Technical Information For Hyster Service Centres

Part No 1517320
Technical Information for

Hyster Service Centres
This manual is addressed exclusively to the specialised

technicians of the Hyster service network
R1.4
R1.4H
R1.6
R1.6H
C435........... R1.6N AC..
R2.0
R2.0H
R2.0W
R2.5
Section: CONTENTS SERVICE
GENERAL SAFETY PRESCRIPTIONS
CONTENTS
NEVER DO ANY CLEANING, LUBRICATING OR SERVICING WITH THE BATTERY CON-

NECTED.
DO NOT WEAR RINGS, WATCHES, JEWELLERY, LOOSE CLOTHING SUCH AS SCARVES,

UNBUTTONED OR UNZIPPED JACKETS OR SHIRTS THAT COULD GET CAUGHT UP IN MOV-
ING PARTS. WE RECOMMEND INSTEAD THAT THE OPERATOR WEAR APPROVED SAFETY
CAPS CLOTHING: HARD HAT, NON-SLIP FOOTWEAR, GLOVES, SAFETY GLASSES.
DO NOT USE PETROL, DIESEL FUEL OR OTHER FLAMMABLE LIQUIDS AS DETERGENTS:

USE INSTEAD NON-FLAMMABLE, NON-TOXIC COMMERCIAL SOLVENTS.
DO NOT SMOKE, USE NAKED FLAMES OR CAUSE ANY SPARKS NEARBY WHEN HANDLING
EASILY FLAMMABLE MATERIALS.
When working on the truck outside the workshop, park on a level surface, if possible, and chock the
wheels. If working on a gradient is unavoidable, chock the wheels to prevent the truck moving and
transfer it to a level area as soon as it is safe to do so.
Disconnect the batteries and label all the controls to warn of the work in progress. Immobilize the
machine and all equipment that has to be lifted.
When towing, use solely the prescribed towing points and make sure the pins and/or bolts are firmly
secured before starting to pull. Lift and handle all heavy parts with lifting equipment of suitable capac-
ity. Use the lifting eyes provided. Beware of persons in the vicinity of the load to lift.
Do not get chains or steel ropes tangled up.
Do not use damaged chains or kinked ropes for lifting or pulling. Always wear safety gloves when
handling ropes or chains.
Handle all parts carefully, do not put your hands or fingers between one part and another.
Wear approved safety clothing such as safety goggles, gloves and footwear.
The area where maintenance work is performed must be kept clean and dry. Clean up any spilt
water or oil immediately.
Do not pile up greasy or oily rags: they constitute a serious fire risk. Always store these materials in
a closed metal container.
Do not carry out any servicing on the machine with persons at the controls, unless they are qualified
operators helping in the work to be done.
When using compressed air to clean parts, protect your eyes with goggles that have side shields.
Welding
When welding, always wear the prescribed safety gear: welding goggles, helmet, overalls, gloves
and footwear. Dark goggles should also be worn by anyone working in the vicinity of the welding
operation. Never look at the welding arc without appropriate eye protection.
Batteries
When using batteries, remember that the both ends of cables must be connected to the terminals as
prescribed: (+) to (+) and (-) to (-).
Take care not short the terminals.
The gas given off during battery recharging is highly flammable. When recharging, leave the battery
compartment open for better ventilation and remove the caps.
Page: 2 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

SERVICE Section: CONTENTS
NEVER CAUSE SPARKS OR ALLOW ANY NAKED FLAMES NEAR THE BATTERY!
CONTENTS
Do not check the battery charge level by placing metal objects across the terminals.
Before carrying any operations, check the electrical system for short-circuits.
Always disconnect the batteries before working on the electrical system.
For battery chargers and similar equipment, use only auxiliary power supplies with an efficient earth
connection in order to avoid the risk of electric shock.
Hydraulic system
Pressurised fluid escaping through a tiny hole may be virtually invisible although projected with sufficient
force to penetrate the skin; when checking for possible leaks, always use a piece of card or wood.
Never use your hands.
Always use the appropriate instruments when checking system pressure.
NOTE: THIS MANUAL IS NOT INTENDED AS A SUBSTITUTE FOR THE USE AND MAINTENANCE
MANUAL BUT AS A SUPPLEMENT TO IT
NOTES:
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 3

Section: ELECTRICAL SYSTEM

CONTENTS
1.0 INTRODUCTION TO THE TRUCK ........................................................................................................... 10

2.0 INSTALLING THE TRUCK ...................................................................................................................... 11
1.0 KEY TO ELECTRICAL DIAGRAMS ........................................................................................................ 14
2.0 KEY TO LOCATION OF ELECTRICAL COMPONENTS .......................................................................... 16
3.0 TABLE OF FUNCTION INPUTS .............................................................................................................. 18
4.0 PARAMETER TABLES ..........................................................................................................................20
5.0 PROCEDURE FOR ACCESSING THE CALIBRATION FUNCTION FOR THE VARIOUS
MODULES .............................................................................................................................................24
5.1 MODULE SEARCH PROCEDURE .........................................................................................................25
5.2 AC2 TRACTION INVERTER BATTERY VOLTAGE SETTING .................................................................. 26
6.0 TRACTION START SEQUENCE .............................................................................................................27
6.3 HYDRAULIC FUNCTIONS START SEQUENCE ..................................................................................... 28
7.0 SPEED CUTBACK ................................................................................................................................. 29
8.0 MODULES REPLACEMENT PROCEDURE ........................................................................................... 30
8.1 REPLACING MODULES 2 OR 5 - AC2 TRACTION INVERTER ............................................................. 30
8.2 REPLACING MODULE 1 - I/O CAN ....................................................................................................... 32
8.3 REPLACING MODULE 16 - SICOS (DISPLAY) ......................................................................................33
8.4 REPLACING MODULE 9 - MHYRIO ....................................................................................................... 34
8.5 REPLACING MODULE 6 - EPS-AC ......................................................................................................34
9.0 SICOS (DISPLAY) .................................................................................................................................. 36
9.1 GENERAL DESCRIPTION OF CONTROL COMPONENTS AND INSTRUMENTS ................................... 36
9.3 BATTERY CHARGE STATUS INDICATOR .............................................................................................. 37
9.4 SPEED CUTBACK INDICATOR .............................................................................................................. 37
9.5 TRAVEL DIRECTION AND WHEEL ROTATION INDICATOR ...................................................................38
9.6 SELECTED HYDRAULIC FUNCTION INDICATOR .................................................................................. 38
9.7 TRACTION OPERATING MODE INDICATOR .......................................................................................... 39
9.8 HOUR METER ACTIVE INDICATOR ....................................................................................................... 39
9.9 TRUCK SPEED, TRUCK HOUR METER, FORKS HEIGHT, MODULE ALARM INDICATOR ................... 40
9.10 PARKING BRAKE SELECTOR BUTTON ............................................................................................... 41
9.11 AUXILIARY HYDRAULIC FUNCTION SELECTOR BUTTON ...................................................................41
9.12 DRIVE PERMISSIVE FUNCTION SELECTOR BUTTON .........................................................................42
10.0 DISPLAY MENUS .................................................................................................................................. 42
10.1 MAIN MENU 1 .......................................................................................................................................42
10.2 TESTER MENU ..................................................................................................................................... 43
10.3 ALARMS MENU .................................................................................................................................... 43
10.4 PROGRAM OFFSET .............................................................................................................................44
10.5 INSERT PASSWORD ............................................................................................................................ 44
10.6 MAIN MENU 2 .......................................................................................................................................44
10.8 PROGRAM PASSWORD ....................................................................................................................... 46
10.9 READ USERS MENU ........................................................................................................................... 47
11.0 PRE-HEIGHT SELECTOR ......................................................................................................................48
11.3 OPERATION WITHOUT REACH CARRIAGE IN SEQUENCE ................................................................. 49
11.4 OPERATION WITH REACH CARRIAGE IN SEQUENCE ....................................................................... 50
11.5 ADJUSTING THE PRE-HEIGHT SELECTOR .......................................................................................... 51
11.6 PROGRAMMING IN SELF-TEACH MODE .............................................................................................51
11.8 USING THE PRE-HEIGHT SELECTOR .................................................................................................. 53
12.0 ALARMS ................................................................................................................................................54
13.0 DIAGNOSTICS .......................................................................................................................................55
13.1 TROUBLESHOOTING GUIDE ................................................................................................................55

Section: ADDITIONAL FUNCTIONS
CONTENTS
OPTION SHEET No. 1 - Setting of the steering for a turn of “360° and 90°”...........................................................4
OPTION SHEET No. 2 - DC_DC converter installation........................................................................................6
OPTION SHEET No. 3 - Flashing rotating light installation.................................................................................8
OPTION SHEET No. 4 - Working light installation..........................................................................................10
OPTION SHEET No. 5 - Reverse motion audible alarm installation ...................................................................12
OPTION SHEET No. 6 - Height preselector installation .....................................................................................14
OPTION SHEET No. 7 - Installation and enabling for the 5. function....................................................................16
OPTION SHEET No. 8 - Deceleration of the “HE” mast lifting limit switches........................................................19
OPTION SHEET No. 9 - Electric block of the lowering forks with 1200mm pallet...................................................21
OPTION SHEET No. 10 - Warmed seat installation.............................................................................................23
OPTION SHEET No. 11 - Cab for - 30° refrigerating room....................................................................................27
OPTION SHEET No. 12 - Seat belt installation...................................................................................................35
Section: HYDRAULIC SYSTEM

1.01 KEY TO HYDRAULIC SYSTEM SYMBOLS ................................................................................................ 2
HYDRAULIC DIAGRAMS ........................................................................................................................... 2a
1.02 CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS ......................................................................... 3
1.03 HYDRAULIC UNIT COMPONENTS ............................................................................................................. 4
1.04 TABLE OF HYDRAULIC UNIT COMPONENTS ........................................................................................... 5
1.05 BASIC TRUCK HYDRAULIC SYSTEM ........................................................................................................ 6
1.06 TABLE OF BASIC TRUCK HYDRAULIC SYSTEM COMPONENTS ............................................................ 6
1.07 MAST HYDRAULIC SYSTEM ..................................................................................................................... 7
1.08 TABLE OF MAST HYDRAULIC SYSTEM COMPONENTS .......................................................................... 7
1.09 SINGLE-ACTING LATERAL LIFT CYLINDER ............................................................................................... 8
1.10 TABLE OF SINGLE-ACTING LATERAL LIFT CYLINDER COMPONENTS .................................................. 8
1.11 SINGLE-ACTING CENTRAL LIFT CYLINDER .............................................................................................. 9
1.12 TABLE OF SINGLE-ACTING CENTRAL LIFT CYLINDER COMPONENTS................................................... 9
1.13 SINGLE-ACTING LIFT CYLINDERS WITH HYDRAULIC CUSHIONING AT DOWN
AND UP STROKE LIMITS .......................................................................................................................... 10
1.14 PLUNGER TYPE LATERAL LIFT CYLINDER ............................................................................................. 11
1.15 TABLE OF PLUNGER TYPE LATERAL LIFT CYLINDER COMPONENTS .................................................. 11
1.16 PLUNGER TYPE CENTRAL LIFT CYLINDER ............................................................................................ 12
1.17 TABLE OF PLUNGER TYPE CENTRAL LIFT CYLINDER COMPONENTS ................................................. 12
1.18 PLUNGER TYPE LIFT CYLINDERS ........................................................................................................... 13
1.19 REACH CARRIAGE CYLINDER ................................................................................................................. 14
1.20 TABLE OF REACH CARRIAGE CYLINDER COMPONENTS ..................................................................... 14
1.21 FORKS TILT CYLINDER............................................................................................................................. 15
1.22 TABLE OF FORKS TILT CYLINDER COMPONENTS ................................................................................. 15
1.23 FORKS SIDESHIFTER CYLINDER ............................................................................................................ 16
1.24 TABLE OF FORKS SIDESHIFTER CYLINDER COMPONENTS ................................................................. 16
2.00 REMOVING THE LATERAL LIFT CYLINDERS FROM THE MAST ............................................................. 17
2.01 REPLACEMENT OF THE LATERAL SINGLE-ACTING CYLINDER SEALS ................................................ 19
2.02 REMOVING THE CENTRAL LIFT CYLINDERS FROM THE MAST ............................................................ 20
2.03 REPLACEMENT OF THE SINGLE-ACTING CENTRAL LIFT CYLINDER SEALS ........................................ 22
2.04 REPLACEMENT OF THE LATERAL PLUNGER CYLINDER SEALS .......................................................... 23
2.05 REPLACEMENT OF THE CENTRAL PLUNGER CYLINDER SEALS ......................................................... 25

2.06 REMOVING THE FORKS TILT CYLINDER ................................................................................................. 27

CONTENTS
2.07 REPLACING THE SEALS .......................................................................................................................... 29

2.08 REPLACEMENT OF THE SIDESHIFTER CYLINDER SEALS .................................................................... 30
2.09 REMOVING THE REACH CYLINDER ........................................................................................................ 31
2.10 REPLACEMENT OF THE REACH CYLINDER SEALS .............................................................................. 32
2.11 REPLACEMENT OF HYDRAULIC HOSES OF THE TILT CYLINDER AND SIDESHIFTER
CYLINDER ................................................................................................................................................. 33
2.12 REMOVING THE CENTRAL CYLINDER HYDRAULIC SUPPLY HOSE ...................................................... 34
Section: MASTS
1.00 MAST TYPES ............................................................................................................................................. 3
1.01 SIDESHIFTER COMPONENTS ................................................................................................................... 3
1.02 TABLE OF SIDESHIFTER COMPONENTS ................................................................................................. 3
1.03 BETA MAST ................................................................................................................................................ 4
1.04 HE 140L MAST ........................................................................................................................................... 5
1.05 HE 140 MAST ............................................................................................................................................. 6
1.06 HE 140R MAST .......................................................................................................................................... 7
2.00 PROCEDURE FOR REMOVING THE MAST .............................................................................................. 8
2.01 DIAGRAM WITH MAST ASSEMBLY DIRECTIONS .................................................................................... 10
2.02 MAST INCLINATION TABLE ....................................................................................................................... 11
2.03 FORK ARM CARRIAGE REMOVAL PROCEDURE .................................................................................... 12
2.04 BEARING REPLACEMENT PROCEDURE ................................................................................................ 14
2.05 GREASING THE BEARING ....................................................................................................................... 15
2.06 PROCEDURE FOR REPLACING THE MAST BEARINGS ......................................................................... 16
2.07 LIFTING CHAIN .......................................................................................................................................... 17
2.08 CHAIN MEASUREMENT ........................................................................................................................... 18
2.09 REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT) .............................................................................. 19
2.10 REPLACING THE LATERAL LIFT CHAINS ................................................................................................. 20
Section: MECHANICS
1.00 TABLE OF SCREW TIGHTENING TORQUES ............................................................................................. 2

1.01 DRIVE WHEEL REPLACEMENT PROCEDURE ......................................................................................... 3
1.02 LOAD WHEELS REPLACEMENT PROCEDURE (MODELS R1.4-R1.6-R1.6N) .......................................... 4
1.03 LOAD WHEELS REPLACEMENT PROCEDURE (MODELS R1.6 OPT.-R2.0-R2.0H-R2.0W-R2.5) ............. 5
2.00 FORKS SIDESHIFTER SLIDING SHOES REPLACEMENT PROCEDURE ................................................. 7
2.01 BATTERY BLOCK FUNCTION .................................................................................................................... 9
2.02 BATTERY BLOCK REMOVAL PROCEDURE ............................................................................................. 10
2.02 REPLACING THE LATCH AND SPRING .................................................................................................... 11
3.00 TRACTION MOTOR REPLACEMENT PROCEDURE ................................................................................. 12
3.01 TRACTION MOTOR COMPONENTS .......................................................................................................... 13
3.01 TABLE OF TRACTION MOTOR COMPONENTS ........................................................................................ 13
3.02 REPLACING THE ENCODER BEARING .................................................................................................... 14
4.00 PUMP MOTOR REMOVAL PROCEDURE ................................................................................................. 16
4.01 REPLACING THE PUMP CONNECTING FLANGE OIL SEAL .................................................................... 17
4.02 PUMP MOTOR COMPONENTS ................................................................................................................ 18

5.00 STEERING GEARED MOTOR REMOVAL PROCEDURE .......................................................................... 20
CONTENTS
5.01 STEERING MOTOR COMPONENTS ......................................................................................................... 21
6.00 STEERING UNIT ........................................................... ...................................................................... 23
6.01 STEERING UNIT LINKAGE COMPONENTS .............................................................................................. 24
6.02 TABLE OF STEERING UNIT LINKAGE COMPONENTS ............................................................................. 25
6.03 REPLACING THE STEERING UNIT GAS SPRING ..................................................................................... 26
6.04 ADJUSTING STEERING HANDWHEEL ROTATION RESISTANCE ............................................................. 27
6.05 DISASSEMBLING THE HANDWHEEL - DISPLAY UNIT ............................................................................ 28
Section: REACH CARRIAGE

1.00 REACH CARRIAGES UTILISED ................................................................................................................. 2
1.01 REACH CARRIAGE COMPONENTS .......................................................................................................... 2
1.02 TABLE OF REACH CARRIAGE - TRUCK COMBINATIONS ........................................................................ 3
1.03 TABLE OF REACH CARRIAGE COMPONENTS ......................................................................................... 4
2.00 REACH CARRIAGE DISASSEMBLY PROCEDURE ................................................................................... 5
2.01 BEARING REPLACEMENT ........................................................................................................................ 6
2.02 REPLACING THE REACH CARRIAGE GUIDE SHOES .............................................................................. 6
Section: REDUCTION GEAR

1.00 REDUCTION GEAR COMPONENTS .......................................................................................................... 2
1.01 TABLE OF REDUCTION GEAR COMPONENTS ......................................................................................... 2
2.00 REDUCTION GEAR REMOVAL PROCEDURE ........................................................................................... 3
2.01 REPLACING THE MOTOR SHAFT OIL SEAL ............................................................................................ 5
2.02 REPLACING THE DRIVE WHEEL AXLE OIL SEAL .................................................................................... 6
Section: BRAKING SYSTEM

1.00 ELECTROMAGNETIC BRAKE COMPONENTS .......................................................................................... 2
1.01 TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS ........................................................................ 2
1.02 LOAD WHEEL BRAKING SYSTEM COMPONENTS .................................................................................. 3
1.03 TABLE OF BRAKING SYSTEM COMPONENTS ....................................................................................... 3
1.04 LOAD WHEELS BRAKE COMPONENTS ................................................................................................... 4
1.05 TABLE OF LOAD WHEELS BRAKE COMPONENTS ................................................................................. 4
1.06 BRAKING SYSTEM .................................................................................................................................... 5
2.00 REMOVAL AND ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE ..................................................... 6
2.01 ADJUSTING AND PUTTING INTO SERVICE THE ELECTROMAGNETIC BRAKE ....................................... 7
3.00 REMOVING THE BRAKE MASTER CYLINDER .......................................................................................... 8
3.01 REPLACING THE LOAD WHEEL BRAKES ................................................................................................ 9
3.02 BLEEDING AIR FROM THE BRAKE CIRCUIT ............................................................................................ 11

Section: ELECTRICAL SYSTEM SERVICE
NOTES:
ELECTRICAL SYSTEM

SERVICE Section: ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
INTRODUCTION
INSTALLING
THE TRUCK
D INTRODUCTION TO THE TRUCK ......................................................... 8
D INSTALLING THE TRUCK .................................................................... 9

1.0 INTRODUCTION TO THE TRUCK

ELECTRICAL SYSTEM
The reach trucks of the new range differ from the previous models because of a series of innovations in
terms of ergonomics and performance.
The truck is equipped with AC motors driven by the latest generation of controllers, and an electronic
system composed of 6 modules that communicate and interact via a CAN BUS. This system has made
it possible to achieve significant improvements in the truck’s hydraulic and traction performance
characteristics.
The hydraulic system is managed by a group of proportional solenoid valves that can be driven by three
different control systems all of which are equipped with potentiometric joysticks.
The current range is composed of seven chassis models and four mast models that can be combined in
various configurations in accordance with the required lift heights and capacities
The trucks are equipped with dataplates showing the serial number and located on the motor compartment
hood next to the operator seat, the serial number of the mast punch marked on the right-hand external mast
channel at a height of 1500 mm and a residual capacity dataplate located under the overhead guard in the
centre of the external cross-member as shown in the following figure.
The following sections of the manual contain detailed descriptions of truck components, functions, and
performance specifications. The service manual is completed by the “AC MOTORS MODULAR CONTROL
SYSTEMS” manual and the “EPS-AC” steering motor management system manual.
TRUCK RESIDUAL
CAPACITY
RATING PLATE Fig. 3 MAST SERIAL NUMBER
PUNCH MARKING
Fig. 4
TRUCK SERIAL NUMBER

DATAPLATE
Fig. 2 Fig. 1

2.0 INSTALLING THE TRUCK

MODEL ALL MODELS
ELECTRICAL SYSTEM
Trucks are delivered after testing and checking of all the factory parameters. Certain truck models are
delivered with the mast removed because the overall height exceeds the maximum permissible height for
transportation purposes.
All functions of the trucks are tested, after which the mast is removed and the fork arm carriage is secured
to its base in such a way that it does not tend to slide along the internal mast section. All hydraulic
connections are suitably plugged to prevent the egress of oil during transportation.
When the truck arrives at its destination the mast must be installed and all the various functions must be
tested.
To refit the mast, use a crane of suitable height or an overhead crane and a lifting sling of suitable capacity
to lift the mast from the ground and install it on the basic truck (see figure below)
There is a bag secured to the mast containing the fixing screws and shims to be inserted behind the mast
base to impart the required inclination in accordance with the height. For directions on mast installation and
positioning of the shims, refer to the section “masts, heading 2.01-2.02 page 10-11”.
Set the battery voltage (Adjust Battery) on AC2 traction inverter and AC2 pump inverter (see procedure on
pag. 26)
Fig. 5

NOTES:
ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
ELECTRICAL
SYSTEM
D KEY TO ELECTRICAL DIAGRAMS ...................................................14
D KEY TO POSITION OF ELECTRICAL COMPONENTS ........................16
D FUNCTION INPUTS TABLE ................................................................ 18
D PARAMETER TABLES....................................................................... 20
D ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS M ... 24
D TRACTION START SEQUENCE ......................................................... 27
D SPEED CUTBACK ............................................................................. 29
D MODULES REPLACEMENT PROCEDURE ....................................... 30

D SICOS DISPLAY ................................................................................ 36
D DISPLAY MENUS .............................................................................. 42
D PRE-HEIGHT SELECTOR .................................................................. 48

D ALARMS ............................................................................................ 54
D DIAGNOSTICS ................................................................................... 55
D TROUBLESHOOTING GUIDE ............................................................ 55

1.0 KEY TO ELECTRICAL DIAGRAMS
MODEL ALL MODELS
ELECTRICAL SYSTEM
D i a g ra m D ia g r a m
D e sc ri p ti o n o f C o m p o n e n t
S y m b o l R e f. P a g e R e f.
SW 1 1/7 E m e rg e n c y p u s h b u t t o n
SW 2 1/7 K e y s w it c h
SW 3 2/7 O p e ra t o r p re s e n c e in d u c t ive s e n s o r
SW 4 2/7 S t e e r w h e e l c e n t re d in d u c t ive s e n s o r
SW 5 3/7 S p e e d re d u c t io n a n d h e ig h t in d ic a t o r z e ro in d u c t ive s e n s o r
SW 6 3/7 S p e e d re d u c t io n in h e ig h t in d u c t ive s e n s o r
SW 7 3/7 In d u c t ive s e n s o r - R e a c h c a rria g e fo rw a rd s t o p - R e a c h c a rria g e re tra c t d e c e le ra t io n
SW 8 3/7 In d u c t ive s e n s o r - R e a c h c a rria g e re tra c tio n s to p - R e a c h c a rria g e fo rw a rd d e c e le ra t io n
SW 9 3/7 F o rk s lo w e rin g d e c e le ra t io n in d u c t ive s e n s o r
S W 10 3/7 F o rk s lo w e rin g in t e rlo c k in d u c t ive s e n s o r
S W 11 3/7 L o a d p re s e n c e o n fo rk s in d u c t ive s e n s o r
S W 12 4/7 F o rw a rd t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r
S W 13 4/7 R e ve rs e t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r
S W 14 4/7 F o rw a rd /re ve rs e t ra ve l S t a rt in d u c t ive s e n s o r
S W 15 4/7 P e d a l b ra k e c o n tro l in d u c t ive b ra k in g s e n s o r
S W 16 4/7 B a t te ry o u t o f p o s it io n in d u c tive s e n s o r
S W 17 4/7 O p e ra t o r p re s e n c e m ic ro s w itc h lo c a t e d u n d e r s e a t (o p tio n a l)
S W 18 5/7 Tra c t io n p e rm is s ive p u s h b u t t o n w it h b a t t e ry o u t
S W 19 5/7 P a rk in g p e rm is s ive p u s h b u tt o n
S W 20 5/7 L o w s p e e d t ra ve l p e rm is s ive b u t t o n a n d p e rfo rm a n c e c h a n g e (S L O W - S TD - H A R D -
S W 21 4/7 H o rn b u t to n
S W 22 5/7 F ifth h y d ra u lic c irc u it c o n t ro l p u s h b u t to n
S W 23 5/7 A u t o m a t ic s c a le s c o n tro l p u s h b u t to n
S W 24 4/7 W o rk lig h t s p o w e r O N p u s h b u t t o n
S W 25 4c /7 F o rw a rd t ra ve l s e le c t o r b u t to n o n d a s h b o a rd
S W 26 4c /7 R e ve rs e t ra ve l s e le c t o r b u t to n o n d a s h b o a rd
FU1 1/7 A C 2 t ra c t io n c o n tro lle r 3 0 0 A p o w e r fu s e
FU2 1/7 A C 2 p u m p c o n t ro lle r 3 0 0 A p o w e r fu s e
FU3 1/7 E P S A C c o n t ro lle r 3 2 A p o w e r fu s e
FU4 1/7 A u x ilia ry lin e 1 0 A fu s e
FU7 2/7 A u x ilia ry lin e 6 A fu s e
EM B 2/7 E le c t ro m a g n e t ic b ra k e
ENC. M T R 2/7 Tra c t io n m o t o r e n c o d e r
EN C . M S 2/7 S t e e rin g m o t o r e n c o d e r
EN C . M P 3/7 P um p m otor enc oder
EN C . H .I 3/7 H e ig h t in d ic a tio n e n c o d e r
EV I 3/7 P ro p o rt io n a l lo w e rin g s o le n o id va lve
EV 2 3/7 P ro p o rt io n a l lift in g s o le n o id va lve
EV 3 3/7 R e a c h c a rria g e re t ra c t io n p ro p o rt io n a l s o le n o id va lve
EV 4 3/7 R e a c h c a rria g e e x t e n s io n p ro p o rt io n a l s o le n o id va lve
EV 5 3/7 Tilt B a c k s o le n o id va lve
EV 6 3/7 Tilt F W D s o le n o id va lve
EV 7 3/7 F o rk s rig h t -h a n d s id e s h ift s o le n o id va lve
EV 8 3/7 F o rk s le ft -h a n d s id e s h ift s o le n o id va lve
OPT. 1 3/7 O p tio n s s o le n o id va lve w irin g c o n n e c t o r
OPT. 2 3/7 O p tio n s s o le n o id va lve w irin g c o n n e c t o r
H1 4/7 H o rn
H2 4/7 R e ve rs e t ra ve l w a rn in g s o u n d e r
H3 4/7 W o rk lig h t s
H4 3/7 Tru c k in m o t io n fla s h in g w a rn in g b e a c o n
M1 2/7 M o t o r c o m p a rt m e n t c o o lin g fa n
M2 3/7 M o t o r c o m p a rt m e n t c o o lin g fa n
L O A D C EL L 3/7 L o a d c e ll fo r d e te c t in g w e ig h t o f lo a d o n fo rk s
M TR 1/7 A C t ra c t io n m o t o r
MP 1/7 A C pum p m otor
MS 1/7 A C s t e e rin g m o t o r
POT. 1 4/7 Tra c t io n s p e e d va ria t io n p o t e n t io m e t e r
S 1/7 B a t te ry to m a c h in e e le c t ric a l s y s te m c o n n e c t o r p lu g
S .S . 2/7 S t e e rin g s te p p e r m o to r
T. M TR 2/7 Tra c t io n m o t o r t e m p e ra t u re p ro b e
T. M P 3/7 P u m p m o t o r te m p e ra t u re p ro b e
T. M S 2/7 S t e e rin g m o t o r t e m p e ra tu re p ro b e
J 1 (2 a x i x ) 4 -4 c / 7 F o rk s lift/ lo w e r c o n t ro l a n d re a c h c a rria g e e x t e n d /re t ra c t c o n t ro l jo y s tic k
J 2 (2 a x i x ) 4 -4 c / 7 F o rk s B a c k / F w d t ilt a n d rig h t / le ft s id e s h ift c o n t ro l jo y s t ic k
J1 4 a -4 d /7 F o rk s lift/ lo w e r c o n t ro l jo y s tic k
J2 4 a -4 d /7 R e a c h c a rria g e e x t e n d / re t ra c t c o n t ro l jo y s tic k
J3 4 a -4 d /7 F o rk s b a c k /fw d t ilt c o n t ro l jo y s t ic k
J4 4 a -4 d /7 F o rk s rig h t /le ft s id e s h ift c o n t ro l jo y s t ic k

SERVICE Sezione: ELECTRICAL SYSTEM
FUNCTIONAL ELECTRICAL DIAGRAM 1/7

MOTORS AND CONTROLLERS CONNECTION
CONTROL CIRCUITS POWER SUPPLY
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14a


AC TRACTION MODULE CONNECTION
Reference to diagram number at top right EPS AC MODULE CONNECTION
Fuse after Solenoid valves power Auxiliary services 4a -4d,/7 joysticks R1 power supply positi- DC-DC CONVERTER FOR 12/24V
keyswitch supply fuse power supply fuse ve (Resistor for cold store version) POWER SUPPLY (OPTIONAL
M 1
1B - 2B PONTE CONFIGURAZIONE INVERTER

24V ALL’INSERZIONE - 19V DI ALIMENTAZIONE PRESENTE = POMPA / NON PRESENTE = TRAZIONE
1 24V ON THE START UP - 19V TO KEEP EMB OPEN 2 1B - 2B INVERTER JUMPER CONFIGURATION 1501469-2
CLOSED = PUMP / OPEN = TRACTION
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14b


AC PUMP MODULE CONNECTION
MHYRIO MODULE CONNECTION
1B - 2B PONTE CONFIGURAZIONE INVERTER
1
PRESENTE = POMPA / NON PRESENTE = TRAZIONE
1B - 2B INVERTER JUMPER CONFIGURATION 2 24V ALL’INSERZIONE - 19V DI ALIMENTAZIONE
24V ON THE START UP - 19V TO KEEP EMB OPEN 3 SE SW5 NON E’ PRESENTE PONTICELLARE 15A CON 12A
IF SW5 IS NOT MOUNTED JUMPER 15A WITH 12A
CLOSED = PUMP / OPEN = TRACTION
1501469-3
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14c


CAN I/O MODULE CONNECTION
2-JOYSTICK HYDRAULIC CONTROL
FWD/REV TRAVEL CONTROL ON PEDALS
Function Range Function Ra nge

Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
Low 2,4V - 0.5V Tilt Down 2,4V - 0.5V
POT. J1 POT. J2
Forw. Carr. 2,4V - 0,5V Side Shift rh. 2,6V - 4,5V
Rev. Carr. 2,6V - 4.5V Side Shift sh 2,4V - 0.5V
SW13
SW12
DUAL FUNCTION PEDAL WITH DIRECTIONAL NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
CONTROL FORW/REV NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL
AND TWO JOYSTICKS HYDRAULIC CONTROL ON THE PEDALS IS UTILIZED
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14d

FUNCTIONAL ELECTRICAL DIAGRAM 4a/7


Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
POT. J1 POT. J3
B Low 2,4V - 0.5V Tilt Down 2,4V - 0.5V
POT. J2 POT. J4
SW13
SW12
DUAL FUNCTION PEDAL WITH DIRECTIONAL NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
CONTROL FORW/REV NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL R1 RESITOR FOR COLD STORE VERSION
AND FOUR JOYSTICKS HYDRAULIC CONTROL ON THE PEDALS IS UTILIZED
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14e

FUNCTIONAL ELECTRICAL DIAGRAM 4b/7

SINGLE JOYSTICK HYDRAULIC CONTROL
SW13
SW12
CON PEDALIERA DOPPIA IN FUNZIONE, IL COMANDO SUL JOYSTICK E’ DISATTIVATO

WITH DUAL FUNCTION PEDAL, THE SPEED CONTROL IS DISABILITY
DUAL FUNCTION PEDAL WITH DIRECTIONAL NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A
CONTROL FORW/REV IS NOT PRESENT WHEN THE TRAVEL DIRECTION
AND ONLY ONE JOYSTICKS HYDRAULIC CONTROL CONTROL ON THE PEDALS IS UTILIZED
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14f

FUNCTIONAL ELECTRICAL DIAGRAM 4c/7

FWD/REV TRAVEL CONTROL
ON INSTRUMENT PANEL
Function Range Function Range

Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
POT. J1 POT. J2
SW26 SW25
FORWARD BACKWARD WITH SWITCH NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
AND TWO JOYSTICKS FOR IDRAULIC CONTROL PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE
INSTRUMENT PANEL IS UTILIZED
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14g

FUNCTIONAL ELECTRICAL DIAGRAM 4d/7

TRAVEL CONTROL ON INSTRUMENT PANEL

Lift 2,6V - 4,5V Tilt Up 2,6V - 4,5V
POT. J1 POT. J3
B POT. J2 POT. J4
SW26 SW25
FORWARD BACKWARD WITH SWITCH NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS
PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE R1 RESITOR FOR COLD STORE VERSION
AND FOUR JOYSTICKS FOR IDRAULIC CONTROL
INSTRUMENT PANEL IS UTILIZED
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14h

FUNCTIONAL ELECTRICAL DIAGRAM 4e/7

TRAVEL CONTROL ON JOYSTICK
SW25
SW26
FORWARD BACKWARD AND HYDRAULIC NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS PRESENT
CONTROL WITH ONLY JOYSTICK WHEN THE ITT JOYSTICK IS UTILIZED WITH INTEGRAL TRAVEL
CONTROL
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14i


SICOS MODULE CONNECTIONS
1501469 - 10
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14l


CAN BUS MODULES CONNECTION
1501469 - 11
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14m


CONNECTION DIAGRAM
POWER CABLES
1501486
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14n

INPUT / OUTPUT CONNECTORS

MODULES AC2 T, AC2 P
Input / output connectors module AC2 TRAZIONE Input / output connectors module AC2 POMPA
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14o


MODULES EPS AC, MHYRIO
Input / output connectors module EPS AC Input / output connectors module MHYRIO
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14p


MODULES CAN I/O, SICOS
(display)
Input / output connectors module CAN I/O Input / output connectors module SICOS
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14q

NOTES:
ELECTRICAL SYSTEM

2.0 KEY TO POSITION OF ELECTRICAL COMPONENTS

ELECTRICAL SYSTEM
MODEL ALL MODELS
Diagram Diagram
Ref. Description of Component
Symbol Ref. Page Ref.
1 MTR 1/7 AC traction motor - 6.4 kW 70 Hz
2 MP 1/7 AC pump motor - 11 kW 8 Hz
3 MS 1/7 AC steering motor - 0.4 kW 95 Hz
4 SW3 2/7 Operator presence inductive sensor
5 Pot 1 4/7 Acceleration traction potentiometer
6 SW14 4/7 Forward/reverse travel start inductive sensor
7 SW12 4/7 Forward travel selection inductive sensor on pedal
8 SW13 4/7 Reverse travel selection inductive sensor on pedal
9 SW15 4/7 Brake pedal control braking inductive sensor
10 H1 4/7 Horn
11 SW16 4/7 Battery out of position inductive sensor
12 SW4 2/7 Steer wheel centred inductive sensor
13 SW8 3/7 Inductive sensor - reach carriage forward deceleration and retraction stop
14 SW7 3/7 Inductive sensor - reach carriage retraction deceleration and forward stop
15 M1 2/7 Motor compartment cooling fan
16 S.S. 2/7 Steering stepper motor
17 EPS AC Logic 2/7 AC steering motor control module
18 SW25 4c/7 Forward travel selection switch on dashboard
19 SW26 4c/7 Reverse travel selection switch on dashboard
20 SW21 4/7 Horn button
AC2 Traction
21 2/7 AC traction motor control module
Logic
AC2 Pump
22 3/7 AC pump motor control module
Logic
23 CAN I/O 4/7 CAN I/O control module
24 Mhyrio 3/7 Mhyrio control module for valves bank management
25 Sicos 5/7 Sicos (display) control module for alarms and test information
26 M2 3/7 Panels cooling fan
27 Enc Height Ind 3/7 Height indication encoder
28 SW5 3/7 Height encoder, speed reduction inductive zero sensor
29 SW1 1/7 Emergency circuit breaker
30 SW2 1/7 Keyswitch
31 FU7 2/7 Auxiliary line fuse
35 J1 (2axix) 4-4c/7 Joystick - forks Up/Down control, reach carriage extend/retract
36 J2 (2axix) 4-4c/7 Joystick - forks tilt back/fwd control and forks left/right sideshift control
37 J1 4a-4d/7 Joystick - forks lift/lower
38 J2 4a-4d/7 Joystick - reach carriage forward/back control
39 J3 4a-4d/7 Joystick - forks tilt Fwd/Back control
40 J4 4a-4d/7 Joystick - forks left/right sideshift control
Multifunction Joystick. Displace lever up and down for lift and lower, displace right
41 J ITT 4b-4e/7
and left for reach carriage movements
42 Travel forward / reverse control pushbutton
43 Forks tilt Fwd / Back control pushbutton
44 Forks right and left sideshift control pushbutton
45 Horn button

MOTORS COMPARTMENT ELECTRICAL COMPONENTS WITH

FORWARD/REVERSE TRAVEL PUSHBUTTONS ON PEDALS
MODEL ALL MODELS
16
15
3
17
1
5
6
12
9 5 11
13 14
6
10
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 16a

MOTORS COMPARTMENT ELECTRICAL COMPONENTS

FORWARD/REVERSE TRAVEL CONTROL WITH DIRECTION
CHANGE CONTROL ON INSTRUMENT PANEL
MODEL ALL MODELS
16
15
3
17
1
19 18
4
20
12
9 5 11
13 14
6
10
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 16b

SERVICE 4 Section: ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS AND

POSITION OF CONTROL MODULES
MODEL ALL MODELS
25
44 30 29 30 29 30 29
43
42 37 38 39
35 40
36
28 45
41
19 19 18
27 18
20
20
23
22
21
30
26
32
31 24
34 29
33
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 16c

POSITIONING OF DECELERATION
SENSORS ON REACH CARRIAGE
MODEL ALL MODELS
140-150mm
3
1
2
4
3
STANDARD AND PLUS REACH CARRIAGE WITH
4 SENSOR POSITIONING ACCORDING TO
BASIC TRUCK BATTERY SIZE
STANDARD AND PLUS REACH CARRIAGE
WITH FOUR SENSOR HOLDER SLOTS
BASIC TRUCK WITH THREE
BASIC TRUCK WITH THREE POSITIONS OF SENSORS WITH REFERENCE TO BASIC TRUCK AND BATTERY DIMENSIONS
R1.4 R1.4H R1.6 R1.6H R1.6N R2.0 R2.0H R2.0W R2.5
1 Slot Ref. Battery Dimensions
"A" "A" "A" "A" "A" "A" "A" "A" "A"
Read distance between the two sensors 140-150mm
1 Din C 420A (1220x280x784) 127 109 39
2 Din C 560A (1220x352x784) 127 109 39 39 51
3 Din C 700A (1220x424x784) 127 109 39 39 51 51 22 23
2 4 Din C 840A (1220x496x784) 51 51 22 23
1 Din B 420A (1032x350x784) 39

BASIC TRUCK WITH TWO NARROW REACH CARRIAGE
2 Din B 560A (1032x440x784) 39
SENSOR READING CAMS WITH TWO SENSOR HOLDER SLOTS
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 16d

NOTES:
ELECTRICAL SYSTEM

3.0 TABLE OF FUNCTION INPUTS

ELECTRICAL SYSTEM
MODEL ALL MODELS
The tables show all the sensors and microswitches that are activated in accordance with the requested
functions.
Key
Input = List of sensor inputs in the modules with specification of pins and
access connector.
Description of Functions = Description of the function to be executed
Enabled function = Description of the requested enabled function
Control = Controller involved
Pin = Pin corresponding to signal output
Status = State of the sensor at the time of the function request
SW4 - SW23 = Sensors activated on the basis of the requested function
NOTES:

