconnect
the battery. D
Phase 1
Use the T-handle socket wrench to unscrew and remove the motor cover
fixing nuts (ref.A fig.1). C
Phase 2
13 mm T-HANDLE SOCKET WRENCH - PHILLIPS SCREWDRIVER
Mark the wires and remove all the faston connectors from the switch. Using the T-handle socket wrench
take out the screw securing the bracket to the switch (ref.C fig.2).
Using the screwdriver, remove the two fixing screws of the emergency main switch (ref.D fig.2) and make
the replacement.
INSTALLATION
Before connecting them again, make sure the Faston connectors are suitably tight. If not,
tighten the connectors with Faston pliers.
39
REPLACEMENT OF THE DISPLAY

Equipment and tools
B
T-handle socket
wrench
13 mm
Procedure Fig. 1

Move the carriage to a safe place, away from areas of C
transit of other vehicles and all pedestrians. Lower the
forks to the ground, turn the keyswitch to OFF and dis-
D
connect the battery.
Phase 1
fixing nuts (ref.A fig.1).
Fig. 2
Phase 2
Disconnect the wiring connector (ref.E fig.2).
Loosen the nuts securing the retaining bracket (ref.C fig.3). Remove the
bracket (ref.D fig.2).
Remove the display and proceed with replacement.
40
REPLACEMENT OF THE KEY SWITCH

Equipment and tools
T-handle socket
wrench
10 - 13 mm
Fig. 1
Procedure
Before starting work, ensure that you are wearing suitable protective clothing. Move the
carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.
Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.
Phase 1 Fig. 2
T-HANDLE SOCKET WRENCH SIZE 13 mm B
Phase 2
Remove the ignition key(fig.2).
Unscrew the ferrule (ref. B fig.2), remove the switch block from the
dashboard (fig.3). Fig. 3
Disconnect the connectors and proceed with the replacement.
INSTALLATION
Before connecting them again, make sure the Faston con-

nectors are suitably tight. If not, tighten the connectors
with Faston pliers.
41
REPLACEMENT OF THE WARNING BUZZER

Equipment and tools
B
T-handle socket
wrench
10 - 13 mm
Procedure Fig. 1

keyswitch to OFF and disconnect the battery.
Phase 1
Phase 2
Using the T-handle socket wrench unscrew and remove the horn fastening nut (ref.C fig.2). Disconnect
the connectors, remove the horn and proceed with replacement.
INSTALLATION
Before connecting them again, make sure the Faston connectors are suitably tight. If not,
tighten the connectors with Faston pliers.
42
FUSE REPLACEMENT
• 4A fuse (F3)
• 175A power fuse (F2)
Equipment and tools
B
T-handle socket
wrench
13 mm
Fig. 1
Procedure
keyswitch to OFF and disconnect the battery. D
C
Phase 1
Phase 2
Fig. 2
Remove the fuse (ref.C fig.2) from its socket and proceed with the re-
placement.
Using the T-handle socket wrench remove the nuts that fasten the power
fuse (ref.D fig.2), remove the fuse and proceed with the replacement.
43
TILLER BOARD REPLACEMENT

Equipment and tools
T handle hex key small flat blade

2.5 - 4 mm screwdriver A B
Fig. 1 C
Procedure
connect the battery. D
Fig. 2
EF G
Phase 1
H
Unscrew the bolts securing the upper casing ref.A,B,C fig.1).
Phase 2
Lift the upper casing and detach it from the lower casing (fig.2). Discon-
nect the serial cable connector (ref.D fig.2) and place the cover on a
clean work bench.
Fig. 3
Phase 3
T-HANDLE HEX KEY SIZE 2.5 mm
Loosen the screw securing one of the two throttles (ref.E fig.3) and re-
move the washer (ref.F fig.3). Remove the throttle from the pin (ref.G
fig.3). Remove the other butterfly control complete with the guide pin
(ref.H fig.3).
Phase 4
K
SMALL FLAT BLADE SCREWDRIVER
Unscrew the screw securing the tiller board retaining clip (ref.I fig.4).
Remove the retaining clip (ref.J fig.4) and the board from its slot (ref.K
fig.4), disconnect the connectors of the various microswitches.
Proceed with replacement. J
Fig. 4 I
44
REPLACEMENT OF TILLER BUTTONS

Equipment and tools
A B
Fig. 1 C
T handle hex key small flat blade
4 mm screwdriver
Procedure
Move the carriage to a safe place, away from areas of D
forks to the ground, turn the keyswitch to OFF and dis- Fig. 2
Fig. 3
Phase 1
Phase 2
clean work bench.
Phase 3
Using the screwdriver, prise open the clips (fig.4) and push the button Fig. 4
out of its seat (fig.4,5).
Proceed with replacement
Fig. 5
45
REPLACEMENT OF THE TILLER CONTROL SPRINGS

Equipment and tools
T handle hex key small flat head

2.5 - 4 mm screwdriver
Procedure
A B
Fig. 1 C
Phase 1
D
Fig. 2
Phase 2
Fig. 3
clean work bench.
EF G
H
Phase 3
T-HANDLE HEX KEY SIZE 2.5 mm
Loosen the screw securing one of the two throttles (ref.E fig.3) and re-
move the washer (ref.F fig.3). Remove the throttle from the pin (ref.G
fig.3). Remove the other throttle complete with the guide pin (ref.H fig.3).
46
BUTTERFLY CONTROL SPRING

Fig. 4
Phase 4
SMALL FLAT BLADE SCREWDRIVER J
Using the screwdriver, prise out the throttle guide bush (ref.I fig.4). In the
same way, prise out the throttle control spring (ref.J fig.4).
Proceed with the replacement.
BELLY AND HORN BUTTON SPRINGS

Fig. 5
Phase 4
With the screwdriver, apply leverage under the belly switch in correspond-
ence with the locking pin (fig.5). Take out the button (ref.K fig.6) and
remove the spring (ref.L fig.6).
In the same way, apply leverage under the horn button in correspondence
with the locking pin (fig.5). Take out the button (ref.M fig.6) and remove
the spring (ref.N fig.6).
Proceed with replacement.
Fig. 6
K
L
N
47
REPLACEMENT OF THE TILLER ASSENT SENSOR

Equipment and tools
T-handle socket
T handle hex key
wrench
4 mm
13 mm
fixed spanner
28 mm
Fig. 2
Procedure
Before starting work, ensure that you are wearing suitable D
Phase 1
Phase 2
Disconnect the sensor connector located next to the traction motor (ref.C
fig.2).
§Using the hexagonal "T" section spanner, unscrew and remove the two
screws fastening the upper cover to the tiller base (ref.D fig.2). Remove
the cover.
48
Phase 3
Fig. 3
OPEN ENDED SPANNER 28 mm
Lower the tiller. While keeping the tiller completely lowered, use the span-
D
ner to unscrew the nut fastening the sensor (ref.E fig.3).
Take the sensor out of its housing, remove the wire and proceed with
the replacement.
The optimal sensor sensitivity distance from the cam is

4 mm.
49
REPLACEMENT OF OPTIONAL STEERING SENSOR

Equipment and tools
B
T-handle socket open-ended
wrench spanner
13 mm 28 mm
Procedure Fig. 1