SERVICE Sezione: IMPIANTO ELETTRICO
INPUT TABLE OF THE

FUNCTIONS (Sheet 1/3)
Inputs
AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
= INPUT ACTIVITY 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A
SLOW D.
REV. SLOW D.
RESET ENCODER
WEIGHT BUTTON
CUT OUT FORW.
BATTERY OUT
BATTERY OUT
OPTIONAL 1-2
SLOW SPEED
PEDAL MODE
EMERGENCY
PUMP MODE
ENABLE TILT
REDUCTION
REDUCTION
REDUCTION
SEAT SWITC
AUTOMATIC
STOP
LOW FORKS
SPEED LOW
SPEED AND
INTERLOCK
BACKWARD
(OPTIONAL)
SPEED LIFT
CARRIAGE
PRESENCE
CARRIAGE
REV. STOP
SIDE SHIFT
DEAD MAN
DEAD MAN
CARRIAGE
CARRIAGE
CARRIAGE
IDR.VALVE
FORWARD
CLACSON
REVERSE
POSITION
LIFT/LOW
PARKING
CUT OUT
BUTTON
BUTTON
BUTTON
BUTTON
BUTTON
ENABLE
ENABLE
ENABLE
ENABLE
BRAKE
STEER
LOAD
FOR.
FOR.
STATU
FUNCTION DESCRIPTION FUNCTION OPERATED CONTROL PIN SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12/25 SW13/26 SW14 SW15 SW16 SW17 SW3 SW1 J1/J1 J1/J2 J3 J4 SW21 SW18 SW20 SW19 SW22 SW23
S
TRACTION MAX SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l
TRACTION MAX SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l
TRACTION MAX SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l
FORWARD/BACKWARD
WITH SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l l l
TRACTION MAX SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l
FORWARD/BACKWARD
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l
WITH SLOW DOWN BUTTON ACTIVITY
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW ELECTROMAGNETIC BRAKE AC2-TR 9/F ON l l l l l l
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l
DUAL FUNCTION PEDAL
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l l
FORWARD/BACKWARD
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l l
FORWARD/BACKWARD
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l
WITH FORKS OVER FREE LIFT
DUAL FUNCTION PEDAL
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l
DUAL FUNCTION PEDAL
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l
FORWARD/BACKWARD
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l
FORWARD/BACKWARD
TRACTION SPEED REDUCTION FORWARD SPEED AC2-TR ON l l l l l l l l
WITH CARRIAGE ALL OUT
DUAL FUNCTION PEDAL
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l
DUAL FUNCTION PEDAL
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l
FORWARD/BACKWARD
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l
FORWARD/BACKWARD
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517320 Page 18a

INPUT TABLE OF THE

Inputs
AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
= INPUT ACTIVITY 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A
RESET ENCODER
WEIGHT BUTTON
SLOW D.
FORW.
REV. SLOW D.
BATTERY OUT
BATTERY OUT
OPTIONAL 1-2
SLOW SPEED
EMERGENCY
PEDAL MODE
PUMP MODE
ENABLE TILT
SEAT SWITC
REDUCTION
REDUCTION
REDUCTION
LOW FORKS
SPEED LOW
AUTOMATIC
(OPTIONAL)
INTERLOCK
SPEED AND
SPEED LIFT
BACKWARD
PRESENCE
SIDE SHIFT
DEAD MAN
DEAD MAN
CARRIAGE
CARRIAGE
CARRIAGE
FORWARD
IDR.VALVE
POSITION
REVERSE
CLACSON
LIFT/LOW
CUT OUT
PARKING
STOP
BUTTON
BUTTON
BUTTON
BUTTON
BUTTON
ENABLE
ENABLE
ENABLE
CARRIAGE
CARRIAGE
STOP
ENABLE
BRAKE
STEER
LOAD
CUT OUT
FOR.
FOR.
REV.
FUNCTION DESCRIPTION FUNCTION OPERATED CONTROL PIN STATUS SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12/25 SW13/26 SW14 SW15 SW16 SW17 SW3 SW1 J1/J1 J1/J2 J3 J4 SW21 SW18 SW20 SW19 SW22 SW23
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l
WITH BATTERY OUT
DUAL FUNCTION PEDAL
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l
WITH BATTERY OUT
DUAL FUNCTION PEDAL
TRACTION REDUCTION SPEED FORWARD SPEED AC2-TR ON l l l l l l l l l l l
WITH BATTERY OUT
FORWARD/BACKWARD
TRACTION REDUCTION SPEED BACKWARD SPEED AC2-TR ON l l l l l l l l l l l
WITH BATTERY OUT
FORWARD/BACKWARD
PARKING BRAKE ACTIVITY FORWARD SPEED AC2-TR OFF l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW
OR SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F OFF l l l l l l l
PARKING BRAKE ACTIVITY BACKWARD SPEED AC2-TR OFF l l l l l l l
DUAL FUNCTION PEDAL
WITH DIRECTIONAL CONTROL FW/ BACKW
OR SWITCH ELECTROMAGNETIC BRAKE AC2-TR 9/F OFF l l l l l l l
STRIGHT WELL ELECTIRC STEERING EPS-AC ON l l
MOTOR PUMP AC2-PU ON
LIFT FORKS MAX SPEED
EV2 MHYRIO 7/G ON l l l l l l l
LIFT FORKS REDUCTION SPEED
EV2 MHYRIO 7/G ON l l l l l l l l
LOWER FORKS MAX SPEED EV1 MHYRIO 8/G ON l l l l l l
LOWER FORKS REDUCTION SPEED EV1 MHYRIO 8/G ON l l l l l l l
CARRIAGE FORWARD MAX SPEED
CARRIAGE FORWARD REDUCTION SPEED
MOTOR PUMP AC2-PU OFF
CARRIAGE FORWARD STOP
EV4 MHYRIO 5/G OFF l l l l l l
CARRIAGE REVERSE MAX SPEED
CARRIAGE REVERSE REDUCTION SPEED
EV3 MHYRIO ON l l l l l l l
MOTOR PUMP AC2-PU OFF
CARRIAGE REVERSE STOP
EV3 MHYRIO 6/G OFF l l l l l l
TILT UP
TILT DOWN
EV6 MHYRIO ON l l l l l l l
SIDE SHIFT RIGHT
SIDE SHIFT LEFT
OPTIONAL 1
OPT.1 MHYRIO 3/F ON l l l l l l l l
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517320 Page 18b

INPUT TABLE OF THE

Inputs
AC2-TR EPS-AC AC2-PU MHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS
= INPUTACTIVITY 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A
OPTIONAL 1-2 IDR

RESET ENCODER
WEIGHT BUTTON
FORW.
.VALVE BUTTON
BATTERY OUT
BATTERY OUT
SLOW SPEED
ENABLE SIDE
PEDAL MODE
EMERGENCY
ENABLE TILT
SLOW D.
PUMP MODE
SLOW D.
SEAT SWITC
REDUCTION
REDUCTION
REDUCTION
LOW FORKS
SPEED LOW
AUTOMATIC
SPEED AND
BACKWARD
(OPTIONAL)
INTERLOCK
SPEED LIFT
PRESENCE
DEAD MAN
DEAD MAN
CARRIAGE
CARRIAGE
CARRIAGE
FORWARD
CLACSON
REVERSE
POSITION
PARKING
LIFT/LOW
CUT OUT
BUTTON
BUTTON
BUTTON
BUTTON
ENABLE
ENABLE
ENABLE
BRAKE
STEER
STOP
SHIFT
LOAD
CARRIAGE
CARRIAGE
STOP
FOR.OUT
FOR.
REV.
REV.
CUT
FUNCTIONDESCRIPTION FUNCTIONOPERATED CONTROL PIN STATUS SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12/25 SW13/26 SW14 SW15 SW16 SW17 SW3 SW1 J1/J1 J1/J2 J3 J4 SW21 SW18 SW20 SW19 SW22 SW23
MOTORPUMP AC2-PU ON
OPTIONAL 2
OPT.2 MHYRIO 2/F ON l l l l l l l l
MOTORPUMP AC2-PU ON
LIFTANDCARRIAGEFORWARDMAXSPEED
EV2-EV4 MHYRIO 7/G-5/G ON l l l l l l l l l l
LIFTANDCARRIAGEFORWARDREDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV4 MHYRIO 7/G-5/G ON l l l l l l l l l
MOTORPUMP AC2-PU OFF
LIFTANDCARRIAGEFORWARDSTOP
EV2-EV4 MHYRIO 7/G-5/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LIFTANDCARRIAGEREVERSEMAXSPEED
EV2-EV3 MHYRIO 7/G-6/G ON l l l l l l l l l l
LIFTANDCARRIAGEREVERSEREDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV3 MHYRIO 7/G-6/G ON l l l l l l l l l
LIFTANDCARRIAGEREVERSESTOP
EV2-EV3 MHYRIO 7/G-6/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LOWERANDCARRIAGEFORWARDMAXSPEED
EV2-EV4-EV1 MHYRIO 7/G-5/G-8/G ON l l l l l l l l l l
LOWERANDCARRIAGEFORWARDREDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV4-EV1 MHYRIO 7/G-5/G-8/G ON l l l l l l l l l
LOWERANDCARRIGAFORWARDSTOP
EV2-EV4-EV1 MHYRIO 7/G-5/G-8/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LOWERANDCARRIAGEREVERSEMAXSPEED
EV2-EV3-EV1 MHYRIO 7/G-6/G-8/G ON l l l l l l l l l l
LOWERANDCARRIAGEREVERSE REDUCTION MOTORPUMP AC2-PU ON
SPEED EV2-EV3-EV1 MHYRIO 7/G-6/G-8/G ON l l l l l l l l l
LOWERANDCARRIAGEREVERSESTOP
EV2-EV3-EV1 MHYRIO 7/G-6/G-8/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
LOWERANDSIDESHIFTRIGHT
EV7-EV1 MHYRIO 2/G-8/G ON l l l l l l l l
MOTORPUMP AC2-PU
LOWERANDSIDESHIFTLEFT
EV8-EV1 MHYRIO 1/G-8/G ON l l l l l l l l
LOWERWITHCARRIAGEALLREVERSE
EV1 MHYRIO 8/G OFF l l l l l l l
ANDINTERLOKFORKSDEVICEACTIVITY
CARRIAGEREVERSEWITHFORKSALLDOWN MOTORPUMP AC2-PU OFF
ANDINTERLOKFORKSDEVICEACTIVITY EV3 MHYRIO 6/G OFF l l l l l l l l
MOTORPUMP AC2-PU ON
AUTOMATICWEIGHTLOAD
CLACSON H2 CANI/O 8/G ON l l
BACKUPALARMDUALFUNCTIONPEDAL REVERSESPEED AC2-TR ON
WITHDIRECTIONALCONTROLFW/BACKW H3 CANI/O 7/G ON l l l l l l
BACKUPALARMFORWARDBACWARD REVERSESPEED AC2-TR ON
WITHSWITH H3 CANI/O 7/G ON l l l l l l l
OR OR OR OR OR OR
FLSHINGBEACON
H1 AC2-PU 8/F ON l l l l l l l l l l l
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517320 Page 18c
NOTES:
ELECTRICAL SYSTEM

4.0 PARAMETERS TABLE
MODULE 2 AC2 TRACTION
ELECTRICAL SYSTEM
The values of certain levels programmed in the “PARAMETER CHANGE” main menu are displayed in
different ways depending on how the “PERFORMANCE TYPE” parameter in the config. menu “SET
OPTIONS” is set on the SICOS display module.
“PERFORMANCE TYPE” can be set in four different modes by means of the console (see following
numbers) or directly by means of the button on the display (see description):
0) “SLOW” = Cutback speed 1 activation

1) “SOFT” = Reduction of parameters “ACCELERATION DELAY”, “RELEASE BRAKING”,
“INVERSION BRAKING” and “MAX SPEED” by one level.
2) “STDN” = Parameters programmed from the console
3) “HARD” = Increase of parameters “ACCELERATION DELAY”, “RELEASE BRAKING”,
“INVERSION BRAKING” and “MAX SPEED” by one level.
NOTE: In order to change the value of the parameters in the “PARAMETER CHANGE” of the AC2
traction inverter you must have the parameter “PERFORMANCE TYPE” of the SICOS 2 (the display
must indicate the letters STDN).
MODULE (DISPLAY) PARAMETERS AC2 TRACTION

HOUR COUNTER RUNNING KEYON
SET OPTIONS
BATTERY CHECK ON OFF

CONFIG MENU'
STOP ON RAMP ON OFF

AUX OUTPUT Brake
PEDAL BRAKING Digital Analog
SET BATTERY TYPE 48V
ADJUST
ADJUST BATTERY 51,6V

ADJUSTMENT # 1 LEVEL 3
ADJUSTMENT # 2 LEVEL 5
ACCELER. DELAY 1 Max = 9
RELEASE BRAKING 7 Max = 9
PARAMETER CHANGE
INVERS. BRAKING 8 Max = 9

PEDAL BRAKING 9 Max = 9
MAIN MENU'
MAX SPEED FORW . 105 Hz Min 95Hz - Mx 114Hz

MAX SPEED BACK 105 Hz Min 95Hz - Mx 114Hz
CURVE CUTBACK 44%
STEER DEAD ANGLE 6%
FREQUENCY CREEP 1,20 Hz
MAXIMUN CURRENT 7 Max = 9
AUXILIARY TIME 1.5 Min 0sec - Max 5sec

4.1 PARAMETER TABLES

MODULE 5 AC2 PUMP
ELECTRICAL SYSTEM
M O DULE (DIS P L AY) P ARAM ET ERS AC2 P UM P
SET OPTIONS
CONFIG MENU'
HO UR CO UNTE R RUNNING KE YON

ADJUST
S E T B A TTE RY TY P E 48V
A DJUS T B A TTE RY 51,6V

PARAMETER CHANGE
MAIN MENU'
M A XIM UN CURRE NT 7 M ax 9

MODULO 6 EPS-AC
M ODULE (DIS P LA Y ) P A RA M E TE RS E P S -A C S TE E RING

SET OPTIONS
HOUR COUNTE R RUNNING K E Y ON

CONFIG MENU'
A UTO IM P UT A CTIV E 1
RA NGE 360 ON OFF
SET S TE E R 0-P OS . 5.000V

ADJUST
SET M IN. E NCODE R 2,5V

SET M A X E NCODE R 7,2V
SET 180 E NCODE R 10.0V
S P E E D LIM IT 7 M ax = 9
PARAMETER CHANGE
A UX FUNCTION 3 5 M ax = 9
MAIN MENU'
S E NS IB ILITY 0 M ax = 9
A UX FUNCTION 2 5 M ax = 9
CRE E P S P E E D 5 M ax = 9
COM P E NS A TION 2 M ax = 9
A UXILIA RY TIM E 2 M ax = 9
A NTIROLLB A CK 40% M in 0% M ax 70%


MHYRIO MODULE 9
ELECTRICAL SYSTEM
M ODULE (DIS P LAY) P ARAM ETERS M HYRIO

E V 2 TY P E OP TION # 2
SET OPTIONS
OP TION # 1
CONFIG MENU'
E V 5TY P E
S E T B A TTE RY TY P E 48V
ADJUST
Not available Not available

PARAMETER CHANGE
MAIN MENU'
4.4 SICOS MODULE 16

PARAMETERS TABLE
S ICOS M ODULE (DIS P LA Y ) P A RA M E TE RS

P E RFORM A NCE TY P E 0
HOUR COUNTE R RUNNING K E Y ON
SET OPTIONS
E NCODE R TY P E 0 1
LOA D S E NS OR ON OFF
CONFIG MENU
P RE -HE IGHT S E LE CTOR ON OFF

P A S S W ORD ON OFF
A UX FUNCTION 1 ON OFF
OP TIONA L 1-2 HY D ON OFF
A UTOM A TIC W E IGHT ON OFF
PARAMETER CHANGE ADJUST
E NCODE R A DJUS TM E NT 127 M in 1 M ax 255

MAIN MENU

SERVICE Section: ELECTRIC SYSTEM
4.4.1 MODULE 16 “SICOS” PARAMETER TABLE
This table does not substitute the previous one, but it is an integral part of it.
The update refers to the weighing function enabling
ELECTRIC
The update begins from the serial number of Module 16 “SICOS” P/N 300206213
MODULE 16 "SICOS" PARAMETERS

PARAMETER LEVEL
PERFORMANCE TYPE 0 1-2-3
HOUR COUNTER RUNNING KEY ON
SET OPTIONS
ENCODER TYPE 0 1
AUX INPUT 1 0 1-2
CONFIG MENU
PRE-HEIGHT SELECTOR ON OFF

PASSWORD ON OFF
AUX FUNCTION ON OFF
OPTIONAL 1-2 HYD ON OFF
AUTOMATIC WEIGHT ON OFF
ENCODER ADJUSTMENT 127 Min. 1 Max 255
ADJUST
ADJ 2000 KG POIN 2000 Kg value to be stored

PARAMETER CHANGE
MAIN MENU
UPDATES TO BE INSERTED IN TO THE SERVICE MANUAL R1.4/2.5

SECTION "ELECTRIC SYSTEM"
Release Update description Page
1 4.4.1 New Module 16 "SICOS" parameter table 22
2 4.5.1 New Module 1 "CAN I/O" parameter table 23
UPDATE 0 1 2 3 4 5 6 Date: March 2004 Comp. No.: 1517320 Page: 22a

Section: ELECTRIC SYSTEM SERVICE
ELECTRIC
Page: 22b Comp. No.: 1517320 Date: March 2004 0 1 2 3 4 5 6 UPDATE


CAN I/O MODULE 1
ELECTRICAL SYSTEM
MODULE (DISPLAY) PARAMETERS CAN I/O
CHECK UP TYPE 0 1
HOUR COUNTER RUNNING KEYON
SET OPTIONS
BATTERY CHECK ON OFF

CHECK UP DONE ON OFF
CONFIG MENU'
SEAT SWITC ON OFF

SINGLE FUNCTION ON OFF
AUX FUNCTION 1 ON OFF
0% Max 17%
ADJUST
THROTTLE 0 ZONE
THROTTLE X ZONE 45% Min 18% Max 100%
THROTTLE Y ZONE 47% Min 4% Max 100%
CUTBACK SPEED 1 3 Max = 9
CUTBACK SPEED 2 3 Max = 9
1 ST SPEED COARSE 9 Max = 9
5 ST SPEED COARSE 6% Max = 9
PUMP CREEP # 1 0 Max = 9
PUMP CREEP # 2-3 0 Max = 9
PARAMETER CHANGE

MAIN MENU'
LIFT SPEDD CTB 8 Max = 9

LOW SPEED CTB 8 Max = 9
SPEED 2 CUTBACK 3 Max = 9
PUMP ACC. # 1 0 Max = 9
PUMP ACC. # 2-3 3 Max = 9
PUMP ACC. # 4-5 2 Max = 9
PUMP DEC DELAY 1 Max = 9
PU DEC DEL # 2-3 5 Max = 9
ADJUST # 2 4 Max = 9
PRE-H. LIFT CTB 5 Max = 9
PRE-H. LOW CTB 5 Max = 9
OPTION 03 5 Max = 9
OPTION 04 5 Max = 9
OPTION 05 5 Max = 9
OPTION 06 5 Max = 9

Section: ELECTRIC SYSTEM SERVICE
4.5.1 MODULE CAN I/O PARAMETER TABLE
This table does not substitute the previous one, but it an integral part of it.
The updates concern the possibility of disabling the reduction speed function with the carriage completely
ELECTRIC
extended.
The update begins from the serial number of Module 1 “CAN I/O” P/N 300208628
MODULE 1 "CAN I/O" PARAMETERS

PARAMETER LEVEL
CHECK UP TYPE
HOUR COUNTER
SET OPTIONS
BATTERY CHECK
CHECK UP DONE
SEAT SWITCH
CONFIG MENU
SINGLE FUNCTION
AUX FUNCTION 1
AUX FUNCTION 2
AUX FUNCTION 3
SPEED LIMIT
ADJUSTMENT
Not available
CUTBACK SPEED 1 3 Min = 0 Max = 9

CUTBACK SPEED 2 3 Min = 0 Max = 9
1ST SPEED COARSE 9 Min = 0 Max = 9
2ND SPEED COARSE 6 Min = 0 Max = 9
3RD SPEED COARSE 7 Min = 0 Max = 9
4TH SPEED COARSE 6 Min = 0 Max = 9
5TH SPEED COARSE 6 Min = 0 Max = 9
PUMP CREEP # 1 0 Min = 0 Max = 9
PUMP CREEP # 2-3 0 Min = 0 Max = 9
PARAMETER CHANGE

MAIN MENU
LIFT SPEED CTB 8 Min = 0 Max = 9

LOW SPEED CTB 8 Min = 0 Max = 9
SPEED 2 COT BACK 3 Min = 0 Max = 9
PUMP ACC # 1 0 Min = 0 Max = 9
PUMP ACC # 2-3 3 Min = 0 Max = 9
PUMP ACC # 4-5 2 Min = 0 Max = 9
PUMP DEC DELAY 1 Min = 0 Max = 9
PUMP DEC # 2-3 5 Min = 0 Max = 9
ADJUST # 1 4 Min = 0 Max = 9
PRE-H. LIFT CTB 3 Min = 0 Max = 9
PRE-H. LOW CTB 3 Min = 0 Max = 9
OPTION 03 5 Min = 0 Max = 9
Page: 23a Comp. No.: 1517320 Date: March 2004 0 1 2 3 4 5 6 UPDATE

SERVICE Section: ELECTRIC SYSTEM
ELECTRIC
UPDATE 0 1 2 3 4 5 6 Date: March 2004 Comp. No.: 1517320 Page: 23b

5.0 ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS MODULES

MODEL ALL MODELS
ELECTRICAL SYSTEM
MODULES CAN BUS

CONNECTION DIAGRAM
Fig. 6
Each module (controller) is identified by a number. Thanks to the CAN BUS connection you can access
programming of each module by means of the “SET MODEL MENU”, using the console to connect to any
module by typing the relevant address.
When a module assumes alarm status it inhibits all the other module by means of a signal transmitted
on the CAN BUS. The display shows a description of the alarm and an indication of the module concerned.
The most accessible module on the reach truck for connection of the programming console is the “EPS”
which is accommodated behind the seat. To access this module simply move the seat forward and
remove the “EPS” connector cover working through the opening in the truck body panel (Ref. A Fig. 9); now
insert the console connector. For the access procedure to find the module required, refer to the sequence
of operations described on the next page.
NOTE: Before connecting the console

to the module, set the keyswitch
to OFF.
Fig. 8
Fig. 7 A Fig. 9

5.1 MODULE SEARCH PROCEDURE
ELECTRICAL SYSTEM
MODEL ALL MODELS
CONFIG. MENU / SET MODEL
EPS-AC NA 0.15 1) Initial display

DISPLAY 48V 300 A 0000
2) Press ROLLUP+SETUP simultaneously

KEYPAD
3) The heading of the SET MODEL menu is displayed

CONFIG MENU
SET MODEL
4) Press ENTER
5) A number is displayed corresponding to the connected

module
CONNECTED TO
1
6) Use SET UP or SET DOWN to select a different
connected module
CONNECTED TO 7) The newly selected module is displayed

5
8) Press OUT to quit the selection procedure
9) A prompt asking you to confirm the change is displayed

ARE YOU SURE?
YES=ENTER NO=OUT
10) Press ENTER to confirm or OUT to cancel the change
11) The heading of the SET MODEL menu is displayed

CONFIG MENU
SET MODEL
12) Press ROLL DOWN, ENTER, and SET DOWN
simultaneously
13) The display will show the screen relative to the

AC2P 2B NA 0.21 selected module from which you can view/edit all the
48V 300 A 0000 associated menus
Fig. 10

5.2 AC2 TRACTION INVERTER BATTERY VOLTAGE SETTING

MODEL ALL MODELS
ELECTRICAL SYSTEM
Before handing over the truck to the end customer, it is indispensable to set the battery voltage on the “AC2
Traction” inverter and on the “AC2 Pump” inverter.
Before making these settings it is advisable to execute a supplementary charge of the truck battery to
ensure that it is able to deliver the maximum voltage.
With the truck switched off connect the programming console to the “EPS-AC” module (see procedure
on page 17) and execute the procedure for selection of the “AC2 Traction” inverter “module 2” (see
procedure on page 18); now select “MAIN - MENU - ADJUSTMENT” and select the “ADJUST
BATTERY” parameter.
Use a tester to check the exact battery voltage on the “AC2 Traction” inverter between -Batt. (negative
power connection to the inverter) and the positive as present on pin 1 of connector F keyswitch input (Fig.
11); this value must be entered in the “ADJUST BATTERY” parameter.
Select “AC2 Pump” inverter module 5 and set the same value in the “ADJUST BATTERY” parameter
of the main menu “ADJUSTMENT”. Switch off the keyswitch and then power on again to store the new
settings.
If when the truck is switched on with the battery fully charged the display should indicate a battery charge
of 90%, increase the value of the “ADJUSTMENTS # 1” parameter in the “CONFIG MENU’”.
This setting is indispensable to obtain the correct battery charge reading on the display.
“AC2 TRACTION” INVERTER
+ -
Fig. 11

6.0 TRACTION START SEQUENCE

MODEL ALL MODELS
ELECTRICAL SYSTEM
When you board the truck, before starting observe the sequence described
below.
6.1 TRUCK WITH TRAVEL DIRECTION REVERSAL PEDAL
CONTROL
1) Set the keyswitch to ON and activate the main circuit breaker.
2) Press the deadman button (SW3 Fig. 15). Fig. 12
3) Select forward or reverse travel buy pressing the relevant button
(SW12 or SW13 Fig. 15).
4) Press the accelerator. SW13
NOTE: If this sequence is not executed, the alarm “INCORRECT START”
SW12
will appear on the display.
If you release the deadman control the truck hydraulic functions will
remain enabled for 1 minute. At the end of the function the
“INCORRECT START” alarm will be shown on the display. SW3
6.2 TRUCK WITH TRAVEL DIRECTION REVERSAL CONTROL
ON THE INSTRUMENT PANEL Fig. 15
2) Press the deadman button (SW3 Fig. 20).
3) Select forward or reverse travel by pressing the relevant button
(SW25 or SW26 Fig. 19-21).
4) Press the accelerator.
NOTE : If this sequence of operations is not observed the “INCORRECT
START” alarm will appear on the display.
If the deadman control is released the truck hydraulic functions will
remain enabled for 1 minute. At the end of the function the Fig. 13
“INCORRECT START” alarm will appear on the display.
SW26 SW25
SW3
Fig. 19
Fig. 21 Fig. 20 Fig. 14
SW26 SW25
Fig. 18 Fig. 17 Fig. 16

6.3 HYDRAULIC FUNCTIONS START SEQUENCE

MODEL ALL MODELS
ELECTRICAL SYSTEM
For the hydraulic functions perform the following sequence:
2) Press the deadman button (SW3 Fig. 23).
3) Select the required hydraulic function (depending on the group of joysticks installed on the truck
(Fig. 24)
NOTE: If you release the deadman control the hydraulic functions will remain enabled for 1 minute, after
which the “INCORRECT START” alarm will be shown on the display.
1 JOYSTICK 2 JOYSTICKS 4 JOYSTICKS
Fig. 24
SW3
Fig. 23 Fig. 22

7.0 SPEED CUTBACK
ELECTRICAL SYSTEM
This heading describes all the speed cutback options available on the truck.
7.1 BATTERY TROLLEY OUT OF POSITION (BATTERY EXTRACTED

In these circumstances the truck travel controls are inhibited and the only available hydraulic function is
reach carriage extend/retract. It is still possible however to move the truck by pressing the button
on the display.
7.2 BATTERY DISCHARGED BY MORE THAN 80%

In these circumstances the “BATTERY LOW” alarm is shown on the display. In addition to inhibiting the
forks lift function, the truck traction function is reduced to 50% of the maximum available current.
This parameter cannot be modified from the programming console.
7.3 FAULTY STEER WHEEL CENTRED SENSOR

In this case the steering function remains active but truck travel speed is reduced by 50% of the maximum
available current (Alarm “EPS NOT ALIGNED”)
7.4 SPEED CUTBACK WITH FORKS LIFTED BEYOND THE FREE

LIFT HEIGHT
This function is possible only in the presence of (SW5 Fig. 25) connected to Mhyrio
Module 9 (see electrical diagram). Function adjustable with the programming
console by means of the parameter “CUTBACK SPEED 2” of the CAN I/O Module
1 parameter change menu. It is advisable to maintain this parameter as per the
SW5
factory setting.
Fig. 25
7.5 SPEED CUTBACK WITH PUSHBUTTON (SLOW)
Function adjustable from the programming console by means of the parameter “CUTBACK SPEED 1”
of the CAN I/O Module 1 parameter change menu. It is advisable to maintain this parameter as per the
factory setting.
7.6 SPEED CUTBACK WITH DRIVE WHEEL IN STEERING TURN

This function provides speed reduction that increases progressively to the maximum value, which
corresponds to the value entered in the “CURVE CUTBACK” parameter (Parameter Change menu of AC2
Traction Inverter Module 2).
When the wheel is steered through an angle of 90°, the angle percentage with respect to the centred wheel
within which maximum speed is still available can be defined by means of the parameter “STEER DEAD
ANGLE” (AC2 Traction Inverter Module 2 Parameter Change menu).
It is advisable to maintain the parameters recommended by the manufacturer.
7.7 SPEED CUTBACK WITH REACH CARRIAGE EXTENDED

In these circumstances with the reach carriage fully extended the truck travels with a speed reduction
corresponding to 50% of the maximum available current.

8.0 MODULES REPLACEMENT PROCEDURE

ELECTRICAL SYSTEM
The following headings contain a description of the procedure for replacing each individual module in such
a way that at the end of the operation the truck operates in exactly the same way as with the original
modules.
Note: Ensure you perform this procedure without skipping any of the steps in the sequence.
Incorrect operations could damage the new module.
Before replacing any of the modules check the table of settings relative to the module as shown in the
manual and compare them with the parameters stored on the module in the PARAMETER CHANGE and
SET OPTIONS submenus. The values could be different depending on the options enabled.
At the end of the replacement operation always check that the new module is programmed in exactly the
same way as the original module.
8.1 REPLACING MODULES 2 OR 5 - TRACTION OR PUMP INVERTER AC2
Before starting the replacement procedure save the controller settings on the console by means of the
SAVE PARAMETERS submenu present in the MAIN MENU (for more details refer to the “AC MOTORS
MODULAR CONTROL SYSTEM” manual).
1) Switch off the keyswitch an press the emergency pushbutton.
2) Disconnect the battery.
3) Only when the battery is disconnected: connect a resistor of between 33 and 100 Ohm 50W across
the inverter positive B+ and negative B-. Wait for approximately 8 seconds while for the controller
internal capacitors to discharge and then disconnect the resistor.
Note: To avoid short-circuits ensure that the resistor is insulated.
If it is impractical to use an external resistor to discharge the capacitors you must wait at least 90
seconds before disconnecting any of the power cables.
1234
1234
60 Ohm 50W
1234
1234
RESISTOR
1234
1234
1234
1234
Fig. 26

4) Disconnect the power cables, ensuring that they are still marked in relation to the corresponding
connectors; if the cables are not marked, mark them before disconnecting.
ELECTRICAL SYSTEM
5) Disconnect auxiliary connectors C,D,F. In the case of the PUMP inverter, remember to disconnect the
jumper on connector B to apply it to the new controller. Without this jumper the system is unable to
operate. This jumper is not present on the TRACTION inverter.
TRACTION MOTOR
POWER CABLES
BATTERY CABLES
D2
A2 B2 C2
F2 E2
Fig. 27
PUMP MOTOR
POWER CABLES
BATTERY CABLES
D5
A5 B5 C5
F5 E5
Fig. 28

6) Unscrew the screws that secure the controller to the truck and remove the inverter.
ELECTRICAL SYSTEM
7) Install the new module fitting the screws, connectors and cables in accordance with a reverse
sequence of operations with respect to the removal procedure. Remember that connector B of the
PUMP inverter must be equipped with a jumper.
8) Connect the console to the inverter
9) After having checked the correct connection of the cables, connect the battery, reset the emergency
switch and set the keyswitch to ON.
10) By means of the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller
the module settings previously saved to the console by means of the SAVE PARAMETERS
procedure.
11) With the assistance of the table in the manual check that all the PARAMETER CHANGE and SET
OPTIONS submenu settings correspond.
12) Test all the truck functions.
8.2 REPLACING MODULE 1 - CAN I/O
Note: the CAN I/O module is identical in terms of size, shape, and connector positions, to the MHYRIO
module. Therefore, when replacing this module pay special attention to the identification label on the
outer case.
The truck duty hours are stored on the CAN I/O and SICOS (display) modules. If it should become
necessary to renew the CAN I/O module you must first execute a procedure that makes it possible to
transfer the duty hours value stored in the display to the new CAN I/O module.
1) With the keyswitch set to OFF connect the console to the SICOS module (display). Set the keyswitch
to ON.
2) In the CONFIG MENU>SET OPTIONS submenu set the AUX FUNCTION 1>parameter to OFF.
This allows the CAN I/O module to set up to receive the truck duty hour data stored on the DISPLAY.
Before starting the replacement procedure remember to save the controller settings to the console by
means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to
the “AC MOTORS MODULAR CONTROL SYSTEM” manual).
3) Switch off the keyswitch and press the emergency pushbutton.
5) Disconnect all the connectors after checking that their positions are clearly identified.
6) Unscrew the screws that secure the module to the truck and remove the module.
7) Install the new module, fitting the screws and connectors by following the removal steps in reverse
order.
8) After having checked that the connectors are correctly inserted, connect the console to the CAN I/O
module by means of the adapter that you removed from the faulty module and then inserted on the
relative connector of the new CAN I/O module.
9) Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.

10) With the console, via the RESTORE PARAMETERS submenu present in the MAIN MENU upload
to the controller the settings of the module previously saved on the console by means of the SAVE
ELECTRICAL SYSTEM
PARAMETERS procedure.
11) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE
and SET OPTIONS submenus correspond, including any option settings.
8.3 REPLACING SICOS MODULE 16 (display)
The truck duty hours are stored on the SICOS module and CAN I/O bus. If you need to replace the
SICOS module you must perform a procedure that makes it possible to transfer the duty hours memorized
on the CAN I/O to the SICOS.
1) With the keyswitch set to OFF connect the console to the SICOS module. Set the keyswitch to ON.
2) In CONFIG MENU>SET OPTIONS set the parameter AUX FUNCTION 1>to OFF.
In this manner the SICOS module sets up to accept the truck operating hours stored on the CAN I/
O bus.
3) Switch off the keyswitch and press the emergency pushbutton.
6) Unscrew the screws that secure the module to the truck and remove the module.
order.
8) After having checked that the connectors are correctly inserted, connect the console to the SICOS
relative connector of the new SICOS module.
9) Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.
10) Using the console, by means of the RESTORE PARAMETERS submenu located in the MAIN
MENU, download to the controller the settings of the original module saved on the console by means
of the SAVE PARAMETERS procedure.
11) With the assistance of the table in the manual check that all the adjustments relative to the
PARAMETER CHANGE and SET OPTIONS submenus correspond, including possible changes
relative to the option settings.
Note: If the options “PASSWORD” or “PRE-HEIGHT SELECTOR” were enabled on the previous
display, these functions must be completely reset by means of the new display (see relative
heading).

8.4 REPLACING MODULE 9 - MHYRIO

ELECTRICAL SYSTEM
1) Set the keyswitch to OFF and press the emergency pushbutton.
4) Unscrew the screws that secure the controller to the truck and remove the module.
order.
6) After having checked that the connectors are correctly inserted, connect the console to the MHYRIO
relative connector of the new MHYRIO module.
7) Connect the battery, activate the emergency switch and set the keyswitch to ON.
8) With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU,
download to the controller the module settings previously saved to the console by means of the SAVE
8.5 REPLACING MODULE 6 - EPS-AC
1) Set the keyswitch to OFF and press the emergency pushbutton.
4) Unscrew the screws that secure the controller to the truck and remove the module.
order.
6) After having checked that the connectors are correctly inserted, connect the console to the EPS-AC
relative connector of the new EPS-AC module.

7) Connect the battery, activate the emergency switch and set the keyswitch to ON.
ELECTRICAL SYSTEM
8) With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU,
download to the controller the module settings previously saved to the console by means of theSAVE
10) Perform the most appropriate EPS-AC setup procedure depending whether or not the 360° steering
or +90° -90° steering option is enabled (see “EPS-AC” manual).
NOTES:

9.0 SICOS (DISPLAY)

ELECTRICAL SYSTEM
9.1 GENERAL DESCRIPTION OF CONTROL COMPONENTS AND INSTRUMENTS

The following section contains a description of the controls indicated on the display, the position of the
controls, and their method of use.
1 17 16 2 3 4 15
S
+ -
100
50 OP
F
20
T Kmh 00 01
12 5 10 6 7 8 9
14 13 11 Fig. 29
9.2 TABLE OF DISPLAY SYMBOLS WITH DESCRIPTIONS

Ref. Description
1 Auxiliary hydraulic function (5th function) selector button
2 Traction permissive selection button with battery out
3 Parking brake function selector button
4 Traction mode selector button
5 LCD screen
6 Numerical keypad for altimeter / pre-height selector settings (when installed)
7 ENTER' key to use during reading of the various display menus
8 UP and DOWN keys to use during reading of the display menus
9 Out key to use during reading of the display menus
10 Indicator for truck speed, hour meter, forks height, alarms on module
11 Travel direction and drive wheel rotation indicator
12 Hour meter running indicator
13 Parking brake indicator
14 Battery charge status indicator
15 Selected hydraulic function indicator
16 Speed cutback indicator
17 Selected traction functional mode indicator

9.3 BATTERY CHARGE STATUS INDICATOR
ELECTRICAL SYSTEM
Provides a proportional reading of battery charge status. The AC2 traction inverter reads the battery voltage
and transmits the information to the display. Battery charge status is shown on the display by means of
ten lines, each of which corresponds to 10%. When the battery charge falls to 30%, the corresponding
three lines start flashing. At this point it is advisable to charge the battery. When battery charge reaches
20%, Traction inverter AC2 transmits a message to the display to give a 20% charge reading, and another
message to the AC2 pump controller instructing it to inhibit the lift function, leaving only the reach carriage
operational. Furthermore, the available traction current is reduced by 50% (this precaution serves to allow
the truck to proceed to the charging station) (Fig. 30).
NOTE: The battery charge indicator can operate correctly only if the ADJUST BATTERY procedure has
been performed correctly prior to delivery of the truck (see the section of the manual regarding the
electrical system).
S
+ -
100
Battery
charge 50 O
F
indicator
20
T Kmh 00 01
Fig. 30
9.4 SPEED CUTBACK INDICATOR

This indicator is activated when ‘SLOW’ traction mode is selected (Fig. 31) pressing the button with
the symbol , (the display presents the same symbol). Or when the following speed reduction
speed states are tripped:
- Reach carriage extended (50% current supplied to traction motor, not adjustable).
- Forks height above free lift height (SW5 mast sensor connected to MHYRIO unit; speed cutback
intensity is adjustable by means of CUTBACK SPEED 2 in CAN I/O).
Speed
cutback
selector
button
S
+ -
100
50 O P
Speed F
cutback
20
T Kmh 00 01
indicator
Fig. 31

9.5 TRAVEL DIRECTION AND DRIVE WHEEL ROTATION INDICATOR

ELECTRICAL SYSTEM
This indicator performs the following three functions: indication of truck forward travel direction, reverse
travel direction and drive wheel rotation (in 45° steps).
The drive wheel angular position and truck travel direction are shown by the arrow positioned inside the
truck logo.
When the truck is in use the arrow illuminates in accordance with the forward/reverse travel selector when
the operator presses the accelerator pedal. The arrow shows the travel direction of the truck with respect
to the seated operator; the right hand arrow illuminates when the truck proceeds in reverse, while the left
hand arrow indicates that the truck is travelling forward (Fig. 32)
S
+ -
100
50 O
F
20
T Kmh 00 01
Travel direction
and drive wheel
rotation
indicator Fig. 32
9.6 SELECTED HYDRAULIC FUNCTION INDICATOR
An arrow on the display indicates the type of hydraulic movement being performed: reach carriage extend/
retract, lift/lower, tilt back/forward (Fig. 33).
S
+ -
100
Selected
50 OP hydraulic
F
20
T Kmh 00 01 function
indicator
Fig. 33

9.7 SELECTED TRACTION OPERATING MODE INDICATOR
ELECTRICAL SYSTEM
Indicates the traction mode selected by means of the relevant pushbutton ; this function allows
the operator to personalize truck traction functions without requiring the intervention of a skilled
technician.
There are four different preset levels that are shown on the display:
SLOW / STND / SOFT / HARD
SLOW - Maximum speed settable by means of the console connected to the CAN I/O module,
edit the CUTBACK SPEED 1 parameter.
STND - The acceleration, release braking, and top speed parameters
programmed in the AC2 Traction Inverter module are applied.
SOFT - The acceleration, release braking, and top speed functions are executed at a level below
the levels programmed in the AC2 Traction Inverter module 2.
HARD - The acceleration, braking, release braking, and top speed functions are executed at
a level above the levels programmed in AC2 Traction Inverter module 2 (Fig. 34).
S
+ -
100
50 O
F
20
T Kmh 00 01
Selected traction
mode indicator
Fig. 34
9.8 HOUR METER RUNNING INDICATOR
Flashes during execution of any of the truck functions, thereby indicating that the hour meter is running
(Fig. 35).
S
+ -
100
50 O
F
20
T Kmh 00 01
Hour meter
running
indicator Fig. 35

9.9 INDICATOR FOR TRUCK SPEED, TRUCK HOUR METER, FORKS HEIGHT,
MODULE ALARM
ELECTRICAL SYSTEM
HOUR METER / SPEEDOMETER
For two seconds after the truck is switched on this meter indicates the total truck duty hours, reading the
value stored on the CAN I/O module; the indication is subsequently replaced by a display of the truck speed.
To display the truck duty hours without turning off the keyswitch press the ENTER key to access the main
menu and then the OUT key to exit. This action will generate a two-second display of truck duty hours.
NOTE:When the SICOS or CAN I/O module is replaced the truck duty hours can be retained (see
below).
PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE CAN I/O MODULE
Before renewing the CAN I/O module use the console to check that AUX FUNCTION 1 in SICOS is set to
OFF, and then change the CAN I/O module by following the directions on page 30. When the truck is
switched on the RESET HOUR METER alarm is displayed. After 1 minute the alarm message will be
cleared and the duty hours memorized in SICOS will be transferred to the CAN I/O module and shown on
the display.
PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE SICOS MODULE
Change the SICOS module in accordance with the directions on page 31. When the truck is switched on
the RESET HOUR METER alarm will be displayed; at this point you have one minute to connect the console
to the SICOS module and change AUX FUNCTION 1 from OFF to ON. This done, the RESET HOUR
METER alarm will be cleared and the duty hours memorized on the CAN I/O module will be shown on the
display. We recommend resetting AUX FUNCTION 1 in SICOS from ON to OFF (default value) when the
operation is terminated.
SPEED/MODULE ALARM
If an alarm is generated, the relevant name and the module on which the alarm is present will be shown
in place of the truck speed display. To perform additional diagnostics the programming console must be
connected to the faulty module.
SPEED/FORKS HEIGHT INDICATION
When a forks height indicator is installed with the relative correctly calibrated encoder, the height of the
forks is displayed in place of the truck speed (Fig. 36).
S
+ -
100
50 O
F
20
T Kmh 00 01
Indicator of truck speed,
hour meter, module alarm
Fig. 36 forks height

9.10 PARKING BRAKE SELECTOR BUTTON PARKING BRAKE INDICATOR
ELECTRICAL SYSTEM
The parking brake must be applied by pressing the relevant button with the “P” symbol; at this point
the display will shown the letter “P” and all drive functions are inhibited, although the truck’s hydraulic
functions remain active. When the button is pressed again the parking brake is released and truck
drive functions are re-enabled (Fig. 37).
ATTENTION The parking brake selector can be activated only when the keyswitch is set
to 1 (ON). Do not use the parking brake as a service brake during normal operation of the truck.
Parking brake
selector button
S
+ -
100
Parking brake
50 O P
indicator F
20
T Kmh 00 01
Fig. 37
9.11 AUXILIARY HYDRAULIC FUNCTION SELECTION BUTTON (5th FUNCTION)
Enables an auxiliary hydraulic function (5th function). The function must be set initially with the programming
console connected to the SICOS module, selecting “CONFIG MENU’ - SET OPTIONS”, and subsequently
selecting the parameter “OPTIONAL 1-2 HYDRAUL VALVE ON/OFF”.
When level OFF is selected the pushbutton has no effect.
When level ON is selected the function is shown in place of the forks down indicator by means of an icon
representing a hydraulic gripper (Fig. 38).
Auxiliary
hydraulic
function
selection button
(5th function)
+
100
-
S The fork logo

50 O P changes and
F
20
T Kmh 00 01 is replaced
with a
hydraulic
Fig. 38 gripper icon

9.12 TRACTION PERMISSIVE WITH BATTERY OUT FUNCTION SELECTOR BUTTON

ELECTRICAL SYSTEM
This button serves to allow limited truck traction mobility in order to facilitate a battery change.
When, during loading and unloading of a battery to and from the battery change rollerway, it becomes
necessary to move the truck slightly backwards or forwards, the truck safety systems prevent the normal
travel controls from being used. In these circumstances, to move the truck the operator, seated at the
controls, must press the relevant permissive button and then press the accelerator pedal.
The resulting travel speed corresponds to 50% of the current available at Vmax. This value cannot be
adjusted by means of the console (Fig. 39).
ATTENTION This control must not be used during normal working procedures. Pressing
this button at any speed would result in intensive deceleration.
Traction with
battery out
permissive
function
selector button
S
+ -
100
50 O
F
20
T Kmh 00 01
Fig. 39
10.0 DISPLAY MENU
10.1 MAIN MENU 1
Press the ENTER key to access the main menu 1 (Fig. 40). Pressing the ENTER key from a given position
of the cursor arrow opens the page relative to the selected option.
The MAIN MENU 1 submenus are described in the following headings.
main menu 1
TESTER SLAVES
ALARMS
PROGRAM OFFSET
INSERT PASWORD
Fig. 40

10.2 TESTER MENU
ELECTRICAL SYSTEM
When you enter the TESTER menu you will be presented with the most important information relative to
the traction motor inverter and pump motor inverter status and the operating hours of the various modules
(Fig. 41). To go from tester screen 1 to tester screen 2 and then tester screen 3, press the DOWN ARROW
KEY (Fig. 41).
tester 1
CURRENT TRACTION = 004 AMP.
VOLTAGE TRACTION = 009 %
FREQUENCY TRAC. = 000 HERZ
TEMPERATURE TR. = 025 GRADI
tester 2
CURRENT PUMP = 004 AMP.
VOLTAGE PUMP = 009 %
FREQUENCY PUMP = 000 HERZ
TEMPERATURE PU. = 026 GRADI
tester 3
TR.HOUR COUNTER = 00011
PU. HOUR COUNTER = 00006
EPS HOUR COUNTER = 00003
EV HOUR COUNTER = 00129
Fig. 41
10.3 ALARMS MENU

When you open the ALARMS menu you will be presented with the last 5 alarms stored with the information
regarding the module concerned, the number of times the alarm has occurred, the temperature, and the
time of the alarm (Fig. 42). Press OUT to display the message CLEAR ALARMS, at this point press OUT
to leave the alarms in the memory, or press ENTER to erase them.
ALARMS HOURS NUM NTC MOD

1)BATTERY OUT 0001 01 17 1
2)HEIGHT ENC. ERROR 0003 04 29 1
3)CAN BUS KO 0003 01 29 2
4)BATTERY OUT 0003 01 27 1
5)NULL
Fig. 42

10.4 PROGRAM OFFSET

ELECTRICAL SYSTEM
To be set exclusively when either the forks height indicator or the vertical pre-height selector is present.
The height indicator encoder installed on the mast starts reading at the end of the free lift. The PROGRAM
OFFSET parameter makes it possible to program the free lift height in millimetres. This value will be added
by the display module to the height indicator encoder count value.
1. KEY ON
2. Lift the forks up to the free lift before the mast sections begin to extend. Measure the distance of the forks
from the ground in millimetres.
3. Press ENTER on the display to enter MAIN MENU 1.
4. Select the PROGRAM OFFSET menu using the up arrow / down arrow keys.
5. Press the ENTER key on the display to enter PROGRAM OFFSET .
6. Set the forks height from the ground value in millimetres using the display numerical keypad.
7. Press ENTER on the display: the message ‘MEMO’ will appear to confirm that the settings have been
saved.
8. KEY OFF and then KEY ON to save all settings (Fig. 43).
ADJUSTMENT
OFFSET VALUE 02150
Fig. 43
10.5 INSERT PASSWORD

This submenu serves to input the password that provides access to use of the truck when this option is
programmed (see PROGRAM PASSWORD heading). If the option is not set, selecting this function will
automatically return you to the main menu.
10.6 MAIN MENU 2
In addition to MAIN MENU 1, there is a second menu designated MAIN MENU 2. This menu is ‘concealed’
from the operator and can be accessed by holding down the OUT key while setting the keyswitch to ON.
In this case MAIN MENU 1 will appear and MAIN MENU 2 can be accessed by means of the down arrow
key.
main menu 1
TESTER SLAVES ENTER
ALARMS
PROGRAM OFFSET
INSERT PASWORD
main menu 2
PROGRAM BLOCK DOWN
PROGRAM PASSWORD ARROW
READ USERS
Fig. 44

By pressing the ENTER key with the cursor arrow positioned on a given option, you will automatically
open the page relative to the option in question.
ELECTRICAL SYSTEM
The MAIN MENU 2 submenus are described in the following headings (Fig. 44).
10.7 PROGRAM BLOCK

Serves to set an electrical lifting limit stop.
This function is available solely when the pre-height selector or height indicator is installed.
CALIBRATION PROCEDURE
1. KEY ON pressing the OUT key simultaneously, the MAIN DISPLAY appears.
S
+ -
100
50 O
F
20
T Kmh 00 01
Fig. 45
2. Press the ENTER key on the display to enter MAIN MENU 1.

3. Select the PROGRAM OFFSET menu with the down arrow / up arrow and check that the programmed
free lift value is correct.
4. Press the OUT key on the display twice in succession to return to the MAIN DISPLAY.
5. Lift the forks until you reach the desired height.
7. Enter MAIN MENU 2 by pressing the DOWN ARROW key.
8. Press the ENTER key on the display to enter the PROGRAM BLOCK function.
autoteaching
HEIGHT VALUE = 04814
ENCODER VALUE = 05900
Fig. 46
9. Press the ENTER key on the display to save the value shown on the display; the message ‘MEMO’ will
appear to confirm that the value has been effectively saved.
8. KEY OFF then KEY ON to save all settings (Fig. 45 - 46).

10.8 PASSWORD PROGRAM

ELECTRICAL SYSTEM
The password program serves to set up to 5 passwords to allow the truck to be used by 5 different
operators.
To store the 5 passwords in this menu enable the PASSWORD function as described in the following
procedure.
1. Connect the programming console to the SICOS (module 16), see AC Motors Modular Control
System service manual (Programming Section).
2. KEY ON
3. With the console enter the SICOS CONFIG MENU/SET OPTIONS submenu.
4. Select the PASSWORD menu and set to ON to configure SICOS (Display) at the password function
press OUT and then ENTER on the console to save the setting.
5. KEY OFF, you can now disconnect the console from the SICOS module.
6. KEY ON pressing the OUT key.
8. Enter MAIN MENU 2 using the DOWN ARROW key
9. Select PASSWORD PROGRAM with the UP ARROW key and then press ENTER on the display to
enter the program.
set password
PASS1 = 1986
PASS2 = 0000
PASS3 = 0000
PASS4 = 0000
PASS5 = 0000 Fig. 47
10. Select the password to be set using the DOWN ARROW and UP ARROW keys.
11. Press ENTER and set the password with the numerical keypad.
12. Press ENTER; the message ‘MEMO’ will be displayed to confirm that the data have been saved. The
same procedure applies to all five passwords.
13. KEY OFF then KEY ON to save all your changes (Fig. 47).
From this time on in order to use the truck functions it is necessary to enter one of the preset passwords.
With the PASSWORD function enabled, when the truck is powered on the message ‘ALARM ON MOD
16 PASSWORD NEEDED’ is displayed (Fig. 48).
S
+ -
100
50 O
F ALARM ON MOD 16
20
T PASSWORD NEEDED
Fig. 48

To input the access password:
ELECTRICAL SYSTEM
1. Press ENTER to enter MAIN MENU 1 of the main display.
2. Select INSERT PASSWORD with the DOWN ARROW and open the function by pressing ENTER
INSERT YOUR
PASSWORD !
1986
Fig. 49
3. Type the password on the numerical keypad.

4. Press ENTER to return to the main display; the truck functions will have been enabled (Fig. 49).
10.9 MENU READ USERS
By entering the READ USERS menu of MAIN MENU 2 It is possible to visualize the work hours at the end
of each shift of each operator.
users logbook
USERS = 1986
HOURS = 0006
Fig. 50
NOTE:

11.0 PRE-HEIGHT SELECTOR

ELECTRICAL SYSTEM
11.1 COMPONENTS NEEDED
The essential components for the correct operation of the pre-height selector are the encoder, installed
on the mast to measure forks height from the ground, and the zero sensor (SW5).
HEIGHT INDICATOR
ZERO SENSOR
ENCODER
Fig. 51
A microswitch or sensor to indicate the presence of a load on the forks can be used together with the pre-
height selector although it is not indispensable. This component is used to indicate whether or not the
operator intends to perform a picking cycle (forks not loaded) or a put away cycle (forks loaded). If the
indicator is not installed this definition is specified manually.
11.2 OPERATING MODES

The pre-height selector gives the operator the opportunity to perform picking and put-away cycles on
shelves on 21 programmable levels (00-20) in a semi-automatic manner.
The various heights to perform these operations on various levels of shelving are programmed on the
display beforehand.
The programming procedures are described in the following headings.
When the pre-height selector function is selected, the operator must indicate whether he intends to
perform a put away (load) cycle or a picking (unload) cycle.
If the forks load sensor (load cell) is installed, the display provides an indication of forks with or without load
and the consequent put away or picking cycle is executed.
If the load indicator is not present, the put-away (load) or picking (unload) selection is performed manually
by the operator by means of the up arrow/down arrow keys shown on the display; the pre-height selector
informs the operator with regard to the hydraulic functions necessary to complete the mission. These
functions can be either lifting or lowering depending on the position of the forks at the time of the level
request.
Lifting hydraulic deceleration and stroke end cushioning are performed automatically.
There are two types of possible programming.
1) Consider automatic movements of the reach carriage.
2) Do not consider automatic movements of the reach carriage.
Both types of programming are illustrated below.

11.3 OPERATION WITHOUT REACH CARRIAGE IN SEQUENCE
ELECTRICAL SYSTEM
A) UNLOAD SEQUENCE - EXAMPLE STARTING FROM GROUND
5. Lifting - UNLOADING OFFSET value defined with console in CANI/O -

PARAMETER CHANGE - OPTION 06 (see USING THE PRE-HEIGHT
SELECTOR)
PALLET 4. Reach carriage retract (sequence end)
3. Lifting end - height programmed by means of the display (see point 1).
2. Deceleration phase - value defined with console in CAN I/O - PARAMETER

CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see USING THE PRE-
HEIGHT SELECTOR
1. Lifting (sequence start) - height programmed on display.
At points 1, 3 and 5 this symbol is

presented on the display to indicate
that a lift movement is required to reach
the selected level.
(indicated at point 3 because in this
case extraction of the truck is not
considered and the symbol is the same
symbol as referred to in point 5).
Fig. 52
B) LOAD SEQUENCE - EXAMPLE STARTING FROM GROUND
5. Lowering - LOAD OFFSET value defined with the console in CANIO

SELECTOR)
4. Reach carriage extension.
3. Lifting end.
2. Deceleration phase - value defined with the console in CAN I/O -

PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see
USING THE PRE-HEIGHT SELECTOR
1. Lifting (sequence start) - height programmed on display plus DEPOSIT

OFFSET value (OPTION 5), see USING THE PRE-HEIGHT SELECTOR
heading
At point 5 this symbol is presented

on the display to indicate that a
lowering movement is required to
reach the selected level.
At point 1 this symbol is presented

PALLET on the display to indicate that a lift
movement is required to reach the
selected level.
Fig. 53

11.4 OPERATION WITH REACH CARRIAGE IN SEQUENCE

ELECTRICAL SYSTEM
C) UNLOAD SEQUENCE - EXAMPLE STARTING FROM GROUND
5. Lifting - UNLOADING OFFSET value defined with console in CANI/O -

SELECTOR)
PALLET
6. Reach carriage retract (sequence end)
3. Lifting end - height programmed by means of the display (see point 1).
2. Deceleration phase - value defined with console in CAN I/O - PARAMETER
4.Reach CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see USING THE PRE-
carriage HEIGHT SELECTOR
extension. 1. Lifting (sequence start) - height programmed on display.
At point 6 this symbol is presented on the
display to indicate that the reach carriage
must be retracted.
At point 4 this symbol is presented on

the display to indicate that the reach
carriage must be extended.
At points 1 and 5 this symbol is

presented on the display to indicate that
a lift movement is required to reach the
selected level.
Fig. 54
D) LOAD SEQUENCE - EXAMPLE STARTING FROM GROUND

5. Lowering - LOAD OFFSET value defined with the console in CANIO
SELECTOR)
4. Reach carriage extension.
3. Lifting end.
2. Deceleration phase - value defined with the console in CAN I/O -
PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see
USING THE PRE-HEIGHT SELECTOR
6. Reach
1. Lifting (sequence start) - height programmed on display plus DEPOSIT
carriage
OFFSET value (OPTION 5), see USING THE PRE-HEIGHT SELECTOR
retract
heading
(sequence At point 6 this symbol is presented on
end) the display to indicate that the reach
carriage must be retracted.
the display to indicate that a lowering
selected level.
the display to indicate that the reach
carriage must be extended.
PALLET At point 1 this symbol is presented on
the display to indicate that a lift
selected level. Fig. 55

11.5 PRE-HEIGHT SELECTOR ADJUSTMENT
ELECTRICAL SYSTEM
Before programming the various values relative to the required heights remember to enable the pre-heights
selector function (trucks configured with the necessary components).
The enable procedure is as follows:
A) PRE-HEIGHT SELECTOR FUNCTION ENABLE WITHOUT REACH CARRIAGE IN SEQUENCE
1. Connect the programming console to the SICOS module 16, see AC Motors Modular Control System
service manual (Programming Section).
2. KEY ON.
3. With the console enter the CONFIG MENU/SET OPTIONS submenu.
4. Select the PRE-HEIGHT SELECTOR parameter and set to ON to configure SICOS (Display) at the
PRE-HEIGHT SELECTOR function; this done, press ENTER to save your settings.
5. KEY OFF to save all data; now the console can be disconnected from the SICOS module.
B) PRE-HEIGHT SELECTOR FUNCTION ENABLE WITH REACH CARRIAGE IN SEQUENCE
1. Connect the programming console to the CAN I/O module 1, see AC Motors Modular Control System
2. KEY ON.
3. With the console enter the CONFIG MENU/SET OPTIONS submenu.
4. Select the AUX FUNCTION 2 parameter and set to ON to configure CAN I/O at the PRE-HEIGHT
SELECTOR function; this done, press ENTER to save your settings.
5. KEY OFF to save all data; now the console can be disconnected from the CAN I/O module.
After having enabled the function there are two methods to program the pre-height selector, one
AUTOTEACHING (recommended) and the other in manual mode.
Before performing the programming procedure (in both AUTOTEACHING and manual mode) you will need
to check that the PROGRAM OFFSET value has been set correctly (see heading PROGRAM OFFSET
in MAIN MENU1, DISPLAY MENU).
11.6 PROGRAMMING IN AUTOTEACHING MODE (RECOMMENDED METHOD)

1. KEY ON, the MAIN DISPLAY appears (Fig. 56).
S
+ -
100
50 T
N
20
D Mm 5025
Fig. 56
2. Lift the forks to the required height (the lowest programmable level must be higher than the value of
(PROGRAM OFFSET).
3. Type the number of the level to be programmed (e.g. 03) on the display numerical keypad.
The pre-height selector working screen is displayed (Fig. 57).
PRE-HEIGHT SEL
LEVEL NUMBER = 03
LOAD
PROGRAM = ENTER Fig. 57

4. Press ENTER to enter the pre-height selector programming screen.

ELECTRICAL SYSTEM
Autoteaching
LEVEL NUMBER = 03

Fig. 58
5. Press ENTER again to save the value acquired in AUTOTEACHING (value shown under the heading
ENCODER VALUE).
6. Press OUT to return to the pre-height selector working screen and the press OUT again to return to the
MAIN DISPLAY.
7. Programming of additional levels in AUTOTEACHING must always start from the MAIN DISPLAY with
manual lifting.
8. KEY OFF to save all your data (Fig. 58).
11.7 MANUAL PROGRAMMING FROM THE DISPLAY
1. KEY ON, the MAIN DISPLAY appears (Fig. 59).
S
+ -
100
50 O
F
20
T Kmh 00 01
Fig. 59
2. Type the number of the level you wish to program (e.g. 03) with the display numerical keypad. The pre-
height selector working screen is displayed (Fig. 60).
PRE-HEIGHT SEL
LEVEL NUMBER = 03
HIEGHT VALUE = 00000
LOAD
PROGRAM = ENTER Fig. 60
3. Press ENTER to enter the pre-height selector programming screen (Fig. 61).
Autoteaching
LEVEL NUMBER = 03
ENCODER VALUE = 00000 Fig. 61
4. Specify the desired height in millimetres using the numerical keypad next to the item HEIGHT VALUE
and then strike ENTER to save the value; use the UP ARROW and DOWN ARROW keys to move on
to programming of further levels. Press OUT OUT to return to the main display.
5. KEY OFF to save all your data.

11.8 USING THE PRE-HEIGHT SELECTOR
ELECTRICAL SYSTEM
From the main menu select the required level (e.g. 03) using the display numerical keypad.
If the forks load sensor is not installed, the pre-height selector working screen is displayed in LOAD mode
by default; if, however, the forks are empty and you intend execute an UNLOAD cycle, press the UP
ARROW or DOWN ARROW to set UNLOAD.
Screen heading Function requested to follow the

programmed sequence
Selected level
PRE-HEIGHT SEL
Level preset UP ARROW
LEVEL NUMBER = 03
height
Current forks ENCODER VALUE = 00000
height LOAD DOWN ARROW
PROGRAM = ENTER
To go to the level
programming screen
Sequence to execute
LOAD/UNLOAD Fig. 62
IMPORTANT: If the forks load sensor is not installed, the LOAD/UNLOAD sequence must be set correctly
before starting the sequence, otherwise there is a risk of damaging the shelving and/or the material stored
on the shelves.
ATTENTION: If the pre-height selector is set with the reach carriage movement option included, lift (or
lower) the forks with the reach carriage retracted, extend the carriage, pick up the load, and then retract
the carriage (sequence end).
The pre-height selector working display (above) shows, with the forks symbol, the inputs required to
complete each phase of the selected sequence; the operator must activate the appropriate joystick in
relation to the requested function and maintain the function enabled until it stops automatically on the preset
value. At this point the operator will be prompted for the next input required, and so forth until the end of the
sequence.
To modify (when necessary) the deceleration phase at the end of the lift/lower movement in such a way
as to reach the selected level compensating for inertia and ensuring that the forks stop at the programmed
height:
Connect the console to the CAN I/O module

1. Connect the programming console to the CAN I/O module, see AC Motors Modular Control System
2. KEY ON
3. With the console enter the MAIN MENU/PARAMETER CHANGE submenu
4. Select the parameter OPTION 03 to modify deceleration during upward movement (default value is 5)
Select the parameter OPTION 04 to modify deceleration during downward movement (default value 5)
Increase the value to increase the deceleration distance.
5. Press OUT and then ENTER on the console to save the new setting.
6. KEY OFF to save all your changes; you can now disconnect the console.

For reasons of headroom available above the load and the shelving, it may prove necessary to adjust the
lifting distance to lift the pallet from the shelf or the lowering distance to deposit the pallet on the shelf(LOAD
ELECTRICAL SYSTEM
OFFSET and UNLOAD OFFSET) see operating examples in the headings OPERATION WITHOUT
REACH TRUCK and OPERATION WITH REACH TRUCK IN SEQUENCE.
To edit these values:
1. Connect the programming console to the CAN IOO module, see AC Motors Modular Control System
2. KEY ON
3. With the console enter the MAIN MENU/PARAMETER CHANGE submenu
4. Select the OPTION 05 parameter to modify the LOAD OFFSET (default value is 5)
Select parameter OPTION 06 to edit the UNLOAD OFFSET (default value 5)
Increasing the value of OPTION 05 corresponds to an increase in the loading stroke
Increasing the value of OPTION 06 corresponds to an increase in the unloading stroke
5. Press ENTER, followed by OUT and then ENTER again on the console to save the modified value.
6. KEY OFF to save all data; at this point the programming console can be disconnected from the SICOS
module.
12.0 ALARMS
All the alarms are shown on the display together with an indication of the module on which the fault has
occurred.
Connect the console to the most accessible module (Module 6 EPS-AC) and perform the procedure
indicated on page 23 in order to address the required module.
CAN BUS KO: Every 200msec messages arrive from the MHYRIO, CAN I/O, PUMP,
TRACTION and EPS modules as they confirm their connected status.
If within this interval one of the modules should fail to transmit the message
to the DISPLAY, an alarm status results:
CAN BUS KO MHYRIO: the mhyrio module has not transmitted its message
CAN BUS KO CAN I/O: the can i/o module has not transmitted its message
CAN BUS KO PUMP: the pump module has not transmitted its message
CAN BUS KO TRACTION: the traction module has not transmitted its
message
CAN BUS KO EPS: the eps module has not transmitted its message
-Connect to the specified module to identify the alarm condition.
NO CAN MESAGE: If no message reaches the display via the CAN BUS, the display
assumes alarm status.
Possible causes:
- Interrupted communication due to a missing connection - Restore the
connection.
- Faulty display - Renew the SICOS module 16
NOTE: CAN BUS alarms on the display assume priority with respect to all other alarms.
12.1 ALARMS CONCERNING THE DISPLAY
PASSWORD NEEDED This alarm is generated when the truck access Passwords are
requested.
- Enter the access Password

EEPROM KO: This alarm appears in the presence of a fault in the memory area in which
the setup parameters are stored; the EEPROM KO alarm inhibits operation
ELECTRICAL SYSTEM
of the truck.
Set the keyswitch to OFF and then to ON again; if the alarm is cleared note
that the parameters stored previously have been erased and replaced by the
factory default parameters.
If the alarm persists - Renew the controller.
ENCODER RESET: This alarm is generated when the truck is equipped with pre-height selector
and zero sensor.
When the keyswitch is set to ON the forks are above the zero level
Possible causes:
- Zero sensor faulty - Renew sensor
- Sensor not reading - Reduce the sensor gap for more positive reading
RESET HOUR METER: This alarm appears when the display hour meter count and the CAN I/O
count are different.
The differences are eliminated after 1 minute with the transfer of the hours
value from the display to the CAN I/O module.
Refer to the procedure for transferring the hours value from the display
module to the CAN I/O module and vice versa - page 38.
13.0 DIAGNOSTICS
13.1 TROUBLESHOOTING GUIDE
The tables shown below are provided to complete the “diagnostics” section of the modules manual entitled
“AC Motors Modular Control System”.
For more rapid troubleshooting we recommend consulting both manuals.
NOTE:

ELECTRICAL SYSTEM
AC2-TRACTION (MODULE 2)
SYMBOL
COMPONENT ON CONNECT. FAULT TYPE TRUCK REACTION ALARM ACTIONS REQUIRED
DIAGRAM
Page: 56
1D the truck travels w ithout alarms until it
one of the w ires is not exceeds a speed of 2 km/h. At this Check encoder connections and
2D 02 ENCODER ERROR
connected point the traction function is inhibited renew encoder if necessary
3D, 5D and the alarm is tripped
Traction motor encoder phases A and B are the truck travels at reduced speed No Check encoder connections and
ENEC-MTR 3D, 5D None
encoder feedback shorting alarm displayed renew encoder if necessary
the truck travels w ithout alarms until it
exceeds a speed of 2 km/h. At this
the encoder phases are at - Check encoder connections and
3D, 5D point the traction function is inhibited 02 ENCODER ERROR
B renew encoder if necessary
and the alarm is tripped
Part No.: 1517320

inputs open, negative 06 MAIN CONT. OPEN, if occurs
Permissive f rom fault to be found on electric steering
11F, 5F permissive signal transmitted traction inhibited and alarm active during traction; 02 INCORRECT START
electric steering system. Check alarms on EPS-AC
by EPS-AC is missing during startup
no active alarms. Brake engaged. The

3F, 9F coil or w ires in open circuit renew electromagnetic brake
motor tends to run w ith braking applied
Electromagnetic
EMB
brake 02 COIL SHORTED, if this fault occurs
check electromagnetic brake
3F, 9F coil or w ires short-circuited functions blocked and alarm active during traction; 02 INCORRECT START
connection or renew the brake
if the fault trips during startup
Date: Mar. 2002

Traction motor check thermal cutout connections and
0
thermal overload T.MTR 6F, 12F open circuit alarm active 02 MOTOR TEMPERATURE general condition. Analyze reasons
cutout for motor temperature rise
1
functions blocked. Alarm active only
02 INCORRECT START only after renew operator presence sensor (left-
4F sensor output interrupted af ter having pressed the accelerator
2
Operator presence having pressed the accelerator hand pedal)
SW3 pedal
sensor
3
sensor output in short circuit functions blocked. Alarm active w hen renew operator presence sensor (left-
02 INCORRECT START
(+Vbat f ixed) keysw itch is set to ON hand pedal)
4
16 NO CAN MESSAGE; 01 CAN BUS
check CAN-BUSS lines connections.
CAN-BUS 1C-4C open circuit functions blocked. Alarm active KO EPS or 01 CAN BUS KO TR in the
Renew the module if necessary
5
case of intermittent connections
01 CAN BUS KO TR immediately; 05 check keysw itch and relative
6
Keysw itch SW2 1F open no function. Alarm active
CAN BUS KO later, connections
alarm active if tripped at start-up. No check pow er fuses and pow er
#NAME? open 02 VMN LOW
alarm if tripped during traction connection
TROUBLESHOOTING GUIDE
UPDATE
(AC2 TRACTION MODULE 2)
SERVICE
UPDATE
EPS-AC (MODULE 6):
SERVICE
SYMBOL
COMPONENT ON CONNECT. FAULT TYPE TRUCK REACTION ALARM ACTIONS REQUESTED
0
DIAGRAM
Brief steering turn follow ed by
1
6A +5V open
functions inhibit w ith alarm active
Steering motor Brief steering turn follow ed by Check encoder connections and
2
ECN-MS 8A B- open 06 MOTOR LOCKED
encoder feedback functions inhibit w ith alarm active renew encoder if necessary
3
encoder phases A and B are Brief steering turn follow ed by
16A, 17A
short-circuited functions inhibit w ith alarm active
4
the drive w heel steers clockw ise for 5
5
12B sensor output open circuit seconds and then the alarm trips and 06 NOT ALIGNED check w heel centred sensor and
Wheel centred
SW4 the truck travels at reduced speed relative connections. Renew if
6
sensor
necessary
sensor output short-circuited
Stepping motor 4B common open
STEPPER check stepper motor connections.
(steering no function. Alarm active 06 D LINE SENSOR KO
MOTOR 3B, 9B channels A/B open Renew if necessary
transducer)
check connection and general
Steering motor traction speed reduction and alarm
T.MS 11A, 7A open circuit 06 MOTORE TEMPERATURE condition of thermal cutout. Analyze
thermal cutout active
reasons for motor temperature rise
Date: Mar. 2002

3A, 4A, check CAN-BUS lines connection. If
CAN-BUS open circuit functions inhibited. Alarm active 16 NO CAN MESSAGE
13A, 14A necessary renew the module
01 CAN BUS KO EPS starting to steer;

check keysw itch and relative
Keysw itch SW2 11B open no function. Alarm active 16 CAN BUS KO EPS at keysw itch
connections
pow er-on
alarm active if tripped at pow er up. No check pow er fuse and pow er
#NAME? open 06 POWER FAILURE #2
alarm if tripped during traction connections
Part No.: 1517320

(EPS-AC TRACTION MODULE 2)
Page: 57
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
Page: 58
AC2-PUMP (MODULE 5)
SYMBOL ON
COMPONENT CONNECT. FAULT TYPE TRUCK REACTION ALARM ACTIONS REQUIRED
DIAGRAM
1D
one of the wires is not

2D connected the pump rotates slowly without alarms
Pump motor encoder until the rotation speed increases. At this check encoder connections and renew
ENC-MP 05 ENCODER ERROR
feedback point the functions are inhibited and the encoder if necessary
encoder phases A and B are alarm is tripped
3D
short-circuited
Part No.: 1517320

5D encoder phases are at -B
check connection and general condition
Thermal cutout T.MP 6F, 12F open alarm active 05 MOTOR TEMPERATURE of thermal cutout. Analyze reasons for
motor temperature rise
Pump inverter check for presence of jumper on

1B, 2B open no function. Alarm active 16 CAN BUS KO PU
configuration jumper connector B.
16 NO CAN MESSAGE; if connection is

intermittent or open during operation: 01 check CAN-BUS lines connection. If
Date: Mar. 2002

CAN-BUS 1C-4C open circuit no function. Alarm active
CAN BUS KO EPS& 01 CAN BUS KO necessary, renew the module
0
TR
Keyswitch SW2 1F open no function. Alarm active 16 CAN BUS KO PU check keyswitch and relative connections
1
2
#NAME? open alarm active 05 VMN LOW check power fuse and power connection
3
4
5
6
UPDATE
(AC2 PUMP MODULE 5)
SERVICE
MHYRIO (MODULE 9) - (1°)
SYM BOL
COM PONENT ON CONNECT. FAULT TYPE TRUCK REACTION ALARM ACTIONS REQUIRED
DIAGRAM
UPDATE
3D one of the w ires is not
SERVICE
Height indicator ECN-HEIGHT connected the value of the height indicator check the encoder connections and
1D none
encoder IND remains f ixed on the display replace if necessary
encoder phases A and B are
0
4D, 2D
short-circuiting
1
Height
CUTBACK SPEED 2 active. If open at f irst check correct adjustment of
indicator/traction SW5 12A output not activated 16 RESET ENCODER
the time of pow er-on, alarm active inductive sensor. Renew if necessary
2
speed cutback af ter
output in short circuit (alw ays No alarm. The value of the height
none
3
at +Vbat) indicator remains f ixed on the display
Lif ting speed
4
SW6 1A sensor output interrupted lif ting speed reduction not active none none
reduction sensor
in short circuit lif ting speed reduction alw ays active none renew sensor
5
No carriage retracted stop if output
opens w hile f unction is active; no
6
carriage f orw ard f unction if already
completely at retracted stroke limit.
Reach carriage
SW7 2A sensor output interrupted Resetting the keysw itch it is possible none renew f aulty sensor
f orw ard limit sensor
to activate the carriage f orw ard
movement w ith reduced pump speed
until the opposite stroke limitsw itch
trips
carriage retracted stroke limit not
sensor output short-circuited f unctioning; carriage extended speed
Date: Mar. 2002

reduction not f unctioning
No carriage f orw ard stop if output
opens w hile f unction is active; no

carriage retracted f unction if already
completely at f orw ard stroke limit.
sensor output interrupted Resetting the keysw itch it is possible none renew f aulty sensor
Reach carriage to activate the carriage back
SW8 3A
back limit sensor movement w ith reduced pump speed
until the opposite stroke limitsw itch
trips
carriage f orw ard stroke limit not
Part No.: 1517320

sensor output short-circuited f unctioning; carriage retracted speed
reduction not f unctioning
(MHYRIO MODULE 9)
Page: 59
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
Page: 60
MHYRIO (MODULO 9) - (2°)
SYMBOL
DIAGRAM
Low ering speed SW9 5A sensor output interrupted lowering speed reeduction not none renew faulty sensor
lowering speed reduction always
renew short-circuiting sensor
Part No.: 1517320

enabled
solenoid valve coil open check coil of solenoid valve 8 and
Solenoid valves *8 10G-7G; no function. No active alarm none
circuit renew if necessary
3B-8G;11G-
a) soneoid valve coils shorted:
6G;16G- In the case of FF VALVES identify the
hydraulic functions disabled and alarm
Solenodi valves 5G;15G- a) 09 FF VALVES b) 09 short-circuiting coil and renew; in the
Shorted active; b) coil control driver shorted:
connection inputs 2G;12G- DRIVER SHORTED case of DRIVER SHORTED, renew the
hydraulic functions inhibited and alarm
1G;13G- module
active
4G;9G-3G
Date: Mar. 2002

Coils power supply 09 DRIVER OPEN, also 16 RESET
6B open check connection
+Batt ENCODER on start
0
check keysw itch and relative
Keyswitch SW2 2B open no function. Alarm active 16 CAN BUS KO VALVE
1
connections
01 CAN BUS KO EPS at power on; 16

check CAN-BUS lines connection. If
2
CAN-BUS 4B, 1B open circuit no function. Alarm active NO CAN MESSAGE if tripped during
necessary, renew the module
operation
3
4
5
6
UPDATE
(MHYRIO MODULE 9)
SERVICE
CANIO (MODULE 1) - (1°)
SYMBOL
DIAGRAM
Forw ard travel SW12 3G sensor output interrupted no forw ard travel none renew forw ard travel sensor
UPDATE
at time of reverse travel enable,
SERVICE
sensor output short-circuit functions are inhibited and alarm is 01 FORW & REV
tripped
0
Reverse travel SW13 4G sensor output interrupted no reverse travel none renew forw ard travel sensor
1
at time of forw ard travel enable,
sensor output short-circuit functions are inhibited and alarm is 01 FORW & REV
2
tripped
no traction. Alarm w hen almost at
3
Start sensor SW14 1G open circuit 01 VACC NOT OK renew start sensor
accelerator stroke limit
4
closed circuit alarm active 01 INCORRECT START
5
Brake pedal sensor SW15 2G sensor output interrupted pedal braking not functioning none renew brake pedal sensor
6
sensor output short-circuit no traction
only reach carriage function available.
Battery out sensor SW16 9A sensor output interrupted Reduced speed traction possible w ith 01 BATTERY OUT renew battery out sensor
"battery out" button
same functions as w hen battery is in
sensor output short-circuit none
position
Traction POT1 4A positive open alarm at keysw itch pow er-on, after 1 01 VACC NOT OK perform PROGRAM VACC procedure
Date: Mar. 2002

5A central open
01 VACC NOT OK, pedal dow n 01

7A negative open no traction, alarm activated
PEDAL WIRE KO
check seat sensor and renew if
Seat sensor SW17 14A sensor outupt interrupted no traction, alarm activated 01 INCORRECT START
necessary
sensor output short-circuit traction normal operation none none
Horn sw itch SW21 13A open not operational none none
Operator presence SW3 5G sensor output interrupted alarm as soon as function is selected 01 INCORRECT START check operator presence sensor (left-
Part No.: 1517320

sensor output short-circuit alarm at keysw itch pow er-on
(CAN I/O MODULE 1)
Page: 61
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM

SYM BOL
COM PONENT ON CONNECT. FAULT TYPE TRUCK REACTION ALARM ACTIONS REQUIRED
DIAGRAM
Page: 62
Emergency circuit alarm active if contacts are opened 05 LOGIC FA ILURE #2, 01 check emergency circuit breaker
SW1 6G open circuit
breaker f ollow ing pow er-on. EMERGENCY contacts and circuit breaker.
if the alarm appears at the time of
Lif t/low er pow er-on: f unction blocked. If this check potentiometer connections and
J1/POT1 3B positive open 01 POT #1 NOT OK
potentiometer alarm trips during operations, only renew the joystick if necessary.
low ering movements are allow ed.
2B central open f unction not available, no alarm
6B negative open f unction not available, alarm present 01 POT #1 NOT OK
Lif t/low er enable

J1 1B open circuit alarm active 01 POT #1 NOT OK
sw itch
closed circuit alarm at keysw itch pow er-on 01 INCORRECT STA RT none
Part No.: 1517320

Reach carriage immediate alarm at pow er-on, all check potentiometer connections and
J1/POT2 3B positive open 01 POT #1 NOT OK
potentiometre hydraulic f unctions inhibited. renew joystick if necessary.
5B central open f unction available - no alarm
alarm present at keysw itch pow er-on

6B negative open 01 POT #1 NOT OK
and f unctions activation
Reach carriage
J1 4B open circuit alarm active 01 POT #2 NOT OK
f w d/back enable
Date: Mar. 2002