Phase 1
D C
Phase 2
OPEN ENDED SPANNER 28 mm
Disconnect the sensor connector located behind the traction motor (ref.C
fig.2).
Use the spanner to loosen the nut fastening the sensor (ref.E fig.3).
Take the sensor out of its housing, remove the wire and proceed with
the replacement.
The optimal sensor sensitivity distance from the cam is 4

mm.
50
SERVICE HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC FUNCTIONS�� 2
FORK LIFTING AND LOWERING�� 2
OIL SUPPLY TO THE HYDRAULIC CIRCUIT�� 3
PRESSURE REGULATING VALVES�� 3
DIRECTIONAL VALVES�� 3
HYDRAULIC DIAGRAMS�� 4
SYMBOLS�� 4
MAIN HYDRAULIC DIAGRAM�� 5
HYDRAULIC DIAGRAMS BY FUNCTION�� 6
HYDRAULIC DIAGRAM FOR FORK LIFTING�� 7
HYDRAULIC DIAGRAM FOR FORK LOWERING�� 8
HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE�� 9
HYDRAULIC COMPONENTS �� 10
REMOVAL OF THE PRESSURE RELIEF VALVE�� 10
CALIBRATION OF THE PRESSURE RELIEF VALVE�� 12
CHANGING THE OIL FILTER�� 13
CARTRIDGE SOLENOID VALVES�� 14
KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS�� 14
REMOVAL OF THE SOLENOID VALVE�� 15
CYLINDERS�� 17
SINGLE ACTING CYLINDERS�� 17
LIFTING CYLINDER�� 17
IDENTIFICATION OF THE LIFTING CYLINDER COMPONENTS�� 18
REMOVAL OF THE LIFTING CYLINDER�� 19
REPLACEMENT OF THE LIFTING CYLINDER SEALS�� 21
LIFT PUMP�� 23
KEY TO LIFT PUMP COMPONENTS�� 23
REMOVAL OF THE LIFT PUMP�� 24
REPLACEMENT OF THE PUMP�� 26
REPLACEMENT OF THE CYLINDER SUPPLY PIPE�� 27
1
HYDRAULIC SYSTEM SERVICE
HYDRAULIC FUNCTIONS
• Fork Lifting
• Fork Lowering
FORK LIFTING/LOWERING
The fork lifting speed is determined by the rpm at which the pump motor transmits drive to the pump drive
shaft.
In the lowering stage the check valve prevents the flow of oil through the pump and the oil returns to the
reservoir through the flow control valve.
2
HYDRAULIC CIRCUIT POWER SUPPLY

Fixed cylinder capacity pumps
With fixed capacity cylinders, the oil flow is constant, providing the speed
of crank shaft rotation remains unchanged.
A reduction in the drive shaft revs lowers the load capacity: if the revs
are reduced so is the flow and vice versa; the pressure, providing the
load is unchanged, remains constant.
PRESSURE REGULATING VALVES

Pressure limiting valves
The "pressure limiting" or "pressure relief" valves are mainly used to
guarantee the maximum pressure admitted into the system and to protect
the pump from experiencing pressure that might exceed its own structural
specifications.
The use of pressure limiting devices is not restricted to the functions
described above, but they are commonly used in many devices where it
is crucial to prevent pressure build ups. An example are anti-shock and
anti-knock valves.
As long as the circuit is not subjected to excess pressure conditions, the
pressure limiting device remains in the closed position: the force exerted by the pressurised oil is lower than
that exerted by the opposing spring. With the piston at its end-of-stroke or if an anomalous situation arises
which generates forces in excess of the set level (for example with a load in excess of the load capacity),
the over-pressured oil overcomes the force of the spring and flows towards the oil outlet.
DIRECTIONAL VALVES
One-directional and restraining valves.
The function of "one-directional" or "non-return" valves is to allow the oil to flow in one direction only, while
the flow in the opposite direction is not permitted.
They are essentially comprised of a fixed part connected to the end of the pipe; in the appropriate inner
housing runs the moving element which might be a bearing or a conical plug.
Check valves instead have an opposing spring. In the direction of free flow, the oil pressure must exceed
the force exerted by the spring.
3
HYDRAULIC PLANS
SYMBOLS
TWO POSITION SOLENOID THREE POSITION

VALVE SOLENOID VALVE
ONE-DIRECTIONAL
FILTER
VALVE
DOUBLE ACTING
CYLINDER PROPORTIONAL VALVE
SINGLE ACTING CYLINDER PUMP
TANK HYDRAULIC MOTOR
LINE CONNECTION ELECTRIC MOTOR
PRESSURE RELIEF VALVE FLOW VALVE
MANUAL COCK BY-PASS VALVE
4
MAIN HYDRAULIC DIAGRAM
5
HYDRAULIC PLANS ORDERED ACCORDING TO

FUNCTION
• Fork Lifting
• Fork Lowering
SOLENOID VALVE OPERATION CHART
Function Pump EV1
Fork Lifting P -
Fork Lowering +
pressure
P
= pump in operation
relief valve in
+
= solenoid valve coil powered the tank
6
HYDRAULIC FORK LIFTING PLAN
7
HYDRAULIC FORK LOWERING PLAN
8
HYDRAULIC PLAN FOR OIL RELEASE INTO THE TANK THROUGH THE PRESSURE RELIEF VALVE
The pressure relief or pressure limiting valves are used in hydraulic systems in order to guar-
antee the extreme pressures introduced into the system and to protect and safeguard the
system against sudden pressure increases that could seriously damage the components.
The pressure relief valve may come into operation in the following instances:
• Pressure regulation not suitable for the truck load capacity.
• Attempts to lift a load in excess of the truck's load capacity
• Blocked or faulty valve
9
HYDRAULIC COMPONENTS
REMOVAL OF THE PRESSURE RELIEF VALVE
Equipment and tools
T-handle socket open ended span-

torx key
wrench oil resistant gloves ner
T30
13 mm 12 mm
Procedure
Before starting work, ensure that you are wearing suitable protective clothing.
Move the truck to a safe place, away from the transit areas of other vehicles and pedestri-
ans. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.
The hydraulic fluid gets very hot during system operation and can cause burns. It is
advisable to wear gloves that are resistant to oil and high temperatures.
Phase 1
Use the T-handle socket wrench to
unscrew and remove the motor cover
Remove the motor cover by pressing
your hands first on the left and then on
B
the right-hand side to trip the locking
clips (ref.B fig.1).
Fig. 1
Phase 2
Carry out the procedure to remove the lift pump (see "REMOVAL OF THE LIFT PUMP").
10
Phase 3
T30 TORX KEY - OIL RESISTANT GLOVES
Wear the oil resistant gloves.
Unscrew the tank fastening screws using the torx key (ref.C fig.2). Re-
move the tank.
Fig. 2
Fig. 3
Phase 4
FIXED 12 mm SPANNER
Use the spanner to unscrew and remove the valve assembly (ref.D fig.3)
and proceed with the replacement.
INSTALLATION
Install the valve and tighten with a torque wrench to 15 Nm.
After replacement, before reassembling the tank, regulate the valve

(see "REGULATING THE PRESSURE RELIEF VALVE")
11
PRESSURE RELIEF VALVE CALIBRATION

The calibration of pressure relief valve is required following replacement.
Equipment and tools
10mm open
ended spanner small wrench
Procedure
The valve pressure setting is approx. 35/40 bar for each screw turn.
Phase 1
FIXED 10 mm SPANNER - A SMALL FLAT HEAD SCREWDRIVER Fig. 1
Loosen the valve fastening bolt with the fixed gauge spanner (ref.A fig.1).
With a screwdriver completely unscrew the valve adjusting screw (fig.1)
and then screw it back in by 4½ turns. Use the spanner to tighten the
lock nut (ref.A fig.1), to lock the adjusting screw in position. A
Screw
Phase 2
Reassemble the pump on the truck, connect the battery and switch on
the truck (starter key to ON).
Place on the forks a load equivalent to the truck's load capacity, as indi-
cated on the truck's dataplate.
Carry out a few trial lifts and lowering manoeuvres with the load on the
forks, checking that the pressure setting is sufficient to cope with the pressure surge during the initial lifting
stage.
Otherwise, adjust once more by turning the screw another ½ turn.
12
CHANGE OIL FILTER
Procedure
Phase 1
Unscrew the filter (ref.A fig.1) from the oil suction hose (ref.B fig.1) and
proceed with the replacement. Fig. 1
13
CARTRIDGE SOLENOID VALVES

The solenoid valves of the directional control valve are of the screw-in cartridge type.
This type of valve is comprised of a body with a fixed hex nut, a threaded part, a set of static seals; inside
a moving element allows communication between the various chambers.
KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS
2 1
Ref. Description
1 Coil
2 Chassis valve
14
SOLENOID VALVE DISMANTLING