0
if the alarm is generated at the time of
keysw itch pow er-on: f unction
1
unavailable. For alarm during check potentiometer connections and
Tilt Potentiometer J2/POT1 3C positive open 01 POT #1 NOT OK

operations tilt movement backw ards, renew the joystick if necessary.
2
or return to neutral f rom f orw ard
3
(dow n) position.
2C central open f unction not available, no alarm
4
alarm present at keysw itch pow er-on
6C negative open 01 POT #1 NOT OK
5
and f unctions activation
6
Tilt back/f orw ards
J2 1C open circuit active alarm 01 POT #3 NOT OK
enable sw itch
UPDATE
(CAN I/O MODULE 1)
SERVICE
SYM BOL
DIAGRAM
if the alarm is present at pow er-on:
Sideshift check potentiometer connections and
UPDATE
J2/POT2 3C positive open function not available. If the alarm is 01 POT #1 NOT OK
potentiometer renew joystick if necessary.
tripped during operations sideshift to
SERVICE
0
1
5C central open function not available, no alarm.
2
alarm present at keysw itch pow er on
6C negative open 01 POT #1 NOT OK
and functions activation
3
4
Rh/lh sideshift
J2 4C open circuit alarm active 01 POT #4 NOT OK
enable sw itch
5
closed circuit alarm present at keysw itch pow er-on 01 INCORRECT START none
6
18A, 14G, 16 CAN BUS KO EPS, 16 NO CAN check battery negative, connections
Battery negative B- open circuit alarm af ter slight delay
10F MESSAGE and CAN I/O; renew if necessary
Check keysw itch, connections and
Keysw itch E3-A1 9F open circuit alarm at keysw itch pow er-on 16 CAN BUS KO IO
CAN I/O; renew if necessary
Check connection betw een CAN I/O
BUS connection
1F, 2F open circuit alarm at keysw itch pow er-on 16 CAN BUS KO IO and SICOS and renew modules if
w ith SICOS module
necessary.
closed circuit alarm at keysw itch pow er-on 16 NO CAN MESSAGE
Date: Mar. 2002

CAN joystick: to CANIO
Connection No alarm at keysw itch pow er-on,
Check connections, joystick and CAN

betw een Joystick J7 2D, 3D open circuit alarm present and no function at 01 CAN BUS KO JOY
I/O; renew joystick if necessary.
and CAN I/O activation of first action.
check pow er supply negative,
Joystick pow er immediate alarm at keysw itch pow er-
J7 4D open circuit 16 NO CAN MESSAGE connections and CAN I/O; renew if
supply negative on; all hydraulic operations inhibited
necessary.
no alarm at pow er-on, alarm present
Joystick pow er check +12v, connections, joystick and
J7 1D open circuit after short interval or w ith functions 01 CAN BUS KO JOY
supply positive CAN I/O; renew if necessary.
activation
All sw itches except
Part No.: 1517320

forw ard/reverse J7 open or closed circuit alarm active 01 INCORRECT START none
and horn
(CAN I/O MODULE 1)
Page: 63
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
SICOS - Display (MODULO 16)

SYMBOL
DIAGRAM
Page: 64
Traction permissive SW18 1A open circuit no movement even though sw itch is Check sw itch and connections; renew
no movement even though sw itch is

closed circuit
activated
Holding or parking Check sw itch and connections; renew

SW19 2A open circuit function request not fulfilled; no alarm
switch sw itch if necessary.
Parking brake active, alarm present at
closed circuit 02 HANDBRAKE
traction request.
Low speed travel Check sw itch and connections with
SW20 6A open circuit function request not fulfilled, no alarm.
Part No.: 1517320

switch SICOS and renew sw itch if
closed circuit function request not fulfilled, no alarm.
Check sw itch and connections; renew
Optional Valves SW22 3A open circuit function request not fulfilled, no alarm
sw itch if necessary.
same as when open, but translation
closed circuit
not executed.
Automatic capacity Check sw itch and connections; renew
SW23 15A open circuit function request not fulfilled, no alarm.
detector sw itch if necessary.
alarm at keyswitch pow er-on, no 01 INCORRECT START, also "TON"
closed circuit
Date: Mar. 2002

hydraulic functions permitted. display
Check battery negative and SICOS
0
Battery negative C4 10F, 18A open circuit no functions permitted. 16 NO CAN MSG,
module (renew module if necessary).
1
Display and functions unavailable if Check the keysw itch, connections
open at pow er-on; all functions with the SICOS module, and the SICOS
2
Keyswitch E4-A1 9F open circuit
available if circuit opens w hen truck is module itself (renew the sw itch or
3
already operating. SICOS if necessary)
Bus connection All functions available with truck in Check connections w ith CAN I/O:
4
16 CAN KO EPS, then 16 NO CAN
w ith CAN I/O 1F, 2F open circuit operation, for other possibilities no Check SICOS and CAN I/O and renew
MSG,
5
module functions available. if necessary.
6
UPDATE
(SICOS MODULE 1)
SERVICE
NOTES:
ELECTRICAL SYSTEM

14 WIRING HARNESS CONNECTION DIAGRAM
ELECTRICAL SYSTEM
The following diagrams are to be used in the event of replacement of wiring harnesses or auxiliary cables
between connectors and modules.
Each diagram carries indications of connectors and the relative cable insulation colours.
NOTES:

VEDI VEDI VEDI WIRING DIAGRAM

Pag. 66e Pag. 66f Pag. 66i AUXILIARI CABLES
VEDI VEDI
VEDI
Pag. 66g Pag. 66C
Pag. 66b
VEDI
VEDI Pag. 66f
VEDI
Pag. 66c Pag. 66g
VEDI
Pag. 66g
VEDI VEDI
Pag. 66h Pag. 66i
VEDI
Pag. 66e
VEDI
Pag. 66i
VEDI
Pag. 66d
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66a

WIRING CONNECTIONS
MODULE AC2 TRAZIONE
MODULE AC2 POMPA
WIRING CONNECTIONS MODULE AC2 TRAZIONE WIRING CONNECTIONS MODULE AC2 POMPA
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66b

WIRING CONNECTIONS
MODULE EPS - AC,
MODULO CA I/O
WIRING CONNECTIONS MODULE EPS - AC WIRING CONNECTIONS MODULE CAN I/O
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66c

WIRING CONNECTIONS
MODULE MHYRIO, ELETTROVALVES,
SENSORS
COLLEGAMENTO FILI MODULO MHYRIO
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66d

WIRING CONNECTIONS
MODULE SICOS, JOYSTICK ITT
WIRING CONNECTIONS JOYSTICK ITT

WIRING CONNECTIONS MODULE SICOS
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66e

WIRING CONNECTIONS
GROUP 2 JOYSTICKS
GROUP 4 JOYSTICKS
WIRING CONNECTIONS 2 JOYSTICKS WIRING CONNECTIONS 4 JOYSTICKS
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66f

WIRING CONNECTIONS
INVERSORE MARCIA, HORN BUTTON,
EMERGENCY SWITCH, KEYSWITCH,
PANEL FAN
TRACTION INVERTER HORN BUTTON EMERGENCY SWITCH KEY SWITCH PANEL FAN
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66g

WIRING CONNECTIONS
SENSORS, POTENTIOMETER
COLLEGAMENTO FILI SENSORI
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66h

WIRING CONNECTIONS
ENCODER, THERMAL SENSORS,
SENSORS,
WORK LIGHTS, FLASHING BEACON
ENCODER AND MOTOR THERNMAL SENSOR WIRING CONNECTIONS
WORK LIGHTS AND FLASHING BEACON WIRING CONNECTIONS
AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Marzo 2002 Part No: 1517319 Pag. 66i

SERVICE Section: ADDITIONAL FUNCTIONS
ADDITIONAL
FUNCTIONS
! OPTION SHEET No. 1 -
Setting of the steering for a turn of “360° and 90°”............................4
DC_DC converter installation............................................................6
Flashing rotating light installation......................................................8
Working light installation...................................................................10
Reverse motion audible alarm installation ......................................12
Height preselector installation .........................................................14
Installation and enabling for the 5. function......................................16
Deceleration of the “HE” mast lifting limit switches.........................19
Electric block of the lowering forks with 1200mm pallet..................21
Warmed seat installation..................................................................23
Cab for - 30° refrigerating room.......................................................27
Seat belt installation..........................................................................35
! UPDATE
OPTION SHEET No. 1 -
Intermediate lifting lock sensor
Function release by means of the push button on the display.........37
! UPDATE
Enabling of the weighing function.....................................................42
! UPDATE
removal of the speed reduction function with the carriage
completely extended.........................................................................43
REVISION 0 1 2 3 4 5 6 Date: Mar. 2002 Comp. No.: 1517320 Page: 1

Section: ADDITIONAL FUNCTIONS SERVICE
NOTES:
Page: 2 Comp. No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 REVISION

ADDITIONAL FUNCTIONS
According to the different functions, which can be applied on this model, it might be necessary
to install further components and above all to change some settings on various modules in
order to obtain the desired function.
This section aims at guiding the technician through the installation and through the settings,
which are necessary for the new function.
Every function sheet consists of 3 parts:
X NECESSARY ADDITIONAL COMPONENTS
X INSTALLATION NOTES
X MODULE CONFIGURATION
The section “CONFIG MENU” indicates the adjustments, which must be carried out on each
model in order to obtain the desired function.
The table containing such data is described below.
Progressive No. Accessories Module MAIN MENU CONFIG MENU Parameters Settings
Parameter to be modified
Setting to be modified
Module configuration
submenu access manu
Machine parameter access menu
Module on which you must be act
Devices to be used
Progressive number

OPTION SHEET No. 1
a) STEERING SETTING FOR “360°” MOVEMENTS
PROCEDURE TO CONNECT THE “EPS - AC” MODULE TO SET THE STEERING

FOR THE “360°” MOVEMENT ON PAGE 4a
Pict. 1
b) STEERING SETTING FOR “90°” MOVEMENTS

PROCEDURE TO CONNECT THE “EPS - AC” MODULE TO SET THE STEERING
FOR THE “ 90° “ MOVEMENT ON PAGE 4b
Pict. 2

OPTION SHEET No. 1/A
360° STEERING GUIDE EPS-AC

CONTROL
-NONE CONSOLE
5mm CONNECTOR
Allen wrench
To carry out this operation open the engine compartment bonnet by means of a 5mm Allen
wrench in order to see the steering movement during the tests.
Remove the cap form the EPS module connector and once the machine is off, connect the
console and adjust the steering refeRring to the “EPS - AC” manual on page 19. Proceed
as shown in the table enclosed
NOTE: This table does not substitute the procedure described in the “EPS_AC” CONSOLE COUPLING EPS -
Service Manual. It is only an indication to connect uickly to the module. AC CONNECTOR
EPS
CONNECTOR
CAP
CONSOLE
MODULE CONFIGURATION TABLE
Pict. 3
STEERING ADJUSTMENT TO ACT AT 360°

Sequence
Accessories Module MAIN MENU' CONFIG MENU' Parameters Setting Description of the operations to be performed
No.
W hen the machine is off, connect the console to the EPS module. Place the
1 key switch in position ON and check that the automatic wheel reaches the
central position
Key switch on OFF and then on ON. Check that the wheel reaches
3 SET OPTIONS RANGE 360° ON automatically the central position. If the wheel is not centered consider the
following point
SET OPTIONS LIMIT DEVICE OFF Remove the stop of the steering wheel at 90° and perform the steering at 360°
EPS - AC Increase the value displayed in order to adjust the centering of the wheel
clockwise (+5mV). Decrease the value displayed to adjust the centering of
4 ADJUSTMENT SET STEER 0-POS Va lue displa ye d 5V
the wheel anticlockwise (-5mv). Key switch OFF than ON. Check that at the
starting the automatic wheel reachs the central position
5 Rotate the steering clockwise till 180° position is reached,
If the SET 180° ENC parameter does not correspond to 10V, position on the
Va lue displa ye d
6 ADJUSTMENT SET 180° ENC parameter, press ENTER. From the centered wheel position, steer the wheel
10V
clockwise until 10V appears, press OUT then ENTER
REVISION 0 1 2 3 4 5 6 Date: March 2002 Comp. No.: 1517320 Page 4a

OPTION SHEET No. 1/B
EPS-AC
CONTROL
90°STEERING GUIDE

CONSOLE
5mm Allen wrench CONNECTOR
-NONE
X INSTALLATION NOTE
To carry out this operation open the engine compartment bonner by means of a 5 mm Allen
wrench in order to see the steering movement during the tests.
Remove the cap from the EPS module connector and once the machine is off connect the
console and adjust the steering referring to the “EPS - AC” manual on page 19. Procede
as shown in the table enclosed CONSOLE COUPLING EPS -
AC CONNECTOR
NOTE: This table does not substitute the procedure described in the “EPS_AC” EPS
CONNECTOR
Service manual, but it is an indication of quick connection to the module. CAP
CONSOLE
MODULE CONFIGURATION TABLE Pict. 4
STEERING ADJUSTMENT TO ACT AT 90°

S eq u en ce
Accesso ries Mo d ule M AIN M E N U C ON F IG M E N U P aram eters S etting D escription of th e o peratio n to b e perfo rm ed
No.
W hen the m ac hine is off, c onnec t the c ons ole to the E P S M odule. P lac e the
1 k ey s witc h in pos ition ON and c hec k the autom atic wheel reac hes the c entral
pos ition
K ey s witc h on OFF and then on ON. Chec k that the wheel reac hes
2 S ET O P TIO NS RANG E 360 O FF autom atic ally the c entral pos ition. If the wheel is not c entered c ons ider the
following point.
Inc reas e the value dis play ed to adjus t the c entering of the wheel c loc k wis e
(+ 5m V ). Dec reas e the value dis play ed to adjus t the c entering of the wheel
3 ADJUS TM ENT S ET S TEER 0-P O S V a lue displa ye d 5V
antic loc k wis e (-5m v). K ey s witc h OFF then O N. A nd c hec k that at the
s tarting the autom atic wheel reac hes the c entral pos ition
EP S - AC
K ey s witc h on OFF then on O N. Chec k that the wheel reac hes autom atic ally
4 S ET O P TIO NS LIM IT DEV ICE ON
the c entral pos ition.
Rotate the s teering c loc k wis e in order to reac h the 90° pos ition (value
V a lue displa ye d dis play ed 7,4V ). S ave the value s et by pres s ing E NTE R then O UT and s till
5 ADJUS TM ENT S ET M AX ENC
7,4V E NTE R, then plac e the k ey s witc h in pos ition O FF then in pos ition ON and
c hec k that at the s tarting the autom atic wheel reac hes the c entral pos ition
Rotate the s teering antic loc k wis e until the 90° degrees pos ition is reac hed
V a lue displa ye d (value dis play ed 2,4V ). S ave the value s et by pres s ing E NTE R then O UT and
6 ADJUS TM ENT S ET M IN ENC
2,4V s till E NTE R, then plac e the k ey s witc h in pos ition O FF and then in pos ition
O N and c hec k that the autom atic wheel reac hes the c entral pos ition
7 S ET O P TIO NS LIM IT DEV ICE ON S et on O N. K ey s witc h on OFF to s ave the param eters .
REVISION 0 1 2 3 4 5 6 Date: March 2002 Comp. No.: 1517320 Page 4b

NOTES:

OPTION SHEET No. 2
DC-DC CONVERTER INSTALLATION AND CONNECTION

- DC_DC CONVERTER KIT
-NONE
NECESSARY STANDARD TOOLS
Slotted Phillips 13mm 5mm Allen

screwdriver screwdriver Spanner wrench
The DC-DC converter is provided with a kit including connection sheaths and fastening screws and is
assembled behind the seat next to “EPS_AC” 6 module.
For the assembly, it is necessary to open the engine compartment bonnet by means of a 5 mm Allen
wrench and fix, by means of the Allen wrench itself, the converter to the holes already provided. Open
the system compartment bonnet by means of the Phillips screwdriver, connect a cable terminal to the
Pump AC2 module B-Batt by means of the 13mm wrench, connect the other cable terminal to the Fu7
fuse B+ 48V by means of the slotted screwdriver as shown in the drawing below. The sheath with
connector is linked to the converter output; the converter is used for the auxiliary system connections.
NOTE: Before starting the assembly and the connection, put the key switch in position OFF and
disconnect the battery
Pict. 5
Connector to join the

auxiliary systems
B+ 48V connection to B- Batt connection to

the FU7 Aux fuse the Pump AC2 module

DC-DC CONVERTER
WIRING DIAGRAM
DC-DC CONVERTER
CONNECTION

OPTION SHEET No. 3
FLASHING ROTATING LIGHT CONNECTION AND INSTALLATION

- FLASHING ROTATING LIGHT KIT
-NONE
Medium Phillips 5mm Allen

screwdriver wrench
The flashing rotating light is provided with a kit complete with connection sheath and fastening screws
and it is assembled on the roof in the outer over the support column (as shown in the picture).
For the assembly it is necessary to open the bonnet under the steering wheel and the system compartment
bonnet by means of the Phillips screwdriver. The assembly point is provided with two M6 holes to fasten
the flashing rotating light and a Ø 30 hole for the cable. Insert the cable in the hole and make it pass
through the roof interspace, by following the direction indicated by the arrow, then join the connector end
cable and drag it completely up to the Inverter Pump AC2 5 Module and insert the connector in the
connector No.26. Connect the other end of the cable to the flashing rotating light and fix it to the roof by
means of the 5mm Allen wrench.
Connector already provided

and connected to Pin 2/F - Ø 30 hole
FLASHING ROTATING LIGHT
8/F of the PUMP AC2 for the cable
module passage
Cable passage
interspace
Pict. 6 Pict. 7

FLASHING ROTATING LIGHT

WIRING DIAGRAM FOR THE
CONNECTION
FLASHING
ROTATING LIGHT
CONNECTION

OPTION SHEET No. 4
WORKING LIGHT INSTALLATION AND CONNECTION

X NECESSARY ADDITIONAL components
- WORKING LIGHT KIT
-NONE
Medium Phillips 5mm

screwdriver Allen wrench
The working lights are provided with a kit complete with connection sheaths, selector for the starting and
fastening screws assembled on the outer part of the roof facing the mast (as shown in the picture).
For the assembly open the bonnet under the steering wheel and the system compartment bonnet by
means of the Phillips screwdriver. The assembly point is provided with four M6 holes, two each light, and
two Ø 30 holes for the cable passage (as shown in pict. 8). Insert the cable in the holes and make it pass
through the roof interspace by following the direction indicated by the arrow. Then join the cables and
drag them completely up to the connector No. 24; insert the starting selector sheath, fix the key switch on
the dashboard and join the two connectors.Connect the other ends of the cables to the lights and fix
them to the roof by means of the 5mm Allen wrench.
NOTE: Before starting the assemble and the connection, put the key switch in position OFF and
Interspace for the

cable passage
Ø 30 holes provided for
sheath passage Pict. 8
Connector already provided

and connected: Pin 1/24 to
B- Batt, 2/24 to FU4 B+ Batt
48V Pict. 9 Pict. 10

LIGHT CONNECTION
FOR THE WORKING
WIRING DIAGRAM
WORKING LIGHT
CONNECTION

OPTION SHEET No. 5
INSTALLATION AND CONNECTION OF THE REVERSE MOTION AUDIBLE

ALARM
- AUDIBLE ALARM KIT
NECESSARY STANDARD TOOL
Medium Phillips 5mm Allen

srewdriver wrench
The buzzer is provided with a kit complete with a connection sheath and is assembled under the board
on a slotted bracket near the klaxon (as shown in picture 11).
For the assembly it is necessary to open the engine compartment bonnet and the board by means of the
5mm Allen wrench, remove the system compartment bonnet by means of
the Phillips screwdriver. Loosen the buzzer ring nut and insert the buzzer
itself in the proper slot and tighten the buzzer ring nut to fasten the buzzer to
the bracket. Bring the sheath connector in the system compartment by making
it follow the way of the sensors and join it to connector No. 28.
NOTE: Before starting the assembly and the connection, put the key
selector in position OFF and disconnect the battery
Pict. 12
Connector joint to the

Pin 16/G - 7/G of the
Buzzer CAN I/O module
application Pict. 11

SERVICE
REVISION
0 1
2 3
4
CONNECTION
CAN I/O MODULE CONFIGURATION TABLE

A L A R M
R E V E R S E
MOTION AUDIBLE
Section: ADDITIONAL FUNCTIONS
ADJUSTMENT TO ENABLE THE AUDIBLE ALARM W HEN THE TRUCK IS RUNNING

Se que nce MENU CONSOLE De scription of the ope ra tions to be
Acce ssorie s Module SETTING
No. CON.CONSOLE PARAMETER ca rrie d out
ALARM CONNECTION
W hen the machine is off connect the console

to CAN I/O module, ON key switch.
WIRING DIAGRAMFOR THE
5 6 Date: Mar. 2002 Comp. No.: 1517320

REVERSE MOTION AUDIBLE
AUX ON Audible alarm enabled with reverse movement

1 CAN I/O SET OPTIONS
FUNCTION 3 OFF Audible alarm enabled with forward movement
Page: 13
OPTION SHEET No. 6

ENABLING OF THE HEIGHT PRESELECTOR FUNCTION
THERE ARE TWO CONFIGURATION POSSIBILITIES
a) RETRACTABLE CARRIAGE INCLUDED IN THE DRAWING/STORING AUTOMATIC SEQUENCE

b) RETRACTABLE CARRIAGE EXCLUDED IN THE DRAWING/STORING AUTOMATIC SEQUENCE
- HEIGHT PRESELECTOR KIT
SW5 =
NYLON THREAD FOR LIFTING SPEED REDUCTION
THE ENCODER SENSOR
OPERATION
ENCODER RESET.
INDUCTIVE
ENCODER
SHEATH
CONNECTORS
LINKED TO THE
MHYRIO MODULEPict. 13
CONNECTION INDUCTIVE ENCODER AND SPEED REDUCTION SENSOR ON THE MODULE 6

“ MHYRIO”
Pict. 14 MODULE 6
“MHYRIO”
CONNECTOR “A”
FOR THE ENCODER
RESET SENSOR
CONNECTION
CONNECTOR “D”
ENCODER
CONNECTION

PROCEDURE TO INSTALL THE HEIGHT PRESELECTOR COMPONENTS

OPTION SHEET No. 6/A HEIGHT PRESELECTOR
COMPONENT TABLE NECESSARY STANDARD TOOLS
Ref. Description of Components

1 Height measurement encoder
Tapeline
2 Fork lifting deceleration sensor
3 Sensor support bracket Drill
4 Encoder locking bolts
Ladder
Screw tap ø 8,5 10mm
6 5 Nylon thread for the encoder rotation Pliers for faston Drill Spanner
6 Spring coupling upper ring INSTALLATION PROCEDURE
7 Tightening spring
Before starting the working, make sure to wear suitable safety clothing.
8 Insert for the thread connection
7 9 Thread coupling lower ring
Drive the truck in a safety area far from the passage of pedestrians and other vehicles
move forward the retractable carriage, lower the forks till they touch the ground, put the
ROTATION DIRECTION key switch in position OFF, disconnect the battery.
5 8 OF THE THREAD ON
THE PULLEY 1) 10mm SPANNER, LADDER WITH PLATFORM - Position the ladder on the right side of
Pict. 16
the column and assemble the ENCODER on the proper bracket (Pict. 17).
5
2) DRILL COMPLETE WITH 5mm DRILL , TAP WRENCH COMPLETE WITH M6 SCREW
TAP, LADDER WITH PLATFORM , 10mm SPANNER - Draw the holes (as shown in the
3 picture enclosed) of the sensor support bracket of the fixed mast (Ref. 3 Pict. 17), carry out
the holes and thread. Draw the holes (as shown in the picture enclosed) of the bracket with
ring on the lower part of the intermediate mast upper crosspiece (Ref. 6 Pict. 16), carry out
2 the holes and thread. Fasten the bracket complete sensor and the bracket with ring by
means of the spanner.
+ 50mm
estension 3) PLIERS FOR FASTON - Take the nylon rope and form a ring (Ref. 8 Pict. 16) and by means
2 of the pliers tighten the crimp in order to fix it; hook the spring to the ring fixed on the mast
crosspiece, hook the ring of the nylon rope to the spting lower hook (Pict. 19). By means of
1 the nylon rope make a complete revolution on the encoder pulley observing the direction of
revolution (as shown in pict. 19) by letting the other end of the rope fall down.
4) Move the ladder far from the truck, connect the battery and put the key switch in position
4 ON. Lift the forks till the lower crosspiece of the intermediate mast reaches 1m height
from the floo; position the beam under the mast (Pict. 20), lower the forks and lean the
mast on the beam, put the key switch in position OFF and disconnect the battery.
WARNING: The beam has a safety function and so it must be positioned well.
Pict. 19 5) DRILL COMPLETE WITH 5mm DRILL, TAP WRENCH COMPLETE WITH M6 SCREW
Pict. 17 TAP, 10mm SPANNER- Draw the holes (as shown in the picture enclosed) of the bracket
with ring on the upper part of the intermediate mast lower crosspiece (Pict. 18-20), draw
the holes and thread. Fix the bracket by means of the bracket.
6) PLIERS FOR FASTON - Make the nylon rope end go through the ring and tighten it by
5 pulling it until the spring is stretched of about 50mm (Pict. 19); using the nylon rope form
a ring and tighten the crimp in order to fix (Ref. 8 Pict. 4), cut the exceeded rope.
8 7) Fasten the onnection cable to the right mast cylinder by moving the connector upwards;
connect the cable lower ends to the MHYRIO module (see diagram on page 10), join the
encoder and sensor connectors. Connect the battery, put the key switch in position ON,
lift the forks and remove the beam, lower the forks till they touch the ground and program
the preselector referring to the table enclosed and the Service manual on page 51 of the
electric section.
9 Bracket Support
Pict.15 Pict. 18 Pict. 20
locked by ring beam

OPTION SHEET No. 6/B WIRING DIAGRAM TO CONNECT

- INDUCTIVE ENCODER
- DECELERATION SENSOR
INDUCTIVE (UPWARD MOVEMENT)
AND ENCODER RESET
ENCODER
MHYRIO Sw5
6 MODULE INDUCTIVE
ENCODER
INDUTTIVO
ENCODER

OPTION SHEET No. 6/C EPS-AC
ENABLING OF THE HEIGHT PRESELECTOR FUNCTION WITHOUT RETRACTABLE CARRIAGE
-CONSOLE CONNECTION NOTES
To carry out this operation the console must be linked to the “SICOS” 16 module in order to enable the preselector function.
All the height setting operations are carried out by means of the “SICOS” (Display) module keyboard.
To enable the “SICOS” 16 module to the preselector function, the console can be connected (when the machine is off) to the “EPS-AC” 6 module by
means of the access hole located behind the seat; by means of the CAN BUS connection the “SICOS” 16 module can be entered. To search the
module, refer to the “SERVICE MANUAL” (electric section)on page 24-25 CONSOLE CONNECTION
CONNECTOR
NOTE: This table does not substitute the procedure described on the Manual Service; it is an indication of a function quick configuration Pict. 21
ENABLING OF THE HEIGHT PRESELECTOR WITHOUT RETRACTABLE CARRIAGE IN SEQUENCE
Sequence CONSOLE CONSOLE SELECTION MAIN MENU 1 MAIN MENU 2 SELECTION CONSOLE DISPLAY SELECTION
Accessories Module Setting Description of the operations to be performed
No. MAIN MENU CONFIG MENU KEY DISPLAY DISPLAY DISPLAY KEY DISPLAY PARAMETER PARAMETER KEY DISPLAY
When the machine is off, connect the console to the SICOS

1
(Display) 16 Module. Put the key switch in position ON
2 SET OPTIONS ENCODER TYPE
16 - SICOS Set 1 to enable SICOS to read the encoder
(Diaplay)
PRE-HEIGHT
Set ON to enble Sicos to the HEIGHT PRESELECTOR
3 SET OPTIONS ON function, press OUT, then ENTER to store. Put the key
SELECTOR
switch in position OFF to save. Remove the console. Put the
key switch in position ON
DOWN arrow PROGRAM Lift the forks up to the level after which the withdrawing of the
4 Enter MAIN MENU 1 Enter
UP arrow OFFSET mast begins. Measure the fork height from the ground. Set
the value using the numeric keyboard.
5 Enter MEMO
Put the key switch in position OFF then on ON to save the
value.
16 - SICOS Lift the forks till the desired height is reached (the
(Diaplay) programmed level must be higher than the "PROGRAM
6 LEVEL SETTING - SEQUENCE TO BE REPEATED FOR ALL THE LEVELS
OFFSET" value). Type the No. Of the desired level (i.e. 03)
To enter the "AUTOTEACHING" selector program
7 Enter
To save the value acquired
8 Enter
To restore the preselector working screen and to restore the
9 OUT OUT main DISLAY
DELTA ADJUSTMENT FOR THE DRAWING AND THE STORE OF THE PALLET ON THE SHELF
PRAMETER To modify the store stroke delta (default value 5) increasing
10 OPTION 5 the value the store stroke delta is increased.
CHANGE
CAN I/O
PRAMETER To modify the drawing stroke delta (default value 5)
11 OPTION 6
CHANGE Increasing the value the drawing stroke is increased.
REVISION 0 1 2 3 4 5 6 Date: March 2002 Comp. No.: 1517320 Pag. 14c

OPTION SHEET No. 6/D EPS-AC
ENABLING OF THE HEIGHT PRESELECTOR FUNCTION WITH RETRACTABLE CARRIAGE IN SEQUENCE
-CONSOLE CONNECTION NOTES
To carry out this operation the console must be linked to the “SICOS” 16 module in order to enable the preselector function. All the height setting operations are
carried out by means of the “SICOS” (Display) module key board.
To enable the “SICOS” 16 module to the preselector function, the console can be connected (when the machine is off) to the “EPS-AC” module by means of the
access hole located behind the seat; By means of the CAN BUS connection the “SICOS” 16 module can be entered. to search the module, refer to the “SERVICE
MANUAL” (electric section) on page 24-25 CONSOLE CONNECTION
CONNECTOR
NOTE: This table does not substitute the procedure described on the Service Manual; it is an indication of a function quick configuration Pict. 22
HEIGHT PRESELECTOR ENABLING WITHOUT RETRACTABLE CARRIAGE IN SEQUENCE

SELECTION SELECTION
Sequence CONSOLE CONSOLE MAIN MENU 1 MAIN MENU 2 CONSOLE PARAMETRO SELECTION
Accessories Module KEY KEY Setting Description of the operations to be performed
No. MAIN MENU CONFIG MENU DISPLAY DISPLAY PARAMETER DISPLAY KEY DISPLAY
DISPLAY DISPLAY
When the machine is off, connect the console to the SICOS

1
(Display) 16 module. Put the key switch in position ON
2 SET OPTIONS ENCODER TYPE
Set 1 to enable the SICOS to read the encoder
16 - SICOS PRE-HEIGHT
3 SET OPTIONS ON Set ON to link Sicos to the HEIGHT PRESELECTOR
(Diaplay) SELECTOR
function, press OUT, then ENTER to store.
AUX FUNCTION Set ON to link Sicos to operate with retractable carriage,

4 SET OPTIONS ON press OUT, then ENTER to store. Put the key switch in
2
position OFF to save. Remove the console. Put the key
switch in position ON
DOWN arrow PROGRAM Lift the forks up to the level after which the withdrawing of the
5 Enter MAIN MENU 1 Enter
UP arrow OFFSET mast begins. Measure the fork height from the ground. Set
the value using the numeric keyboard on the display.
6 Enter MEMO Put the key switch in position OFF then in position ON to
save the value.
16 - SICOS Lift the forks till the desired height is reached (the
(Diaplay) programmed level must be higher than "PROGRAM
7 LEVEL SETTING - TO BE REPEATED FOR ALL THE LEVELS
OFFSET" value). Type the No. of the desired level (i.e. 03)
To enter the "AUTOTEACHING" selector program
8 Enter
To save the value acquired
9 Enter
To restore the preselector working screen and to restore the
10 OUT OUT main display
DELTA ADJUSTMENT FOR THE DRAWING AND THE STORE OF THE PALLET ON THE SHELF
PARAMETER To modify the store stroke delta (default value 5). Increasing
11 OPTION 5 the value, the store stroke is increased.
CHANGE
CAN I/O
PARAMETER To modify the drawing stroke delta (default value 5).
12 OPTION 6
CHANGE Increasing the value, the drawing stroke is increased.
REVISION 0 1 2 3 4 5 6 Date: March 2002 Comp. No.: 1517320 Page 14d

NOTES:

OPTION SHEET No. 7
ENABLING OF THE 5. HYDRAULIC FUNCTION
- 5. HYDRAULIC FUNCTION KIT
PUSHBUTTON TO BE PRESSED
TO ENABLE THE 5. FUNCTION
S Y M B O L
APPEARING IN
THE DISPLAY
WINDOW
S
+ -
100
50 T
N
20
D
Pict. 23
CONNECTOR “F”
5. FUNCTION FOR THE SOLENOID
PIPE FITTING TO CONNECT THE
HOSE REEL SUPPLY PIPE
VALVE CONNECTION
SOLENOID VALVE IN
ADDITION TO THE
HYDRAULIC UNIT
Pict. 24

INSTALLATION NOTES
Before ordering the assembly kit, refer to the hose reel/”H3” mast height and assembled
battery piring table (Page 12a).
13-17-18-19mm ELECTRIC ø 4 and 8,5 TAPELINE

SMALL
SPANNER DRILL STEEL DRILL
SLOTTED
SCREWDRIVER
M10 SCREW 6mm ALLEN SCRIBE SQUARE LADDER

TAP WRENCH
WITH TAP WRENCH
PROCEDURE
Before starting any work always wear suitable safety clothing.

Drive the truck in a safety area, far from the passage of pedestrians or other vehicles, move
forward the retractable carriage, lower the forks till they touch the ground, put the key switch in
position OFF, disconnect the battery.
1) LADDER WITH PLATFORM, SCRIBE, SQUARE, TAPELINE - Place the ladder on the left side of
the truck connected with the mast, climb the ladder with the tools and the drawing in order to mark
the position of the holes to fix the hose reel support bracket.
NOTE:
With the “HE” mast, the holes must be performed on the crosspiece as shown in picture 26 page
18a
With the “BETA” mast the holes must be performed aside the mast as shown in picture 27 page
18a
2) ELECTRIC DRILL, Ø 4 e 8,5 STEEL DRILL, M10 SCREW TAP COMPLETE WITH TAP WRENCH,
17mm SPANNER- Carry out the holes marked earlier by means of the Ø 4 small drill and then
with the Ø 8,5 large drill and then thread using the M10 screw tap. Fasten the bracket to the
column by means of the spanner and then fix the hose reel
complete with hoses on the bracket itself.
3) No. 2 13mm spanner - Loosen the valve (Ref. Pict. 30) to A

discharge the pressure inside the valve unit, tighten the valve. C
By means of the same spanner unscrew the threaded bar stop B
nuts keeping the valve unit joint (Ref. B-B1 Pict. 30). Take out B1
the threaded bars and replace them with the longer ones E
contained in the kit, add the new solenoid valve with the proper
O-Rings (Ref. C Pict. 30) and tighten paying attention that the
O-Rings do not move from their seat. Carry out the solenoid
valve electric connection referring to the wiring diagram enclosed D
on page 18b.
Pict. 30

4) 17-18-19mm SPANNER - Screw the pipe fittings of an end of the hoses twined to the hose reel pipe
fittings and bring the other end of the hoses to the hydraulic unit; bind them to the hoses located on
the mast by means of clamps and screw the solenoid valve pipe fittings to the 5. function solenoid
valve.
5) SCRIBE, TAPELINE, SQUARE - Connect the battery, enable the emergency pushbutton and put the
key switch in position ON. Enable the lifting and move the upper part of the fork holder plate to the
height of 1 m. Mark the position of the holes (see the enclosed picture) on the fork holder plate
shoulder (Ref. 9 Pict. 20 on page 18a) by means of the tools in order to apply the support bracket of
the revolving joint.
6) ELECTRIC DRILL, Ø 4 e 8,5mm STEEL DRILL, M10 SCREW TAP - Carry out the holes on the points
marked earlier with the Ø 4mm small drill and then with the Ø 8.5mm large drill, thread the holes by
means of M10 screw tap.
7) 17mm SPANNER, 6mm ALLEN WRENCH - Fix the bracket to the fork holder plate shoulder by means
of the spanner (Ref. 9 Pict. 20 page 18a) and fasten the revolving joint to the bracket by means of the
Allen wrench (Ref. 7 Pict. 20 page 18a).
8) 18-19mm SPANNER- Act the lifting and align the revolving joint with the hose reel lower base, with the
pipes completely rolled load the spring by turning the hose reel clockwise three times and connect
the hose pipe fittings to the revolving joint pipe fitting. Perform a complete lifting and lowering movement
and make sure that the hose reel twined hose is always tightened.
9) Connect the console to the “SICOS” 16 module and carry out the procedure to enable the 5. function
by referring to the table on page 18b and to the “Service Manual” on page 41 of the electric section.
NOTES:

OPTION SHEET No. 7/A COMPONENTS TO ASSEMBLE THE

5. HYDRAULIC FUNCTION
4
6
3
2
1
5
HOSE REEL WITH SUPPORT FOR THE A 709 (HE) MAST HOSE REEL WITH SUPPORT FOR THE A 708 (BETA) MAST
Pict. 26 Pict. 27
10
7
9 8 11
Pict. 29
COMPONENTS FOR THE 5. HYDRAULIC FUNCTION APPLICATION

Pict. 25 Pict. 28 Re f. Com pone nt de scription
1 Hose reel for "HE" Ø 340mm & Ø 400mm mast
TABLE OF COUPLING HOSE REEL H3 MAST 2 Hose reel support bracket for the "HE" mast
TYPE OF MAST A708 & A709 A709 3 Bolts to fasten the hose reel to the bracket
HOSE REEL DIAMETER Ø 340m m Ø 400m m NOTES 4 Hose reel for Ø 340mm & Ø 400mm "BETA" mast
TYPE OF BATTERY H3 H3 5 Hose reel support bracket for "BETA" mast
DIN "C" 1220 X 784 X 280 420 Ah FROM 4500 TO 6700 FROM 6700 TO 9800 6 Bolts to fasten the hose reel to the bracket
DIN "C" 1220 X 784 X 352 560 Ah FROM 4500 TO 6700 FROM 6700 TO 9800 7 Rotating joint to connect the hoses
DIN "C" 1220 X 784 X 424 700 Ah FROM 4500 TO 6700 FROM 6700 TO 9800 8 Rotating joint support bracket
DIN "C" 1220 X 784 X 496 840 Ah FROM 4500 TO 6700 FROM 6700 TO 9800 9 Bolts to fasten the bracket to the fork holder plate
10 Solenoid valve to be added for the 5. Function
DIN "B" 1032 X 784 X 350 420 Ah FROM 4500 TO 6700 FROM 6700 TO 8700 Only for 11 Threaded bars to connect the solenoid valve
DIN "B" 1032 X 784 X 440 560 Ah FROM 4500 TO 6700 FROM 6700 TO 8700 NARROW truck 12 Hydraulic hose kit (supplied according to the column height)

-SOLENOID VALVE CONNECTION DIAGRAM

OPTION SHEET No. 7/B
-MODULE CONFIGURATION TABLE
Page
Page
MODULO 6
MHYRIO
5. FUNCTION
5. FUNCTION
Se que nce CONSOLE CONSOLE SELECTION CONSOLE De scription of the ope ra tion to
Acce ssorie s Module Se tting
No. MAIN MENU CONFIG MENU KEY PARAMETER be pe rform e d
W hen the machine is off, connect

the console to the 16 SICOS
(Display) module. Place the key
1 switch in position ON
16 - SICOS Select OFF, key switch OFF the
(Diaplay) ON in oder to save. By pressing the
SET OPTIONS OPTIONAL 1-2
key the 5. Function is enabled and
2 HYDRAUL OFF
on the display the fork symbol is
VALVE ON/OFF
replaced by the hydraulic jaws
symbol.

OPTION SHEET No. 8
DECELERATION OF THE SIDE CYLINDERS AND OF THE CENTRAL

CYLINDER AND OF THE “HE” MAST (LAST 50mm - UPWARD MOVEMENT)
DECELERATION SENSOR OF
THE SIDE CYLINDERS
DECELERATION SENSOR OF
THE CENTRAL CYLINDER
READING CAM OF READING CAM FOR

THE SIDE CYLINDER THE CENTRAL
SENSOR READING
Pict. 31 CYLINDER SENSOR

OPERATING PROCEDURE OF THE DECELERATION KIT (UPWARD MOVEMENT)
-DECELERATION KIT (UPWARD MOVEMENT)
-NONE
X OPERATION NOTES
The kit is applied on the great elevation “HE” masts where some hole rod plunger cylinders without any
internal deceleration device are assembled. This equipment is applied to avoid any metallic flapping at
the end of every forward movement of the central cylinder and of the side cylinders.
POSITIONING OF THE DEVICES
1) The deceleration sensor of the free lifting (central cylinder) is fastened on a plate, already provided
with threaded holes) and welded on the outer side of the fixed mast (Ref. 1-2 Pict. 40 on page 20b). The
reading cam is welded on the rear side between the fork holder plate and the mast shoulder (Ref. 3 Pict.
39 on page 20b).
2) The side cylinder deceleration sensor is fixed on a plate welded on a metallic collar, fastened on the
upper end of the right cylinder (Ref. 1-2 Pict. 34 page 20a). The reading cam is welded on the internal
withdrawing device base (Ref. 3 Pict. 33 page 20a) bent as shown in pict. 36-37 on page 20a.
3) The connection is obtained by means of a sheath with two connectors to join the two sensors, which
becomes a sole connector. It joins on “A” “Pin 1-16-19” connector of the “MHYRIO” 6 module. See the
connection diagram enclosed on page 20c
OPERATION
When the lifting is carried out and the free lifting cam is connected with the sensor.
The pump motor reduces the number of revolutions decelerating the stroke in the last 50mm. Once the
stroke is over the pump motor increases the number of revolutions carrying out the lifting with the maximum
speed until the second cam is connected with the second sensor causing the decreasing of the pump
motor revolution number and decelerating the side cylinder stroke in the last 50mm.