Equipment and tools
T-handle socket open ended span-

small cross-head
oil resistant gloves wrench ner
screwdriver
13 mm 19-24 mm
Procedure
The hydraulic fluid gets very hot during system operation and can cause burns. It is
advisable to wear gloves that are resistant to oil and high temperatures.
Phase 1
T-HANDLE SOCKET WRENCH SIZE
13 mm
Use the T-handle socket wrench to B
unscrew and remove the motor cover
clips (ref.B fig.1). A
Fig. 1
Phase 2
SMALL PHILIPS SCREWDRIVER
Unscrew the fastening screws and disconnect the energy supply con-
nector of the solenoid valve coil (fig.2).
Fig. 2
15
Phase 3
OIL RESISTANT GLOVES - 19-24 mm OPEN ENDED SPANNER
D C
With the 19 mm spanner, unscrew the nut securing the coil (ref.C fig.3).
Withdraw the coil.
Using the 24 mm spanner, unscrew the nut securing the valve body to
the hydraulic unit (ref.D fig.3. Proceed with replacement
Fig. 3
INSTALLATION
On refitting the valve body, tighten the retaining nut to a
torque of 35 Nm. Tighten the coil retaining nut to a torque
of 6 Nm.
16
CYLINDERS
SINGLE ACTING CYLINDER
SINGLE acting cylinders receive and discharge the oil through a single pipe and the pressurised oil acts
on just one side of the piston (single acting pushing cylinders) or on the flat face of the rod in the case of
plunger type cylinders.
Single-acting plunger type cylinders
In this type of cylinder the piston is replaced by the flat end face of the piston rod or plunger; these cylinders
are usually mounted vertically or in other positions in which the force of gravity returns the plunger to the
rest position. Usually the diameter of the lower end of the rod is increased by a few millimetres in order to
avoid it slipping out at the end of it's upstroke; this gives rise to a hydraulic damping effect during the last
stages of the stroke which helps the slowing of the rod and avoids recoil on the upper end cap. Place in
the latter, the necessary static sealing gaskets which avoid seepage of oil to the exterior.
In order to replace these gaskets one must unscrew the gasket case bushing.
Single acting cylinder with hollow rods differ in that before the lifting stroke begins the rod is also filled with
oil. This solution is used on particularly tall masts to increase the resistance of the cylinders at the greater
heights and make it possible to use smaller barrels and shafts.
Static and dynamic gaskets
The dynamic gaskets, assembled on the piston, avoid the seepage of the fluid from one barrel chamber
to the next, the static gaskets, placed in the points where the parts meet (gasket case bushing - barrel) or
between the sliding parts (shaft- chamber), avoid oil seepage from inside to outside.
LIFTING CYLINDER
Shaft
Height H3
Type of cylinder diameter
mm
mm
Type “A” single-acting plunger

50 130
cylinder with solid rod
H3
17
KEY TO LIFTING CYLINDER COMPONENTS

The cylinder is of the single-acting plunger type.
After the replacement of the entire cylinder one must carry out the bleeding of the air through the bleeding
valve.
The static gaskets are replaced with the cylinder mounted in the machine.
1
2
10
5
9
6
7
11
7
Ref. Description Ref. Description
1 Spacers 7 O-ring
2 Locking key 8 Liner
3 Rod and piston 9 Sealing gasket
4 Oil scraper seal 10 Gasket case bush
5 Sealing gasket 11 Bottom
6 Gasket housing bushing
18
REMOVAL OF THE LIFTING CYLINDER

Equipment and tools
T-handle socket socket wrench open ended span-

T handle hex key
wrench with flexible ner
5 mm
13 mm handle 18 mm
13 mm
oil protecting
"Parker" cap 2 wooden blocks
gloves
Procedure
Move the carriage to a safe place, away from areas of transit of other vehicles and all
pedestrians. Lower the forks to the ground.
The hydraulic fluid gets very hot during system operation and can cause burns. It is ad-
visable to wear gloves that are resistant to oil and high temperatures.
Phase 1
clips (ref.B fig.1).
Phase 2
B
2 WOODEN BLOCKS
Raise the forks to the maximum height.
Place the wooden blocks under the
forks and lower them until they rest
on them. A
Fig. 1
19
Fig. 2
Position the key switch to OFF and disconnect the battery.
Phase 3
5 mm T HANDLE HEX KEY C
Open the cover of the battery compartment. From the battery compart-
ment, with the T-handle hex key, unscrew and remove the screw securing
the upper cover of the cylinder (ref.C fig.2). Remove the upper cover of
the cylinder by sliding it out upwards.
Phase 4
13 mm SOCKET WITH FLEXIBLE HANDLE
Fig. 3
With the swivel socket wrench loosen the three nuts of the cylinder's
central cover (ref.D fig.3). Raise the cover upwards to remove it.
D
Connect the battery and position the ignition key on ON
Phase 5
OIL RESISTANT GLOVES - 18 mm OPEN ENDED SPANNER - "PARK-
ER" SERVICE PLUG
Fig. 4
Remove the cylinder locking key (ref.E fig.4) and press the forks down
button, use your hand to push the stem down to its limit stop. Turn off
the truck. E
Using the spanner, unscrew the hydraulic hose union (ref.F fig.4).
Fit the service plug to the hydraulic hose.
Withdraw the cylinder from its housing, place it on a clean workbench
with a vice and proceed with disassembly or replacement.
ASSEMBLY
Before tightening the hydraulic connections, consult the table of

reference (see "CORRECT METHOD OF APPLYING FEMALE CON- F
NECTIONS” "PREMISES" section).
20
REPLACEMENT OF THE LIFTING CYLINDER SEALS

Equipment and tools
small flat head oil protecting

hook wrench chain pipe wrench
screwdriver gloves
work bench vice brush
Procedure
pedestrians. Lower the forks to the ground.
The hydraulic fluid gets very hot during system operation and can cause burns. It is ad-
visable to wear gloves that are resistant to oil and high temperatures.
Phase 1
Carry out the lifting cylinder removal procedure (see “REMOVAL OF THE LIFTING CYLINDER”).
REPLACEMENT OF THE UPPER SEALS

Fig. 1
Phase 2
WORK BENCH - VICE - OIL RESISTANT GLOVES - C SPANNER - A
CHAIN WRENCH
Secure the cylinder in the vice, interposing a rubber protection between
the vice jaws and the cylinder barrel.
Apply the C spanner to one of the notches on the seal carrier bush (ref.A
fig.1) and apply the pipe wrench to the cylinder barrel (ref.B fig.1). Un-
screw the bush from the cylinder and slide it off the rod (fig.1).
21
Phase 3
Using the screwdriver, remove the external O-rings (ref.C fig.2) and the C
seals inside the bush (ref.D fig.2) and proceed with replacement.
REPLACEMENT OF THE LOWER SEALS D

Fig. 2
Phase 4
Remove the stem from the cylinder, remove the bottom (ref.E fig.3) and
remove the seal carrier bush (ref.F fig.3).
E
Fig. 3
Phase 5
With the small flat blade screwdriver, remove the seals and proceed with
replacement (ref.G fig.4). G
G
Fig. 4
INSTALLATION
Fitting the seals is a delicate stage in the lift cylinder as-

sembly procedure. Most maintenance operations are to
be ascribed to gasket leakage.
Clean the seal carrier bush and lubricate the seal contact
faces in the bush and the seals themselves with clean hy-
draulic oil before installation.
The bush should be tightened to a torque of 275 Nm.
22
LIFT PUMP
KEY TO LIFT PUMP COMPONENTS
5
4
3
2
9
6
Ref. Description
1 Pump motor
2 Solenoid valve coil
3 Solenoid valve body
4 Pump baseboard
5 check valve
6 Oil intake pipe
7 Filter
8 Pressure relief valve
10
9 O-ring
10 Reservoir
23
LIFT PUMP DISMANTLING

Equipment and tools
fixed gauge span- T-handle socket

small cross-head oil protecting
ner wrench
screwdriver gloves
10-13-19 mm 13 mm
Procedure
pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect
the battery.
The hydraulic fluid gets very hot during system operation and can cause burns. It is rec-
ommended that oil protecting gloves resistant to high temperatures be used.
Phase 1
Fig. 1
24
Phase 2
Fig. 2
10-13 mm open ended spanner C
Using the open ended spanner, unscrew the nuts fastening the pump
motor power cables (ref.C fig.2).
Take note of the position of the cables. Extract the cables.
Phase 3
SMALL CROSS-HEAD SCREWDRIVER Fig. 3
Unscrew the retaining screws and disconnect the power supply connector
of the solenoid valve coil (ref.D fig.3).
D
Phase 4
OIL RESISTANT GLOVES - 19 mm open ended spanner
Wear the gloves.
Using the spanner, unscrew the connection fitting of the hydraulic pipe
(ref.E fig.3). E
Fig. 4
Phase 5
Remove the battery (reverse the procedure described in “BATTERY
INSTALLATION, “INSTALLATION AND SETTINGS” section).
F
Phase 6
FIXED GAUGE 13 mm SPANNER
Support the pump assembly with one hand and using the spanner unscrew
and remove the fixing screws located inside the battery compartment
(ref.F fig.4).
Recover the pump and proceed with replacement or disassembly.
F
25
REPLACEMENT OF THE PUMP

Equipment and tools
T handle hex key torx key

oil resistant gloves
5 mm T30
Procedure
forks to the ground. Turn the keyswitch to OFF and dis-
Fig.1
Phase 1
Carry out the procedure to remove the lift pump (see "REMOVAL OF Fig. 2
THE LIFT PUMP").
Phase 2
T30 TORX KEY - OIL RESISTANT GLOVES
Put the oil proof gloves on.
Unscrew the tank fastening screws using the torx key (ref.A fig.1). Re-
move the tank.
Phase 3
HEXAGONAL 5 mm "T" SECTION SPANNER
Use the hexagonal T-handle spanner to unscrew and remove the bolts
fastening the pump chassis to the flange (ref.B fig.2), remove the pump
and proceed with the replacement.
INSTALLATION
On installation tighten the nuts securing the pump to the

flange with a torque wrench to 29 Nm. Use medium Loc-
tite.
26
REPLACEMENT OF THE CYLINDER SUPPLY PIPE

Equipment and tools
T handle hex key fixed spanner oil protecting

"Parker" caps
5-6 mm 19 mm gloves
Procedure
forks to the ground. Turn the keyswitch to OFF and dis-
The hydraulic fluid gets very hot during system operation
and can cause burns. It is recommended that oil protecting
gloves resistant to high temperatures be used.
Phase 1
T-HANDLE SOCKET WRENCH SIZE 13 mm A
fixing nuts.
on the right-hand side to trip the locking clips.
Phase 2
OIL RESISTANT GLOVES - 19 mm OPEN ENDED SPANNER - "PARK-
ER" PLUGS
Wear the oil resistant gloves. Fig. 1
Using the spanner unscrew the couplings of the hydraulic pipe (ref.A
fig.1).
Apply the caps to the connectors. Recover the hydraulic pipe and proceed
with replacement.
27
28
SERVICE MECHANICS
MECHANICS
TRACTION WHEEL�� 2
KEY TO TRACTION WHEEL COMPONENTS�� 2
REMOVING THE TRACTION WHEEL�� 3
CASTOR WHEELS ASSEMBLY�� 4
KEY TO CASTOR WHEELS ASSEMBLY COMPONENTS�� 4
REMOVING THE CASTOR WHEELS ASSEMBLY�� 6
ADJUSTING THE WHEEL HEIGHT..............................................................................................................................8
LOAD WHEELS�� 10
KEY TO LOAD WHEEL COMPONENTS�� 10
REPLACING THE LOAD WHEELS�� 11
REPLACING THE LOAD WHEELS ASSEMBLY�� 12
LINKAGE�� 13
KEY TO LINKAGE ASSEMBLY COMPONENTS�� 13
REMOVING THE LINKAGE ASSEMBLY�� 14
LINKAGE ASSEMBLY GREASING POINTS�� 17
TILLER�� 18
KEY TO TILLER COMPONENTS�� 18
REMOVING THE TILLER..............................................................................................................................................20
TILLER SPRING REPLACEMENT�� 22
TRACTION MOTOR...................................................................................................................................................24
KEY TO MOTOR COMPONENTS.............................................................................................................................24
REMOVING THE TRACTION MOTOR........................................................................................................................25
1
MECHANICS SERVICE
TRACTION WHEEL
IDENTIFICATION OF TRACTION WHEEL COMPONENTS
1 2
Ref. Description
1 Vulkollan ring complete with hub

2 Traction wheel fastening nut
2
SERVICE MECHANICS
DISMANTLING THE TRACTION WHEEL

Equipment and tools
T-handle socket
socket wrench ratchet with
hydraulic jack 2 wooden blocks wrench
18 mm extension bar
13 mm
Procedure
Move the truck to a safe place, away from the transit areas of other vehicles and pedes-
trians. Raise the forks to the maximum height, turn the keyswitch to OFF and disconnect
the battery.
Fig. 1
B
Phase 1
Use the T-handle socket wrench to unscrew and
remove the motor cover fixing nuts (ref.A fig.1). A
Remove the motor cover by pressing your hands
first on the left and then on the right-hand side to
trip the locking clips (ref.B fig.1).
Phase 2
HYDRAULIC JACK - 2 WOODEN BLOCKS Fig. 2
Position the hydraulic jack on the right-hand side of the truck body and
raise the truck sufficiently to insert the wooden block underneath. Lower
the jack so that the truck rests on the wooden block. Repeat the operation
on the left-hand side of the truck body (fig.2)
Phase 3
18 mm SOCKET WRENCH - RATCHET - EXTENSION - TORQUE
WRENCH
Unscrew and remove the 5 nuts securing the traction wheel to the axle
shaft and remove the wheel (ref.C fig.2).
INSTALLATION
The traction wheel retaining nuts must be tightened using a

torque wrench to a torque of 120 Nm.
3
MECHANICS SERVICE
PIVOTING WHEEL ASSEMBLY
KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS
15 2
16
17 3
19
14
13
17 4
16 11
15 18
10
12
6
9
11
7
8
13
14
4
SERVICE MECHANICS
Ref. Description
1 Cap
2 Circlip
3 Upper plate
4 Pivot assembly rotation bearing
5 Elastic ring
6 Yoke
7 Nut
8 Screw
9 Rubber bush
10 Wheel lower yoke
11 Split pin
12 Wheel pin
13 Adjustable segment
14 Flanged screw
15 Dust cover
16 Spacer
17 Wheel bearing
18 Wheel
19 Bush
5
MECHANICS SERVICE
DISMANTLING OF PIVOT WHEEL ASSEMBLY

Equipment and tools
hydraulic jack 8 mm T-handle open ended socket wrench small flat blade
2 wooden blocks ratchet
swivel hex key spanner 13-15-19 mm screwdriver
wrench 13 -19 mm
Fig. 1
T-handle socket hammer clamp gudgeon B

small external
wrench
circlip pliers
13 mm
A
Procedure
Before starting work, ensure that you are
wearing suitable protective clothing. Move
the truck to a safe place, away from the
transit areas of other vehicles and pedestrians. Raise the clamps to the maximum height,
turn the keyswitch to OFF and disconnect the battery.
Fig. 2
Phase 1
Phase 2
HYDRAULIC JACK - 2 WOODEN BLOCKS
Position the hydraulic jack on the right-hand side of the truck body and Fig. 3
C
the jack so that the truck rests on the wooden block. Repeat the opera-
tion on the left-hand side of the truck body (fig.2)
Phase 3
15 mm SOCKET WRENCH - RATCHET
Using the socket wrench and ratchet, unscrew and remove the four bolts,
along with their nuts and washers, securing the castor wheel assembly
to the truck body (ref.C fig.3).
Remove the wheel assembly and proceed with its replacement or disas-
sembly.
6
SERVICE MECHANICS
DISMANTLING OF PIVOTING WHEEL
Phase 4
13 mm SOCKET WRENCH - RATCHET - 13 mm OPEN ENDED SPAN-
NER - PIN PUNCH - HAMMER
Using the open ended spanner, lock one of the two screws fastening
the castor wheel pin, while with the socket wrench and ratchet unscrew
and remove the other screw (ref.F fig.4). Using the hammer and the pin E
punch, extract the wheel pin (ref.E fig.4), remove the adjuster segment
(ref.D fig.4) and extract the wheel from its seat.
Proceed with replacement. D F
DISASSEMBLY OF THE PIVOTING WHEEL Fig. 4
Phase 5
Fig. 5
SMALL FLAT BLADE SCREWDRIVER G
Using the small flat blade screwdriver, extract the dust cap (ref.G fig.5), H
remove the spacers (ref.H fig.5), bearings (ref.I fig.5) and bush (ref.L
fig.5).
Proceed with replacement I
L
I
REMOVAL OF THE BUFFERS
H
Phase 6
19 mm SOCKET WRENCH - RATCHET - 19 mm open ended spanner G
Counterhold the self-locking nut (ref.M fig.6) with the open ended span-
ner, while unscrewing and removing the screws of the yoke (ref.N fig.6)
using the socket wrench and the ratchet. Remove the buffers (ref.O fig.6). N
Proceed with replacement
REMOVAL OF THE UNIT ROTATION BEARING O
Phase 7
Fig. 6 M
MEDIUM PLIERS FOR OPENING CIRCLIPS - LARGE PLIERS FOR
CLOSING CIRCLIPS - SMALL FLAT BLADE SCREWDRIVER Fig. 7
P
Using the screwdriver, remove the plug (ref.P fig.7). Using the medium
external circlip pliers, remove the ring fastening the upper plate to the Q
yoke (ref.Q Fig.7), extract the plate together with the bearing. Using the
large pliers for closing circlips, remove the locking ring (ref.S fig.7) and
remove the bearing (ref.R fig.7).
Proceed with replacement R
S
INSTALLATION
The nut securing the castor wheel must be tightened using

a torque wrench to a torque of 85 Nm.
7
MECHANICS SERVICE
ADJUSTMENT OF THE WHEEL HEIGHT