POSITION OF THE READING SENSOR ON

OPTION SHEET No. 8/A THE RIGHT LIFTING CYLINDER COM P ONENTS FOR THE DECELERATION OF THE S IDE APPLICATION OF THE SENSOR AND CAM TO
CYLINDER END OF S TROKE
DECELERATE THE SIDE CYLINDERS OF THE
Re f. Com pone nt de scription
1 S ens or s upport with fas tening c ollar on the c y linder “HE” MAST (LAST 50mm UPWARD
1 2 Induc tive s ens or MOVEMENT)
3 S ens or reading c am
4 Connec tion s heath
CAM WELDING ON “A 708 CAM WELDING ON “A 709

BETA” MAST “HE” MAST
3
Pict. 34
3
POSITION OF THE READING CAM ON

THE INTERMEDIATE MAST
Pict. 36 Pict. 37
Pict. 33
Pict.. 35
Pict. 32

OPTION SHEET No. 8/B APPLICATION OF THE SENSOR AND CAM TO

DECELERATE THE CENTRAL CYLINDER OF
THE “HE” MAST (LAST 50mm - UPWARD
MOVEMENT)
POSITION OF READING
SENSOR ON THE MAST
UNDER THE CROSSPIECE
Pict. 40
COMPONENTS FOR THE SLOW ING DOW N OF THE
CENTRAL CYLINDER END OF STROKE
1 Plate to be welded to support the sensor
2 Inductive sensor
3 Sensor reading cams
4 Connection sheath
POSITION OF THE READING

CAM ON THE REAR SIDE OF
THE FORK HOLDER PLATE
3
Pict. 38 Pict. 39

OPTION SHEET No. 8/C WIRING DIAGRAM FOR THE DECELERATION SENSOR
CONNECTION OF THE CENTRAL CYLINDER AND THE SIDE
LAST 50mm LIFTING SLOWING CYLINDERS (LAST 50mm - UPWARD MOVEMENT)
DOWN SENSOR OF THE
CENTRAL CYLINDER
CON. 16/B
CON. 16/A
CON. 16
CON. 16/C
LAST 50 mm LIFTING
SLOWING DOWN SENSOR
19/A
16/A
OF THE SIDE CYLINDERS
1/A
Page
Page
5. Function
REVISION 0 1 2 3 4 5 6 Date: March 2002 Comp. No.: 1517320 Page 20c

OPERATING PROCEDURE OF THE DECELERATION KIT APPLICATION OF THE PHOTOCELL FOR THE
(UPWARD MOVEMENT) WITH PHOTOCELL DECELERATION IN THE LAST 50 mm
(UPWARD MOVEMENT) OF THE HE” AND
The kit is applied on the great elevation “HE” masts where some hole rod “BETA” MAST SIDE CYLINDERS
plunger cylinders without any internal deceleration device are assembled. This
equipment is applied to avoid any metallic flapping at the end of every forward
movement of the central cylinder and of the side cylinders. OPERATION
POSITION OF THE PHOTOCELL When the lifting is carried out and the free lifting cam is connected with the first
reading sensor.
1) The deceleration photocell of the side cylinders is fixed on a plate. The Plate The pump motor reduces the number of revolutions decelerating the stroke in
is fixed on the front part connecting to the fixed mast (Ref. A Pict. 2-3) the last 50mm. Once the stroke is over the pump motor increases the number
of revolutions carrying out the lifting with the maximum speed until the rear
2) The rear reflector is welded on the internal withdrawing device base (Hin. B reflector is connected with the photocell causing the decreasing of the pump
Pict. 4) motor revolution number and decelerating the side cylinder stroke in the last
50mm.
3) The electric connection is obtained by means of a sheath complete with
connectors. A connector is joint to the photocell connector, the other one is NOTE: In case the photocell is assembled on operating machines, it is advisable
joint to the sensor and the third one to the connector 16, which is connected to to carry out some tests in order to determine the right position, before fixing
connector “A” on the “Pin 1-16-19” of “MHYRIO” modul 6. See the connection the photocell and sticking the rear reflector.
diagram (page 20c)
Ref. Component Description

1 Reading Photocell
2 Photocell Support
3 Photocell Fixing Plate (welded)
4 Photocell Reading Reflective Strip
A
1
2
3
Fig. 1
Fig. 4
Fig. 2 Fig. 3
REVISION 0 1 2 3 4 5 6 Date: March 2002 Comp. No.: 1517320 Page 20d

OPTION SHEET No. 9
FORK LOCK WITH 1200mm PALLET (DOWNWARD MOVEMENT)
sensor
Reading
cam
Pict. 41

OPERATING PROCEDURE OF THE LOCK WITH 1200mm PALLET

(DOWNWARD MOVEMENT)
-FORK BLOCK KIT (DOWNWARD MOVEMENT)

X OPERATION NOTES
The kit is applied on the machines using the pallet from the1200mm side. This equipment is applied to
avoid that during the lowering phase with retractable carriage completely retracted, the pallet flaps
against the truck wheelbase.
NOTES: This option allows lowering the forks till they touch completely the ground only when the sideshift
carriage is completely extended. In some narrow aisles it will be impossible to draw or store the pallet
placed on the ground.
POSITION OF THE DEVICES.
1) The lock sensor is fastened on a plate welded on the left shoulder of the retractable carriage under the
mast support (Ref. 1-2 Pict. 43 on page 22a for the Standard machine, Ref. 1-2 PICT. 45 ON PAG. 22a
for the Narrow machine) and it is joint electrically to connector 19 already preset on “MHYRIO” “Pin 7-
17-20 CN A” 6 module. See the wiring diagram on page 22b.
2) The reading cam is welded on the mast side fork holder plate shoulder (Ref. 3 Pict. 44 on page 22a for
Standard machine, Ref. 3 Pict. 46 on page 22a for Narrow machine)
OPERATION
When the pallet resting on the forks is lowered and the retractable carriage is completely retracted, the
cam reaches the sensor and locks the lowering. This prevents the pallet from flapping against the
wheelbase. To place the pallet on the ground it is necessary to extend the retractable carriage.
CAN I/O MODULE CONFIGURATION TABLE
To enable the machine to work with the pallet forked on the 1200mm side it is necessary to perform
the procedure described below, by setting AUX FUNCTION 1 in position ON.
ADJUSTMENT TO ENABLE THE MACHINE TO THE 1200mm PALLET DRAWING

Sequence MENU CON. CONSOLE Description of the operation to
Accessories Module SETTINGS
No. CONSOLE PARAMETER be carried out
When the machine is off, connect
the console to the CAN I/O
module, key switch ON.
To enable the machine to draw
the 1200mm pallet and to prevent
AUX
1 CAN I/O SET OPTIONS ON the pallet from leaning on the
FUNCTION 1
wheelbase with rectractable
carriage retracted.

OPTION SHEET No. 9/A APPLICATION OF THE SENSOR AND CAM FOR
THE FORK LOWERING LOCK WITH 1200mm
PALLET
COM P ONENT TO AP P LY THE FORK LOW ERING

BLOCK W ITH 1200m m P ALLET
1
Re f Com pone nt de scription
1 P late to be welded for the s ens or s upport
2 Induc tive s ens or 2
3 S ens or reading c am
4 Connec tion s heath 1
Pict. 43 Pict. 45
SENSOR POSITION ON THE

SENSOR POSITION ON THE “STANDARD” “NARROW” RETRACTABLE
RETRACTABLE CARRIAGE CARRIAGE
READING CAM POSITION FOR THE READING CAM POSITION FOR

“STANDARD” MACHINE “NARROW” MACHINE
3 3
Pict. 44 Pict. 46
Pict. 42

OPTION SHEET No. 9/B WIRING DIAGRAM TO CONNECT THE

INTERLOCK SENSOR OF THE LOWERING
FORKS WITH 1200mm PALLET
INTERLOCK MODULE 6 “MHYRIO”
SENSOR OF THE
LOWERING
FORKS WITH
1200mm PALLET
20/A
17/A
7/A
page
page
SW10
INTERLOCK SENSOR
MHYRIO OF THE LOWERING
FORKS WITH
6 MODULE 1200mm PALLET
EV opt

OPTION SHEET No. 10
WARMED SEAT
CONNECTOR TO
JOIN THE
RESISTANCE
Pict. 47

PROCEDURE TO INSTALL THE WARMED SEAT KIT
- WARMED SEAT KIT
X MODULE CONFIGUARATION
-NONE
STANDARD NECESSARY TOOLS
Phillips 5mm
screwdriver Allen wrench
The warmed seat is equipped with a kit complete with connecting sheaths.
For the assembly it is necessary to open the motor compartment bonnet by means of the Allen wrench
take out the stardard seat and assemble the warmed seat on the same guides.
Open the system compartment bonnet by means of the Phillips screwdriver and disconnect the engine
compartment cooling fan connection from connector “L”. Join the sheath male connector to the system
connector “L”, the famale connector “L” to the cooling fan and the sheath connector “G” to the seat
connector. See the picture below.
SHEATH FEMALE
CONNECTOR “G”
MUST BE JOINT TO WARMED SEAT
SHEATH MALE THE SEAT
CONNECTOR “L” MUST BE
JOINT TO THE SYSTEM
CONNECTOR “L”
SHEATH
CONNECTOR
“L” JOINT TO
THE SYSTEM
SHEATH FEMALE
CONNECTOR “L”
MUST BE JOINT TO
THE FAN
Pict. 48

TO CONNECT THE
WIRING DIAGRAM
WARMED SEAT
STARTING
INTERNAL
THERMOSTAT
WARMED SEAT
RESISTANCE
CONNECTION FOR
THE
REFRIGERATING
ROOM

NOTES:

OPTION SHEET No. 11
- 30° REFRIGERATING ROOM
Pict. 49
INTERCOM FOR
THE EXTERNAL
COMMUNICATION
FIXED INSIDE ON
THE ROOF
COLUMN Pict. 50
ELECTRIC DEVICE AND

PROGRAMMING CONSOLE
CASE
Pict. 51
ELECTRIC COMPONENTS OF THE REFRIGERATING ROOM

22 23
25
24
Pict. 52
1 7
4 10 11 12 13 14 15 16
8
5
6
3
17 18 19 20 21
Pict. 53
ELECTRIC COMPONENT POSITION
The electric components shown in the previous page are described in the table below.

1 Card
2 Resistance container to heat the cab
3 Fan to heat the cab
4 Main remote control switch
5 Resistance remote control switch to heat the secondary devices
6 Resistance remote control switch to heat the primary devices
7 Primary resistances
8 Cab heating resistance thermal switch
9 Connector connection
10 Fuse 3A to protect the control card
11 Fuse 3A to protect the starting key
12 Fuse 3A to protect the fan
13 Fuse 10A to protect the cab heating resistance ( 1 )
14 Fuse 10A to protect the cab heating resistance (1a)
15 Fuse 10A to protect the cab heating resistance ( 2 )
16 Fuse 10A to protect the cab heating resistance (2a)
17 Fuse 7,5A to protect the windscreen defroster resistance
18 Fuse 3A to protect the upper roof glass defroster resistance
19 Fuse 5A to protect the driver's side front glass defroster resistance
20 Fuse 1A to protect the side door glass defroster resistance
21 Fuse 5A to protect the central door glass defroster resistance
22 Console to program the temperatures and the intercom audio
23 Upper air recirculation louver
24 Lower air recirculation louver
25 Control panel closing door
NOTE: All the Hyster codes of the components are contained in the spare part catalogue

-NONE
-NONE
X OPERATION NOTES
ELECTRIC SYSTEM OPERATION DESCRIPTION
“CAB CONSOLE”
CAB TIME ADJUSTMENT INTERCOM

TEMPERATURE OF THE GLASS VOLUME
ADJUSTMENT RESISTANCE ADJUSTMENT
LED LED LED

HEATER GLASS HEATER INTERCOM
20° +
00
ON
ON 15°
ON
TALK
10° MINUTES -
RESISTANCE
STARTING
TIME
By using the console you can adjust:
1) The inner temperature of the cab by acting on the “HEATER” keys.
2) The glass resistance operating time to allow the refrigeration room inlet and outlet defrosting by
acting on the “GLASS HEATER” keys.
3) Variation of the volume of the intercom for the external audio connection by acting on the
“INTERCOM” keys.
The procedures of the adjustments are described in the following pages.

1) “HEATER” CAB HEATING
LED LED LED

20° +
00
ON
ON 15°
ON
TALK
10° MINUTES
-
ON KEY “ON” - By pressing this key the resistance starting remote control switch to heat the cab
is enabled and disabled
GREEN LED - If it is on, it indicates that the resistance starting remote control switch is
enabled.
20°
TEMPERATURE INDICATOR - It indicates the set or the real temperature (from 10°C to 20°C
with level of 1°C). The indication of the set temperatur occurs immediately when the key “ON”
15° is enabled and not when the machine is started. The real temperature is displayed by pressing
the arrows and at the same time. If the temperature is lower than the minimum scale
temperature the first LED of the indicator flashes. If the temperature is higher than the maximum
10° scale temperature the whole indicator scale flashes.
UP and DOWN ARROWS - To vary the set temperature press one of the two keys a second
at least till the desired temperature is reached. To display the real temperature press both
keys at the same time.
The two cab heating elements are inserted at the same time till the set temperature is reached
(1 or 2 degrees earlier), afterwards, the resistances 2 and 2A are automatically disabled and
the heating operates with a heating element only: resistances 1 and 1A.
After the manual disabling of the function, the fan remains enabled for about 5 minutes.
The last set temperature is stored when the machine is turned off.

2) ENABLING TIME ADJUSTMENT OF THE “GLASS HEATER” GLASS

DEFROSTING RESISTANCES
LED LED LED

20° +
00
ON
ON 15°
ON
TALK
10° MINUTES -
KEY “ON” - By pressing this key the glass reistance automatic starting remote control switch
is enabled and disabled.
ON NOTES: a) The glass heater starting and the cab heating starting must not be performed at
the same time.
b) The glass resistances must be enabled 5 minutes before going in or out the
refrigerating room.
GREEN LED - If it is on it indicates that the glass heating resistance remote control switch is
enabled.
00 MINUTE INDICATOR DISPLAY - It indicates the real time during which the heater is operating
(the minute scan) and the initial set time displayed when the machine is started. The time
MINUTI selection can occur between 1 and 15 minutes. When the machine is stopped, the last set
datum is stored.
UP AND DOWN ARROW - To vary the heating time press one of the tow key for at least 1/2
second until the desired value is reached. To display the set time press both keys at the same
time.

3) “INTERCOM” EXTERNAL COMMUNICATION AUDIO VOLUME

ADJUSTMENT
LED LED LED

20° +
00
ON
ON 15°
ON
TALK
10° MINUTES -
KEY “ON” - By pressing the key, the audio reception from the inside to the outside of the cab
ON is enabled.
GREEN LED - If it is on, it indicates that the audio function is enabled.
TALK KEY “TALK” - By keeping pressed this key the audio transmission from the inside to the
outside of the cab is enabled, by releasing the key the audio transmission stops.
+
VOLUME INDICATION - It indicates the 10 different levels of volume intensity coming from
the outside and displayed any time the intercom is started. When the machine is stopped, the
last set value is stored.
UP and DOWN ARROW - To vary the volume intensity from the outside to the inside press
one of the two keys for 1/2 second till the desired volume is reached.
ADJUSTMENT OF THE VOLUME FROM THE INSIDE TO THE OUTSIDE - It can be adjusted
by means of a trimmer located inside the cab on the intercommunication system/loudspeaker
unit.

POSITION OF THE COMPONENTS ON THE REFRIGERATING ROOM CAB PANEL
RES - 1 - 1A
RES - 2 - 2A
THERMAL
J1 DEVICE
FAN
J4
CONNECTOR TO JOIN THE HEATER

J2
F1
F2 F5
F3 F6
J3
F4 F7
F11 F8
F12 F9
F13 F10
J5
+
BATT
J6 T1 T2 T3
CONNECTOR TO JOIN THE HEATER

-
BATT

SERVICE Section: ELECTRIC INSTALLATION
WIRING DIAGRAM TO CONNECT THE CABLES

OF THE REFRIGERATING ROOM CAB
MOD. ALL THE MODELS
“CONTROL” ELECTRONIC CARD
J1 J4
J2 J3 J5 J6
1 2 GRUPPO ALTOPARLANTE
1 8 1 2 1 6 1 5
SULLA PORTA
VIOLET
BLEU
VIOLET
ORANGE
BLACK
BLACK
BLEU
BROWN
RED
BLEU
RED
RED
SCREENED CABLE 8
POLES
T1 T2 TERMICA T3 OUT
MC
F11 + MIC.
-
F13 F14 RES-1 RES-2 DEFROSTER + BATT -
FAN
SCREENED CABLE
& POLES
W IRING DIAGRAM
Dia gra m
De scription of the function Fuse va lue
re f.
F1 Fuse to protect the RES-2 10A
F2 Fuse to protect the RES-2A 10A
F3 Fuse to protect the RES-1 10A
T1 T2 F4 Fuse to protect the RES-1A 10A
T3
F5 Not used
F6 Fuse to protect the central door defroster resistance 5A
F5 F6 F7 F8 F9 F10 F7 Fuse to protect the side door defroster resistance 1A
RED F8 Fuse to protect the driver front glass defroster resistance 5A
F3 F4 F1 F2 F9 Fuse to protect the roof upper glass defroster resistance 3A
RED
F10 Fuse to protect the windscreen glass defroster resistance 7,5A
RED F11 Fuse to protect the fan of the air recirculation in the cab 3A
RES-2 RES-2A - BATT F12 Fuse to protect the control card output cable 3A
400 H 400 H F13 Fuse to protect the control card input cable 3A
HEATER
T1 RES-1 e 1A remote control switch
CONNECTOR
T2 RES-2 e 2A remote control switch
RES-1 RES-1A DOOR DEFROSTER T3 Door defroster remote control switch
400 H 400 H RESISTANCES RES-1-1A 400 H cab heating resistances
RES-2-2A 400 H cab heating resistances
V fan of warm air recirculation in the cab
MIC Microphone to communicate with the outside
+Ba tt Battery positive connection cable
-Ba tt Battery negative connection cable

OPTION SHEET No. 12
SEAT BELT
-SEAT BELT KIT
-NONE
ELECTRIC 8,5mm 5-6mm ALLEN 13mm

DRILL STEEL DRILL WRENCH SPANNER
TAPELINE SCRIBE SQUARE
PROCEDURE
Before starting working, make sure to wear suitable safety clothing.
Drive the carriage in a safety area, far from the passage of pedestrians and other vehicles, move
forward the retractable carriage, lower the forks, put the key switch in position OFF, disconnect
the battery.
1) 5mm ALLEN WRENCH, TAPELINE, SCRIBE, SQUARE - By means of Allen wrench open the
engine compartment bonnet and remove the seat by taking it out from the guides (Pict. 54 page 29a).
By means of the tapeline, the scribe and the square mark the holes to fix the seat belt support bracket
on the bonnet observing the measures shown in pict. 56 for the NARROW truck and Pict. 57 for the
STANDARD truck on page 29a).
2) ELECTRIC DRILL, SCRIBE, 6mm ALLEN WRENCH, 13mm SPANNER - Assemble the drill and
carry out the holes in the marked points; by means of the two keys assemble the bracket complete
with seat belt as shown in picture (Pict. 58 on page 36a).

NOTES:

OPTION SHEET No. 12a SEAT BELT HOOKUP
SEAT BELT UNIT

COMPLESSIVO CINTURA
ASSEMBLE
MONTATO
Pict. 58
Pict. 55
No. 2 Ø 8,5
holes
No. 2 Ø 8,5
holes
HOLE TO APPLY THE NARROW TRUCK SEAT HOLE TO APPLY THE STANDARD
BELT TRUCK SEAT BELT
Pict. 56 Pict. 57
Pict. 54

OPTION SHEET: UPDATE No. 1
-INTERMEDIATE LIFTING LOCK SENSOR (“SW11”)

-FUNCTION RELEASE BY MEANS OF THE PUSH BUTTON ON THE
DISPLAY (“SW18”)
Picture 01
UPDATES TO BE INSERTED IN THE SERVICE MANUAL R1.4/2.5

SECTION "ADDITIONAL FUNCTIONS" Page 36
Release Update description
Description of the lifting lock sensor assembly and SICOS
1
module configuration
2 Description of the weighing function programming
Description of the speed reduction removal speed with
3
carriage completely extended
UPDATE 0 1 2 3 4 5 6 Date: March 2004 Comp. No.: 1517320 Page: 37

OPERATING PROCEDURE OF THE LIFTING LOCK KIT
! NECESSARY ADDITIONAL COMPONENTS
- LIFTING BLOCK KIT
! OPERATION NOTE
The kit is generally installed on machines, which are not provided with encoder or height preselector. The
equipment is used for programming an intermediate lifting lock, in case some hindrances prevents the
operator from working with the mast completely withdrawn.
POSITION OF THE EQUIPMENT
The sensor is fixed on a collar, which is generally fastened on the right lifting cylinder of the column
(Picture 04-05). The sensor is turned to the internal mast (Picture 05-06) . It is connected to connector
20, which is already provided on module 9 “MHYRIO” “Pin 8-17-20 CN A”.
The sensor reading cam correspond to the internal mast profile (Ref. B Picture 06) whereas the final end
is the base of the mast itself (Ref. A Picture 06).
HOW IT OPERATES
When performing the lifting, the internal mast base reaches

the sensor and stops the lifting to the established position. To
disable the lock, press push button “BATTERY OUT” located
on the display panel (Picture 02) and, in the same time, pull
the lifting lever (Joystick) to take the forks to the maximum PUSH BUTTONS LOCATED ON THE DISPLAY AND
height. USED FOR ENABLING THE INTERMEDIATE
LIFTING REALESE Picture 02
CONFIGURATION TO MODULE 16 SICOS TABLE
To enable the lifting lock function, follow the procedure below by setting “AUX INPUT 1” to 2 of the SET
OPTION configuration menu.
ADJUSTMENT TO ENABLE THE LIFTING LOCK

MENU
Sequence CONSOLE Description of the operations
Accessorie s Module CONFIGURATI SETTING
No. PARAMETER to be follow ed
ON CONSOLE
W hen the machine is off, connect
the console to the module 6
"EPS" control and enter module
16 "SICOS", then start the
machine, (key switch "ON")
To enable an intermediate lifting

block with realese by means of
1 SICOS SET OPTIONS AUX INPUT 1 2
key "BATTERY OUT" on the
display keyboard
Page: 38 Comp. No.: 1517320 Date:March 2004 0 1 2 3 4 5 6 UPDATE

INSTALLATION OF THE LIFTING LOCK SENSOR (“SW11”)
Picture 04
LIFTING LOCK SENSOR KIT
SENSOR SUPPORTING UNIT

Picture 05 FIXED ON THE CYLINDER
SENSOR (B)
READING
PROFILE
Picture 06 (A)
SENSOR
READING FINAL INTERMADIATE
Picture 03 POINT MAST

" INSTALLATION NOTE
5-6mm No. 2 13mm

ALLEN WRENCH OPEN ENDED
PROCEDURE SPANNER
Before starting to work wear suitable safety clothes.
Park the truck in a safe area, away from the transit of other motor vehicles and from the passage
of pedestrians,extend the retractable carriage
1) 5mm ALLEN WRENCH - Unscrew the bolts fastening the valve unit on the carriage, remove the
bonnet to reach module 9 “MHYRIO”. To lock, lift the forks, until the desired height is reached. Disable
the key switch, disconnect the battery.
2) No. 2 13mm OPEN ENDED SPANNER - Assemble the various components of the sensor kit. Fix the
collar complete with sensor to the lifting cylinder (Picture 05) by means of the spanner and position it
near the end of the intermediate mast (Picture 06 arrow “A”). Connect the sensor to Module 9
“MHYRIO” (see diagram on page 41), bind the cable to the cylinder by means of a clamp. Connect
the battery, set the key to “ON”, lower the forks and enable the sensor by performing the configuration
procedure of Module 16 “SICOS” (see table on page 2).

SW11 LOCK SENSOR CONNECTING DIAGRAM

ENABLING OF THE WEIGHING FUNCTION
! OPERATION NOTE
This option allows enabling the automatic weighing function of the weight lifted by the forks. Carry out the
weighing by keeping the forks in “FFL” (free fork lift) and by lifting them up to about 1000mm. To store the
real weight to be lifted, it is necessary to store two weighings:
a) Weight with empty forks
b) Weight with different loads (1.000 Kg, 1.500 Kg,2.000 Kg) according to the nominal capacity weight
written on the residual capacity plate.
a) WEIGHT WITH EMPTY FORKS
1) Connect the console (see table) and perform

procedure 1 and 2. Press push button “SW23”
provided with the balance symbol (Picture 07)
located on the display. The system starts the
weighing.
2) Pull the lifting lever (Joystick), the forks lift only PUSH BUTTON (“SW23”)TO SELECT THE
few seconds by keeping constant speed. It is WEIGHING FUNCTION Picture 07
now possible to detect the weight value. This
value is shown on the display about 4/5
seconds then it disappears and appears
automatically the weighing function.
b) WEIGHT WITH LOADS ON THE FORKS
3) Carry out table procedure 3. Put the nominal load on the forks. Take the forks with the load up to
1000mm, press push button “SW23” provided with the balance symbol (Picture 07). Carry out proce-
dure “2” to detect the weight.
TABLE OF CONFIGURATION TO MODULE 16 SICOS

To enable automatic weighing function, follow the procedure below
WEIGHING FUNCTION ENABLING

Sequence Description of the operations to be
Accessories Module Config Menu Parameters Settings
No. performed
When the machine is off, connect the
console to the Module 6 "EPS-AC" and
SICOS
enter Module 16 "SICOS". Start the
machine (set key switch to "ON")
AUTOMATIC Press "ENTER" to save the data, press
1 SET OPTIONS ON
WIEGHT "OUT" to quit
(See description 1 and 2 ).Press
ADJ 0 KG
2 ADJUSTMENTS "ENTER" and store the weight without
POINT
load
(See description 3 and 2). Press
ADJ 1000 KG
3 ADJUSTMENTS "ENTER" to store the sample weight.
POINT
Press "OUT" to quit.

REMOVAL OF THE SPEED REDUCTION FUNCTION WITH THE CARRIAGE

COMPLETELY EXTENDED
! OPERATION NOTE
This option allows removing the speed reduction function with the carriage completely extended. To
disable the speed reduction, connect the console to Module 1 “CAN I/O, enter the parameter Speed Limit
and set to OFF. (the parameter is generally set to “ON”). Perform the procedure described in the enclosed
table.
TABLE OF CONFIGURATION TO MODULE 1 CAN I/O
PROCEDURE TO REMOVE SPEED REDUCTION FUNCTION WITH WITHDRAWN CARRIAGE

Sequence Description of the operations to be
Accessories Module Config Menu Parameters Settings
No. performed
When the machine is off, connect the
console to Module 6 "EPS-AC" and
SICOS
enter Module 1 "CAN-I/O". Start the
machine (set the key switch to "ON")
Press "ENTER" to save the data,
1 SET OPTIONS SPEED LIMIT OFF
press "OUT" to quit


SERVICE Section: HYDRAULIC SYSTEM
HYDRAULIC
HYDRAULIC SYSTEM
SYSTEM
a KEY TO HYDRAULIC SYSTEM SYMBOLS ............................................................ 2
a ELECTRICAL DIAGRAMS ..................................................................................... 2a
a CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS ..................................... 3
a HYDRAULIC UNIT COMPONENTS ......................................................................... 4
a BASIC TRUCK HYDRAULIC SYSTEM .................................................................... 6
a BETA TYPE MAST HYDRAULIC SYSTEM ............................................................. 7
a SINGLE ACTING LATERAL LIFT CYLINDER ........................................................... 8
a SELF-BRAKING DURING LOWERING .................................................................... 8
a SINGLE ACTING CENTRAL LIFT CYLINDER .......................................................... 9
a SELF BRAKING DURING LIFTING AND LOWERING .............................................. 9
a SINGLE ACTING LIFT CYLINDERS WITH STROKE END HYDRAULIC
CUSHIONING IN LIFTING AND LOWERING DIRECTIONS .................................... 10
a LATERAL PLUNGER TYPE LIFT CYLINDER ........................................................ 11
a CENTRAL PLUNGER TYPE LIFT CYLINDER ....................................................... 12
a PLUNGER TYPE LIFT CYLINDERS ...................................................................... 13
a REACH TRUCK REACH CYLINDER ..................................................................... 14
a FORKS TILT CYLINDER........................................................................................ 15
a FORKS SIDESHIFT CYLINDER ............................................................................ 16
a DISASSEMBLING LATERAL LIFT CYLINDERS FROM MAST .............................. 17
a REPLACING SINGLE ACTING LATERAL CYLINDER SEALS ............................... 19
a DISASSEMBLING CENTRAL LIFT CYLINDERS FROM MAST ............................. 20
a REPLACING SINGLE ACTING CENTRAL CYLINDER SEALS .............................. 22
a REPLACING THE LATERAL PLUNGER CYLINDER SEALS ................................. 23
a REPLACING THE CENTRAL PLUNGER CYLINDER SEALS ................................ 25
a DISASSEMBLING THE FORKS TILT CYLINDER .................................................. 27
a REPLACING THE SEALS ..................................................................................... 29
a REPLACING THE FORKS SIDESHIFT CYLINDER SEALS ................................... 30
a DISASSEMBLING THE REACH TRUCK CYLINDER ............................................. 31
a REPLACING THE FORKS REACH CYLINDER SEALS ........................................ 32
a REPLACING THE OIL SUPPLY HOSES TO THE TILT CYLINDER
AND SIDESHIFT CYLINDER ................................................................................. 33
a DISASSEMBLING THE CENTRAL CYLINDER OIL SUPPLY LINE ........................ 34

Section: HYDRAULIC SYSTEM SERVICE
1.01 KEY TO HYDRAULIC SYSTEM SYMBOLS

MODEL ALL MODELS
Here we give the symbols used in the diagrams in this section with their meanings.
HYDRAULIC SYSTEM
TWO-POSITION SOLENOID THREE-POSITION

VALVE SOLENOID VALVE
FILTER CHECK VALVE
DOUBLE-ACTING
CYLINDER PROPORTIONAL VALVE
PUMP
SINGLE-ACTING CYLINDER
HYDRAULIC MOTOR
TANK
LINE CONNECTION ELECTRIC MOTOR
FLOW CONTROL VALVE

PRESSURE RELIEF VALVE
MANUAL VALVE BY-PASS VALVE

HYDRAULIC FUNCTIONAL DIAGRAM

MODEL ALL MODELS
Ev2
Ev4 Ev6 Ev8
Ev1
Ev4 Ev6 Ev8
Ev1
Ev3 Ev5 Ev7
Ev3 Ev5 Ev7

Ev2

LIFTING AND LOWERING

3 THE INPUT MODULE IS HMT TYPE FOR LIFT TRUCKS, CONTROL VALVES BANK
8 DESIGNED TO RESTRICT INTERNAL LEAKAGE DURING MODEL ALL MODELS
DOWNWARD MOVEMENT TO 3 CM3 PER MINUTE AT FULL LOAD.
A B C D
E 5
LIFTING VALVE
(1) PROPORTIONAL VALVE

A B C D (3)PRESSURE RELIEF VALVE
This is a cartridge type valve
9 M Composed of adjuster screw (A), spring
R When it is activated it opens completely and
A (C), spool (D) and poppet (E).
the oil flow is proportional to the pump motor
The function of this valve is to regulate
rpm.
pressure in the hydraulic circuit. The relief
It provides proportional operation exclusively
B valve is calibrated at between 200 and
P for simultaneous movements (fork lift/reach
2 220 bar depending on the rated capacity
carriage extension)
1 of the truck
H Min. opening 250mA
Max. opening 650mA
A C D
C
B
B A B C D
A
6 (6) CHECK VALVE
7 Composed of plug (A), spring (C), plunger
(D)
4
INPUT MODULE The function of the check valve is to prevent
oil from returning to tank through the valve
and pump when the joystick is in the rest
position
LOWERING VALVES BANK

Ev7
Ev8
(7) EMERGENCY LOWERING VALVE

Composed of screw (A), sector (B), and
Ev5
Ev6
spool (C).
This valve is used to lower the forks without
electrical command signals
Ev3
Ev4
8 5 (4) REGULATOR SPOOL (5) PRESSURE

(2) PILOT VALVE Composed of spool (A), pre- COMPENSATOR
Composed of magnet (A) and calibrated spring (B) and adjuster Composed of spool (A) and
3 1 pilot valve (B) screwed into the spring (B).
screw (D).
block. The pilot valve serves to The function of the regulator spool The pressure compensator
drive the regulator spool
Ev1
is to control oil flow during serves to assure constant speed

lowering movements. of hydraulic movements in
Ev2
7 2 loaded or unloaded conditions

Screw: adjustment for maximum
4 speed (16.8 mm opening)
16.8mm
6

REACH CARRIAGE AND FORKS "UP"

OVERCENTRE VALVE INSTALLED ON THE TILT CYLINDERS
TILT "BACK" / "FORWARD"
CONTROL VALVES BANK
MODEL ALL MODELS
SOLENOID VALVE
100 bar
FORKS TILT MOVEMENT
200 bar P
12 bar
If a load on the forks generates

VALVE PILOT TRANSMISSION pressure of 100 bar, the pilot
RATIO 1-8 pressure required in point “P” will
be: 200 - 100
= 12
8
3
PRESSURE COMPENSATOR
(REACH CARRIAGE 10 BAR) FORKS TILT VALVES BANK
Closed centre solenoid valve on After valve EV5 or EV6 opens oil In the event of tilt problems, with the
Ev4 Ev6 Ev8 return line to prevent hydraulic flows through the overcentre valve load tending to descend when no
accumulator effects resulting from located on the tilt cylinders, which command is present, renew the
Ev1 the large amount of oil contained in operates on the tilt "forward" stroke overcentre valve - do not attempt
the truck's hydraulic lines. to clean
EV5 fork tilt "back" control
1 EV6 fork tilt "forward" control
INPUT MODULE
1) EV3 carriage retraction 3) Pressure compensator.
REACH antishock valve EV3 The pressure compensator performs a
CARRIAGEVALVES BANK calibrated at 60 bar. dual function in forks lifting and reach
2) EV4 carriage extension carriage extension movement. This
antishock valve calibrated at component provides pressure
80 bar. compensation that eliminates
Proportional 4-way closed centre Removing the plug reveals performance differences in loaded and
solenoid valve a spring that exerts unloaded conditions
2 carriage retract control valve EV3 pressure on a check ball; in . lifting 200 bar
carriage extend control valve EV4 Example
the event of malfunctions carriage 50 bar
remove the parts and clean
235mm
the seat
3) TRANSLATION MOVEMENT
Ev3 Ev5 Ev7 A and B proportional spools for Solenoid valves proportional BLOCKED.
Ev2
maximum opening adjusted to a opening The compensator closes and the oil is
distance between stroke limits of min. 390 mA - max 900 mA dumped to tank through the pressure
235 mm relief valve. Remove the valve, unscrew
A the plug, clean the internal parts
thoroughly and then refit
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2c

HYDRAULIC CIRCUIT STATUS

IN FORKS LIFTING PHASE
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7

OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2d


IN FORKS LOWERING PHASE
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7
OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2e

HYDRAULIC CIRCUIT STATUS IN REACH

CARRIAGE EXTENSION PHASE
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7
OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2f
HYDRAULIC CIRCUIT STATUS IN REACH

CARRIAGE RETRACTION PHASE
ITT JOYSTICK HYDRAULIC CONTROL
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7
OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2g


IN FORKS UPWARD TILT PHASE
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7

OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2h


IN FORKS FORWARD TILT PHASE
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7
OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2i

IN FORKS SIDESHIFT TO LEFT
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7

OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2l


IN FORKS SIDESHIFT TO RIGHT
Ev2
Ev4 Ev6 Ev8

Ev1
Ev3 Ev5 Ev7

OIL DELIVERY
OIL RETURN
UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page 2m

1.02 CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS
To ensure an oil-tight connection between the female unions and adapters shown in this manual, observe
the following procedure, which differs from that used for flexible hoses.
FEMALE UNIONS WITHOUT SEALS (METAL TO METAL COUPLING)
HYDRAULIC SYSTEM
Snug the nut by hand and then tighten with a wrench by no more than 1/4 turn.
FEMALE UNIONS WITH O-RING SEAL

12
Snug the nut by hand and then use a wrench to tighten by no more than a further 1/2 turn.
In all cases, ensure that the line is correctly aligned before tightening the adapter nut.
Note: The values supplied in the tables are typical for the recommended assembly method in
the case of galvanized unions. Unions made of different materials call for the use of
alternative values.
TORQUE VALUES
TORQUE VALUES TORQUE VALUES

METRIC FEMALE UNION ORFS
Nm Nm
METRIC UNF THREAD SIZE
OUTSIDE ø
THREAD NOMINAL MIN./MAX MIN MAX
M12x1,5 6 20 15-25 9/16-18 -4 14 16

M14x1,5 8 38 30-45 11/16-16 -6 24 27
8 13/16-16 -8 43 47
M16x1,5 45 38-52 1-14 -10 60 68
10
10 1.3/16-12 -12 90 95
M18x1,5 51 43-58 1.3/16-12 -14 90 95
12
M20x1,5 12 58 50-65 1.7/16-12 -16 125 135
14 1.11/16-12 -20 170 190
M22x1,5 74 60-88 2-12 -24 200 225
15
M24x1,5 16 74 60-88
M26x1,5 18 105 85-125 Table 2
20
M30x2 135 115-155
22
25
M36x2 166 140-192
28
M42x2 30 240 210-270
M45x2 35 290 255-325
38
M52x2 330 280-380
42
Table 1
TORQUE VALUES TORQUE VALUES
JIC 37° FEMALE UNION FEMALE UNION BSP
Nm
Nm
UNF THREAD SIZE
NOMINAL MIN./MAX BSPP THREAD
NOMINAL MIN./MAX
7/16-20 -4 15 9-21
1/2-20 -5 20 13-27 G1/4 20 15-25
9/16-18 -6 30 18-42 G3/8 34 27-41
3/4-16 -8 50 30-70 G1/2 60 42-76
7/8-14 -10 69 44-94 G5/8 69 44-94
1.1/16-12 -12 98 63-133 G3/4 115 95-135
1.3/16-12 -14 118 73-163
G1 140 115-165
1.5/16-12 -16 140 90-190
1.5/8-12 -20 210 135-285 G1.1/4 210 140-280
1.7/8-12 -24 290 200-380 G1.1/2 290 215-365
2.1/2-12 -32 450 300-600 G2 400 300-500
Table 3 Table 4
1.03 HYDRAULIC UNIT COMPONENTS
13 11 8 10
3 2
EV4 EV6 EV8
6
EV1
HYDRAULIC SYSTEM
15 200/220 60 bar
bar
16
17
1
14
80 bar
12
38
5
EV2 4 EV3 EV5 EV7
9 Fig. 1
11 7
36
32 33 32 34 35
24 25
27
30 29 26
28
23
Ev2
Ev4 Ev6 Ev8

Ev1
Ev5 Ev7
2 Ev3
21
13
18 22 31
19 20
Fig. 2
37
37

1.04 TABLE OF HYDRAULIC UNIT COMPONENTS

MODEL ALL MODELS
The hydraulic unit components illustrated on the previous page are described in the following table.
Key:
Ref. Component reference in exploded view
HYDRAULIC SYSTEM
Ref. Diagram Reference to symbol in functional diagram
Component Description Function of component
Re f. Re f. Dia gra m Com pone nt de scription

1 Oil inlet module
2 Hydraulic pressure regulator valve (set at between 200 and 220 bar)
3 EV1 Mast lowering proportional solenoid valve
4 EV2 Mast lifting proportional solenoid valve
5 EV3 Reach carriage cylinder "retract" proportional solenoid valve
6 EV4 Reach carriage "extend" proportional solenoid valve
7 EV5 Tilt cylinder "back" solenoid valve
8 EV6 Tilt cylinder "forward" solenoid valve
9 EV7 Forks sideshifter cylinder "Lh" movement solenoid valve
10 EV8 Forks sideshifter cylinder "Rh" movement solenoid valve
11 Adjustment of proportional spools for maximum opening of the reach carriage valve
Lowering movement oil flow regulator spool adjusted with maximum capacity at
12
51 l. and at 155 bar (screw adjusted for maximum speed 16.8 mm opening).
13 Valve for emergency lowering when no electrical controls are available
14 P Connection union for oil delivery hose arriving from pump
15 H Connection union for lift cylinders delivery hose
16 R Connection union for oil return line to tank
17 M Pressure gauge connection union for system pressure testing
18 Pump motor
19 Lift pump
20 Return oil filer
21 Valve bank hydraulic supply line (lift pump to valves bank)
22 Oil return line (valves bank to tank)
23 Lift cylinders supply line (valves bank to cylinders) 3/8"
24 Reach carriage cylinder supply lines (valves bank to cylinder) 1/4"
25 Tilt cylinders supply lines (valves bank to cylinders) 1/4"
26 Forks sideshifter cylinders hydraulic supply lines (valves bank, cylinders)
27 Valve controlling oil flow to forks sideshifter cylinders
28 Tilt cylinders pressure relief valve
29 Reach cylinder anti-shock valve located internally to the valves bank
30 LB Valve controlling oil flow of cylinders during lowering
31 DW Pressure compensation valve for simultaneous activation of lift function and reach
32 Mast lifting lateral cylinders
33 Mast lifting central cylinder
34 Extend/Retract reach carriage cylinder
35 Forks "back/forward" tilt cylinders
36 Forks right/left sideshift cylinder
37 Oil tank
38 DW Pressure compensator valve for mast descent
NOTE: All Hyster Part Numbers are given in the parts catalogue.