The pivot wheel assembly is equipped with a system for adjusting the height of the wheels, to be done when:
• the drive wheel is worn out and slips when driving
• one of the two pivot wheels is much more worn than the other one
• both pivot wheels are worn out and the weight of the truck rests solely on the drive wheel
Wear on the wheels must be checked on a perfectly flat floor.
Equipment and tools
open ended socket

hydraulic jack n. 2 wood stocks ratchet
spanner 13 mm
13 mm
Procedure
pedestrians. Raise the clamps to the maximum height, turn the keyswitch to OFF and
disconnect the battery.
Phase 1
Use the T-handle socket wrench to unscrew and Fig. 1
remove the motor cover fixing nuts (ref.A fig.1).
first on the left and then on the right-hand side to B
8
SERVICE MECHANICS
Phase 2
Fig. 2
HYDRAULIC JACK - N. 2 WOODEN STOCKS
Position the hydraulic jack on the right-hand side of the truck body and
the jack so that the truck rests on the wooden block. Repeat the opera-
tion on the left-hand side of the truck body (fig.2)
Phase 3
13 mm SOCKET WRENCH - RATCHET - 13 mm OPEN ENDED SPAN-
NER
Using the open ended spanner, lock one of the two screws fastening the
castor wheel pin, while with the socket wrench and ratchet loosen the
other screw (ref.A fig.3). Loosen the two screws until the adjuster ring
nuts (ref.B fig.3) can be sufficiently extracted so as to be able to adjust
the desired height using the reference split pins (ref.C fig.3).
Screw the fixing screws back on and carry out the same operation on A A
the other wheel. Fig. 3
C B
9
MECHANICS SERVICE
LOAD WHEELS
IDENTIFICATION OF LOAD WHEEL COMPONENTS
4
5
9
8
10
11
8 9
Ref. Description
1 Shaft fastening screw

2 Shaft
3 Elastic dowel
4 Tie-rod pivot pin
5 Bushing
6 Spring pin
7 Load wheel pin
8 Dust cover
9 bearing
10 Load wheel
11 Spacer
10
SERVICE MECHANICS
LOAD WHEEL REPLACEMENT

Equipment and tools
2 wooden blocks clamp gudgeon pin punch small flat blade cartridge grease
hammer
150 x 150 x 500 Ø 15 mm Ø 4 mm screwdriver nipple
mm
Procedure
pedestrians. Raise the forks to the maximum height, press the down button to discharge
the pressure from the hydraulic system, set the keyswitch onto OFF and disconnect the
battery.
Fig. 1
Phase 1
2 WOODEN BLOCKS
Position the wooden blocks under the forks (fig.1). Lower the forks so
that they rest on the wooden blocks and continue lowering until the load
wheels are raised off the ground by about 2 cm.
Turn the keyswitch to OFF and disconnect the battery.
Phase 2
HAMMER - PIN PUNCH - DRIVING TOOL
Using the hammer and the pin punch, drive out the spring pin securing B
the pivot pin (ref.A fig.2). Drive out the pivot pin (ref.B fig.2) using the
driving tool and the hammer, then take the load wheel out of its seat and
proceed with dismantling or replacement.
Phase 3 A
Fig. 2
Using the small flat blade screwdriver, prise off the dust cap (ref.C fig.3)
and recover the bearings (ref.D fig.4)and the spacer (ref.E fig.4). Lastly
remove any remains of lubricant from the load wheel and then
proceed with replacement. E
D
INSTALLATION C
C
Following installation of new load wheels, grease the bearings us-
D
ing a grease gun.
Fig. 3
11
MECHANICS SERVICE
LOAD WHEEL ASSEMBLY REPLACEMENT

Equipment and tools
clamp gudgeon 2 wooden blocks socket pin extractor

hammer ratchet
Ø 15 mm 150 x 150 x 500 13 mm Ø 4 mm
mm
Procedure
pedestrians. Raise the forks to the maximum height.
Fig. 1
Phase 1
2 WOODEN BLOCKS
Position the wooden blocks under the forks (fig.1). Lower the forks so
that they rest on the wooden blocks and continue lowering until the load
wheels are raised off the ground by about 2 cm.
Phase 2
13MM SOCKET WRENCH - RATCHET
Using the socket wrench and ratchet, unscrew the screw (ref.A fig.2).
Drive out the pivot pin using the driving tool and the hammer (ref.B fig.2).
B
A
Fig. 2
Phase 3
Using the hammer and the pin punch, drive out the spring pin securing C
the pivot pin (ref.C fig.3). Extract the pivot (ref.D fig.3) using the clamp
gudgeon and the hammer. Withdraw the load wheel assembly from its
housing.
D
Proceed with replacement.
Fig. 3
12
SERVICE MECHANICS
LINKAGE
KEY TO LINKAGE ASSEMBLY COMPONENTS
1 13
2 3 12
14
12
4
4 10
9
5 7 8 11
1
4
Ref. Description
1 Screw fixing traction assembly frame pivot pin

2 Traction assembly frame pivot pin
3 Grease nipple
4 Bush
5 Rocker arm
6 Front forks frame pivot pin
7 Linkage assembly pivot pin
8 Screw fixing linkage to wheel assembly
9 Rear forks frame pivot pin
10 Elastic dowel
11 Wheels assembly pivot pin
12 Bushing
13 Wheel
14 Grease nipple
13
MECHANICS SERVICE
REMOVAL OF THE LINKAGE ASSEMBLY

Equipment and tools
hoist T-handle socket pin punch clamp gudgeon socket

load capacity spreader bar wrench hammer 13 mm
Ø 4 mm Ø 15 mm
2000 kg 13 mm
ratchet extension
Procedure
pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect
the battery.
When performing maintenance work that requires removing the rocker arm, it is essential
for the main frame and the forks frame to be properly supported so they cannot lower or
swing when there is no connection.
The battery is very heavy. It is recommended to be careful when handling it or working
near it to avoid any damage to persons or property.
Do not place hands, arms, feet and/or legs between the material and a solid object. Make
sure that the capacity of the lifting device and of the spreader bar is greater than the
weight of the battery, which is normally stamped on its body. The spreader bar must not
be made of metal or must be provided with insulating belts.
Phase 1 Fig. 1
remove the motor cover fixing nuts (ref.A fig.1). B
first on the left and then on the right-hand side
to trip the locking clips (ref.B fig.1).
A
14
SERVICE MECHANICS
Phase 2
Fig. 2
BRIDGE CRANE - SPACER BAR
Put wooden blocks on both sides of the truck near to the battery compart-
ment and under both forks.
Hook the spacer bar to the bridge crane. Position the bridge crane above
the battery compartment.
Attach the spreader bar to the battery; carefully lift the battery clear of
the battery compartment with the bridge crane (fig.2).
Gently lower the battery to the ground and detach the spreader bar.
Disconnect all the hydraulic and electrical connections