1.05 BASIC TRUCK HYDRAULIC SYSTEM

MODEL ALL MODELS
HYDRAULIC SYSTEM COMPONENTS

HYDRAULIC SYSTEM
8
7
6
3 10
9 2
11
13
14
12
1
4
Fig. 3
1.06 TABLE OF BASIC TRUCK HYDRAULIC SYSTEM COMPONENTS

Ref. Component description
1 Lift pump l. 11 - R2.0 - R2.5
1 Lift pump l. 16 - R1.4 - R1.4H - R1.6 - R1.6H - R2.0H - R2.0W
2 Solenoid valves bank
3 Reach carriage cylinder
4 Oil suction line (tank/pump)
5 Oil pressure line (pump/valves bank)
6 Oil return line (valves bank/tank)
7 Cylinders delivery diverter block
8 Connection line between valves bank and cylinders delivery diverter block
9 Return oil filter
10 Oil filter housing
11 Oil tank
12 Pump suction line union
13 Pump pressure line union
14 11 KW pump unit

1.07 MAST HYDRAULIC SYSTEM

MODEL ALL MODELS
HYDRAULIC SYSTEM COMPONENTS
HYDRAULIC SYSTEM
1
6
3
9
8 7
12
10 11
1 2
3
Fig. 4
1060175
1.08 TABLE OF MAST HYDRAULIC SYSTEM COMPONENTS

1 Connection hose to central cylinder
2 Connection hose to lateral cylinders
3 Twin connection hoses to forks sideshifter cylinder
4 Twin connection hoses to tilt cylinder
5 Pulleys unit for hoses on mast
6 Pulleys unit for hoses on central cylinder
7 Single-acting central lift cylinder with upward stroke cushioning
8 Single-acting Rh lateral lift cylinder with downward stroke cushioning
9 Single-acting Lh lateral lift cylinder with downward stroke cushioning
10 Bracket for twin hoses and central cylinder
11 Bracket for twin hoses
12 Hose connecting bracket

1.09 SINGLE ACTING LATERAL LIFT CYLINDER

WITH SELF-BRAKING DURING LOWERING
MODEL BETA - HE140L - HE140
CYLINDER COMPONENTS
HYDRAULIC SYSTEM
4
5
1 2
9
8
Fig. 5
6
1.10 TABLE OF LATERAL SINGLE ACTING CYLINDER COMPONENTS

1 Complete cylinder
2 Cylinder barrel
3 Cylinder rod
4 Gasket bushing
5 Set of seals for gasket bushing
6 LB hose break safety valve (prevents oil flow in the event of a hose break)
7 Seals holder piston and lowering cushioning valve
8 Set of cylinder piston seals
9 Cushioning valve

1.11 CENTRAL SINGLE ACTING LIFT CYLINDER

WITH SELF-BRAKING DURING LIFTING
MODEL BETA - HE140L - HE140
CYLINDER COMPONENTS
HYDRAULIC SYSTEM
4
5
7
6
8 9
Fig. 6
1.12 TABLE OF SINGLE ACTING CENTRAL CYLINDER COMPONENTS

1 Complete cylinder
2 Cylinder barrel
3 Cylinder rod
4 Gasket bushing
6 LB hose break safety valve (prevents oil flow in the event of a burst supply hose)
7 Sealks holder piston and lift stroke cushioning valve
8 Set of seals for cylinder piston
9 Cushioning valve

1.13 SINGLE ACTING LIFT CYLINDERS WITH HYDRAULIC lateral

STROKE-END CUSHIONING IN LOWERING AND LIFTING lift cylinder
The cylinders with hydraulic cushioning are designed using special features
that provide hydraulic cushioning at the end of each lift or lower cycle, thereby
eliminating mechanical impact at the stroke end positions.
HYDRAULIC SYSTEM
OPERATION OF LATERAL LIFT CYLINDER WITH CUSHIONING IN

LOWERING
During lowering movement, when the piston guide ring (Ref. A Fig. 7) reaches
the position of the oil return port (Ref. B Fig. 7), it partially restricts the outward
oil flow thus causing the descent movement to decelerate through the final
40 mm.
OPERATION OF CENTRAL CYLINDER WITH CUSHIONING ON LIFT

STROKE B
The cylinder rod features a hollow core (Ref. G Fig. 8) which is terminated with
a seals holder piston (Ref. F) complete with valve (Ref. E Fig. 8); the rod also
A
features two oilways for forced oil flow (Ref. C-D Fig. 8). C
Fig. 7
Before starting the lifting movement pour 150 cc of oil inside the cylinder barrel central
through the plug (Ref. A Fig. 8). lift cylinder
During the lift stroke, when the piston (Ref. F Fig. 8) reaches its stroke limit it
causes the oil previously poured into the barrel to be compressed against the
bush (Ref. B) thus causing a pressure rise that causes the oil to enter the B
hollow core in the piston rod by way of the hole (Ref. C) thus compressing the
air in the hollow core (Ref. G) and resulting in the slowing of upward movement
during the final 40 mm of the stroke.
A
During the lowering stroke the thrust exerted by the rod decreases as the air
pressure in the core decreases, thus causing the 150 cc of oil to flow out of the
rod core into the cylinder barrel.
The function of the valve (Ref. E Fig. 8) is that of maintaining constant pressure
in the rod cavity at the time of ingress of the oil compressed the bushing.
The valve is calibrated in order to witstand the compression of 150cc of oil. G
OIL LEVEL
Any excess oil unloaded to the conventional circuit through the valve.
If no deceleration occur over the final 4-5 mm of stroke this indicates that the D
valve has ceased functioning and must therefore be replaced.
C
Through prolonged use and with constant pressure changes inside the
cylinder, the oil in the barrel tends to return to the normal hydraulic circuit due
to infiltration past the piston seals. To counter this problem, 150 cc of oil must E
be poured into the cylinder barrel through the plug (Ref. A) every 500-600 duty
hours.
F
Fig. 8

1.14 LATERAL PLUNGER TYPE LIFT CYLINDER

MODEL HE140 - HE140R
CYLINDER COMPONENTS
10 10
HYDRAULIC SYSTEM
11 4
5
5 4
3
3
1
8
7
6 8
9
9
1511146_1
7
Fig. 9
1.15 TABLE OF LATERAL PLUNGER TYPE LIFT CYLINDER COMPONENTS

1 Complete cylinder
2 Cylinder barrel
3 Hollow rod
4 Gasket bushing
6 LB hose break safety valve (prevents oil flow in the event of a hose burst)
7 Hollow rod lower plug
8 Rod guide bush
9 Valve for oil flow to rod cavity
10 Rod air bleed plug
11 Hollow rod upper plug

1.16 CENTRAL PLUNGER TYPE LIFT CYLINDER

MODEL HE140 - HE140R
CYLINDER COMPONENTS
HYDRAULIC SYSTEM
5
8
3
1
6 2
2
7 1512290_1
Fig. 10
1.17 TABLE OF CENTRAL PLUNGER TYPE CYLINDER COMPONENTS

1 Complete cylinder
2 Cylinder barrel
3 Cylinder rod
4 Gasket bushing
6 LB hose break safety valve (prevents oil flow in the event of a hose burst)
7 Rod guide bush
8 Cylinder air bleed plug

1.18 PLUNGER TYPE LIFT CYLINDERS LATERAL CYLINDER

A
LATERAL PLUNGER TYPE CYLINDER WITH HOLLOW ROD
The lateral plunger cylinders with hollow rod are utilised on high lift masts. In
these cylinders, unlike single acting cylinders, both the barrel and the rod are
HYDRAULIC SYSTEM
filled with oil before starting the lift stroke.
This solution is adopted to increase the strength of the cylinders at maximum B
elevation, and to make it possible to use compactly sized barrels and rods.
OPERATION
When the cylinder is assembled in the test phase the air must be bled out by
opening the bleed screws (A - B Fig. 11).
Before supplying oil to the cylinder it is essential to loosen the two bleed
screws on the rod (A Fig. 11) and the barrel (B Fig. 11).
When oil is supplied to the cylinder the first cavity to be filled is the rod; continue
to pump in oil until only oil and no air escapes through the bleed screw (A
Fig.11); this indicates that the rod is full of oil and empty of air and so the bleed
screw must be tightened.
1511146_1
In the second stage the cylinder barrel is filled; continue to pump in oil until only Fig. 11
oil and no air escapes through the bleed screw (B Fig. 11); this indicates that
the barrel is full of oil and empty of air and so the bleed screw must be
CENTRAL CYLINDER
tightened.
The oil pressure formed inside the rod and in the barrel increases the strength
of the cylinder assembly and reduces the flexibility of the parts at full
extension.
CENTRAL PLUNGER TYPE CYLINDER

A
This type of cylinder differs from the lateral type because it does not have a
hollow rod. The operating characteristics and the air bleed procedure through
the bleed screw (A Fig. 12) are identical to those of the lateral cylinder.
Fig. 12
1512290_1

1.19 REACH CARRIAGE CYLINDER

MODEL ALL MODELS
CYLINDER COMPONENTS
HYDRAULIC SYSTEM
1
9
8
6 2 4
7 3
5
Fig. 13
1.20 TABLE OF REACH CARRIAGE CYLINDER COMPONENTS

1 Complete cylinder
2 Cylinder barrel
3 Cylinder rod
4 Gasket bushing
6 Set of cylinder seals
7 Set of bushing seals
8 Rod eye
9 Grease nipple

1.21 FORKS TILT CYLINDER

MODEL ALL MODELS
CYLINDER COMPONENTS
HYDRAULIC SYSTEM
1
10
8
6
3
9 2
4
5
Fig. 14
1.22 TABLE OF FORKS TILT CYLINDER COMPONENTS

1 Complete cylinders block
2 Cylinder rod
3 Rod piston
4 Gasket bushing
5 Bushing retaining circlip
6 Piston seal
7 Piston O-ring
8 Set of bushing external seals
9 Set of bushing internal seals
10 Piston to rod fixing screw

1.23 SIDESHIFT CYLINDER

MODEL ALL MODELS
CYLINDER COMPONENTS
HYDRAULIC SYSTEM
4
6
Fig. 15
1.24 TABLE OF FORKS SIDESHIFT CYLINDER COMPONENTS

1 Piston cylinder incorporated in fork arm carriage
2 Cylinder rod
3 Rod guide bush
4 Rod guide bush circlip
5 Seal
6 Wiper seal

2.00 REMOVING THE LATERAL LIFT CYLINDERS FROM THE MAST

MODEL ALL MODELS
To replace the seals of the single acting lateral cylinders the complete cylinders must first be removed from
the mast. The operations described below are also applicable to the removal of lateral plunger type
cylinders for integral renewal.
To perform these procedures it is important to work in a place with sufficient headroom for the truck with
HYDRAULIC SYSTEM
the mast at its full extension and equipped with an overhead crane; it is also necessary to have access
to suitable equipment for the recovery of the cylinder.
SPECIAL TOOLS REQUIRED
® Long lifting sling with a capacity of 2000 kg

® Short lifting sling with a capacity of 3000 kg
® “Parcher” type male/female 1/2" plugs for hydraulic hoses
® Ladder with overhead platform
® Operator lift for recovery of the cylinder
STANDARD TOOLS REQUIRED
4 mm ALLEN OVERHEAD CRANE

WRENCH
A
13-22-24 mm MEDIUM EXTERNAL

HEX WRENCH CIRCLIP PLIERS
PROCEDURE
Fig. 17
Before starting work, make sure you are wearing
suitable safety clothing.
Park the truck in a safe place away from moving

vehicles and pedestrians. Bring the reach carriage
to its fully forward position.
1) LADDER WITH PLATFORM - CIRCLIP PLIERS -

13 mm HEX WRENCH - Place the ladder on the side of Fig. 18
the mast in order to access one of the cylinders, and B
ascend with the necessary tools.
Use the circlip pliers to remove the circlip from the end
of the cylinder (Ref. A Fig. 17).
Use the hex wrench to unscrew and remove the cylinder
mounting bracket fixing screws (Ref. B Fig.18); this
done, descend the ladder and remove it from the work
area.
C Fig. 19
Fig. 16

2) 22-24 mm HEX WRENCH - HYDRAULIC PLUGS - The hydraulic

hoses must be detached from inside the reach carriage. Use the
24 mm hex wrench to unscrew the hydraulic supply hose union on
the cylinder to be removed (Ref. C Fig. 19).
With the 22 mm wrench fit the male plug to the hose union (Ref. D
Fig. 20) and the female plug to the cylinder union (Ref. E Fig. 20).
HYDRAULIC SYSTEM
3) SHORT LIFTING SLING - OVERHEAD CRANE - Attach the short

lifting string to the top of the inner mast section and attach the to
ends of the sling to the overhead crane (Fig.16). Start lifting with the
only cylinder still connected and simultaneously lift with the overhead
crane; continue the lift stroke to maximum height and allow the sling D
to take the strain.
E G Fig. 20
The same operation must be used to remove the second cylinder.
4) LONG LIFTING SLING - 4 mm ALLEN WRENCH - LIFT TRUCK

- Attach the sling to the mid point of the cylinder (Ref. F Fig. 16),
attach the sling to the lift truck and take the strain.
Use the wrench to unscrew the cylinder fixing grub screw (Ref. G
Fig. 20), lift the cylinder and extract it from the lower seat; now lower
the cylinder and angle it towards the outside so that it can be
extracted from the upper cross member. Bring the cylinder to a
horizontal position and place it on a workbench.
Now either fit a new cylinder or strip the original unit and renew the
seals. F
Fig. 21
NOTES:

2.01 REPLACING LATERAL SINGLE-ACTING CYLINDER SEALS

MODEL R1.4 - R1.6
HYDRAULIC SYSTEM
® Tube clamp Ø 60÷80
® Oil collection container
C-SPANNER MEDIUM SLOTTED

Ø 60 ÷ 80 SCREWDRIVER
PROCEDURE
H
Before starting work, make sure you are wearing suitable safety
clothing.
1) TUBE CLAMP - OIL COLLECTION CONTAINER - C-SPANNER -

Position the cylinder in the clamp and tighten carefully to avoid
distorting the barrel, position the container under the cylinder bush.
Use the wrench to completely unscrew the seal holder bush (Ref. H
Fig. 22), remove the bush from the rod and withdraw the rod from the
barrel; place the bush on a clean workbench and fit new seals.
2) SMALL SCREWDRIVER - Use the screwdriver to remove the seals

from the bush and from the rod piston; carefully clean and oil the seal
seats to facilitate refitting. Now fit the new seals.
To reassemble, perform the disassembly steps in reverse order.
Fig. 22

2.02 REMOVING THE CENTRAL LIFT CYLINDER FROM THE MAST

MODEL ALL MODELS
To renew the single acting central cylinder seals the cylinders must be first removed from the mast. The
operations described below also apply to the removal of central plunger type cylinders for complete
HYDRAULIC SYSTEM
replacement purposes.
® Long sling with lifting capacity of 2000 kg

® Parcher type male-female 3/4 plugs for hydraulic hoses
® Wooden beam 100x100x800
PROCEDURE 13-22-24 mm 4 mm
HEX WRENCH ALLEN WRENCH
clothing.
Park the truck in a safe place away from moving vehicles and
pedestrians. Bring the reach carriage to its fully forward position.
Fig. 25 Fig. 26
Fig. 27 Fig. 24
Fig. 23

1) WOODEN BEAM - Raise the forks until the fork arm carriage is high enough to clear the beam on the
floor (Fig. 23). Position the beam and then lower the forks until the fork arm carriage is supported on
the beam. Continue to lower the forks until the cylinder is completely closed.
Warning: The beam is of fundamental importance to safety for the entire duration of the
work and must therefore be in a stable and secure position before proceeding.
HYDRAULIC SYSTEM
2) 13 mm HEX WRENCH - Use the hex wrench to unscrew and remove the fixing screw from the fork
shaped plate of the pulleys assembly (Ref. L Fig. 25), remove the plate and lift the pulleys assembly
complete with hoses and chain, withdrawing it from the cylinder. Use the same wrench to unscrew and
remove the cylinder mounting bracket fixing screws (Ref. I Fig. 24): now remove the bracket.
3) 22-24 mm HEX WRENCH - 4 mm ALLEN WRENCH - Use the 24 mm hex wrench to unscrew the
cylinder oil supply hose union (Ref. N Fig. 24); now use the 22 mm wrench to fit the male plug to the
hose union and the female plug to the cylinder union. Use the Allen wrench to unscrew the cylinder
securing grub screw (Ref. M Fig. 27).
4) LIFTING SLING - OVERHEAD CRANE - Attach one end of the sling to the cylinder in the vicinity of the
bush; attach the other end to the overhead crane hook. Take the strain with the sling and then continue
to lift in order to extract the cylinder from the top of the fork arm carriage; this done, use the crane to
transfer the cylinder to a workbench. Now either fit a new cylinder or strip the original unit and renew the
seals.
NOTES:

2.03 REPLACING THE SINGLE ACTING CENTRAL CYLINDER SEALS

MODEL R1.4 - R1.4H - R1.6 - R1.6H - R1.6N

HYDRAULIC SYSTEM
® Tube clamp Ø 60 ÷ 80
® Container for collecting oil

Ø 60 ÷ 80 SCREWDRIVER
PROCEDURE
Before starting work, make sure you are wearing suitable safety O
clothing.
1) TUBE CLAMP, OIL COLLECTION CONTAINER, C-SPANNER - Place

the cylinder in the clamp and tighten with care to avoid distortion of the
cylinder barrel, place the container beneath the cylinder bush. Use the
wrench to completely unscrew the seals holder bush (Ref. O Fig. 28),
withdraw the bush from the rod and the rod from the cylinder barrel;
place the assembly on a clean workbench and renew the seals.
2) SMALL SCREWDRIVER - Use the screwdriver to remove the seals

from the bush and the rod piston, clean the seal seats thoroughly and
oil them to facilitate insertion of the new seals. Now fit the new seals.
Fig. 28

2.04 REPLACING THE LATERAL PLUNGER CYLINDER SEALS

MODEL R1.6H - R2.0 - R2.0H - R2.0W - R2.5
® Wooden chock 100x100x800
HYDRAULIC SYSTEM
® Ladder with platform
MEDIUM EXTERNAL MEDIUM SLOTTED C-SPANNER CHAIN TYPE

CIRCLIP PLIERS SCREWDRIVER Ø 100 ÷ 110 OIL FILTER WRENCH
PROCEDURE
Before starting work, make sure you are wearing suitable safety clothing.
Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach
carriage to its fully forward position.
Q
Fig. 31
P
Fig. 29 Fig. 30

1) CIRCLIP PLIERS - LADDER WITH PLATFORM -

Place the ladder on the side of the mast in order to
access one of the cylinders, and use the circlip pliers
to remove the circlip from the cylinder rod (Ref. Q
Fig. 31).
2) WOODEN BLOCK - Raise the forks until the block can

HYDRAULIC SYSTEM
be inserted under the central mast profile as shown

(Fig. 32). Position the beam and then lower the forks
until the mast rests on the beam and the cylinder whose
circlip has been removed has closed with the rod Fig. 32
completely inside the barrel.
3) C-SPANNER - CHAIN TYPE OIL FILTER WRENCH - SMALL CROSSHEAD SCREWDRIVER - Two
persons are required in order to unscrew the ringnut.
Fit the filter wrench at the mid point of the cylinder barrel (Ref. P Fig. 29) in such a way that it tightens
in the reverse direction with respect to the direction in which the bush must be unscrewed.
Use the C-spanner to unscrew the ring completely and then withdraw it from the cylinder rod. Now renew
the seals.
4) SMALL SLOTTED SCREWDRIVER - Remove the seals from the bush, clean and oil the seats. Renew
the seals.
Repeat the same procedure for the cylinder on the other side of the mast.
NOTES:

2.05 REPLACING THE CENTRAL PLUNGER CYLINDER SEALS

MODEL R1.6H - R2.0 - R2.0H - R2.0W - R2.5
HYDRAULIC SYSTEM
13 mm C-SPANNER MEDIUM SLOTTED

HEX WRENCH Ø 100 ÷ 110 SCREWDRIVER
PROCEDURE
Fig. 35
Fig. 35b
Fig. 34
Fig. 33

1) WOODEN BEAM - Raise the forks to the height necessary to clear the beam as shown (Fig. 33).
Position the beam under the fork arm carriage, lower the forks until the carriage is resting on the beam.
Continue to lower the forks until the cylinder has retracted completely, causing the hoses and chain to
become slack.
Warning: The wooden block is of fundamental importance to safety for the entire duration
of the work and must therefore be in a stable and secure position before proceeding.
HYDRAULIC SYSTEM
2) 13 mm HEX WRENCH - Unscrew and remove the fixing screw of the pulleys assy. mounting plate
(Ref. R Fig. 35), withdraw the mounting plate from the cylinder and lift the complete pulleys assy away
from the cylinder.
3) C-SPANNER - Completely unscrew the bush from the cylinder, withdraw it from the rod and place it on
a workbench.
4) SMALL SLOTTED SCREWDRIVER - Remove the seals from the bush, clean and oil the seal seats
to facilitate fitting of the new seals; renew the seals.

NOTES:

2.06 REMOVING THE FORKS TILT CYLINDER

MODEL ALL MODELS
Wooden block 100x100x200
HYDRAULIC SYSTEM
®
19 mm SOCKET WRENCH LARGE SLOTTED 17-19 mm 5-10 mm

WITH RATCHET SCREWDRIVER HEX WRENCH ALLEN WRENCH
PROCEDURE
carriage to its fully forward position and lift the forks to a position one metre above the ground.
1) Disassemble the fork arm carriage (refer to “mechanics section” heading 2.01 page 9).
Fig. 37
Fig. 38
Fig. 36

2) 19 mm SOCKET WRENCH WITH RATCHET - WOODEN

BLOCK - Activate the tilt control lever in the up direction until
the tilt cylinders are at their fully extended position.
Use the wrench to unscrew and remove the nuts responsible
for securing the cylinder rods to the plate (Ref. T Fig. 38),
and wedge the block between the oscillating plate and the
mast (Ref. S Fig. 36). Activate the tilt control lever in the
HYDRAULIC SYSTEM
down direction and cause the rods to retract into the

cylinders (Fig. 40). Set the keyswitch to “OFF” and disconnect
the battery. Fig. 39
Warning: The wooden block is of fundamental U U

importance to safety for the entire duration of the
work and must therefore be in a stable and secure
position before proceeding.
3) 5 mm ALLEN WRENCH - 17 mm HEX WRENCH - Use the

hex wrench to unscrew the unions on the cylinder supply Fig. 40
hoses (Ref. Z Fig. 42) and detach the hoses.
Use the Allen wrench to unscrew and remove the two fixing
screws of the valve block (Ref. V Fig. 42) and remove the
block, taking care not to lose the O-rings inserted between
valve and cylinder.
4) 10 mm ALLEN WRENCH - Unscrew and remove the fixing

bolts of the cylinder restraints (Ref. U Fig. 40). Remove the
restraints and remove the cylinder (Fig. 39) for complete
replacement or so that it can be stripped down in order to
replace the seals. Fig. 41
To reassemble, perform the disassembly steps in reverse V

order. Z
NOTES: Fig. 42

2.07 REPLACING THE TILT CYLINDER SEALS

MODEL ALL MODELS
HYDRAULIC SYSTEM
MEDIUM INTERNAL MEDIUM SLOTTED
CIRCLIP PLIERS SCREWDRIVER
PROCEDURE
A
1) CIRCLIP PLIERS - After having disassembled
the cylinder place it on a workbench and use the
relative pliers to remove the circlip (Ref. A Fig. 43);
now extract the rod complete with bush.
2) SMALL SCREWDRIVER - Remove the bush

(Ref. D Fig. 44) from the rod and then use the
screwdriver to remove the outer seals (Ref. C Fig. 43
Fig. 44), the inner seals (Ref. E Fig. 44) and the
piston seals (Ref. B Fig. 44).
Before fitting the new seals clean the parts and oil
the seats to facilitate installation; now fit the new
seals and reassemble the cylinder.
To reassemble, perform the disassembly steps

in reverse order.
A
E B
C
D Fig. 44

2.08 REPLACING THE SIDESHIFT CYLINDER SEALS

MODEL ALL MODELS

HYDRAULIC SYSTEM
MEDIUM INTERNAL MEDIUM SLOTTED

CIRCLIP PLIERS SCREWDRIVER
PROCEDURE
carriage to its fully forward position and lift the forks to a position one metre above the ground. Set
the keyswitch to “OFF” and disconnect the battery.
1) Remove the fork arm carriage (see “mechanics

section” heading 2.01 page 9). I
H
2) CIRCLIP PLIERS - SMALL SCREWDRIVER - G
Extract the piston from its seat; use the small F
screwdriver to remove the wiper seal (Ref. F
Fig. 45-46) and use the circlip pliers to remove
the circlip (Ref. G Fig. 47).
Extract the rod guide bush (Ref. H Fig. 45) and
then remove the seal (Ref. I Fig. 45).
Before fitting the new seals clean the parts
carefully and oil the seats to facilitate
replacement. Now fit the new seals.
To reassemble, perform the disassembly steps Fig. 45

in reverse order.
I
F
Fig. 46 Fig. 47

2.09 REMOVING THE REACH CYLINDER

MODEL ALL MODELS
HYDRAULIC SYSTEM
13-19 mm 5 mm
PROCEDURE HEX WRENCH ALLEN WRENCH
carriage to its fully forward position and lift the forks to a position one metre above the ground.
1) 5 mm ALLEN WRENCH - Unscrew and remove the fixing screws of the valves assembly protective
guard on the reach carriage; remove the guard.
2) 13-19 mm HEX WRENCH - Use the 13 mm hex wrench to unscrew and remove the screw responsible
for securing the cylinder to the reach carriage (Ref. N Fig. 50). Lift the cylinder and withdraw from the
rod.
Operate the cylinder control lever and cause the rod to retract; then set the keyswitch to “OFF” and
disconnect the battery.
Use the 19 mm wrench to unscrew the unions of the cylinder hydraulic hoses (Ref. L Fig. 51) and detach
the relative hoses.
Use the 13 mm wrench to unscrew the second cylinder fixing screw (Ref. M Fig. 49) then raise and
withdraw from the rod. Recover the cylinder by extracting it from the mast direction.

L L
Fig. 51
N
M Fig. 49 Fig. 50
Fig. 48

2.10 REPLACING THE REACH CYLINDER SEALS

MODEL ALL MODELS

HYDRAULIC SYSTEM

Ø5 SCREWDRIVER
PROCEDURE
1) C-SPANNER - SMALL SCREWDRIVER - When the cylinder has been removed, place it on a
workbench equipped with a vice. Lock the cylinder in the vice taking care not to deform the barrel. Use
the c-spanner to unscrew and remove the ringnut (Ref. O Fig. 52), extract the rod complete with seals
holder piston. Use the screwdriver to remove the seals from the bush and the rod piston. Before fitting
the new seals clean the parts and oil the seats to facilitate installation; now fit the new seals.
Fig. 52

2.11 REPLACING THE TILT AND SIDESHIFT CYLINDERS OIL SUPPLY HOSES
AND THE CENTRAL CYLINDER SUPPLY HOSE
MODEL ALL MODELS
The procedure for disassembling the tilt, sideshift, and central cylinders oil supply hoses are identical,
because the hoses follow the same path and run on different pulleys.
HYDRAULIC SYSTEM
® Ladder with platform

13-16-18-22 mm 5-6 mm 22 mm
HEX WRENCH ALLEN WRENCH HEX WRENCH
PROCEDURE
Fig. 55
Q R
Fig. 56
S
Fig. 53 Fig. 57 Fig. 54

1) WOODEN BEAM - Raise the forks until the fork arm carriage is high enough to clear the beam on the
floor (Fig. 53). Position the beam and then lower the forks until the fork arm carriage is supported on
the beam. Continue to lower the forks until the chain and hoses become slack. Set the keyswitch to
“OFF” and disconnect the battery.
HYDRAULIC SYSTEM
2) 10-13 mm HEX WRENCH - 5 mm ALLEN WRENCH - Use the 13 mm wrench to unscrew and
remove the hoses anti-shear bracket fixing bolts (Ref. U Fig. 60) and remove the bracket.
Use the 10 mm hex wrench and 5 mm Allen wrench to unscrew and remove the bolts from the hose
restraining block (Ref. S Fig. 57). Use the Allen wrench to unscrew and remove the hose restraint fixing
bolts (Ref. X Fig. 61). After this sequence of operations all the hoses will be loose along their entire
length.
3) 13 mm HEX WRENCH - 6 mm ALLEN WRENCH - LADDER WITH PLATFORM - Use the Allen wrench
to unscrew and remove the fixing bolts of the upper hose carrier bracket (Ref. T Fig. 59). Remove the
bracket with the hoses.
To access the lower ones place the ladder alongside the mast next to the hydraulic lines and then climb
the ladder and use the 13 mm wrench to unscrew and remove the bracket fixing bolts (Ref. P Fig. 55).
Remove the bracket and shift the upper hydraulic lines support.
4) 18 mm HEX WRENCH - Unscrew the twin hose unions (Ref. R Fig. 56) and unions (Ref. Y-Z
Fig. 61). Remove the pipelines and fit replacements.
To reassemble, perform the disassembly

steps in reverse order.
T
Fig. 59
2.12 REMOVING THE CENTRAL
CYLINDER OIL SUPPLY LINE
1) 22 mm HEX WRENCH - Unscrew the hose

union at the base of the cylinder (Ref. V
Fig. 61) and the hose union on the mast U
(Ref. Q Fig. 56). Remove the hose and fit a
replacement. Fig. 60
To reassemble, perform the disassembly

steps in reverse order.
V Z
X
Fig. 61
Fig. 58 Y

NOTES:
HYDRAULIC SYSTEM

NOTES:
HYDRAULIC SYSTEM

SERVICE Section: MASTS
MASTS
MASTS
a TYPE OF MASTS ....................................................................... 3
a MAST REMOVAL PROCEDURE ................................................ 8
a DRAWING WITH MAST ASSEMBLY NOTES ........................... 10
a MAST TILT ANGLES TABLE ..................................................... 11
a FORK ARM CARRIAGE REMOVAL PROCEDURE ................... 12
a BEARINGS REPLACEMENT PROCEDURE ............................. 14
a GREASING OF BEARING ........................................................ 15
a MAST BEARINGS REPLACEMENT PROCEDURE .................. 16
a LIFT CHAIN ............................................................................... 17
a REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT) ............. 19
a REPLACING THE LATERAL LIFT CHAINS ................................ 20

Section: MASTS SERVICE
NOTES:
MASTS

TABLE OF MAST - TRUCK COMBINATIONS
COMPOSITION OF TRUCK AND MAST IN RELATION TO CAPACITY AND LIFT HEIGHT

Ma st Ma st Ma st Ma st Ge a re d Ge a re d Drive r Drive r Loa d Loa d Loa d Load
Ma x im un Truck Front Re a r W he e lba se
Mode l Cha nne l Cha nne l Cha nne l Cha nne l Motor Motor W he e l W he e l W he e l W he e l W he e l w heel
He ight Type Forks tilt Y
Be ta HE140 HE140L HE140R MDU 150 MDU 170 305x 140 342x 140 250x 100 285x 100 350x 100 B racke
R1.4 4500/6700 x 1 2° / 4° 1435 x x x No
R1.4H 7000/8700 x 2 2° / 4° 1450 x x x No
R1.6 4500/6700 x 3 2° / 4° 1485 x x x O ption
R1.6H 7000/9200 x 3 2° / 4° 1485 x x x O ption
R2.0 4500/6300 x 4 2° / 4° 1550 x x x Std
R2.0H 6700/8000 x 4 2° / 4° 1550 x x Std
R2.0H 8500/11400 x 4 2° / 4° 1550 x x Std
R2.5 4500/8000 x 5 2° / 4° 1650 x x Std
R2.5 8500/11400 x 5 2° / 4° 1650 x x Std
R1.6N 4500/6700 x 6 2° / 4° 1435 x x x No
R1.6N 7000/8700 x 6 2° / 4° 1435 x x x No
R2.0W 4500/8000 x 7 2° / 4° 1580 x x x Std
R2.0W 8500/11400 x 7 2° / 4° 1580 x x x Std
BETA MAST HE 140 - 140L MAST HE 140 R MAST

POSITION OF PUNCH MARKING SHOWNIG

DIAMETER OF BEARINGS UTILIZED ON
MAST MODELS HE 140L - HE 140 - HE 140R
EXTERNAL CENTRAL INTERNAL TOURELLE COMPLETE

BEARING 1 BEARING 2 BEARING 3 BEARING 4
DETAIL W
DETAIL X DETAIL Y DETAIL Z
BEARINGS 4 & 6
BEARING 2 INFO INFO MARKING
BEARING 1 INFO MARKING MARQUAGE INFO MARQUAGE INFO
MARQUAGE INFO GALET 7 GALET 8
MARKING
GALET 3 ET 5
INTERNAL MAST CENTRAL MAST EXTERNAL MAST

SECTION SECTION SECTION
GALET 5 GALET 6 GALET 7 GALET 8

INFO MARKING (LETTER A, B OR C) INFO MARKING (LETTER A, B OR C) INFO MARKING (LETTER A, B OR C)
ON OUTER SIDE OF BEARING 1 MAST TOP LETTER: BEARING 3 ON OUTER SIDE OF BEARING 7
CHANNEL BOTTOM LETTER: BEARING 5 MAST CHANNEL
DETAIL X
DETAIL Y DETAIL Z
FOR BEARING 2 APPLY FOR BEARINGS 4 & 6 APPLY FOR BEARINGS 4 & 6 APPLY NOTE: DETAIL W
SYMMETRICAL MARKING ON SYMMETRICAL MARKING ON OTHER SYMMETRICAL MARKING ON OTHER - PUNCH THE LETTER ON BOTH SIDES OF THE FINAL RESULT AFTER
OTHER SIDE OF CHANNEL SIDE OF CHANNEL SIDE OF CHANNEL CHANNEL MARKING
- USE PUNCHES WITH 12 MM LETTER HEIGHT
- MARK LETTERS ON ALL A709 MODELS: INFO BEARING
HE140L LETTER DIAMETER
HE140
HE140R

1.00 MAST TYPES
The masts installed on the new reach trucks are available in 4 models (“Beta”, “HE 140”, “HE 140L”,
“HE 140R”) and are all of the telescopic triplex F.F.L. (Full Free Lift) type with tilt cylinder and fork sideshift
cylinder integrated in the fork arm carriage.
Tables 1 and 2 show the characteristics of the masts in relation to: lift height, load capacity, and carriage
type.
More detailed technical information is given in the following pages.
1.01 FORK SIDESHIFTER COMPONENTS

MODEL BETA - HE 140 - HE 140L - HE 140R 12
MASTS
18
12
2 11
6 10
14 4
13
13
99 15
17
5
16
7
3
8 8 Fig. 1
1.02 TABLE OF FORK SIDESHIFTER COMPONENTS

1 Sideshifter carriage
2 Tilt plate incorporating sideshifter cylinder
3 Forks sideshifter plate
4 Tilt cylinders assy.
5 Forks sideshifter cylinder rod
6 Sideshifter movement upper shoe
7 Sideshifter movement lower shoe
8 Forks sideshifter plate mechanical stop
9 Forks sideshifter rod guide bush
10 Forks tilt cylinder rod
11 Forks tilt cylinder assy. mechanical stop
12 Valve controlling oil flow to tilt cylinder
13 Kit of seals for tilt cylinder
14 Tilt cylinder bush retaining circlip
15 Tilt cylinder rod guide bush
16 Forks sideshifter cylinder seals kit
17 Forks sideshifter cylinder rod guide retaining circlip
18 Mast channel bearings

1.03 “BETA” MAST
The “BETA” mast is installed on truck models R1.4 - R1.6 - with maximum elevation of 6700 mm. (see
table 1 page 2a).
SPECIFICATIONS:
The external stage is built of “C” profiles and anchored to the reach carriage by means of two pins welded
to each side of the mast, to be fastened to the reach carriage supports.
The lower part of the mast is secured to the reach carriage by means of three screws
The intermediate and internal stages are constructed of “J” section profiles. Reciprocal movement of the
two sections is assured by interposed bearings.
The fork arm carriage runs inside the internal mast section. The carriage incorporates the mast tilt cylinder
MASTS
and forks sideshift cylinder.

The mast is equipped with a total of 8 “taper roller ” bearings Ø 91 mm (Fig. 2).
The roller journals are welded in an inclined position to allow them to run on the internal
corner of the profile.
Specially designed shims of various dimensions are utilized to reduce play between the
mast stages.
The fork arm carriage is equipped with 4 Ø 81mm taper roller bearings.
The journals of the upper rollers are welded in an inclined position with the angle in the Fig. 2
opposite direction with respect to the lower roller journals in order to eliminate front and side
play.
The lateral lift cylinders are of the “Single acting self-braking” type, with cushioning activated on the
downward stroke (for more information consult the hydraulic section of the manual).
The central cylinder is of the “Single acting self-braking” type with cushioning activated at the top of the
upward stroke (for more information consult the hydraulic section of the manual).
The lift chains are prime quality “Fleyer series AL and BL” type, wherein Fleyer denotes a traction type
chain.
MAST VIEWED
FROM
FORKS SIDE
MAST VIEWED
FROM ABOVE
MAST VIEWED
FROM VIEW OF BEARING
CYLINDERS SIDE POSITIONS IN MAST CHANNEL
Fig. 3

1.04 MAST “HE 140L”
Mast model “HE 140L” is installed on trucks with lift heights from 4500 mm to 8000 mm according to the
rated load capacity of the truck (see table 1 page 2a).
SPECIFICATIONS:
The external, intermediate, and internal stages are constructed of “HE” section channels. Anchorage to
the reach carriage is identical to that of the “Beta” mast, thus ensuring that the masts are fully
interchangeable on the same reach carriage.
The fork arm carriage runs within the internal mast stage and it incorporates the mast tilt
cylinder and forks sideshift cylinder. 1
MASTS
The mast complete with fork arm carriage is equipped with a total of 12 “Combined roller” 2
bearings Ø 101 mm (Fig. 4).
The bearings are composed of an outer roller that runs in a plane parallel to the mast channel
and a lateral roller that runs on the internal profile; this combination, with the aid of suitable Fig. 4
shims, has made it possible to minimize play between lateral and front mast sections.
The lateral lift cylinders are of the “Single acting self-braking” type with cushioning activated on the
downward stroke (for more information consult the hydraulic section of this manual).
The central cylinder is of the “Single acting self-braking” type with cushioning activated at the top of the
upward stroke (for more information consult the hydraulic section of the manual).
chain.
MAST VIEWED
FROM
FORKS SIDE
MAST VIEWED
FROM ABOVE
MAST VIEWED
FROM
CYLINDERS SIDE VIEW OF BEARING
POSITIONS IN MAST CHANNEL
Fig. 5

1.05 MAST “HE 140”
Mast model HE 140 is installed on trucks with lift heights from 6700 mm to 9200 mm according to the rated
load capacity of the truck (see table 1 page 2a).
SPECIFICATIONS:
The specifications of this mast are analogous the data quoted for type HE 140L.
The principal difference lies in the use of different types of lateral lift cylinders.
The lateral lift cylinders are “Plunger type with hollow rod” (for more information consult the hydraulic
section of this manual).
The central cylinder is “Single acting self-braking” type with cushioning activated at the top of the upward
stroke (for more information consult the hydraulic section of the manual).
MASTS
chain.
VIEW OF MAST
FROM FORKS SIDE
VIEW OF MAST
FROM ABOVE
VIEW OF MAST
FROM
VIEW OF BEARING
CYLINDERS SIDE
POSITIONS IN THE MAST CHANNEL
Fig. 6

1.06 MAST TYPE “HE 140R”
Mast model “HE 140R” is installed on trucks with lift heights up to 11400 mm (see table 1 page 2a).
SPECIFICATIONS:
The specifications of the mast profile and bearings are identical to those quoted for mast model “HE 140L”.
To enable the mast to reach high elevations a series of reinforcements have been applied to the external
stage and the intermediate stage. This mast also utilizes different lift cylinders.
The lateral lift cylinders are “Plunger with hollow rod” type (for more information consult the hydraulic
section of this manual).
The central lift cylinder is of the “Plunger” type (for more information consult the hydraulic section of this
MASTS
manual).
chain.
VIEW OF MAST FROM

FORKS SIDE
VIEW OF MAST
FROM ABOVE
VIEW OF MAST
FROM CYLINDERS SIDE
VIEW OF BEARING POSITIONS
IN MAST CHANNEL
Fig. 7

2.00 MAST REMOVAL PROCEDURE

MODEL BETA - HE 140 - HE 140L - HE 140R
The mast must be disassembled from the carriage when they are to be completely renewed or in order
to renew the bearings.
The removal procedure is identical for all models.
SPECIAL EQUIPMENT REQUIRED

® Sling with max. load capacity of 3000 kg
® Overhead crane with lifting capacity of 4000 kg max.

MASTS
6-8 mm 17-19-24 mm 24 mm SOCKET WRENCH OVERHEAD CRANE

ALLEN WRENCH HEX WRENCH WITH RATCHET
G G
Fig. 12
F Fig. 10
E D A
H
Fig. 11 Fig. 9
C
Fig. 8 B
Fig. 14 Fig. 13 Fig. 15
PROCEDURE
carriage to its forward position.
1) SLING - CRANE - 6-8 mm ALLEN WRENCH - Lift the forks until they are positioned at one metre above
the ground, then use the 7 mm. Allen wrench to unscrew and remove the fixing screws of the load
restraint grille (Ref. G Fig. 10). Remove the grille from the fork arm carriage.
Using the 8 mm Allen wrench unscrew and remove the forks mechanical locking screw (Ref. F Fig. 10).
Move the forks one at a time towards the centre of the carriage and remove them with the aid of the
overhead crane and the sling.
MASTS
2) SLING - OVERHEAD CRANE - Attach one end of the sling to the top cross beam of the external mast
stage (Fig. 8). Attach the other end of the sling to the crane hook and then allow the crane to take the
strain.
3) WOODEN BEAM - Lift the the fork arm carriage beyond the free lift thus exposing the screws that fasten
the mast to the reach carriage (Fig. 9) and then continue to lift until the beam can be inserted under the
intermediate section; place the beam under the section (Ref. H Fig. 9) then lower the forks until they are
supported on the beam. Now set the keyswitch to “OFF” and disconnect the battery.
Warning: the beam fills an important safety function for the entire duration of the work and
must therefore be positioned where it is perfectly stable and safe.
4) 24 mm SOCKET WRENCH - Unscrew and remove the three screws that secure the mast to the reach
carriage (Ref. A Fig. 9). Connect the battery and set the keyswitch to “ON”. Lift the mast by
10 centimeters and remove the wooden beam. Now lower the mast until it is completely closed and then
set the keyswitch to “OFF” and disconnect the battery. Use the same wrench to unscrew and remove
the mast stop screws on the reach carriage (Ref. C Fig. 11). Remove the upper stops.
5) 17-19-24 mm HEX WRENCHES - Use the 17 mm wrench to unscrew the unions of the twin hydraulic
lines supplying the tilt cylinder and sideshift cylinder (Ref. D Fig. 12).
With the 24 mm hex wrench unscrew the central cylinder hydraulic hose union (Ref. E Fig. 12).
With the same wrench unscrew the union of the lateral cylinders hydraulic supply line (Ref. B Fig. 13).
6) Lift the mast ensuring that the mast base, supported on the reach carriage, does not foul the
solenoid valve pipelines and that the lateral profiles transit past the mast stabilizer mechanical
stops (Fig.14-15).
Now lower the mast to the ground and proceed with repair work or fit new bearings.

2.01 DIAGRAM WITH DESCRIPTION OF MAST ASSEMBLY STEPS
Notes on installing or removing the mast with indications of the shims to be inserted to provide the correct
inclination in relation to height and screw torquing directions for mast installation.
TORQUE TO 300 Nm / ASSEMBLE

WITH LOCTITE 243 / 4 SCREWS
MASTS
TORQUE TO 300 Nm / ASSEMBLE

WITH LOCTITE 243 / 4 SCREWS
SHIMS TO ADD OR REMOVE

TO ADJUST THE MAST
INCLINATION ANGLE
CHAIN/CARRIAGE
VIEWED FROM BELOW
NOTA:
FARENOTE:
ATTENZIONE AD INSERIRE
LA COLONNA
ENSURE NELLA PIASTRA
THE MAST DI
IS CORRECTLY
FERMO DEL CARRO RETRATTILE
INSERTED IN THE REACH CARRIAGE
RETAINER PLATE
Fig. 15a

2.02 TABLE OF MAST INCLINATION ANGLES

The following table gives the inclination measurements for the various mast types and the ground to
stabilizer shoe distance in relation to the height and model.
Quota “A” - +

MASTS
Quota “B”
h1
STABILIZER SHOE - GROUND

DISTANCE

MAST INCLINATION Fig. 15b
MAST INCLINATION
Stabilizer shoe
A708 BETA A709 HE 140 A709 HE 140L A709 HE 140R Adjustment
Horizontal Horizontal Horizontal Horizontal
Reference H3 Reference H1 distance distance distance distance Shoe to Ground
mm mm reference reference reference reference Clearence mm
H1 mm H1 mm H1 mm H1 mm
4500 2075 11 9 9 30
5000 2275 11 9 9 30
5400 2376 12 10 10 30
6000 2575 12 10 10 30
6300 2675 13 11 11 30
6500 2775 13 11 11 30
6700 2825 14 12 12 30
7000 2925 12 12 30
7500 3175 13 13 30
8000 3325 13 13 13 30
8500 3525 14 14 14 20
8700 3725 14 14 14 20
9000 3825 15 15 15 20
9300 3925 15 15 15 20
9500 3975 16 20
10000 4275 16 10
10500 4425 17 10
11400 4725 17 10
QUOTA "A" QUOTA "B"

2.03 FORK ARM CARRIAGE REMOVAL PROCEDURE

The procedure for removal of the fork arm carriage is identical for all
models of masts.
The form arm carriage must be removed when new bearings are to be
fitted.
SPECIAL EQUIPMENT REQUIRED G G
® Sling with load capacity of 2000 kg max.

® Overhead crane with lifting capacity of 2000 kg max.

MASTS
F Fig. 20
5-6-8 mm ALLEN 17-19 mm HEX

WRENCH WRENCH
OVERHEAD CRANE REGULAR PLIERS
Fig. 17
L
N
Fig. 16 I
Fig. 18 Fig. 19
PROCEDURE
1) 6-8 mm ALLEN WRENCH - Lift the forks until they are one metre above the ground. Use the 6 mm
wrench to unscrew and remove the load restraint grille fixing screws (Ref. G Fig. 20). Remove the load
restraint grille from the fork arm carriage.
With the 8 mm wrench unscrew and remove the forks mechanical fastening screw (Ref. F Fig. 20).
Move the forks towards the centre of the carriage one at a time and then use the crane and sling to
remove them.
MASTS
2) SLING - OVERHEAD CRANE - Attach one end of the sling to the fork arm carriage (Fig. 16) and attach
the other end to the crane hook; now allow the crane to take the strain. Continue to lift until the lift chain
and tilt/sideshift cylinder hydraulic hoses have become slack.
3) 5 mm ALLEN WRENCH - REGULAR PLIERS - 17 mm HEX WRENCH - Use the 5 mm Allen wrench
to unscrew and remove the hose carrier block (Ref. I Fig. 18), use the hex wrench to unscrew the
hydraulic hose unions (Ref. L Fig.19).
Use the pliers to remove the circlip from the chain pin (Ref. N Fig. 18). Remove the chain fixing pin
(Ref. M Fig. 18).
Lower the fork arm carriage to the ground and then remove the lifting sling.
4) Attach one end of the sling to the mast internal section cross beam (Fig. 16) and attach the other end
to the crane hook and then take the strain with the crane. Lift the mast section until the fork arm carriage
is free of its location. Place the fork arm carriage on a workbench and proceed to repair the carriage
or replace the bearings.
To reassemble, perform the disassembly steps in reverse order
NOTES:

2.04 BEARING REPLACEMENT PROCEDURE

MODELS HE 140 - HE 140L - HE 140R
The combined bearings are available in three different sizes characterized
by the following outside diameters “Ø 101.5 - Ø 101.9 - Ø 102.3” (Ref. N
Fig. 21). When the mast is assembled the bearings are first tested by
running them inside the channels so that the bearing that offers the
smallest frontal play can be utilized (Fig. 22). Shims are also utilized to N
insert on the journal at the rear of the bearing in order to eliminate lateral
play (Fig. 22). Once the mast has been assembled, the measurement of
the rollers is punched onto each profile in the form of a letter that identifies
the diameter utilized.
For more information regarding the position of the punch marking (see
Page 2b).
The bearings must be renewed every 6000/7000 duty hours.
The lifetime of the bearings depends basically on the conditions and work
MASTS
cycles, the working environment, and the grease lubrication frequency.

Failure to observe correct maintenance practices can result in excessive Fig. 21
play on the mast profiles both in the frontal and axial directions, or even
seizure of the internal rollers due to inadequate lubrication. In this situation
it becomes necessary to renew the rollers before the normal end of their
working life. Alternatively, it is possible to measure both the axial and frontal 0,5
clearance of the rollers in the mast channels caused by cold deformation
and, if the tolerance values surpass the values shown in (Fig. 22) it is
advisable to renew the bearings.
If at the time of refitting it should be noted that the original size bearing
presents clearances that are outside the requested tolerance, this bearing
must be substituted for the bearing of the next diameter up and punch mark
the letter indicating the size of the new bearing (see position on page 2b).
The roller is supplier as a spare part complete with a contrast roller but
without the weld-on journal.
The procedures for removing and refitting bearings on the mast and on the
fork arm carriage are identical. 0,5
Fig. 22
Mast channel
3 mm ALLEN
WRENCH
PROCEDURE
clothing.
1) 3 mm ALLEN WRENCH - Unscrew the four fixing screws securing the
welded journal bearing (Ref. O Fig. 24), remove the plate and bearing
complete with contrast roller and fit a new replacement part. Fig. 23
Fork arm carriage Fig. 25 Fig. 24 O

2.05 GREASING THE BEARING

The bearing lubrication frequency depends on several factors such as the environment in which lifting is
performed and the type of work that the truck is called to carry out.
Dusty and corrosive environments, with high or excessively low temperatures and constant use of the
truck over multiple shifts will make it necessary to increase the frequency of maintenance.
For normal use of the truck in low dust environments with temperatures within average values the required
greasing frequency is once every 300/400 duty hours.
Recommended lubricants:
Standard bearing grease = “Mobil Grease 532”
Low temperature bearing grease = “Texaco Regal AFB2”
Mast lubricant = “Molykotez Graphitized Grease”
MASTS
® Grease gun
GREASE NIPPLE 3 mm
ALLEN WRENCH
PROCEDURE
1) 3 mm ALLEN WRENCH, GREASE GUN, GREASE NIPPLE - Using the Allen wrench unscrew and
remove the grub screw currently plugging the bore (Ref. P Fig. 29) fit a 6 mm diameter grease nipple
(Ref. Q Fig. 26) and proceed to inject grease. Repeat the same procedure for all four mast bearings.
This procedure must be repeated every 300/400 duty hours.
With the same frequency it is good practice to lubricate the bearing tracks by brushing them with grease
as shown (Fig. 30).
Fig. 29
Fig. 27 P Fig. 30
Q
Fig. 26 Fig. 28

2.06 MAST BEARINGS REPLACEMENT PROCEDURE

MODEL BETA
The roller utilised in conjunction with the “BETA” mast is composed of a ball bearing inside a steel shell
with radiused outer edge.
The bearing is fitted over a welded journal inclined with respect to the mast channel in such a way that the
rounded part of the bearing runs on the internal corner of the channel (Ref. S Fig. 31).
To minimise lateral and frontal play shims, in the required number and
thicknesses, are installed on the journal behind the bearing (Ref. T Fig.
31).
The bearings must be renewed every 6000/7000 duty hours.
The bearings, not equipped with grease nipples, are sealed and
MASTS
S
prelubricated with long life grease.
The roller must be renewed when play is detected between shell and
internal bearing, or when the dimensional tolerance of the convex section
of the roller becomes too great and the roller ceases to run truly in the
corner of the mast channel (Ref. S Fig. 31).
T
In both cases it will be necessary to remove the mast from the truck. Fig. 31
STANDARD TOOLS REQUIRED R
Fig. 32
MEDIUM CIRCLIP
PLIERS
PROCEDURE
Before starting work, make sure you are wearing suitable

Fig. 33
safety clothing.
1) CIRCLIP PLIERS - Remove the bearing retaining circlip from the journal
(Ref. R Fig. 32) and remove the shims. Remove the bearing and fit a
replacement part.

If you notice that the new bearing presents excessive play in the mast
channel, insert one of the previously removed shim washers under the
circlip.
To ensure the maximum freedom of movement of the bearings, use a brush

to apply a coating of grease to the mast channel as shown (Fig. 34). This
operation should be performed every 400 ÷ 500 duty hours using “Molykotez
Graphitized Grease”. Fig. 34

2.07 LIFT CHAIN
The chains are prime quality “Fleyer series AL and BL” type traction
chains.
The chains installed are subjected to levels of mechanical stress that are
significantly lower than their effective breaking strength.
GREASING THE CHAINS
Long life of the chains is assured by performing proper lubrication.

The chains should therefore be lubricated periodically using a brush as
shown (Fig. 35) or spray canister.
The frequency with which the chains are to be lubricated depends largely
on the type of work performed and the environment conditions in the
MASTS
workplace.
CHAIN STRETCHING
Fig. 35
Over a period of time and with constant use the chains tend to stretch.
The resulting length increase can be compensated for using the chain
tensioner.
The maximum possible compensation for chain stretching is 2% of total
length. When the chains stretch beyond this point they must be renewed.
Measure chain elongation over a number of sections of 10 links in length
selected from the parts of the chain most subject to stress. This check
should be performed every 1500/2000 duty hours. The 10 links
measurement is shown in the following table in reference to the type of
mast and relative chain.
LIFT CHAIN STRETCH REFERENCE TABLE
Lateral Central
Maximum Stretch
Mast Mast Sample Length Equal to
Mast Type Referred to Sample
Chains Chains N° 10 Links
Length
Pitch L== Pitch L=
P 15,875 158,75 162
BETA
P 25,40 254 259
P 15,875 158,75 162
HE 140
P 25,40 254 259
P 15,875 158,75 162
HE 140L
P 25,40 254 259
P 15,875 158,75 162
HE 140R
P 25,40 254 259

2.08 MEASURING THE CHAIN

B
If chains are found to display an insignificant degree of stretching (less than A
2%), this fact alone cannot be construed as indicating that the chains are
in perfect condition.
On the contrary, chains may display signs of stress-related distortion; for
this reason it is good practice to carefully inspect the chain over its entire G D
length.
F
CHECKING CHAIN LINKS
C
Prepare for the inspection by cleaning the chain with paraffin or a paraffin-
based solvent. E
The chains may be inspected without removing them from the mast.
MASTS
Inspect the chain and associated components (Fig. 36-37): Fig. 36
A) Wear of the journal

B) Condition of the journal (possible damage)
C) Cracked links
D) Wear of the link edges
E) Wear of the link bores
F) Excess play between the links
G) Rust
H) Out of round of the chain tensioner bore
I) Wear of the chain pivot pin H
If the chains and/or associated parts display one or more of the foregoing
defects, they must be replaced.
Fig. 37
NOTES:

2.09 REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT)

13 mm
PROCEDURE REGULAR PLIERS HEX WRENCH
MASTS
1) WOODEN BEAM - Raise the forks until the beam can be inserted under them; position the beam under
the forks (Fig. 38); lower the forks until they are resting on the beam and then continue to lower until the
chain and hydraulic hoses become slack. Set the keyswitch to “OFF” and disconnect the battery.
2) 13 mm HEX WRENCH - Unscrew and remove the anti-derailment bracket fixing screws (Ref. L Fig. 41).
Remove the bracket.
3) REGULAR PLIERS - Remove the split pins and chain pivot pins, (Ref. M-N
Fig. 40-41), remove the chain, and fit a replacement.
L
Fig. 41
N
Fig. 38 Fig. 40 Fig. 39

2.10 REPLACING THE LATERAL LIFT CHAINS

PROCEDURE
REGULAR PLIERS
MASTS
O O
Fig. 35
Fig. 36
P
P
Fig. 34
Fig. 38 Fig. 37

1) WOODEN BEAM - Lift the forks beyond the free lift until the beam can be inserted under
the internal section (Fig. 34).
Insert the beam and lower the forks until the internal section is resting on the beam; continue to
lower the forks until the chains become slack.
Set the keyswitch to “OFF” and disconnect the battery.
2) REGULAR PLIERS - Remove the split pins and chain pivot pins at the base of the
internal section (Ref. P Fig. 37-38) and then disengage the chain from the terminal connection.
Remove the split pins and the chain pivot pins from the chain tensioners (Ref. O Fig. 35). Recover the
chains and fit replacements.
MASTS
NOTES:

NOTES:
MASTS

SERVICE Section: MECHANICS
MECHANICS
MECHANICS
a TABLE OF SCREW TIGHTENING TORQUES ................................ 2
a DRIVE WHEEL REPLACEMENT PROCEDURE ............................ 3
MECHANICS
a LOAD WHEELS REPLACEMENT PROCEDURE .......................... 4
a FORK SIDESHIFTER SHOES REPLACEMENT PROCEDURE ..... 7
a FUNCTION OF THE BATTERY RESTRAINT ................................... 9
a BATTERY RESTRAINT REMOVAL PROCEDURE ....................... 10
a REPLACING THE LATCH AND SPRING ...................................... 11
a REPLACING THE TRACTION MOTOR ......................................... 12
a TRACTION MOTOR COMPONENTS ............................................ 13
a ENCODER BEARING REPLACEMENT ....................................... 14
a REMOVAL OF THE PUMP MOTOR ............................................. 16
a PUMP MOTOR COMPONENTS .................................................. 18
a REPLACING THE ENCODER BEARING ...................................... 19
a STEERING GEARED MOTOR REMOVAL PROCEDURE ............ 20
a STEERING MOTOR COMPONENTS ........................................... 21
a ENCODER BEARING REPLACEMENT ....................................... 22
a STEERING UNIT .......................................................................... 23

Section: MECHANICS SERVICE
1.00 TABLE OF SCREW TIGHTENING TORQUES
NOTE: before disassembling and reassembling parts of the truck and fasteners, read the
following information carefully.
LOCTITE 270 is used to lock threaded fasteners and ensure that they will not work loose during operation.
A certain amount of resistance may be encountered when undoing bolts, etc. Should they prove impossible
to unfasten using normal tools, do not use extensions (the head of the bolt might shear off), but instead,
heat the area slightly so as to eliminate the effects of the Loctite (max 50 °C).
In the cases described above, apply a moderate amount of Loctite when refitting (generally speaking, 30%
of the mating surface should be coated)
The tightening torque applied to threaded fasteners is of maximum importance for the safety of the joint
itself and therefore for the safety of the machine.
The following table indicates the classes of nuts and bolts normally used on the machine with the relative
tightening torques.
MECHANICS
NOM SIZE TENSILLE PROPERTY CLASS 5.8 PROPERTY CLASS 8.8 PROPERTY CLASS 10.9
X STRESS CLAMP TORQUE (N.m CLAMP TORQUE (N.m) CLAMP TORQUE (N.m)
PITCH AREA LOAD DRY LUBEET LOAD DRY LUBED LOAD DRY LUBED
As (mm) W (N) K=0.20 K=0.15 W (N) K=0.20 K=0.15 W (N) K=0.20 K=0.15
M4 x 0,5 8,78 2 400 1,92 1,44 3 830 3,07 2,30 5 220 4,17 3,13
M5 x 0,8 14,20 3 880 3,88 2,91 6 200 6,20 4,65 8 430 8,43 6,33
M6 x 1 20,10 5 490 6,58 4,94 8 770 10,50 7,90 11 950 14,30 10,80
M8 x 1,25 36,60 9 990 16,00 12,00 15 975 25,60 19,20 21 750 34,80 26,10
M8 x 1 39,20 10 700 17,10 12,80 17 100 27,40 20,50 23 275 37,30 27,90
M10 x 1,5 58,00 15 825 31,70 23,80 25 325 51,00 38,00 34 450 69,00 52,00
M10 x 1,25 61,20 16 700 33,40 25,10 25 725 53,00 40,10 36 350 73,00 55,00
M12 x 1,75 84,30 23 025 55,00 41,40 36 800 88,00 66,00 50 075 120,00 90,00
M12 x 1,25 92,10 25 150 60,00 45,30 40 200 96,00 72,00 54 700 130,00 98,00
M14 x 2 115,00 31 400 88,00 66,00 50 200 140,00 105,00 68 300 190,00 145,00
M14 x 1,5 125,00 34 125 96,00 72,00 54 550 155,00 115,00 74 250 210,00 155,00
M16 x 2 157,00 42 850 135,00 105,00 68 525 220,00 165,00 93 250 300,00 225,00
M16 x 1,5 167,00 45 600 145,00 110,00 72 900 235,00 175,00 99 200 320,00 240,00
M20 x 2,5 245,00 66 875 270,00 200,00 106 950 430,00 320,00 145 550 580,00 435,00
M20 x 1,5 272,00 74 250 295,00 225,00 118 750 475,00 355,00 161 550 650,00 485,00
Table 1
NOTE: The truck is assembled using screws and bolts of PROPERTY CLASS 8.8 - LUBED.

1.01 DRIVE WHEEL REPLACEMENT PROCEDURE

MODEL ALL MODELS
® N° 2 wooden blocks 150x150x200
MECHANICS
5-10 mm 19 mm SOCKET HYDRAULIC JACK
ALLEN WRENCH WRENCH
WITH RATCHET
PROCEDURE
MECHANICS
carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and
1) HYDRAULIC JACK - WOODEN BLOCKS - Set the jack in the centre of the truck in correspondence
with the drive wheel, and raise the truck until the blocks can be inserted. Position the blocks as shown
(Fig. 2) and lower the jack until the truck is resting on the blocks. Remove the jack.
2) 5-10 mm ALLEN WRENCH - Use the 5 mm Allen wrench to open the motor compartment door, then
use the 10 mm Allen wrench to remove the wheel protection plate (Ref. A Fig. 1).
3) 19 mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the wheel fixing screws (Ref. B
Fig. 2). Remove the drive wheel and fit a replacement.
Fig. 1 B Fig. 2
A

1.02 LOAD WHEELS REPLACEMENT PROCEDURE

MODEL R1.4 - R1.4H - R1.6 - R1.6H - R1.6N
® 2 wooden blocks 150x150x200
D
STANDARD TOOLS REQUIRED Fig. 3
HYDRAULIC JACK
3 mm ALLEN 1 kg HAMMER Ø 20x200 DRIFT

WRENCH
Fig. 4
MECHANICS
PROCEDURE
clothing.
Park the truck in a safe place away from moving vehicles and pe-
destrians. Bring the reach carriage to its forward position, lower the
forks to the ground, set the keyswitch to “OFF” and disconnect the
battery. C
Fig. 5
1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack alongside the
load wheel and raise the truck until the block can be inserted.
Position the block alongside the jack (Fig. 4) and lower the jack so that
the truck is resting on the block. Repeat the same procedure for the
opposite side wheel.
2) 3 mm ALLEN WRENCH - HAMMER - DRIFT - Using the 3 mm Allen

wrench unscrew and remove the wheel spindle fixing screws (Ref. C
Fig. 5)
Use the hammer and drift to drive out the wheel spindle (Ref. D Fig. 3) as Fig. 6
shown (Fig. 6). Remove the wheel and proceed to change the entire
wheel or the bearings only.
Recover the shims interposed between the bearings and the load wheel
channels because they must be refitted together with the new wheel.
Fig. 7

1.03 LOAD WHEELS REPLACEMENT PROCEDURE

MODEL R1.6 H Optional - R2.0 - R2.0H - R2.0W - R2.5

HYDRAULIC JACK
MECHANICS
5-8 mm ALLEN 1 kg HAMMER Ø 25x200 DRIFT
WRENCH
E Fig. 9
MECHANICS
7-14 mm HEX C-SPANNER FOR COMPASS WRENCH
WRENCH RINGNUTS Ø 40 WITH Ø 5 mm PINS
PROCEDURE
Before starting work, make sure you are wearing suitable safety G Fig. 10
clothing.
Park the truck in a safe place away from moving vehicles and pe-
destrians. Bring the reach carriage to its forward position, lower the
forks to the ground, set the keyswitch to “OFF” and disconnect the
battery.
1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack at the side of

the load wheel and raise the truck until the block can be inserted. F H Fig. 11
Place the block alongside the jack and lower the jack so that the truck is
resting on the block.
Repeat the same procedure for the opposite side wheel.
2) 14 mm HEX WRENCH - Empty and remove the brake fluid line union nut
with thru hole (Ref. E Fig. 9) and collect the brake fluid, ensuring that it I
does not come into contact with the brake unit.
3) 5 mm ALLEN WRENCH - Unscrew and remove the five screws that

secure the brake unit to the truck body (Ref. F Fig. 11) thereby freeing the
wheel.
Fig. 12
4) COMPASS WRENCH - 8 mm ALLEN WRENCH - Position the compass
wrench pins in the holes in the spindle (Ref. G Fig. 10). Using the Allen
wrench, unscrew and remove the spindle fixing screw (Ref. H Fig. 11).

5) HAMMER - DRIFT - Use the hammer and drift to drive out the wheel
spindle from the inside of the straddle channel towards the outside
(Ref. I Fig. 12). Remove the wheel and place it on a workbench.
6) C-SPANNER - Unscrew and remove the ring responsible for fixing the
brake unit to the wheel (Ref. L Fig. 13).
Remove the brake unit and proceed to change the wheel and the
bearings (Fig. 14).
L Fig. 13
NOTE: it is advisable to order and replace the wheel complete with
hub; this ensures that the new wheel will be perfectly
centred.
7) 7 mm HEX WRENCH - Bleed the brake circuit of air (see procedure in

the “braking system” section, heading 6.02 Page 13).
Fig. 14
NOTES:
MECHANICS

2.00 FORKS SIDESHIFT SHOES REPLACEMENT PROCEDURE

MODEL ALL MODELS
Due to constant use of the sideshift facility, the shideshift shoes tend to wear with the result of excess
friction during sliding movements or, in extreme cases, jamming of the mechanism. The lifetime of the
shoes depends basically on the working conditions and cycles, the working environment, and the
frequency of use of the sideshift.
For normal use in a low dust environment with average temperatures and greasing carried out every 300/
400 duty hours, the shoes should be renewed on average every 4000/5000 duty hours.
The replacement procedure is described below.
MECHANICS
® Lifting sling with terminal rings and max load capacity of 2000 kg
MECHANICS
8-12 mm ALLEN OVERHEAD CRANE MAX. LOAD
WRENCH CAPACITY 2000 kg
PROCEDURE
Before starting work, make sure you are wearing suit- Fig. 15
able safety clothing.
Park the truck in a safe place away from moving vehi-

cles and pedestrians. Bring the reach carriage to its
forward position, raise the forks until they are one me-
tre from the ground, set the keyswitch to “OFF” and
1) 8 mm ALLEN WRENCH - SLING - OVERHEAD CRANE -

Unscrew the forks fixing screw located at the centre of the
fork arm carriage (Ref. M Fig. 16).
Shift the forks towards the centre of the carriage one at a time Fig. 16
M
to the position of the lower forks latch.
Attach the two ends of the sling to the fork (one end
next to the fork tip and the other near
the fork heel (Fig. 15). Attach the mid-section of the sling to
the crane hook and then lift the fork, detaching it from the fork
arm carriage.
Fig. 17
N

2) 12 mm ALLEN WRENCH - SLING - OVERHEAD CRANE -

Attach the ends of the sling to the top bar of the fork arm
carriage (Fig. 18). Attach the mid section of the sling to the
crane hook and allow the crane to take the strain.
Using the Allen wrench unscrew and remove the fixing
screws of the sideshift blocks (Ref. N Fig. 17) and remove the
blocks.
Move the base of the carriage outwards and lift
until it is possible to remove the sideshift and thus expose the
sliding shoes (Ref. O - P Fig. 19); at this point, remove the
shoes Fig. 18
and fit replacement parts.
After replacing the shoes apply a generous amount of grease
to the sliding surface. It is good practice to grease the parts
every 300 ÷ 400 duty hours
To reassemble, perform the disassembly steps in reverse

order.
MECHANICS
O P Fig. 19
NOTES:

2.01 FUNCTION OF THE BATTERY RESTRAINT

MODEL ALL MODELS
The battery restraint performs the important job of keeping the

battery secured when the truck is in operation, while also SITUATION
allowing the extraction of the battery compartment for charg- OF BRACKET
DURING BATTERY
ing purposes. The bracket complete with hooks is anchored EXTRACTION
below the battery enclosure, hook E engages with pin F during
extraction, while hook B engages with pin C in the locked, work
position.
DESCRIPTION OF HOW THE MECHANISM WORKS
MECHANICS
E
- Battery extraction F
Bring the reach carriage to the position in which it is completely
located against the battery. D
Use your shoe heel to press pedal (Ref. A Fig. 22) located B C
opposite the accelerator pedal alongside the motor hood, and
then lift the pin (Ref. C Fig. 23).
At this point spring (D) forces the bracket to the left, thus mov-
ing hook (B) out of the centre of pin (C) and simultaneously
MECHANICS
engaging hook (E) with reach carriage pin (F).
Now move the reach carriage towards the load wheels, caus-
ing the battery to be drawn out of is compartment in the truck Fig. 20
body (Fig. 20).
- Reinserting the battery C

Once the battery has been charged, move the reach carriage
back towards the battery compartment. When it reaches its
Fig. 23
stroke limit the bevel of hook (B) slides over pin (C) causing
the bracket to move to the right and, thanks to the force ex-
erted by spring (D) it engages with the pin, thus locking the
battery in the truck body battery compartment (Fig. 21).
- Battery in working position

As can be seen (Fig. 21) hook (B) of the bracket is engaged
with pin (C) and, assisted by the force exerted by spring (D), it
maintains the bracket locked to the hook thus enabling the truck
to be operated with the battery completely restrained in its
position.
Due to the sliding friction of the bracket hooks when the
locate with the pins, it is advisable to keep all the parts
properly greased to facilitate engagement and
disengagement movements.
F E
D
B
C
SITUATION OF
BRACKET DURING
A BATTERY LOCKING
Fig. 22 Fig. 21

2.02 BATTERY RESTRAINT REPLACEMENT PROCEDURE

MODEL ALL MODELS
13-32 mm REGULAR PLIERS 5 mm ALLEN MEDIUM EXTERNAL

HEX WRENCH WRENCH CIRCLIP PLIERS
PROCEDURE
carriage to its forward position, lower the forks, set the keyswitch to “OFF” and disconnect the
battery.
MECHANICS
1) 5 mm ALLEN WRENCH - Open the motor compartment door and remove the platform.
2) 13 mm HEX WRENCH - Extract the battery towards

the load wheels. Use the wrench to unscrew and
remove the restraint assy. fixing screws (Ref. Q Fig. 26).
Remove the assy. and fit a complete replacement or
strip down the original assy to replace the worn parts.
3) 13 mm HEX WRENCH - REGULAR PLIERS - Use the

wrench to loosen the locking nut (Ref. R Fig. 27)
Use the pliers to disengage the pin restraining clips
(Ref. S Fig. 27) and then remove the pin (Ref. T Fig. 28)
taking care to recover the bush (Ref. V Fig. 28).
Manually keep the pin pressed upwards (Fig. 28) and
unscrew the latch and nut. Withdraw the pin complete
with spring (Fig. 29) and fit replacement parts. Fig. 24
To reassemble, perform the disassembly steps in

reverse order.
T V
S
Fig. 25
R
Q
U
Fig. 27 Fig. 28 Fig. 29 Fig. 26
LATCH AND SPRING REPLACEMENT
4) CIRCLIP PLIERS - 5 mm ALLEN WRENCH Move

the reach carriage towards the load wheels.
To access the bracket you will need to lie on the
ground and, using a worklight to illuminate the area,
proceed with removal.
Use the Allen wrench to unscrew and remove the
spring fixing screws (Ref. W Fig. 30-31) and then
remove the spring.
Use the pliers to remove the circlip (Ref. Z Fig. 30-
MECHANICS
31), remove the latch from the pivot pin and fit a
replacement.
W Z Fig. 30
reverse order.
MECHANICS
W
Fig. 31

3.00 TRACTION MOTOR REPLACEMENT PROCEDURE

MODEL ALL MODELS
® Lifting sling with hook
12
12
12
12
12
5 mm ALLEN OVERHEAD CRANE 13-17 mm 8 mm Ø 8 mm EYEBOLT

WRENCH HEX WRENCH CAPACITY 100 KG
MECHANICS
PROCEDURE
carriage to its forward position, lower the forks, set the keyswitch to “OFF” and disconnect the
battery.
1) 5 mm ALLEN WRENCH - Open the battery compartment door

and remove the platform.
2) 13 - 17 mm HEX WRENCH - Use the 17 mm wrench to unscrew

the power cable terminals on the motor and detach the cables.
Use the 13 mm wrench to unscrew and remove the four screws
that secure the motor to the gear unit (Ref. Y Fig. 32).
3) EYEBOLT - SLING - OVERHEAD CRANE - Screw the eyebolt

into the rotor shaft through the electromagnetic brake unit (Fig. 32).
Attach the sling hook to the eyebolt and attach the other end of the
sling to the crane hook.
Carefully lift the motor clear of the gear unit in order to fit a
replacement or to strip down the original motor.
Y Fig. 32

3.01 TRACTION MOTOR COMPONENTS

MODEL ALL MODELS
7 10 9
2 3 13
5
MECHANICS
11
12
8
1
MECHANICS
6 Fig. 33
TABLE OF TRACTION MOTOR COMPONENTS

1 Rotor
2 Stator
3 Casing
4 Upper motor flange
5 Lower motor flange
6 Tie rod ø 8
7 Terminal block
8 Encoder bearing
9 Encoder connector
10 Motor thermal cutout connector
11 Dust seal
12 Circlip
13 Wiring between terminal block and stator
Table 2

3.02 REPLACING THE ENCODER BEARING

MODEL ALL MODELS
Once the motor has been removed from the truck it can be stripped down to access the various parts.
13-17 mm MEDIUM EXTERNAL 5 mm ALLEN BEARING PULLER

HEX WRENCH CIRCLIP PLIERS WRENCH
PROCEDURE
MECHANICS
clothing.
1) 5 mm ALLEN WRENCH - 17 mm HEX WRENCH - Place the motor

in a vice and clamp the casing carefully. Use the hex wrench to
unscrew and remove the motor power cable terminal nuts (Ref. A
Fig. 35).
Use the Allen wrench to unscrew and remove the screws securing the
terminal block to the motor (Ref. B Fig. 35). Remove the terminal
block.
Fig. 34
2) 13 mm HEX WRENCH - Unscrew and remove the fixing nuts of the
flange connecting tie bars (Ref. C Fig. 37) and remove the four bars
(Ref. D Fig. 37) thereby freeing the flanges.
Withdraw the rotor complete with upper flange (Fig. 38). A B
3) 5 mm ALLEN WRENCH - Remove the casing from the vice and, in its
place, insert the rotor after fitting the vice jaws with aluminium cheeks
to prevent marring of the rotor. Clamp the rotor carefully. Fig. 35
Use the wrench to unscrew and remove the fixing screws of the
bearing retaining flange (Ref. E Fig. 39). Remove the flange from the
rotor (Fig. 40).
D Fig. 36
E Fig. 39 Fig. 38 C Fig. 37

4) CIRCLIP PLIERS - PULLER - Use the pliers to remove the bearing

circlip (Ref. F Fig. 41). Fit the puller to the bearing (Fig. 42) and
withdraw the bearing from the rotor shaft (Fig. 43); fit a new bearing
(Fig. 44).
Fig. 40
MECHANICS
F Fig. 41
MECHANICS
Fig. 44 Fig. 43 Fig. 42

4.00 PUMP MOTOR REMOVAL PROCEDURE

MODEL ALL MODELS
® Sufficiently large container to hold 30 l of oil.

® Lifting sling with hook
12
12
12
12
12
12
5 mm ALLEN OVERHEAD CRANE 17-19-22-24 mm Ø 8 mm EYEBOLT MEDIUM SLOTTED

WRENCH HEX WRENCH LOAD CAPACITY SCREWDRIVER
100 kg
PROCEDURE
MECHANICS
1) 5 mm ALLEN WRENCH - Open the hatch to access the motor

compartment.
2) OIL COLLECTION CONTAINER - At the base of the tank next to the

pump suction hose there is a Ø 8 mm vertically disposed oil tube that
functions as an oil level gauge. This line also serves to empty the oil
tank.
Detach the line from the upper restraint and insert it into the 30 litre oil
collection drum, allowing the oil tank to empty completely.
3) SLOTTED SCREWDRIVER - 17-22 mm HEX WRENCH - Once the

tank is empty, use the screwdriver to loosen the steel clamp securing Fig. 45
the suction hose (Ref. I Fig. 46) and detach the hose from the pump.
Using the 22 mm hex wrench unscrew the pump pressure line union
(Ref. H Fig. 46).
Using the 17 mm hex wrench unscrew the motor cable terminal nuts and
detach the cables from the terminals.
4) 17 mm HEX WRENCH - EYEBOLT - SLING - OVERHEAD CRANE - H

Screw the eyebolt into the pump rotor shaft (Fig. 45) and attach one end
of the sling to the eyebolt and the other to the crane hook. Take the strain
with the crane and then use the wrench to unscrew and remove the pump
support fixing nuts (Ref. G Fig. 46); now lift the pump and transfer it to a
I
workbench.
G Fig. 46

5) 17-19 mm HEX WRENCH - Use the 17 mm wrench to unscrew

and remove the two screws responsible for fixing the pump casing
to the motor (Ref. M Fig. 47), detach the pump casing.
Use the 19 mm wrench to unscrew and remove the four screws
responsible for fixing the support to the motor (Ref. L Fig. 47) and
remove the support. Now fit a completely new unit or strip down the
original motor.
MECHANICS
L M Fig. 47
4.01 REPLACING THE PUMP CONNECTION FLANGE
OIL SEAL
Remove the pump motor (see heading 4.00 Page 16).
1) 17 mm HEX WRENCH - MEDIUM CROSSHEAD SCREWDRIVER

- Use the wrench to unscrew the screws that fix the pump to the
MECHANICS
flange (Ref. M Fig. 47) and remove the pump body.
Use the screwdriver to remove the flange oil seal (Ref. N Fig. 48)
and fit a replacement seal.

N Fig. 48
NOTES:

4.02 PUMP MOTOR COMPONENTS

MODEL ALL MODELS
7 10 9
2 3
14
4
8
11
12
13
5
1
MECHANICS
6 Fig. 49
PUMP MOTOR COMPONENTS TABLE

1 Rotor
2 Stator
3 Casing
4 Lower pump body flange
5 Upper flange
6 Flange connecting tie rod
7 Terminal block
8 Encoder bearing
9 Encoder connector
11 Lower flange oil seal
12 Lower flange bearing
13 Lower flange bearing circlip
14 Wiring between terminal block and stator
Table 3


MODEL ALL MODELS
Once the complete pump motor has been removed strip it down in order to access the various parts.
NOTE: The encoder bearing can be removed also without first removing the motor from the
truck.
MECHANICS
Fig. 50
5 mm 13-17 mm BEARING
ALLEN WRENCH HEX WRENCH PULLER TOOL
MECHANICS
PROCEDURE S

Q
safety clothing.
1) 17 mm HEX WRENCH - 5 mm ALLEN WRENCH - Place the

motor in a vice and carefully clamp the casing. Use the hex
wrench to unscrew and remove the power cable terminal nuts
(Ref. S Fig. 51). Use the Allen wrench to unscrew and remove the R Fig. 51
screws fixing the terminal block to the motor (Ref. Q Fig. 51) and
remove the terminal block.
2) 13 mm HEX WRENCH - Unscrew and remove the flange

connection tie bar nuts (Ref. R Fig. 51). Remove the flange to gain
access to the encoder bearing (Fig. 52-53).
3) PULLER - Fit the puller to the bearing and withdraw the encoder/
bearing from the rotor (Fig. 54-55) and proceed to fit a replacement.