before removing the linkage assembly.
Phase 3
T-HANDLE SOCKET WRENCH - PIN PUNCH -
HAMMER - RATCHET - EXTENSION BAR - 13MM D
SOCKET WRENCH
Unscrew the fastener securing the pivot pin joining D
the bracket and linkage (ref.C fig.2), insert the pin Fig. 2
punch into the hole (ref.D fig.2) and, with the aid of the
hammer, extract the pin.
Repeat this operation on the opposite side and
free the linkage assembly from the frame (fig.3).
Fig. 3
Phase 4
13mm SOCKET WRENCH - PUNCH PIN - HAMMER
Unscrew the fasteners securing the pivot pins of the rear linkage (ref.F F
fig.4) and, with the aid of the pin punch and hammer, extract the pin
(ref.E fig.4).
E Fig. 4
15
MECHANICS SERVICE
Phase 5
T-HANDLE SOCKET WRENCH - PIN PUNCH - HAMMER
Using the T-handle key wrench, unscrew the fastener securing the linkage
pivot pin to the wheel assembly (ref.G fig.5) and, with the aid of the pin
punch and hammer, extract the pin (ref.H fig.5). Repeat this operation
on the other side too.
H
G
Fig. 5
I
Phase 6
Using the hammer and the pin punch, drive out the spring pin securing L
the pivot pin (ref.I fig.6). Drive out the pivot pin (ref.L fig.6) using the
driving tool and the hammer. Withdraw the load wheel assembly from
its housing. After repeating the operation on the other side too, you can
separate the linkage from the cover and make the replacement (Fig.7).
Fig. 6
Fig. 7
16
SERVICE MECHANICS
LINKAGE ASSEMBLY GREASING POINTS
Set the truck on wooden blocks

to access the grease fittings.
Grease gun
17
MECHANICS SERVICE
TILLER
KEY TO TILLER COMPONENTS
1
20
6
3 4
5 7
4 8
11
14 9
13
12
15
18 10
17
19
16
18
SERVICE MECHANICS
Ref. Description
1 Tiller head assembly
2 Screw
3 Nut
4 Cover
5 Nut
6 Ball pivot pin
7 Spring
8 Fastening clamp
9 Steering reduction proximity sensor
10 Bushing
11 Cover
12 Screw
13 Washer
14 Tiller handle pivot pin
15 Screw
16 Grommet
17 Nut
18 Screw
19 Tiller covering bracket
20 Washer
19
MECHANICS SERVICE
REMOVAL OF THE TILLER

Equipment and tools
clamp gudgeon
fixed spanner hammer ratchet socket wrench 5 mm T-handle
Ø 15 mm
13 mm 13 mm hex key
Procedure
pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect
the battery.
Phase 1
Fig. 1
B
Fig. 2
Phase 2
T-HANDLE HEX KEY WRENCH
Disconnect the tiller wire harnesses then, using
a T-handle hex key, unscrew the four screws
fastening the tiller to the transmission unit and
remove the screws with their washers (ref.C
fig.2). C
20
SERVICE MECHANICS
Phase 3
Fig. 3
Remove the plastic plugs (ref.D fig.3) to access the tiller spring and then
discharge the spring pressure.
The spring should be removed by tapping with the pin punch (ref.D fig.3).
WARNING
The tiller spring contains pressurized gas and lubricating
hydraulic oil.
D D
E F
Phase 4
FIXED 13 mm SPANNER - 5mm HEXAGONAL "T"" SECTION SPANNER
Disconnect the tiller wiring connector.
Using one of the spanners, restrain the self-locking nut securing the tiller Fig. 4
spring (ref.H fig.4) and unscrew and remove the spring retaining bolt with
the other spanner (ref.G fig.4). Recover the self-locking nut.
H
G
Phase 5
HAMMER - CLAMP GUDGEON
Unscrew the bolt (ref.I fig.5) and remove the pivot pin (ref.L fig.5) using Fig. 5
the pin punch and the hammer.
Remove the tiller assembly and proceed with its disassembly or replace-
ment.
I
21
MECHANICS SERVICE
TILLER SPRING REPLACEMENT

Equipment and tools
fixed spanner T handle hex key socket wrench

ratchet
13 mm 5 mm 13 mm
Procedure
pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect
the battery.
Phase 1
Fig. 1
B
Phase 2
Fig. 3
Remove the plastic plugs (ref.D fig.3) to access the tiller spring and
then discharge the spring pressure.
.
WARNING
The tiller spring contains pressurized gas
and lubricating hydraulic oil.
D D
E F
22
SERVICE MECHANICS
Phase 3
Fig. 4
2 x 13 mm OPEN ENDED SPANNERS
Disconnect the tiller wiring connector.
Using one of the spanners, restrain the self-locking nut securing the tiller
spring (ref.H fig.4) and unscrew and remove the spring retaining bolt with
the other spanner (ref.G fig.4). Recover the self-locking nut.
H
G
Phase 4
Fig. 5
HAMMER - CLAMP GUDGEON
Unscrew the bolt (ref.I fig.5) and remove the pivot pin (ref.L fig.5) using
the pin punch and the hammer. I
Remove the tiller assembly and proceed with its disassembly or replace-
ment.
Phase 5 Fig. 6
HEXAGONAL 5 mm "T" SECTION SPANNER - 13mm SOCKET
WRENCH - RATCHET
Remove the plastic cap (ref.M fig.6), then unscrew and remove the
fixing screw of the upper part of the spring (ref.N fig.6).
M
Withdraw the spring from the tiller and proceed with replacement.
N M
23
MECHANICS SERVICE
TRACTION MOTOR
KEY TO TRACTION MOTOR COMPONENTS
Ref. Description
Screws fastening the motor to the reduction
1
unit
2 Motor body
3 Speed sensor
24
SERVICE MECHANICS
TRACTION MOTOR DISMANTLING

Equipment and tools
2 open ended T-handle socket

hexagonal "T" brush
spanners wrench
section spanner
10 mm 13 mm
6 mm
Procedure
Fig. 1
B
Phase 1
remove the motor cover fixing nuts (ref.A fig.1). A
Phase 2 Fig. 2
T-HANDLE HEX KEY WRENCH
Disconnect the tiller wire harnesses then, using a
T-handle hex key, unscrew the four screws fasten-
ing the tiller to the transmission unit and remove the
screws with their washers (ref.C fig.2), then remove
the bracket together with the tiller.
C
Phase 3
Carry out the electromagnetic brake removal procedure (see "REMOVAL
OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM"
section).
25
MECHANICS SERVICE
Phase 4
Fig. 3
2 x 10 mm OPEN ENDED SPANNERS
Using the two spanners, unscrew the nuts securing the traction motor
power supply cables (ref.D fig.3). Note the position of the cables prior
to removing them. Disconnect all the wiring connectors.
Phase 5 Fig. 4
Unscrew and remove the four screws and their washers (ref.E fig.4)
fastening the traction motor to the gearbox.
Phase 5
Lift the motor until the drive shaft is completely free of the reducer. Remove it from the truck body and
proceed with replacement or disassembly.
INSTALLATION
Before installing the motor on the reduction unit, lubricate the drive shaft with a thin, even
layer of grease.
During the coupling stage, carefully rotate the wheel shaft to help the motor shaft engage
with the pinion.
The screws securing the reduction unit to the chassis must be tightened using a torque
wrench to a torque of 24 Nm.
26
SERVICE MECHANICS
27
SERVICE REDUCER
REDUCER
KEY TO THE REDUCTION UNIT COMPONENTS�� 2
REMOVAL OF THE REDUCTION UNIT�� 3
CHANGE REDUCTION GEAR BEARING�� 5
1
REDUCER SERVICE
KEY TO REDUCTION UNIT COMPONENTS
type gearbox supplier code
TYP.
part number COD.
C.P.N.
production date DATE NR serial number
Ref. Description
1 Reduction gear
2 Reduction gear bearing
Screws fastening the bearing to the reduction
3
gear
4 Reduction gear identification plate
2
SERVICE REDUCER
REMOVAL OF THE REDUCTION UNIT

Equipment and tools
lifting rope socket extension

bridge crane spreader bar hydraulic jack 2 wooden blocks
13-21 mm
hammer clamp gudgeon ratchet

Ø 15 mm
Procedure
Phase 1
Carry out the drive wheel removal procedure (see “REMOVAL OF THE DRIVE WHEEL” in the “MECHAN-
ICS” section).
Phase 2
Carry out the tiller removal procedure (see “REMOVAL OF THE TILLER” in the “MECHANICS” section).
Phase 3
Carry out the lift cylinder dismantling procedure (see “LIFT CYLINDER DISMANTLING” in the "HYDRAULIC
SYSTEM" section).
Phase 4
Carry out the traction motor removal procedure (see “REMOVAL OF THE TRACTION MOTOR” in the
“MECHANICS” section).
3
REDUCER SERVICE
Phase 5
Fig. 1
Make sure you have put wooden blocks on both sides of the truck near
to the battery compartment and under both forks.
Attach the spreader bar to the bridge crane. Position the bridge crane
above the battery compartment.
Attach the spreader bar to the battery; carefully lift the battery clear of
the battery compartment with the bridge crane (fig.1).
Gently lower the battery to the ground and detach the spreader bar.
Phase 6
13MM HEX WRENCH - PIN PUNCH - HAMMER A
Unscrew the fastener securing the pin joining the bracket and linkage
(ref.A fig.2), insert the pin punch into the hole (ref.B fig.2) and, with the
aid of the hammer, extract the pin.
Repeat this operation on the opposite side and free
the linkage assembly from the frame.
B
B Fig. 2
Phase 7
21MM SOCKET WRENCH
Unscrew the 4 fasteners securing the drive assembly bracket to the frame
(ref.C fig.3), then remove it together with the reduction gear.
Remove the reduction unit (fig.4), place it on a clean workbench and
proceed with replacement or disassembly.
C Fig. 3
Fig. 4
INSTALLATION
The screws securing the drive assembly bracket to the

chassis must be tightened using a torque wrench to a
torque of 25 Nm.
4
SERVICE REDUCER
CHANGE REDUCTION GEAR BEARING

Equipment and tools
6 mm hex socket oil protecting

vice
wrench gloves
Procedure
Phase 1
OIL PROTECTING GLOVES
Wear the oil proof gloves.
Carry out the reducer dismantling procedure (see “REDUCER DISMANTLING”).
Phase 2
VICE - MEDIUM SIZE FLAT HEAD SCREWDRIVER
Position the reducer in the vice and clamp firmly.
B Fig. 1
Phase 3
SOCKET WRENCH
Unscrew the 8 screws (ref.A fig.1) securing the bearing (ref.B fig.1) to
the reduction gear, then remove the bearing and make the change.
A
5
SERVICE BRAKING SYSTEM
BRAKING SYSTEM
IDENTIFICATION OF THE ELECTROMAGNETIC BRAKE COMPONENTS�� 2
OPERATION�� 3
BRAKING SYSTEM�� 3
DISMANTLING OF THE ELECTROMAGNETIC BRAKE�� 4
ELECROMAGNETIC BRAKE ADJUSTMENT�� 6
1
BRAKING SYSTEM SERVICE
IDENTIFICATION OF THE ELECTROMAGNETIC BRAKE COMPONENTS
4
3
Ref. Description
1 Dust cap
2 Brake
3 Fixing screws
4 Adjusting screw
2
OPERATION
The electromagnetic brake mounted on the traction motor is a spring-operated brake.
When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the
latter to rotate freely.
When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction
disc, thus applying the brake.
BRAKING SYSTEMS
There are 4 braking systems used:
• Release braking drive control release
• Braking on direction reversal
• Emergency braking
• Parking brake
A) Release braking
Release braking is performed by the drive motor and controls the
deceleration ramp when the drive control is released.
B) Braking on direction reversal

Controls the deceleration ramp when the travel direction is inverted.
“Braking on direction reversal", also know as counter current braking, direction reversal
consists of reversing the current supplied to the motor, thus changing the
direction of travel when the truck is in motion.
The braking current must be adjusted so that the truck stops in a distance
that is at least not less than the length of the truck itself.
C) Emergency braking
Emergency braking takes place when an alarm is triggered that requires
immediate traction arrest of when the tiller sensor is disactivated (tiller in
rest position or completely lowered).
The braking is performed by the electromagnetic brake attached to the
traction motor.
D) Stationary brake
The "stationary brake" is performed by the electromagnetic brake and takes place when the machine is
stationary and the tiller is in the rest position.
3
DISMANTLING OF THE ELECTROMAGNETIC BRAKE

Equipment and tools
socket wrench fixed spanner 5 mm T-handle

scissors
size 13mm 15 mm hex key
Procedure
Before starting work, ensure that you are equipped with all suitable safety clothing.
Lock the wheels to prevent sudden movements.
Fig. 1
Phase 1
SOCKET WRENCH SIZE 13 mm
Use the socket wrench to unscrew and remove B
the motor cover fixing screws (ref.A fig.1).
Remove the motor cover by pressing your
hands first on the left and then on the right-hand
side to trip the locking clips (ref.B fig.1).
A
Fig. 2
Phase 2
5 MM T-HANDLE HEX KEY
Disconnect the tiller wire harnesses then, using a T-handle hex key,
unscrew the four screws fastening the tiller to the transmission unit and
remove the screws with their washers (ref.C fig.2), then remove the
bracket together with the tiller.
4
Phase 3
Fig. 3
Discharge the capacitor of the control device by connecting a 25W - 100 D
ohm resistor to connectors B+ and B- (ref.D fig.3) and disconnect the
wire harnesses of the control handle and the proximity sensor of the tiller
boom located on top of the drive motor.
Phase 4
E Fig. 4
OPEN ENDED SPANNER - T-HANDLE HEX KEY SIZE 5 mm

Remove the dust cap (ref.E fig.4)
Disconnect the brake wire harness connector then, using the T-handle
hex key, unscrew and remove the three cap screws (ref.F fig.4) securing
the brake assembly to the motor and remove the brake (fig.5). F
Fig. 5
ASSEMBLY
After assembly proceed with the adjustment of the elec-

tromagnetic brake.
5
ELECTROMAGNETIC BRAKE ADJUSTMENT
B
A
Fig. 1
After re-installing the electromagnetic brake assembly, before using the truck, the friction disc must be
adjusted.
To obtain a good braking action, the distance between the friction disc and the brake plate (ref.A fig.1) must
not be greater than 0.35 mm. For this purpose one must use a feeler gauge of this size.
With the three nuts loose (ref.B fig.1), insert the feeler gauge near one of the bolts, tighten the retaining
screw (ref.C fig.1) with the Allen wrench and position the plate so the feeler gauge can be withdrawn with
a little friction. Repeat the operation with all three bolts.
Tighten the nuts using the fixed gauge spanner (ref.B fig.1).
6
REDUCER SERVICE
6
SERVICE ROUTINE MAINTENANCE
ROUTINE MAINTENANCE
OILS AND LUBRICANTS�� 4
CLEANING PRODUCTS�� 4
SCHEDULED MAINTENANCE�� 5
1
ROUTINE MAINTENANCE SERVICE
WARNINGS
• If maintenance operations are carried out immediately after the truck is stopped, some components of
the motor and of the hydraulic system could be hot. Always wear the personal protective equipment in
situations requiring it.
• Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbut-
toned jackets or tops with open zippers that can get caught up in moving parts.
• Never do any cleaning, lubrication or maintenance work with the battery connected.
• Never perform any servicing on the machine with persons at the controls, unless they are accredited
operators and help with the operation to be performed.
• Using compressed air to clean the parts, protect yourself with goggles that have side protection. The
maximum air pressure must not exceed 1 bar.
• Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable
and non-toxic trade solvents.
• Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away
into a closed metal container.
• The capacitors in the transistor control unit can keep an electric charge even after disconnecting the
battery. To avoid electric shocks and personal injury, discharge the capacitors before inspecting or
repairing any component in the electric compartment. Wear safety glasses. Make sure the battery has
been disconnected.
• Do not file or lubricate the contacts of the contactors. This could cause the contacts to stick and, as a
result, loss of control and damage to property or injury to people.
• Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.
Special companies can be employed to dispose of or recycle industrial oils according to the laws in
force in individual countries.
• Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate
under the skin; in such cases, having to make a check, use a card or a piece of wood.
• Protect the hydraulic system from dirt or contaminants getting inside when checking the fluid level of
changing the filter.
• Never operate the pump without an adequate quantity of fluid in the hydraulic system. Operation with
low levels of hydraulic fluid will damage the hydraulic pump.
• Do not place any tools on the battery. Metal items on the battery can generate accidental short-circuit-
ing and possibly damage or injury.
• The batteries generate explosive gases. Keep the vents clean. Keep sparks and flames well away
from the battery compartment. Pay attention not to create any sparks when disconnecting the battery
cables. Disconnect the battery during maintenance work.
• Always use a spreader bar and slings to raise the battery vertically with the specific eyelets. Do not
use chains or slings without a spreader bar, you would risk damaging the battery casing. Check that
the battery compartment is clean and dry. When the battery is in service, the aeration plugs must all be
installed. If the aeration plugs are not installed, electrolyte can come out, corroding the battery casing
and compartment.
2
• The acid in the electrolyte can cause injury. If the electrolyte gets spilled it should be cleaned up with
water. Neutralize the acid with a solution of sodium bicarbonate (soda). Areas of the skin that come
into contact with the acid must be rinsed with water immediately. Acid splashed into the eyes must be
washed away with water constantly for at least 10 minutes, then call a doctor.
• The batteries belong to the counterweight system of the lift truck. When installing a battery that is too
small, the lift truck might not have enough weight for the nominal load. When replacing a battery, see
the truck identification data plate to check that the battery has the rated capacity and correct dimen-
sions. See “TRUCK AND LOAD CAPACITY IDENTIFICATION DATA” in the “PRESENTATION” sec-
tion for the exact battery specifications for the lift truck at issue.
• Do not work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage
from lowering during maintenance work on the mast and on the lifting chains.
• Never repair damaged forks using heat or welding. The forks are made of steel that is hardened with
special procedures. Replace damaged forks.
• Before servicing the hydraulic system you must eliminate any residual pressure inside it.
Close the valves at the end of the maintenance work.
3
OILS AND LUBRICANTS
Application Std Cold store Type
OIL  SHELL TELLUS S2 VX 46