Fig. 52
Fig. 55 Fig. 54 Fig. 53

5.00 STEERING GEARED MOTOR REMOVAL PROCEDURE

MODEL ALL MODELS
5 mm 10-13 mm
ALLEN WRENCH HEX WRENCH
PROCEDURE
MECHANICS
1) 5 mm ALLEN WRENCH - Open the motor compartment hatch. Use the same wrench to unscrew and
remove the pinion fixing screw (Ref. O Fig. 57) and extract the pinion.
2) 10-13 mm HEX WRENCH - Use the 10 mm wrench to unscrew and remove the motor power cable
terminal nuts.
Use the 13 mm wrench to unscrew the four screws that secure the geared motor to the gear unit flange
(Ref. P Fig. 57), extract the geared motor and either fit a replacement part or strip down the original part
on a workbench.
Fig. 56 O Fig. 57

5.01 STEERING MOTOR COMPONENTS

MODEL ALL MODELS
11
10
9
4 3
MECHANICS
5
6 8
MECHANICS
1 2 Fig. 58
TABLE FO STEERING MOTOR COMPONENTS

1 Rotor
2 Stator
3 Casing
4 Lower flange
5 Upper flange
6 Lower flange oil seal
7 Lower flange bearing
8 Upper flange encoder bearing
9 Terminal block
10 Encoder connector
Table 4


MODEL ALL MODELS
Once the motor has been removed from the truck it can be stripped
down to access the various parts.
4-5 mm BEARING PULLER

ALLEN WRENCH
T Fig. 60
PROCEDURE
MECHANICS

safety clothing.
1) 5 mm ALLEN WRENCH - Place the motor in a vice and carefully

clamp the jaws. Using the wrench unscrew and remove the
screws that fix the gear unit to the motor (Ref. T Fig. 60). Remove
the gear unit paying attention to the shims and gears, which should
not be moved from their locations.
2) 4 mm ALLEN WRENCH - PULLER - Unscrew and remove the Fig. 61

upper and lower motor flange fixing screws (Ref. U-V Fig. 62-63).
Remove the upper flange.
Fit the puller to the lower flange for connection to the gear unit
(Fig. 64), detach the flange from the motor bearing and extract the
rotor from the stator (Fig. 65).
Remove the motor casing from the vice and insert the rotor in its
place, ensuring you first fit aluminium cheeks to the vice jaws to
prevent marring. Clamp the vice carefully (Fig. 66).
Fit the puller to the bearing/encoder and remove it from the rotor
shaft. Now fit a new bearing.
To reassemble, perform the disassembly steps in reverse order. V Fig. 63 U Fig. 62
Z Fig. 66 Fig. 65 Fig. 64

6.00 STEERING UNIT

MODEL ALL MODELS
The steering unit is designed so that it can be adjusted to suit the preferences of the operator by means
of a gas spring and series of linkages.
Activating lever no. 1 (Fig. 68), which is located on the instrument panel next to the hydraulic joysticks,
causes a valve to be operated in the gas spring by means of a wire cable and sheath system, thus allowing
the steering unit to be positioned at the most comfortable height for the operator.
MECHANICS
Activating lever no. 2 (Fig. 69) provides two adjustment functions: extending or shortening the reach of the
steering unit and up/down rotation of the panel.
Lever no. 2 operates an eccentric pin that serves to unlock rotary movement of the steering handwheel
unit and display, while simultaneously loosening the conical plug in the tube so that steering handwheel
reach can be adjusted and the handwheel rotated until the operator finds the most comfortable position.
The following pages present the components that make up the steering unit, with details of the disassembly
steps required for repair or replacement.
MECHANICS
LEVER Fig. 68
1
ROTATION
G
IN
H EN G
T IN
NG TEN
LE R
O
SH LEVER 2
REACH ADJUSTMENT
TUBE
GAS
VALVE CONTROLLED SPRING
Fig. 67 BY LEVER 1 Fig. 69

6.01 STEERING UNIT LINKAGE COMPONENTS
MODEL ALL MODELS
5 36
33 34
1
35
32 40
38
41
29 39
STEERING UNIT ASSEMBLY DRAWING
30
26
25 31
24
2
28 44
MECHANICS
23
43
2
22
42 37
27
HANDWHEEL BEARING ENCODER SECTIONAL VIEW STEERING UNIT SECTIONAL VIEW
14
13 2
3
19 3
20
14 13
7
15 4
16
21 17 12
6 4
7
STEERING LINKAGES ASSEMBLY DRAWING
9 11
18
5 8
10 10
2
RETURN GAS SPRING STEERING LINKAGES SECTIONAL VIEW
Fig. 70
6.02 TABLE OF STEERING LINKAGE COMPONENTS

MODEL ALL MODELS
The components of the steering unit illustrated on the previous page are described in the following table
Key:
Ref. Component reference in exploded view
1 Steering unit assembly
2 Display assy. and steering handwheel assy. support bracket
MECHANICS
3 Steering assy. fixed support tube
4 Steering assy. reach adjustment tube
5 Steering assy. gas spring
6 Steering assy. reach adjustment locking conical tube
7 Conical tube sliding and locking threaded bar
8 Steering assy. angle adjustment eccentric pin
9 Eccentric pin adjuster plate
10 Eccentric pin precision bushings
11 Rotary pin for screw torquing of the threaded bar inserted in the eccentric pin
MECHANICS
12 Locking lever angle adjuster pins
13 Locking lever acting on the eccentric pin
14 Locking lever knob
15 Locking lever locknut
16 Eccentric pin adjuster plate thrust spring
17 Locking lever system circlip
18 Spring retainer washer
19 Conical tube retainer washer
20 Conical tube self-locking nut
21 Sliding tube locking nut
22 Steering encoder
23 Encoder drive shaft bearing support
24 Steering encoder drive shaft
25 Steering encoder shaft guide bearing
26 Steering encoder drive shaft guide bearing circlip
27 Screws or fixing encoder to bracket and to bearing support
28 Encoder fixing bolt nuts
29 Teflon pin for stiffening steering action
30 Steering action stiffening Teflon pin thrust spring
31 Steering action stiffening system shims
32 Steering handwheel
33 Handwheel knob
34 Screws for fixing steering handwheel to the encoder drive shaft
35 Shim
36 Steering handwheel central bore cover
37 Steering and display assy. lower cover
38 Steering and display assy. upper cover
39 Display
40 Control buttons
41 Button locking nuts and washers
42 Upper and lower covers fastening screws
43 Fastening screws
44 Display fixing screws

6.03 REPLACING THE STEERING UNIT GAS SPRING

MODEL ALL MODELS
The gas spring fills an important function in moving the steering unit to the position that the operator
considers to be most comfortable. Therefore, when the spring no longer provides sufficient force, it must
be renewed.
13 mm MEDIUM EXTERNAL MEDIUM REGULAR PLIERS

HEX WRENCH CIRCLIP PLIERS CROSSHEAD
SCREWDRIVER
PROCEDURE
MECHANICS
Fig. 72
A
D
D
Fig. 73
E
A F
F
Fig. 71 Fig. 75 Fig. 74

1) MEDIUM CROSSHEAD SCREWDRIVER, REGULAR PLIERS - Using the screwdriver, unscrew and
remove the fixing screws of the hood under the steering handwheel unit (Ref. A Fig. 71) and remove
the hood. Use the pliers to remove the pin securing the steel cable of the lever that operates the gas
spring valve (Ref. C fig. 73).
2) CIRCLIP PLIERS, 13 mm HEX WRENCH - Remove the circlips that couple the gas spring to the bracket
(Ref. D Fig. 73) and extract the gas spring and place it on a workbench. Use the hex wrench to loosen
the locking nut (Ref. E Fig. 74) and unscrew the lever (Ref. F Fig. 74-75); remove the lever and then
screw it to the new gas spring. Now fit the new gas spring in place of the original part.
MECHANICS
6.04 ADJUSTING STEERING HANDWHEEL TORQUE
MODEL ALL MODELS
If the handwheel turns too easily, the turning torque can be increased to suit the expectations of the
operator. Beneath the handwheel there are two Teflon pins that exert frictional force on the handwheel;
by increasing the pressure of the relative thrust spring by adding shims it is possible to increase the effort
required to turn the handwheel.
MECHANICS
G
5 mm ALLEN SMALL SLOTTED
WRENCH SCREWDRIVER
PROCEDURE

safety clothing.
Fig. 76
Park the truck in a safe place away from moving vehicles
and pedestrians. Bring the reach carriage to its forward
position, lower the forks to the ground, set the keyswitch to
“OFF” and disconnect the battery. H
1) 5 mm ALLEN WRENCH, SLOTTED SCREWDRIVER - Use the L

screwdriver to remove the handwheel central cover cap (Ref. G M
Fig. 76). Using the Allen wrench, unscrew and remove the N I
handwheel locking screw (Ref. H Fig. 77). Remove the handwheel
from the shaft. Remove the Teflon pin (Ref. L Fig. 77), remove L
the spring (Ref. M Fig. 77) and add shimming washers until
obtaining the required stiffness of handwheel rotation. M
To reassemble, perform the disassembly steps in reverse N

order.
Fig. 77

6.05 DISMANTLING THE HANDWHEEL - DISPLAY

ASSEMBLY
MODEL ALL MODELS
The following pages illustrate the method for dismantling the entire
linkage system. The same procedure is used for replacement of the
complete display.
UPPER COVER
STANDARD TOOLS REQUIRED DISPLAY
13 mm MEDIUM 6 mm
HEX WRENCH CROSSHEAD ALLEN WRENCH
SCREWDRIVER LOWER COVE
R
MECHANICS
O Fig. 78
REGULAR
MEDIUM EXTERNAL PLIERS
CIRCLIP PLIERS
Q
PROCEDURE

safety clothing. S R
Park the truck in a safe place away from moving vehicles

and pedestrians. Bring the reach carriage to its forward
position, lower the forks to the ground, set the keyswitch to
“OFF” and disconnect the battery.
T
1) Remove the handwheel (see heading N° 5.04 page 27)
Z Fig. 79
2) CROSSHEAD SCREWDRIVER - Detach the steering tube
protective bellows from the hood side and the display side
(Ref. W Fig. 80). Using the screwdriver, unscrew and remove the
fixing screws of the upper hood and lower truck body side hood
(Fig. 71); remove the hoods to gain access to the spring and
display electrical connectors. Using the same screwdriver,
unscrew and remove the fixing screws of the display upper and
lower covers (Ref. O Fig. 78) and remove the covers to expose
the complete display. Unscrew and remove the display fixing
W
screws (Ref. P Fig. 78); disconnect the electrical connector, and
remove the display. Disconnect the power cable connector from
the electrical system side under the hood.
Fig. 80

3) 6 mm ALLEN WRENCH - Loosen the guide screw of the sliding tube (Ref. R Fig. 79), loosen the
eccentric pin lever (Ref. Q Fig. 79) to unlock the linkage system, and then extract the assembly from
the supporting tube (Ref. S Fig. 79) and place it on a workbench (Fig. 81).
4) 13 mm HEX WRENCH - Unscrew and remove the locknut of the

conical tube guide bar (Ref. Z Fig. 79-82), withdraw the short conical
tube and the long conical tube as shown in (Fig. 82).
MECHANICS
5) REGULAR PLIERS - Unscrew the threaded bar from the pin (Ref. U
Fig. 83), and extract the eccentric pin from its seat as shown in
(Fig. 84).
Fig. 81
6) CIRCLIP PLIERS - Remove the circlip (Ref. V Fig. 85), extract the
spring (Ref. J Fig. 85) and disassemble the eccentric pin as shown
MECHANICS
in (Fig. 85); carry out the necessary replacement or repair operations.

Z
Fig. 82
V
J
U
Fig. 85 Fig. 84 Fig. 83

NOTES:
MECHANICS

SERVICE Section: REACH CARRIAGE
REACH
CARRIAGE
a REACH CARRIAGES UTILIZED ............................................... 2
a REACH CARRIAGE REMOVAL PROCEDURE ........................ 5
REACH CARRIAGE

Section: REACH CARRIAGE SERVICE
1.00 REACH CARRIAGES UTILIZED

MODEL ALL MODELS
1.01 REACH CARRIAGE COMPONENTS
12 “STANDARD” TRUCK
4 13
8 3
16 14
10 9 7
15
11
2
9 1 9 2
REACH CARRIAGE
5 6 Fig. 1
“NARROW” TRUCK
12
4
8 13
3
8
16
10 14
9 7
15
11
2
9 1 2
9
5 6 Fig. 2

12 “PLUS” WIDE TRUCK

4
13
8
3
16
10 9
14
7
15
11
2
9
1 2
9
REACH CARRIAGE
5 6 Fig. 3
1.02 TABLE OF REACH CARRIAGE - TRUCK COMBINATIONS
REACH CARRIAGE - TRUCK COMBINATIONS

Re a ch Ca rria ge Com bina tion w ith Truck
R1.4 - R1.4H
R1.6 - R1.6H
Sta nda rd
R2.0 - R2.0H
R2.5
Na rrow R1.6N
Plus R2.0W

1.03 TABLE OF REACH CARRIAGE COMPONENTS

MODEL ALL MODELS
The components shown are described in the following table
Key:
Ref. Component reference

LIST OF REACH CARRIAGE COMPONENTS

1 Reach carriage
2 Sliding carriage guide blocks
3 Upper Lh mast channel fixing support
4 Upper Rh mast channel fixing support
5 Carriage guide shoe
6 Carriage guide shoe shim washer
7 Carriage rollers
8 Battery return buffers
9 Carriage rollers grease nipples
10 Carriage equipment cover plate
11 Carriage guide fixing screws
12 Upper mast supports fixing screws
REACH CARRIAGE
13 Spring washers for support screws

14 Equipment cover plate fixing screws
15 Rollers to carriage fixing screws
16 Battery extraction attachment pin
NOTE: All Hyster Part Numbers are given in the spare parts catalogue.
NOTES:

2.00 REACH CARRIAGE REMOVAL PROCEDURE

MODEL ALL MODELS
The reach carriage is equipped with four roller bearings and two “U” guides mounted to the left-hand side
of the truck next to the cylinder.
The bearings run on case hardened plates secured to the inside of the load wheel support straddles. The
guides run in a case hardened plate secured to the left-hand straddle to avoid possible sideways play during
forward and backward carriage movements.
Movement must be uniform and frictionless. Therefore, when either the bearings or shoes must be
replaced, it is essential to slide the reach carriage out of the truck.
The procedure is described below.
® Lifting sling with three hooks, max. capacity 1000 kg
ALLEN WRENCH MEDIUM SLOTTED OVERHEAD
REACH CARRIAGE
HEX WRENCH
3-5 mm 13-19-24 mm SCREWDRIVER CRANE
D Fig. 9
C Fig. 8 C Fig. 7 B
Fig. 6
A
Fig. 5
Fig. 4

PROCEDURE
1) Remove the mast (see “masts section” heading 2.01 page 10)
2) 13 mm HEX WRENCH - 5 mm ALLEN WRENCH

- With the Allen wrench unscrew and remove the
two reach carriage travel limit stops (Ref. A Fig. 5);
use the hex wrench to unscrew and remove the
cylinder fixing screw (Ref. B Fig. 6), lift the cylinder
and remove it from its pivot pin.
3) HEX WRENCH 19-24 mm - Use the 19 mm

wrench to loosen the guide shoe fixing screws
(Ref. C Fig. 7-8).
Using the 24 mm wrench unscrew the solenoid
valve bank hydraulic line unions (Ref. D Fig. 9) and
disconnect the Mhyrio board electrical connector.
4) SLING - OVERHEAD CRANE - Attach the sling to

the reach carriage in such a way that it can be
withdrawn horizontally (Fig.10).
REACH CARRIAGE
Attach the other end of the sling to the bridge crane

and allow it to take the strain.
Extract the reach carriage outwards and then
renew the bearings and sliding shoes.
2.01 BEARING REPLACEMENT

Fig. 10
5) 3 mm ALLEN WRENCH - Unscrew and remove
the fixing screws of the bearing retainer cover (Ref. E Fig. 11).
Remove the cover and renew the bearings.
2.02 REPLACING THE CARRIAGE GUIDE

SHOES
6) MEDIUM SLOTTED SCREWDRIVER - Using the

screwdriver press the shoe pin through the
assembly hole in the guide (Ref. F Fig.11).
Remove the shoe and fit a replacement part.
E
reverse order.
F
Fig. 11

NOTES:
REACH CARRIAGE

NOTES:
REACH CARRIAGE

SERVICE Section: REDUCTION GEAR
REDUCTION
GEAR
a REDUCTION GEAR COMPONENTS ..................................... 2
a REDUCTION GEAR REMOVAL PROCEDURE .....................3
a REPLACING THE MOTOR SHAFT OIL SEAL ..................... 5
a REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL ..6
REDUCTION GEAR

Section: REDUCTION GEAR SERVICE
1.00 REDUCTION GEAR COMPONENTS

MODEL ALL MODELS
4 2
2
8
5
6
4
5
8
7 1
Fig. 1
1.01 TABLE OF REDUCTION GEAR COMPONENTS

REDUCTION GEAR

1 Complete reduction gear
2 Upper flange
3 Drive wheel
4 Drive motor shaft oil seal
5 Drive wheel axle shaft oil seal
6 Wheel stud
7 Motor shaft
8 Steering gear wheel
9 Oil filler plug
MDU 150 Oil Kg 2,00 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel

2.00 REDUCTION GEAR REMOVAL PROCEDURE

MODEL ALL MODELS
There are two different models of reduction gear utilized, identifiable by means of a code:
- MDU 150 installed on models R1.4 - R1.4H - R1.6 - R1.6N

- MDU 170 installed on models R1.6H - R2.0 - R2.0H - R2.0W - R2.5
The technical specifications of the two units are similar and the units are interchangeable.
The removal and installation procedure is therefore identical for both units.
® 500 mm lever with flat bladed end

® 2 Wooden blocks 150x150x200
® Sling with two hooks
12
12
12
12
12
HEX WRENCH EYEBOLT ALLEN WRENCH OVERHEAD HYDRAULIC

10-13-17-24 mm 5-6 mm CRANE JACK
PROCEDURE
REDUCTION GEAR
1) 5-6 mm ALLEN WRENCH - Use the 6 mm Allen wrench to
open the motor compartment hood, and use the 5 mm Allen
wrench to remove the floor panel.
2) HYDRAULIC JACK - Place the jack alongside the drive

wheel and lift the truck until the blocks can be inserted
under it.
Place the blocks at the sides (Fig. 2) and lower the jack
so that the truck is supported on the blocks. Remove the
jack.
3) Remove the steering motor (see “mechanical section”

Fig. 2
heading 5.00, page 20).
4) Remove the drive motor (see “mechanical section”

heading 3.00 page 12).

5) Remove the drive wheel (see “mechanical section” heading

1.01 page 3).
6) LIFTING SLING - EYEBOLTS - Screw the eyebolts into two

opposite side drive motor fixing holes, (Fig. 4).
Attach the lifting sling hooks to the two eyebolts (Fig. 4) and the
other end of the sling to the overhead crane hook. A
Take the strain with the sling.
7) TWO 24 mm HEX WRENCHES - LEVER - Unscrew the nuts of

the bolts responsible for fixing the reduction gear to the truck body
(Ref. A Fig. 3) and withdraw the bolts.
The reduction gear fixing holes are equipped with precision steel Fig. 3
bushings that protrude 20 mm above the seat.
When the reduction gear unit is installed the protruding part of the
bushings is inserted in the holes in the truck body with the maximum
precision.
In order to extract the bushings in order to remove the reduction
gear, insert the lever or screwdriver between the reduction gear
unit and the truck body (Ref. B Fig. 4) and pry the reduction gear
until the bushings are disengaged. Remove the reduction gear and
replace it or strip it down in order to replace the necessary
components. B
NOTES: Fig. 4
REDUCTION GEAR

2.01 REPLACING THE MOTOR SHAFT OIL SEAL

MODEL ALL MODELS
The motor shaft oil seal is located in the reduction gear upper flange and cannot be removed without first
removing the drive motor.
HEX WRENCH ALLEN WRENCH MEDIUM SLOTTED

13-17 mm 5 mm SCREWDRIVER
PROCEDURE
1) Remove the drive motor (see heading “mechanical section” heading 3.00 page 12).
2) SLOTTED SCREWDRIVER - Use the screwdriver to prise the oil seal (Ref. C Fig. 5), remove the oil
seal and fit a replacement.
C REDUCTION GEAR
Fig. 6
Fig. 5

2.02 REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL

MODEL ALL MODELS
The oil seal can be removed without having to remove the reduction gear from the truck.
® Lever or tube Ø 30x300

® Loctite sealing compound for gaskets
® 2 wooden blocks 150x150x200
ALLEN WRENCH HEX WRENCH SOCKET WRENCH HYDRAULIC MEDIUM SLOTTED

5-10 mm 13 mm 13-19 mm WITH JACK SCREWDRIVER
RATCHET
C-SPANNER FOR DRIFT Ø 30x200 MEDIUM-WEIGHT RUBBER SMALL CHISEL

Ø 60 RINGNUTS STEEL HAMMER MALLET
REDUCTION GEAR
F
Fig. 7
G
E
Fig. 10 Fig. 8
D Fig. 9

PROCEDURE
clothing. H
pedestrians. Bring the reach carriage to its forward position, lower
the forks to the ground, set the keyswitch to “OFF” and disconnect
the battery.
1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack in the centre of

the carriage alongside the drive wheel, and lift the truck until the wooden
blocks can be inserted. Place the blocks alongside the jack and then lower
the jack until the truck body is resting on the blocks. Now remove the jack.
2) ALLEN WRENCH 5-10 mm - Use the 5 mm wrench to open the motor Fig. 11
compartment hood. With the 10 mm Allen wrench remove the guard in
correspondence with the drive wheel.
3) Remove the drive wheel (see “mechanical section” heading 1.01

page 2).
4) 10 mm ALLEN WRENCH - OIL COLLECTION CONTAINER - Position the

container under the reduction gear drain plug (Ref. D Fig. 9), using the Allen
wrench unscrew and remove the plug and allow the oil to drain out of the
reduction gear.
Fig. 12
5) 13 mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the
reduction gear cover fixing screws (Ref. E Fig. 9). Remove the cover to
gain access to the gears.
6) CHISEL - MEDIUM-WEIGHT STEEL HAMMER - Using the hammer and

chisel raise the clenched lip of the locking ring in the axle shaft seat (Ref. F
Fig. 7) so that the locking ring can be unscrewed.
7) C-SPANNER - LEVER OR TUBE - Fit two screws into the axle shaft flange
and between them insert the tube or lever; use the C-spanner to unscrew
the locking ring completely (Fig. 14).
REDUCTION GEAR
8) RUBBER MALLET - DRIFT - Place the drift on the shaft (Ref. G Fig. 8) and
using the hammer to drive out the shaft from the opposite side. Fig. 13
Attention is required because inside the reduction gear there are a distance
ring and several shims located beyond the bevel gear; these components
must be recovered and then re-fitted when the unit is reassembled
(Fig. 12).
9) SLOTTED SCREWDRIVER - Use the screwdriver to prise between the oil

seal and bearing (Ref. H Fig. 11). Extract the oil seal from its seat and fit
a replacement part.

Fig. 14

NOTES:
REDUCTION GEAR

SERVICE Section: BRAKING SYSTEM
BRAKING
SYSTEM
a ELECTROMAGNETIC BRAKE COMPONENTS ................................... 2
a LOAD WHEEL BRAKING SYSTEM COMPONENTS ........................... 3
a LOAD WHEEL BRAKE COMPONENTS .............................................. 4
a BRAKING SYSTEM ............................................................................. 5
a REMOVING AND ADJUSTING THE ELECTROMAGNETIC BRAKE ..... 6
a ADJUSTING THE ELECTROMAGNETIC BRAKE AND PUTTING

IT INTO SERVICE ................................................................................ 7
a REMOVING THE BRAKE MASTER CYLINDER ................................... 8
a REPLACING THE LOAD WHEEL BRAKES ......................................... 9
a BLEEDING AIR THE BRAKES CIRCUIT ............................................ 11
BRAKING SYSTEM

Section: BRAKING SYSTEM SERVICE
1.00 ELECTROMAGNETIC BRAKE COMPONENTS

MODEL ALL MODELS
55
6 1 5
4
Fig. 1a
1.01 TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS

1 Complete electromagnetic brake
2 Electromagnet coil
3 Brake disc
BRAKING SYSTEM
4 Brake disc guide pinion

5 Fixing screws
6 Brake disc adjuster nut

1.02 LOAD WHEEL BRAKING SYSTEM COMPONENTS

MODEL R1.6 OPTIONAL - R2.0 - R2.0H - R2.0W - R2.5
14
10 9
13
15
11
12
4
6
3 7
2
8
5
1
1.03 TABLE OF BRAKING SYSTEM COMPONENTS Fig. 1b

1 Brake master cylinder
2 Master cylinder plunger rod
3 Brake cylinder pipelines distributor connection
4 Master cylinder supply line union
5 Brake pedal sensor
6 Master cylinder fixing screws
7 Brake fluid reservoir
BRAKING SYSTEM
8 Rh brake line branch connection

9 Rh wheel brake unit
10 Lh wheel brake unit
11 Line connecting master cylinder to Rh brake unit
12 Line connecting master cylinder to Lh brake unit
13 Line connecting brake fluid reservoir to master cylinder
14 Brake unit pipeline union
15 Brake pedal

1.04 LOAD WHEEL BRAKE COMPONENTS

MODEL R1.6 OPTIONAL - R2.0 - R2.0H - R2.0W - R2.5
8 3 14
1
2
9
7 10
6 13
11 12
19
11 9
G
17 15
16
18
Fig. 1c
1.05 TABLE OF LOAD WHEEL BRAKE COMPONENTS

1 Load wheel
2 Brake unit complete
3 Brake shoes
4 Brake shoe support spring
5 Brake shoe tension spring
6 Brake/wheel pivot pin
7 Brake unit pin assembly flange
8 Brake cylinder
9 Taper roller bearings
10 Dust seal
11 Bearing shield rings
BRAKING SYSTEM
12 Serrated lock washer

13 Locking ring
14 Brake block holder plate
15 Wheel pivot pin
16 Pin restraining washer
17 Wheel spindle fixing screw
18 Screws securing brake unit to straddle arm
19 Screws for securing spindle and brake unit

1.06 BRAKING SYSTEM

MODEL ALL MODELS
The reach trucks are fitted with four braking systems:
A) Release braking.
B) Service or reverse travel braking.
C) Emergency braking.
D) Parking braking.
A) RELEASE BRAKING
Activates a deceleration ramp when the travel control is released.
“Release braking” is activated by releasing the travel pedal when the truck is travelling in either direction.
This action results in regenerative braking, the intensity of which is proportional to the current value entered
using the programming console (“RELEASE BRAKING” parameter): level 9 corresponds to maximum
intensity. Since release braking and service braking are separate functions, release braking intensity can
be customized on the basis of the customer’s preferences.
B) SERVICE BRAKING
Service braking involves application of a deceleration ramp when the travel direction signal is inverted.
“Service braking”, which as also known as “reverse current braking”, consists of reversing the current
delivered to the drive motor thereby changing the travel direction when the truck is moving.
When the motor current is inverted the truck starts to decelerate at an intensity that is proportional to the
current value entered with the programming console (“INVERSION BRAKING” parameter): level 9
corresponds to maximum intensity.
Braking current must be regulated in such a way that the truck stops in a distance that is no less than its
length.
C) EMERGENCY BRAKING
Applies a deceleration ramp when the travel control is released and the brake pedal switch contacts are
closed.
“Emergency braking” consists of a regenerative braking action that is activated when the brake pedal is
pressed.
This action is combined with regenerative braking associated with the release of the accelerator pedal,
thereby causing the truck to stop in a shorter distance. Once the truck is stationary the electromagnetic
brake is applied.
Braking intensity is proportional to the current value entered with the programming console (“PEDAL
BRAKING” parameter).
Simply pressing the accelerator pedal will cause the electromagnetic brake to be released.
All truck models are equipped with this type of brake function.
Truck models R1.6 OPTIONAL, R2.0, R2.0H, R2.0W, R2.5, which are heavier vehicles, are additionally
equipped, on the load wheels, with brake units that are activated by means of a brake master cylinder
connected to the brake pedal.
The load wheel brakes are activated after regenerative braking has been applied, by increasing the
BRAKING SYSTEM
pressure exerted on the brake pedal.

D) PARKING BRAKE
The “parking brake function” is provided by the electromagnetic brake mounted on the drive motor.
The electromagnetic brake is applied in two situations:
A) If the operator releases the deadman button when the truck is stationary. In this case power is
disconnected from the electromagnetic brake coil causing the brake to be applied.
B) If a button marked with the brake symbol on the instrument panel is pressed when the truck is on a grade.
In this case power is disconnected from the electromagnetic brake coil causing the brake to be applied
and inhibiting drive; hydraulic functions, however, remain operational.
2.00 REMOVING AND ADJUSTING THE ELECTROMAGNETIC BRAKE

MODEL ALL MODELS
Having described the truck’s brake system, this section illustrates the procedures for removing the various
units in the system so that they can be renewed or so that their subassemblies can be renewed.
Due to rubbing friction during braking, the brake disk is subject to wear. Once the depth of wear exceeds
4 mm the disc must be renewed.
The removal and adjustment procedure is described below.
6 mm 13 mm CIRCLIP PLIERS FEELER GAUGE

PROCEDURE
1) 6 mm ALLEN WRENCH - 13 mm HEX WRENCH - Use the Allen wrench to open the motor
compartment hood.
Using the 13 mm hex wrench loosen the three locking nuts (Ref. A Fig. 2).
Now use the Allen wrench to unscrew and remove the three electromagnetic brake fixing screws
(Ref. B Fig. 2) and detach the brake from the motor.
2) CIRCLIP PLIERS - Withdraw the brake disk from the guide pinion; use the circlip pliers to remove the
circlip from the motor shaft and extract the brake disk guide pinion.
NOTE: When you fit a new brake disk it is essential to renew

also the pinion.
BRAKING SYSTEM
B
To reassemble, perform the disassembly steps in reverse order. A
Fig. 2

2.01 ADJUSTING THE ELECTROMAGNETIC BRAKE AND PUTTING IT INTO SERVICE

MODEL ALL MODELS
- After refitting the brake assembly, before operating the truck you must adjust the brake disk.
- To obtain good braking action, the distance between the brake disk and the electromagnet plate (Ref. S
Fig. 3) should be no more than 0.4 mm. You will therefore need a feeler gauge of this size.
- With the three nuts (Ref. R) loosened off, insert the

feeler gauge next to one of the bolts and then tighten
bolt (Ref. V) with the 6 mm Allen wrench. G
V
Adjust the plate so that the feeler gauge can be with
drawn with slight friction. Repeat the same operation
on all three bolts (Ref. V).
Tighten nuts (Ref. R).
R
S
- Adjusting braking distance: start the truck and travel at
maximum speed.
Remove your foot from the deadman button. The truck
must brake in a distance that is no less than and no
P
greater than its own length. To optimize the braking
distance turn adjuster nut (Ref. G): turn clockwise to
reduce braking distance and counter-clockwise to
increase it.
Fig. 3
NOTES:
BRAKING SYSTEM

3.00 REMOVING THE BRAKE MASTER CYLINDER

MODEL R1.6 optional - R2.0 - R2.0H - R2.0W - R2.5
The brake unit master cylinder is a hydraulic system and it is subject to wear of the seals and internal parts.
In the case of worn internal parts, a new master cylinder must be fitted in order to restore efficient braking
action.
5-6 mm 13-17-19-22 mm
PROCEDURE
1) 5-6 mm ALLEN WRENCH - Use the 6 mm Allen wrench to unscrew the motor compartment hood fixing
screws to gain access to the brake system. With the 5 mm Allen
wrench unscrew and remove the floor panel fixing screws (Ref. F Fig.
5); remove the floor panel.
C
2) 17 mm HEX WRENCH - Unscrew the brake master cylinder supply

line union (Ref. C Fig. 4); detach the brake cylinder pipeline and use
self-locking pliers to clamp the line to prevent the brake fluid from
draining out and emptying the reservoir.
D E Fig. 4
3) 22 mm HEX WRENCH - Unscrew the union of the load wheel brake
unit supply pipelines (Ref. D Fig. 4) and detach the union from
the master cylinder.
4) 13 mm HEX WRENCH - Unscrew the two screws responsible

BRAKING SYSTEM
for fixing the master cylinder to the support (Ref. E Fig. 4),
recovery the defective master cylinder and fit a replacement
unit.
To reassemble, perform the disassembly steps in reverse

order.
For information on how to bleed the brake circuit of air, F

Fig. 5
refer to the procedure on page 11.

3.01 REPLACING THE LOAD WHEEL BRAKES

MODEL R1.6 OPTIONAL - R2.0 -R2.0H - R2.0W - R2.5
5-8 mm 7-10-14 mm REGULAR PLIERS C-SPANNER FOR Ø 60

ALLEN WRENCH HEX WRENCH RINGNUTS
500 g HAMMER HYDRAULIC JACK DRIFT Ø 25x200 mm COMPASS SPANNER

WITH Ø 5 PINS
PROCEDURE
clothing
pedestrians. Bring the reach carriage to its forward position, lower
the forks to the ground, set the keyswitch to “OFF” and
Fig. 6
1) Remove the load wheel (see “mechanical section” heading 1.02
page 4).
BRAKING SYSTEM
2) C-SPANNER - Unscrew the ring that fastens the brake unit boss to the
wheel (Ref. G Fig. 7) and withdraw the kit from the wheel hub as
shown (Fig. 6).
Now strip down the brake unit in order to renew individual parts or
renew the entire unit.
G Fig. 7

3) 5 mm ALLEN WRENCH - To renew the complete brake unit you must first L
remove the bearings (Ref. H Fig. 8) and then use the wrench to unscrew H
the screws responsible for fastening the spindle to the brake unit (Ref. M
Fig. 9). Extract the spindle and renew the brake unit.
Using the same procedure described in point 3 it is also possible to replace

exclusively the spindle. Fig. 8
4) 10 mm HEX WRENCH - To renew the brake cylinder (Ref. L Fig. 8)

unscrew the screws that secure the cylinder to the shoe carrier plate
(Ref. M Fig. 9), remove the cylinder and fit a replacement. M
5) REGULAR PLIERS - To replace the brake shoes, remove the retaining

springs using the pliers, remove the shoes, and then fit replacement parts.
Fig. 9
I
NOTES:
BRAKING SYSTEM

3.02 BLEEDING AIR FROM THE BRAKE CIRCUIT

MODEL R1.6 Optional - R2.0 - R2.0H - R2.0W - R2.5
After changing the brake units, the brake cylinder, the load wheel or the master cylinder it is essential to
bleed air from the brake fluid circuit.
To bleed the brakes efficiently it is advisable to prepare two stands of approximately 300 ÷ 400 mm in height,
each equipped with a container for collecting drained oil. Fit one end of a Ø 6 mm tube to the brake unit
bleed union and insert the other end in the collection container (Ref. N Fig. 10).
® 2 stands (Fig.12)
® Rubber tube, inside Ø 6 - length 200 mm
® 2 litres of brake fluid
N Fig. 10
7-8 mm
HEX WRENCH
P O
1) Remove the dust cap from the bleed screw located behind the
brake unit (Fig. 10).
2) 7-8 mm HEX WRENCH - STAND - CONTAINER - Place the

stand complete with container and tube next to the wheel and
fit the tube to the bleed union. Using the wrench loosen the
bleed union by rotating it through 3/4 of a turn (Ref. N Fig. 10);
repeat the same procedure on the opposite side wheel and
then pour brake fluid into the two containers until the bleed
screw connecting tube is completely submerged. Fig. 11
3) Fill the master cylinder reservoir with brake fluid (Ref. O
Fig. 11) to start the flow of brake fluid to the collection containers.
Slowly depress the brake pedal and release it ten times in
succession (Ref. P Fig.11) after which do not press the pedal
for approximately five minutes, allowing the brake fluid to flow
into the container under the pressure accumulated in the
BRAKING SYSTEM
circuit.
The brake fluid reservoir is higher than the collection containers
positioned next to the load wheels, therefore the fluid in the
master cylinder will be transferred into the containers via the
master cylinder, forcing all the air out of the circuit in the
process. Ensure that the reservoir is kept permanently full of
oil.
Repeat the sequence of brake pedal cycles at five minute
intervalsuntil all the air has been expelled from the circuit. Fig. 12
Now use the wrench to tighten the bleed union screws.

4) Fit the cap to the brake fluid reservoir and remove the collection containers; depress the brake pedal
4 or 5 times to pressurize the circuit, until you meet solid resistance when attempting to depress the
pedal, indicating that the master cylinder has no internal leakage. Now re-close the various panels and
hoods on the truck.
Test the brake circuit with the truck in motion. If you detect a spongy feel when pressing the brake pedal,
this indicates that there is still air in the circuit so the air bleeding operation described above must be
repeated.
NOTES:
BRAKING SYSTEM

NOTES:
BRAKING SYSTEM

Part N° 1517320
BRAKING SYSTEM

Technical Information For Hyster Service Centres

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Technical Information For Hyster Service Centres

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Part No 1517320

Technical Information for

This manual is addressed exclusively to the specialised

NEVER DO ANY CLEANING, LUBRICATING OR SERVICING WITH THE BATTERY CON-

DO NOT WEAR RINGS, WATCHES, JEWELLERY, LOOSE CLOTHING SUCH AS SCARVES,

DO NOT USE PETROL, DIESEL FUEL OR OTHER FLAMMABLE LIQUIDS AS DETERGENTS:

Page: 2 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 3

Section: ELECTRICAL SYSTEM

1.0 INTRODUCTION TO THE TRUCK ........................................................................................................... 10

Page: 4 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

Section: ADDITIONAL FUNCTIONS

Section: HYDRAULIC SYSTEM

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 5

2.06 REMOVING THE FORKS TILT CYLINDER ................................................................................................. 27

2.07 REPLACING THE SEALS .......................................................................................................................... 29

1.00 TABLE OF SCREW TIGHTENING TORQUES ............................................................................................. 2

Page: 6 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

5.00 STEERING GEARED MOTOR REMOVAL PROCEDURE .......................................................................... 20

Section: REACH CARRIAGE

Section: REDUCTION GEAR

Section: BRAKING SYSTEM

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 7

Page: 8 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

D INSTALLING THE TRUCK .................................................................... 9

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 9

1.0 INTRODUCTION TO THE TRUCK

TRUCK SERIAL NUMBER

Page: 10 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

2.0 INSTALLING THE TRUCK

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 11

Page: 12 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

D KEY TO ELECTRICAL DIAGRAMS ...................................................14

D KEY TO POSITION OF ELECTRICAL COMPONENTS ........................16

D FUNCTION INPUTS TABLE ................................................................ 18

D ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS M ... 24

D TRACTION START SEQUENCE ......................................................... 27

D SPEED CUTBACK ............................................................................. 29

D MODULES REPLACEMENT PROCEDURE ....................................... 30

D DISPLAY MENUS .............................................................................. 42

D PRE-HEIGHT SELECTOR .................................................................. 48

D TROUBLESHOOTING GUIDE ............................................................ 55

UPDATE 0 1 2 3 4 5 6 Date: Mar. 2002 Part No.: 1517320 Page: 13

Page: 14 Part No.: 1517320 Date: Mar. 2002 0 1 2 3 4 5 6 UPDATE

FUNCTIONAL ELECTRICAL DIAGRAM 1/7

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14a

FUNCTIONAL ELECTRICAL DIAGRAM 2/7

1B - 2B PONTE CONFIGURAZIONE INVERTER

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14b

FUNCTIONAL ELECTRICAL DIAGRAM 3/7

1B - 2B PONTE CONFIGURAZIONE INVERTER

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14c

FUNCTIONAL ELECTRICAL DIAGRAM 4/7

Function Range Function Ra nge

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14d

FUNCTIONAL ELECTRICAL DIAGRAM 4a/7

Function Range Function Ra nge

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14e

FUNCTIONAL ELECTRICAL DIAGRAM 4b/7

CON PEDALIERA DOPPIA IN FUNZIONE, IL COMANDO SUL JOYSTICK E’ DISATTIVATO

AGGIORNAMENTO 0 1 2 3 4 5 6 Data: Mar. 2002 Part No: 1517319 Pag. 14f

FUNCTIONAL ELECTRICAL DIAGRAM 4c/7

Function Range Function Range