for lubrication of the
HYDRAULIC CIRCUIT  SHELL AEROSHELL FLUID 41
OIL
for lubrication   SHELL SPIRAX
REDUCER
OIL SHELL ADVANCE TEFLON

for lubrication of MDU GEARS   CHAIN
GREASE  SHELL ALBIDA GREASE EP2

for lubrication of
PINS, TIE RODS  AEROSHELL GREASE 6
Insulation
Pure vaseline
BATTERY TERMINALS
CLEANING PRODUCTS
CASING AND PLASTIC COVER CLEANING - CLEANING OF PAINTED TRUCK PARTS
For general cleaning of the truck, use only dry air, damp rags or degreasing detergents.
Do not use water jets, vapours, solvents or flammable products that may damage the
truck or that can be dangerous for the operator.
MOTOR AND ELECTRONIC SYSTEM CLEANING

For general cleaning purposes use dry air at low pressure and a clean dry brush.
Do not use wet rags, water jets, vapour, solvents or flammable products that may damage
the truck or that may be dangerous for the operator.
MAST PROFILE AND SMALL MAST CLEANING

Use degreasing solvents.
Do not use water jets, vapour, solvents or flammable products that may damage the small
mast or be harmful to the operator.
4
SCHEDULED MAINTENANCE
 = check and maintenance

 = operator check Maintenance intervals
x = replacement
every every every
Operation description 8 hours 1000 hours 3000 hours
1 day 12 months 36 months
Check the tightening of the nuts and bolts 

FRAME
Check welded joints 

General cleaning 
Check release braking  

BRAKING SYSTEM
Check reverse braking  

Check emergency braking  
Check parking mode braking  
Check brake lining wear (1)

Check for oil leaks  

HYDRAULIC SYSTEM
Check hydraulic functions  

Check oil level in tank 
Check flexible hoses (2) 
Tank oil change x
Change oil filter x
Visual oil leak check  

REDUCTION
Check reduction unit noise 

UNIT
Change oil in reduction unit (4)


FORKS
Check state of forks 

Check traction wheel wear (1)  

WHEELS & TYRES
Check load wheels wear (1)

 
Check wear of castor wheels (1)  
Check the tightening of traction wheel fastening nuts 
Check tightening of pivoting wheel fastening nuts 
Check load and castor wheels bearings (1)

Check castor wheels support bearings  
RODS
TIE-
Check state of linkage 
Check the condition and operation of the tiller 

TILLER
Check gas spring efficiency 

GREASING
MDU gear greasing

POINTS

Grease pins, tie rods
5
 = check and maintenance

 = operator check Maintenance intervals
x = replacement
every
every every
every every 1000
2000 3000
Operation description 8 hours 500 hours hours
hours hours
1 day 6 months 12
24 months 36 months
months
Check Belly Switch operation 
CHECKS
Check horn operation 

Check SNAIL button operation 
Check battery socket integrity 

ELECTRICAL
Check electronic connections 

SYSTEM
Check electric wire harnesses 

Check sensor efficiency 
Check cable connections  
Check for liquid leakage  
BATTERY
Check battery insulation 

Check electrolyte density 
Check electrolyte level (3) 
Check pictograms and labels 
Check all machine functions using activation controls 
(1)
replace if necessary
(2)
replace in the following situations:
• a shift of the connection on the pipe;
• the presence of damage, cuts or abrasions on the superficial layer;
• hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure;
• the presence of cracks, damages or strong corrosion on the connection;
• the presence of leaks along the pipe or at the coupling joint;
• the presence of permanent creases, compression, flattening or twists in the pipe;
• the presence of blisters, softening, wear of the external coat.
(3)
fill up the electrolyte levels whenever they fall to 5 - 10 mm from the plate unit.
(4)
change unnecessary, long-life oil.
Trucks working in cold stores must be lubricated every 500 hours, or even more frequently in the
case of particularly intensive use
6
7
Codice: 550127938 Revision: 1 (05/2018)

Yale MP22 1

Uploaded by

Copyright:

Available Formats

You might also like

Yale MP22 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Yale MP22 1

Uploaded by

Copyright:

Available Formats

Part no.

: 550127938 Overhaul: 1 (05/2018)

Technical information for Yale service

This manual is intended solely for the specialized technicians of

Product support group

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

Signals disposal/recycling of harmful substances under the protection of current legislation.

GENERAL SAFETY RULES

SAFETY AT THE WORKPLACE

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE

Using suspension elements under conditions of unbalanced load

Belt capacity table

purple 1000 2000 1400 800

Rope capacity table

black 35 500 1000 700 400

Suspension element capacity table

purple 1000 1400 2100 2100

TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

M4 0.7 7 3 2400 1.92 1.44 3.07 2.3 4.17 3.13

CORRECT METHOD FOR APPLYING FEMALE FITTINGS

METRIC REVOLVING FEMALE REVOLVING FEMALE jic 37°

BSP REVOLVING FEMALE ORFS REVOLVING FEMALE

INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS

VIEWS OF THE TRUCK

TRUCK AND LOAD IDENTIFICATION DATA

The truck identification data plate is located in the battery

• Manufacturer's name • Max. battery weight

TRUCK SERIAL NUMBER

The truck serial number is stamped on top of

The truck documentation is located in the battery

1.4 Steering: tiller, pedestrian, standing, sitting tiller tiller

3.2 Tyre size, front ø (mmxmm) 250 x 75 250 x 75

4.21 Overall width b1/b2 (mm) 712 712

6.2 Lift motor, SR 15% rating kW 1.2 1.2

8.1 Type of control AC ~ Mosfet AC ~ Mosfet

10.7 Noise level at driver's position dB (A) < 70 < 70

1.4 Steering: tiller, pedestrian, standing, sitting tiller tiller

3.2 Tyre size, front ø (mmxmm) 250 x 75 250 x 75

4.21 Overall width b1/b2 (mm) 712 712

6.2 Lift motor, SR 15% rating kW 1.2 1.2

8.1 Type of control AC ~ Mosfet AC ~ Mosfet

10.7 Noise level at driver's position dB (A) < 70 < 70

INSTALLATION AND SETTINGS

fork lift truck bridge crane 2 lifting slings

TOPPING UP THE OIL RESERVOIR

Equipment and tools

socket wrench Fig. 1

INSTALLATION OF THE BATTERY

bridge crane hexagonal "T"

WITH LATERAL REMOVAL

CONNECTION OF CABLES TO BATTERY

_ Tag coloured BLUE

Tag coloured RED

LIST OF THE SETTINGS AND ADJUSTMENTS TO BE CARRIED OUT

VERIFY THE TRUCK USE CONDITIONS

• maximum traction speed

DESCRIPTION OF MODULE CONNECTORS